Panel Alignment Marks for Multi-Layer Lamination Without Interference
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Solution Overview
Problem
Existing methods for aligning and laminating large-sized and medium-sized cholesterol liquid crystal display panels face challenges due to the low strength of thin glass substrates, which can cause damage, and the interference of alignment marks on middle panels, leading to panel damage or pollution, and require additional expensive photomasks.
Innovation Solution
A method using a photomask to form alignment marks on four corners of each panel, with symmetrical and asymmetrical marks, allowing panels to be rotated and aligned without interference, and using multiple cameras to capture clear images for accurate alignment and laminating, forming multi-layer panels without additional processing or damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thin glass substrate is used to capture alignment marks, then alignment mark visibility is improved, but substrate strength deteriorates causing damage during placement or touching
Solution Approach 1:
The patent changes the parameter of substrate thickness from thin to medium or large thickness, which improves strength while maintaining alignment mark visibility through optical imaging techniques that can penetrate thicker substrates
2Area of stationary object
If medium-sized or large-sized panels are used, then panel size is improved, but alignment mark clarity deteriorates due to interference from middle position alignment marks
Solution Approach 1:
The patent segments the alignment marks into different types: corner alignment marks and shifting marks. The shifting marks at middle positions are designed with different characteristics (asymmetric shape, different size) than corner marks, allowing the imaging system to distinguish and prioritize corner marks for alignment while filtering out interference from middle position marks
Solution Approach 2:
The patent applies asymmetry by designing shifting marks with asymmetric shapes that differ from the symmetric corner alignment marks. This asymmetry allows the imaging system to differentiate between corner marks (used for alignment) and middle position marks (to be filtered), thereby improving alignment mark clarity for large-sized panels
3Measurement precision
If alignment marks are eliminated or canceled to avoid interference, then alignment mark clarity is improved, but panel damage or pollution occurs or additional expensive photomask investment is required
Solution Approach 1:
The patent makes the photomask universal by designing it to form both corner alignment marks and shifting marks in a single exposure process. The same photomask serves multiple functions: creating alignment marks for corner alignment and creating shifting marks that will be filtered out, eliminating the need for separate photomasks or additional processing steps
Solution Approach 2:
The patent uses optical copying through imaging systems to capture alignment marks without physical contact. The imaging system creates an optical copy of the alignment marks on the panel surface, allowing alignment to be performed visually or through image processing without requiring physical manipulation that could cause damage or pollution
Data Source
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AI summary
A method of aligning and laminating for panels includes forming alignment marks on each of the panels via a photomask, aligning and laminating the first panel and the second panel to form a double layer panel and aligning and laminating the double layer panel and the third panel to form a triple layer panel. The shifting mark is asymmetric to the first corner mark, the second corner mark and the third corner mark. The first corner mark and the third corner mark of the first panel are aligned to the third corner mark and the first corner mark of the second panel, respectively, and the double layer panel is formed after laminating. The second corner mark and the shifting mark of the first panel are aligned to the second corner mark and the shifting mark of the third panel, respectively. The triple layer panel is formed after laminating.