Display Workpiece Adhesive Patterning to Eliminate Air Bubbles
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Solution Overview
Problem
Existing methods struggle to effectively eliminate air gaps and air bubbles between substrates in display articles, leading to optical defects such as trapped air bubbles during the bonding process.
Innovation Solution
A method involving the deposition of a liquid optically clear adhesive in specific patterns on each substrate, followed by controlled compression and alignment to eliminate air gaps, using a dam structure to manage adhesive flow and ensure precise bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a liquid optically clear adhesive is deposited between substrates using conventional methods, then bonding is achieved, but air gaps and air bubbles remain trapped between the substrates causing optical defects
Solution Approach 1:
The adhesive deposition is segmented into two distinct patterns: a first pattern deposited on the first substrate and a second pattern deposited on the second substrate. This segmentation allows each pattern to be optimized independently, with the first pattern designed to eliminate air gaps from the first substrate side and the second pattern designed to eliminate air gaps from the second substrate side, thereby completely eliminating trapped air bubbles while maintaining bonding quality
Solution Approach 2:
The dual pattern adhesive system acts as an intermediary mechanism between the substrates. Rather than using a single adhesive layer that may trap air, the invention introduces two coordinated adhesive patterns that work together to displace and eliminate air gaps, serving as a mediating system that ensures complete substrate contact without optical defects
2Manufacturing precision
If adhesive is deposited in a continuous layer between substrates, then complete coverage is achieved, but air gaps cannot be effectively eliminated and optical defects occur
Solution Approach 1:
The continuous adhesive layer is replaced by two segmented patterns deposited on opposite substrates. The first pattern on the first substrate and the second pattern on the second substrate are positioned to complement each other, creating a coordinated system that maintains complete adhesive coverage while actively working to eliminate air gaps through their respective displacement mechanisms
Solution Approach 2:
Instead of depositing adhesive from one substrate side only, the invention inverts the approach by depositing adhesive patterns on both substrates and then bringing them together. This inverted methodology allows air gaps to be eliminated from both sides simultaneously, preventing trapped air while ensuring complete coverage
3Productivity
If substrates are bonded without eliminating air gaps first, then bonding speed is maintained, but optical defects such as reflected light and refractive index mismatches occur
Solution Approach 1:
The adhesive patterns are deposited in advance on each substrate separately before the substrates are joined. This preliminary action allows each pattern to be optimized for its specific function of eliminating air gaps from its respective substrate side, ensuring that when the substrates are bonded, air elimination has already been prepared and optical defects are prevented without sacrificing bonding speed
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 method ensures optically clear bonding without air bubbles, providing robust and defect-free display articles with minimized reflection and refractive index mismatches.
Implementation Method 1
depositing a liquid optically clear adhesive in a first fill pattern onto the first substrate such that the first fill pattern is spaced apart from the dam to thereby form a coated first substrate
Implementation Method 2
pre-curing the dam material to form a dam
Data Source
AI summary
A workpiece for a display article includes a coated first substrate including a first substrate; a liquid optically clear adhesive disposed on the first substrate in a first fill pattern; and a dam disposed on the first substrate, spaced apart from the first fill pattern, and configured to restrain a flow of the liquid optically clear adhesive. The workpiece also includes a coated second substrate adjacent the coated first substrate and including a second substrate and the liquid optically clear adhesive disposed on the second substrate in a second contact pattern.