Irregular-Shaped Lamination Alignment via Tangent-Derived Straight Lines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The lamination process for touch panels with irregular shapes faces challenges in alignment, leading to appearance defects and reduced yield due to the inability to accurately align non-planar and curved materials.
Innovation Solution
A method is developed to define a shape-aligned feature by drawing a tangent line on the irregular-shape laminating material, moving it to form a parallel line, removing the region between them to create a straight line feature, which is recognized by the lamination machine for alignment, ensuring the material does not overhang and aligning it with the laminated object using equations like E=½√(X²+Y²+Z²) for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional lamination machines use CCD alignment or mechanical alignment for irregular-shaped materials, then alignment capability is improved, but the materials still overhang over the laminated object causing appearance defects
Solution Approach 1:
The patent applies preliminary action by pre-defining shape-aligned features (straight lines derived from tangent lines) on the irregular-shaped laminating material before the lamination process. This preprocessing step creates reference features that enable the lamination machine to accurately determine the alignment relationship between the laminating material and the laminated object, preventing overhang and appearance defects before they occur.
2Manufacturing precision
If the lamination machine adjusts tolerances to prevent overhanging, then appearance quality is improved, but alignment complexity increases
Solution Approach 1:
The patent applies self-service by making the laminating material itself provide the alignment reference through its shape-aligned features. The straight lines defined on the irregular-shaped material serve as self-contained alignment references that the lamination machine can detect and use, eliminating the need for complex external alignment mechanisms or procedures.
3Adaptability or versatility
If irregular-shaped materials are used for non-planar products, then product versatility is improved, but alignment accuracy deteriorates
Solution Approach 1:
The patent applies local quality by introducing shape-aligned features (straight lines) at specific locations on the irregular-shaped laminating material. These localized features provide precise alignment references without requiring the entire irregular shape to be regular, thus maintaining both product versatility and alignment accuracy.
Data Source
AI summary
A method for laminating and aligning an irregular-shape material is disclosed. Since the existing laminating material has an irregular shape, there is a problem with disabling alignment in a lamination process. Thus, the irregular shape of the laminating material is used to form a straight line correlated with a tangent line to the shape, and the straight line is used as the shape-aligned feature of the laminating material. Besides, the definition of an alignment relationship between the laminating material and a laminated object is established to adjust a lamination tolerance and prevent the laminating material from overhanging over the laminated object, thereby satisfying consumers' aesthetic needs for the appearance of products.