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Alongside previous bonding technologies such as AirGap, LOCA and OCA, DATA MODUL AG is now implementing the fourth process at the production location in Weikersheim: gel bonding. DATA MODUL AG thus reaffirms its technology lead in the field of display optimization and visual solutions.
This additional process became necessary especially in the further processing of frameless displays. These do not have a metal bezel, and can therefore only be sealed in the LOCA process with a passage at a great cost. In liquid bonding, some penetration of the glue into the display cannot be excluded even when taking great care, due to its design. Even dry bonding with OCA is not applicable for frameless displays, since neither the sensor/glass nor the display can be applied via roll lamination.
Furthermore, many industry clients count on equally frameless MIP and Blanview displays for applications for outdoor use in direct sunlight. The adhesive tape of AirGap bondings can be applied here only with difficulty and, even if the process is successful, additional reflective edges and resulting visual losses arise through the generated air gap.
These reasons were crucial for the decision of integrating the gel bonding process into DATA MODUL’s range of services. This process offers a great number of benefits: The bonding is extremely UV-resistant and therefore perfectly suited to outdoor applications. In conjunction with the frameless displays for example of Ortustech and its Blanview technology, a temperature resistance of -30 to +80 degrees can even be achieved without any issues - depending on the materials used. DATA MODUL uses the high-quality polyarylate material instead of widespread and cheaper silicone, since the gel has a significantly higher adhesive quality and UV resistance than silicone.
Gel pads are tailored to the size of the display surface and can be adapted to a specific project. The pads are used in varying degrees of thickness depending on the display structure. Frameless displays require pads only 0.1 to 1mm thick. Displays with a surrounding frame under the polarizer, on the other hand, require thicker pads to also be able to bond the frame. The cut is applied to the touch unit (glass pane incl. touch sensor) via roll lamination. The touch unit in the vacuum - prevalent in the bonding machine - is then placed on the display. The mechanical strain for the display surface here is not critical, so any kind of glass pane and touch technology can be used. DATA MODUL evaluated the process in Q4/2017, switched client orders with frameless displays to the process. Diagonals from 1.3” to 14” can be implemented in existing systems, mobile applications with round memory-in-pixel displays are also already bonded in the gel process.
The bonding process used is ultimately chosen based on the component and technology range in the project and directly with the client. Thanks to previous and extensive investments in bonding technologies, DATA MODUL is now in the comfortable position of being able to provide the optimal bonding procedure with a choice of four processes, in correspondence with the respective requirements.
In 2018, the company will make further investments in the expansion of the clean room, supplement the machinery for the increasing capacity and probably establish another bonding process in Q3. On site insights and more information about the bonding processes are available on request.