Asymmetric Alignment Marks for Interference-Free Panel Lamination

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Solution Overview

Problem

Existing methods for aligning and laminating large-sized and medium-sized cholesterol liquid crystal display panels face issues with panel damage and pollution due to the use of thin glass substrates and interference from alignment marks, requiring additional processing that is costly and inefficient.

Innovation Solution

A method involving the use of four alignment marks on each panel, with symmetrical and asymmetrical configurations, allowing panels to be aligned and laminated without additional processing, using a photomask to form multi-layer panels without interference, and employing cameras for precise alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If thin glass substrate is used to capture clear image of alignment marks, then measurement precision is improved, but strength and reliability deteriorate causing panel damage during placement or touch

Engineering Contradiction:

Improveclarity of alignment mark imageVSAvoidsubstrate strength

Core Design Contradiction:

Measurement precisionVSStrength

Solution Approach 1:

The patent replaces the thin glass substrate with a disposable adhesive tape that has sufficient strength for handling and lamination. The tape is used only for the alignment and lamination process and then removed, avoiding the need for fragile thin glass substrates while maintaining measurement precision through the adhesive surface.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Measurement precision

If alignment marks of middle panel are eliminated via laser or chemical agents, then measurement precision is improved by avoiding interference, but panels are damaged or polluted

Engineering Contradiction:

Improveclarity of captured alignment mark imageVSAvoidpanel damage and pollution

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an asymmetric shifting mark with a specific shape that differs from the corner marks. This asymmetric design allows the lamination equipment to distinguish and capture only the relevant alignment marks (corner marks or shifting mark) while ignoring the middle panel's alignment marks, eliminating interference without requiring laser or chemical processing.

Inventive Principle:

Principle #4Asymmetry

3Measurement precision

If photomask is modified to cancel alignment marks of middle panel, then measurement precision is improved by avoiding interference, but additional investment of expensive photomask is required

Engineering Contradiction:

Improveclarity of captured alignment mark imageVSAvoidphotomask complexity and cost

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses the same photomask for all panels including the middle panel, copying the alignment marks onto each panel. The asymmetry in the shifting mark design and the lamination process allow the system to selectively capture only the necessary alignment marks without modifying the photomask, avoiding additional investment while maintaining measurement precision.

Inventive Principle:

Principle #26Copying

4Measurement precision

If additional processing is applied to eliminate alignment mark interference, then measurement precision is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvealignment mark capture clarityVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent enables the lamination equipment to automatically capture and identify the correct alignment marks (corner marks or asymmetric shifting mark) without requiring additional processing steps. The system self-adjusts by recognizing the asymmetric shifting mark or corner marks while ignoring middle panel marks, simplifying the manufacturing process while maintaining high measurement precision.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250353288A1Method of aligning and laminating for panels and alignment mark

Publication Date: 2025.11.20 IRIS OPTRONICS INC

AI summary

A method of aligning and laminating for panels includes forming alignment marks on each of the panels via a photomask, aligning and laminating the first panel and the second panel to form a double layer panel and aligning and laminating the double layer panel and the third panel to form a triple layer panel. The shifting mark is asymmetric to the first corner mark, the second corner mark and the third corner mark. The first corner mark and the third corner mark of the first panel are aligned to the third corner mark and the first corner mark of the second panel, respectively, and the double layer panel is formed after laminating. The second corner mark and the shifting mark of the first panel are aligned to the second corner mark and the shifting mark of the third panel, respectively. The triple layer panel is formed after laminating.