Liquid crystal cells with uniform cell gap and methods of manufacture
A laminate structure and method of manufacture, such as a processed silicon wafer with an overlying layer or cover, includes a first layer or substrate which has a generally-planar region and a peripheral contoured region with falloff from a planar region of the first layer, and a second layer which overlies the first layer and is spaced from the planar region of the first layer a uniform distance by a plurality of uniform spacers, and peripheral spacers located in the peripheral contoured region which extend from the first layer to the second layer to maintain the second layer in the same plane as it extends over the falloff of the peripheral contoured region of the first layer to increase the useable area of the laminate structure. Spherical, deformable and fixed dimension spacers are used.
1. A laminate structure comprising:
a first layer having a planar region and a peripheral contoured region;
a planar second layer parallel to and spaced from the first layer and overlying the generally planar region and the peripheral contoured region of the first layer; and
a plurality of uniform spacers positioned between the first and second layers and spacing the second layer a uniform distance from the planar region of the first layer, and one or more peripheral spacers positioned between the first and second layers in the peripheral contoured region, the peripheral spacers extending between the peripheral contoured region of the first layer and the planar second layer, the peripheral spacers having a vertical dimension greater than a vertical dimension of the uniform spacers; wherein the peripheral spacers are deformable adhesive between the first and second layers in the peripheral contoured region;
the planar second layer lying entirely in a single, plane spaced from the planar region and the peripheral contoured region of the first layer.
2. The laminate structure of claim 1 wherein the first layer is a wafer.
3. The laminate structure of claim 1 wherein the first and second layers are generally circular, and the peripheral contoured region of the first layer is at the periphery of the circular first layer.
4. The laminate structure of claim 1 wherein the uniform spacers and the peripheral spacers are generally spherical.