WIRE MANAGEMENT SYSTEM

Abstract

The invention relates to a wire management system for a wire saw having a cutting wire guided through a cutting area. The system comprises a wire supplying unit for supplying cutting wire to the cutting area and a wire receiving unit for receiving cutting wire from the cutting area. At least one of the wire supplying unit and the wire receiving unit comprises: at least one rotatable reservoir spool for carrying the cutting wire in overlapping windings, at least one rotatable storage spool for temporarily receiving the cutting wire in windings, wherein the rotational axis of the storage spool coincides with the rotational axis of the reservoir spool, a wire guiding means for guiding the wire when being wound up on the storage spool, such that the wire windings on the storage spool do not overlap each other and/or have a lower density than the windings on the reservoir spool.

Claims

1. A wire management system for a wire saw, comprising: a wire supplying unit for supplying a cutting wire to a cutting area of the wire saw, and a wire receiving unit for receiving cutting wire from the cutting area of the wire saw, wherein either the wire supplying unit or the wire receiving unit or both comprise(s): at least one rotatable reservoir spool configured to carry at least a portion of the cutting wire, said at least one rotatable reservoir spool having a reservoir spool axis, at least one rotatable storage spool configured to temporarily receive a portion of the cutting wire in windings, said at least one rotatable storage spool having a storage spool axis that essentially coincides with said reservoir spool axis, a wire guide movable along said storage spool axis, said wire guide configured to guide cutting wire towards said at least one rotatable storage spool, wherein said at least one rotatable reservoir spool is mounted to the at least one rotatable storage spool in a detachable manner.

2. The system according to claim 1, wherein the at least one rotatable reservoir spool is configured to carry at least a portion of the cutting wire in overlapping windings.

3. The system according to claim 1, wherein the wire guide is movable along said reservoir spool axis.

4. The system according to claim 1, wherein the wire management system comprises a cutting wire wrapped around said at least one rotatable reservoir spool and said at least one rotatable storage spool.

5. The system according to claim 1, wherein the wire saw has a cutting wire which is guided through a cutting area.

6. The system according to claim 1, wherein the wire guide is configured to guide cutting wire towards said at least one rotatable storage spool, such that the wire windings on the storage spool do not overlap each other and/or that the wire windings on the storage spool have a lower density than the windings on the reservoir spool.

7. The system according to claim 1, wherein said at least one rotatable reservoir spool is configured to carry cutting wire in a first set of windings, and wherein said at least one rotatable storage spool is configured to temporarily receive cutting wire in a second set of windings, wherein said second set of windings has a lower density than said first set of windings.

8. The wire management system of claim 1, wherein the rotatable storage spool receives the cutting wire in non-overlapping windings.

9. The wire management system of claim 1, wherein the rotatable reservoir spool has a first cutting wire density and the rotatable storage spool has a second cutting wire density, wherein the first cutting wire density is greater than the second cutting wire density.

10. The wire management system of claim 1, wherein the wire guide is also adapted to guide the cutting wire towards the rotatable reservoir spool.

11. The wire management system of claim 1, wherein the rotatable reservoir spool has a first axial length and the rotatable storage spool has a second axial length, wherein the second axial length is greater than the first axial length.

12. The wire management system of claim 1, wherein the mounting of the at least one rotatable reservoir spool to the at least one rotatable storage spool in a detachable manner comprises axial clamping.

13. The wire management system of claim 1, wherein the mounting of the at least one rotatable reservoir spool to the at least one rotatable storage spool in a detachable manner detachable manner comprises radial clamping.

14. The wire management system of claim 1, wherein the mounting of the at least one rotatable reservoir spool to the at least one rotatable storage spool in a detachable manner comprises pushed clamping.

15. The wire management system of claim 1, wherein the mounting of the at least one rotatable reservoir spool to the at least one rotatable storage spool in a detachable manner comprises eccentric clamping.

16. The wire management system of claim 1, wherein the mounting of the at least one rotatable reservoir spool to the at least one rotatable storage spool in a detachable manner comprises a linear actuator.

17. The wire management system of claim 1, wherein the mounting of the at least one rotatable reservoir spool to the at least one rotatable storage spool in a detachable manner comprises a tensioning rod.

18. A wire management system for a wire saw, comprising: a wire supplying unit for supplying a cutting wire to the cutting area of the wire saw and a wire receiving unit for receiving cutting wire from the cutting area of the wire saw, wherein either the wire supplying unit or the wire receiving unit or both comprise(s): at least one rotatable reservoir spool configured to carry at least a portion of the cutting wire, said at least one rotatable reservoir spool having a reservoir spool axis, at least one rotatable storage spool configured to temporarily receive a portion of the cutting wire in windings, said at least one rotatable storage spool (2) having a storage spool axis that essentially coincides with said reservoir spool axis, a wire guide movable along said storage spool axis, said wire guide configured to guide cutting wire towards said at least one rotatable storage spool, wherein the length of the wire carrying surface of said at least one rotatable storage spool is larger than the length of the wire carrying surface of said at least one rotatable reservoir spool.

19. The system according to claim 18, wherein the at least one rotatable reservoir spool is configured to carry at least a portion of the cutting wire in overlapping windings.

20. The system according to claim 18, wherein the wire guide is movable along said reservoir spool axis.

21. The system according to claim 18, wherein the wire management system comprises a cutting wire wrapped around said at least one rotatable reservoir spool and said at least one rotatable storage spool.

22. The system according to claim 18, wherein the wire saw has a cutting wire which is guided through a cutting area.

23. The system according to claim 18, wherein the wire guide is configured to guide cutting wire towards said at least one rotatable storage spool, such that the wire windings on the storage spool do not overlap each other and/or that the wire windings on the storage spool have a lower density than the windings on the reservoir spool.

24. The wire management system of claim 18, wherein the rotatable storage spool receives the cutting wire in non-overlapping windings.

25. The wire management system of claim 18, wherein the rotatable reservoir spool has a first cutting wire density and the rotatable storage spool has a second cutting wire density, wherein the first cutting wire density is greater than the second cutting wire density.

26. The wire management system of claim 18, wherein the wire guide is also adapted to guide the cutting wire towards the rotatable reservoir spool.

27. The wire management system of claim 18, wherein the rotatable reservoir spool has a first axial length and the rotatable storage spool has a second axial length, wherein the second axial length is greater than the first axial length.

28. The wire management system of claim 18, wherein the at least one rotatable reservoir spool is mounted to the at least one rotatable storage spool in a detachable manner comprising axial clamping.

29. The wire management system of claim 18, wherein the at least one rotatable reservoir spool is mounted to the at least one rotatable storage spool in a detachable manner comprising radial clamping.

30. The wire management system of claim 18, wherein the at least one rotatable reservoir spool is mounted to the at least one rotatable storage spool in a detachable manner comprising pushed clamping.

31. The wire management system of claim 18, the at least one rotatable reservoir spool is mounted to the at least one rotatable storage spool in a detachable manner comprising eccentric clamping.

32. The wire management system of claim 18, wherein the at least one rotatable reservoir spool is mounted to the at least one rotatable storage spool in a detachable manner comprising a linear actuator.

33. The wire management system of claim 18, wherein the at least one rotatable reservoir spool is mounted to the at least one rotatable storage spool in a detachable manner comprising a tension rod.

34. A wire management system for a wire saw, comprising: at least one wire supplying unit for supplying a cutting wire to a cutting area, at least one wire receiving unit for receiving the cutting wire from the cutting area, wherein either the at least one wire supplying unit or the at least one wire receiving unit or both comprise(s): a rotatable reservoir spool portion configured to carry the cutting wire, said rotatable reservoir spool portion having a reservoir spool axis, a rotatable storage spool portion configured to temporarily receive cutting wire windings, said rotatable storage spool portion having a storage spool axis that essentially coincides with said reservoir spool axis, said rotatable reservoir spool portion being coupled to said rotatable storage spool portion in a detachable manner, and a wire guide movable along said at least one wire supplying unit or said at least one wire receiving unit, said wire guide configured to guide cutting wire towards said rotatable reservoir spool portion and said rotatable storage spool portion.

35. The wire management system of claim 34, wherein the rotatable storage spool portion receives the cutting wire in non-overlapping windings.

36. The wire management system of claim 34, wherein the rotatable reservoir spool portion has a first cutting wire density and the rotatable storage spool portion has a second cutting wire density, wherein the first cutting wire density is greater than the second cutting wire density.

37. The wire management system of claim 34, wherein the rotatable reservoir spool portion has a first axial length and the rotatable storage spool portion has a second axial length, wherein the second axial length is greater than the first axial length.

38. The wire management system of claim 34, wherein the rotatable reservoir spool portion has a first wire carrying surface diameter and the rotatable storage spool portion has a second wire carrying surface diameter, wherein the first wire carrying surface diameter is greater than the second wire carrying surface diameter.

39. The wire management system of claim 34, wherein said rotatable reservoir spool portion is coupled to said rotatable storage spool portion in a detachable manner comprising axial clamping.

40. The wire management system of claim 34, wherein said rotatable reservoir spool portion is coupled to said rotatable storage spool portion in a detachable manner comprising radial clamping.

41. The wire management system of claim 34, wherein said rotatable reservoir spool portion is coupled to said rotatable storage spool portion in a detachable manner comprising pushed clamping.

42. The wire management system of claim 34, wherein said rotatable reservoir spool portion is coupled to said rotatable storage spool portion in a detachable manner comprising eccentric clamping.

43. The wire management system of claim 34, wherein said rotatable reservoir spool portion is coupled to said rotatable storage spool portion in a detachable manner comprising a linear actuator.

44. The wire management system of claim 34, wherein said rotatable reservoir spool portion is coupled to said rotatable storage spool portion in a detachable manner comprising a tensioning rod.

45. A wire management system for a wire saw, comprising: at least one wire supplying unit for supplying a cutting wire to a cutting area, at least one wire receiving unit for receiving the cutting wire from the cutting area, wherein either the at least one wire supplying unit or the at least one wire receiving unit or both comprise(s): a rotatable reservoir spool portion configured to carry the cutting wire, said rotatable reservoir spool portion having a reservoir spool axis, a rotatable storage spool portion configured to temporarily receive cutting wire windings, said rotatable storage spool portion having a storage spool axis that essentially coincides with said reservoir spool axis, wherein said rotatable reservoir spool portion has a first axial length and said rotatable storage spool portion has a second axial length, wherein said first axial length is less than said second axial length, and a wire guide movable along said at least one wire supplying unit or said at least one wire receiving unit, said wire guide configured to guide cutting wire to said rotatable reservoir spool portion and towards said rotatable storage spool portion.

46. The system of claim 46, wherein the rotatable reservoir spool portion is coupled to the rotatable storage spool portion in a detachable manner.

47. The system of claim 47, wherein the detachable manner comprises clamping.

48. The system of claim 46, wherein the rotatable storage spool portion receives the cutting wire in non-overlapping windings.

Description

[0094] Further embodiments according to the present disclosure are indicated in the figures and in the remaining disclosure, including drawings. The list of reference marks forms part of the disclosure. The invention will now be explained in detail by the drawings. In the drawings:

[0095] FIG. 1 shows a wire saw having a wire management system according to the invention,

[0096] FIG. 2 shows a wire management system with the storage spool carrying a cutting wire portion,

[0097] FIG. 3 shows the wire management system of FIG. 2 with the cutting wire being partially unwound from the storage spool,

[0098] FIG. 4 shows the wire management system of FIG. 2 with the cutting wire being completely unwound from the storage spool,

[0099] FIG. 5 shows the wire management system of FIG. 2 with the cutting wire being partially received by storage spool,

[0100] FIG. 6 shows the wire management system of FIG. 2 with the cutting wire being unwound from the reservoir spool,

[0101] FIG. 7 shows an embodiment of the wire management system each spool having a separate rotational drive,

[0102] FIG. 8 shows an embodiment in which the storage spool and the reservoir spool are fixedly connected with each other,

[0103] FIG. 9 shows an embodiment in which the transition area between the spools has guide elements for a smooth transition of the cutting wire,

[0104] FIG. 10 shows an embodiment in which the transition area has tapered shape,

[0105] FIG. 11 shows a reservoir spool without flanges,

[0106] FIGS. 12a to 12m show the steps of an inventive cutting method,

[0107] FIGS. 13a to 13l show the steps of an alternative inventive cutting method,

[0108] FIGS. 14 to 21 show the steps of an embodiment of the cutting method, and

[0109] FIGS. 22 and 23 the wear or abrasion of cutting wire sections.

[0110] FIG. 1 shows a wire saw 8 for cutting a piece of material, preferably semiconductor, sapphire or quartz material in form of an ingot, brick or core. The wire saw 8 has a cutting area 13 and wire guide rollers 14 guiding the cutting wire 3 through the cutting area 13 thereby forming from the cutting wire 3 a wire web. The wire saw 8 comprises drives 15 for alternately driving the cutting wire 3 in a first direction and a second direction which is opposite to the first direction. The wire saw according to present disclosure may also have wires crossing each other as is the case in a squarer. In addition, the cutting web in the cutting area may also consist of a single wire.

[0111] Wire saw 8 has a wire management system 7 comprising a wire supplying unit 5 for supplying cutting wire 3 to the cutting area 13 of the wire saw 8 and a wire receiving unit 6 for receiving cutting wire 3 from the cutting area 13 of the wire saw 8. In a so-called Pilgrim mode, the moving direction of the wire 3 is alternately reversed such that also the supplying unit 5 has a receiving function and the receiving unit 6 has a supplying function depending on the actual moving direction. According to the shown embodiment, however, when adding new cutting wire portions to the cutting area 13, this is done by winding an additional wire portion from the supplying unit 5, the supplying unit 5 comprising the reservoir spool 1 with new wire. The receiving unit 6 comprising a reservoir spool 1 for collecting used up wire for disposing of it.

[0112] In the embodiment of FIG. 1 both supplying unit 5 and receiving unit 6 are of similar construction.

[0113] Each unit comprises a rotatable reservoir spool 1 for carrying the cutting wire 3 in overlapping windings and a rotatable storage spool 2 for temporarily receiving the cutting wire 3 in windings (not shown). Preferably the windings on the storage spool 2 do not overlap.

[0114] As can be seen from FIG. 2, the rotational axis 2b of the storage spool 2 coincides with the rotational axis 1b of the reservoir spool 1.

[0115] Each unit comprises a wire guide 9 adapted for guiding the cutting wire 3 when being wound up on (or wound from) the respective storage spool 2, such that the wire windings on the storage spool 2 do not overlap each other and/or have a lower cutting wire density than the windings on the reservoir spool 1. In the present embodiment, the wire guide 9 is a traveler pulley 4 which is movable in a direction which is essentially parallel to the rotational axes of the spools 1, 2.

[0116] FIG. 2 shows a supply unit 5 (or a receiving unit 6) in more detail. The diameter of the wire carrying surface 2a of the storage spool 2 is larger than the diameter of the wire carrying surface 1a of the reservoir spool 1. The length of the wire carrying surface 2a of the storage spool 2 is larger than the length of the wire carrying surface 1a of the reservoir spool 1.

[0117] FIG. 2 shows the a situation in which storage spool 2 is almost completely wound with cutting wire 3. When moving the cutting wire 3 in the direction of the cutting area 13 (FIG. 13) wire is successively unwound from the storage spool 2. In FIG. 3 the cutting wire is partially unwound from storage spool 3 and in FIG. 4 storage spool 2 is free from cutting wire 3. During the unwinding procedure traveler pulley 4 continuously runs from right to left.

[0118] The wire supplying unit 5 and the wire receiving unit 6 each comprises a synchronizer capable of synchronizing the rotational speed of the reservoir spool 1 and the rotational speed of the storage spool 2 with each other. In the FIGS. 3 to 6 and 8 to 10 the synchronizer includes a fixed mechanical connection between the spools 1, 2. This ensures here, that the spools 1, 2 have the same rotational speed. In this case the storage spool 2 and the reservoir spool 1 have a common rotational drive.

[0119] In an embodiment shown in FIG. 7 each of the storage spool 2 and the reservoir spool 1 has its own rotational drive 10, 11, e.g. a motor. In this embodiment the synchronizer is a control device 16 connected to both the rotational drives 10, 11 and controlling their rotational speed. If a synchronizer is used for synchronization, the reservoir spool 1 and the storage spool 2 may be accelerated or decelerated independently to compensate of the difference in the diameter of their wire receiving surfaces or their wire windings top surfaces, respectively. Since the spools 1, 2 can be rotated independently, their speeds may also be changed independently and even in time parallel. Moreover, if the wire receiving surface of the storage spool 2 has a greater diameter (than the wire winding top surface on the reservoir spool), the rotational speed of the reservoir spool may be slightly higher so that when the wire crosses over from the reservoir spool to the storage spool, their wire winding top surfaces have the same speed. The same possibility may be used when going from the storage spool 2 to the reservoir spool 1.

[0120] Preferably, the reservoir spool 1 is mounted to the storage spool 2 in a detachable manner. This may be accomplished e.g. by a de-lockable snap-action mechanism, axial clamping, radial clamping, and pushed clamping. When supplying new wire to the wire saw, a complete spool can be attached to the storage spool or to a common axle. In axial clamping, bolts or tension rods are used, possibly in combination with a support ring (or a support disc) to clamp the reservoir spool to the storage spool. A spring may be used to control the force of the bolt (or tension rod). Alternatives for axial clamping are as follows: (1) multiple bolts positioned in e.g. a circular pattern, the bolts possibly comprising threaded rods and a nut, the bolts extending at least partially through the storage spool; (2) eccentric clamping may be used; (3) a linear actuator may be used to pull or push the spools together. In radial clamping, the spools may be held together via radial force. For example, radial inward clamping may be used. Radial outward clamping may also be used. In pushed clamping, a (cone-shaped) tailstock pushes the reservoir spool towards the storage spool.

[0121] In any case, or in other cases, a cone-like flange may be pulled into the reservoir spool and the flange is then e.g. bolted to the axle (the axle is shared between the reservoir spool and the storage spool). In other cases, a tensioning rod comprises a flange, and the flange is bolted to a portion of the storage spool adjacent to the reservoir spool. Using the exemplary mechanisms described above, the reservoir spool is detachable and thus replaceable without requiring a removal of the storage spool.

[0122] Regardless of the manner in which the reservoir spool is detachably mounted, its separability from the storage spool without any destructive effect is a critical element of the present invention which allows for the reinstalling of wire to be completed in a minimal amount of time.

[0123] The space or connection between the storage spool and the reservoir spool may comprise a transition area. In the embodiments of FIGS. 8, 9 and 10 a transition area 12 between the storage spool 2 and the reservoir spool 1 is provided. The transition area 12 may be a simple connection rod (FIG. 8) or may comprise guide elements for protecting the cutting wire in the transition area 12 (FIG. 9).

[0124] In FIG. 10, the transition area 12 has a tapered shape. The transition area 12 may formed by a separate member being inserted between storage spool 2 and reservoir spool 1 and may be soft to protect the wire.

[0125] The reservoir spool 1 and the storage spool 2 may be mounted on a common axle (FIG. 8). The axle may be supported between the reservoir spool 1 and the storage spool 2 by a support (FIG. 9). In this way the reservoir spool 1 can be mounted from one side only and thus being readily exchangeable. The mounting further can have a (static or rotating, free or forced) slanted portion (FIG. 9) that facilitates the cross-over of the wire 3 from the reservoir spool 1 to the storage spool 2 and vice versa. The support further increases stiffness of the system.

[0126] The wire carrying surface 2a of the storage spool 2 may comprise wire guiding grooves with a spiral run.

[0127] The reservoir spool 1 and the receiving spool 2 rotate synchronically, i.e. have the same rotational speed. At the start of a new spool of wire, the wire is mostly on the reservoir spool 1 of the supplying unit 5, but to a certain extent also around the storage spool 2. The wire runs over a traveler pulley 4 (which is a roll positioning the wire when spooling wire onto or off a roll) to the wire web. The distal end of the cutting wire 3 is connected to the reservoir spool 1 of the receiving unit 5.

[0128] FIG. 11 shows an embodiment of a reservoir spool 1 without flanges on its ends. Arranging the wire 3 in a trapezoid shape will hold the wire in the right place. If there are no flanges, the transition between reservoir spool and storage spool may be facilitated. The flange may also form the tapered shape of the transition area 12.

[0129] When the wire 3 starts cutting, the reservoir spool 1 and the associated storage spool 2 rotate (the upper part of both spools moves out of the plane of the drawing of FIG. 2). The wire 3 now rolls off the storage spool and the dancer pulley 20 which is held by pulley arms 21 keeps the tension in the wire constant and more or less perpendicular to the rotational axis of the storage spool 2 and the traveler pulley 4 makes sure that the wire windings are correctly positioned on the spool.

[0130] Rotating the storage spool 2 further removes virtually all wire 3 from the storage spool 2. Now there are two options: [0131] a) no addition of a new wire portion from the reservoir spool to the working section. In this case the rotation of the storage spool 2 is reversed before wire is unrolled off the reservoir spool 1 (i.e. storage spool 2 is rotated in opposite direction and the bottom part of storage spool 2 moves out of the plane of the drawing) and the wire 3 is pulled from the wire web and spooled onto the storage spool again.

[0132] b) addition of new wire to the working section. The storage spool 2 is rotated further (top side of the storage spool 2 out of the plane of the drawing) so that new wire is spooled off the reservoir spool 1, which synchronically rotates with the storage spool 2. Once the right amount of new wire has been taken off the reservoir spool 1, the method continues as described under point a), winding the used wire onto the storage spool 2 (and at first onto the reservoir spool 1 in order to reach the storage spool 2, if the traveler pulley 4 happens to be in the position as shown in FIG. 6. Ideally, the traveler pulley 4 is not in this position when the wire has to be wound onto the storage spool. Its position may be controlled and monitored such that when the transition takes place, the traveler pulley 4 is located right next to the storage spool. This is e.g. achieved by adding less or more wire from the reservoir spool).

[0133] It is important to note that usually: [0134] a wire segment that has gone thru the wire web once has normally not been used up. Therefore this segment is preferably treated as gently as the new wire. Moreover, preferably also the receiving unit 6 has a storage spool 2. [0135] the wire is being decelerated before the direction of the wire movement is reversed. This means that during most of the time the e.g. 500 meters used wire is wound off the storage spool 2, the wire 3 has its maximum speed. Near the end of the used wire part, and thus near the (left) end of the storage spool 2, the wire 3 is decelerated. This slower speed is beneficial for making the transition to the reservoir spool 1. Since the diameters of the wire winding top surfaces on the spools are almost never exactly identical and thus the speeds of the wires on that top surfaces are not the same, the tension in the wire will change rapidly during the transition. The system, especially the dancer has to be fast enough to compensate for this change. At lower speeds, the change is slower and the system can compensate better.

[0136] At a transition between the spools the difference in speed may be adjusted, in order to unload the dancer pulley 20 and to avoid an impact. The dancer pulley 20 should come as soon as possible in its neutral position.

[0137] Since the diameter of the reservoir spool 1 (actually the diameter of the wire contact surface 1a plus the wire still on the spool) varies over time and the diameter of the storage spool 2 stays constant (beside some wear), the wire may experience a shock during the transition. Only if both, diameter of reservoir spool and storage spool, are constant, there arises no shock. If the wire speed is low, the system used for absorbing shocks in the wire 3 may be fast enough to balance this shock. This system may be comparable to the weights in JP2000-158436A and in JP2000-024905A. An additional shock absorber may be inserted in the path between the reservoir spool/storage spool and the cutting area (e.g. wire web), preferably adjacent to the traveler pulley 4 (upstream or downstream). Another way is to change the relative speed of the reservoir spool and the storage spool, which is possible if both have a drive of their own as shown in FIG. 7. An important thing is to absorb the shock and/or to try keeping the speed of the wire leaving the storage spool and the speed of the wire leaving the reservoir spool a moment later as close together as possible. If the diameters of the wire winding top surfaces on the spools 1 and 2 are quite different, it may be beneficial to not make the speeds as equal as possible. If for example the wire winding top surface of the reservoir spool has a smaller diameter, the speed of that spool may be slightly higher so that the additional wire that has to be wound (coming from the difference in angle of the wire between the traveler pulley 4 and the storage spool 2 and the traveler pulley 4 and the reservoir spool 1 respectively) may be wound as fast as possible. A de-coupling of the rotational speeds may also take place if the wire is not wound to the storage spool.

[0138] Preferably the traveller pulley 4 is adapted to align (automatically or manually) the wire segment extending between itself and the storage spool 2 or reservoir spool 1 with the wire carrying surface 2a of that spool. Since the diameter of the wire bearing surface 2a of the reservoir spool 1 changes more compared to that of the storage spool 2 (which only changes because of wear), it is especially preferred if the traveller pulley 4 is adjustable when serving the reservoir spool 1 and preferably lockable when serving the storage spool 2 so that it's position is fixed when serving the storage spool 2. Good alignment and locking in that position ensures a more steady behaviour of the wire, leading to less wear, better wafer quality and less wire breakage.

[0139] If the roll and the drum are mechanically connected to each other, it is also possible to have a first rotational speed as long as the wire 3 is on the storage spool 2 and just when it no longer is on the storage spool 2 the rotational speed (of both, reservoir and storage spool) is increased (assuming that the reservoir spool has a smaller diameter).

[0140] The goal is to control the speed of the wire in the wire web because this results in the best wafer quality. The speed of the wire outside the wire web may temporarily deviate from this speed due to the transition between a reservoir spool and a storage spool or to control the tension in the wire.

[0141] FIGS. 12a to 12m show an embodiment of the inventive method of cutting a piece of material.

[0142] Initialization (FIGS. 12a-12d)

[0143] In FIG. 12a the wire web 17 is set and the distal end of the cutting wire is connected to the reservoir spool 1 of the receiving unit 6 (i.e. at the used wire side 19 of the wire web 17). Used wire side 19 is that side to which the wire leaves the cutting area 13 in the direction towards the receiving unit 6. New wire side 18 is that side to which the wire leaves the cutting area 13 in the direction towards the supplying unit 5. New and used refers to the fact, that the reservoir spool of the supplying unit 5 carries new (unused) wire and the reservoir spool of the receiving unit 6 carries old (already used) wire. FIG. 12a shows a reservoir spool and a storage spool with basically identical diameter.

[0144] In FIG. 12b the cutting wire 3 moves in a first direction being transferred from the reservoir spool 1 of the supplying unit 5 via the new wire side 18 to the wire web 17 and being transferred via the used wire side 19 to the storage spool 2 of the receiving unit 6, such that its wire carrying surface holds preferably along its whole length a wire portion in non-overlapping windings.

[0145] In FIG. 12c the storage spool 2 of the supplying unit 5 is wound up with cutting wire 3 coming from the wire web 17 via the new wire side 18 while the cutting wire 3 is unwound from the storage spool 2 of the receiving unit 6. The cutting wire moves in the second direction. If desired the wire web 17 can already cut material.

[0146] In FIG. 12d the storage spool 2 of the supplying unit 5 is completely filled. Wire 3 does not move. The Initialization is finished.

[0147] Cutting (FIGS. 12e and 12f)

[0148] In FIG. 12e cutting is in progress. The cutting wire 3 moves in the first direction and the wire 3 is wound on the storage spool 2 of the receiving unit 6.

[0149] In FIG. 12f cutting is in progress. The cutting wire 3 moves in the second direction and the wire 3 is wound on the storage spool 2 of the supplying unit 5.

[0150] Outward transfer of used (old, worn) wire, loading of new (unused, fresh) wire (FIGS. 12g-12m)

[0151] In FIG. 12g the storage spool 2 of the supplying unit 5 is completely filled. The first cutting cycle is finished. Wire 3 does not move. The wire saw 8 is now ready for a subsequent sawing cycle. The steps of FIGS. 12e and 12f may be repeated as often as appropriate. Alternatively the wire saw 8 is ready for outward transfer of used wire (to the reservoir spool of the receiving unit) and loading of new wire (from the reservoir spool of the supplying unit).

[0152] In FIG. 12h a portion of a used wire (old or worn wire) coming from the wire web 17 via the old wire side 19 is wound on the reservoir spool 1 of the receiving unit 6. The amount of used wire to be wound to the reservoir spool 1 of the receiving unit 6 can be freely chosen depending on the specific process demand. If desired the wire web 17 can continue to cut material. Preferably the wire speed is slow.

[0153] In FIG. 12i the winding process on the reservoir spool is finished and the wire 3 passes the transition area between the reservoir spool 1 and storage spool 2 while moving. If desired the wire web 17 can cut material. Preferably, the wire speed is slow.

[0154] In FIG. 12j the cutting wire 3 moves in the first direction and the wire 3 is wound on the storage spool 2 of the receiving unit 6. The latter is e.g. filled to 95%.

[0155] In FIG. 12k the wire 3 is decelerated. The wire 3 is completely removed from the storage spool 2 of the supplying unit 5. Now the addition of new wire (unused or fresh wire) to the wire web 17 via the new wire side 18 coming from the reservoir spool 2 of the supplying unit 5 starts as is shown in FIG. 12l.

[0156] In FIG. 12m the storage spool 2 of the receiving unit 6 is completely filled again and the step of outward transfer of a used (old, worn) wire portion and loading of a new (unused, fresh) wire portion is completed. Now the cutting process continues with the steps shown in FIG. 12f-FIG. 12e-FIG. 12f and so on.

[0157] FIGS. 13a to 13l show an alternative embodiment of the inventive method of cutting a piece of material.

[0158] Initialization (FIGS. 13a-13c)

[0159] In FIG. 13a the wire web 17 is set and the distal end of the cutting wire is connected to the reservoir spool 1 of the receiving unit 6 at the used wire side 19 of the wire web 17.

[0160] In FIG. 13b the cutting wire 3 moves in a first direction being transferred from the reservoir spool 1 of the supplying unit 5 via the new wire side 18 to the wire web 17 and being transferred via the used wire side 19 to the storage spool 2 of the receiving unit 6, such that its wire carrying surface holds a wire portion in non-overlapping windings.

[0161] However, not the whole length of the storage spool 2 of the receiving unit 6 is filled with wire, in order to have place for additional wire at a later stage. This situation is shown in FIG. 13c.

[0162] Cutting (FIGS. 13d-13l)

[0163] In FIG. 13d cutting is in progress. The cutting wire 3 moves in the second direction and the wire 3 is wound on the storage spool 2 of the supplying unit 5.

[0164] Not the whole length of the storage spool 2 of the supplying unit 5 is filled with wire, in order to have place for additional wire at a later stage. This situation is shown in FIG. 13e.

[0165] In FIG. 13f cutting is in progress. The cutting wire 3 moves in the first direction and the wire 3 is wound on the storage spool 2 of the receiving unit 6 until the situation of FIG. 13c is reached. The steps of FIGS. 13d to 13f may be repeated as often as appropriate.

[0166] Loading of new (unused, fresh) wire, outward transfer of used (old, worn) wire (FIGS. 13g-13l)

[0167] In FIG. 13g contrary to the step shown in FIG. 13c the wire 3 continues to move in the first direction. A desired portion of new wire of the reservoir spool 1 of the supplying unit 5 is transferred to the wire web 17 via the new wire side 18 and the same amount of the cutting wire 3 coming from the wire web 17 via the used wire side 19 is transferred to the storage spool 2 of the receiving unit 6.

[0168] In FIG. 13h the addition of new wire to the wire web 17 is completed.

[0169] In FIG. 13i cutting wire 3 is transferred from the storage spool 2 of the receiving unit 6 to the wire web 17 via the used wire side 19 and cutting wire is transferred from the wire web 17 via the new wire side 18 to the storage spool 2 of the supplying unit 5. If desired the wire web 17 can continue to cut material.

[0170] In FIG. 13j the storage spool 2 of the supplying unit 5 is filled. The methods shown in FIGS. 12 and 13 respectively can be used interchangeably. It can be switched between the methods shown in FIG. 12 and FIG. 13 when the states are equal as shown in FIGS. 12g and 13j.

[0171] In FIG. 13k a used portion of the wire (old or worn wire) coming from the wire web 17 via the used wire side 19 is wound on the reservoir spool 1 of the receiving unit 6. The amount of old wire can be freely chosen depending on the specific process demand. After the desired amount of old wire is wound on the reservoir spool 1 of the wire receiving unit 6 the wire 3 passes the transition area between the reservoir spool 1 and storage spool 2 while moving. If desired the wire web 17 can continue to cut material during the whole step shown in FIG. 13k. Preferably the wire speed is slow.

[0172] In FIG. 13I the step of loading a new (unused, fresh) wire portion and outward transfer of a used (old, worn) wire portion is completed. Now the cutting process continues with the steps shown in FIG. 13f-FIG. 13d-FIG. 13e-FIG. 13f and so on.

[0173] The direction of wire movement is indicated in these figures. During wire movement cutting action is usually performed.

[0174] FIGS. 14 to 21 show an alternative embodiment of the cutting method.

[0175] FIG. 14 shows a first cutting cycle, comprising a plurality of reversals of the moving direction of the cutting wire 3. During the first cutting cycle the moving direction of the cutting wire 3 is reversed before the cutting wire 3 is completely unwound from the storage spool 2 of the supplying unit 5, such that during the first cutting cycle a section 22, preferably a unused section, of cutting wire 3 is stored on/remains on the storage spool 2 of the supplying unit 5 without reaching the cutting area 13.

[0176] In a transitional step following the first cutting cycle also cutting wire 3 from the previously unused section 22 is brought into the cutting area 13, i.e. becomes part of the wire web or is at least moved towards the cutting area 13. The unused section 22 of cutting wire becomes successively smaller (FIG. 15).

[0177] FIG. 16 shows a second cutting cycle, comprising a plurality of reversals of the moving direction of the cutting wire 3. During the second cutting cycle the moving direction of the cutting wire 3 is reversed such that a section of cutting wire 3 which during the first cutting cycle has been stored on the storage spool 2 of the supplying unit 5 without having reached the cutting area 13 is brought into the cutting area 13, and that during the second cutting cycle the moving direction of the cutting wire 3 is reversed before the cutting wire 3 is completely unwound from the storage spool 2 of the receiving unit 6, such that during the second cutting cycle a used section 23 of cutting wire 3 is stored on the storage spool 2 of the receiving unit 6 without reaching the cutting area 13 (in consecutive reversals of the moving direction of cutting wire 3 aimed to cut material). The steps of FIG. 15 are repeated until almost all wire on the storage spool 2 of supply unit 5 is used.

[0178] Also visible in FIGS. 15 through 16 is that over time more and more used cutting wire (represented by dashed line) is temporarily stored on the storage spool 2 of the receiving unit 6.

[0179] Once all wire on the storage spools 2 has been used up, all wire is removed from the storage spool 2 of the supply unit 5. This is shown in FIG. 17.

[0180] In a preferred embodiment the cutting method comprises a step of transferring a used section of cutting wire 3 from the storage spool 2 of the receiving unit 6 to the reservoir spool 1 of the receiving unit 6. This is doneaccording to FIG. 18by completely unwinding the used section of cutting wire 3 from the storage spool 2 of the receiving unit 6 (i.e. pulling it into the cutting area 13, i.e. wire web) followed by reversal of the moving direction of the cutting wire 3 and winding the used section of cutting wire 3 on the reservoir spool 1 of the receiving unit 6 (FIG. 19). It is mentioned that the illustrations of FIGS. 14 to 23 are just schematically. Particularly, the cutting wire may be wound on the reservoir spool of course in multiple overlapping windings/layers.

[0181] The step of transferring a used section of cutting wire 3 from the storage spool 2 of the receiving unit 6 to the reservoir spool 1 of the receiving unit 6 is done between two successive cuts, i.e. during this step no piece of material is cut or is in contact with the cutting wire. It is also noteworthy that the length of the reservoir spool is less than the length of the storage spool. Furthermore, the reservoir spool typically contains overlapping windings while the storage spool typically does not. Therefore, both the length of the spools and the diameter of windings on the spools differ. The reservoir spool's shorter length and thicker diameter of wound wire allows for ease of transportation and storage while keeping the dimensions of the wire saw small at the same time. Reservoir spools may often be interchanged without removing the storage spool, allowing the storage spool to remain in place and to require less removal for maintenance.

[0182] Now, new wire is unwound from the reservoir spool 1 of the supplying unit 5 towards the cutting area 13 (FIG. 20). On the other side of the cutting area 13 cutting wire 3 is spooled on the storage spool 2 of the receiving unit 6. In FIG. 21 a new cutting cycle is started. The steps as described according to the FIGS. 14 to 20 may now be repeated. It has to mentioned that the cutting wire in the Figures is illustrated schematically and that the wires (particularly the wires illustrated with dashed lines) continuously extend throughout the surface of the spools.

[0183] The great advantage of this embodiment is that the interchange from used and unused cutting wire 3 can be accomplished during a cut (i.e. during the wire web is in contact with a piece of material) without taking wire from the reservoir spool 1. To enable this wire length which is spooled fromor ontothe storage spool between two successive reversals is smaller than the length of cutting wire initially stored on the storage spool 2. The interchange from used to unused cutting wire 3 can be done continuously by means of a difference between the pilgrim length during movement in a first direction and the pilgrim length during the subsequent movement in the opposite direction.

[0184] The basic idea of the following method (FIGS. 22 and 23) is principally independent of the embodiments described above. However, it is of course possible to perform this method with the wire management system as described above.

[0185] FIGS. 22 and 23 show the extent of wear of cutting wire sections. The abscissa corresponds to the length of the cutting wire 3 and the ordinate to the wear or extent of abrasion. The mark MAX denotes to the maximal possible extent of abrasion of cutting wire which is acceptable for cutting. Going beyond this point would lead to unacceptable risk of wire breakage and cuts of poor quality. The abrasion profile of a wire section used within a cutting cycle comprising a plurality of reversals of the moving direction of the cutting wire 3 has an approximately trapezoidal shape. The plateau of the abrasion function refers to a range 27 of wire points having between two successive reversals of a cutting cycle essentially the same effective interaction length with the piece of material: complete usage section. Thus their wear is the same. At the beginning of the cutting wire section wear increases until the plateau is reached. At the end of the cutting wire section wear decreases again. This slope has its origin in the fact, that the effective interaction length with the piece of material becomes smaller towards the end of a wire section: wire points in this section do not travel through the complete wire web before the moving direction of the wire is reversed. Consequently these points do not see as much material to be cut as points in the complete usage section. There is a wire point which, during a cutting cycle, comes into contact with one point only of the material to be cut. In order to account for these wearing differences at the end of the respective wire section the following method is proposed:

[0186] The method of cutting a piece of material, preferably semiconductor material, preferably in form of an ingot, brick or core, is performed with a wire saw 8 comprising a wire management system 7 having a cutting wire 3 which is guided through a cutting area 13. The wire management system 7 comprises a wire supplying unit 5 for supplying cutting wire 3 to the cutting area 13 of the wire saw 8 and a wire receiving unit 6 for receiving cutting wire 3 from the cutting area 13 of the wire saw 8. It is not necessary, that the wire management system has the same build-up as described above.

[0187] During a first cutting cycle, comprising a plurality of reversals of the moving direction of the cutting wire 3, a first section 24 of cutting wire 3 is used in the cutting area 13 for cutting the piece of material, the first section 24 being defined by all wire points that between reversals of the first cutting cycle come into contact at least once with the piece of material to be cut. Over time wear becomes successively larger. (dashed lines in FIG. 22 show intermediate abrasion states of the wire.)

[0188] During a second cutting cycle, comprising a plurality of reversals of the moving direction of the cutting wire 3, a second section 25 of cutting wire 3 is used in the cutting area 13 for cutting the piece of material, the second section 25 being different to the first cutting section 24 and being defined by all points which between the reversals of the second cutting cycle come into contact with the piece of material to be cut.

[0189] The first section 24 of cutting wire 3 and the second section 25 of cutting wire 3 overlap in their end regions, forming overlapping range 26. In the end regionsas can be seen from FIG. 23the extent of wear resulting from the first cutting cycle sums up with the extent of wear resulting from the second cutting cycle and surprisingly a constant wear along the whole wire length is obtained due to addition of virtual triangles in the end regions of the wire sections 24, 25. In such a manner the cutting wire 3 may be exploited to an optimal extent by constantly using overlapping cutting sections, preferably up to 100%, leaving only at the very beginning and at the very end of the entire cutting wire 3 regions with sub-optimal wear.

[0190] Preferably, the overlapping range 26 is located outside, preferably immediately adjacent to a range 27, 28 of wire points having between two successive reversals of a cutting cycle essentially the same effective interaction length with the piece of material (plateau of FIG. 22). This embodiment is shown in FIG. 23, where the overlapping range 26 comprises two ramp-shaped ranges of the abrasion profile.

[0191] If the maximal wear off (MAX) is not reached after one cut, the wire segment may be used for a second consecutive cut without addition of a new wire portion from the reservoir spool. If the maximal wear off (MAX) is not reached after a second cut, the wire segment may be used for a third consecutive cut without addition of a new wire portion from the reservoir spooland so forth. If the wire quality does not suffice for one complete cut, multiple wire sections may be used for one cut. Alternatively the cutting recipe may be chosen such (especially pilgrim length and cutting pressure) so that after a number of complete cuts, the wire is almost completely worn off in the complete usage section.

[0192] The invention is not restricted to these embodiments. Other variants will be readily apparent for the person skilled in the art, and are considered to lie within the scope of the invention as formulated in the appended claims. Individual features described in above specification, particularly with respect to the figures may be combined with each other to form other embodiments and/or applied mutatis mutandis to what is described in the claims and to the rest of the description.

LIST OF REFERENCE LABELS

[0193] 1 reservoir spool [0194] 1a wire carrying surface of the reservoir spool 1 [0195] 1b rotational axis of the reservoir spool 1 [0196] 2 storage spool [0197] 2a wire carrying surface of the storage spool 2 [0198] 2b rotational axis of the storage spool 2 [0199] 3 cutting wire [0200] 4 traveler pulley [0201] 5 wire supplying unit [0202] 6 wire receiving unit [0203] 7 wire management system [0204] 8 wire saw [0205] 9 wire guide [0206] 10 rotational drive [0207] 11 rotational drive [0208] 12 transition area [0209] 13 cutting area [0210] 14 wire guide rollers [0211] 15 drives [0212] 16 control device [0213] 17 wire web [0214] 18 new wire side [0215] 19 used wire side [0216] 20 dancer pulley [0217] 21 pulley arm [0218] 22 unused section of cutting wire 3 [0219] 23 used section of cutting wire 3 [0220] 24 first section of cutting wire 3 [0221] 25 second section of cutting wire 3 [0222] 26 overlapping range [0223] 27 range of (completely) worn wire points, complete usage section [0224] 28 range of (completely) worn wire points, complete usage section