Unified Vacuum Lamination System for Mobile Screens
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Solution Overview
Problem
Existing technologies for laminating and de-bubbling mobile electronic device screens face challenges such as imperfect alignment, large machine size, inefficiency, high power consumption, and the need for multiple machines, which result in increased time, effort, and cost, and are not adaptable to varying atmospheric pressures or new device models without frequent software updates.
Innovation Solution
A unified machine unit with a metal vacuum pressure chamber, internal/external vacuum pump, and central computer server for laminating and de-bubbling, equipped with lamination molds, actuators, and internet-connected software for remote operation and data management, ensuring precise alignment and efficient processing across different device models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single machine unit with integrated lamination and de-bubbling chambers is used, then machine size, space occupation, power consumption, and weight are reduced, but the complexity of integrating multiple functions into one unit increases
Solution Approach 1:
The patent combines the lamination chamber and de-bubbling chamber into a single machine unit, integrating multiple functions (lamination, de-bubbling, vacuum creation, pressure application) into one compact system. This merging eliminates the need for separate machines and reduces overall space occupation while maintaining all necessary functions through shared components like the vacuum pump and control system.
Solution Approach 2:
The single machine unit is designed to perform multiple functions: lamination of the glass layer onto the LCD screen, de-bubbling to remove air pockets, vacuum creation for the lamination process, and pressure application for both lamination and de-bubbling. This multi-functionality is achieved through a unified chamber design that can accommodate different operational modes using the same hardware infrastructure.
2Productivity
If existing molds are used for alignment and placement, then the lamination process can proceed, but the outer glass layer is not aligned perfectly resulting in breaking, poor fitting, or large bubbles that are impossible to remove
Solution Approach 1:
The patent replaces manual alignment and placement operations with an automated mechanical system consisting of a movable platform, positioning mechanisms, and computer-controlled actuators. This mechanical automation ensures precise alignment of the outer glass layer with the LCD screen by eliminating human error and enabling sub-millimeter positioning accuracy, thereby preventing glass breaking and ensuring proper fit.
Solution Approach 2:
The system incorporates feedback through computer control that monitors the positioning and alignment of the outer glass layer during the lamination process. The computer-controlled platform and positioning mechanisms adjust based on real-time data to ensure perfect alignment, preventing misalignment issues that would lead to breaking or poor fitting of the glass layer.
3Ease of manufacture
If airbag or piston methods are used for applying pressure during lamination, then the lamination process can be performed, but the success rate of perfect lamination is not high
Solution Approach 1:
The patent employs a vacuum pump to create a vacuum environment within the lamination chamber, which is a pneumatic method for applying pressure during lamination. The vacuum removes air pockets and ensures uniform pressure distribution across the glass layer and LCD screen, significantly improving the success rate of perfect lamination compared to traditional airbag or piston methods.
Solution Approach 2:
The system changes the pressure parameter dynamically during the lamination process by first creating a vacuum (negative pressure) to remove air pockets, then gradually applying positive pressure to ensure uniform adhesion. This parameter change approach, controlled by the vacuum pump and computer system, improves lamination success by preventing trapped bubbles and ensuring complete bonding between the glass layer and LCD screen.
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 provides efficient, space-saving, and cost-effective lamination and de-bubbling with precise alignment, reduced human effort, and real-time remote management, adapting to atmospheric pressures and new device models without manual software updates.
Implementation Method 1
creating a vacuum within the vacuum pressure chamber
Implementation Method 2
applying pressure so that the replacement outer layer glass adheres on to the existing LCD/OLED screen
Implementation Method 3
a layer of adhesive on to the existing LCD/OLED screen
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A system for laminating and/or de-bubbling mobile electronic device screens, comprises a machine unit comprising a metal vacuum pressure chamber with lid, safety sensors and o-ring; an internal or external vacuum pump; a piston 5 chamber, piston and piston plate; a central air distribution block with solenoid valves and pressure sensor; a control PCB (printed circuit board) with processor and operating software system for controlling the machine unit; actuators; an on/off power switch; a power inlet; an operations button; an air inlet port and an external air compressor.