Patent Publication Number: US-2013233136-A1

Title: Apparatus and Method for Supplying Deposition Material

Description:
CLAIM OF PRIORITY 
     This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 from an application earlier filed in the Korean Intellectual Property Office on the 7 th  of March 2012 and there duly assigned Serial No. 10-2012-0023573. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present information relates generally to an apparatus and method for supplying a deposition material. More particularly, the invention relates to an apparatus and method for supplying a deposition material to a crucible that melts the deposition material. 
     2. Description of the Related Art 
     As a display device which displays an image, the organic light emitting diode (OLED) display has come into the spotlight in recent years. 
     Unlike a liquid crystal display (LCD) device, the OLED display has a self-luminous characteristic and does not need a separate light source, thereby reducing its thickness and weight. Furthermore, the OLED display exhibits high-quality characteristics such as low power consumption, high luminance, and a high reaction speed. 
     In generation, the OLED display includes a first electrode, a second electrode, and an organic emission layer provided between the first and second electrodes, and the second electrode is formed as a single layer by deposition of a metal material. 
     A deposition material forming the second electrode is supplied to a crucible by an apparatus for supplying a deposition material, is melted therein, and is then vaporized from the crucible so that the second electrode is formed. 
     A conventional apparatus for supplying a deposition material supplies a deposition material as a deposition wire to the crucible using a nozzle, and when the deposition wire supplied to the crucible moves backward in the direction of the nozzle, an end portion of the deposition wire is fixed in a half-melt state to the nozzle of the apparatus so that an interference occurs when the deposition wire is supplied to the crucible again. 
     The above information disclosed in this Background section is only for enhancement of an understanding of the background of the described technology and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art. 
     SUMMARY OF THE INVENTION 
     The present invention has been developed in an effort to provide an apparatus and method for supplying a deposition material, the apparatus having the advantage of preventing a deposition wire from being fixed to a nozzle. 
     One aspect of the present invention provides an apparatus for supplying a deposition material to a crucible that melts the deposition material, and the apparatus for supplying the deposition material includes: a wire supply roll around which the deposition material is wound as a wire; a nozzle corresponding to the deposition crucible, and guiding the deposition wire into the deposition crucible; and a wire cutting unit disposed between the wire supplying roll and the nozzle to guide the deposition wire into the nozzle, and cutting the deposition wire into a predetermined length. 
     The wire cutting unit includes: a plurality of supply rolls respectively arranged opposite each other for interposing the deposition wire therebetween, and for moving the deposition wire in a direction of the nozzle by self-rotating; and a plurality of cutting rolls respectively arranged opposite each other and between the plurality of supply rolls and the nozzle for interposing the deposition wire therebetween, and for moving the deposition wire in the direction of the nozzle by self-rotating and, at the same time, cutting the deposition wire into a predetermined length. 
     One of the plurality of cutting rolls may include a cutter provided in a surface thereof. 
     The wire cutting unit may further include an interlocking belt for connection between rotation shafts of the plurality of supply rolls and rotation shafts of the plurality of cutting rolls. 
     The wire cutting unit may further include a guide channel provided between the plurality of supply rolls and the plurality of cutting rolls for guiding the position wire to the plurality of cutting rolls from the plurality of supply rolls. 
     One of the plurality of cutting rolls may include a groove formed in a surface thereof for insertion of the deposition wire thereinto, and the cutting roll may further include a cutter provided in the groove. 
     Another cutting roll disposed opposite the previously described cutting roll may have a flat surface. 
     The wire cutting unit may further include a plurality of stretching rolls disposed opposite each other for interposing the deposition wire between the plurality of cutting rolls and the nozzle, and for moving the deposition wire in the direction of the nozzle by self-rotating. 
     The plurality of stretching rolls may rotate faster than the plurality of supply rolls and the plurality of cutting rolls. 
     The deposition wire may include metal. 
     The apparatus for supplying the deposition material may further include one or more guide rolls provided between the wire supply roll and the wire cutting unit for guiding the deposition wire. 
     According to one exemplary embodiment, an apparatus for supplying a deposition material and for preventing a deposition wire from being fixed to a nozzle can be provided. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, in which like reference symbols indicate the same or similar components, wherein: 
         FIG. 1A  shows an apparatus for supplying a deposition material according to a first exemplary embodiment of the invention, and  FIG. 1B  shows a method for supplying the deposition material. 
         FIG. 2  shows a portion “A” of  FIG. 1A . 
         FIG. 3  shows a wire cutting unit of an apparatus for supplying a deposition material according to a second exemplary embodiment of the invention. 
         FIG. 4  shows a wire cutting unit of an apparatus for supplying a deposition material according to a third exemplary embodiment of the invention. 
         FIG. 5  shows a wire cutting unit of an apparatus for supplying a deposition material according to a fourth exemplary embodiment of the invention. 
         FIG. 6  shows a portion “B’ of  FIG. 5 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. As those skilled in the art will realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. 
     In order to clarify the present invention, parts that are not connected with the description will be omitted, and the same elements or equivalents are referred to by the same reference numerals throughout the specification. 
     In several embodiments, the same reference numerals are used for elements having the same configuration to representatively explain the elements in a first embodiment, and only a different configuration from that of the first embodiment will be described in other embodiments. 
     The size and thickness of each element are arbitrarily shown in the drawings, and the present invention is not necessarily limited thereto. 
     In addition, unless explicitly described to the contrary, the word “comprise” and variations such as “comprises” or “comprising” will be understood to imply the inclusion of stated elements but not the exclusion of any other elements. 
     Hereinafter, an apparatus for supplying a deposition material according to a first exemplary embodiment of the invention will be described with reference to  FIGS. 1A ,  1 B and  2 . The apparatus according to the first exemplary embodiment is a device for supplying a deposition material which forms a second electrode to a crucible, but the present invention is not limited thereto. Here, the second electrode is formed as a single layer and is included in an organic light emitting diode (OLED) display. 
       FIG. 1A  shows the apparatus for supplying the deposition material according to the first exemplary embodiment of the invention, and  FIG. 1B  shows a method for supplying the deposition material. 
     As shown in  FIG. 1A , the apparatus for supplying the deposition material according to the first exemplary embodiment supplies a deposition material to a deposition crucible  10  which melts the deposition material, and the apparatus includes a wire supply roll  100 , a guide roll  200 , a nozzle  300 , and a wire cutting unit  400 . 
     Deposition material in the form of deposition wire  20  is wound on a wire supply roll  100 . The deposition wire  20  may include a metal, particularly, aluminum (Al). The wire supply roll  100  self-rotates, and the deposition wire  20  is unwound and supplied to the guide roll  200  when the wire supply roll  100  rotates in a counterclockwise direction in the state shown in  FIG. 1A  (see step  30  of  FIG. 1B ). 
     The guide roll  200  is disposed between the wire supply roll  100  and the wire cutting unit  400 , and transports the deposition wire  20  to the wire cutting unit  400  from the wire supply roll  100  without being loosened by self-rotating. The guide roll  200  may be provided singularly or in plural, and the number of guide rolls  200  may be changed according to an installation space and an installation format. 
     The nozzle  300  corresponds to the deposition crucible  10 , and guides the deposition wire  20 , cut to a predetermined length by the wire cutting unit  400 , into the deposition crucible  10  through the guide roll  200  from the wire supply roll  100 . An end portion of the nozzle  300 , disposed opposite an inner side of the deposition crucible  10 , may be formed as a taper. 
     The wire cutting unit  400  is disposed between the wire supply roll  100  and the nozzle  300  so as to cut the deposition wire  20 , transferred without being sagged by the guide roll  200 , to a predetermined length (see steps  32  and  34  of  FIG. 1B ). Since the deposition wire  20  is cut to the predetermined length by the wire cutting unit  400 , the cut deposition wire  20  freely drops into the deposition crucible  10  from the nozzle  300  by gravity (see step  36  of  FIG. 1B ). Accordingly, the deposition wire  20  supplied to the deposition crucible  10  does not need to move backward in the direction of the nozzle  300  so that the deposition wire  20  can be prevented from being fixed in a half-melt state to the nozzle  300 . Accordingly, no interference occurs when the deposition wire  20  is supplied again to the deposition crucible  10  where melting of the deposition material takes place (see step  38  of  FIG. 1B ). 
       FIG. 2  shows the portion “A” of  FIG. 1 . 
     As shown in  FIG. 2 , the wire cutting unit  400  includes a plurality of supply rolls  410  and a plurality of cutting rolls  420 . 
     The plurality of supply rolls  410  are respectively disposed facing each other, interposing the deposition wire  20  therebetween, and they self-rotate so as to move the deposition wire  20  in the direction of the nozzle  300 . The plurality of supply rolls  410  that face each other respectively rotate in opposite directions so as to make the deposition wire  20  move toward the plurality of cutting rolls  420 . A driving unit, such as a gear, may be connected to at least one of the plurality of supply rolls  410  so as to drive rotation of the supply roll  410 . 
     The plurality of cutting rolls  420  are disposed between the plurality of supply rolls  410  and the nozzle  300 , and are respectively disposed facing each other with the deposition wire  20  interposed therebetween. The plurality of cutting rolls  420  self-rotate so as to move the deposition wire  20  in the direction of the nozzle  300  and, at the same time, cut the deposition wire  20  to the predetermined length. A driving unit, such as a gear, may be connected to at least one of the plurality of cutting rolls  420  so as to drive rotation of the cutting roll  420 . One of the plurality of cutting rolls  420  includes a cutter C provided in the surface thereof, and the plurality of cutting rolls  420  disposed facing each other respectively rotate in opposite directions so that the deposition wire  20  is moved in a direction of the nozzle  300  and, at the same time, is cut to the predetermined length by the cutter C provided in the surface of the cutting roll  420 . That is, the deposition wire  20  is cut to the predetermined length by the cutting roll  420  and freely drops into the deposition crucible  10  through the nozzle  300 . A plurality of cutters C may be included in the cutting roll  420  according to the predetermined cutting length of the deposition wire  20 . 
     As described, in the apparatus for supplying the deposition material according to the first exemplary embodiment, the deposition wire  20  is cut to the predetermined length by the cutter C provided in the surface of the cutting roll  420  of the wire cutting unit  400  so that the cut-out deposition wire  20  freely drops into the deposition crucible  10  from the nozzle  300  by gravity. Accordingly, there is no need to move the deposition wire  20  backward in the direction of the nozzle  300  after supplying of the deposition wire  20  to the deposition crucible  10 . That is, since the deposition wire  20  cannot be fixed to the nozzle  300  when the deposition wire  20  is in a half-melted state, the apparatus for supplying the deposition material according to the first exemplary embodiment is not interfered with by the nozzle  300  when supplying the deposition wire  20  back to the deposition crucible  10 . 
     An apparatus for supplying a deposition material according to a second exemplary embodiment will now be described with reference to  FIG. 3 . 
     Hereinafter, only characteristic parts distinguished from the first exemplary embodiment are selectively described and the other parts, the description of which is omitted, are as in the first exemplary embodiment. In the second exemplary embodiment, for better comprehension and ease of description, the same constituent elements are designated by the same reference numerals as in the first exemplary embodiment of the present invention. 
       FIG. 3  shows a wire cutting unit of the apparatus for supplying the deposition material according to the second exemplary embodiment of the invention. 
     As shown in  FIG. 3 , a wire cutting unit  402  of the apparatus for supplying the deposition material according to the second exemplary embodiment includes a plurality of supply rolls  410 , a plurality of cutting rolls  420 , and an interlocking belt  430 . 
     The interlocking belt  430  interconnects rotation shafts of a supply roll  410  and a cutting roll  420  which are adjacent to each other among the plurality of supply rolls  410  and the plurality of cutting rolls  420 . Since the rotation of the supply roll  410  and the rotation of the cutting roll  420  are interlocked by the interlocking belt  430 , rotations of the supply roll  410  and the cutting roll  420  can be interlocked even though a driving unit, such as a gear, is connected to only one of the supply roll  410  and the cutting roll  420 . Accordingly, rotation of one of the two rolls  410  and  420  can be prevented from being faster than rotation of the other so that a deposition wire between the supply roll  410  and the cutting roll  420  can be cut to a predetermined length without being stretched. 
     As described above, in the apparatus for supplying the deposition material according to the second exemplary embodiment, the wire cutting unit  402  includes the interlocking belt  430 , and thus the rotation of the supply roll  410  and the rotation of the cutting roll  420  are interlocked. Accordingly, the deposition wire  20  can be cut to the predetermined length without being stretched between the supply roll  410  and the cutting roll  420 . That is, since the deposition wire  20  is cut to the predetermined length without being stretched and is then supplied to a deposition crucible  10  through a nozzle  300 , the supply amount of the deposition wire  20  per hour with respect to the deposition crucible  10  can be controlled by controlling the supply roll  410  or the cutting roll  420  of the wire cutting unit  402 . 
     An apparatus for supplying a deposition material according to a third exemplary embodiment will now be described with reference to  FIG. 4 . 
     Hereinafter, only characteristic parts distinguished from the second exemplary embodiment are selectively described and the other parts, the description of which is omitted, are as in the second exemplary embodiment. In the third exemplary embodiment, for better comprehension and ease of description, the same constituent elements are designated by the same reference numerals as in the second exemplary embodiment. 
       FIG. 4  shows a wire cutting unit of the apparatus for supplying the deposition material according to a third exemplary embodiment of the invention. 
     As shown in  FIG. 4 , a wire cutting unit  403  of the apparatus for supplying the deposition material according to the third exemplary embodiment includes a plurality of supply rolls  410 , a plurality of cutting rolls  420 , an interlocking belt  430 , and a guide channel  440 . 
     The guide channel  440  is provided between the plurality of supply rolls  410  and the plurality of cutting rolls  420 , and guides a deposition wire  20  to the plurality of cutting rolls  420  from the plurality of supply rolls  410 . The guide channel  440  may be formed in the shape of a nozzle, but the shape of the guide channel  400  is not limited thereto. The guide channel  440  may have any shape that can guide the deposition wire  20  to the plurality of cutting rolls  420  from the plurality of supply rolls  410 . The guide channel  440  can prevent the deposition wire  20  from being loosened or separated from a channel between the supply roll  410  and the cutting roll  420 . 
     As described, in the apparatus for supplying the deposition material according to the third exemplary embodiment, the wire cutting unit  403  includes the interlocking belt  430  and the guide channel  440 , and thus the rotation of the supply roll  410  and the rotation of the cutting roll  420  can be interlocked and, at the same time, the deposition wire  20  can be prevented from being loosened or separated from the channel. Accordingly, the deposition wire  20  can be cut to the predetermined length without being stretched, loosened, or separated from the channel. That is, since the deposition wire  20  is cut to the predetermined length and then supplied to the deposition crucible  10  without being stretched, loosened, or separated from the channel, a proper amount of deposition wire  20  can be supplied to the deposition crucible  10  per unit so that the amount of the deposition wire  20  supplied per hour with respect to the deposition crucible  10  can be controlled by controlling the supply roll  410  or the cutting roll  420  of the wire cutting unit  403 , and separation of the deposition wire  20  from the wire cutting unit  403  can be prevented. That is, reliability of the apparatus for supplying the deposition material can be wholly improved. 
     An apparatus for supplying a deposition material according to a fourth exemplary embodiment will now be described with reference to  FIG. 5  and  FIG. 6 . 
     Hereinafter, only characteristic parts distinguished from the first exemplary embodiment are selectively described and the other parts, the description of which is omitted, are as in the first exemplary embodiment. In the fourth exemplary embodiment, for better comprehension and ease of description, the same constituent elements are designated by the same reference numerals as in the first exemplary embodiment. 
       FIG. 5  shows a wire cutting unit of an apparatus for supplying the deposition material according to the fourth exemplary embodiment of the invention. 
     As shown in  FIG. 5 , a wire cutting unit  404  of the apparatus for supplying the deposition material according to the fourth exemplary embodiment includes a plurality of supply rolls  410 , a plurality of cutting rolls  420 , and a plurality of stretching rolls  450 . 
     The plurality of stretching rolls  450  are disposed between the plurality of cutting rolls  420  and the nozzle  300 , and respectively face each other with a deposition wire  20  interposed therebetween. The plurality of stretching rolls  450  self-rotate so as to move the deposition wire  20  in the direction of the nozzle  300 . The plurality of stretching rolls  450  rotate faster than plurality of supply rolls  410  and the plurality of cutting rolls  420 . As described, since the plurality of stretching rolls  450  rotate faster than the plurality of supply rolls  410  and the plurality of cutting rolls  420 , the deposition wire  20  can be stretched even though the deposition wire  20  is not cut to a predetermined length by a cutter C of the cutting roll  420  so that the deposition wire  20  can be supplied to the deposition crucible  10  through the nozzle  10  by being cut due to a stretching force. 
       FIG. 6  shows a portion “B” of  FIG. 5 . 
     As shown in  FIG. 5  and  FIG. 6 , one of the plurality of cutting rolls  420  includes a groove G formed in the surface thereof for insertion of the deposition wire  20  into it, and the cutter C is provided in the groove G. In addition, the other cutting roll  420  disposed opposite the cutting roll  420  among the plurality of cutting rolls  420  has a flat surface. As described, since one of the plurality of cutting rolls  420 , which are disposed opposite each other, includes the groove G and the cutter C is provided in the groove G, and since the other cutting rolls  420  disposed opposite the cutting roll  420  has a flat surface, the deposition wire  20  inserted into the groove G can be cut by the cutter C provided in the groove G even through a gap is formed between the cutting rolls  420  disposed opposite each other among the plurality of cutting rolls  420 . 
     As described, in the apparatus for supplying the deposition material according to the fourth exemplary embodiment, one of the cutting rolls  420  includes the groove G and the cutter C provided in the groove G, and the other cutting roll  420  disposed opposite to the cutting roll  420  has a flat surface so that the deposition wire  20  inserted into the groove G can be cut by the cutter C provided in the groove G even through a gap is formed between the cutting rolls  420  disposed opposite each other. Although the deposition wire  20  is not cut by the cutter C, the deposition wire  20  is stretched by the stretching roll  450  so that the deposition wire  20  that is partially cut can be completely cut due to the stretching force applied to the deposition wire  20  and is then supplied to the deposition crucible  10  through the nozzle  300 . Accordingly, the deposition wire  20  can be cut to a predetermined length and then supplied to the deposition crucible  10 . That is, reliability of the apparatus for supplying the deposition material can be wholly improved. 
     While the invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.