A full lamination method for a hard screen assembly

Abstract

The present invention relates to a method for fully laminating a rigid screen assembly, comprising the following steps: S1. providing a first rigid screen, and setting a first adhesive layer on the first surface of the first rigid screen; S2. providing a second rigid screen, and setting a plurality of convex points on the first surface of the second rigid screen; S3. performing a pre-lamination operation, so that each convex point forms a temporary bond with the first adhesive layer, so as to temporarily fix and determine the alignment relationship between the first rigid screen and the second rigid screen, and each convex point forms a gap between the first adhesive layer and the second rigid screen, thereby obtaining a pre-lamination assembly; S4. transferring the pre-lamination assembly into a closed cavity and evacuating the cavity to completely remove the gas remaining in the gap; S5. performing a pressing operation on the pre-lamination assembly under a vacuum environment, so that the convex points are pressed into the first adhesive layer until the gap is completely eliminated, thereby achieving bubble-free full lamination and obtaining a rigid screen assembly. The present invention can reduce process difficulty and significantly improve production efficiency.

Description

Technical Field

[0001] The present invention relates to the field of display technology, and in particular to a method for fully laminating a hard screen assembly. Background Art

[0002] Currently, the production process for display screens generally requires a full lamination process for rigid screen components. This involves completely filling the gaps between the rigid screens with a transparent adhesive layer. This process eliminates the air gap between the rigid screens, thereby reducing reflections from the air gap and improving the display's contrast and viewing experience in bright environments. This lamination process is typically performed in a vacuum environment to remove any air trapped between the rigid screens.

[0003] However, the existing laminating process for rigid screen assemblies is typically performed by a laminating machine. This alignment and laminating process is performed after each rigid screen assembly (including the first and second rigid screens) is placed into a vacuum chamber, resulting in very low production efficiency. This is particularly true when laminating multiple batches of rigid screen assemblies, as each lamination requires vacuuming, making it difficult to meet mass production requirements. When the first rigid screen consists of two or more pieces, requiring 2-to-1 or N-to-1 lamination, production efficiency is even lower. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for fully laminating a rigid screen assembly, which can reduce the process difficulty and significantly improve production efficiency. The technical solution adopted is as follows:

[0005] A method for fully laminating a rigid screen assembly, characterized by comprising the following steps:

[0006] S1. Providing a first hard screen, and providing a first adhesive layer on a first surface of the first hard screen;

[0007] S2 provides a second hard screen, a plurality of bumps are provided on the first surface of the second hard screen;

[0008] S3. Perform a pre-lamination operation, positioning the first surface of the second rigid screen body opposite to the first surface of the first rigid screen body and bringing them closer together, so that the protrusions on the second rigid screen body and the first adhesive layer on the first rigid screen body form a temporary bond, thereby temporarily fixing and determining the alignment relationship between the first and second rigid screen bodies. The protrusions form a gap between the first adhesive layer and the first surface of the second rigid screen body, thereby producing a pre-lamination assembly;

[0009] S4. The pre-lamination assembly is transferred to a closed cavity and the closed cavity is evacuated to completely remove the residual gas in the gap, so that the pre-lamination assembly is in a vacuum environment;

[0010] S5. Perform a pressing operation on the pre-bonded assembly in a vacuum environment, apply directional pressure to the first hard screen or the second hard screen, so that the second hard screen is relatively displaced toward the first hard screen, so that the protrusions on the second hard screen are pressed into the first adhesive layer on the first hard screen until the gap is completely eliminated, thereby achieving bubble-free full bonding between the first hard screen and the second hard screen, and obtaining the hard screen assembly.

[0011] The first hard screen and the second hard screen can be a display screen, a touch screen, a protective lens, or any hard screen component used in a display screen. Specifically, the first hard screen is a liquid crystal display screen, and the second hard screen is a protective lens made of glass.

[0012] In the above-mentioned method for fully laminating a rigid screen assembly, in step S3, after the first surface of the first rigid screen is arranged relative to the first surface of the second rigid screen, a small pressure can be applied to the first rigid screen or the second rigid screen, or gravity can be used, or only the adhesive force of the first adhesive layer itself can be used to bring the first rigid screen and the second rigid screen closer to each other, so that the various protrusions on the second rigid screen form a temporary bond with the surface of the first adhesive layer on the first rigid screen, thereby realizing the pre-lamination operation of the first rigid screen and the second rigid screen. At this time, based on the adhesive effect between the top of the protrusion and the first adhesive layer, the first rigid screen and the second rigid screen are temporarily bonded. The two rigid screens will not slide against each other, thus achieving temporary fixation and determining the alignment relationship between the first rigid screen and the second rigid screen, thereby producing a pre-bonded component. Since steps S1-S3 can all be performed in an atmospheric environment, the operating environment is relaxed, the operation is more flexible, and no large equipment is required, thereby reducing the difficulty of the process. In steps S4-S5, the pre-bonded component is transferred to a vacuum environment, and a pressing operation is performed on the pre-bonded component in a vacuum environment, so that the protrusions on the second rigid screen are pressed into the first adhesive layer on the first rigid screen until the gap is completely eliminated, thereby achieving bubble-free full bonding between the first rigid screen and the second rigid screen.

[0013] Specifically, when performing the pre-lamination operation of the first rigid screen and the second rigid screen, the mutual alignment of the first rigid screen and the second rigid screen can be achieved with the assistance of a positioning jig. For example, a positioning jig with a double-layer positioning groove can be used to first position the first rigid screen in the bottom positioning groove, and then place the second rigid screen in the top positioning groove. The depth of the bottom positioning groove and the top positioning groove are designed so that the bonding surfaces of the first rigid screen and the second rigid screen are in contact, so that the first rigid screen and the second rigid screen are positioned and pre-laminated. Alternatively, the second rigid screen can be placed in a specific position first, and then the first rigid screen can be grabbed by a robot or a suction cup, and the alignment features or alignment marks of the first rigid screen and the second rigid screen (respectively preset in the first rigid screen and the second rigid screen) can be captured by a camera. Then, the first rigid screen can be positioned and placed on the second rigid screen, so that the first rigid screen and the second rigid screen can be positioned and pre-laminated.

[0014] As a preferred embodiment of the present invention, the first adhesive layer is a transparent, paste-like or semi-solid adhesive layer. Specifically, the first adhesive layer can be a transparent adhesive layer primarily composed of acrylic, whose refractive index generally matches that of the glass substrate. Thus, in step S3, the bumps on the second rigid screen can be temporarily bonded to the first adhesive layer within the first adhesive layer to temporarily fix the alignment between the first and second rigid screens, while also ensuring that they are not completely embedded within the first adhesive layer, thereby facilitating the formation of the gap between the first and second rigid screens.

[0015] As a further preferred embodiment of the present invention, the viscosity coefficient of the first adhesive layer is not less than 15,000 centipoise (cP).

[0016] As a preferred embodiment of the present invention, in step S3, the raised dots are provided on the first surface of the first rigid screen by printing or patterning. The raised dots may be formed on the first surface of the first rigid screen by printing (e.g., by printing), or by pre-coating the first surface of the first rigid screen with a photosensitive resin and then patterning it through exposure and development. Specifically, the raised dots may be arranged as a dot matrix, and the height of the raised dots generally does not exceed the thickness of the first adhesive layer.

[0017] As a further preferred embodiment of the present invention, the top of the bump is non-planar. The bump can be made smaller, and the bump of the photosensitive resin can be softened by a heat baking process to make the top of the bump non-planar. This makes it easier to press the bump into the first adhesive layer in step S5.

[0018] As another preferred embodiment of the present invention, in step S2, a second adhesive layer is first applied to the first surface of the second rigid screen, and then powder is sprinkled on the surface of the second adhesive layer. The powder adheres to the second adhesive layer to form the raised dots. This eliminates the need for pre-fabricating the raised dots on the first surface of the second rigid screen, and the method is suitable for the first surface of the second rigid screen made of a wide variety of materials, for example, a plastic surface. Because the powder is sprinkled on the second adhesive layer, its lateral dimensions are smaller, making it easier to press it into the first adhesive layer (or the second adhesive layer) in step S5.

[0019] As a further preferred embodiment of the present invention, the powder is silicon spheres, glass powder, or plastic powder. Specifically, the powder is spacers (SPACER) used in the liquid crystal display industry and related spreading processes, and its distribution density can reach 10-300 particles / cm². Specifically, the powder can be spherical, strip-shaped, or irregularly shaped particles. The powder can be selected from particles of uniform size, such as particles of approximately 50 μm, so that in step S3, a relatively uniform gap thickness can be formed between the first adhesive layer and the first surface of the second rigid screen body.

[0020] As a further preferred embodiment of the present invention, the height of the powder does not exceed the sum of the thicknesses of the first adhesive layer and the second adhesive layer, thereby ensuring that the powder can be completely embedded in the first adhesive layer and the second adhesive layer in step S5, thereby facilitating complete bonding between the first adhesive layer and the second rigid screen body.

[0021] As a further preferred embodiment of the present invention, the height of the powder is 30% to 70% of the total thickness of the first adhesive layer and the second adhesive layer.

[0022] As a further preferred embodiment of the present invention, the thickness of the second adhesive layer is 80% to 120% of the first adhesive layer. Thus, in step S5, the powder can be pressed into both the first and second adhesive layers simultaneously, minimizing deformation of the adhesive layers, reducing stress on the adhesive layers, and improving bonding stability.

[0023] As a preferred embodiment of the present invention, the number of first rigid screens provided in step S1 is at least two; in step S3, the first surface of each first rigid screen is arranged opposite to the first surface of the second rigid screen, and the first adhesive layer on each first rigid screen is temporarily bonded to each protrusion on the second rigid screen to fix the alignment relationship between each first rigid screen and the second rigid screen; in step S5, directional pressure is applied to each first rigid screen to cause each first rigid screen to be relatively displaced toward the second rigid screen, so that the protrusion on the second rigid screen is pressed into the first adhesive layer on each first rigid screen until the gap is completely eliminated, thereby achieving bubble-free full bonding between each first rigid screen and the second rigid screen to obtain the rigid screen assembly.

[0024] As a preferred embodiment of the present invention, before proceeding to step S4, steps S1-S3 are repeated to produce multiple pre-laminated components. In step S4, the multiple pre-laminated components are moved together into the same enclosed cavity and the cavity is evacuated to completely remove any residual gas from the gaps between the multiple pre-laminated components. In step S5, the multiple pre-laminated components are simultaneously pressed together to produce multiple rigid screen components. The pre-laminated components produced in steps S1-S3 can be temporarily stored until a certain number are reached and then transferred to the vacuum cavity to perform steps S4 and S5. This allows the pressing of multiple pre-laminated components to be completed simultaneously, significantly improving efficiency.

[0025] As a further preferred embodiment of the present invention, in step S4, a plurality of the pre-laminated components are first placed vertically and stacked together horizontally, and then these stacked pre-laminated components are moved together into the same closed cavity; in step S5, lateral pressure is applied to these pre-laminated components, and the pressing operation of these pre-laminated components is completed at the same time.

[0026] Compared with the prior art, the present invention has the following advantages:

[0027] This method for fully laminating a rigid screen assembly first pre-laminates the first rigid screen and the second rigid screen, temporarily fixes and determines the alignment relationship between the first rigid screen and the second rigid screen using convex adhesion to form a pre-laminated assembly, and then performs a pressing operation on the pre-laminated assembly in a vacuum environment to achieve bubble-free, fully laminating between the first rigid screen and the second rigid screen. Since the alignment and full lamination of the rigid screens are completed in steps, and steps S1-S3 are all performed in an atmospheric environment, the operating environment is relaxed, the operation is more flexible, and no large equipment is required, which reduces the process difficulty, significantly improves production efficiency, and increases the degree of freedom of process combination. It is suitable for 2-to-1 laminating or N-to-1 laminating processes of rigid screens. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a flow chart of a method for fully laminating a hard screen assembly provided in Example 1 of a preferred embodiment of the present invention.

[0029] Figure 2 It is a structural schematic diagram of the hard screen assembly prepared in Example 1 of the preferred embodiment of the present invention.

[0030] Figure 3 It is a flow chart of a method for fully laminating a rigid screen assembly provided in Example 2 of a preferred embodiment of the present invention. DETAILED DESCRIPTION

[0031] Example 1, as Figure 1-Figure 2 As shown, this method for fully laminating a rigid screen assembly includes the following steps:

[0032] S1 provides a first hard screen body 1, and provides a first adhesive layer 101 on the first surface of the first hard screen body 1;

[0033] S2 provides a second hard screen body 2, a plurality of bumps 201 are provided on the first surface of the second hard screen body 2;

[0034] S3. Perform a pre-lamination operation, positioning the first surface of the second rigid screen 2 relative to the first surface of the first rigid screen 1 and bringing them closer together. The bumps 201 on the second rigid screen 2 are temporarily bonded to the first adhesive layer 101 on the first rigid screen 1, thereby temporarily fixing and confirming the alignment of the first rigid screen 1 and the second rigid screen 2. The bumps 201 form a gap 120 between the first adhesive layer 101 and the first surface of the second rigid screen 2, thereby producing a pre-lamination assembly 3.

[0035] S4. The pre-lamination assembly 3 is transferred to the enclosed cavity 4 and the enclosed cavity 4 is evacuated to completely remove the residual gas in the gap 120, so that the pre-lamination assembly 3 is in a vacuum environment 40;

[0036] S5. Perform a lamination operation on the pre-lamination component 3 in a vacuum environment 40, apply directional pressure to the first rigid screen body 1 or the second rigid screen body 2, so that the second rigid screen body 2 is relatively displaced toward the first rigid screen body 1, so that the protrusion 201 on the second rigid screen body 2 is pressed into the first adhesive layer 101 on the first rigid screen body 1 until the gap 120 is completely eliminated, thereby achieving bubble-free full lamination between the first rigid screen body 1 and the second rigid screen body 2, and obtaining the rigid screen assembly.

[0037] In this embodiment, the first rigid screen body 1 is a liquid crystal display screen, and the second rigid screen body 2 is a protective lens made of glass.

[0038] In this embodiment, the first adhesive layer 101 is a transparent, paste-like or semi-solid adhesive layer, and the viscosity of the first adhesive layer 101 is no less than 15,000 centipoise (cP). Specifically, the first adhesive layer 101 is primarily composed of an acrylic transparent adhesive layer, and its refractive index generally matches that of the glass substrate. Therefore, in step S3, the bumps 201 on the second rigid screen 2 can both achieve temporary bonding within the first adhesive layer 101 to temporarily secure the alignment between the first and second rigid screens 1 and 2, while also ensuring that they are not completely embedded within the first adhesive layer 101, thereby facilitating the formation of a gap 120 between the first adhesive layer 101 and the second rigid screen 2.

[0039] In this embodiment, in step S3, the bumps 201 are provided on the first surface of the first rigid screen 1 by printing or patterning, with the top of the bumps 201 being non-planar. The bumps 201 can be formed on the first surface of the first rigid screen 1 by printing (e.g., printing), or by pre-coating the first surface of the first rigid screen 1 with a photosensitive resin, which is then patterned by exposure and development. Specifically, the bumps 201 can be arranged as a dot matrix, with the height of the bumps 201 not exceeding the thickness of the first adhesive layer 101. The bumps 201 can be made smaller, and the photosensitive resin bumps 201 can be softened by thermal baking, so that the tops of the bumps 201 are non-planar. This facilitates pressing the bumps 201 into the first adhesive layer 101 in step S5.

[0040] In this embodiment, the number of first rigid screens 1 provided in step S1 is two; in step S3, the first surfaces of the two first rigid screens 1 are arranged opposite to the first surface of the second rigid screen 2, and the first adhesive layers 101 on the two first rigid screens 1 are temporarily bonded to the protrusions 201 on the second rigid screen 2 to fix the alignment relationship between the two first rigid screens 1 and the second rigid screen 2; in step S5, directional pressure is applied to the two first rigid screens 1 to cause the two first rigid screens 1 to be relatively displaced toward the second rigid screen 2, so that the protrusions 201 on the second rigid screen 2 are pressed into the first adhesive layers 101 on the two first rigid screens 1 until the gap 120 is completely eliminated, thereby achieving bubble-free and full bonding between the two first rigid screens 1 and the second rigid screen 2, and obtaining a rigid screen assembly.

[0041] In this embodiment, before proceeding to step S4, steps S1-S3 are repeated to produce multiple pre-laminated components 3. In step S4, the multiple pre-laminated components 3 are moved together into the same enclosed cavity 4 and the enclosed cavity 4 is evacuated to completely remove any residual gas within the gaps 120 between the multiple sets of pre-laminated components 3. In step S5, the multiple pre-laminated components 3 are simultaneously pressed together to produce multiple rigid screen components. The pre-laminated components 3 produced in steps S1-S3 can be temporarily stored and, when a certain number is reached, transferred to the vacuum cavity to perform steps S4 and S5. This allows the pressing operation of multiple pre-laminated components 3 to be completed at once, significantly improving efficiency.

[0042] In this embodiment, in step S4, multiple pre-laminated components 3 are first placed vertically and stacked together horizontally, and then these stacked pre-laminated components 3 are moved together into the same closed cavity 4; in step S5, a clamp 5 is used to apply lateral pressure to these pre-laminated components 3, and the pressing operation of these pre-laminated components 3 is completed at the same time.

[0043] Example 2, reference Figure 3 While all other aspects are identical to those of Example 1, the differences are as follows: in step S2, a second adhesive layer 202 is first formed on the first surface of the second rigid screen 2, and then powder 21 is sprinkled on the surface of the second adhesive layer 202. The powder 21 adheres to the second adhesive layer 202 to form bumps 201. In step S3, a slight pressure is applied to the first rigid screen 1 to bring the first and second rigid screens 1 and 2 closer together. This eliminates the need for pre-fabricating the bumps 201 on the first surface of the second rigid screen 2, making it suitable for the first surface of the second rigid screen 2 made of a wider range of materials, such as plastic. Because the powder 21 is smaller in lateral dimensions after being sprinkled on the second adhesive layer 202, it is more easily pressed into the first adhesive layer 101 (or the second adhesive layer 202) in step S5.

[0044] In this embodiment, powder 21 is silicon spheres, glass powder, or plastic powder. Specifically, powder 21 is a spacer used in the liquid crystal display industry and its related spreading process, with a distribution density of 10-300 particles / cm². Powder 21 is spherical, strip-shaped, or irregularly shaped particles. Powder 21 can be selected from particles of uniform size, such as approximately 50 μm, to facilitate forming a relatively uniform gap 120 between the first adhesive layer 101 and the first surface of the second rigid screen body 2 in step S3.

[0045] In this embodiment, the thickness of the second adhesive layer 202 is 80% of the thickness of the first adhesive layer 101, and the height of the powder 21 is 50% of the combined thickness of the first adhesive layer 101 and the second adhesive layer 202. This ensures that in step S5, the powder 21 can be simultaneously pressed into the first adhesive layer 101 and the second adhesive layer 202, minimizing deformation of the adhesive layer, reducing stress in the adhesive layer, and improving bonding stability.

[0046] In addition, it should be noted that the names of the various parts of the specific embodiments described in this specification may be different. Any equivalent or simple changes based on the structure, features, and principles of the patent concept of the present invention are included in the scope of protection of the patent of this invention. Those skilled in the art of the art to which the present invention relates may make various modifications, supplements, or replace the specific embodiments described in the present invention with similar methods. As long as they do not deviate from the structure of the present invention or exceed the scope defined by the claims, they shall fall within the scope of protection of the present invention.

Claims

1. A method for fully laminating a rigid screen assembly, characterized in that The steps include: S1. Providing a first hard screen, and providing a first adhesive layer on a first surface of the first hard screen; S2 provides a second hard screen, a plurality of bumps are provided on the first surface of the second hard screen; S3. Perform a pre-lamination operation, positioning the first surface of the second rigid screen body opposite to the first surface of the first rigid screen body and bringing them closer together, so that the protrusions on the second rigid screen body and the first adhesive layer on the first rigid screen body form a temporary bond, thereby temporarily fixing and determining the alignment relationship between the first and second rigid screen bodies. The protrusions form a gap between the first adhesive layer and the first surface of the second rigid screen body, thereby producing a pre-lamination assembly; S4. The pre-lamination assembly is transferred to a closed cavity and the closed cavity is evacuated to completely remove the residual gas in the gap, so that the pre-lamination assembly is in a vacuum environment; S5. Perform a pressing operation on the pre-bonded assembly in a vacuum environment, apply directional pressure to the first hard screen or the second hard screen, so that the second hard screen is relatively displaced toward the first hard screen, so that the protrusions on the second hard screen are pressed into the first adhesive layer on the first hard screen until the gap is completely eliminated, thereby achieving bubble-free full bonding between the first hard screen and the second hard screen, and obtaining the hard screen assembly.

2. A method for fully laminating a rigid screen assembly according to claim 1, characterized in that: The first adhesive layer is a paste-like or semi-solid transparent adhesive layer, and the viscosity coefficient of the first adhesive layer is not less than 15,000 centipoise (cP).

3. The method for fully laminating a rigid screen assembly according to claim 1, wherein: The convex points are arranged on the first surface of the first rigid screen body by printing or graphic means, and the tops of the convex points are non-planar.

4. The method for fully laminating a rigid screen assembly according to claim 1, wherein: In the step S2, a second adhesive layer is firstly provided on the first surface of the second rigid screen body, and then powder is sprinkled on the surface of the second adhesive layer. The powder adheres to the second adhesive layer to form the convex dots.

5. The method for fully laminating a rigid screen assembly according to claim 4, wherein: The powder is silicon balls, glass powder or plastic powder.

6. The method for fully laminating a rigid screen assembly according to claim 4, wherein: The height of the powder does not exceed the sum of the thicknesses of the first adhesive layer and the second adhesive layer.

7. A method for fully laminating a rigid screen assembly according to claim 6, characterized in that: The height of the powder is 30% to 70% of the total thickness of the first adhesive layer and the second adhesive layer.

8. The method for fully laminating a rigid screen assembly according to claim 4, wherein: The thickness of the second adhesive layer is 80% to 120% of the first adhesive layer.

9. The method for fully laminating a rigid screen assembly according to claim 1, wherein: The number of first rigid screens provided in step S1 is at least two; in step S3, the first surface of each first rigid screen is arranged opposite to the first surface of the second rigid screen, and the first adhesive layer on each first rigid screen is temporarily bonded to each protrusion on the second rigid screen to fix the alignment relationship between each first rigid screen and the second rigid screen; in step S5, directional pressure is applied to each first rigid screen to cause each first rigid screen to be relatively displaced toward the second rigid screen, so that the protrusion on the second rigid screen is pressed into the first adhesive layer on each first rigid screen until the gap is completely eliminated, thereby achieving bubble-free full bonding between each first rigid screen and the second rigid screen, thereby obtaining the rigid screen assembly.

10. The method for fully laminating a rigid screen assembly according to claim 1, wherein: Before performing step S4, repeat steps S1-S3 to obtain a plurality of pre-laminated components; in step S4, move the plurality of pre-laminated components together into the same closed cavity and evacuate the closed cavity to completely remove the gas remaining in the gaps on the plurality of pre-laminated components; in step S5, perform a pressing operation on the plurality of pre-laminated components at the same time to obtain a plurality of hard screen components.

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