Roll-to-roll two-point horizontal alignment exposure splicing method
By using a two-point horizontal alignment method, and by measuring the positioning hole group and setting the expansion and contraction coefficient of the exposure machine, the problems of unstable and misaligned graphic dimensions in roll-to-roll exposure splicing were solved, achieving stability of graphic dimensions and accuracy of exposure, thereby improving product quality and processing yield.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- ZHUHAI TANLIAN OPTOELECTRONICS TECHNOLOGY CO LTD
- Filing Date
- 2026-04-28
- Publication Date
- 2026-06-02
AI Technical Summary
In existing roll-to-roll exposure splicing technology, the unstable graphic size and the misalignment of the front and rear dies caused by four-point centering compensation, especially in the process of infinitely long roll-to-roll splicing, affect product quality and processing yield.
A two-point horizontal alignment method is adopted. The expansion and contraction coefficient is calculated by measuring the longitudinal and transverse center distances of the positioning hole group, and the fixed graphic size of the exposure machine is set accordingly. The first positioning camera captures the line connecting the center points of the positioning holes as the horizontal reference line, and the second positioning camera detects the existence of the positioning holes on the second side edge to ensure accurate exposure.
This achieves stability in graphic dimensions and accuracy in exposure, avoiding instability and misalignment in graphic dimensions caused by changes in hole positions, and improving the splicing quality of products and the yield of subsequent processing.
Smart Images
Figure CN122131555A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of roll-to-roll exposure stitching technology, and more particularly to an exposure stitching method with two points horizontally aligned on roll-to-roll. Background Technology
[0002] In the field of roll-to-roll exposure splicing technology, especially for products with continuous strip structures such as flexible circuit boards, it is usually necessary to accurately transfer engineering patterns on the product surface. In the existing technology, exposure equipment mostly adopts a four-point alignment mode, that is, multiple charge-coupled device (CCD) cameras respectively capture four positioning holes on the product to be produced, and software calculates the relative positional relationship between each hole position, thereby transferring the engineering pattern to the product surface. In order to cope with the dimensional variables brought about by the previous process, existing exposure programs have developed a variety of compensation modes, including automatic expansion and contraction, linear expansion and contraction, non-linear expansion and contraction, and fixed expansion and contraction, in order to match the hole position changes of the actual product by adjusting the pattern size, thereby ensuring the accuracy of pattern transfer.
[0003] However, the aforementioned existing technologies still have significant drawbacks in practical applications. In automatic expansion and contraction, linear expansion and contraction, and nonlinear expansion and contraction modes, the engineering pattern will be stretched or deformed according to the actual changes in the hole positions on the product to be produced. This results in differences in the size of the transferred pattern between different product batches or different sections of the same roll. This unstable pattern size makes it difficult for the product to be accurately matched with the standard fixture during subsequent manufacturing processes, thus causing misalignment problems. In the fixed expansion and contraction mode, although the pattern size is set to a fixed value, it still adopts the traditional four-point alignment method, that is, centering compensation is performed by calculating the center position of the four positioning holes. Since the four positioning holes may not be completely on the same horizontal line in the actual product due to variables in the previous process, the pattern exposed with the four-point center as the reference will have a vertical misalignment between the front and rear dies. Especially in the process of infinitely long roll-to-roll splicing, this misalignment problem will accumulate and amplify with the increase of splicing length, seriously affecting the splicing quality of the product and the processing yield of subsequent processes.
[0004] Therefore, the inventors urgently need to provide a roll-to-roll two-point horizontal alignment exposure splicing method to solve the problem of vertical misalignment of the front and rear molds caused by unstable graphic size and four-point centering compensation in the prior art. Summary of the Invention
[0005] To address the shortcomings of the prior art, this invention provides a roll-to-roll two-point horizontal alignment exposure stitching method, aiming to solve the problem of vertical misalignment between the front and rear molds caused by unstable graphic dimensions and the use of four-point centering compensation alignment in the prior art roll-to-roll exposure stitching technology.
[0006] To achieve the above objectives, the technical solution adopted by this invention is: a roll-to-roll two-point horizontal alignment exposure stitching method, comprising the following steps: S1. Fixed graphic size step: Obtain a roll of product to be produced, measure a plurality of positioning hole groups arranged sequentially along the length direction of the product to be produced, wherein each group of positioning hole groups includes two positioning holes arranged opposite to each other along the width direction, calculate the measured data of each group based on the longitudinal center distance and the transverse center distance of the rectangular areas formed by two adjacent groups of positioning hole groups, compare the measured data of each group with the preset engineering standard value to obtain the expansion and contraction coefficient, and set the expansion and contraction coefficient as the fixed graphic size of the exposure machine; S2. Two-point horizontal alignment step: The product to be produced is transported to the exposure station, the first positioning camera is controlled to move to the first side edge of the product to be produced, and the two positioning holes located on the first side edge in the two adjacent positioning hole groups are sequentially picked up. The line connecting the center points of the two positioning holes is used as the horizontal reference line, and the position of the exposure pattern is determined according to the horizontal reference line. S3. Foolproof confirmation step: Control the second positioning camera to move to the second side edge of the product to be produced, and detect whether the two positioning holes located on the second side edge in the two adjacent positioning hole groups exist. If the two positioning holes located on the second side edge are detected, the exposure step is performed. If they are not detected, the exposure is stopped and a prompt is issued.
[0007] Based on the above, the beneficial effect of a roll-to-roll two-point horizontal alignment exposure stitching method is that it solves the problem of vertical misalignment between the front and rear molds caused by unstable graphic dimensions and the use of four-point centering compensation alignment in the existing roll-to-roll exposure stitching technology; mainly reflected in: 1. This invention obtains a roll of product to be produced, measures the longitudinal and transverse center distances of several rectangular areas formed by two adjacent sets of positioning holes arranged sequentially along the length of the product, calculates the measured data for each set, compares the measured data with a preset engineering standard value to obtain the expansion and contraction coefficient, and sets the expansion and contraction coefficient as the fixed pattern size of the exposure machine. This achieves the goal of fixing the size of the exposed pattern to a constant value determined based on the measured data, avoiding the problem of unstable pattern size caused by the dynamic expansion and contraction of the pattern due to the actual changes in the hole positions on the product to be produced. 2. This invention controls the first positioning camera to move to the first side edge of the product to be produced, and sequentially grabs two positioning holes located on the first side edge in two adjacent positioning hole groups. The line connecting the center points of the two positioning holes is used as a horizontal reference line, and the position of the exposure pattern is determined according to the horizontal reference line. This realizes the use of the horizontal reference line determined by the two positioning holes on the same side edge as the alignment reference, replacing the original alignment method of centering compensation with the center of the four positioning holes. This eliminates the vertical misalignment of the front and rear molds caused by the incomplete horizontality of the four positioning holes after centering compensation of the exposure pattern.
[0008] Furthermore, step S1 further includes: measuring the longitudinal center distance and the transverse center distance of the three rectangular areas formed by the four adjacent sets of positioning holes on the product to be produced using a two-dimensional measuring instrument to obtain three sets of measured data, calculating the arithmetic mean of the three sets of measured data, and comparing the arithmetic mean with the engineering standard value to obtain the expansion and contraction coefficient.
[0009] Based on the above, the beneficial effects of the two-dimensional measuring instrument are: accurate acquisition of the actual dimensions between multiple sections of the positioning hole group on the product to be produced; the beneficial effect of four adjacent positioning hole groups is that each group of four positioning holes forms three independent rectangular areas; the beneficial effect of the three rectangular areas is that the positioning holes in the four adjacent positioning hole groups respectively enclose three independent rectangular areas, realizing multiple independent measurements of the longitudinal and transverse dimensions within different length sections of the roll material; the beneficial effect of the three sets of measured data is that the longitudinal center distance and transverse center distance of the three rectangular areas are recorded respectively, realizing the quantitative acquisition of dimensional deviations at multiple different locations on the roll material; the beneficial effect of the arithmetic mean is the comprehensive balancing of multiple measurement results, reducing the impact of single measurement anomalies on the calculation of the expansion and contraction coefficient.
[0010] Furthermore, in step S1, the number corresponding to the product to be produced is entered into the operation interface of the exposure machine, the calculated expansion and contraction coefficient is input into the exposure machine, and the exposure machine automatically stretches the exposure pattern according to the expansion and contraction coefficient.
[0011] Based on the above, the beneficial effects of the operating interface are: it enables human-machine interaction between the operator and the exposure machine, facilitating the accurate configuration of the calculated expansion and contraction coefficient into the equipment; the beneficial effect of the numbering is to uniquely identify the type or batch of the product to be produced, enabling quick retrieval of engineering data and preset parameters matching the product to be produced within the operating interface of the exposure machine; the beneficial effect of the expansion and contraction coefficient is to reflect the deviation ratio between the measured size of the product to be produced and the engineering standard value, quantifying the actual size change of the product to be produced into a numerical parameter that the exposure machine can adjust; the beneficial effect of the exposure machine is to automatically stretch the exposure pattern according to the input expansion and contraction coefficient, accurately compensating the size of the engineering pattern to a fixed pattern size that matches the actual size of the product to be produced; and the beneficial effect of the exposure pattern is that the pattern can be transferred to the product to be produced with a constant and matching size in subsequent exposure steps.
[0012] Furthermore, step S2 further includes: in the graphical interface of the exposure machine, selecting and setting four positioning holes of two adjacent positioning hole groups in the exposure pattern by box selection; manually moving the first positioning camera to above the first positioning hole on the first side edge of the product to be produced and confirming it, the first positioning camera automatically moves to above the second positioning hole on the first side edge according to preset coordinates, thereby capturing the two positioning holes.
[0013] Based on the above, the beneficial effects of the graphical interface are that it displays the exposure pattern and allows the operator to perform a selection operation, realizing the intuitive setting of the position of the positioning hole in the exposure pattern; the beneficial effect of selection is that by defining a rectangular area in the graphical interface of the exposure machine to select the four positioning holes of two adjacent positioning hole groups in the exposure pattern, it is possible to quickly and in batches complete the setting of the alignment marks in the exposure pattern; the beneficial effect of manual operation is that it allows the alignment of the first positioning camera with the actual positioning hole to be confirmed manually during the initial positioning.
[0014] Furthermore, in step S2, the first positioning camera is a movable CCD camera, which is positioned above the exposure station and located at the first side edge of the product to be produced, for capturing an image of the positioning hole of the product to be produced located at the first side edge.
[0015] Based on the above, the beneficial effect of the first positioning camera is that it enables targeted image acquisition of two adjacent positioning holes on the first side edge of the product to be produced; the beneficial effect of the movable CCD camera is that it can move along a predetermined trajectory above the exposure station to different positioning hole positions, thereby enabling the sequential acquisition of images of two positioning holes located on the first side edge and in different positioning hole groups.
[0016] Furthermore, step S3 further includes: manually moving the second positioning camera above the first positioning hole on the second side edge of the product to be produced and confirming that the first positioning hole on the second side edge belongs to the same positioning hole group as the first positioning hole on the first side edge; the second positioning camera automatically moving to the second positioning hole on the second side edge according to preset coordinates, wherein the second positioning hole on the second side edge belongs to the same positioning hole group as the second positioning hole on the first side edge, to detect whether the second positioning hole on the second side edge exists.
[0017] Based on the above, the beneficial effect of the second positioning camera is that it enables image acquisition and existence verification of the positioning hole position on the second side edge of the product to be produced.
[0018] Furthermore, in step S3, the second positioning camera is a movable CCD camera, which is positioned above the exposure station and located at the second side edge of the product to be produced, and is used to detect whether the positioning hole exists on the second side edge of the product to be produced.
[0019] Furthermore, in step S1, the rectangular area is composed of four positioning holes from two adjacent groups of positioning holes. The four positioning holes are respectively the first positioning hole and the third positioning hole located on the first side edge of the product to be produced, and the second positioning hole and the fourth positioning hole located on the second side edge of the product to be produced. The longitudinal center distance is the distance between the first positioning hole and the second positioning hole or between the third positioning hole and the fourth positioning hole, and the lateral center distance is the distance between the first positioning hole and the third positioning hole or between the second positioning hole and the fourth positioning hole.
[0020] Based on the above, the beneficial effect of the rectangular area is that it defines a geometric unit on the product to be produced where the longitudinal and lateral center distances can be quantified and measured; the beneficial effect of the first positioning hole is that it cooperates with the third positioning hole on the same side to determine the lateral center distance, and with the second positioning hole to determine the longitudinal center distance; the beneficial effect of the third positioning hole is that it cooperates with the first positioning hole to determine the lateral center distance, and with the fourth positioning hole to determine the longitudinal center distance; the beneficial effect of the longitudinal center distance is that it quantifies the dimensional deviation along the length direction within the same rectangular area on the product to be produced; the beneficial effect of the lateral center distance is that it quantifies the dimensional deviation along the width direction within the same rectangular area on the product to be produced.
[0021] Furthermore, the product to be produced is a flexible circuit board roll, and the method is used for the infinitely long splicing exposure process of a roll-to-roll exposure machine.
[0022] Based on the above, the beneficial effect of the roll-to-roll exposure machine is that it receives and executes the method described above, realizes pattern transfer during the continuous conveying of flexible circuit board rolls, and supports the engineering implementation of infinitely long splicing exposure.
[0023] To make the above features of the present invention and the objectives to be achieved clearer, the present invention will be further described below in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description
[0024] Figure 1 : This is a flowchart of the present invention; Figure 2 : This is a schematic diagram of the product to be produced according to the present invention. Detailed Implementation
[0025] See Figure 1 and Figure 2 As shown, This invention discloses a roll-to-roll two-point horizontal alignment exposure stitching method, comprising the following steps: S1. Fixed graphic size step: Obtain a roll of product to be produced, measure a plurality of positioning hole groups arranged sequentially along the length direction of the product to be produced, wherein each group of positioning hole groups includes two positioning holes arranged opposite to each other along the width direction, calculate the measured data of each group based on the longitudinal center distance and the transverse center distance of the rectangular areas formed by two adjacent groups of positioning hole groups, compare the measured data of each group with the preset engineering standard value to obtain the expansion and contraction coefficient, and set the expansion and contraction coefficient as the fixed graphic size of the exposure machine; S2. Two-point horizontal alignment step: The product to be produced is transported to the exposure station, the first positioning camera is controlled to move to the first side edge of the product to be produced, and the two positioning holes located on the first side edge in the two adjacent positioning hole groups are sequentially picked up. The line connecting the center points of the two positioning holes is used as the horizontal reference line, and the position of the exposure pattern is determined according to the horizontal reference line. S3. Foolproof confirmation step: Control the second positioning camera to move to the second side edge of the product to be produced, and detect whether the two positioning holes located on the second side edge in the two adjacent positioning hole groups exist. If the two positioning holes located on the second side edge are detected, the exposure step is performed. If they are not detected, the exposure is stopped and a prompt is issued.
[0026] In this embodiment, step S1 further includes: measuring the longitudinal center distance and transverse center distance of the three rectangular regions formed by the four adjacent sets of positioning holes on the product to be produced using a two-dimensional measuring instrument to obtain three sets of measured data, and calculating the arithmetic mean of the three sets of measured data. The arithmetic mean is then compared with the engineering standard value to obtain the expansion and contraction coefficient. Specifically, during measurement, a roll of the product to be produced is taken, and the longitudinal center distance and transverse center distance of each of the three rectangular regions formed by the four adjacent sets of positioning holes are measured using a two-dimensional measuring instrument, resulting in three sets of longitudinal center distances and three sets of transverse center distances. The arithmetic mean is calculated to obtain the average longitudinal center distance and the average transverse center distance. Both are then compared with the preset engineering standard value, and the change of the measured average value relative to the engineering standard value is calculated as the expansion and contraction coefficient. For example, when the standard longitudinal center distance in the engineering standard value is 500 mm, and the average measured longitudinal center distance is 500.2 mm, the expansion and contraction coefficient is calculated to be 0.04%.
[0027] In this embodiment, in step S1, the number corresponding to the product to be produced is loaded into the operation interface of the exposure machine, and the calculated expansion and contraction coefficient is input into the exposure machine. The exposure machine automatically stretches the exposure pattern according to the expansion and contraction coefficient. Specifically, after loading the number into the operation interface, the calculated expansion and contraction coefficient is filled into the expansion and contraction size compensation column in the operation interface.
[0028] In this embodiment, step S2 further includes: in the graphical interface of the exposure machine, selecting and setting four positioning holes of two adjacent positioning hole groups in the exposure pattern; manually moving the first positioning camera to above the first positioning hole on the first side edge of the product to be produced and confirming it; the first positioning camera automatically moves to above the second positioning hole on the first side edge according to preset coordinates, thereby capturing two positioning holes; specifically, by selecting and setting four positioning holes of two adjacent positioning hole groups in the exposure pattern using the mouse in the graphical interface, and manually moving the first positioning camera to above the first positioning hole on the first side edge, the interface of the exposure machine displays the imaging screen of the first positioning camera. After the operator observes the positioning holes through the imaging screen, clicks to confirm the position. After the first positioning camera captures two positioning holes, the software of the exposure machine calculates the distance between the center points of the two positioning holes, compares this distance with the standard distance between the corresponding two positioning holes in the exposure pattern, obtains the difference value, and centers the exposure pattern according to the difference value.
[0029] In this embodiment, in step S2, the first positioning camera is a movable CCD camera. The first positioning camera is positioned above the exposure station and located at the first side edge of the product to be produced, and is used to capture an image of the positioning hole of the product to be produced located at the first side edge.
[0030] In this embodiment, step S3 further includes: manually moving the second positioning camera above the first positioning hole on the second side edge of the product to be produced and confirming that the first positioning hole on the second side edge belongs to the same positioning hole group as the first positioning hole on the first side edge; the second positioning camera automatically moves to above the second positioning hole on the second side edge according to preset coordinates, wherein the second positioning hole on the second side edge belongs to the same positioning hole group as the second positioning hole on the first side edge, to detect whether the second positioning hole on the second side edge exists; specifically, when manually moving the second positioning camera above the first positioning hole on the second side edge, the interface of the exposure machine displays the image of the second positioning camera. After the operator observes the positioning hole through the image, they click to confirm the position. If the second positioning camera does not detect the second positioning hole on the second side edge, the exposure machine stops the exposure operation and pops up a dialog box to prompt the operator.
[0031] In this embodiment, in step S3, the second positioning camera is a movable CCD camera. The second positioning camera is set above the exposure station and located at the second side edge of the product to be produced, and is used to detect whether the positioning hole exists on the second side edge of the product to be produced.
[0032] In this embodiment, in step S1, the rectangular area is composed of four positioning holes from two adjacent groups of positioning holes. The four positioning holes are respectively the first positioning hole and the third positioning hole located on the first side edge of the product to be produced, and the second positioning hole and the fourth positioning hole located on the second side edge of the product to be produced. The longitudinal center distance is the distance between the first positioning hole and the second positioning hole or between the third positioning hole and the fourth positioning hole. The lateral center distance is the distance between the first positioning hole and the third positioning hole or between the second positioning hole and the fourth positioning hole.
[0033] In this embodiment, the product to be produced is a flexible circuit board roll, and the method is used for the infinitely long splicing exposure process of a roll-to-roll exposure machine.
[0034] In this embodiment, during the exposure step, the exposure light source of the exposure machine scans the product to be exposed and transfers the exposure pattern onto the product to be exposed.
[0035] The above description is merely the optimal embodiment of the present invention and is not intended to limit the present invention. Any modifications or substitutions made by those skilled in the art without departing from the essence and scope of protection of the present invention should also be within the scope of protection of the present invention.
Claims
1. A roll-to-roll two-point horizontal alignment exposure stitching method, characterized in that, Includes the following steps: S1. Fixed graphic size step: Obtain a roll of product to be produced, measure a plurality of positioning hole groups arranged sequentially along the length direction of the product to be produced, wherein each group of positioning hole groups includes two positioning holes arranged opposite to each other along the width direction, calculate the measured data of each group based on the longitudinal center distance and the transverse center distance of the rectangular areas formed by two adjacent groups of positioning hole groups, compare the measured data of each group with the preset engineering standard value to obtain the expansion and contraction coefficient, and set the expansion and contraction coefficient as the fixed graphic size of the exposure machine; S2. Two-point horizontal alignment step: The product to be produced is transported to the exposure station, the first positioning camera is controlled to move to the first side edge of the product to be produced, and the two positioning holes located on the first side edge in the two adjacent positioning hole groups are sequentially picked up. The line connecting the center points of the two positioning holes is used as the horizontal reference line, and the position of the exposure pattern is determined according to the horizontal reference line. S3. Foolproof confirmation step: Control the second positioning camera to move to the second side edge of the product to be produced, and detect whether the two positioning holes located on the second side edge in the two adjacent positioning hole groups exist. If the two positioning holes located on the second side edge are detected, the exposure step is performed. If they are not detected, the exposure is stopped and a prompt is issued.
2. The exposure stitching method for roll-to-roll two-point horizontal alignment according to claim 1, characterized in that, Step S1 further includes: measuring the longitudinal center distance and the transverse center distance of the three rectangular areas formed by the four adjacent sets of positioning holes on the product to be produced using a two-dimensional measuring instrument to obtain three sets of measured data, calculating the arithmetic mean of the three sets of measured data, and comparing the arithmetic mean with the engineering standard value to obtain the expansion and contraction coefficient.
3. The exposure stitching method for roll-to-roll two-point horizontal alignment according to claim 2, characterized in that, In step S1, the number corresponding to the product to be produced is entered into the operation interface of the exposure machine, and the calculated expansion and contraction coefficient is input into the exposure machine. The exposure machine automatically stretches the exposure pattern according to the expansion and contraction coefficient.
4. The exposure stitching method for roll-to-roll two-point horizontal alignment according to claim 1, characterized in that, Step S2 further includes: in the graphical interface of the exposure machine, selecting four positioning holes of two adjacent positioning hole groups in the exposure pattern by box selection; manually moving the first positioning camera to above the first positioning hole on the first side edge of the product to be produced and confirming it, the first positioning camera automatically moves to above the second positioning hole on the first side edge according to preset coordinates, thereby capturing the two positioning holes.
5. The exposure stitching method for roll-to-roll two-point horizontal alignment according to claim 4, characterized in that, In step S2, the first positioning camera is a movable CCD camera, which is positioned above the exposure station and at the first side edge of the product to be produced, for capturing an image of the positioning hole of the product to be produced at the first side edge.
6. The exposure stitching method for roll-to-roll two-point horizontal alignment according to claim 1, characterized in that, Step S3 further includes: manually moving the second positioning camera above the first positioning hole on the second side edge of the product to be produced and confirming that the first positioning hole on the second side edge belongs to the same positioning hole group as the first positioning hole on the first side edge; the second positioning camera automatically moving to the second positioning hole on the second side edge according to preset coordinates, wherein the second positioning hole on the second side edge belongs to the same positioning hole group as the second positioning hole on the first side edge, to detect whether the second positioning hole on the second side edge exists.
7. The exposure stitching method for roll-to-roll two-point horizontal alignment according to claim 6, characterized in that, In step S3, the second positioning camera is a movable CCD camera. The second positioning camera is set above the exposure station and located at the second side edge of the product to be produced, and is used to detect whether the positioning hole exists on the second side edge of the product to be produced.
8. The exposure stitching method for roll-to-roll two-point horizontal alignment according to claim 1, characterized in that, In step S1, the rectangular area is composed of four positioning holes from two adjacent groups of positioning holes. The four positioning holes are the first and third positioning holes located on the first side edge of the product to be produced, and the second and fourth positioning holes located on the second side edge of the product to be produced. The longitudinal center distance is the distance between the first positioning hole and the second positioning hole or between the third positioning hole and the fourth positioning hole. The lateral center distance is the distance between the first positioning hole and the third positioning hole or between the second positioning hole and the fourth positioning hole.
9. The exposure stitching method for roll-to-roll two-point horizontal alignment according to claim 1, characterized in that, The product to be produced is a flexible circuit board roll, and the method is used for the infinitely long splicing exposure process of a roll-to-roll exposure machine.