Dispenser Alignment Using Image Cameras and Marks
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Solution Overview
Problem
The existing methods for aligning liquid crystal dispensers in large-scale liquid crystal display panel fabrication are inefficient, leading to significant waste of sealant material, degradation of alignment layers, and increased production costs due to manual handling and space requirements, as well as the need for a dummy substrate that increases processing time and the risk of damage.
Innovation Solution
An apparatus and method for aligning a dispenser using a table with alignment marks, an alignment plate, and image cameras to precisely position syringes for forming seal patterns, eliminating the need for a dummy substrate and allowing for automated alignment and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling and dummy substrate are used for dispenser alignment, then alignment process can be performed, but processing time increases and risk of damage occurs
Solution Approach 1:
The patent replaces manual mechanical handling with an automated alignment system that uses image cameras to capture alignment marks, processes images through a control unit, and automatically adjusts dispenser positions. This eliminates manual operations while maintaining high alignment accuracy and significantly reduces processing time.
Solution Approach 2:
The alignment system performs self-alignment by automatically detecting alignment marks on the substrate, calculating position deviations, and adjusting dispenser positions without requiring dummy substrates or manual intervention. The system serves itself by using the actual production substrate for alignment rather than separate dummy substrates.
2Reliability
If dummy substrate is used for alignment, then alignment can be performed, but clean room space utilization decreases
Solution Approach 1:
The patent extracts the alignment function from the dummy substrate and integrates it directly into the actual production substrate. By detecting alignment marks printed on the substrate itself, the system eliminates the need for separate dummy substrates, thereby freeing up clean room space while maintaining alignment capability.
Solution Approach 2:
The substrate serves multiple functions: it is both the production substrate for sealant dispensing and the alignment reference substrate. The alignment marks on the substrate provide reference for both alignment operations and subsequent production processes, eliminating the need for dedicated dummy substrates.
3Reliability
If traditional alignment method is used, then dispenser can be aligned, but sealant material waste increases
Solution Approach 1:
The alignment system uses image cameras to capture alignment marks, processes the images to calculate position deviations, and provides feedback to automatically adjust dispenser positions. This closed-loop feedback mechanism ensures high alignment precision, enabling accurate sealant dispensing that minimizes material waste.
Solution Approach 2:
The patent replaces manual alignment operations with an automated image-based alignment system that precisely determines dispenser positions relative to substrate features. This automated system achieves superior alignment accuracy compared to manual methods, resulting in more precise sealant application and reduced material waste.
Data Source
AI summary
An apparatus for aligning a dispenser includes a table having a first alignment mark, an alignment plate provided along at least one side of the table, at least one syringe supplying a dispensing material to the alignment plate through a nozzle provided at one end portion thereof to form a second alignment mark, a first image camera provided along a side of the syringe and detecting an image of the second alignment mark, a second image camera detecting an image of the first alignment mark, and an alignment control unit aligning the image of the second alignment mark and a first reference position, and aligning an image of the first alignment mark and a second reference position.