Pressure-Sensing Stages For Lamination Systems

• US 20160136937A1
• Filed: 09/20/2013
• Published: 05/19/2016
• Est. Priority Date: 09/20/2013
• Status: Active Grant

• Current Assignee: LG Display Co., Ltd.
• Original Assignee: Apple Inc.
• Inventors: Kim, Yong-Soo, Sung, Kuo-Hua
• Granted Patent: US 9,868,273 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B30B 15/22 controlling the degree of pressure applied by the ram during the pressing stroke
• CPC Class Codes: B32B 2457/202 LCD, i.e. liquid crystal displays
• CPC Class Codes: B32B 37/1009 using vacuum and fluid pressure
• CPC Class Codes: B32B 41/00 Arrangements for controlling or monitoring lamination processes; Safety arrangements

Abstract

A lamination system (110) may be provided for attaching together display layers (45,46) for an electronic device display. The system may include one or more pressure-sensing lamination stages (124, 126) for temporarily mounting the display layers during lamination operations. A pressure-sensing lamination stage (124) may include one or more pressure sensors (130) configured to sense pressures that are applied to the display layers during lamination operations. The pressure-sensing lamination stages may include a fixed mounting stage (126) and a movable mounting stage (124). The movable mounting stage may be moved so that a first set of display layers is pressed against a second set of display layers to attach the first and second sets of display layers. The pressure with which the first set of display layers (45;46) is pressed against the second set of display layers may be adjusted based on pressure data gathered using the pressure sensors (130).

Claims

1. A lamination system for laminating a first structure to a second structure, the system comprising:

a mounting stage for mounting the first structure;

a movable mounting stage for mounting the second structure, wherein the movable mounting stage includes at least one pressure sensor; and

computing equipment coupled to the movable mounting stage and the at least one pressure sensor, wherein the computing equipment is configured to gather pressure data associated with pressures on the second structure using the at least one pressure sensor.

2. The lamination system defined in claim 1 wherein the at least one pressure sensor is has an outer surface that is formed in a common plane with a surface of the movable mounting stage.

3. The lamination system defined in claim 1 wherein the at least one pressure sensor is embedded within the movable mounting stage.

4. The lamination system defined in claim 1 further comprising:

computer-controlled positioning equipment,

wherein the computing equipment is configured to adjust a position of the movable mounting stage using the computer-controlled positioning equipment based on the gathered pressure data.

5. The lamination system defined in claim 1 wherein the at least one pressure sensor comprises at least first and second pressure sensors mounted at discrete locations on the movable mounting stage.

6. The lamination system defined in claim 1 wherein the at least one pressure sensor comprises pressure sensing layer of the movable mounting stage.

7. The lamination system defined in claim 1 wherein the mounting stage for mounting the first structure comprises a fixed mounting stage for mounting a display assembly for an electronic device display.

8. The lamination system defined in claim 7 wherein the movable mounting stage for mounting the second structure comprises a movable mounting stage for mounting a liquid crystal display cell to be laminated to the display assembly.

9. The lamination system defined in claim 8 wherein the fixed mounting stage comprises an electrostatic chuck that secures the display assembly in a fixed position.

10. The lamination system defined in claim 9, further comprising a vacuum chamber, wherein the fixed mounting stage and the movable mounting stage are mounted within the vacuum chamber.

11. A method of laminating a first rigid structure to a second rigid structure using hard-to-hard lamination equipment having a first stage and a second stage, wherein the second stage is a pressure-sensing stage having a plurality of pressure sensors, the method comprising:

temporarily attaching the first rigid structure to the first stage;

temporarily attaching the second rigid structure to the pressure-sensing stage;

gathering pressure data using the plurality of pressure sensors; and

laminating the first rigid structure to the second rigid structure by positioning the pressure-sensing stage based on the gathered pressure data.

12. The method defined in claim 11, further comprising:

before gathering the pressure data using the plurality of pressure sensors, moving the pressure-sensing stage so that the first rigid structure contacts the second rigid structure.

13. The method defined in claim 12 wherein gathering the pressure data using the plurality of pressure sensors comprises gathering absolute pressure data corresponding to a pressure with which the first rigid structure is pressed against the second rigid structure.

14. The method defined in claim 12 wherein gathering the pressure data using the plurality of pressure sensors comprises gathering relative pressure data corresponding to a uniformity of pressure with which the first rigid structure is pressed against the second rigid structure.

15. The method defined in claim 11 wherein laminating the first rigid structure to the second rigid structure by positioning the pressure-sensing stage based on the gathered pressure data comprises comparing the gathered pressure data to target pressure data.

16. The method defined in claim 15 wherein laminating the first rigid structure to the second rigid structure by positioning the pressure-sensing stage based on the gathered pressure data further comprises modifying the position of the pressure-sensing stage based on the comparison of the gathered pressure data to the target pressure data.

17. A method of using a laminating system to attach a liquid crystal display cell to an assembly that includes a glass layer, a touch-sensor substrate attached to the glass layer, and a sheet of optically clear adhesive on the touch-sensor substrate, the method comprising:

securing the assembly in a fixed position;

securing the liquid crystal display cell to a movable pressure-sensing mounting stage;

gathering pressure data using the movable pressure-sensing mounting stage; and

pressing the liquid crystal display cell against the sheet of optically clear adhesive material while gathering the pressure data using the movable pressure-sensing mounting stage.

18. The method defined in claim 17 wherein gathering the pressure data using the movable pressure-sensing mounting stage comprises:

generating pressure signals using pressure sensors on the movable pressure-sensing mounting stage; and

generating the pressure data from the pressure signals.

19. The method defined in claim 17, further comprising adjusting an orientation of the movable pressure-sensing mounting stage based on the gathered pressure data.

20. The method defined in claim 17 wherein securing the assembly in the fixed position comprises temporarily attaching the assembly to a fixed pressure-sensing mounting stage.