3-dimensional curved substrate lamination

• US 8,123,894 B2
• Filed: 09/24/2008
• Issued: 02/28/2012
• Est. Priority Date: 05/07/2008
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Sung, Kuo, Edwards, Troy, Feinstein, Casey, Zhong, John, Hotelling, Steve Porter, Lauder, Andrew David
• Primary Examiner(s): Nguyen, Khanh P
• Assistant Examiner(s): Patel, Vishal I
• Application Number:
  US12/237,281
• Publication Number:
  US 20090277578A1
• Time in Patent Office: 1,252 Days
• Field of Search: 156/286, 156/86, 156/87, 270/52.12, 269/47, 264/278
• US Class Current: 156/286
• CPC Class Codes: B29C 63/0047 Preventing air-inclusions
• CPC Class Codes: B29C 63/0073 of non-flat surfaces, e.g. curved, profiled B29C63/042 takes precedence
• CPC Class Codes: B32B 17/10 of synthetic resin
• CPC Class Codes: B32B 2037/264 Pressure equalizing layers
• CPC Class Codes: B32B 2038/047 Perforating
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 37/003 to avoid air inclusion
• CPC Class Codes: B32B 37/0053 Constructional details of laminating machines comprising rollers; Constructional features of the rollers
• CPC Class Codes: B32B 37/10 characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 38/1858 using vacuum
• CPC Class Codes: B32B 38/1866 conforming the layers or laminate to a convex or concave profile
• CPC Class Codes: G06F 3/03543 Mice or pucks G06F3/03541 takes precedence
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1028 by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
• CPC Class Codes: Y10T 156/17 Surface bonding means and/or assemblymeans with work feeding or handling means
• CPC Class Codes: Y10T 156/1793 Grip or clamp for web end
• CPC Class Codes: Y10T 156/18 Surface bonding means and/or assembly means with handle or handgrip

Abstract

A method of laminating a surface of a flexible material to a surface of a rigid, curved material. The method includes pressing an area of the surface of the flexible material into the surface of the rigid, curved material with a holder to create a contact area while the flexible material is conformed to the holder, which has a curvature greater than a curvature of the rigid, curved material surface; and changing the contact area between the surface of the flexible material and the surface of the rigid, curved material while maintaining pressure on the contact area until the surface of the flexible material and the surface of the rigid curved material are laminated.

Claims

1. A method of laminating a surface of a flexible material to a surface of a curved material, the method comprising:

attaching the flexible material to alignment pins to position the flexible material as a flat surface which is spaced apart from the surface of the curved material;

pressing an area of the surface of the flexible material at a first area edge-of the flexible material into the surface of the curved material with a holder moving along a z direction to create a contact area while the flexible material is conformed to the holder and in direct contact with the holder at least at the contact area; and

shifting the contact area across the flexible material to adjacent areas of the flexible material by translating the holder along x and y directions while maintaining pressure on the contact area until the surface of the flexible material and the surface of the curved material are laminated;

further comprising securing the flexible material using break away tabs such that the flexible material detaches from the alignment pins when pressing with the holder.

2. The method of claim 1, wherein the curved material is curved in a plurality of axes.

3. The method of claim 1, further comprising applying pressure uniformly on the contact area.

4. The method of claim 1, further comprising initially establishing the contact area at a first edge of the surface of the curved material.

5. The method of claim 1, wherein shifting the contact area includes changing the shape of the contact area.

6. The method of claim 1, further comprising using an adhesive to laminated the flexible material and the curved material.

7. The method of claim 6, wherein the adhesive is selected from the group consisting of pressure-sensitive adhesives (PSAs), re-workable PSAs, thermoplastic film, thermoset film, thermal cure liquid, UV curing liquid, and multiple-component adhesives.

8. The method of claim 6, further comprising heating at least one of the flexible material and the curved material.

9. The method of claim 1, wherein the holder holds the flexible material by suctioning vacuum holes.

10. The method of claim 1, further comprising pushing out air bubbles formed between the flexible material and the curved material as the contact area shifts.

11. The method of claim 1, further comprising conforming the curved material in a base.

12. The method of claim 1, further comprising laminating a stiffener to the flexible material, the stiffener being other than the flexible material and the curved material.

13. The method of claim 12, further comprising positioning the stiffener in a recessed portion of the holder prior to pressing.

14. The method of claim 1 further comprising walking a microbead surface over the surface of the flexible material to remove air bubbles between the laminated flexible material and the curved material.

15. The method of claim 1 wherein the holder comprises an expandable bag or balloon.

16. The method of claim 13, further comprising securing the flexible material using break away tabs such that the flexible material detaches from the alignment pins when pressing.

17. The method of claim 14 wherein the flexible material has a conductive trace pattern and the method further comprises forming the microbead surface to have a size and spacing to conform to the conductive trace pattern.