Method for aligning composite and apparatus therefor

A method for manufacturing a composite, the method comprising, in random order:

• dicing a first material to provide a first slab having a plurality of posts and a plurality of kerfs;
• dicing a second material to provide a second slab having a plurality of posts, at least one alignment kerf, and a plurality of kerfs;
• coupling the first slab and the second slab in a manner that the first slab and the second slab are intermeshed with each other;
• and
• filling a kerf material in between each of the plurality of posts of the first slab and corresponding one of the plurality of posts of the second slab, wherein
• the at least one alignment kerf is disposed on both edges or one of the edges of the second slab in a direction along which the plurality of posts and the plurality of kerfs are arranged, and is narrower than each of the plurality of kerfs of the second slab such that the at least one alignment kerf fits with a corresponding post of the second slab.

A method for manufacturing a composite, the method comprising, in random order:

• dicing a first material to provide a first slab having a plurality of posts, at least one alignment post, and a plurality of kerfs;
• dicing a second material to provide a second slab having a plurality of posts, at least one alignment kerf, and a plurality of kerfs;
• coupling the first slab and the second slab in a manner that the first slab and the second slab are intermeshed with each other;
• and
• filling a kerf material in between each of the plurality of posts of the first slab and corresponding one of the plurality of posts of the second slab, wherein
• the at least one alignment post is disposed on both edges or one of the edges of the first slab in a direction along which the plurality of posts and the plurality of kerfs are arranged, and is wider than each of the plurality of posts of the first slab such that the at least one alignment post fits with a corresponding kerf or the alignment kerf of the second slab, and
• the at least one alignment kerf is disposed on both edges or one of the edges of the second slab in a direction along which the plurality of posts and the plurality of kerfs are arranged, and is narrower than each of the plurality of kerfs of the second slab such that the at least one alignment kerf fits with a corresponding post or the alignment post of the second slab.

A method for manufacturing a composite, the method comprising, in random order:

• dicing a first material to provide a first slab having a plurality of posts and a plurality of kerfs;
• dicing a second material to provide a second slab having a plurality of posts and a plurality of kerfs, the second slab being different from the first slab;
• coupling the first slab and the second slab in a manner that the first slab and the second slab are intermeshed with each other;
• and
• filling a kerf material in between each of the plurality of posts of the first slab and corresponding one of the plurality of posts of the second slab, wherein
• the coupling includes attaching an alignment shim on an outer surface of an outermost post on both edges of one of the edges of the first slab such that the outermost post is inserted with the alignment shim into a corresponding kerf of the second slab.

A method for manufacturing a composite, the method comprising, in random order:

• dicing a first material to provide a first slab having a plurality of posts and a plurality of kerfs;
• dicing a second material to provide a second slab having a plurality of posts and a plurality of kerfs, the second slab being different from the first slab;
• filling a kerf material including a microball for aligning the first slab and the second slab in whole or a part of the plurality of kerfs of the second slab;
• and
• coupling the first slab and the second slab in a manner that the first slab and the second slab are intermeshed with each other.

A method for manufacturing a composite, the method comprising, in random order:

• dicing a first material to provide a first slab having a plurality of posts and a plurality of kerfs;
• dicing a second material to provide a second slab having a plurality of posts and a plurality of kerfs, the second slab being different from the first slab;
• aligning the first slab and the second slab after disposing the first slab and the second slab to couple with each other in a manner that the first slab and the second slab are intermeshed with each other;
• and
• filling a kerf material in between each of the plurality of posts of the first slab and corresponding one of the plurality of posts of the second slab, wherein
• the aligning is performed by using an aligning apparatus including
• a pair of jigs configured to set the first slab and the second slab,
• a pair of pressurizing units configured to pressurize the pair of jigs,
• a guide installed in at least one of the pressurizing units and configured to allow at least one of the jigs to slidably move between the pressurizing units, and
• a microscope for checking a moving distance of the first slab or the second slab between the pressurizing units.

An apparatus for aligning a first slab having a plurality of posts and a plurality of kerfs and a second slab having a plurality of posts and a plurality of kerfs after disposing the first slab and the second slab in a manner that the first slab and the second slab are coupled by being intermeshed with each other, the apparatus comprising:

• a pair of jigs configured to set the first slab and the second slab;
• a pair of pressurizing units configured to pressurize the pair of jigs;
• a guide installed in at least one of the pressurizing units and configured to allow at least one of the jigs to slidably move between the pressuring units;
• and
• a microscope for checking a moving distance of the first slab or the second slab between the pressurizing units.