Display Panel Substrate Alignment Using Optical Microscopes and Grippers
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Solution Overview
Problem
Existing display panel fabrication processes face challenges in accurately and quickly aligning transparent insulating substrates with fabrication devices, leading to inefficiencies and increased costs due to frequent alignment corrections.
Innovation Solution
An apparatus and method that utilize optical microscopes to capture alignment marks, calculate rotation corrections, and adjust gripper unit gaps in real-time to precisely align substrates, incorporating a substrate alignment controller to optimize the alignment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional alignment methods are used to place substrates on fabrication devices, then the alignment process can be completed, but the alignment accuracy is insufficient and requires frequent corrections
Solution Approach 1:
The system performs preliminary alignment by capturing images of alignment marks on the substrate before the main fabrication process begins. The controller calculates the deviation angle and adjusts the gripper units in advance, so that when the substrate is placed on the fabrication device, the alignment is already optimized, eliminating the need for frequent corrections during subsequent processes
Solution Approach 2:
The system uses optical microscopes to capture images of alignment marks, feeds this information back to the controller, which then calculates the deviation angle and automatically adjusts the gripper units. This closed-loop feedback mechanism ensures high alignment accuracy by continuously monitoring and correcting the substrate position based on actual measured data
2Productivity
If manual or conventional automated alignment is used, then the process can proceed, but the alignment speed is slow and affects productivity
Solution Approach 1:
The system replaces manual mechanical alignment operations with an automated optical-mechanical system. Optical microscopes capture alignment mark images, the controller calculates deviation angles, and motorized gripper units automatically adjust substrate position. This substitution of manual mechanical operations with automated sensor-actuator systems dramatically increases alignment speed and overall fabrication productivity
3Manufacturing precision
If simple alignment devices are used, then the device complexity is low, but the alignment precision and correction capability are insufficient
Solution Approach 1:
The alignment device integrates multiple functions into a single system: optical microscopes serve both as imaging devices and as measurement tools for detecting alignment mark positions; the controller performs both image processing and deviation angle calculation; the gripper units provide both substrate holding and precision positioning functions. This multi-functionality achieves high manufacturing precision without proportionally increasing device complexity
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
This approach enables faster and more accurate alignment of substrates, reducing the need for repeated corrections and thereby saving time and costs in the fabrication of display panels.
Implementation Method 1
a plurality of optical microscopes that captures the fabrication substrate and a plurality of alignment marks of the fabrication substrate
Data Source
AI summary
An apparatus for fabricating a display panel includes a loading plate on which a fabrication substrate is loaded, a plurality of optical microscopes that captures the fabrication substrate and alignment marks of the fabrication substrate, a gripper driver that aligns the fabrication substrate by adjusting a gap between gripper units and rotating the gripper units; and a substrate alignment controller that calculates an amount of rotation correction for the gripper units based on a deviated angle of the fabrication substrate to supply it to the gripper driver, calculates a gripper gap setting value for adjusting the gap between the gripper units using a residual of the aligned fabrication substrate, and provides the gripper gap setting value to the gripper driver.