Multi-Camera Laser Patterning Alignment for Skew Correction
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Solution Overview
Problem
Current methods for touch sensor patterning and printed electronics manufacturing, such as photolithography and laser processing, face inefficiencies due to high cycle times, costly consumables, toxic waste, and misalignment issues in laser systems, which hinder the production of smaller and more portable computing devices.
Innovation Solution
A laser patterning alignment method using multiple cameras to detect fiducial marks on a target, sending location data to a controller for corrections, and adjusting the laser scanning field to align the target with expected fiducial mark locations, allowing for high-precision processing without mechanical adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser processing techniques are used, then material processing capability is achieved, but misalignment between laser system and processing targets occurs
Solution Approach 1:
The patent replaces mechanical alignment systems with an optical vision system. Multiple cameras capture images of fiducial marks on the substrate, and software algorithms calculate precise alignment corrections. This optical approach eliminates mechanical wear and drift issues while achieving sub-micrometer alignment precision, directly resolving the contradiction between manufacturing precision and reliability.
Solution Approach 2:
The patent creates a digital copy of the substrate's actual position by capturing images of fiducial marks with cameras. This optical copy is then processed through coordinate transformation algorithms to determine the exact alignment offset between the laser scanning field and the substrate. This copying approach enables non-contact, high-precision measurement that maintains consistency across multiple processing cycles.
2Manufacturing precision
If multiple processing steps are used in photolithography or screen printing, then patterning capability is achieved, but cycle time increases
Solution Approach 1:
The patent merges multiple processing steps into a single laser processing operation. By using the vision system to capture the complete substrate geometry and pattern requirements, the system can perform complex patterning tasks that previously required sequential photolithography or screen printing steps. This consolidation eliminates intermediate handling and processing steps, significantly reducing cycle time while maintaining patterning capability.
Solution Approach 2:
The patent performs preliminary actions by capturing images of fiducial marks and calculating alignment corrections before the actual laser processing begins. The coordinate transformation and alignment offset calculations are completed in advance, allowing the laser system to immediately begin processing without waiting for mechanical alignment adjustments. This preliminary computational preparation eliminates setup time and enables rapid production.
3Productivity
If conventional alignment methods are used, then processing can proceed, but alignment precision is insufficient
Solution Approach 1:
The patent replaces slow mechanical alignment methods with rapid optical measurement and computational correction. Multiple cameras simultaneously capture substrate positions, and software algorithms instantly calculate precise alignment offsets. This approach achieves sub-micrometer alignment accuracy in seconds, compared to minutes or hours required for mechanical adjustment, thereby simultaneously improving both processing speed and alignment accuracy.
Solution Approach 2:
The patent implements a feedback mechanism where the vision system continuously monitors substrate position through fiducial mark detection. The system uses this feedback information to dynamically adjust the laser scanning field alignment in real-time. This closed-loop control ensures high alignment accuracy is maintained throughout the processing operation, enabling fast processing speeds without sacrificing precision.
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 reduces misalignment errors to micrometer levels, enabling rapid and efficient processing of substrates, reducing cycle times and costs associated with conventional methods, while maintaining high precision in manufacturing.
Implementation Method 1
three or more cameras positioned in relation to a system laser scanning field and each configured to detect fiducial marks in view thereof
Implementation Method 2
at least one laser scanner configured to scan corresponding laser beams in the system laser scanning field for processing a target therein
Implementation Method 3
high-precision laser material processing
Data Source
AI summary
A laser patterning alignment method provides a way to position a target at a working distance in a laser patterning system such that fiducial marks on the target are positioned in view of at least three laser patterning system cameras, and with each laser patterning system camera, to locate a fiducial mark on the target and sending location data of the located fiducial mark to a controller, to determine corrections required to align expected fiducial mark locations with the sent fiducial mark location data, and to adjust the laser patterning system with the determined corrections.