Flexible Circuit Board Processing with Dynamic Target Alignment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for processing flexible circuit boards face challenges due to their non-rigid nature, which causes shifting, stretching, or deformation during processing, leading to positional errors and requiring rigid support or frequent chuck plate changes, resulting in delays and misaligned patterns.

Innovation Solution

The method involves breaking down a single-panel application into multiple applications, aligning and processing each region sequentially using coarse and panel targets, and refreshing alignment information for each application, allowing for dynamic correction of positional errors and accommodating varying panel sizes without the need for frequent chuck plate changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If rigid support or frequent chuck plate changes are used to process flexible circuit boards, then positional accuracy is improved, but processing time increases and device complexity increases

Engineering Contradiction:

Improvefeature placement accuracyVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system dynamically adjusts processing parameters and re-locates targets between processing applications. The controller continuously updates the coordinate system based on measured target locations, allowing the processing system to adapt to panel deformation in real-time without requiring rigid support or frequent chuck plate changes

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system measures the location of targets on the panel and uses this feedback information to correct the coordinate system for subsequent processing applications. This closed-loop feedback mechanism compensates for panel deformation and maintains feature placement accuracy without requiring physical repositioning of the panel or chuck plate

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If rigid support is used to prevent shifting and stretching of flexible circuit boards, then manufacturing precision is improved, but the panel cannot accommodate its non-rigid nature and requires additional support structures

Engineering Contradiction:

Improvepositional accuracyVSAvoidsupport structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system replaces mechanical rigid support structures with a software-based coordinate correction system. Instead of using complex rigid fixtures and support structures to prevent panel deformation, the system uses optical target measurement and computational coordinate transformation to compensate for deformation, eliminating the need for additional mechanical support structures

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If frequent chuck plate changes are performed to accommodate varying panel sizes, then adaptability is improved, but processing time increases and productivity decreases

Engineering Contradiction:

Improvepanel size accommodationVSAvoidprocessing throughput

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The chuck plate is designed to universally accommodate multiple panel sizes without requiring changes to the processing system. The system measures targets on panels of varying sizes and automatically adjusts the coordinate system, allowing a single chuck plate to handle different panel configurations, thereby eliminating the need for frequent chuck plate changes and maintaining high productivity

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If multiple applications are processed in sequence on the same load, then productivity is improved by reducing chuck plate changes, but positional errors may accumulate without dynamic correction

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidpositional accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary target location measurements before each processing application and pre-calculates the coordinate transformation needed. By measuring targets and updating the coordinate system in advance of each application, the system prevents positional errors from accumulating and ensures accurate feature placement throughout the multi-application sequence

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS7437207B2Method and apparatus for automatically processing multiple applications in a predetermined order to affect multi-application sequencing

Publication Date: 2008.10.14 ELECTRO SCI IND INC

AI summary

An apparatus and method performing a sequence of processing steps on a load supported by a processing plate. The load can include a single sheet on which a plurality of applications are performed or can include a plurality of panels on which respective applications are performed. For each application, at least one coarse target and at least one panel target are used to adjust the programmed coordinates for that application. After the first application of the load is processed using the coarse and panel targets, coarse and panel targets are located for the second application. Using the alignment provided by these targets, the second application is processed. Each subsequent application is similarly aligned and processed.