Patent Application
20120275024
The present disclosure relates generally to the field of laminated assemblies, and more particularly, to systems and methods related to manufacturing polarizer assemblies having one or more adhesive layers.
Conventionally, laminated display assemblies such as liquid crystal displays include one or more polarizing films and additional components such as cover glasses and/or touch screen displays. There are challenges associated with producing such laminated display assemblies.
One embodiment relates to a film assembly comprising a polarizer having a first side and a second side opposite the first side; a first layer of adhesive bonded to the first side of the polarizer; and a second layer of adhesive bonded to a second side of the polarizer; wherein the first and second layers of adhesive and the polarizer form a rollable film.
Another embodiment relates to a method for making a laminated assembly, the method comprising providing a flexible polarizer; providing a first adhesive layer; laminating the first adhesive layer to a first side of the flexible polarizer; providing a second adhesive layer; and laminating the second adhesive layer to a second side of the flexible polarizer opposite the first side to form a flexible film.
Another embodiment relates to a film assembly comprising a flexible polarizer having a first side and a second side opposite the first side; a first layer of pressure sensitive adhesive bonded to the first side of the flexible polarizer; and a second layer of pressure sensitive adhesive bonded to a second side of the flexible polarizer; wherein the first and second layers of pressure sensitive adhesive and the flexible polarizer form a rollable film.
Referring to
According to an exemplary embodiment, display assembly 10 includes a display 12 and a cover assembly 14. Display 12 may be a generally planar display assembly, and may be a rigid, semi-rigid, or flexible display. For example, in some embodiments, display 12 is or includes a liquid crystal display (LCD) assembly. In other embodiments, other types of displays may be used. In one embodiment, cover assembly 14 is laminated to a surface 15 of display 12. Cover assembly 14 may comprise a variety of components, either individually, or in combination, including a cover glass (e.g., a rigid or semi-rigid and generally transparent substrate, etc.), a touch screen display (e.g., configured to receive inputs via a stylus, a fingertip, etc.), optical enhancement or retardation films, and the like.
Traditional methods of applying cover assemblies involve multiple lamination steps of differing types. For example, in order to bond a cover glass to an LCD display, an adhesive would first be cut to size and then laminated to a surface of the display or cover glass(e.g., via a flexible-to-rigid lamination process), after which the cover glass would then be laminated to the display via the adhesive (e.g., via a rigid-to-rigid lamination process). Various embodiments herein are directed to assemblies and methods of assembly that may reduce the number of steps involved, and therefore reduce the time and cost required in connection with bonding cover assemblies to displays such as LCD displays (e.g., by reducing the number of cutting operations required to otherwise cut individual components such as an adhesive and a polarizer film to specific sizes).
Referring now to
In some embodiments, as shown in
According to an exemplary embodiment, first adhesive layer 22 and second adhesive layer 24 may have substantially similar thicknesses, while in other embodiments, first adhesive layer 22 and second layer 24 may have different thicknesses. For example, first adhesive layer 22 may be a relatively thicker adhesive layer (e.g., a relatively thicker layer of PSA) and second adhesive layer 24 may be a relatively thinner adhesive layer (e.g., a relatively thinner layer of PSA). In one embodiment, first adhesive layer 22 may be a relatively thinner layer of pressure sensitive adhesive having a thickness of approximately 0.001 inches, and second adhesive layer 24 may be a relatively thicker layer of pressure sensitive adhesive having a thickness of approximately 0.007 inches. In other embodiments, the thicknesses of first adhesive layer 22 and second adhesive layer 24 may be varied (e.g., in one embodiment, second adhesive layer 24 is approximately 0.040 inches thick, etc.). In other embodiments, one or both adhesive layers may be as thick as 0.060 inches, 0.100 inches, or greater than 0.100 inches.
According to various exemplary embodiments, adhesive layers 22, 24 may include a variety of suitable pressure sensitive adhesives. Generally, pressure sensitive adhesives are adhesives (e.g., provided in rolled form, sheet form, etc.) that are configured to form a bond when pressure is applied (e.g., in the case of applying a compressive force to two rolled goods having a layer of pressure sensitive adhesive therebetween). The pressure sensitive adhesive may include a protective layer (e.g., a layer 29 shown in
As indicated earlier, in some embodiments, first adhesive layer 22 (e.g., which may be a relatively thinner adhesive layer) is configured to provide a bond between a first surface of polarizer 26 and a liquid crystal display component (e.g., a glass substrate component of an LCD) to form an LCD display. Second adhesive layer 24 is configured to provide a bond between a second surface of polarizer 26 and a cover assembly or other component (e.g., cover assembly 14 shown in
Referring now to
In some embodiments, once the first and second adhesive layers are applied to the polarizer, the resulting polarizer assembly may be rolled or otherwise stored for later usage/additional processing (e.g., cutting, etc.). In some embodiments, the resulting polarizer is a flexible and/or rollable film suitable for future lamination via roll-to-roll processes, flexible-to-rigid lamination processes, etc.
Referring further to
A cover assembly may be bonded to the polarizer assembly via the second adhesive layer (step 38). For example, cover assembly 14, such as a cover glass, touch screen, or other component, may be bonded to the LCD assembly. Any protective layer, such as a protective layer 29 shown in
Referring to
For purposes of this disclosure, the term “coupled” shall mean the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. Such joining may also relate to mechanical, fluid, or electrical relationship between the two components.
It is important to note that the construction and arrangement of the elements of the polarizer and display assembly as shown in the exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the embodiments. Accordingly, all such modifications are intended to be included within the scope of the present disclosure as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and/or omissions may be made in the design, operating conditions, and arrangement of the exemplary embodiments without departing from the spirit of the present disclosure.
