Abstract: A multi-layer device assembly system including a substrate source, a plurality of dispenser modules, a feeder, a control system having a number of alignment cameras corresponding to the dispenser modules, an inspection camera, and a defect camera. The substrate source provides a substrate having a plurality of base elements. Each dispenser module includes an actuation mechanism configured to laminate a layer element onto one of the base elements or onto a previously laminated layer element. The feeder metes out the substrate from the substrate source to advance each base to a subsequent dispenser module between lamination steps. The control system determines alignments, defects, and lamination errors via the alignment cameras, inspection camera, and defect camera.

Abstract: A multi-layer device assembly system including a substrate source, a plurality of dispenser modules, a feeder, a control system having a number of alignment cameras corresponding to the dispenser modules, an inspection camera, and a defect camera. The substrate source provides a substrate having a plurality of base elements. Each dispenser module includes an actuation mechanism configured to laminate a layer element onto one of the base elements or onto a previously laminated layer element. The feeder metes out the substrate from the substrate source to advance each base to a subsequent dispenser module between lamination steps. The control system determines alignments, defects, and lamination errors via the alignment cameras, inspection camera, and defect camera.

Abstract: A method of applying a registered pattern to a continuous web of material involves determining a position of a next pattern such that the next pattern is in registration with a previous pattern, adjusting the position to maintain a transverse location relative to the web, and adjusting a rotation of the pattern so that the pattern is substantially aligned with a longitudinal axis of the web. Registration features of the web and registration features of the next pattern are used to determine longitudinal, transverse, and rotational errors between the registered position of the next pattern and the path of the web. The registered position of the next pattern is adjusted along a transverse axis of the web according to a transverse error to maintain the transverse location. A rotation of the registered position is adjusted according to an angle that is determined using the transverse error and a distance from a registration feature to a center of the pattern along a longitudinal axis of the pattern.

Abstract: A method of applying a registered pattern to a continuous web of material involves determining a position of a next pattern such that the next pattern is in registration with a previous pattern, adjusting the position to maintain a transverse location relative to the web, and adjusting a rotation of the pattern so that the pattern is substantially aligned with a longitudinal axis of the web. Registration features of the web and registration features of the next pattern are used to determine longitudinal, transverse, and rotational errors between the registered position of the next pattern and the path of the web. The registered position of the next pattern is adjusted along a transverse axis of the web according to a transverse error to maintain the transverse location. A rotation of the registered position is adjusted according to an angle that is determined using the transverse error and a distance from a registration feature to a center of the pattern along a longitudinal axis of the pattern.