Lamination apparatus and lamination method using the same

Abstract

The present invention is directed to a lamination apparatus and a lamination method using the same. The lamination apparatus includes a process chamber and a pump connected with one side of the process chamber for making the interior of the process chamber a vacuum. Inside the process chamber, a first and a second supply unit, an injection unit, and a bonding unit are provided. The first and the second supply units supply a first and a second metal sheet, respectively. The injection unit injects a bonding material between the first and the second metal sheets supplied, and the bonding unit bonds the first and the second metal sheets with each other. According to the present invention, a bonding force of the bonding material may be enhanced and various kinds of bonding materials may be used.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This U.S. non-provisional patent application claims priority under 35 U.S.C § 119 from Korean Patent Application 2005-81099 filed on Sep. 1, 2005, the entire contents of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

The present invention relates to a bonding apparatus and, more particularly, to a lamination apparatus and a lamination method using the same.

Generally, metal sheets are bonded by means of brazing, soldering, plasma welding or laser welding according to the kinds of metals.

Welding is wherein metal sheets are bonded by solidifying bonding surfaces of the metal sheets after partially fusing the bonding surfaces. Plasma welding or laser welding should be used to fully seal the interior defined by the bonding. Unfortunately, plasma welding and laser welding incur much higher costs than soldering. Namely, the plasma welding and the laser welding have a low economical efficiency.

Soldering is wherein metal sheets are bonded by solidifying a bonding material after fusing the bonding material having a lower fusing point than the metal sheets to flow between the metal sheets bonded by a capillary phenomenon. The soldering is performed at a temperature of 430 degrees centigrade or lower. Unlike the soldering, brazing is performed at a temperature of 430 degrees or higher. Soldering and brazing are selectively applied according to the kinds of metal sheets.

When metal sheets are bonded by means of soldering, there is a limitation in selecting a bonding material because the bonding material should have a lower fusing point than the metal sheets. Further, bonding materials may be different in thickness and become porous to drop in density. Since the soldering is performed in the air, the bonding materials are apt to be oxidized. For these reasons, bonding force of a bonding material may diminish considerably.

SUMMARY OF THE INVENTION

Exemplary embodiments of the present invention are directed to a lamination apparatus and a lamination method using the same. In an exemplary embodiment, the lamination apparatus may include a process chamber; a first supply unit and a second supply unit disposed inside the process chamber for supplying a first and a second metal sheet, respectively; an injection unit for injecting a bonding material between the first and the second metal sheets supplied; a bonding unit for bonding the first and the second metal sheets with each other; and a pump connected to one side of the process chamber for making the interior of the process chamber a vacuum.

In an exemplary embodiment, the lamination method may include making the interior of a process chamber vacuum, the process chamber including a first and a second metal sheet; supplying the first and the second metal sheets; injecting a bonding material between the first and the second metal sheets supplied; bonding the first and the second metal sheets with each other; and heating the bonded metal sheets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a lamination apparatus according to the present invention.

FIG. 2 is a cross-sectional view when two lamination tapes are bonded by the lamination apparatus according to the present invention.

FIG. 3 is a cross-sectional view of a metal lamination tape in which a superconductive tape and a stabilization metal tape are bonded by means of a conventional lamination method.

FIG. 4 is a cross-sectional view of a metal lamination tape in which a superconductive tape and a stabilization metal tape are bonded by means of a lamination method according to the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which a preferred embodiment of the invention is shown. This invention, however, may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, the thicknesses of elements are exaggerated for clarity. Like numbers refer to like elements throughout.

A lamination apparatus according to the present invention is illustrated in FIG. 1. A first reel 21, a second reel 22, and a third reel 23 are disposed inside a process chamber 10. A first metal lamination tape 1t wound on the first reel 21 is provided by rotation of the first reel 21, and a second metal lamination tape 2t wound on the second reel 22 is provided by rotation of the second reel 22.

A metal evaporator 30 injects metallic vapor that is a bonding material 30m between the first and second metal lamination tapes 1t and 2t provided. The metal evaporator 30 includes a sealed housing 30h and an injection outlet 30e. A metallic substance is introduced into the housing 30h through a sample slot (not shown) formed at the housing 30h and inert gas is introduced into the housing 30h through a gas inlet (not shown). At this point, instead of inert gas, a metallic substance may be injected thereinto after turning to a high-temperature vapor. Inside the housing 30h, heating means (not shown) is provided for evaporating the metallic substance introduced into the housing 30h. The inert gas and evaporated metallic substance inside the housing 30h are injected fast through the injection outlet 30e. A width of the injection outlet 30e may be equal to that of the first or second metal lamination tape 1t or 2t. The evaporated metallic substance injected becomes the bonding material 30m, bonding the first and second metal lamination tapes 1t and 2t with each other. Metallic substances used as bonding materials are, for example, silver (Ag), zinc (Zn), copper (Cu), lead (Pb) and so forth. A temperature controller 34 is connected with the heating means for constantly controlling a temperature of the metallic substance. A position adjuster 32 is connected with the bottom of the metal evaporator 30 for adjusting the position of the metal evaporator 30. In order to enhance a deposition efficiency of the bonding material 30m, the injection outlet 30e is maximally closely adjacent to a bonding portion of the first and second metal lamination tapes 1t and 2t. In the metal evaporator 30, metal evaporation may be done by heating using a heater or high-frequency induction heating.

A heat shielding film 36 may be provided between the metal evaporator 30 and the metal lamination tapes 1t and 2t for preventing radiant heat of the metal evaporator 30 from excessively heating the metal lamination tapes t1 and t2. A bonding unit 25 enables the first and second metal lamination tapes 1t and 2t to adhere closely and to be bonded with each other, which is done by rotation of a roller.

The first and second metal lamination tapes are bonded with each other, constituting a metal lamination tape t3. The metal lamination tape t3 is wound on the third reel 23.

A heater 40 may be provided between the roller 25 and the third reel 23. The heater 40 may be one selected from the group consisting of a high-frequency induction heater, an infrared heater, and a halogen heater. The heater 40 may be installed inside the roller 25. The heater 40 heats the metal lamination tape 3t to enhance a bonding force. The heating temperature is lower than a fusing point of the bonding material 30m.

A pump 50 is disposed at one side of the process chamber 10, making the interior of the process chamber 10 a vacuum. Thus, the metallic substance evaporated by the metal evaporator 30 may be provided to a bonding portion of the first and second metal lamination tapes 1t and 2t without being oxidized. An adsorption sheet 55 may be provided between the process chamber 10 and the pump 50. The adsorption sheet 55 adsorbs the metallic vapor, i.e., the bonding material 30m to prevent the metallic vapor from flowing into the pump 50.

FIG. 2 is a cross-sectional view when two metal lamination tapes are bonded by the lamination apparatus according to the present invention.

Referring to FIG. 2, a first metal lamination tape 1t and a second metal lamination tape 2t are bonded by means of a bonding material 30m. The bonding material 30m sandwiched between the first and second metal lamination tapes 1t and 2t has a uniform thickness. Although not illustrated in this figure, the bonding material 30m has a high density and a fine structure.

FIG. 3 is a cross-sectional view of a metal lamination tape in which a first metal lamination tape and a second lamination tape are bonded by means of a conventional lamination method. FIG. 4 is a cross-sectional view of a metal lamination tape in which a first metal lamination tape and a second metal lamination tape are bonded by means of a lamination method according to the present invention.

Referring to FIG. 3, a superconductive tape 11t includes a substrate film 11t1, a buffer film 11t2, a superconductive film 11t3, and a protective film 11t4. The superconductive tape 11t and a stabilization metal tape 12t are bonded by a bonding material 30m. The buffer film 11t2 is made of a dielectric substance and sandwiched between the superconductive film 11t3 and the substrate film 11t1. Therefore, if overcurrent higher than critical current flows to the superconductive film 11t3, current flows through the stabilization metal tape 12t to restrict a capacity for the overcurrent.

Referring to FIG. 4, a superconductive tape 21t has the same structure as the conventional superconductive tape shown in FIG. 3. However, a width of the superconductive tape 21t is smaller than that of a stabilization metal tape 22t. Thus, if the superconductive tape 21t and the stabilization metal tape 22t are bonded by a bonding material 30m, the bonding material 30m is deposited even on a side of the superconductive tape 21t. Further, the bonding material 30m may surround the superconductive tape 21t. Since the bonding material 30m made of a metal, i.e., has conductivity, a superconductive film 21t3 may be electrically connected to a substrate film 21t1. This may enable the overcurrent of the superconductive film 21t3 to be bypassed through the substrate film 21t1 and the stabilization metal tape 22t. As a result, a capacity for the overcurrent may increase.

According to the present invention, vacuum deposition is conducted to easily raise a temperature and gain a high vapor pressure in vacuum even when a fusing point of a bonding material is high. Thus, lamination tapes are bonded using various kinds of bonding materials. Since a vapor pressure of a bonding material inside an injection unit is precisely controlled by a temperature controller, a constant deposition rate is obtained to make a thickness of the bonding material uniform. In the vacuum deposition, an element-state bonding material is injected fast to be deposited. Therefore, a high-density bonding film is obtained. Since the vacuum deposition is conducted while reducing oxidation reactive gas, the possibility of oxidizing the bonding material is reduced. Even when the oxidation reactive gas remains, a high vapor pressure established at a bonding portion of two lamination sheets prevents the oxidation reactive gas from flowing to the bonding portion. For these reasons, a bonding force of the bonding material is enhanced. In addition, the cost of manufacturing and maintaining a lamination apparatus using the vacuum deposition is low. In a case where a superconductive tape and a stabilization metal tape are bonded by means of the lamination method according to the invention, the superconductive tape is electrically connected to a substrate film because the conductive bonding material is deposited on a side of the superconductive tape. Thus, overcurrent is bypassed through the substrate film and the stabilization metal tape to increase a capacity for the overcurrent.

Although the present invention has been described in connection with the embodiment of the present invention illustrated in the accompanying drawings, it is not limited thereto. It will be apparent to those skilled in the art that various substitution, modifications and changes may be thereto without departing from the scope and spirit of the invention.

Claims

1. A lamination apparatus comprising:

a process chamber;

a first and a second supply unit disposed inside the process chamber for supplying a first and a second metal sheet, respectively;

an injection unit for injecting a bonding material between the first and the second metal sheets supplied;

a bonding unit for bonding the first and the second metal sheets with each other; and

a pump connected to one side of the process chamber for making the interior of the process chamber a vacuum.

2. The lamination apparatus of claim 1, wherein the metal sheets are tape-type sheets, respectively;

wherein the first and the second supply units are a first and a second reel, respectively; and

wherein the tape-type first and second metal sheets are supplied by rotation of the first and second reels.

3. The lamination apparatus of claim 2, wherein the first and the second reels are different in width.

4. The lamination apparatus of claim 2, wherein the bonding unit is a roller for rolling the first and the second metal sheets to closely stick and bond the same to each other.

5. The lamination apparatus of claim 2, further comprising a third reel on which the metal sheets bonded by the bonding unit are wound.

6. The lamination apparatus of claim 1, wherein the bonding unit bonds the first and the second metal sheets by closely sticking the same to each other.

7. The lamination apparatus of claim 1, further comprising a heater for heating the metal sheets bonded by the bonding unit to enhance a bonding force of the first and the second metal sheets.

8. The lamination apparatus of claim 7, wherein the heater is one selected from the group consisting of a high-frequency induction heater, an infrared heater, and a halogen heater.

9. The lamination apparatus of claim 7, wherein the heater is installed inside the bonding unit.

10. The lamination apparatus of claim 1, wherein the injection unit is a metal evaporator.

11. The lamination apparatus of claim 1, wherein an injection outlet of the injection unit has the same width as the first or the second metal sheet.

12. The lamination apparatus of claim 1, further comprising a position adjuster for adjusting a position of the injection unit relative to the bonding unit.

13. The lamination apparatus of claim 1, further comprising a temperature controller connected with the injection unit for controlling a temperature of the injection unit.

14. The lamination apparatus of claim 1, further comprising a heat shielding film interposed between the first metal sheet and the injection unit and between the second metal sheet and the injection unit.

15. The lamination apparatus of claim 1, further comprising an adsorption sheet disposed between the process chamber and the pump for adsorbing a vapor of the bonding material to prevent the bonding material from flowing into the pump.

16. A lamination method comprising:

making the interior of a process chamber a vacuum, the process chamber including a first and a second metal sheet;

supplying the first and the second metal sheets;

injecting a bonding material between the first and the second metal sheets supplied;

bonding the first and the second metal sheets with each other; and

heating the bonded metal sheets.

17. The lamination method of claim 16, wherein the first metal sheet is a superconductive tape, and the second metal sheet is a stabilization metal tape.

18. The lamination method of claim 17, wherein a width of the superconductive tape is smaller than that of the stabilization metal tape.

19. The lamination method of claim 18, wherein the superconductive tape includes a protective film, a superconductive film, a buffer film, and a substrate film that are stacked in the order named.

20. The lamination method of claim 19, wherein the bonding material surrounds the superconductive tape.

21. The lamination method of claim 17, wherein injection of the bonding material is done by means of metallic evaporation.

22. The lamination method of claim 21, wherein the metallic evaporation is

performed by heating using a heater or high-frequency induction heating.

23. The lamination method of claim 17, wherein heating the bonded metal sheets is done by means of one selected from the group consisting of high-frequency induction heating, infrared heating, and heating using a halogen heater.