Photomask Edge Test Patterns for Multi-Exposure Alignment
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Solution Overview
Problem
During the manufacturing of large-sized display devices, misalignment of photomasks can occur when using smaller masks, leading to wires being formed at boundaries between exposure regions with shapes different from their original design.
Innovation Solution
A photomask with test patterns of varying shapes along its edges, allowing for the detection of alignment errors through a series of exposure processes, enabling correction and ensuring wires are formed as originally designed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a photomask smaller than the display device is used and shifted for multiple exposures, then the photomask can be used for large-sized display devices, but misalignment occurs leading to wires positioned at boundaries differently from their originally designed shape
Solution Approach 1:
The patent applies preliminary action by placing test patterns on the photomask before the exposure process. These test patterns enable detection of alignment errors before actual wire formation, allowing correction of misalignment issues that would otherwise cause wires to be positioned incorrectly at boundaries during multi-exposure processes for large-sized display devices
Solution Approach 2:
The patent implements feedback by using test patterns that provide information about alignment accuracy. The test patterns are exposed along with the main patterns, and their resulting positions are measured to determine whether the photomask was properly aligned during shifting. This feedback mechanism allows operators to detect and correct alignment errors, ensuring wires are formed at their intended positions rather than at incorrect boundary locations
2Productivity
If photomask alignment is not checked, then the manufacturing process is simpler and faster, but wires are formed at boundaries with shapes different from their original design
Solution Approach 1:
The patent applies preliminary action by incorporating test patterns into the photomask design before manufacturing begins. These test patterns are exposed simultaneously with the main wire patterns, enabling alignment verification to be performed as part of the normal exposure process without requiring separate additional steps, thus maintaining manufacturing speed while ensuring wire shape accuracy
Solution Approach 2:
The patent implements self-service by designing the photomask to contain its own alignment verification mechanism. The test patterns on the photomask automatically provide alignment information during the exposure process itself, eliminating the need for external alignment checking equipment or procedures. This allows the photomask to serve both as the exposure tool and as its own alignment verification system, maintaining productivity while ensuring manufacturing precision
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 method effectively checks and corrects alignment errors during the exposure process, ensuring that wires are formed with their intended shape, thereby improving the accuracy of display device manufacturing.
Implementation Method 1
A photo process includes an exposure process and a development process, and a photomask may be used during the exposure process. Light may not pass through a portion of the photomask in which a predetermined pattern is formed while light may pass through a portion on which the predetermined pattern is not formed.
Data Source
AI summary
A photomask according to an exemplary embodiment includes: a mask substrate; and a first test pattern and a second test pattern disposed along a first edge of the mask substrate, wherein the first test pattern has a first outer shape and a first inner shape, the second test pattern has a second outer shape, and the second outer shape of the second test pattern is larger than the first inner shape of the first test pattern and smaller than the first outer shape of the first test pattern.


