Deformable Alignment Rods with Capacitance Detection for Substrate Protection

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Solution Overview

Problem

Existing substrate alignment apparatuses for LCD and OLED displays face challenges with fragile substrates due to rigid alignment elements, which can damage thinner substrates, and suffer from high false alarm rates using vacuum systems, affecting production precision and efficiency.

Innovation Solution

An alignment apparatus with deformable alignment rods containing a capacitor element that changes capacitance upon deformation, triggering an alarm when a preset threshold is exceeded, reducing false alarms and substrate damage by using a soft rubber housing and a gain element to adjust capacitance change values.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If rigid alignment elements (hard PEK) are used for substrate alignment, then alignment precision is improved, but substrate damage risk increases for thin substrates

Engineering Contradiction:

Improvealignment precisionVSAvoidsubstrate damage risk

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The alignment rod is constructed with a flexible housing made of soft rubber material that can deform elastically when contacted by the substrate. This flexible structure replaces the traditional rigid alignment element, allowing it to adapt to thin substrates without causing damage while still providing effective alignment through controlled deformation.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The invention changes the mechanical parameter of the alignment element from rigid to flexible by using soft rubber material. This parameter change allows the alignment rod to exhibit elastic deformation characteristics, reducing impact force on thin substrates while maintaining alignment functionality through the deformation-based capacitance detection mechanism.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If vacuum systems are used for alignment error detection, then alignment monitoring is improved, but false alarm rate increases

Engineering Contradiction:

Improvealignment monitoring capabilityVSAvoidfalse alarm rate

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The invention replaces the vacuum-based mechanical detection system with a capacitance-based electrical detection system. The capacitance element inside the flexible alignment rod detects alignment errors through electrical signal changes caused by rod deformation, eliminating the false alarms associated with vacuum system timing and threshold issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The capacitance element serves as an intermediary between the alignment rod's mechanical deformation and the alarm system. It converts the physical deformation of the flexible rod into electrical capacitance changes, providing a more reliable and precise detection mechanism that reduces false alarms compared to direct vacuum pressure monitoring.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If rigid alignment elements are used, then structural stability is improved, but adaptability to thin substrates deteriorates

Engineering Contradiction:

Improvestructural stabilityVSAvoidadaptability to thin substrates

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The alignment rod employs a flexible housing made of soft rubber that can deform to accommodate thin substrates. This flexible shell structure maintains the overall stability of the alignment rod while adapting its shape during contact with substrates of varying thicknesses, thereby improving adaptability without sacrificing structural integrity.

Inventive Principle:

Principle #30Flexible shells and thin films

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides precise and cost-effective alarm detection with reduced substrate damage and false alarms, enabling accurate alignment of thinner substrates while improving the alignment system's flexibility and reducing wear on components.

Implementation Method 1

a capacitor element provided inside the alignment rod, and a capacitance of the capacitor element is changeable as the alignment rod deforms

Methodology Applied

Scientific EffectCapacitance: Capacitance

Implementation Method 2

the housing being made of soft rubber

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9939248B2Alignment apparatus and alignment detection method

Publication Date: 2018.04.10 BOE TECHNOLOGY GROUP CO LTD

AI summary

An alignment apparatus and an alignment detection method, which fall within a field of display technology, are disclosed herein. The alignment apparatus includes: a work table; a plurality of alignment rods provided on the work table, wherein a capacitor element is provided inside the alignment rod, and a capacitance of the capacitor element is changeable as the alignment rod deforms; and an alarm element connected to the capacitor element for giving an alarm when it receives a capacitance change value which exceeds a preset threshold value.