Patent Publication Number: US-2023138692-A1

Title: Trap device and substrate processing apparatus comprising the same

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority from Korean Patent Application No. 10-2021-0147339 filed on Oct. 29, 2021 in the Korean Intellectual Property Office, and all the benefits accruing therefrom under 35 U.S.C. 119, the contents of which in its entirety are herein incorporated by reference. 
     BACKGROUND 
     1. Technical Field 
     The present disclosure relates to a trap device and a substrate processing apparatus comprising the same. 
     2. Description of the Related Art 
     In order to manufacture display devices such as an LCD panel, a PDP panel and an LED panel, printing is performed on a substrate using an inkjet head. A meniscus position in a nozzle of the inkjet head is one of the central elements that determine injection characteristics of ink. The meniscus position may be controlled by a meniscus pressure controller (MPC). 
     SUMMARY 
     Aspects of the present disclosure provide a substrate processing apparatus capable of stably controlling a meniscus position without malfunction. 
     Aspects of the present disclosure also provide a trap device used in a substrate processing apparatus. 
     The technical aspects of the present disclosure are not restricted to those set forth herein, and other unmentioned technical aspects will be clearly understood by one of ordinary skill in the art to which the present disclosure pertains by referencing the detailed description of the present disclosure given below. 
     TECHNICAL SOLUTION 
     According to an aspect of the present disclosure, there is provided a substrate processing apparatus, comprising: a head unit configured to discharge a medical fluid; a reservoir configured to store the medical fluid and supply the medical fluid to the head unit; a pressure control unit configured to control pressure in the reservoir; and a trap unit disposed between the reservoir and the pressure control unit and configured to trap a mist generated by the reservoir. 
     According to another aspect of the present disclosure, there is provided a substrate processing apparatus, comprising: a stage configured to process a substrate: a gantry disposed to cross the stage; and an inkjet head module installed in the gantry and configured to discharge ink to the substrate, wherein the inkjet head module comprises: a head unit configured to discharge the ink; a reservoir configured to store the ink and supply the ink to the head unit; a pressure control unit configured to control pressure in the reservoir; and a trap unit disposed between the reservoir and the pressure control unit and configured to trap a mist generated by the reservoir, wherein the trap unit comprises: a body; a first line installed in the body, connected to the reservoir and extending in a first direction; a second line installed in the body, connected to the pressure control unit and extending in a second direction; a third line installed to penetrate the first line and the second line from an upper surface of the body; and a trap layer installed on an inner wall of the first line or an inner wall of the second line and configured to trap the mist. 
     According to an aspect of the present disclosure, there is also provided a trap device comprising: a body; a first line installed in the body, connected to an inlet and extending in one direction; a second line installed in the body, connected to an outlet and extending in the one direction; a third line installed to penetrate the first line and the second line from an upper surface of the body; and a trap layer installed on an inner wall of the first line or an inner wall of the second line and configured to trap a mist. 
     Specific details of other embodiments are included in the detailed description and the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects and features of the present disclosure will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings, in which: 
         FIG.  1    is a block diagram illustrating a substrate processing apparatus according to some embodiments of the present disclosure; 
         FIG.  2    is a view illustrating in detail the supply reservoir, the trap unit, and the pressure control unit of  FIG.  1   . 
         FIG.  3    is a cross-sectional view illustrating a trap unit according to a first embodiment of the present disclosure; 
         FIG.  4    is a diagram illustrating a mist motion in the trap unit of  FIG.  3   ; 
         FIG.  5    is a cross-sectional view illustrating the trap unit according to a second embodiment of the present disclosure; 
         FIG.  6    is a cross-sectional view illustrating the trap unit according to a third embodiment of the present disclosure; 
         FIG.  7    is a cross-sectional view illustrating the trap unit according to a fourth embodiment of the present disclosure; 
         FIG.  8    is a cross-sectional view illustrating a trap unit according to a fifth embodiment of the present disclosure; 
         FIG.  9    is an exemplary diagram illustrating a facility to which the substrate processing apparatus according to some embodiments of the present disclosure is applied; and 
         FIG.  10    is a flowchart illustrating the substrate processing method according to some embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Hereinafter, embodiments of the present disclosure will be described with reference to the attached drawings. The merits and characteristics of the present disclosure and a method for achieving the merits and characteristics will become more apparent from the embodiments described in detail in conjunction with the accompanying drawings. However, the present disclosure is not limited to the disclosed embodiments, but may be implemented in various different ways. The embodiments are provided to only complete the disclosure of the present disclosure and to allow those skilled in the art to understand the category of the present disclosure. The present disclosure is defined by the category of the claims. Like numbers refer to like elements throughout the description of the figures. 
     The spatially relative terms “below,” “beneath,” “lower,” “above,” “upper” may be used to easily describe the correlation of a device or components with other devices or components. Spatially relative terms are to be understood as including terms in different directions of the device in use or operation in addition to the directions shown in the figures. For example, when flipping a device shown in the figure, a device described as “below” or “beneath” of another device may be placed “above” of another device. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device can also be oriented in other directions, so that spatially relative terms can be interpreted according to orientation. 
     Although the first, second, etc. are used to describe various elements, components and/or sections, these elements, components and/or sections are of course not limited by these terms. These terms are only used to distinguish one element, component or section from another element, component or section. Therefore, the first device, the first component, or the first section mentioned below may be a second device, a second component, or a second section within the technical spirit of the present disclosure. 
     Hereinafter, preferred embodiments according to the present disclosure are described in detail with reference to the accompanying drawings. The same or similar elements are assigned the same reference numerals irrespective of their reference numerals, and a redundant description thereof is omitted. 
       FIG.  1    is a block diagram illustrating a substrate processing apparatus according to some embodiments of the present disclosure.  FIG.  2    is a view illustrating in detail the supply reservoir, the trap unit, and the pressure control unit of  FIG.  1   . 
     First, referring to  FIG.  1   , a substrate processing apparatus  1  according to some embodiments of the present disclosure includes a head unit  210 , a supply reservoir  220 , a pressure control unit  230 , a buffer reservoir  240 , and a trap unit  100 . 
     The head unit  210  receives a medical fluid from the supply reservoir  220  and discharges the received medical fluid onto the substrate. The head unit  210  includes a plurality of nozzles configured to discharge the medical fluid onto the substrate. The medical fluid supplied to the head unit  210  may be supplied by gravity from the supply reservoir  220  disposed in an upper portion of the head unit  210 , but the present disclosure is not limited thereto. 
     The supply reservoir  220  is provided in the upper portion of the head unit  210 . The supply reservoir  220  receives and stores the medical fluid from the buffer reservoir  240  disposed in an upper portion of the supply reservoir  220 . 
     The pressure control unit  230  is connected to the supply reservoir  220  and controls pressure in the supply reservoir  220 . The pressure control unit  230  may be a meniscus pressure controller (MPC). 
     The pressure control unit  230  supplies positive pressure and/or negative pressure into the supply reservoir  220  to control the pressure in the supply reservoir  220 . 
     Specifically, the pressure control unit  230  may control the supply of the medical fluid from the supply reservoir  220  to the head unit  210  by controlling the pressure in the supply reservoir  220 . For example, the supply of the medical fluid from the supply reservoir  220  to the head unit  210  is performed by gravity, and the suspension of the medical fluid supply is performed by allowing the pressure control unit  230  to supply the negative pressure into the supply reservoir  220 . 
     Furthermore, the pressure control unit  230  controls the medical fluid to be in a concave meniscus state (i.e., a state where a surface of the medical fluid increases in the center relative to the surroundings due to a surface tension) in a plurality of nozzle ends provided in the head unit  210 . When the medical fluid is in the concave meniscus state, the medical fluid does not flow down from the end of the nozzle, which can reduce substrate defects. 
     Meanwhile, the buffer reservoir  240  receives and stores the medical fluid from an external medical fluid supply source (not shown), and supplies the received medical fluid to the supply reservoir  220 . When the medical fluid is supplied from the medical fluid supply source (not shown) to the buffer reservoir  240 , the inside of the medical fluid supply source is pressurized. When the medical fluid supply source is directly connected to the supply reservoir  220 , the internal pressure of the supply reservoir  220  is affected by the medical fluid supply source. However, since there is the buffer reservoir  240  between the medical fluid supply source and the supply reservoir  220 , the influence of the medical fluid supply source on the supply reservoir  220  may be blocked. 
     The trap unit  100  is installed between the supply reservoir  220  and the pressure control unit  230 . The trap unit  100  traps a mist generated in the supply reservoir  220 . 
     Herein, referring to  FIG.  2   , a heater  222  is installed in the supply reservoir  220  so as to control the temperature of the medical fluid. Although  FIG.  2    illustrates that the heater  222  is installed on the bottom surface of the supply reservoir  220 , the present disclosure is not limited thereto. In other words, the heater  222  may also be installed on a sidewall or an upper surface of the supply reservoir  220 . 
     The pressure control unit  230  is connected to the supply reservoir  220  through tubes  229  and  239 . An interlock sensor  232  is installed in the tube  239 . The interlock sensor  232  may be, for example, a liquid detection sensor. The pressure control unit  230  is vulnerable to liquid (i.e., medical fluid, etc.). When the pressure control unit  230  is exposed to liquid, malfunction may occur or meniscus control may become inaccurate. Accordingly, when the liquid is detected in the interlock sensor  232  before the liquid reaches the pressure control unit  230 , an interlock for stopping the operation occurs. 
     Meanwhile, the trap unit  100  is disposed between the supply reservoir  220  and the pressure control unit  230 . In other words, the trap unit  100  is connected to the supply reservoir  220  through the tube  229  and is connected to the pressure control unit  230  through the tube  239 . 
     As described above, since the heater  222  is installed in the supply reservoir  220 , mist (i.e., medical fluid mist or vaporized medical fluid) may be generated by the heating operation of the heater  222 . When the mist is delivered to the pressure control unit  230 , this may cause malfunction of the pressure control unit  230 . Alternatively, the installation purpose of the interlock sensor  232  is to detect the occurrence of overflow; however, when the mist is detected by the interlock sensor  232 , the interlock may take place. Although the medical fluid has not overflown from the supply reservoir  220 , the interlock sensor  232  may recognize that the medical fluid has overflown (i.e., a malfunction of the interlock sensor  232  occurred). 
     Accordingly, the trap unit  100  is disposed below the interlock sensor  232  to block the mist so that the mist generated by the supply reservoir  220  is not delivered to the interlock sensor  232  or the pressure control unit  230 . 
     The trap unit  100  is inclined at an acute angle (θ) with respect to an upper surface  220   a  of the supply reservoir  220 . As will be described below, a contact surface between the mist and the trap unit  100  is increased so that the mist may be more trapped in the trap unit  100 . Furthermore, when the liquefied medical fluid from the trap unit  100  drops to the supply reservoir  220 , it flows slowly along the inclined tube  229  to prevent bubbles from occurring in the supply reservoir  220 . 
     Hereinafter, various embodiments of the trap unit  100  will be described with reference to  FIGS.  3  to  7   . 
       FIG.  3    is a cross-sectional view illustrating a trap unit according to a first embodiment of the present disclosure.  FIG.  4    is a diagram illustrating a mist motion in the trap unit of  FIG.  3   . 
     First, referring to  FIG.  3   , the trap unit  100  according to a first embodiment of the present disclosure includes a body  105 , a first line  110 , a second line  120 , a third line  130 , a first trap layer  116 , and a second trap layer  126 . 
     The body  105  may be made of, for example, metal, and the first line  110 , the second line  120 , and the third line  130  are installed in the body  105 . 
     The first line  110  is connected to the supply reservoir  220  (see  FIG.  2   ) and extends in a first direction. The first trap layer  116  configured to trap the mist is installed on an inner wall of the first line  110 . The first trap layer  116  may include, for example, at least one of a mesh structure, a membrane structure and a filter structure, but the present disclosure is not limited thereto. The mesh structure may be made of metal such as SUS. The membrane structure and the filter structure may contain mist including pores inside, but the present disclosure is not limited thereto. 
     The second line  120  is connected to the pressure control unit  230  and extends in a second direction. As illustrated in the drawings, the first direction and the second direction may be substantially the same direction (i.e., a parallel direction), but the present disclosure is not limited thereto. The second trap layer  126  configured to trap mist is installed on an inner wall of the second line  120 . The second trap layer  126  may include, for example, at least one of the mesh structure, the membrane structure and the filter structure, but the present disclosure is not limited thereto. 
     The third line  130  connects the first line  110  to the second line  120 . For example, the third line  130  may be installed to penetrate the first line  110  and the second line  120  from an upper surface of the body  105 . A cover  140  may be installed on the upper surface of the body  105  to open or seal one side of the third line  130 . The cover  140  may be, for example, a screw, but the present disclosure is not limited thereto. 
     The first line  110  includes a first connector  111  connected to the third line  130 . The first line  110  includes an inlet  118  disposed in a first side (e.g., the left side) centered on the first connection port  111  and a first buffer region  119  disposed in a second side (e.g., the right side) centered thereon. A first connection member  110   a  for connection with the tube  229  is installed in the inlet  118 . The first connection member  110   a  may be inserted/fixed in the body  105 . 
     Similarly, the second line  120  includes a second connector  121  connected to the third line  130 . The second line  120  includes an outlet  128  disposed in the second side (e.g., the right side) centered on the second connection port  121  and a second buffer region  129  disposed in the first side (e.g., the left side) centered thereon. A second connection member  120   a  for connection with the tube  239  is installed in the outlet  128 . The second connection member  120   a  may be inserted/fixed in the body  105 . 
     In this way, the first line  110 , the second line  120 , and the third line  130  are configured so as to make the movement path of the mist as long as possible. When the movement path of the mist is lengthened, the mist can be liquefied in the trap unit  100  while the mist moves along the movement path. 
     Herein, the mist motion in the trap unit  100  will be described with reference to  FIG.  4   . For example, the first trap layer  116  and the second trap layer  126  are mesh structures made of metal SUS. 
     The mist generated from the supply reservoir  220  is inserted into the trap unit  100  via the first connection member  110   a  and the inlet  118  (see reference mark G 1 ). 
     A part of the mist inserted into the trap unit  100  increases to the first buffer region  119  and is trapped in the first buffer region  119  (see reference mark G 2 ). The mist trapped in the first buffer region  119  is liquefied while it is in contact with the first trap layer  116  with a relatively low temperature, and the liquefied medical fluid flows downwards along the extending direction of the first line  110  and then comes out of the inlet  118 . 
     In addition, a part of the mist inserted into the trap unit  100  reaches the third line  130  (see reference mark G 3 ). To ensure that the mist can move along the third line  130 , the mist needs to pass through the first trap layer  116  with a relatively low temperature. In the process of passing through the first trap layer  116 , the temperature of the mist may decrease or the liquefaction of the mist may occur. 
     In addition, a part of the mist inserted into the third line  130  reaches the second line  120  (see reference marks G 4  and G 5 ). To ensure that the mist can move along the second line  120 , the mist needs to pass through the second trap layer  126  with a relatively low temperature. In the process of passing through the second trap layer  126 , the temperature of the mist may decrease or the liquefaction of the mist may occur. 
     A part of the mist reaching the second line  120  goes to the second buffer region  129  and is trapped in the second buffer region  129  (see reference mark G 5 ). The mist trapped in the second buffer region  129  may be liquefied while it is in contact with the second trap layer  126  with a relatively low temperature, and the liquefied medical fluid may be collected in the second buffer region  129  or flow through the third line  130 . 
     A part of the mist reaching the second line  120  may move in the direction of the outlet  128  (see reference mark G 4 ). However, the mist is continuously in contact with the trap layers  116  and  126  with a relatively low temperature as it passes through a long movement path. Therefore, the mist does not reach the outlet  128  and is mostly liquefied. 
     Meanwhile, the liquefied medical fluid remains in the trap unit  100  or is moved to the supply reservoir  220  through the tube  229 . 
     When the cover  140  is opened, one side of the third line  130  extending to the upper surface of the body  105  is opened. Accordingly, the medical fluid remaining in the trap unit  100  may be extracted through the third line  130  extending to the upper surface of the body  105 . 
     In addition, the trap unit  100  is inclined at an acute angle (θ) with respect to the upper surface  220   a  of the supply reservoir  220 . Accordingly, the tube  229  configured to connect the trap unit  100  and the supply reservoir  220  is also inclined. As a result, the liquefied medical fluid flows slowly along the inclined tube  229  and drops into the supply reservoir  220 . Therefore, bubbles do not occur in the supply reservoir  220 . 
     Accordingly, the trap unit  100  blocks the mist so that the mist generated in the supply reservoir  220  is not delivered to the interlock sensor  232  or the pressure control unit  230 . Therefore, it is possible to prevent malfunction of the interlock sensor  232 , and to enable the pressure control unit  230  to stably operate. 
       FIG.  5    is a cross-sectional view illustrating the trap unit according to a second embodiment of the present disclosure. Hereinafter, the differences from those described with reference to  FIGS.  3  and  4    will be mainly described. 
     Referring to  FIG.  5   , in the trap unit  101  according to the second embodiment of the present disclosure, the first trap layer  116  may not be installed on the entire inner wall of the first line  110 , but may instead be installed only on a part of the inner wall of the first line  110 . The second trap layer  126  may not be installed on the entire inner wall of the second line  120 , but may instead be installed only on a part of the inner wall of the second line  120 . 
     Although  FIG.  5    illustrates that the first trap layer  116  is installed around the inlet  118  and is not installed in the first buffer region  119 , the present disclosure is not limited thereto. For example, the first trap layer  116  may not be installed around the inlet  118 , but may be installed in the first buffer region  119 . 
     Although  FIG.  5    illustrates that the second trap layer  126  is installed around the outlet  128  and is not installed in the second buffer region  129 , the present disclosure is not limited thereto. For example, the second trap layer  126  may not be installed around the outlet  128 , but may be installed in the second buffer region  129 . 
     Even if the trap layers  116  and  126  are installed only on a part of the first line  110  and the second line  120 , the mist may be liquefied as it passes through a long path. 
       FIG.  6    is a cross-sectional view illustrating the trap unit according to a third embodiment of the present disclosure.  FIG.  7    is a cross-sectional view illustrating the trap unit according to a fourth embodiment of the present disclosure. Hereinafter, the differences from those described with reference to  FIGS.  3  to  5    will be mainly described. 
     Referring to  FIG.  6   , unlike the trap unit  100  according to the first embodiment, the trap unit  102  according to the third embodiment of the present disclosure may not be provided with the first buffer region (see  119  of  FIG.  3   ). Referring to  FIG.  7   , unlike the trap unit  100  according to the first embodiment, the trap unit  103  according to the fourth embodiment of the present disclosure may not be provided with the second buffer region (see  129  of  FIG.  3   ). 
       FIG.  8    is a cross-sectional view illustrating a trap unit according to a fifth embodiment of the present disclosure. Hereinafter, the differences from those described with reference to  FIGS.  3  and  4    will be mainly described. 
     Referring to  FIG.  8   , third lines  131 ,  132  and  135  of a trap unit  104  according to the fifth embodiment of the present disclosure have a path longer than that of the third line  130  illustrated in  FIG.  3   . 
     For example, the first line  110  and the second line  120  may be parallel to each other, and the third line  131 ,  132  and  135  may include an intermediate line  135 , a first vertical line  131 , and a second vertical line  132 . The intermediate line  135  is disposed between the first line  110  and the second line  120  and is parallel to the first line  110  and the second line  120 . The first vertical line  131  connects the intermediate line  135  to the first line  110 . The second vertical line  132  connects the intermediate line  135  to the second line  120 . 
     The mist inserted into the inlet  118  may reach the outlet  128  only when it passes through the first line  110 , the first vertical line  131 , the intermediate line  135 , the second vertical line  132 , and the second line  120 . In other words, since an internal path of the trap unit  100  is significantly longer, the mist is liquefied as it passes through the internal path and does not reach the interlock sensor  232  or the pressure control unit  230 . 
       FIG.  9    is an exemplary diagram illustrating a facility to which the substrate processing apparatus according to some embodiments of the present disclosure is applied. 
     Referring to  FIG.  9   , the facility includes a stage PT, a gantry  410 , an inkjet head module  420 , and a control unit  450 . 
     The stage PT may extend long in a first direction Y, and the stage PT may move a substrate Gin the first direction Y (see reference mark S). For example, a plurality of holes are formed in the stage PT, and gas may come out through the holes to levitate a manufacturing substrate. In a state where the manufacturing substrate is levitated, a holder may hold and move the substrate, but the present disclosure is not limited thereto. 
     The gantry  410  is disposed on the stage PT. The gantry  410  is disposed to cross the stage PT. The gantry  410  is disposed to extend in a second direction X different from the first direction Y. 
     The inkjet head module  420  may be installed in the gantry  410  and may move in the second direction X along the gantry  410  (see reference numeral W). The inkjet head module  420  corresponds to the apparatus  1  described with reference to  FIGS.  1  to  8   . 
     In other words, the inkjet head module  420  includes the head unit configured to discharge the ink, the reservoir configured to store the ink and supply the medical fluid to the head unit, the pressure control unit configured to control the pressure in the reservoir, and the trap unit disposed between the reservoir and the pressure control unit to trap the mist generated in the reservoir. 
     Herein, the trap unit may include the body, the first line installed in the body, connected to the reservoir and extending in the first direction, the second line installed in the body, connected to the pressure control unit and extending in the second direction, the third line installed to penetrate the first line and the second line from the upper surface of the body, and a trap layer installed on the inner wall of the first line or the inner wall of the second line and configured to trap the mist. Herein, the body is inclined at the acute angle with respect to the upper surface of the reservoir. 
     The first line includes the first connector connected to the third line, and the first line further includes the inlet disposed in the first side centered on the first connector, and the first buffer region disposed in the second side centered thereon. The second line includes the second connector connected to the third line, and the second line further includes the outlet disposed in the second side centered on the second connector, and the second buffer region disposed in the first side centered thereon. 
     In addition, while the substrate G on the stage PT moves in the first direction Y (i.e., a swathing operation), the inkjet head module  420  may discharge droplets onto the substrate G while moving in the second direction X. 
     The control unit  450  controls the stage PT, the inkjet head module  420  and so forth. The control unit  450  is connected to a memory (not shown), and instructions for operating the stage PT, the inkjet head module  420  and so forth are stored in the memory. 
       FIG.  10    is a flowchart illustrating the substrate processing method according to some embodiments of the present disclosure. 
     Referring to  FIGS.  1  to  3  and  10   , the substrate processing apparatus  1  including the head unit  210 , the supply reservoir  220 , the pressure control unit  230 , and the trap unit  100 . 
     Furthermore, the temperature of the medical fluid in the supply reservoir  220  is controlled using the heater  222  installed in the supply reservoir  220  (S 401 ). 
     The mist (i.e., medical fluid mist or vaporized medical fluid) is generated by the heating operation of the heater  222  (S 403 ). 
     Furthermore, the mist generated in the supply reservoir  220  is delivered to the trap unit  100  through the tube  229 . The mist is liquefied while moving along the path in the trap unit  100 . In other words, the mist may be liquefied by the trap layers  116  and  126  and/or the long movement path (i.e., the first line  110 , the second line  120  or the third line  130 ). The liquefied medical fluid returns to the supply reservoir  220  along the tube  229  or is trapped in the trap unit  100  (S 405 ). 
     Then, the medical fluid remaining in the trap unit  100  is removed (S 407 ). When the cover  140  that seals one side of the third line  130  is opened, one side of the third line  130  extending to the upper surface of the body  105  is opened. Accordingly, the medical fluid remaining in the trap unit  100  may be extracted via the third line  130  extending to the upper surface of the body  105 . 
     Although the embodiments of the present disclosure have been described above with reference to the accompanying drawings, the present disclosure is not limited to the disclosed embodiments, but may be implemented in various different ways, and the present disclosure may be embodied in many different forms without changing technical subject matters and essential features as will be understood by those skilled in the art. Therefore, embodiments set forth herein are exemplary only and not to be construed as a limitation.