Multi-Stage Alignment and Lamination for Precise Display Positioning
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Solution Overview
Problem
Existing manufacturing processes for display devices face challenges in reducing alignment errors due to material or process variations, leading to reduced yield.
Innovation Solution
An alignment device and lamination device that include a first stage with multiple base plates and second stages capable of aligning materials in X, Y, and θ directions, along with pitch control units and load distribution units to handle materials of varying sizes and gaps, ensuring precise alignment and load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple materials are aligned simultaneously using a single stage, then productivity is improved, but alignment precision deteriorates due to material and process variations
Solution Approach 1:
The alignment device is divided into multiple independent stages (first stage, second stage, third stage), each capable of independently aligning materials. This segmentation allows simultaneous processing of multiple materials while maintaining individual alignment precision for each material, resolving the contradiction between increased productivity and maintained alignment precision.
2Adaptability or versatility
If the alignment device handles materials of varying sizes and gaps, then adaptability is improved, but device complexity increases
Solution Approach 1:
Each stage is equipped with pitch control units that enable dynamic adjustment of the distance between adjacent base plates. This dynamic adaptability allows the device to handle materials of varying sizes and gaps without requiring multiple fixed configurations, achieving versatility while maintaining manageable structural complexity through standardized modular components.
3Manufacturing precision
If load distribution units are added to handle varying material sizes, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Load distribution units are segmented and assigned to specific stages and base plates where they are most needed. Rather than uniformly distributing complexity across the entire device, the load distribution functionality is strategically placed at critical alignment points, improving manufacturing precision while minimizing overall device complexity through targeted rather than universal implementation.
Data Source
AI summary
An alignment device includes: a first stage; a plurality of base plates disposed on the first stage and on which a material is placed; and a plurality of second stages disposed under the first stage, and connected to the plurality of base plates, respectively, and capable of aligning each of the plurality of base plates in X, Y, and ⊖ directions.