Enhanced liquid crystal display system and methods
Embodiments of methods and systems to generate an enhanced layered display system are described herein. In one embodiment, a method of generating an enhanced layered display system is provided including dispensing an optical bonding liquid onto a first substrate; forming an adhesive preform unit by curing the optical bonding liquid on the first substrate; and laminating the adhesive preform unit to a second substrate to form the enhanced layered display system, where one of the first substrate and the second substrate is a display.
1. A method of generating an enhanced layered display system, comprising:
dispensing a layer of an optical bonding liquid having optical properties onto a first substrate to form a bonding layer, where the first substrate is a glass or plastic overlay;
forming an adhesive preform unit by curing the optical bonding liquid on the first substrate where the adhesive preform unit comprises a shaped preform, where the shaped preform corresponds to a shape of a top surface of a display;
where the curing of the optical bonding liquid to form the adhesive preform unit occurs prior to introduction of the display;
laminating the adhesive preform unit to the display to form the enhanced layered display system;
wherein laminating the adhesive preform unit to the display includes laminating in a vacuum environment; and
where the first substrate is a protective overlay for the display;
positioning the first substrate in an adhesive pool;
filling the adhesive pool to a select level to create a uniform bond line thickness across the first substrate, wherein the optical bonding liquid is extended beyond a perimeter of the first substrate to create an excess preform perimeter;
curing the optical bonding liquid; and
cleaning the excess preform perimeter from the first substrate after curing the optical bonding liquid.
2. The method of claim 1 , wherein the optical bonding liquid includes an adhesive, the adhesive index-matched to at least one of the first substrate or the display.
3. The method of claim 2 , wherein the adhesive includes a two-part silicone adhesive.
4. The method of claim 1 , wherein forming the adhesive preform unit comprises leveling the optical bonding liquid on the first substrate by drawing an edger across a top surface of the optical bonding liquid.
5. The method of claim 1 , wherein forming the adhesive preform unit comprises thermally curing the optical bonding liquid at a temperature of at least 150° C.
6. The method of claim 1 , wherein the vacuum environment comprises creating a vacuum of at least 30 mm of Hg.
7. A method of generating an enhanced layered display system, comprising:
forming an adhesive preform unit on an overlay, forming the adhesive preform unit comprising:
positioning a first substrate in an adhesive pool,
thereafter filling the adhesive pool with an optical bonding liquid having optical properties to a select level to create a uniform bond line thickness across the first substrate, and
thermally curing the optical bonding liquid to form a bonding layer with a uniform surface;
thereafter placing the adhesive preform unit in a vacuum chamber;
placing a display unit in the vacuum chamber;
evacuating the vacuum chamber; and
bringing the adhesive preform unit in contact with the display unit to form the enhanced layered display system, once a vacuum has been achieved.
8. The method of claim 7 , wherein forming the adhesive preform unit comprises thermally curing the optical bonding liquid at a temperature of at least 150° C., and wherein evacuating the vacuum chamber comprises creating a vacuum of at least 30 mm of Hg deforming the adhesive preform unit.
9. The method of claim 7 , wherein the adhesive pool has a depth corresponding to a depth of the bond line thickness.
10. The method according to claim 7 , wherein the optical bonding liquid is fully cured in the adhesive pool.