Flexible Electronic Device Manufacturing Apparatus with Phase Detection
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Solution Overview
Problem
The existing methods for manufacturing flexible electronic devices, such as those using photolithography, require time-consuming and costly processes, and alternative methods like printed electronics face challenges in accurately aligning and stacking multiple layers, increasing manufacturing man-hours and costs.
Innovation Solution
A flexible-electronic-device manufacturing apparatus that utilizes an impression cylinder with attached processing units, including printing and coating devices, and phase detection systems to perform multiple processes sequentially on a base material with reduced positioning requirements, allowing for accurate stacking of layers with fewer manual interventions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple layers are stacked by moving the base material among different apparatuses, then each layer can be formed with dedicated equipment, but the positioning burden and manufacturing time increase significantly
Solution Approach 1:
The patent combines multiple layer formation processes into a single integrated apparatus. The impression cylinder integrates the base material conveyance function and the positioning function, allowing multiple layers to be stacked without moving the base material between separate apparatuses. This merging eliminates the time-consuming positioning operations while maintaining alignment accuracy through the integrated design.
Solution Approach 2:
The impression cylinder serves multiple functions simultaneously: it conveys the base material through the apparatus and provides the positioning reference for stacking multiple layers. This multi-functional design eliminates the need for separate positioning apparatuses, reducing manufacturing time while maintaining precision.
2Manufacturing precision
If photolithography is used to form finely-patterned interconnections, then high manufacturing precision is achieved, but the process becomes time-consuming and costly
Solution Approach 1:
The patent replaces the complex photolithography process with a printing-based approach. Instead of using photomasks, photoresists, and chemical development processes, the invention uses printing means to directly form finely-patterned interconnections. This substitution maintains manufacturing precision while dramatically improving productivity and reducing costs.
Solution Approach 2:
The patent changes the fundamental parameter of the manufacturing process from photolithography (light-based) to printing (mechanical deposition). This parameter change allows for direct pattern formation without the time-consuming steps of photolithography, achieving both high precision and improved productivity.
3Manufacturing precision
If manual positioning is performed for each layer stacking step, then alignment accuracy can be maintained, but the operator burden and manufacturing cost increase
Solution Approach 1:
The impression cylinder performs positioning automatically through its integrated design. The cylinder's structure provides inherent positioning references that guide the stacking process without requiring manual intervention. This self-service mechanism maintains alignment accuracy while eliminating the need for operator positioning operations.
Solution Approach 2:
The impression cylinder acts as an intermediary that provides automated positioning between the layer formation processes. Instead of direct manual positioning, the cylinder mediates the alignment process through its structured design, reducing operator burden while maintaining precision.
Data Source
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AI summary
A flexible-electronic-device manufacturing apparatus (1) for manufacturing an electronic device including a flexible base material (100) and a plurality of functional layers (110, 120, 130, 140) provided thereon includes: an impression cylinder (30) configured to hold and transport the base material (100); impression-cylinder driving means (230) for rotating the impression cylinder (30); processing means (40, 50, 60, 70) for performing a plurality of processes for providing the plurality of functional layers (110, 120, 130, 140) by a printing method or a coating applying method on the base material (100) held on the impression cylinder (30); impression-cylinder phase detecting means (201) for detecting the phase of the impression cylinder (30); and controlling means (200) for controlling the impression-cylinder driving means (230) and the processing means (40, 50, 60, 70) based on the result of detection by the impression-cylinder phase detecting means (201).