U.S. patent application number 14/408810 was filed with the patent office on 2015-07-23 for continuous reel-to-reel arrangement.
The applicant listed for this patent is Impact Coatings AB. Invention is credited to Christofer Andersson, Roger Vigren.
Application Number | 20150203314 14/408810 |
Document ID | / |
Family ID | 49782294 |
Filed Date | 2015-07-23 |
United States Patent
Application |
20150203314 |
Kind Code |
A1 |
Vigren; Roger ; et
al. |
July 23, 2015 |
CONTINUOUS REEL-TO-REEL ARRANGEMENT
Abstract
A continuous reel-to-reel arrangement (1), for transportation of
continuous substrate materials (3) from an unwinding material reel
(2) to a winding material reel (4), comprises at least two guiding
rolls (5) arranged to align the substrate material (3) when being
rolled off from the unwinding material reel (2) before entering
into at least one treatment zone (6), and at least two guiding
rolls (5) arranged to align the substrate material (3) when exiting
the at least one treatment zone (6) before being winded up on the
winding material reel (4). At least one of the guiding rolls (5)
arranged to align the substrate material (3) when exiting the at
least one treatment zone is a driving roll (13), and at least one
of the guiding rolls (5) arranged to align the substrate material
(3) when being rolled off from the unwinding material reel (2) is a
braking roll (12), arranged to apply a constant braking force to
the substrate material (3) when the substrate material (3) is
driven through the at least one treatment zone (6). Thereby, the
risk of plastically deforming the substrate material (3) is low
during transportation and during unwinding/winding and the risk of
subjecting the material to wear is also low.
Inventors: |
Vigren; Roger; (Ljungsbro,
SE) ; Andersson; Christofer; (Linkoping, SE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Impact Coatings AB |
Linkoping |
|
SE |
|
|
Family ID: |
49782294 |
Appl. No.: |
14/408810 |
Filed: |
June 18, 2013 |
PCT Filed: |
June 18, 2013 |
PCT NO: |
PCT/EP2013/062625 |
371 Date: |
December 17, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61663834 |
Jun 25, 2012 |
|
|
|
Current U.S.
Class: |
118/500 ;
242/534 |
Current CPC
Class: |
B65H 23/1806 20130101;
C23C 14/50 20130101; C23C 16/545 20130101; B65H 23/1888 20130101;
B65H 2404/165 20130101; B65H 18/103 20130101; B65H 2301/41284
20130101; B65H 23/188 20130101; C23C 14/562 20130101; B65H 18/106
20130101; B65H 2701/192 20130101; B65H 2301/51145 20130101; C23C
16/458 20130101 |
International
Class: |
B65H 18/10 20060101
B65H018/10; B65H 23/18 20060101 B65H023/18; B65H 23/188 20060101
B65H023/188 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 25, 2012 |
SE |
1250680-4 |
Claims
1. A continuous reel-to-reel arrangement for transportation of
continuous substrate materials from an unwinding material reel to a
winding material reel, wherein said substrate material is arranged
to be driven through at least one treatment zone, said arrangement
comprising: at least two guiding rolls arranged to align said
substrate material when being rolled off from said unwinding
material reel before entering into said at least one treatment
zone, at least two guiding rolls arranged to align said substrate
material when exiting said at least one treatment zone before being
winded up on said winding material reel, at least one of said
guiding rolls arranged to align said substrate material when
exiting said at least one treatment zone is a driving roll, and at
least one of said guiding rolls arranged to align said substrate
material when being rolled off from said unwinding material reel is
a braking roll, arranged to apply a constant braking force to said
substrate material when said substrate material is driven through
said at least one treatment zone.
2. The continuous reel-to-reel arrangement as claimed in claim 1,
wherein the number of guiding rolls arranged to align said
substrate material rolled off from said unwinding material reel are
at least three.
3. The continuous reel-to-reel arrangement as claimed in claim 1,
wherein the number of guiding rolls arranged to align said
substrate material when exiting said at least one treatment zone
are at least three.
4. The continuous reel-to-reel arrangement as claimed in claim 1,
wherein the radius of said guiding rolls is larger than what causes
plastic deformation of said substrate material due to combination
of tensile stress and bending curvature which said substrate
material is subject to in said continuous reel-to-reel
arrangement.
5. The continuous reel-to-reel arrangement as claimed in claim 4,
wherein a smallest radius, R, of said guiding rolls at a given
tension force, F, is when the total tensile stress,
.sigma..sub.tot, acting on said substrate material is equal to the
yield point, .sigma..sub.0.2, of a given substrate material.
6. The continuous reel-to-reel arrangement as claimed in claim 1,
wherein said braking roll is enclosed by said substrate material at
an angle of about 180.degree..
7. The continuous reel-to-reel arrangement as claimed in claim 1,
wherein said braking roll is arranged between a first guiding roll,
guiding said substrate material at an angle of about 90.degree. to
engage said braking roll, and a second guiding roll guiding said
substrate material at an angle of about 90.degree. for further
transportation to said at least one treatment zone.
8. The continuous reel-to-reel arrangement as claimed in claim 1,
wherein at least one of said guiding rolls arranged to align said
substrate material rolled off from said unwinding material reel
before entering into said at least one treatment zone, is providing
said substrate material with a voltage.
9. The continuous reel-to-reel arrangement as claimed in claim 1,
wherein an evacuated environment is provided in at least a section
of said at least one treatment zone.
10. The continuous reel-to-reel arrangement as claimed in claim 1,
wherein said at least one treatment zone comprises at least one
coating chamber.
11. The continuous reel-to-reel arrangement as claimed in claim 1,
wherein one of said guiding rolls arranged to align said substrate
material when exiting said at least one treatment zone before being
winded up on a winding material reel is a cooling roll.
12. The continuous reel-to-reel arrangement as claimed in claim 1,
wherein said substrate material is any one of a strip, a wire, and
a foil.
13. A system comprising at least two of said continuous
reel-to-reel arrangements as claimed in claim 1, wherein said at
least one treatment zone is common for said at least two continuous
reel-to-reel arrangements, and wherein at least two substrate
materials are arranged substantially in parallel when driven
through said at least one common treatment zone.
14. A method of treating at least one continuous substrate
material, said method comprising the steps of: unwinding said at
least one substrate material from at least one unwinding material
reel, guiding said at least one substrate material to at least one
treatment zone by the use of at least two guiding rolls, treating
said at least one substrate material in said at least one treatment
zone, winding up said at least one substrate material on at least
one winding material reel, and braking said at least one substrate
material.
15. A method of feeding at least one continuous substrate material
to at least one treatment zone, said method comprising the steps
of: unwinding said at least one substrate material from at least
one unwinding material reel, guiding said substrate material at an
angle of about 90.degree. around a first guiding roll to engage a
braking roll, enclosing said braking roll by said substrate
material at an angle of about 180.degree., guiding said substrate
material at an angle of about 90.degree. around a second guiding
roll, entering said at least one treatment zone.
16. A continuous reel-to-reel apparatus for transportation of
continuous substrate materials from a pay-out chamber to a take-up
chamber, wherein said substrate material is arranged to be driven
through at least one treatment zone, wherein the pay-out chamber
comprises at least two guiding rolls arranged to align said
substrate material rolled off from an unwinding material reel in
said pay-out chamber before entering into said at least one
treatment zone, and wherein said take-up chamber comprises at least
two guiding rolls arranged to align said substrate material when
exiting said at least one treatment zone before being winded up on
a winding material reel in said take-up chamber, at least one of
said guiding rolls in said take-up chamber is a driving roll, and
at least one of said guiding rolls in said pay-out chamber is a
braking roll, arranged to apply a constant braking force to said
substrate material when said substrate material is driven through
said at least one treatment zone.
17. The continuous reel-to-reel apparatus as claimed in claim 16,
wherein the number of guiding rolls arranged to align said
substrate material rolled off from said unwinding material reel are
at least three.
Description
TECHNICAL FIELD
[0001] The present disclosure relates to a continuous reel-to-reel
arrangement for transportation of continuous substrate materials
from an unwinding material reel to a winding material reel, a
system comprising at least two such arrangements, a method of
feeding substrate materials to at least one treatment zone and a
method of treating substrate materials.
BACKGROUND
[0002] In continuous reel-to-reel apparatuses an elongated
substrate is transported from one reel or roll to another. Such
apparatuses may be used in various areas, for example for paper
processing and label printing. Reel-to-reel apparatuses are also
used for application of coatings or thin films on continuous
flexible substrates and may for example be used in the production
of photovoltaic cells, for coating of various components for the
electronic industry, and for the purpose of decoration.
[0003] Different coating methods, such as electroplating, CVD
(Chemical Vapour Deposition) or PVD (Physical Vapour Deposition)
may be used in such reel-to-reel coating apparatuses.
[0004] For all applications mentioned above a reliable coating
apparatus is essential in which reproducible coating layers of high
quality may be produced on continuous substrates. It is also of
importance to avoid scratching or damaging of the coated surface
when the substrate is transported through the reel-to-reel
apparatus and during winding of the coated substrate material on
the material reel.
[0005] In U.S. Pat. No. 4,763,601 a continuous coating apparatus
for coating of a continuous strip, such as a metal or a plastic
strip, is disclosed. Coating is only applied on one side of the
strip and the coated surface does not come into contact with guide
rollers of the apparatus. Hence, the risk of the coated surface
being scratched is low. The apparatus in this disclosure comprises
a pair of strip supply/take-up devices capable of uncoiling the
strip, supplying the strip in a tensed condition to at least two
coating zones, and taking up and coiling the strip. The at least
two coating zones are at least two of an ion plating coating zone,
a sputtering coating zone and a plasma CVD coating zone arranged in
series in the direction of run of a strip between said strip
supply/take-up devices. Between adjacent coating zones and between
a supply/take-up device and an adjacent coating zone are partition
walls with slits adapted to allow the strip to pass through and to
maintain a vacuum in the coating zones. The partition wall has a
pair of guide rollers located in the vicinity of an upper edge of
the slit so as to tense the strip such that the path of the strip
is slightly convex downwards to keep the strip away from upper and
lower edges of the slit.
[0006] Although the use of the continuous coating apparatus
disclosed in U.S. Pat. No. 4,763,601 may result in the desirable
unscratched coated surface there is a risk of plastically deforming
the continuous strip during transportation through the apparatus
and during unwinding/winding of the strip. In addition, there is a
risk of subjecting the continuous strip to wear by sliding of
different layers of the strip against each other on the strip
take-up device.
SUMMARY OF THE INVENTION
[0007] It is a general object of the present disclosure to provide
an improved continuous reel-to reel arrangement for transportation
of continuous substrate materials. It is a specific object to
provide a continuous reel-to-reel arrangement in which the risk of
plastically deforming the substrate material during transportation
and during unwinding/winding of the substrate material is low and
where the risk of subjecting the substrate material to wear is
low.
[0008] The invention is defined by the appended independent claims.
Embodiments are set forth in the dependent claims, in the attached
drawings and in the following description.
[0009] According to a first aspect, there is provided a continuous
reel-to-reel arrangement for transportation of continuous substrate
materials from an unwinding material reel to a winding material
reel, wherein the substrate material is arranged to be driven
through at least one treatment zone. The arrangement comprises at
least two guiding rolls arranged to align the substrate material
when being rolled off from the unwinding material reel before
entering into the at least one treatment zone, and at least two
guiding rolls arranged to align the substrate material when exiting
the at least one treatment zone before being winded up on the
winding material reel. At least one of the guiding rolls arranged
to align the substrate material when exiting the at least one
treatment zone is a driving roll, and at least one of the guiding
rolls arranged to align the substrate material when being rolled
off from the unwinding material reel is a braking roll, arranged to
apply a constant braking force to the substrate material when the
substrate material is driven through the at least one treatment
zone.
[0010] The winding and unwinding material reels have substantially
no effect on the driving and braking of the substrate material. The
braking roll is a guiding roll which is physically and functionally
separate from the unwinding material reel. The driving roll is a
guiding roll which is physically and functionally separate from the
winding material reel.
[0011] The substrate material may be flexible.
[0012] The guiding rolls arranged to align the substrate material
rolled off from the unwinding material reel are arranged in such a
way that the substrate material may be precisely aligned in the
horizontal position as well as in the vertical position of the
direction of the moving substrate material while being driven
through the at least one treatment zone.
[0013] Inside the treatment zone there are no supporting or guiding
rolls and the substrate material is suspended freely therein.
[0014] When more than one treatment zone is present in the
continuous reel-to-reel arrangement, these may be arranged in
series in the direction of transportation of the substrate
material.
[0015] The use of at least one driving roll and at least one
braking roll, which are physically and functionally separate from
the unwinding and winding material reels, prevent too high forces
to act on the unwinding/winding material reels. The tension force
acting on the substrate material is increased after the braking
roll and decreased after the driving roll and is at its maximum
when the substrate material passes through the treatment zone.
Thereby, the risk of plastically deforming the substrate material
during unwinding/winding may be low. Also, wearing of the substrate
material by sliding of different layers of substrate materials
against each other on the material reels may be avoided. Further, a
possible collapse of the whole winded reel structure is
avoided.
[0016] With this reel-to-reel arrangement the constant braking
force applied to the substrate material by the at least one braking
roll ensures that the substrate material is kept in a tensed
condition when driven through the at least one treatment zone.
Also, the horizontal and vertical position of the substrate
material inside the treatment zone is controlled and kept
substantially constant independently of the amount of substrate
material (number of layers) that is winded on the material
reels.
[0017] With this reel-to-reel arrangement design the mechanical
demands required in the treatment zone can be separated from the
mechanical demands put on the guiding rolls and the
unwinding/winding material reels.
[0018] In one embodiment, the number of guiding rolls arranged to
align the substrate material rolled off from the unwinding material
reel may be at least three.
[0019] In yet an embodiment the number of guiding rolls arranged to
align the substrate material when exiting the at least one
treatment zone may be at least three.
[0020] Also four or more guiding rolls may be arranged to align the
substrate material rolled off from the unwinding material reel and
four or more guiding rolls may be arranged to align the substrate
material when exiting the at least one treatment zone.
[0021] The number of guiding rolls arranged to align the substrate
material rolled off from the unwinding material reel may be
independent of the number of guiding rolls arranged to align the
substrate material when exiting the at least one treatment
zone.
[0022] The radius of the guiding rolls may be larger than what
causes plastic deformation of the substrate material due to
combination of tensile stress and bending curvature which the
substrate material is subject to in the continuous reel-to-reel
arrangement.
[0023] By using guiding rolls with large enough radius, the
substrate material may be transported from one material reel to
another in the continuous reel-to-reel arrangement without
subjecting the substrate material to tensile stress or bending
curvature that could cause plastic deformation of the substrate
material.
[0024] In one specific embodiment a smallest radius, R, of the
guiding rolls at a given tension force, F, may be when the total
tensile stress, .sigma..sub.tot, acting on the substrate material
is equal to the yield point, .sigma..sub.0.2, of a given substrate
material.
[0025] The total tensile stress, .sigma..sub.tot, which the
substrate material is subject to in the continuous reel-to-reel
arrangement, is the sum of tensile stress due to tension forces, F,
and tensile stress due to bending curvature. The yield point is a
first point at which permanent deformation of a stressed substrate
material begins to take place. For engineering purposes the yield
point is taken as the point at which a certain small amount of
permanent deformation, here 0.2%, .sigma..sub.0.2, has
occurred.
[0026] In one embodiment of the continuous reel-to-reel arrangement
the braking roll may be enclosed by the substrate material at an
angle of about 180.degree..
[0027] The substrate material may be wrapped around the braking
roll at an angle of about 180.degree. in order to avoid slipping or
sliding between the braking roll and the substrate material.
[0028] With a wrap angle of about 180.degree. is here meant an
angle of 180.degree..+-.5.degree..
[0029] The braking roll may be arranged between a first guiding
roll, guiding the substrate material at an angle of about
90.degree. to engage the braking roll, and a second guiding roll
guiding the substrate material at an angle of about 90.degree. for
further transportation to the at least one treatment zone.
[0030] With an angle of about 90.degree. is here meant an angle of
90.degree..+-.5.degree..
[0031] By turning the substrate material as it is transported
between the guiding rolls, braking roll and driving roll only one
side of the substrate material is mechanically touched. By only
using guiding rolls whose axis are directed perpendicular to the
direction of the moving substrate material, the risk of scratching
the surface of substrate material during the transport from the at
least on treatment zone is low.
[0032] In one embodiment at least one of the guiding rolls arranged
to align the substrate material rolled off from the unwinding
material reel before entering into the at least one treatment zone,
may provide the substrate material with a voltage.
[0033] For some applications a substrate material biased with a
voltage may be preferred in the at least one treatment zone.
[0034] In a further embodiment an evacuated environment may be
provided in at least a section of the at least one treatment
zone.
[0035] A typical working vacuum in the treatment zone may be 1-10
mTorr.
[0036] The at least one treatment zone may comprise at least one
coating chamber.
[0037] In this coating chamber deposition techniques such as PVD
and CVD may be used.
[0038] One of the guiding rolls arranged to align the substrate
material when exiting the at least one treatment zone before being
winded up on a winding material reel may be a cooling roll.
[0039] The substrate material may be cooled down after exiting the
treatment zone by a cooling roll which may be placed close to the
exit of the treatment zone. It may comprise a heat absorbing
material which should be able to quickly take up the heat from the
substrate material by conduction and transport the heat from the
substrate material contact area.
[0040] Suitable cooling roll surfaces could be any metal with good
heating conductivity that will not smear or react with the freshly
deposited surface of the substrate material. Alternatively, a heat
conductive ceramic material such as aluminium oxide could be
used.
[0041] The substrate material may be any one of a strip, a wire,
and a foil.
[0042] The substrate material may be substantially flat or being
formed in three dimensions. Substrate materials may for example be
nickel plated copper alloys e.g. brass or bronze, stainless steel,
aluminium, etc.
[0043] According to a second aspect, there is provided a system
comprising at least two of the continuous reel-to-reel arrangements
described above, wherein the at least one treatment zone is common
for the at least two continuous reel-to-reel arrangements, and
wherein at least two substrate materials are arranged substantially
in parallel when driven through the at least one common treatment
zone.
[0044] This system enables simultaneous transportation of more than
one substrate material through the at least one common treatment
zone without having the different substrate materials touching each
other. Each different substrate material pass individual adjusting
guiding rolls including braking/driving rolls in order to precisely
keep the right tension and position of the substrate material when
passing through the at least one treatment zone.
[0045] According to a third aspect there is provided a method of
treating at least one continuous substrate material, the method
comprising the steps of: unwinding the, at least one substrate
material from at least one unwinding material reel, guiding the at
least one substrate material to at least one treatment zone by the
use of at least two guiding rolls, treating the at least one
substrate material in the at least one treatment zone, and winding
up the at least one substrate material on at least one winding
material reel, wherein the method comprises a step of driving and a
step of braking the at least one substrate material.
[0046] According to a fourth aspect there is provided a method of
feeding at least one continuous substrate material to at least one
treatment zone, the method comprising the steps of unwinding the at
least one substrate material from at least one unwinding material
reel, guiding the substrate material at an angle of about
90.degree. around a first guiding roll to engage a braking roll,
enclosing the braking roll by the substrate material at an angle of
about 180.degree., guiding the substrate material at an angle of
about 90.degree. around a second guiding roll and entering the at
least one treatment zone.
[0047] According to a sixth aspect there is provided a continuous
reel-to-reel apparatus for transportation of continuous substrate
materials from a pay-out chamber to a take-up chamber, wherein the
substrate material is arranged to be driven through at least one
treatment zone, wherein the pay-out chamber comprises at least two
guiding rolls arranged to align the substrate material rolled off
from an unwinding material reel in the pay-out chamber before
entering into the at least one treatment zone, and wherein the
take-up chamber comprises at least two guiding rolls arranged to
align the substrate material when exiting the at least one
treatment zone before being winded up on a winding material reel in
the take-up chamber. At least one of the guiding rolls in the
take-up chamber is a driving roll, and at least one of the guiding
rolls in the pay-out chamber is a braking roll, arranged to apply a
constant braking force to the substrate material when the substrate
material is driven through the at least one treatment zone.
[0048] The number of guiding rolls arranged to align the substrate
material rolled off from the unwinding material reel in the
continuous reel-to-reel apparatus may be at least three.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] The above, as well as other aspects, objects and advantages
of the present disclosure, will be better understood through the
following illustrative and non-limited detailed description, with
reference to the appended drawings.
[0050] FIG. 1 shows a schematic overview of a continuous
reel-to-reel arrangement.
[0051] FIG. 2 shows a schematic overview of a continuous
reel-to-reel arrangement with one treatment zone.
[0052] FIG. 3 shows a magnification of a part of the continuous
reel-to-reel arrangement in FIG. 1.
[0053] FIG. 4 shows a side view of a portion of FIG. 3.
[0054] FIG. 5 shows a part of a system comprising eight continuous
reel-to-reel arrangements, in which system the eight substrate
materials are transported substantially in parallel.
[0055] FIG. 6 shows a magnified slightly rotated view of a part of
the system in FIG. 5.
DETAILED DESCRIPTION
[0056] FIG. 1 shows an overview of a continuous reel-to-reel
arrangement 1. The arrangement 1 comprises an unwinding material
reel 2 from which substrate material 3 is rolled off and a winding
material reel 4 onto which substrate material 3 is winded up. A
number of guiding rolls 5 are arranged to align the substrate
material 3 when being rolled off from the unwinding material reel 2
before entering into a treatment zone 6. In the embodiment shown in
FIG. 1. three such guiding rolls 5 are used. In another embodiment
two guiding rolls 5 may be used. In a yet further embodiment more
than three guiding rolls 5 may be used. A number of guiding rolls 5
are arranged to align the substrate material 3 when exiting the
treatment zone 6 before being winded up on the winding material
reel 4. In FIG. 1. an embodiment with three such guiding rolls 5 is
shown. In another embodiment two guiding rolls 5 may be used and in
a further embodiment more than three guiding rolls 5 may be used.
In FIG. 1 also a number of auxiliary guiding rolls 7 are shown.
These auxiliary guiding rolls 7 are physically and functionally
separate from the guiding rolls 5. The number of auxiliary guiding
rolls 7 in a continuous reel-to-reel arrangement 1 may vary. In one
embodiment of the arrangement 1 there are no auxiliary guiding
rolls 7. The guiding rolls 5 are arranged in such a way that the
substrate material 3 can be rolled off from a horizontally placed
material reel 2 and being precisely aligned in the horizontal
position as well as in the vertical position when driven through
the treatment zone 6. In another embodiment (not shown) the
substrate material 3 is rolled off from a vertically placed
material reel 2. In a further embodiment (not shown) the substrate
material 3 is driven vertically though the treatment zone 6.
[0057] Inside the treatment zone 6 there are no guiding rolls 5 or
auxiliary guiding rolls 7 and the substrate material 3 is suspended
freely therein. In the embodiment shown in FIG. 2 there is one
treatment zone 6. In other embodiments two or more treatment zones
6 are arranged in series in the direction of transportation of the
substrate material 3. In the treatment zone 6 any kind of treatment
could be executed. In some embodiments, the continuous reel-to-reel
arrangement 1 may be used without any treatment in the treatment
zone 6. In the treatment zone 6 an evacuated environment may be
provided. Typically, the treatment zone 6 is first evacuated to a
background vacuum level of 0.05-0.001 mTorr. Thereafter a process
gas (such as argon) is added to the treatment zone 6 to a working
pressure of 1-10 mTorr. The treatment zone 6 in FIG. 2 comprises
two deposition chambers 8, 8' arranged in series in the direction
of transportation of the substrate material. In the deposition
chambers 8, 8' deposition techniques such as PVD or CVD may be
used. The presence of more than one deposition chamber 8, 8' render
it possible to coat the substrate material 3 with more than one
coating layer. In some embodiments no or only one deposition
chamber 8, 8' is present in the treatment zone 6. In other
embodiments more than two deposition chambers 8, 8' are arranged in
series in the treatment zone 6. The treatment zone 6 may further
comprise at least one etch chamber 9. After treatment in one
deposition chamber 8, 8' the substrate material 3 may be
transferred to another deposition chamber 8, 8' for a next coating
step. The deposition technique used in the different deposition
chambers 8, 8' may be different or the same.
[0058] The unwinding material reel 2 and the guiding rolls 5
arranged to align the substrate material 3 before entering the
treatment zone 6 are arranged in a so called pay-out chamber 10,
FIG. 2. The guiding rolls 5 arranged to align the substrate
material 3 when exiting the treatment zone 6 before being winded up
on the winding material reel 4 are arranged in a so called take-up
chamber 11. In FIG. 3 a pay-out chamber 10/take-up chamber 11 is
shown with the unwinding material reel 2/winding material reel 4
and guiding rolls 5 including a braking roll 12/driving roll 13.
FIG. 4 is a side view of a portion of the pay-out chamber
10/take-up chamber 11 in FIG. 3, in which the guiding rolls 5
including the braking roll 12/driving roll 13 are shown.
[0059] The winding and unwinding material reels 2, 4 have
substantially no effect on the driving/braking of the substrate
material 3 in this continuous reel-to-reel arrangement 1. The
braking roll 12 is a guiding roll 5 which is physically and
functionally separate from the unwinding material reel 2. The
driving roll 13 is a guiding roll 5 which is physically and
functionally separate from the winding material reel 4.
[0060] The guiding rolls 5 arranged to align the substrate material
3 rolled off from the unwinding material reel 2 are arranged in
such a way that the substrate material 3 may be precisely aligned
in the horizontal position as well as in the vertical position of
the direction of the moving substrate material 3 while being driven
through the at least one treatment zone 6.
[0061] The use of at least one driving roll 13 and at least one
braking roll 12 prevent too high forces to act on the
unwinding/winding material reels 2, 4. The tension force acting on
the substrate material 3 is increased after the braking roll 12 and
decreased after the driving roll 13 and is at its maximum when the
substrate material 3 passes through the treatment zone 6. Thereby,
the risk of plastically deforming the substrate material 3 during
unwinding/winding is low. Also, wearing of the substrate material 3
by sliding of different layers of substrate materials 3 against
each other on the material reels 2, 4 is avoided. Further, a
possible collapse of the whole winded reel structure is
avoided.
[0062] The constant braking force applied to the substrate material
3 by the at least one braking roll 12 ensures that the substrate
material 3 is kept in a tensed condition when driven through the
treatment zone 6. Also, the horizontal and vertical position of the
substrate material 3 inside the treatment zone 6 is controlled and
kept substantially constant independently of the amount of material
(number of layers) that is winded on the material reels 2, 4.
[0063] A typical substrate material 3 that may be handled in this
reel-to-reel arrangement 1 has a thin sheet metal backbone
(0.05-0.2 mm in thickness) with a width ranging from 2 mm up to 5
mm. A thin sheet metal having a distributed weight of .rho..sub.1,
and being suspended between two points of equal horizontal level at
a distance L from each other and being subject to a tension force F
will have a curvature described by the formula:
Y=a.times.(cos h(X/a)-1),
where a is calculated from
a=L/(2.times.arcsin h(g.times..rho..sub.1.times.L/(2.times.F)))
in which g is the earth gravity acceleration. In order to control
the horizontal position of the substrate material 3 without too
much of curvature it is important that the tension of substrate
material 3 is correct and within a certain tolerance region.
[0064] Given the theoretical expressions above, if the tension
force, F, applied to a substrate material 3 with a distributed
weight in the order of 5 grams per meter is 20 to 25 N and the
suspension length of the substrate material 3 is 4 meters, the
resulting curvature of the substrate material 3 will have a lowest
point of approximately 4-5 mm below the suspension points.
[0065] The braking roll 12/driving roll 13 shown in FIG. 3 and FIG.
4 is enclosed by the substrate material 3 at an angle of about
180.degree.. The substrate material 3 is wrapped around the braking
roll 12/driving roll 13 at an angle of about 180.degree. in order
to avoid slipping or sliding between the braking roll 12/driving
roll 13 and the substrate material 3. The larger the wrap angle is,
the lower is the risk of slipping or sliding between the braking
roll 12/driving roll 13 and the substrate material 3. A wrap angle
larger than about 180.+-.5.degree. would not be feasible. A wrap
angle smaller than about 180.+-.5.degree. is not desirable and
would make the geometric placement of the guiding rolls 5 in the
pay-out chamber 10/take-up chamber 11 complicated. No technical
solution would, however, give a wrap angle of exactly 180.degree.
but tolerances and flexural resistance of the substrate material 3
will result in some deviation in wrap angle.
[0066] The material of the guiding rolls 5 should be chosen such
that there is a large friction between the guiding roll 5 and the
substrate material 3. The material of the guiding rolls 5 should
also be chosen such that there is a low risk of scratching the
substrate material 3.
[0067] The driving roll 13 in the take-up chamber 11 may be
propelled by an external electrical motor.
[0068] The braking roll 12 may be arranged between a first guiding
roll 5, guiding the substrate material 3 at an angle of about
90.degree. to engage the braking roll 12, and a second guiding roll
5 guiding the substrate material 3 at an angle of about 90.degree.
for further transportation to the at least one treatment zone 6. By
turning the substrate material 3 as it is transported between the
guiding rolls 5, braking roll 12 and driving roll 13, only one side
of the substrate material 3 is mechanically touched. By only using
guiding rolls 5 whose axis are directed perpendicular to the
direction of the moving substrate material 3, the risk of
scratching the coated surface of the substrate material 3 during
the transport from the at least one treatment zone 6 is low. In
this way, a substrate material 3 that has an extra sensitive side,
such as electrical contact strips, as well as strip material
stamped and formed in the 3.sup.rd dimension may be transported
through the at least one treatment zone 6 without damaging the
often sensitive connector pins.
[0069] The angle of about 90.degree. is a preferred angle. In the
geometry shown in the figures of the continuous reel-to-reel
arrangement 1 of this disclosure, the optimal angle is about
90.+-.5.degree.. Deviations from this angle may result in
undesirable twisting of and tension in the substrate material 3.
Continuous reel-to-reel arrangements 1 with other guiding roll 5
geometries and other guiding angles are also possible. Such
arrangements 1 would, however, result in a more complicated
geometric structure which would be more complicated and more space
requiring to implement.
[0070] The radius of the guiding rolls 5 should be larger than what
causes the substrate material 3 to be deformed due to combination
of tensile stress and bending curvature which the substrate
material 3 is subject to in the continuous reel-to-reel arrangement
1. By using guiding rolls 5 with large enough radius, the substrate
material 3 may be transported from one material reel 2, 4 to
another in the continuous reel-to-reel arrangement 1 without being
subject to tensile stress or bending curvature that could cause
plastic deformation of the substrate material 3.
[0071] A minimum guiding roll 5 radius which may be used for a
specific substrate material 3 may be derived from the following
calculations: Elongation of a substrate material 3 due to bending
curvature is .epsilon.=.DELTA.L/L, wherein L is the geometrical
length of a substrate material 3 having thickness t. The substrate
material 3 is wrapped around a guiding roll 5 with radius R with a
contact angle .alpha.. Thereby, L=.alpha.(R+t/2). The outer surface
of the strip is elongated a(r+t). Thus the elongation due to
bending curvature may be written
.epsilon.=.alpha.[(R+t)-(R+t/2)]/.alpha.[R+t/2]=t/(2R+t), wherein t
is presumed to be tR=>.epsilon.=t/2R
The tensile stress in the substrate material 3 due to bending
curvature, .sigma..sub.B, is E.times..epsilon.=.sigma..sub.B,
wherein E is the Young's modulus of the specific substrate
material. The total tensile stress in the substrate material 3 is
then .sigma..sub.tot=.sigma..sub.B+.sigma..sub.p, wherein
.sigma..sub.p is the tensile stress due to tension forces, F,
acting on the substrate material 3 and may be expressed as
.sigma..sub.p=F/A, wherein A is the cross sectional area of the
substrate material 3. The smallest radius, R, of a guiding roll 5,
which may be used without plastically deforming the substrate
material 3, at a given tension force, F, is when the total tensile
stress, .sigma..sub.tot, is equal to the yield point,
.sigma..sub.0.2, of a given substrate material 3.
[0072] The yield point is a first point at which permanent
deformation of a stressed substrate material begins to take place.
For engineering purposes the yield point is taken as the point at
which a certain small amount of permanent deformation, here 0.2%,
.sigma..sub.0.2, has occurred in the substrate material 3.
[0073] A specific example with a stainless steel strip having a
Young's modulus of 200 MPa (N/mm.sup.2), a yield point,
.sigma..sub.0.2, of 290 MPa (N/mm.sup.2), a strip width of 3 mm and
a strip thickness of 0.1 mm, gives a smallest radius of the guiding
rolls 5 of 49 mm if the strip is stretched with a tension force, F,
of 25 N. If the tension force, F, is 30 N, the radius should be
increased to at least 53 mm to avoid plastic deformation of the
substrate material 3.
[0074] The tension force, F, acting on the substrate material 3 is
at its maximum when the substrate material 3 passes through the
treatment zone 6. The tension force acting on the substrate
material 3 is increased after the braking roll 12 and decreased
after the driving roll 13. Thereby, the risk of plastically
deforming the substrate material 3 during unwinding/winding is
low.
[0075] With this reel-to-reel arrangement 1 design the mechanical
demands required in the treatment zone 6 can be separated from the
mechanical demands put on the devices in the pay-out chamber 10 and
take-up chamber 11.
[0076] During the deposition of materials onto the substrate
material 3 in the deposition chamber 8, 8', energy in form of
condensation heat, thermal radiation and ion flux will increase the
temperature of the substrate material 3. Since the process normally
takes place in a controlled vacuum atmosphere with a pressure in
the order of 1-10 mTorr, convection cooling is negligible. The only
significant cooling method is by thermal radiation or conduction. A
rough and simplified calculation model shows that given a normal
deposition process using a substrate material 3 which is a thin and
flat strip, will take more than 20 seconds to cool down from 600 K
down to 400 K just by radiation cooling. In many process
situations, this is a too long time since the transportation time
from the deposition chamber 8, 8' to the winding material reel 4
will be below this time frame. Since the driving roll 13 and other
guiding rolls 5 in the take-up chamber 11 are made of materials
that are chosen for their large friction and low tendency to
scratch the substrate material 3, they are not very resistant to
elevated temperatures. In order to cool down the substrate material
3 to temperatures suited for the guiding rolls 5, a cooling roll 14
(FIG. 1) can be placed close to the exit of the treatment zone
6.
[0077] The cooling roll 14 should be able to quickly absorb the
heat from the substrate material 3 by conducting and transporting
the heat from the substrate material 3 contact area. Suitable
cooling roll 14 surfaces could be any metal with good heat
conductivity that will not smear or react with the freshly
deposited surface of the substrate material 3. An alternative
material choice could be a heat conductive ceramic material such as
aluminium oxide.
[0078] One of the guiding rolls 5 in the pay-out chamber 10
(preferably the second last or the last guiding roll 5) is carrying
a voltage, i.e. a biasing roll 15, FIG. 1. For some applications a
substrate material 3 biased with a voltage may be preferred in the
treatment zone 6. The voltage may be applied to the biasing roll 15
with a suitable sliding brush contacting the surface of the guiding
roll 5.
[0079] Depending on the preferred orientation of the substrate
material 3, an end stage roll (not shown) may be included before
the treatment zone 6. This end stage roll may be used if the
substrate material 3 is to be fed in horizontal position through
the deposition zone 6.
[0080] A system in which at least two continuous reel-to-reel
arrangements 1 are arranged may be used for simultaneous
transportation of at least two substrate materials 3.
[0081] In FIG. 5 a pay-out chamber 10/take-up chamber 11 of such a
system is shown. In the embodiment shown in FIG. 5 the system
comprises eight continuous reel-to reel arrangements 1, including
eight winding material reels 2/unwinding material reels 4, eight
braking rolls 12/driving rolls 13. In addition, the system also
comprises one common treatment zone 6. The eight substrate
materials 3 in the system are arranged substantially in
parallel.
[0082] The number of continuous reel-to-reel arrangements 1 in the
system may vary. In some applications as few as two arrangements 1
are used in the system and sometimes a system may comprise up to
ten or more arrangements 1.
[0083] The system enables simultaneous transportation of more than
one substrate material 3 through at least one common treatment zone
6 without having the different substrate materials 3 touching each
other. Each different substrate material 3 pass individual
adjusting guiding rolls 5 (that also can serve as biasing roll 15
or cooling roll 14), as seen in FIG. 5 and FIG. 6 including braking
rolls 12/driving rolls 13 in order to precisely keep the right
tension and position of the substrate material 3 within a certain
tolerance region when passing through the at least one common
treatment zone 6.
[0084] The position and distance between the substrate materials 3
in the system are also dependent on the individual tension of the
substrate materials 3 which is controlled by the braking rolls 12.
All guiding rolls 5 may rotate individually for each substrate
material 3 that is fed through the treatment zone 6. The driving
roll 13 normally rotates at a similar speed as the other driving
rolls 13 around the common axis. However, in case of that the
substrate material 3 is stopped (e.g. if the substrate material 3
is at the end), a torque limited brake will release inside that
specific driving roll 13 and it will stop rotating, while the other
substrate materials 3 can continue their motion in the system
independently.
* * * * *