US20170275120A1 - Roll-to-roll apparatus - Google Patents

Roll-to-roll apparatus Download PDF

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Publication number
US20170275120A1
US20170275120A1 US15/260,276 US201615260276A US2017275120A1 US 20170275120 A1 US20170275120 A1 US 20170275120A1 US 201615260276 A US201615260276 A US 201615260276A US 2017275120 A1 US2017275120 A1 US 2017275120A1
Authority
US
United States
Prior art keywords
flexible substrate
roll
unit
supporting
breakage
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US15/260,276
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English (en)
Inventor
Chao-Feng Sung
Yi-Shu Chen
Kuo-Hsin Huang
Hsin-Yun Hsu
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Industrial Technology Research Institute ITRI
Original Assignee
Industrial Technology Research Institute ITRI
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Assigned to INDUSTRIAL TECHNOLOGY RESEARCH INSTITUTE reassignment INDUSTRIAL TECHNOLOGY RESEARCH INSTITUTE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHEN, YI-SHU, HSU, HSIN-YUN, HUANG, KUO-HSIN, SUNG, CHAO-FENG
Publication of US20170275120A1 publication Critical patent/US20170275120A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H26/00—Warning or safety devices, e.g. automatic fault detectors, stop-motions, for web-advancing mechanisms
    • B65H26/02—Warning or safety devices, e.g. automatic fault detectors, stop-motions, for web-advancing mechanisms responsive to presence of irregularities in running webs
    • B65H26/025—Warning or safety devices, e.g. automatic fault detectors, stop-motions, for web-advancing mechanisms responsive to presence of irregularities in running webs responsive to web breakage
    • B65H2515/312—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2553/00—Sensing or detecting means
    • B65H2553/40—Sensing or detecting means using optical, e.g. photographic, elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/10—Handled articles or webs
    • B65H2701/17—Nature of material
    • B65H2701/173—Metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/10—Handled articles or webs
    • B65H2701/17—Nature of material
    • B65H2701/175—Plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2801/00—Application field
    • B65H2801/61—Display device manufacture, e.g. liquid crystal displays

Definitions

  • the present disclosure relates to a roll-to-roll apparatus.
  • the flexible glass has characteristics of being bent and high hardness. It is applicable to a plane substrate of an electronic paper (e-paper), a protective cover of a photovoltaic module, a substrate of a touch sensor, a solid-state light-emitting element, an electronic device and so on.
  • e-paper electronic paper
  • a protective cover of a photovoltaic module a substrate of a touch sensor
  • a solid-state light-emitting element an electronic device and so on.
  • the flexible glass with thin thickness has a considerable degree of flexibility, it retains the brittle property. Stress concentration of the strength may occur in the flexible glass due to surface defects or scratches. Therefore, any unstable delivery, drag, and/or torsion of the flexible glass may cause a breakage of the flexible glass.
  • the current roll-to-roll equipment can transfers the flexible glass via a roll-to-roll process. When the breakage of the flexible glass occurred, even the drive roller stops rotating, the flexible glass continues to produce more unpredictable damages because of its flexibility and inertia effect. Therefore, it is hard to identify the initial broken position and the broken causes, and fail to prevent breakages recurring in the future.
  • a roll-to-roll apparatus may comprise an unwinding unit, a winding unit, at least one supporting unit, at least one breakage sensor, and at least one holding unit.
  • the at least one supporting unit is disposed between the unwinding unit and the winding unit, and supports a flexible substrate to move from the unwinding unit to the winding unit.
  • the at least one breakage sensor senses whether the flexible substrate is broken or not.
  • the at least one holding unit grips the flexible substrate while a breakage of the flexible substrate is sensed by the at least one breakage sensor.
  • FIG. 1 is a schematic view of a roll-to-roll apparatus according to an embodiment of the present disclosure.
  • FIG. 2A is a schematic view illustrating that the roll-to-roll apparatus of FIG. 1 has a breakage occurring in a flexible substrate.
  • FIG. 2B is an enlarged schematic view of a holding unit of FIG. 2A .
  • FIG. 3A is a schematic view illustrating that a holding unit of FIG. 1 grips the flexible substrate after the flexible substrate is broken.
  • FIG. 3B is an enlarged schematic view of the holding unit of FIG. 3A .
  • FIG. 4 is a schematic cross-sectional view of a holding unit of FIG. 1 .
  • FIG. 5 is a schematic cross-sectional view of a holding unit of a roll-to-roll apparatus according to another embodiment of the present disclosure.
  • FIG. 6 is a schematic cross-sectional view of a holding unit of a roll-to-roll apparatus according to yet another embodiment of the present disclosure.
  • FIG. 7 is a partial schematic view of a roll-to-roll apparatus according to yet another embodiment of the present disclosure.
  • FIG. 1 is a schematic view of a roll-to-roll apparatus according to an embodiment of the present disclosure.
  • a roll-to-roll apparatus 100 may comprise an unwinding unit 110 , a winding unit 120 , at least one supporting unit 130 , at least one breakage sensor 140 , and at least one holding unit 150 .
  • the supporting unit 130 is disposed between the unwinding unit 110 and the winding unit 120 .
  • a flexible substrate 50 is supported by the at least one supporting unit 130 to move from the unwinding unit 110 to the winding unit 120 .
  • the at least one breakage sensor 140 may sense whether the flexible substrate 50 is broken or not.
  • the at least one holding unit 150 may grip the flexible substrate 50 while a breakage of the flexible substrate 50 is sensed by the at least one breakage sensor 140 .
  • the roll-to-roll apparatus 100 has the at least one a holding unit 150 .
  • the at least one breakage sensor 140 may detect the flexible substrate 50 from falling, swinging, and/or expansion of damages, so that related manufacturing processes resume easily.
  • Original breaking states of the flexible substrate 50 can be held as much as possible, to find out the broken causes, and to prevent breakages occurring in the flexible substrate 50 again in the future.
  • the unwinding unit 110 and the winding unit 120 are rollers.
  • the at least one supporting unit 130 is a roller, for example, the at least one supporting unit 130 may rotate synchronously with the movement of the flexible substrate 50 to avoid generating a relative displacement between the surface of the supporting unit 130 and the flexible substrate 50 . Thereby, the supporting unit 130 may scratch the flexible substrate 50 as less as possible.
  • the at least one holding units 150 may correspond to the at least one supporting units 130 , respectively, and the flexible substrate 50 is held by both the at least one holding unit 150 and the at least one supporting unit 130 , but the present disclosure is not limited thereto.
  • the roll-to-roll apparatus 100 of this embodiment may further include a processing unit 160 to perform various processes on the flexible substrate 50 .
  • the processing unit 160 may perform sputtering, evaporation, or other suitable processes on the flexible substrate 50 .
  • an exemplary material of the flexible substrate 50 includes glass, but the material of the flexible substrate 50 may include other flexible continuous sheet materials, such as metal, plastic, paper like, and so on.
  • the thickness of the flexible glass substrate may be less than 150 ⁇ m, such as 100 ⁇ m or less.
  • the width of the flexible glass substrate 50 may be greater than or equal to 100 mm, such as more than 200 mm.
  • the length of the flexible glass substrate 50 may be greater than or equal to 1 m, such as more than 10 m.
  • the dimensions of the flexible glass substrate 50 are not limited thereto.
  • each breakage sensor 140 may be a tension sensor.
  • the at least one breakage sensor 140 may be disposed on the at least one supporting unit 130 .
  • a portion of the tension of the flexible substrate 50 may be applied on the at least one supporting unit 130 , and the at least one breakage sensor 140 may calculate a tension of the flexible substrate 50 according to sensed components of the tension.
  • the tension of the flexible substrate 50 should be within a non ial range. Once the at least one breakage sensor 140 senses the tension is beyond the normal range, it may be determined that a breakage occurs in the flexible substrate 50 .
  • the at least one holding unit 150 After the at least one breakage sensor 140 determines that the breakage occurs in the flexible substrate 50 , the at least one holding unit 150 starts to grip the flexible substrate 50 .
  • the time that the roll-to-roll apparatus 100 activates the at least one holding unit 150 to grip the flexible substrate 50 may be less than the time that the flexible substrate 50 falls, so as to facilitate the gripping efficiency achieving.
  • the way to activate the holding unit 150 may include, for example, solenoid valves with air pressure driven, magnetism driven, or motor driven. In the high-speed solenoid valve case, the response time of activation may be less than 15 ms.
  • the supporting unit 130 of the roll-to-roll apparatus 100 may be a roller, for example, a roller-type supporting unit having a diameter of six inches is used to convey the flexible substrate 50 (for example, an ultra-thin glass substrate).
  • a circumferential angle 0 (labeled in FIG. 3B , also known as wrap angle) of a portion of the supporting unit 130 in contact with the flexible substrate 50 is generally in the range of 45° to 135°.
  • the wrap angle of the supporting unit 130 in contact with the flexible substrate 50 is 45° is taken as an example.
  • the length of the supporting unit 130 in contact with the flexible substrate 50 is 5.98 cm by calculation.
  • the maximum possible conveying speed for the flexible substrate 50 is 5 cm/sec, for example, it takes 1.197 seconds to make a move of 5.98 cm on the flexible substrate 50 . While it takes 0.1055 seconds to make the move of 5.98 cm on the flexible substrate 50 with considering the gravity factor (with gravitational acceleration g of the movement).
  • the response time of the solenoid valve is less than 15 ms, and it should be able to meet the requirement.
  • the range of the holding unit 150 in contact with the flexible substrate 50 may be in the range of the wrap angle of the supporting unit 130 with respect to the flexible substrate 50 , that is, in the range of the supporting unit 130 in contact with the flexible substrate 50 .
  • a width of the flexible substrate 50 is L
  • the supporting unit 130 is a roller having a diameter is D
  • an area of the holding unit 150 in contact with the flexible substrate 50 is A
  • the wrap angle is 45°, then A ⁇ L ⁇ D/8.
  • the wrap angle is 135°, then A ⁇ L ⁇ D ⁇ 3/8.
  • FIG. 2A is a schematic view illustrating that the roll-to-roll apparatus of FIG. 1 has a breakage occurring in the flexible substrate.
  • FIG. 2B is an enlarged schematic view of a holding unit of FIG. 2A .
  • the holding unit 150 is arc-shaped. Under the normal operation, the holding unit 150 may not press onto the flexible substrate 50 and keep an appropriate distance D 10 between the holding unit 150 and the flexible substrate 50 .
  • the distance D 10 is less than 100 ⁇ m.
  • the flexible substrate 50 closer to the winding unit 120 may tend to continue moving forward due to inertia, as shown by an arrow in FIG. 2A . Continued forward movement of the flexible substrate 50 may cause another breakage again because the flexible substrate 50 and the winding unit 120 may press each other.
  • the flexible substrate 50 closer to the unwinding unit 110 may tend to spring-back due to counteraction or gravity, as shown by another arrow in FIG. 2A . Spring-back of the flexible substrate 50 may cause another breakage again because the flexible substrate 50 and the unwinding unit 110 press each other or the flexible substrate 50 loses the supporting of the tension, thereby swinging.
  • FIG. 3A is a schematic view illustrating that a holding unit of FIG. 1 grips the flexible substrate after the flexible substrate is broken.
  • FIG. 3B is an enlarged schematic view of the holding unit of FIG. 3A .
  • the breakage sensor 140 may drive the unwinding unit 110 and the winding unit 120 to stop unwinding and winding, respectively, and may drive the holding unit 150 to press onto the flexible substrate 50 on the supporting unit 130 . Therefore, it may control the damage to occur in the initial region, to avoid the damage to spread through other regions of flexible substrate 50 .
  • the breakage sensor 140 may drive all of the plurality of supporting units 150 simultaneously for pressing onto the flexible substrate 50 .
  • a gravity and a mobile inertia force of the flexible substrate 50 between two adjacent supporting units 130 generated by the weight of the flexible substrate are considered.
  • a distance between two adjacent supporting units 130 is 1 m
  • a width and a thickness of the flexible substrate 50 made of glass are 350 mm and 100 ⁇ m, respectively.
  • the weight of the flexible substrate 50 between two adjacent the supporting unit 130 is about 86.1 g.
  • the holding unit 150 may provide a frictional force about 0.84378 Newton to stop the flexible substrate 50 .
  • the motion force after the breakage occurs in the flexible substrate 50 is not take into consideration yet.
  • a material of the holding unit 150 may be such as plastic, rubber, silicone, or other materials having a hardness less than the hardness of the flexible substrate 50 . It may avoid the flexible substrate 50 is scratched during the holding process. Alternatively, the coefficient of sliding friction between the holding unit 150 and the flexible substrate 50 may further be considered.
  • FIG. 4 is a schematic cross-sectional view of a holding unit of FIG. 1 .
  • the holding unit 150 may grip the boundary of the flexible substrate 50 .
  • the boundary of the flexible substrate 50 will not be used in the final product, and the holding unit 150 grips the boundary of the flexible substrate 50 may reduce the probability of damages for the quality of the final product.
  • FIG. 5 is a schematic cross-sectional view of a holding unit of a roll-to-roll apparatus according to another embodiment of the present disclosure.
  • two sides 132 A of a supporting unit 132 may be higher than a middle portion 132 B of the supporting unit 132 .
  • the boundary of the flexible substrate 50 may be in contact with the two sides 132 A of the supporting unit 132 .
  • the supporting unit 132 keeps in contact with the boundary of the flexible substrate 50 may reduce the probability of damages for the quality of the final product.
  • FIG. 6 is a schematic cross-sectional view of a holding unit of a roll-to-roll apparatus according to yet another embodiment of the present disclosure.
  • the holding unit 152 may be a roller, which may keep in contact with the flexible substrate 50 on the supporting unit 132 .
  • the supporting unit 132 in rotating may drive the flexible substrate 50 to move forward, and the frictional force between the flexible substrate 50 and the holding unit 152 may drive the holding unit 152 to rotate.
  • the holding unit 152 may rotate independently to avoid generating the relative displacement between the surface of the holding unit 152 and the flexible substrate 50 , thereby reducing the opportunity that the holding unit 152 scratches the flexible substrate 50 .
  • the at least one holding unit 152 is forced to stop rotating to apply a frictional force, thereby applying the brakes to stop the flexible substrate 50 in time.
  • the holding unit 152 is in contact with the flexible substrate 50 on the supporting unit 132 , which may shorten the time from the breakage occurs in the flexible substrate 50 to the flexible substrate 50 is stopped.
  • the supporting unit 130 without the level difference is applicable in the architecture of FIG. 6 .
  • the supporting unit 130 without the level difference may cooperate with the roller-type supporting unit 152 and keep in contact with the flexible substrate 50 . This may shorten the time from the breakage occurs in the flexible substrate 50 to the flexible substrate 50 is stopped.
  • FIG. 7 is a partial schematic view of a roll-to-roll apparatus according to yet another embodiment of the present disclosure.
  • the at least one holding unit 154 may include a first holding portion 154 A and a second holding portion 154 B. While a breakage sensor 142 senses a breakage occurring in the flexible substrate 50 , the at least one holding unit 154 grips the flexible substrate 50 and the flexible substrate 50 is kept between the first holding portion 154 A and the second holding portion 154 B.
  • the breakage sensor 142 may be such as an image sensor, and may determine whether the flexible substrate 50 is broken or not by capturing and automatically analyzing the images. In other embodiments, the breakage sensor 142 may be such as an optical sensor, and may detect the changes in the amount of light passing through the flexible substrate 50 or in the amount of the light reflected by the flexible substrate 50 to determine whether the flexible substrate 50 is broken or not.
  • the roll-to-roll apparatus may drive the holding unit to grip the flexible substrate to prevent the flexible substrate from continuously moving forward or shaking.
  • Original breaking states of the flexible substrate can be held as much as possible and expanded damages can be prevented, which facilitates the cause analysis for improvement and reduces the difficulty of cleaning breakages.

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  • Container, Conveyance, Adherence, Positioning, Of Wafer (AREA)
US15/260,276 2016-03-28 2016-09-08 Roll-to-roll apparatus Abandoned US20170275120A1 (en)

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Application Number Priority Date Filing Date Title
TW105109606A TWI555695B (zh) 2016-03-28 2016-03-28 卷對卷設備
TW105109606 2016-03-28

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20200299015A1 (en) * 2019-03-20 2020-09-24 Lantech.Com, Llc Packaging material evaluation and apparatus therefor for evaluating simulated flaws
WO2020220601A1 (zh) * 2019-04-29 2020-11-05 武汉华星光电半导体显示技术有限公司 一种柔性显示装置
CN112919195A (zh) * 2021-03-31 2021-06-08 洛阳兴瑞新材料科技有限公司 一种pvdc薄膜磁吸防缠绕装置的操作方法
US20230174261A1 (en) * 2017-09-22 2023-06-08 Lantech.Com, Llc Packaging material quality compensation

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Publication number Priority date Publication date Assignee Title
NL2018889B1 (en) * 2017-05-10 2018-11-15 Vmi Holland Bv Wind-up system and method for winding-up a strip

Family Cites Families (4)

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Publication number Priority date Publication date Assignee Title
US4015799A (en) * 1975-11-14 1977-04-05 International Business Machines Corporation Adaptive reel-to-reel tape control system
CN201033441Y (zh) * 2007-04-13 2008-03-12 富港电子（东莞）有限公司 卷带裁切治具
DE102010063467A1 (de) * 2010-12-17 2012-06-21 Hauni Maschinenbau Ag Bobinenabrollvorrichtung der Tabak verarbeitenden Industrie
TWI557056B (zh) * 2013-04-24 2016-11-11 財團法人工業技術研究院 具撓性基材保護功能的卷對卷輸送設備

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20230174261A1 (en) * 2017-09-22 2023-06-08 Lantech.Com, Llc Packaging material quality compensation
US12037153B2 (en) * 2017-09-22 2024-07-16 Lantech.Com, Llc Packaging material quality compensation
US20200299015A1 (en) * 2019-03-20 2020-09-24 Lantech.Com, Llc Packaging material evaluation and apparatus therefor for evaluating simulated flaws
WO2020220601A1 (zh) * 2019-04-29 2020-11-05 武汉华星光电半导体显示技术有限公司 一种柔性显示装置
CN112919195A (zh) * 2021-03-31 2021-06-08 洛阳兴瑞新材料科技有限公司 一种pvdc薄膜磁吸防缠绕装置的操作方法

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TWI555695B (zh) 2016-11-01

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Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SUNG, CHAO-FENG;CHEN, YI-SHU;HUANG, KUO-HSIN;AND OTHERS;REEL/FRAME:039723/0345

Effective date: 20160829

STCB Information on status: application discontinuation

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