Conformable Liner Lamination for Bubble-Free Curved Adhesive Bonding
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Solution Overview
Problem
Conventional lamination systems and methods for adhesive application to curved components often form air bubbles, leading to poor lamination quality and adverse optical properties, such as light transmission and clarity issues.
Innovation Solution
A system and method utilizing a deformable support pad and conformable liner with specific elastic moduli to ensure the adhesive conforms to the component's shape, reducing or preventing air bubble formation during lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lamination systems are used to laminate adhesive to curved components, then the lamination process can be completed, but air bubbles form between the adhesive and curved components resulting in poor lamination quality
Solution Approach 1:
The patent changes the physical parameters of the support pad (using elastic materials with specific durometer ranges) and the liner (using conformable materials with specific elastic moduli) to enable deformation that eliminates air bubbles during lamination. This parameter optimization allows the system to adapt to curved surfaces while maintaining high lamination quality without bubble formation.
Solution Approach 2:
The support pad and liner are designed to be dynamically deformable rather than rigid. The support pad compresses and rebounds, while the liner stretches and conforms, allowing the system to adapt to the curvature of the component during the lamination process. This dynamic behavior prevents air bubble entrapment that would occur with static, rigid systems.
2Stability of the object's composition
If rigid support structures are used during lamination, then structural stability is maintained, but the adhesive cannot conform to curved surfaces effectively
Solution Approach 1:
The patent employs a flexible liner made of conformable material that can stretch and wrap around curved surfaces while maintaining structural integrity. This thin film approach allows the system to conform to complex geometries without requiring rigid structural support, solving the contradiction between stability and shape adaptability.
Solution Approach 2:
The support pad transitions from a rigid, static structure to a dynamic, elastic element that can deform during compression and rebound. This dynamic flexibility allows the system to maintain stability through elastic recovery while adapting its shape to match curved surfaces during the lamination process.
3Manufacturing precision
If high pressure is applied during lamination to eliminate air bubbles, then lamination quality improves, but the complexity of the lamination system increases
Solution Approach 1:
The elastic support pad acts as an intermediary between the lamination pressure source and the adhesive-component interface. It distributes and modulates the applied pressure through its elastic properties, eliminating the need for complex pressure control systems while still achieving bubble-free lamination through uniform pressure distribution.
Solution Approach 2:
The patent changes the pressure application method from direct, high-pressure contact to indirect pressure through elastic deformation of the support pad. This parameter transformation reduces the peak pressure required while maintaining effective lamination quality, simplifying the overall system design.
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
The system improves lamination quality by ensuring the adhesive effectively adheres to curved surfaces without air bubbles, enhancing optical properties and user experience.
Implementation Method 1
Each of the support pad and the liner undergoes deformation upon engagement of the support pad with the liner. The support pad includes a body made of an elastic pad material.
Implementation Method 2
The liner includes a conformable liner material having a liner elastic modulus from about 5 megapascals (MPa) to about 650 MPa.
Data Source
AI summary
A system for laminating an adhesive to a component includes a liner including a first major surface facing the component and a second major surface opposite to the first major surface. An adhesive is disposed on the first major surface. The adhesive is configured to be laminated to the component. A support pad engages the second major surface of the liner for laminating the adhesive to the component. Each of the support pad and the liner undergoes deformation upon engagement of the support pad with the liner. The support pad includes a body made of an elastic pad material and includes an upper surface facing the component, a lower surface opposite to the upper surface, and a lateral surface disposed between the upper surface and the lower surface. The liner includes a conformable liner material having a liner elastic modulus from about 5 megapascals (MPa) to about 650 MPa.