Suction Alignment via Complementary Surface Relief Features
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Solution Overview
Problem
Existing precision alignment methods face challenges in achieving high accuracy and speed simultaneously, often requiring complex and expensive equipment, and are limited by lateral and asymmetric movements during adhesive curing, necessitating a clean room environment for field-assembly.
Innovation Solution
A method and apparatus utilizing surface relief features with complementary tapered protrusions and recesses, where suction is applied through a channel system to align structures in a plane perpendicular to the drawing direction, restricting relative rotation and allowing precise mating of features, enabling accurate and efficient alignment without the need for clean-room conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If visual passive alignment is used to achieve high accuracy, then alignment precision is improved, but cycle time increases and throughput decreases
Solution Approach 1:
The patent replaces complex mechanical alignment systems with a simplified suction-based mechanical alignment system. The suction cup mechanism provides both alignment and bonding functions, eliminating the need for separate mechanical alignment devices and reducing cycle time while maintaining precision.
Solution Approach 2:
The alignment features on the components self-align through the suction force application. The complementary alignment features guide the components into proper alignment automatically when suction is applied, eliminating the need for external alignment equipment or operators.
2Manufacturing precision
If mechanical passive alignment features are used to achieve high throughput and accuracy, then productivity and precision are improved, but device complexity increases due to grooves and ridges
Solution Approach 1:
The patent extracts the alignment function from complex mechanical features and integrates it into the suction cup mechanism itself. The alignment features are simple protrusions and recesses that work in conjunction with the suction force, rather than requiring separate grooves and ridges on the components.
3Manufacturing precision
If conventional alignment methods are used, then alignment is achieved, but lateral and asymmetric movements occur during adhesive curing
Solution Approach 1:
The patent applies suction force before adhesive curing to establish and maintain alignment. The suction cup holds the components in precise alignment during the entire curing process, preventing lateral and asymmetric movements that would otherwise occur.
Solution Approach 2:
The suction cup acts as an intermediary mechanism that maintains alignment between components during curing. It provides continuous corrective force to counteract any lateral movements, ensuring alignment stability throughout the adhesive curing process.
4Manufacturing precision
If complex aligning equipment is used to achieve high precision alignment, then manufacturing precision is improved, but cost increases
Solution Approach 1:
The suction cup mechanism performs multiple functions: alignment, bonding, and holding during curing. This multi-functionality eliminates the need for separate alignment equipment, reducing overall system cost while maintaining high alignment precision.
5Manufacturing precision
If conventional alignment methods are used, then alignment is achieved, but clean room conditions are required for field-assembly
Solution Approach 1:
The patent replaces complex mechanical alignment systems with a simple suction-based system that is less sensitive to environmental contaminants. The suction mechanism and alignment features are robust enough to function in field conditions without requiring clean room environments.
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
This approach achieves precise alignment with reduced cycle time and cost, allowing for field-assembly of components while maintaining high accuracy, suitable for applications like optical storage technology, by using suction to align structures through surface relief features, thereby overcoming the limitations of existing methods.
Implementation Method 1
applying suction in the channel system to draw the first and second structures together in a drawing direction
Data Source
AI summary
A method of aligning a first and a second structure, the first structure comprising one or more first surface relief features and a channel system communicating with a surface of the first structure at one or more of the first surface relief features, the second structure comprising one or more second surface relief features shaped complementarily to the first surface relief features; the method comprising: generating suction in the channel system to draw the first and second structures together in a drawing direction; wherein, when the first and second structures are drawn together, the interaction between one or more of the first surface relief features and one or more of the second surface relief features aligns the structures in a plane perpendicular to the drawing direction such that the first and second surface relief features mate.