Flexible Circuit Cover Layer Alignment Using Fiducial Cutting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing manufacturing processes for flexible circuits face challenges in accurately aligning layers, requiring high tolerance alignment and limited post-cutting positional adjustment, which hinders yield rate and pattern fineness. Additionally, the use of sacrificial layers for support increases material waste and process complexity.
Innovation Solution
A method and system for manufacturing flexible circuits that involve laminating a first material with a second material containing fiducial information, inspecting the laminated product using a camera to determine the cutting device's position, and cutting the first material using a cutting device, thereby eliminating the need for sacrificial layers and improving layer alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If layers are aligned and laminated before cutting, then layer alignment accuracy is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent applies preliminary action by laminating the workpiece layer with the cover layer before performing cutting operations. This sequence allows alignment to be established prior to cutting, improving alignment accuracy. The fiducial markers are detected and used to determine cutting device repositioning needs before the actual cutting occurs, ensuring precise alignment is maintained throughout the process.
2Stability of the object's composition
If a sacrificial layer is used to maintain pattern positions, then structural connection is improved, but material waste increases
Solution Approach 1:
The patent extracts and eliminates the sacrificial layer from the manufacturing process. Instead of using a separate sacrificial layer to maintain structural connection and pattern positions, the invention uses the cover layer itself in combination with fiducial markers and camera-based detection to achieve the same functional outcomes without the additional material waste.
Solution Approach 2:
The cover layer serves multiple functions: it provides structural support during processing, contains fiducial markers for alignment detection, and eliminates the need for a separate sacrificial layer. This multi-functionality reduces material waste while maintaining the necessary structural connection throughout the manufacturing process.
3Device complexity
If post-cutting positional adjustment is limited, then manufacturing simplicity is maintained, but yield rate decreases
Solution Approach 1:
The patent implements feedback by using a camera to detect fiducial markers on the cover layer after lamination but before cutting. Based on the detected positions, the system determines whether the cutting device needs to be repositioned, allowing for corrective positional adjustments that improve yield rate while maintaining manufacturing simplicity through automated detection and adjustment determination.
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 proposed method and system enhance layer alignment accuracy, reduce material waste, and simplify the manufacturing process by allowing for pre-lamination of layers before cutting, thereby improving yield rate and enabling finer patterns.
Implementation Method 1
inspecting the laminated product via the camera to identify fiducial information the second material
Implementation Method 2
inspecting the laminated product via the camera to identify fiducial information the second material
Data Source
AI summary
A process and a system for manufacturing a flexible circuit, and more particularly, to a process and a system for cutting and/or ablating a material in the manufacture of a flexible circuit. A method of manufacturing a flexible circuit includes supplying a first material, supplying a second material, the second material being a cover layer for the flexible circuit, laminating the first material to the second material to form a laminated product, moving the laminated product proximate to a camera, inspecting the laminated product via the camera to identify fiducial information the second material, determining whether a cutting device needs to be repositioned based on the detected fiducial information, and cutting the first material via the cutting device.