REEL-TO-REEL SURFACE PRESS APPARATUS

Disclosed in a reel-to-reel surface press apparatus. The reel-to-reel surface press apparatus includes an uncoiler and a recoiler, both transferring a component in a reel-to-reel method, a press disposed between the uncoiler and the recoiler, comprising a press plate pressing the component, and having a plurality of reference holes at an equal pitch along an edge of the press plate, a feeder disposed at the rear of the uncoiler and moving the component, and a controller configured to control the component to be transferred based on at least any one of the plurality of reference holes.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of Korean Patent Application No. 10-2021-0128957, filed on Sep. 29, 2021, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.

BACKGROUND

The disclosure relates to an apparatus for pressing a surface of a component transferred in a reel-to-reel method, and more particularly, to a reel-to-reel surface press apparatus which may accurately control a press section.

2. Description of the Related Art

Photo solder resist (PSR) ink for coating a substrate surface is used to allow an electrical signal to flow only through a specific part of a substrate. When a substrate is coated with PSR ink, the substrate is preliminary dried and then pressed by using a roller, a surface pressure press, and the like to improve flatness of the PSR ink, and exposure, development, and curing processes are carried out to finalize the substrate.

A PSR planarization process is carried out for improving flatness of PSR ink to reduce generation of pores in a boundary surface between a die attachment film and a PSR ink surface. However, it is difficult to apply the PSR ink planarization process to a process of continuously coating and drying PSR ink, as in a reel-to-reel method, to make equipment with a vacuum planarization chamber, and furthermore, to uniformly adjust a thickness. Accordingly, the PSR planarization process that is difficult to be applied to a reel-to-reel type has been mainly applied to a panel type only.

In particular, in a reel-to-reel type, a reel is frequently paused and moved, for example, while reel driving is continuously performed in one process, an operation is performed in a stop state in a planarization process. In this process, as an opaque release film covers upper and lower portions of a substrate, a precise displacement of a substrate is difficult so that the substrate may not be accurately located at a desired operation position.

The background description above is technology information that the inventor possessed for the derivation of the disclosure or acquired in the derivation process of the disclosure, and it cannot be said that it is a known technology disclosed to the general public before the filing of the present application.

PRIOR ART DOCUMENT

Patent Literature

SUMMARY

Provided is a reel-to-reel surface press apparatus which may precisely control the position of a substrate by setting a reference point for sensing by forming holes at an edge of a press.

However, such an objective is exemplary, and the objective of the present disclosure to solve is not limited thereby.

According to an aspect of the disclosure, a reel-to-reel surface press apparatus includes an uncoiler and a recoiler, both transferring a component in a reel-to-reel method, a press disposed between the uncoiler and the recoiler, comprising a press plate pressing the component, and having a plurality of reference holes at an equal pitch along an edge of the press plate, a feeder disposed at the rear of the uncoiler and moving the component, and a controller configured to control the component to be transferred based on at least any one of the plurality of reference holes.

In an embodiment, the feeder may include a driving motor operating at the same pitch as the pitch of the plurality of reference holes, and the controller may be further configured to control the feeder to transfer the component at a pitch of an integer multiple of the pitch of the plurality of reference holes.

In an embodiment, the controller may be further configured to stop the uncoiler, the recoiler, and the feeder when the press presses the component, and to operate the uncoiler, the recoiler, and the feeder in a section other than a section in which the press presses the component, to continuously transfer the component.

In an embodiment, the reel-to-reel surface press apparatus may further include a pair of buffer rollers disposed between the uncoiler and the recoiler to face each other in a transfer direction of the component with the press therebetween, and moving in the height direction according to a tension applied to the component, wherein the controller may be further configured to control a movement speed of the component by detecting heights of the pair of buffer rollers.

In an embodiment, the reel-to-reel surface press apparatus may further include a release film attachment portion disposed between the uncoiler and the recoiler and attaching a release film to the component.

In an embodiment, the release film attachment portion may include a release film transfer roller disposed in each of front and rear of the press and attaching a release film to the, a thickness measurement sensor disposed at a side of the release film transfer roller and measuring a thickness of the release film in real time, and a release film driving motor configured to control an operation of the release film transfer roller based on a thickness of the release film measured by the thickness measurement sensor.

In an embodiment, the thickness measurement sensor may include an ultrasound sensor, the release film driving motor may include a servo motor, and the controller may be further configured to control the driving motor to maintain a tension applied to the release film based on the thickness measured by the thickness measurement sensor.

In an embodiment, the reel-to-reel surface press apparatus may further include a centering unit disposed in front of the release film attachment portion and adjusting a position of the release film in the width direction.

In an embodiment, the reel-to-reel surface press apparatus may further include a decover disposed at a rear of the release film attachment portion into which the component is input and including a removal blade to remove the release film.

In an embodiment, the removal blade of the decover may include a pair of removal blades provided apart from each other in the height direction, and as the removal blade located above descends, the component may be inserted between the pair of removal blades and the release film may be removed.

Other aspects, features, and advantages than those described above will become apparent from the following drawings, claims, and detailed description of the disclosure.

DETAILED DESCRIPTION

As the disclosure allows for various changes and numerous embodiments, embodiments will be illustrated in the drawings and described in detail in the written description. However, this is not intended to limit the disclosure to particular modes of practice, and it is to be appreciated that all changes, equivalents, and substitutes that do not depart from the spirit and technical scope of the disclosure are encompassed in the disclosure. In the description of the disclosure, even though illustrated in other embodiments, the same identification numbers are used for the same components.

Hereinafter, exemplary embodiments will be described in detail with reference to the accompanying drawings, and in the description with reference to the drawings, the same or corresponding constituents are indicated by the same reference numerals and redundant descriptions thereof are omitted.

In the following embodiment, it will be understood that although the terms “first,” “second,” etc. may be used herein to describe various components, these components should not be limited by these terms.

In the following embodiment, the expression of singularity in the specification includes the expression of plurality unless clearly specified otherwise in context.

In the following embodiment, when a part may “include” or “have” a certain constituent element, unless specified otherwise, it may not be construed to exclude another constituent element but may be construed to further include other constituent elements.

Sizes of components in the drawings may be exaggerated for convenience of explanation. For example, since sizes and thicknesses of components in the drawings are arbitrarily illustrated for convenience of explanation, the following embodiments are not limited thereto.

The terms used in the specification are merely used to describe embodiments, and are not intended to limit the disclosure. Also, terms such as “include” or “comprise” may be construed to denote a certain characteristic, number, step, operation, constituent element, or a combination thereof, but may not be construed to exclude the existence of or a possibility of addition of one or more other characteristics, numbers, steps, operations, constituent elements, or combinations thereof.

FIG.1illustrates a reel-to-reel surface press apparatus10according to an embodiment of the disclosure.FIG.2illustrates a press300according to an embodiment of the disclosure.FIG.3illustrates a feeder400according to an embodiment of the disclosure.FIG.4illustrates a state of a press according to an embodiment of the disclosure pressing a component.FIG.5illustrates a part of a release film attachment portion700according to an embodiment of the disclosure.FIG.6illustrates a centering unit900according to an embodiment of the disclosure.FIG.7illustrates a decover800according to an embodiment of the disclosure.

The reel-to-reel surface press apparatus10according to an embodiment of the disclosure (hereinafter, referred to as the “surface press apparatus”) is an apparatus for pressing a component P while transferring the component P in a reel-to-reel method. In an embodiment, the component P may be a package substrate, and the component P may not be a sheet type, but may be transferred by being attached to a release film and the like and wound around a reel.

The surface press apparatus10according to an embodiment of the disclosure may include an uncoiler100, a recoiler200, a press300, a feeder400, and the controller500.

As illustrated inFIG.1, the uncoiler100and the recoiler200may be disposed apart from each other, respectively, at one side and the other side of the surface press apparatus10. The component P may be wound around each of the uncoiler100and the recoiler200, and as the uncoiler100and the recoiler200are rotated, the component P wound around the uncoiler100is unwound and moved toward the recoiler200, and then, wound around the recoiler200. Accordingly, as a process proceeds, the diameters of the uncoiler100and the recoiler200, that is, the thickness of the component P being wound, may vary.

In an embodiment, the uncoiler100and the recoiler200may each include a drum having a cylindrical shape, and the like, around which the component P is wound, and a roller for rotating the drum. As the roller rotates, the uncoiler100is rotated, and thus, the component P is moved and undergoes a press process, and then, is wound around the recoiler200.

The press300is disposed between the uncoiler100and the recoiler200and presses the component P. The press300may planarize PSR ink by pressing the component P coated with the PSR ink.

In an embodiment, the press300includes a press plate310for pressing the component P and a plurality of reference holes320at an equal pitch along an edge of the press plate310.

In detail, as illustrated inFIG.2, the press300may include the press plate310having a width greater than the width of the component P. The shape of the press plate310is not particularly limited, and it suffices to cover the entire component P in a width direction thereof. For example, the press plate310may be a rectangle in which edges parallel to a transfer direction of the component P are long sides.

In an embodiment, the press plate310may be provided in a pair. For example, as illustrated inFIG.1, the pair of press plates310are disposed to face each other in the height direction with the component P therebetween, and at least one of the pair of press plates310moves relative to the other to press the component P.

In detail, as illustrated inFIG.4, when the component P enters a press area, the pair of press plates310maintain a state of being separated from each other (In this state, the component P may be in a state of being coated with a release film F). When the component P completely enters the press area, that is, to be located to correspond to the pair of press plates310, the transfer of the component P is stopped.

The pair of press plates310move toward each other to press the component P. Although the press plate310located below is illustrated as ascending, the press plate310located above may move downward, or both of the pair of press plates310may approach each other. After pressing, the pair of press plates310are separated from each other, and the transfer of the component P resumes.

In an embodiment, the reference holes320may be formed at the edge of the press plate310. For example, as illustrated inFIG.2, the reference holes320may be arranged along the long sides of the press plate310. In an embodiment, the reference holes320may be arranged at equal intervals, that is, at an equal pitch.

The reference holes320may be used to precisely control the position of the component P that has entered the press area (an area where the press process is performed, for example, an area covered by the press plate310). In other words, when the component P is temporarily stopped for pressing, a fine press process is possible by setting a stop position of the component P based on the reference holes320, which is described below.

AlthoughFIG.2illustrates four reference holes at each long side as the reference holes320, the number of reference holes320is not particularly limited.

A vision camera S is disposed at one side of the press300and detects the positions of the press300and the component P. The controller500described below may control the position of the component P with respect to any one of the reference holes320, based on the position detected by the vision camera S.

The feeder400is disposed at the rear of the uncoiler100and moves the component P. For example, as illustrated inFIG.1, the feeder400is disposed at the rear of the press300, and may stop the operation before the press process starts and move the component P after the press process is complete.

In an embodiment, the feeder400may include a fixed gripper410, a movable gripper420, and a driving motor430.

As illustrated inFIG.3, the fixed gripper410may be fixedly disposed in front of the feeder400. The fixed gripper410may include a clamp for fixing the component P. When the press process is performed on the component P, that is, the component P is stopped, the clamp of the fixed gripper410may fix the component P. Then, when the press process is complete, the clamp is separated from the component P so that the component P may move again.

The movable gripper420is disposed at the rear of the fixed gripper410, and may be moved by the driving motor430in the transfer direction of the component P. The movable gripper420, like the fixed gripper410, may include a clamp for fixing the component P, and may fix the component P or be separated from the component P to move the component P, according to the press process.

In an embodiment, the driving motor430may be a linear motor that is driven at the same pitch as the reference holes320formed in the press300. In other words, a distance of one step by which the driving motor430moves may be the same pitch as the pitch between the reference holes320. Accordingly, the movable gripper420may transfer the component P at the same pitch as the reference holes320, and thus, the surface press apparatus10according to an embodiment of the disclosure may delicately control the position of the component P.

In detail, according to the reel-to-reel method, while the component P is continuously transferred, in the press process, the component P needs to be stopped for its characteristics. Accordingly, when the component P enters the press area, the component P stops, the press process is performed, and then the component P is transferred again. In other words, in a general surface press apparatus, the component P unavoidably repeats transfer and strop, and in this process, due to allowance of the apparatus, inertia of the component P that moves, or the like, the component P may not be accurately located in the press area.

To address the above issue, in the surface press apparatus10according to an embodiment of the disclosure, any one of the reference holes320formed in the press300is set as a reference position, and the vision camera S detects the position of the component P in real time. When the component P enters the press area, the feeder400adjusts the position of the movable gripper420by using the driving motor430. In this state, the movable gripper420may move at a pitch of an integer multiple of the pitch of the reference holes320. In other words, as the driving motor430operates at the same pitch as the pitch of the reference holes320, the movable gripper420may also move at the same interval as the pitch of the reference holes320. Accordingly, the stop position of the component P may be finely adjusted.

The controller500controls other elements of the surface press apparatus10, may be connected to the uncoiler100, the recoiler200, the press300, the feeder400, and like in a wired/wireless manner to control the same.

In an embodiment, when the component P enters the press area, the controller500sets any one of the reference holes320of the press300as a reference point, based on position information received from the vision camera S. The controller500controls the feeder400to adjust the position of the component P based on the reference holes320corresponding thereto. For example, by controlling the driving motor430of the feeder400, the controller500may control the movable gripper420to move at a pitch of an integer multiple of the pitch of the reference holes320.

In an embodiment, the controller500stops the component P when the press300presses the component P, and move the component P before or after the press300presses the component P. For example, when the press300presses the component P, the controller500may stop the uncoiler100, the recoiler200, and the feeder400, and in a section other than a section in which the press300presses the component P, the controller500may stop the uncoiler100, the recoiler200, and the feeder400. In other words, the surface press apparatus10may stops the component P only in the press area, and continuously transfer the component P in an area other than the press area.

The surface press apparatus10may further include a pair of buffer rollers600. As illustrated inFIG.1, the pair of buffer rollers600may be disposed between the uncoiler100and the recoiler200to face each other in the transfer direction of the component P with the press300therebetween.

In an embodiment, the height of each of the buffer rollers600may vary depending on a tension applied to the component P. For example, when the tension applied to the component P is relatively large, the buffer rollers600ascends, and when the tension applied to the component P is relatively small, the buffer rollers600descends. Accordingly, the controller500may control a movement speed of the component P based on the heights of the buffer rollers600.

The surface press apparatus10may further include a release film attachment portion700. As illustrated inFIG.1, the release film attachment portion700is disposed between the uncoiler100and the recoiler200, and the release film F may be attached to the component P. For example, the release film attachment portion700may be disposed in each of the front and rear of the press300.

In an embodiment, the release film F that the release film attachment portion700applies to the component P may be a secondary release film to prevent the component P from being contaminated in the press process. In other words, before the secondary release film is attached by the release film attachment portion700, a primary release film may be attached to the component P. After the release film attachment portion700applies the secondary release film to the component P, the press process is performed on the component P, and then, after the secondary release film is collected, the primary release film may be removed by a decover800described below.

As illustrated inFIG.5, the release film attachment portion700may include a release film transfer roller710, a thickness measurement sensor720, and a release film driving motor730.

The release film transfer roller710, which is a roller around which the release film F is wound, is disposed in each of the front and rear of the press300, and may transfer the release film F by rotating in one direction. For example, the release film transfer roller710may attach the release film F to the component P that is transferred through the uncoiler100. Furthermore, a roller for attaching the release film F may be disposed in front of the press300, and a roller for collecting the release film F may be disposed at the rear of the press300.

The thickness measurement sensor720is disposed at one side of the release film transfer roller710, and may measure a thickness of the release film F wound around the release film transfer roller710. In detail, as the press process is performed, the thickness of the release film F wound around the release film transfer roller710gradually decreases, and thus, the magnitude of tension applied to the release film F varies. Accordingly, wrinkles and the like may occur in the release film F, which causes degradation of the quality of the component P.

To prevent the above, the thickness measurement sensor720may measure, in real time, the thickness of the release film F wound around the release film transfer roller710. The thickness measurement sensor720may be disposed in at least one of the roller for attaching the release film F and the roller for collecting the release film F. The controller500may control the release film driving motor730that rotates the release film transfer roller710to maintain constant the tension applied to the release film F based on the measured thickness.

In an embodiment, the thickness measurement sensor720may include an ultrasound sensor, and the release film driving motor730may include a servo motor. In other words, the controller500may the release film driving motor730with the thickness of the release film F measured by the thickness measurement sensor720as an input value, and the tension applied to the release film F as an output value. Accordingly, even when a thickness change occurs in the release film F, the tension applied to the release film F may be maintained constant by adjusting a driving speed, a driving cycle, or the like of the release film driving motor730.

The surface press apparatus10may further include the decover800.

As illustrated inFIGS.1and7, the decover800is disposed at the rear of the release film attachment portion700and used to remove the release film F attached to the component P after the press process is complete, in detail, the primary release film before being input to the release film attachment portion700.

In an embodiment, the decover800may include a removal blade810, a blade adjustment portion820, a window830, a support840, and a height adjustment portion850.

The removal blade810may remove the release film F attached to the component P, in detail the primary release film. For example, the removal blade810is provided in a pair disposed apart from each other in the height direction such that blades are disposed to point in a direction in which the component P enters. Accordingly, as the component P passes through the pair of removal blades810, the release film F is removed, and the component P removed of the release film F is discharged through the window830.

The blade adjustment portion820is a member for controlling the position or an orientation angle of the removal blade810. For example, when the thickness of the component P or the release film F is relatively thick, the blade adjustment portion820may control such that end portions of the removal blades810are further separated from each other. In an embodiment, the blade adjustment portion820, which is a roller, may rotate in contact with the removal blade810, and control the orientation angle of the removal blade810.

The window830is an open area formed inside the decover800, through which the component P may enter and exit. In an embodiment, the width of the window830may be greater than the width of the removal blade810.

Other members of the decover800may be disposed and fixed on the support840. Furthermore, the height adjustment portion850is disposed at one side of the support840, and may adjust the height of each of the removal blades810.

The surface press apparatus10may further include a centering unit900.

In an embodiment, the centering unit900is disposed at the rear of the release film attachment portion700into which the component P is input, among a pair of the release film attachment portions700, and may adjust the position of the release film F in the width direction. As illustrated inFIG.6, the centering unit900may include a first roller910, a second roller920, and a roller adjustment portion930.

The first roller910is a roller disposed in the upper side of the centering unit900, and may have a cylindrical shape with a flat outer circumferential surface. The second roller920is disposed below the first roller910, and may have a convex shape toward the first roller910. The release film F enters between the first roller910and the second roller920.

In an embodiment, the second roller920may adjust the position of the release film F. In detail, when the release film F is placed on the second roller920, the position of the second roller920may be adjusted by controlling the roller adjustment portion930. As the second roller920has a shape bent toward the first roller910, the position of the release film F may be adjusted in the width direction according to the position of the second roller920. Accordingly, by aligning the release film F, the release film F may be attached at an accurate position on the component P.

Next, the press process of the component P by using the surface press apparatus10according to an embodiment of the disclosure is described with reference toFIGS.1to7.

First, as the uncoiler100, the recoiler200, and the feeder400operate, the component P wound around the uncoiler100is unwound and transferred in one direction. The pair of buffer rollers600disposed at the rear of uncoiler100and in front of the recoiler200have the heights that vary according to the tension applied to the component P, and the controller500may control a component transfer speed of the uncoiler100and the recoiler200by detecting the heights of the buffer rollers600.

The component P is transferred to the release film attachment portion700by passing through the buffer rollers600. The release film attachment portion700may attach the release film F on the component P. The component P may be already coated with the primary release film, and the release film attachment portion700may attach the secondary release film to the component P before the component P enters the press300. As the release film transfer roller710of the release film attachment portion700rotates, the release film F is attached on the component P, and the thickness measurement sensor720detects, in real time, the thickness of the release film F wound around the release film transfer roller710. The controller500may control the release film driving motor730to apply a constant tension to the release film F, based on the measured thickness.

In an embodiment, the centering unit900may be disposed at the rear of the release film transfer roller710of the release film attachment portion700into which the component P enters. The centering unit900may center the release film F by adjusting the position of the second roller920that is an expander roller having a bent shape.

When the component P enters the press area, the controller500set a stop position of the component P. In detail, the controller500controls the feeder400based on any one of the reference holes320of the reference holes320of the press plate310. The driving motor430of the feeder400may rotate at the same pitch as the pitch of the reference holes320of the press plate310, and the controller500may set the stop position of the component P by controlling the position of the movable gripper420.

When the component P arrives at the stop position, the controller500stops the component P so as not to be further transferred. In other words, the controller500stops the uncoiler100, the recoiler200, and the feeder400to prevent the component P from being further transferred. The fixed gripper410and the movable gripper420of the feeder400may be stopped fixing the component P.

When the component P is stopped, the press plates310are moved toward each other to press the component P. When the press process ends, the press plates310are moved again, and the controller500operates the uncoiler100, the recoiler200, and the feeder400to transfer the component P.

When the component P passes through the press300, the release film transfer roller710of the release film attachment portion700collects the release film F.

When the component P arrives at the decover800, a front end of the removal blade810of the decover800contacts the boundary between the component P and the release film F. As the component P is transferred with the removal blade810being fixed, the release film F may be delaminated from the component P.

The surface press apparatus10according to an embodiment of the disclosure may perform an accurate press process on the component P transferred in a reel-to-reel method.

The surface press apparatus10according to an embodiment of the disclosure may instantly respond to a change in the tensions applied to the component P and the release film F as the process proceeds, the quality of press process may be improved.

The surface press apparatus10according to an embodiment of the disclosure may reduce the total process by configuring the decover function in line with the press process.

As such, although embodiments have been described, these are merely exemplary. Those skilled in the art to which the present disclosure pertains could make various modifications and changes from these descriptions. Accordingly, the technical protection scope of the disclosure should be construed based on the accompanying claims.

The specific technical content described in an embodiment is merely an embodiment, not defining the technical scope of the embodiment. In order to describe the description of the invention concisely and clearly, the description of the general technology and configuration according to the related art may be omitted. Furthermore, connection lines or connection members between the constituent elements shown in the drawings are merely illustrative of functional connections and/or physical or circuit connections. In an actual device, a connection between the constituent elements may be indicated by various functional connections, physical connections, or circuit connections that can be replaced or added. Furthermore, no item or component is essential to the practice of the disclosure unless the element is specifically described as “essential” or “critical.”

The use of terms “a” and “an” and “the” and similar referents in the context of describing the disclosure are to be construed to cover both the singular and the plural. Furthermore, recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. Furthermore, the steps of all methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The embodiment is not limited to the described order of the steps. The use of any and all examples, or language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. Furthermore, numerous modifications and adaptations will be readily apparent to those of ordinary skill in this art without departing from the spirit and scope of the disclosure.