Laser Thermal Imaging Alignment Correction
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Solution Overview
Problem
The existing laser induced thermal imaging method faces challenges in confirming and correcting position inferiority or misalignment of the imaging pattern during mass production, as it is difficult to precisely align the laser beam with the pixel region before the imaging process is completed.
Innovation Solution
A laser induced thermal imaging device and method that includes a substrate stage, a beam radiation portion, an error measurement portion, and a stage moving portion, where cameras measure the pattern error between the laser beam and pixel region from the waste donor film and automatically correct the alignment by moving the substrate stage, ensuring precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual position confirmation using optical microscope is used to align laser beam and pixel region, then position alignment can be achieved, but it is difficult to confirm and correct position inferiority during mass production imaging process
Solution Approach 1:
The patent implements a feedback mechanism where the camera captures the imaging pattern on the substrate, measures the position error between the laser beam and pixel region, and automatically feeds this error information to the stage moving portion for correction. This closed-loop feedback system enables automatic position correction during mass production while maintaining high measurement precision.
Solution Approach 2:
The patent replaces the manual optical microscope-based position confirmation method with an automated optical measurement system. The camera captures images of the imaging pattern, and automated image processing algorithms calculate position errors, eliminating the need for manual observation and correction while improving both automation extent and measurement precision.
2Measurement precision
If pre-imagings are performed to confirm position before imaging process, then position error can be detected, but it cannot correct position inferiority during mass production imaging process
Solution Approach 1:
The patent performs preliminary position measurement by capturing an image of the imaging pattern before the actual imaging process. The measured position error is then used to pre-adjust the stage position, ensuring that the laser beam is correctly aligned with the pixel region before imaging begins. This preliminary action prevents position inferiority from affecting manufacturing precision.
Solution Approach 2:
The system uses feedback from the camera measurement to automatically adjust the stage position before imaging. The position error detected during pre-imagings is fed back to the stage moving portion, which corrects the alignment, ensuring that subsequent imaging operations achieve high manufacturing precision without manual intervention.
3Manufacturing precision
If automatic position correction system is implemented, then position inferiority can be corrected during imaging process, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a unified system: the camera serves both as a measurement device for detecting position error and as a guidance device for correction. The stage moving portion performs both positioning and correction functions. This multi-functionality reduces the need for separate dedicated components, thereby limiting the increase in device complexity while achieving high manufacturing precision.
Solution Approach 2:
The patent introduces a controller as an intermediary that coordinates between the camera measurement system and the stage moving portion. The controller processes the position error data from the camera and generates appropriate correction commands for the stage, simplifying the overall system architecture by providing a centralized coordination point rather than requiring direct complex interconnections between all components.
4Extent of automation
If camera-based measurement system is used to measure pattern error, then automatic position correction becomes possible, but device complexity and cost increase
Solution Approach 1:
The system uses the existing imaging pattern on the substrate as the measurement target, eliminating the need for separate calibration patterns or additional reference markers. The camera captures the actual imaging pattern that will be produced, and the system automatically processes this image to determine position error. This self-service approach reduces device complexity by utilizing already-present features rather than requiring additional measurement infrastructure.
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 solution allows for automatic and precise correction of pixel region positions during the imaging process, reducing position inferiority and ensuring reliable pattern precision across multiple substrates.
Implementation Method 1
radiating a laser beam on the donor film to convert light energy of the laser beam into heat energy
Data Source
AI summary
A laser induced thermal imaging device includes a substrate stage configured to support a substrate and a donor film; a beam radiation portion configured to emit a laser beam toward the donor film to image an imaging layer of the donor film on a pixel region on the substrate; an error measurement portion configured to determine a position of the laser beam and a position of the pixel region from the donor film to measure a pattern error; and a stage moving portion configured to move the substrate stage in accordance with the pattern error to correct the pattern error.