Transfer Roller Alignment via Calibration Plate
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Solution Overview
Problem
The increasing density and integration of devices require higher measurement accuracy for ink patterns formed on substrates during offset printing, which is hindered by assembly errors and measurement errors that increase over time in existing transfer devices.
Innovation Solution
A transfer device utilizing a calibration plate with alignment marks and imagers to adjust the position and orientation of the transfer roller, ensuring accurate alignment and reducing assembly errors, allowing for high-precision transfer of electronic device components to a desired position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If offset printing is used to form patterns on substrates, then the number of manufacturing steps is reduced, but measurement accuracy of the transferred ink pattern deteriorates due to assembly errors and time-dependent measurement errors
Solution Approach 1:
The patent applies preliminary action by performing calibration before the actual printing process. A calibration plate with known alignment marks is printed first to establish reference positions, and measurement errors are detected and corrected in advance. This preliminary calibration step ensures that subsequent production printing maintains high measurement accuracy while still using the efficient offset printing method.
Solution Approach 2:
The patent implements feedback by using alignment marks on the calibration plate to detect measurement errors in the offset printing system. The detected errors are then used to correct the printing process, creating a closed-loop control system. This feedback mechanism continuously monitors and adjusts for assembly errors and time-dependent drift, maintaining measurement accuracy without adding multiple printing steps.
2Measurement precision
If alignment marks are used to correct attachment position errors, then measurement accuracy is improved, but assembly complexity increases due to additional calibration components
Solution Approach 1:
The patent uses copying by creating a calibration plate that contains alignment marks representing the ideal positions. This calibration plate serves as a reference copy that is used to detect and correct errors in the actual printing process. The alignment marks on the calibration plate are copied or replicated to establish the correct positioning, allowing for error detection and correction without significantly increasing assembly complexity.
3Measurement precision
If multiple imagers are used to detect alignment marks in different directions, then measurement accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies universality by designing a single imager that can detect alignment marks in multiple directions through rotational movement. Instead of using separate imagers for different directions, one imager is made multi-functional by enabling it to scan and detect marks along both the first and second directions. This reduces the number of imaging components while maintaining the capability to measure alignment accuracy in multiple orientations.
Solution Approach 2:
The patent implements dynamics by making the imager movable rather than static. The imager can rotate or move to different positions to detect alignment marks in different directions. This dynamic capability allows a single imager to perform the function of multiple fixed imagers, reducing device complexity while maintaining comprehensive measurement accuracy in all required directions.
Data Source
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AI summary
A calibration plate is arranged on a support surface of a table. The calibration plate has first and second alignment marks arranged in one direction, and third and fourth alignment marks arranged in another direction that is orthogonal to the one direction. The first and second alignment marks that move in a front-and-rear direction are imaged by a first camera. The one direction of the calibration plate is made parallel to a front-and-rear direction based on the image. The positions of second and third cameras are adjusted based on the third and fourth alignment marks. The second and third cameras, positions of which have been adjusted, are moved to positions below the transfer roller, and a reference line formed at the transfer roller is imaged by the second and third cameras. An orientation of a rotation shaft of the transfer roller is adjusted in a plane parallel to the support surface based on these images.