AbraxSys Implementing Direct Dry Film Optical Bonding Lamination Technology

AbraxSys is migrating to the newest generation of optical bonding technology. This innovative new vacuum bonding, also known as "Dry Bonding", will replace the current universally standard "wet bonding" technology. AbraxSys new dry optical bonding process uses production jigs, is fully automated and therefore very stable in yield and precision. This is particularly important for smaller sized TFT LCD displays.

Dry Film Bonding
Dry Film Bonding

Dry Bonding adheres flexible substrates such as optical films to rigid LCD substrates using pressure sensitive bonding adhesives. This new bonding process uses a tack-free sheet material that is positioned against one substrate and then mechanically assembled to a second substrate. The panel assembly is then placed inside a vacuum, sealed and further exposed to pressure and temperature in accordance with a prescribed recipe. Dry optical bonding does not cause optical defects as scratches or moiré patterns during the production process, which makes a cosmetic cleanup or additional attention superfluous.

There are several advantages to dry optical bonding over liquid optical bonding:

1. The overall process is much cleaner. The display is laminated without residuals to clean up after bonding and the tooling remains ready for re-use.

2. There is dimensional superiority compared to liquid bonding. No need to account for shrinkage, bond-line control, or varying cure rates that can influence bond-line and internal stress.

3. The process is “green”. No wastage of raw materials. Cleaning solvents are not required.

4. The process is much faster with fewer steps and less equipment. Dry bonding can be completed in less than 30 minutes, whereas with “wet” bonding needs to cure after the bonding process, so typically 3 days.

5. It is much easier to automate since the materials are solid; no mixing, de-airing or pouring; and no chance for rework due to foreign object intrusion, moiré and/or air bubbles.

6. The process produces high yield and is also repairable, which is not the case with many liquid bonding technologies.

Dry Bonding Graphic

There are also many performance- related benefits:

1. The bonding is also more stable up to altitude over 100,000 ft (30,000+ meters). Most of the liquid bonded stacks start deteriorating just over 40,000 ft, (12,000 meters) at least temporarily.

2. It is very easy to add additional layers of optical substrates to improve resistance to boot-kick or ballistic applications.

3. The finished product exhibits excellent resistance to vibration/shock.

4. The display stack of the “dry” bonded processes typically has lower deflection amplitude at resonance than those made using liquid bonding.

5. It also has higher resonance frequency.