Optical Bonding Machine With Visual Feedback and In-Place UV Curing
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Solution Overview
Problem
Existing optical bonding machines face challenges in preventing air pockets and defects during the bonding of substrates, as they require precise control of adhesive spreading and curing, often necessitating vacuum conditions and additional equipment for curing.
Innovation Solution
An optical bonding machine with a transparent datum, a robotic placement head, and a camera for real-time visual feedback, allowing for automated substrate alignment and adhesive flow monitoring, along with a curing source for in-place curing without the need for vacuum, ensuring accurate bonding and defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional optical bonding machines use vacuum conditions and additional curing equipment, then curing can be achieved, but device complexity increases and productivity decreases
Solution Approach 1:
The patent combines the bonding and curing operations into a single integrated machine. The curing source is positioned within the same chamber where substrates are bonded, eliminating the need for separate curing equipment and vacuum systems. This merging of functions reduces device complexity while maintaining reliable curing capability.
Solution Approach 2:
The bonding chamber serves multiple functions: it accommodates both the bonding operation and the curing process. The transparent datum and chamber design allow the same space to be used for both adhesive application and subsequent curing, making the equipment multi-functional and reducing overall system complexity.
2Manufacturing precision
If substrates are bonded with adhesive spreading control, then bonding quality improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates a camera system that captures real-time video of the adhesive flow between substrates. This visual feedback allows operators to monitor adhesive spreading and make adjustments during the process, improving bonding quality without requiring extremely precise pre-control of adhesive application.
Solution Approach 2:
The adhesive spreading process benefits from self-regulation through the capillary effect and visual monitoring. The system allows the adhesive to naturally spread between substrates while providing visual feedback, reducing the need for highly precise mechanical control of the spreading process itself.
3Ease of operation
If real-time visual feedback is implemented with camera and transparent datum, then operator intervention capability improves, but device complexity increases
Solution Approach 1:
The camera system provides real-time visual feedback of the bonding process, allowing operators to monitor adhesive flow and substrate alignment. This feedback capability improves ease of operation by enabling timely interventions while using relatively simple optical components rather than complex sensing systems.
Solution Approach 2:
The transparent datum acts as an intermediary element that allows optical access to the bonding interface. It enables the camera to view the adhesive flow between substrates without requiring complex transparent windows or access mechanisms, simplifying the overall system while providing necessary visual feedback.
4Productivity
If bonding is performed at atmospheric pressure without vacuum, then productivity improves, but manufacturing precision may deteriorate
Solution Approach 1:
The patent changes the operating pressure parameter from vacuum to atmospheric pressure, significantly improving productivity by eliminating vacuum pump requirements and allowing faster cycle times. The transparent chamber design and controlled adhesive application maintain sufficient bonding precision at atmospheric pressure.
Solution Approach 2:
The bonding process is segmented into distinct phases: adhesive application, substrate alignment (monitored via camera), and curing. This segmentation allows each phase to be optimized independently, maintaining precision in alignment and curing even while operating at atmospheric pressure for improved overall 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 machine achieves precise optical bonding at atmospheric pressure with reduced risk of air pockets and defects, providing real-time visual feedback for operator intervention and automatic defect detection, while eliminating the need for separate curing equipment, thus enhancing efficiency and accuracy.
Implementation Method 1
a camera disposed proximate the transparent datum, the camera capturing a video of a flow of an optically clear adhesive between the first substrate and the second substrate
Implementation Method 2
a transparent datum, the transparent datum located within an interior region of the optical bonding machine
Data Source
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AI summary
An optical bonding machine is provided, including a transparent datum located within the optical bonding machine, wherein the transparent datum supports a first substrate, a robotic placement head configured to pick up a second substrate and place the second substrate into contact with the first substrate, on the transparent datum, a camera disposed proximate the transparent datum, the camera capturing a video of a flow of an optically clear adhesive between the first substrate and the second substrate, and a curing source disposed proximate the transparent datum, the curing source emitting UV rays that pass through the transparent datum and the first substrate to cure an optically clear adhesive between a bonded substrate comprising the first substrate, the optically clear adhesive, and the second substrate. An associated method is also provided.