Light Guide Substrate Alignment Marks for Thermal Expansion Compensation
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Solution Overview
Problem
In integrated light-emitting devices with light-emitting elements joined to a light guide plate, thermal treatment during production causes expansion, leading to positional deviations of the light guide plate, which complicates the cutting process and reduces manufacturing yield due to misalignment of cut regions.
Innovation Solution
A light guide body aggregate substrate with a matrix arrangement of unit regions and alignment marks is used, allowing for precise cutting by referencing these marks to minimize the impact of thermal expansion, ensuring accurate positioning and higher yield production of smaller integrated light-emitting devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If light-emitting elements are joined to a light guide plate to reduce device thickness, then the device thickness is reduced, but thermal expansion of the light guide plate causes positional deviations that complicate the cutting process and reduce manufacturing yield
Solution Approach 1:
The patent applies preliminary action by forming alignment marks on the light guide plate before the cutting process. These marks serve as reference points that are established in advance to compensate for thermal expansion deviations that occur during subsequent manufacturing steps. The alignment marks are positioned in regions that remain relatively stable during thermal treatment, allowing the cutting process to reference these pre-established markers for accurate positioning despite thermal expansion of the light guide plate.
2Strength
If thermal treatment is performed during production to join light-emitting elements, then the light-emitting elements are securely attached, but the light guide plate expands causing misalignment of cut regions
Solution Approach 1:
The patent uses alignment marks as an intermediary element that mediates between the thermal expansion of the light guide plate and the cutting process. These marks are positioned in marginal regions or specific stable zones of the light guide plate that experience minimal expansion during thermal treatment. The cutting process references these intermediary alignment marks rather than relying directly on the original design positions, thereby compensating for thermal expansion and maintaining cut region alignment despite the strength-gaining thermal treatment.
3Productivity
If the light guide plate is cut into smaller units after assembly, then individual integrated light-emitting devices are produced, but thermal expansion causes positional deviations that reduce manufacturing yield
Solution Approach 1:
The patent implements feedback by using alignment marks as reference points that provide positional information for the cutting process. The cutting apparatus references these alignment marks to determine accurate cut positions, effectively using the marks as a feedback mechanism to compensate for thermal expansion deviations. This feedback-based positioning system allows the cutting process to adapt to the actual positions of features on the light guide plate after thermal treatment, thereby maintaining high manufacturing precision and productivity.
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
The solution effectively reduces the influence of thermal expansion on the light guide plate, allowing for precise cutting and maintaining high manufacturing yield by using alignment marks to adjust for positional shifts, ensuring accurate placement and concentricity of light guide structures in the final integrated light-emitting devices.
Implementation Method 1
a light guide structure; light emitted from the one or more light-emitting elements enters the light guide structure
Implementation Method 2
light guide structure
Data Source
AI summary
A light guide body aggregate substrate includes: a light-transmitting substrate having a main surface; a plurality of unit regions located at the main surface of the substrate, wherein the plurality of unit regions are spaced apart from each other, wherein the plurality of unit regions are arranged one-dimensionally in one row extending in a first direction and a plurality of columns, or arranged two-dimensionally in a plurality of rows extending in the first direction and a plurality of columns extending in a second direction, and wherein a light guide structure is located in each unit region; a first region located at the main surface of the substrate, surrounding the plurality of unit regions; and a 1-A alignment mark and a 1-B alignment mark arranged at the substrate in the first region.