3-dimensional curved substrate lamination

• US 8,196,636 B2
• Filed: 07/23/2010
• Issued: 06/12/2012
• Est. Priority Date: 05/07/2008
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Sung, Kuo-Hua, Edwards, Troy J., Feinstein, Casey J., Zhong, John Z., Hotelling, Steven Porter, Lauder, Andrew David
• Primary Examiner(s): Nguyen, Khanh P
• Assistant Examiner(s): Patel, Vishal I
• Application Number:
  US12/842,905
• Publication Number:
  US 20100282416A1
• Time in Patent Office: 690 Days
• Field of Search: 156/87, 156/99, 156/579
• US Class Current: 156/579
• 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. An apparatus for laminating a surface of a flexible material to a surface of a curved material, the apparatus comprising:

a first holder configured for contacting the flexible material;

a second holder configured for contacting the curved material;

a support holder having a plurality of alignment pins for supporting the flexible material as a flat surface spaced apart from a contact surface of the first holder and the curved material;

a pressure applying device configured for pressing the first holder against the flexible material to cause the flexible material to press against the curved material at a first portion of the flexible material at a pressure region between the surface of the flexible material and the surface of the curved material;

articulation means for shifting the first holder across the flexible member, the articulation means causing translation of the first holder along both an x and y direction while moving the first holder toward the second holder along a z direction, thus changing at least the position of the pressure region to laminate the flexible material to the curved material and remove air bubbles between the laminated flexible material and the curved material.

2. The apparatus of claim 1, wherein the flexible material is a substantially planar circuit board.

3. The apparatus of claim 1, wherein the flexible material comprises a plurality of conductive traces on its surface and an insulating layer deposited over the conductive traces.

4. The apparatus of claim 1, wherein the laminated flexible material and the curved material are a part of a sensor array, and the sensor array is a part of a multi-touch mouse.

5. The apparatus of claim 1, further comprising an adhesive adapted to laminate the flexible material and the curved material, the adhesive selected from a group consisting of pressure-sensitive adhesives (PSAs), re-workable PSAs, thermoplastic film, thermoset film, thermal cure liquid, UV curing liquid, and multiple-component adhesives.

6. The apparatus of claim 1, wherein the support holder is part of the second holder.

7. The apparatus of claim 1, wherein the first holder is made of a deformable material.

8. The apparatus of claim 1, wherein the pressure applying device is adapted to change an amount of pressure applied to the surface of the flexible material and the surface of the curved material.

9. The apparatus of claim 1, wherein the change of the pressure region is in response to a shape of at least one of the first holder and the second holder.

10. The apparatus of claim 1, wherein the articulation means comprising a gimbal adapted to control movement of the first holder and create a rolling motion of the first holder.

11. The apparatus of claim 1, further comprising a microbead surface adapted to be walked over the flexible material to remove air bubbles between the laminated flexible material and the curved material.

12. The apparatus of claim 11, wherein the flexible material has a conductive trace pattern and microbeads on the microbead surface have a size and spacing to conform to the conductive trace pattern.

13. The apparatus of claim 12, wherein the conductive trace pattern has a plurality of peaks and valleys and the microbeads protrude into the valleys to push air to a perimeter of the laminated flexible material and the curved material during walking.

14. The apparatus of claim 1, wherein break away tabs secure the flexible material to the alignment pins, the break away tabs configured to detach the flexible material from the alignment pins under pressure.

15. The apparatus of claim 14, further comprising a microbead surface adapted to be walked over the flexible material to remove air bubbles between the laminated flexible material and the curved material.

16. The apparatus of claim 15, wherein the flexible material has a conductive trace pattern and microbeads on the microbead surface have a size and spacing to conform to the conductive trace pattern.

17. The apparatus of claim 16, wherein the conductive trace pattern has a plurality of peaks and valleys and the microbeads protrude into the valleys to push air to a perimeter of the laminate during walking.