Abstract:
A laser processing apparatus using a laser. The laser processing apparatus includes a light source for generating a hollow laser beam in a first direction; a reflection member for changing a path of the hollow laser beam toward the first direction into a second direction toward the substrate; a lens for collecting the hollow laser beam reflected by the reflection member; and an air supply unit for supplying air toward particles generated while the substrate is processed by the hollow laser beam, wherein the lens has a first hole passing through the lens, the reflection member has a second hole passing through the reflection member, and the first and second holes form a discharge path of the particles.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATION 
       [0001]    This application claims priority to and the benefit of Korean Patent Application No. 10-2012-0112663, filed on Oct. 10, 2012, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference. 
       BACKGROUND 
       [0002]    1. Field 
         [0003]    The following description relates to a laser processing apparatus. 
         [0004]    2. Description of the Related Art 
         [0005]    In general, a substrate for a display device, such as a liquid crystal display (LCD) device, a plasma display device, or an organic light-emitting display device, may be formed of glass. 
         [0006]    One of the methods of processing a substrate for a display device is a scribe wheel method. The scribe wheel method needs a dummy area having a size equal to or greater than a set or predetermined size and generates particles during the scribing process, and thus additional washing and drying processes for removing the particles are required. Also, the scribe wheel method results in an uneven processed surface and an increase in cost of consumption goods. 
         [0007]    In order to resolve the above-described problems, an apparatus using a laser is used. A laser process has advantages of an even processed surface and ease of control. During the laser process, particles or fumes are generated, and thus it is important to discharge the particles or fumes so as not to hinder processing of a substrate. 
       SUMMARY 
       [0008]    Aspects of embodiments of the present invention are directed toward a substrate processing apparatus, and more particular, a structure of a laser processing apparatus. 
         [0009]    According to an embodiment of the present invention, there is provided a laser processing apparatus using a laser, the laser processing apparatus including: a light source for generating a hollow laser beam in a first direction; a reflection member for changing a path of the hollow laser beam toward the first direction into a second direction toward the substrate; a lens for focusing the hollow laser beam reflected by the reflection member; and an air supply unit for supplying air toward particles generated while the substrate is processed by the hollow laser beam, wherein the lens has a first hole passing through the lens, the reflection member has a second hole passing through the reflection member, and the first and second holes form a discharge path of the particles. 
         [0010]    The first and second holes may be aligned on the same axial line. 
         [0011]    A size of the first hole may be different from that of the second hole. 
         [0012]    The size of the second hole may be smaller than that of the first hole. 
         [0013]    The first hole may include a first groove formed in a first spiral direction along an inner circumferential surface of the first hole, and the second hole may include a second groove formed in the first spiral direction along an inner circumferential surface of the second hole. 
         [0014]    The first groove may swivel around the inner circumferential surface of the first hole in an anticlockwise direction along a direction away from the substrate, and the second groove may swivel around the inner circumferential surface of the second hole in the anticlockwise direction along the direction away from the substrate. 
         [0015]    The air supply unit may supply air in a direction perpendicular to the second direction so as to move the particles to a location corresponding to the first hole. 
         [0016]    The laser processing apparatus may further include a sucking unit that is located at the end of the discharge path of the particles and discharges (sucks) the particles. 
         [0017]    The laser processing apparatus may further include a first window member that is located on the path of the hollow laser beam and spatially separates the light source and the discharge path so that the particles moving toward the first hole do not move toward the light source. 
         [0018]    The laser processing apparatus may further include a second window member that is disposed adjacent to a first surface of the lens facing the reflection member. 
         [0019]    The second window member may contact at least a part of the first surface of the lens. 
         [0020]    The laser processing apparatus may further include a third window member that is disposed adjacent to a second surface of the lens facing the substrate. 
         [0021]    The third window member may contact at least a part of the second surface of the lens. 
         [0022]    The laser processing apparatus may further include a blocking member that forms an air-wall by discharging air toward the substrate in the second direction to prevent the particles from moving to the outside. 
         [0023]    According to another embodiment of the present invention, there is provided a laser processing apparatus using a laser, the laser processing apparatus including: a light source for generating a hollow laser beam; a reflection member for changing a path of the hollow laser beam so that the hollow laser beam proceeds toward the substrate; a lens for focusing the hollow laser beam reflected by the reflection member; and an air supply unit for supplying air toward particles generated while the substrate is processed by the hollow laser beam, wherein the lens and the reflection member form a discharge path of the particles formed on the same axial line as an optical axis of the hollow laser beam. 
         [0024]    The lens may have a first hole aligned on the optical axis of the hollow laser beam, and the reflection member may have a second hole aligned on the optical axis of the hollow laser beam. 
         [0025]    A size of the second hole may be smaller than that of the first hole. 
         [0026]    The discharge path of the particles may include a groove having a spiral shape and swiveling around an inner circumferential surface of the discharge path of the particles in an anticlockwise direction along a direction away from the substrate in an inner surface of the discharge path of the particles. 
         [0027]    The laser processing apparatus may further include a first window member that is located on the path of the hollow laser beam and spatially separates the light source and the discharge path so that the particles do not move toward the light source. 
         [0028]    The laser processing apparatus may further include a window member that is disposed adjacent to at least one of a first surface of the lens, which faces the reflection member, and a second surface of the lens, which faces the substrate, and prevents the lens from being polluted by the particles. 
         [0029]    The window member may have a hole that forms the discharge path of the particles. 
         [0030]    The laser processing apparatus may further include a sucking unit that is located at the end of the discharge path of the particles and discharges (sucks) the particles. 
         [0031]    The laser processing apparatus may further include a blocking member that forms an air-wall by discharging air toward the substrate to prevent the particles from moving to the outside. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0032]    The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which: 
           [0033]      FIG. 1  is a schematic cross-sectional view of a laser processing apparatus according to an embodiment of the present invention; 
           [0034]      FIG. 2(   a ) shows a cross-section of a hollow laser beam generated by a light source shown in  FIG. 1 ; 
           [0035]      FIGS. 2(   b ) and  2 ( c ) are schematic graphs showing an intensity of a laser beam shown in  FIG. 2(   a ); 
           [0036]      FIG. 3  is a schematic cross-sectional view of a laser processing apparatus according to another embodiment of the present invention; 
           [0037]      FIG. 4  is a partial perspective view of a discharge path of particles, according to an embodiment of the present invention; 
           [0038]      FIG. 5  is a schematic cross-sectional view of a laser processing apparatus according to another embodiment of the present invention; and 
           [0039]      FIG. 6  is a schematic cross-sectional view of a laser processing apparatus according to another embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0040]    Various changes in form and details may be made to the present inventive concept and thus should not be construed as being limited to the embodiments set forth herein. The inventive concept is not limited to the embodiments described in the present description, and thus it should be understood that the inventive concept does not include every kind of variation example or alternative equivalent included in the spirit and scope of the inventive concept. Also, while describing the embodiments, detailed descriptions about related well-known functions or configurations that may diminish the clarity of the points of the embodiments of the present invention may be omitted. 
         [0041]    In the present description, terms such as ‘first’, ‘second’, etc. are used to describe various elements. However, it should be apparent that the elements may not be defined by these terms. The terms are used only for distinguishing one element from another element. 
         [0042]    The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
         [0043]    As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
         [0044]    In the drawings, the thicknesses of layers and regions are exaggerated for clarity. Like reference numerals denote like elements throughout the specification. 
         [0045]    Throughout the specification, it will also be understood that when an element such as layer, region, or substrate is referred to as being “on” another element, it can be directly on the other element, or intervening elements may also be present. Expressions such as “at least one of,” when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list. 
         [0046]    In the present specification, a first direction denotes an x-axis direction (or (−x)-axis direction) parallel to a substrate  10 , a second direction denotes a direction perpendicular to and toward the substrate  10 , that is, (−z)-axis direction, and a third direction indicates a direction perpendicular to and away from the substrate  10 , that is, a z-axis direction. 
         [0047]      FIG. 1  is a schematic cross-sectional view of a laser processing apparatus  1  according to an embodiment of the present invention.  FIG. 2(   a ) shows a cross-section of a hollow laser beam B generated by a light source  110  shown in  FIG. 1 .  FIGS. 2(   b ) and  2 ( c ) are schematic graphs showing an intensity of the hollow laser beam B shown in  FIG. 2(   a ). 
         [0048]    Referring to  FIG. 1 , the laser processing apparatus  1  of the current embodiment may include a housing  100 , the light source  110  which generates the hollow laser beam B (hereinafter, referred to as a laser beam), a reflection member  120  disposed on a path of the laser beam B, and a lens  130 . The laser processing apparatus  1  may also include an air supply unit  140  and a sucking (vacuum) unit  180  that are used to discharge particles generated during processing of the substrate  10 , 
         [0049]    Also, the laser processing apparatus  1  may include a first window member  150 , a second window member  160 , and a third window member  170  to prevent (protect) the light source  110  and the lens  130  from being polluted by the particles. A distance between the lens  130  and a top surface  11  of the substrate  10  may be  1  mm or greater. If the distance between the lens  130  and the top surface  11  of the substrate  10  is too short, the particles may hinder processing of the substrate  10 , and thus the processing precision of the substrate  10  may be decreased. 
         [0050]    The housing  100  may provide (guide) a path for the laser beam B generated by the light source  110  and provide (guide) a discharge path of the particles generated during the processing of the substrate  10 . The housing  100  may be bent to be approximately perpendicular. One end of an inner space of the housing  100  is adjacent to the light source  110 , and the other end may be adjacent to the substrate  10  to be processed. 
         [0051]    The light source  110  generates the laser beam B in the first direction. Referring to  FIG. 2(   a ), a cross-section of the laser beam B, which is a hollow laser beam, may be a circular shape (ring shape) having a set or predetermined thickness. 
         [0052]    The laser beam B may have a set or predetermined intensity I in a radial direction, and the intensity I of the laser beam B is shown in  FIG. 2(   b ) or  2 ( c ). Although the laser beam B is completely shown as a round circular shape in the current embodiment, the present invention is not limited thereto. Alternatively, if the laser beam B has a shape having a set or predetermined intensity in a radial direction, the laser beam B may have an oval circular shape. 
         [0053]    In the current embodiment, the same effect as using the lens  130  having a relatively large depth of focus (DOF) may be obtained by allowing the light source  110  to generate the laser beam B. In other words, even if the lens  130  for securing the DOF is not additionally prepared, a DOF sufficient to simultaneously process a bottom surface  12  of the substrate  10  and the top surface  11  of the substrate  10  may be secured by using the laser beam B. 
         [0054]    Also, since the hollow laser beam B is used in the laser processing apparatus  1 , it is possible to process the substrate  10  without hindrance by the particles that are discharged in the third direction which is located on the axial direction of an optical axis of the laser beam B. 
         [0055]    Referring back to  FIG. 1 , the reflection member  120  may bend the optical axis of the laser beam B. For example, the laser beam B proceeding along the first direction may be bent to the second direction that is a direction perpendicular to the substrate  10 . The path of the laser beam B is changed by the reflection member  120 , and thus the laser beam B may proceed toward the substrate  10 . The reflection member  120  may be a reflective mirror, but the present invention is not limited thereto. Alternatively, the reflection member  120  may be, for example, a prism. 
         [0056]    The lens  130  is an optical member for focusing the laser beam B, of which path is changed by the reflection member  120 , on the substrate  10 . The lens  130  may be disposed between the reflection member  120  and the substrate  10 . The top surface  11  and/or the bottom surface  12  are processed by the laser beam B focused on the substrate  10  by the lens  130 , and the particles generated during the processing of the substrate  10  may be discharged in the third direction away from the substrate  10 . 
         [0057]    The reflection member  120  and the lens  130  respectively has a first hole H 1  and a second hole H 2  penetrating therethrough. The first hole H 1  formed in the lens  130  and the second hole H 2  formed in the reflection member  120  may form the discharge path of the particles. The discharge path of the particles may be located on the axial direction of an optical axis of the laser beam B. The first hole H 1  and the second hole H 2  may be located on the same axle as, for example, a ±z-axis perpendicular to the substrate  10 . 
         [0058]    The air supply unit  140  is disposed in a lateral surface of the housing  100  and may supply air toward the particles generated from the substrate  10 . The particles are collected in a portion corresponding to the first hole H 1 /the second hole H 2  due to the air discharged by the air supply unit  140 , and thus the particles proceed along the discharge path formed by the first hole H 1  and the second hole H 2 . Here, the particles are discharged with the air toward a direction out of the housing  100 . 
         [0059]    A size of the first hole H 1  formed in the lens  130  may be greater than that of the second hole H 2  formed in the reflection member  120 . For example, a diameter R 2  of the second hole H 2  may be formed smaller than a diameter R 1  of the first hole H 1 . Accordingly, a difference in pressure between the first hole H 1  and the second hole H 2  is generated to thereby rapidly suck the particles moving in the third direction due to the difference in pressure. 
         [0060]    The sucking unit  180  is disposed at an end of the discharge path. The sucking unit  180  may help the air flow so that the particles move along the discharge path formed by the first hole H 1  and the second hole H 2 . The sucking unit  180  includes a storage space (not shown) to collect the particles having moved along the discharge path. 
         [0061]    In the current embodiment, the particles generated during the processing of the substrate  10  may move in the third direction along the discharge path formed by the first hole H 1  and the second hole H 2 , that is, in the z-axis direction. Here, if some of the particles moving in the third direction move toward the light source  110 , the particles may adhere to a surface of the light source  110 . If the particles adhere to the surface of the light source  110 , it may be difficult for the light source  110  to generate the laser beam B having a sufficient intensity, and a shape of the cross-section of the laser beam B may be distorted, and thus it is difficult to precisely process the substrate  10 . 
         [0062]    However, according to the current embodiment, since the first window member  150  spatially separates the light source  110  and the discharge path of the particles, the above-described problems may be prevented. For example, the first window member  150  may be located between the light source  110  and the reflection member  120  on the path of the laser beam B. Accordingly, even though some of the particles move toward the light source  110 , the particles are blocked by the first window member  150 , and thus the particles may be prevented from depositing or adhering to the surface of the light source  110 . 
         [0063]    The second window member  160  may be disposed adjacent to a first surface of the lens  130  to prevent the first surface of the lens  130 , for example, a top surface of the lens  130 , from being polluted by the particles. For example, the second window member  160  may be disposed to contact at least a part of the first surface of the lens  130  to prevent the particles passing through the first hole H 1  of the lens  130  from depositing or adhering onto the first surface of the lens  130 . 
         [0064]    The third window member  170  may be disposed adjacent to a second surface of the lens  130  so as to prevent a second surface of the lens  130 , for example, a bottom surface of the lens  130 , from being polluted by the particles. For example, the third window member  170  may be disposed to contact at least a part of the second surface of the lens  130  so as to prevent the particles generated from the substrate  10  from depositing or adhering to the bottom surface of the lens  130 . 
         [0065]    A third hole H 3  and a fourth hole H 4  are respectively formed in the second window member  160  and the third window member  170  to form the discharge path of the particles. The third hole H 3  and the fourth hole H 4  may be formed to have the same size of the first hole H 1  formed in the lens  130 . 
         [0066]      FIG. 3  is a schematic cross-sectional view of a laser processing apparatus  2  according to another embodiment of the present invention.  FIG. 4  is a partial perspective view of the discharge path of the particles, according to an embodiment of the present invention. 
         [0067]    Referring to  FIG. 3 , the laser processing apparatus  2  according to the current embodiment may include the housing  100 , the light source  110  which generates the laser beam B, a reflection member  220  disposed on a path of the laser beam B, a lens  230 , the air supply unit  140 , and the sucking unit  180 . The laser processing apparatus  2  may also include the first window member  150 , a second window member  260 , and a third window member  270  to prevent the light source  110  and the lens  230  from being polluted by the particles. A detailed structure and functions of the laser processing apparatus  2  are as described above with reference to  FIGS.1 to 2C . 
         [0068]    However, the laser processing apparatus  2  of the current embodiment is different from the laser processing apparatus  1  of the previous embodiment in that in the current embodiment, first and second grooves (e.g., first and second helical grooves) S 1  and S 2  having a spiral shape are formed on the discharge path of the particles, and thus thrust acting in the same axial direction as the second direction/third direction is additionally applied. Descriptions of components of the current embodiment are the same as those of the components described above with reference to  FIGS. 1 to 2C , and thus only differences between the previous embodiment and the current embodiment will be described below. 
         [0069]    Referring to  FIGS. 3 and 4 , the first and second grooves S 1  and S 2  having a spiral shape may be respectively formed in a first hole H 1 ′ and a second hole H 2 ′ that form the discharge path of the particles. For example, the first hole H 1 ′ may include the first groove S 1  that has a spiral shape and is formed along an inner circumferential surface of the first hole H 1 ′, and the second hole H 2 ′ may include the second groove S 2  that has a spiral shape and is formed along an inner circumferential surface of the second hole H 2 ′. 
         [0070]    The first groove S 1  and the second groove S 2  may be formed in a first spiral direction C 1 , for example, in an anticlockwise direction along the third direction away from the substrate  10 . The first groove S 1  may be formed to swivel around the inner circumferential surface of the first hole H 1 ′ in an anticlockwise direction along the first spiral direction, and the second groove S 2  may be formed to swivel around the inner circumferential surface of the second hole H 2 ′ in an anticlockwise direction along the second spiral direction so as to apply thrust to the particles moving in the third direction. In order to form sufficient thrust for discharging relatively heavy particles, pitches of the first groove S 1  and the second groove S 2  may be repeated at least three times. 
         [0071]    The particles, which are relatively large and heavy, among the particles generated from the substrate  10 , may not easily move only with a difference in pressure generated due to a difference in size between the first hole H 1 ′ and the second hole H 2 ′. However, in the present embodiment, thrust may be applied to discharge the heavy particles by forming the first and second grooves S 1  and S 2  having a spiral shape as described above. 
         [0072]    In the above embodiments, although the first and second grooves S 1  and S 2  having a spiral shape are respectively formed in the first hole H 1 ′ and the second hole H 2 ′, the first and second grooves S 1  and S 2  having a spiral shape may be formed in the entire discharge path of the particles. For example, the grooves having a spiral shape may also be formed in the first spiral direction in inner circumferences of a third hole H 3 ′ and a fourth hole H 4 ′ that are respectively formed in the second window member  260  and the third window member  270 . Also, the grooves having a spiral shape may be formed in a hole formed in the housing  100 , which is a discharge path through which the particles having passed through the second hole H 2 ′ are discharged to the outside. 
         [0073]      FIG. 5  is a schematic cross-sectional view of a laser processing apparatus  3  according to another embodiment of the present invention. 
         [0074]    Referring to  FIG. 5 , the laser processing apparatus  3  according to the current embodiment may include the housing  100 , the light source  110  which generates the laser beam B, the reflection member  120  disposed on a path of the laser beam B, the lens  130 , the air supply unit  140 , and the sucking unit  180 . The laser processing apparatus  3  may also include the first window member  150 , the second window member  160 , and the third window member  170  to prevent the light source  110  and the lens  130  from being polluted by the particles. A detailed structure and functions of the laser processing apparatus  3  are as described above with reference to  FIGS.1 to 2(   c ). 
         [0075]    However, the laser processing apparatus  3  of the current embodiment is different from the laser processing apparatus  1  of the previous embodiment in that the laser processing apparatus  3  of the current embodiment further includes a blocking member (or air-curtain member)  190  for forming an air-wall (air curtain) in the second direction. Descriptions of components of the current embodiment are the same as those of the components described above with reference to  FIGS. 1 to 2(   c ), and thus only differences between the previous embodiment and the current embodiment will be described below. 
         [0076]    The blocking member  190  may discharge air in the second direction to prevent the particles from moving to the outside through a space between the top surface  11  of the substrate  10  and the housing  100 . The air discharged from the blocking member  190  may be high-pressure air. 
         [0077]    Since the particles are prevented from moving out of the housing  100  through the space between the top surface  11  of the substrate  10  and the housing  100  by the particles, the particles generated during the processing of the substrate  10  may be discharged only through the discharge path without leaking. 
         [0078]      FIG. 6  is a schematic cross-sectional view of a laser processing apparatus  4  according to another embodiment of the present invention. 
         [0079]    Referring to  FIG. 6 , the laser processing apparatus  4  according to the current embodiment may include the housing  100 , the light source  110  which generates the laser beam B, the reflection member  220  disposed on a path of the laser beam B, the lens  230 , the air supply unit  140 , and the sucking unit  180 . The laser processing apparatus  4  may also include the first window member  150 , the second window member  260 , and the third window member  270  to prevent the light source  110  and the lens  230  from being polluted by the particles. The first and second grooves (e.g., first and second helical grooves) S 1  and S 2  are disposed on the discharge path of the particles. A detailed structure and functions of the laser processing apparatus  4  are as described above with reference to  FIG. 3 . 
         [0080]    However, the laser processing apparatus  4  of the current embodiment is different from the laser processing apparatus  2  of  FIG. 3  in that the laser processing apparatus  4  further includes the blocking member  190  for forming an air-wall in the second direction. Descriptions of components of the current embodiment are the same as those of the components described above with reference to  FIG. 3 , and thus only differences between the embodiment described with reference to  FIG. 3  and the current embodiment will be described below. 
         [0081]    The blocking member  190  may discharge air in the second direction to prevent the particles from moving to the outside toward a space between the top surface  11  of the substrate  10  and the housing  100 . The air discharged from the blocking member  190  may be high-pressure air. 
         [0082]    Since the particles are prevented from moving out of the housing  100  through the space between the top surface  11  of the substrate  10  and the housing  100  by the particles, the particles generated during the processing of the substrate  10  may be discharged only through the discharge path without leaking. 
         [0083]    The substrate  10  processed by the laser processing apparatus  1 ,  2 ,  3 , or  4  may be a substrate used to manufacture an organic light-emitting diode (OLED) apparatus. However, the present invention is not limited thereto, and the laser processing apparatuses  1 ,  2 ,  3 , and  4  may be used in various ways in industrial fields in which a substrate, for example, a semiconductor device or a solar cell, needs to be processed. 
         [0084]    Although discharging of particles has been described in the above embodiments, the present invention is not limited thereto. Thus, fumes generated during processing of a substrate may also be discharged through the same discharge path as the particles. 
         [0085]    According to one or more embodiments of the present invention, particles generated during processing of a substrate may be rapidly discharged through a set or predetermined path so as to prevent the particles from being formed around the substrate, which is to be processed, during a laser process, thereby obtaining an excellent process quality. 
         [0086]    Also, since a discharge path of the particles may be formed on the axial direction of an optical axis of the laser beam, the particles may be prevented from moving toward a processing area of the substrate and may be rapidly discharged/removed without hindering the processing of the substrate. 
         [0087]    While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims, and equivalents thereof.