WO2011049564A1

WO2011049564A1 - Photoinitiated optical adhesive and method for using same

Info

Publication number: WO2011049564A1
Application number: PCT/US2009/061507
Authority: WO
Inventors: William R. Dunn; Michael Lecave
Original assignee: Manufacturing Resources International, Inc.
Priority date: 2009-10-21
Filing date: 2009-10-21
Publication date: 2011-04-28

Abstract

A method for bonding glass components using an optional encapsulated photo-initiated optical adhesive, and a glass assembly method using said optional adhesive. A mixture containing a catalyst and a resin is provided where either the catalyst or the resin (or both) are encapsulated. The mixture is applied to a glass component. The mixture may be exposed to ultraviolet light causing the capsules to release the portions contained therein and combine to form an adhesive (this may be done before or after applying the mixture to the glass component). A second glass component is then placed on the adhesive so that the adhesive is interposed between the glass components. Alternatively, the mixture may be exposed to UV light after the second glass component is placed. An exemplary method uses a frame to create a uniform thickness of adhesive. Barrier coats and skirting tape may also be used.

Description

PHOTOINITIATED OPTICAL ADHESIVE AND METHOD FOR USING SAME

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application makes no claim of priority.

TECHNICAL FIELD

[0002] Exemplary embodiments relate generally to optical adhesives and methods for using the same to bond glass components.

BACKGROUND AND SUMMARY OF THE INVENTION

[0003] In the manufacturing of LCD displays, it is necessary to bond glass components to one another. The bonded glass components may be used in the formation of LCD stacks, glass front plates, lamination of touch panels, and other glass features found in LCD displays. Generally, glass components are bonded using an optical adhesive interposed between the glass components. Traditional adhesives and bonding processes are time consuming and are subject to problems/defects resulting in a display unfit for consumer use.

[0004] Traditionally, adhesives for display glass components have a two part design. A first part being a resin and a second part being a catalyst. The first and second parts are then mixed together. As the first and second parts of the adhesive contact one another they undergo a reaction and begin to cure. This immediate curing significantly reduces the workable time of the mixture. The short workable time of the material may lead to various defects in the display.

[0005] One such problem with traditional methods is the formation of air bubbles in the adhesive. As the optical adhesive is interposed between two glass components, the display would be ruined if bubbles were present. Another problem that may occur during the bonding process is known as the halo effect or window framing. The halo effect may be caused by using an insufficient amount of adhesive to maintain glass component coverage during the curing phase. As the optical adhesive cures and experiences shrinking, the adhesive may pull away from the edges of the bonded glass components, resulting in both mechanical and optical failures.

[0006] Insufficient amounts of adhesive could also lead to mechanical separation of the glass components. In addition, the immediate curing may not allow for the glass components to be readjusted after coming into contact with the adhesive. When defects in the finally assembled glass are present, the only options left to manufacturers are to either dispose of the rejected components or spend large amounts of time manually removing the adhesive from the glass components. These problems are now magnified as the sizes of LCD displays are increasing which necessitate the need for larger, more expensive glass components.

[0007] To eliminate some of these problems ultraviolet (hereinafter "UV") light cured adhesives have been used. UV cured adhesives may include one or two parts. The adhesive may be applied to the glass component for bonding. After the adhesive is applied, it is cured by using a UV light source to direct UV toward the adhesive. Although these adhesives may provide benefits over traditional mix cured adhesives, some problems still exist. One such problem is the increased cost of production due to the need to maintain the UV light during the curing phase. Another problem is that display features such as grid heaters, anti-reflective layers, or other devices may prevent the UV light from reaching the entire adhesive. The result may be that portions of the adhesive are not cured properly and thus weaken the bond. This weakness may result in increased mechanical separation and image distortion as a result of the uncured adhesive.

[0008] These and other problems related to traditional optical display adhesives may be eliminated through the use of the exemplary embodiments described herein. In one exemplary embodiment an encapsulated two part photo-initiated adhesive may be used to bond glass components of a display. The adhesive may comprise a first part being a resin (hereinafter "part A", "resin portions", or "resin") and a second part being a catalyst (hereinafter "part B", "catalyst portions", or "catalyst") (collectively "components"). As the adhesive resulting from the combination of resin and catalyst may be used to optically bond glass components of a display, the adhesive would preferably be substantially transparent and provide minimal image distortion. Platinum catalysts have been found to provide a suitable optical adhesive.

[0009] To prevent premature contact or reaction between parts A and B, each part (or one of the parts) may be encapsulated. The term 'encapsulated' is used herein to define at least a portion of a mixture which is substantially surrounded by an envelope to prevent the portion from prematurely mixing with other portions. The encapsulated parts A and B may then be mixed together creating a viscose material. The mixture may then be applied to a glass component of a display for bonding. After a sufficient amount of the encapsulated mixture has been applied to the glass component, the mixture is exposed to a UV light source. Upon exposure to UV light, the capsules surrounding parts A and B release the resin and catalyst. Parts A and B then proceed to mix together creating an adhesive. After the adhesive has been formed it may then begin to cure. Another glass component may then be placed on the adhesive, such that the adhesive is interposed between two glass components. The adhesive may then be allowed to cure forming the bond between the glass components.

[0010] The glass components may be any component used in an electronic display or any other type of glass components which may require optical bonding. In an exemplary embodiment, the adhesive may cure simply at room temperature. In some embodiments, it may be desirable to cure the adhesive at an elevated temperature. The UV light source may be required only to release the encapsulated portions and may not be required for the actual curing of the mixed adhesive. Once the adhesive is cured, the remnants of the encapsulating element may be present.

[0011] In another exemplary embodiment, part A may be encapsulated and mixed with part B. In still other exemplary embodiment, part B may be encapsulated and mixed with part A. As the capsule shields do not react with either part A or part B, the parts are not in contact, thus not forming the adhesive. In other exemplary embodiments, the adhesive formed by parts A and B may be able to penetrate the capsule shield. In this manner, capsules not exposed to the UV light may still release their contents, and the resin or catalyst contained therein may be incorporated into the adhesive.

[0012] The described exemplary embodiments provide several advantages over traditional optical adhesives. The ability to premix the resin and the catalyst without adhesive formation increases the production time by eliminating the mixing process. In addition, the ability of the adhesive to release the contents of adjacent capsules allows a more uniform bond between the glass components.

[0013] To further ensure a lack of defects, the adhesives disclosed herein can be applied using an exemplary process. In one exemplary embodiment of this process, a first glass component having a frame is provided, the frame being in contact with the first glass component. A sealant may be used to seal the edge of the frame and the first glass component. This sealant is then allowed to cure. A barrier coat is applied over the sealant. The barrier coat is then allowed to cure. The encapsulated mixture is poured over the entirety on the first glass component and frame. A second glass component is placed on the frame with one end still elevated over the first glass component. The second glass component is slowly lowered until the previously elevated edge rests on the frame, resulting in a layer of the encapsulated mixture interposed between the second glass layer and the first glass layer and the frame. The capsules may then be broken down, the components mix to create the adhesive, and the adhesive is cured. Alternatively, the capsules may be broken down prior to placing the second glass component against the frame.

[0014] In another exemplary embodiment, the barrier coat step is removed and the encapsulated mixture is poured directly onto the first glass component, sealant, and the frame. In still another exemplary embodiment, an edge of the second glass component is placed at the intersection of the first glass component and the frame, still having an edge elevated above the first glass component. The second glass component is slowly lowered until the previously elevated edge rests at the intersection of the first glass component and the frame, resulting in a layer of the encapsulated mixture interposed between the second glass layer and the first glass layer. The capsules may then be broken down, the components mix to create the adhesive, and the adhesive is cured. Alternatively, the capsules may be broken down prior to placing the second glass component against the frame.

[0015] Further features of the exemplary embodiments will be described or will become apparent in the course of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWING(S)

[0016] A better understanding of the disclosed embodiments will be obtained from a reading of the following detailed description and the accompanying drawings wherein identical reference characters refer to identical parts and in which:

[0017] Figure 1 is an exemplary embodiment of a mixture including encapsulated resin portions and encapsulated catalyst portions

[0018] Figure 2 is an exemplary embodiment of a mixture having encapsulated catalyst portions and resin portions.

[0019] Figure 3 is an exemplary embodiment of a mixture having encapsulated resin portions and catalyst portions.

[0020] Figure 4 is an exemplary embodiment of a mixture having encapsulated resin and catalyst portions applied to the surface of a glass component for bonding.

[0021] Figure 5 is an exemplary embodiment of a mixture having encapsulated catalyst portions and resin portions applied to the surface of a glass component for bonding.

[0022] Figure 6 is an exemplary embodiment of a mixture having encapsulated resin portions and catalyst portions applied to the surface of a glass component for bonding.

[0023] Figure 7A is an exemplary embodiment of a mixture having encapsulated catalyst portions where a first glass component is moved underneath a stationary UV light source releasing the contents of the capsules.

[0024] Figure 7B is an exemplary embodiment of a mixture having encapsulated catalyst portions where a UV light source is moved over a stationary first glass component releasing the contents of the capsules. [0025] Figures 7C through 7F show an alternative embodiment where a numeric dispenser is used to apply the mixture to the first glass component.

[0026] Figure 8 is an exemplary embodiment of an adhesive formed on a glass component to be bonded comprising resin and catalyst after the capsules have released their contents.

[0027] Figure 9 is an exemplary embodiment of the adhesive interposed between two glass components so as to bond them together.

[0028] Figure 10 is a top view of an exemplary embodiment of a glass component having a frame.

[0029] Figure 10A is a cross-sectional view of an embodiment of the frame in Figure 10 taken along line 10A-10A as indicated in Figure 10.

[0030] Figure 11 is a side view of an exemplary embodiment of a glass component having a frame.

[0031] Figure 12A is a side view of an exemplary embodiment where a container is filled with the mixture and the mixture is exposed to UV light.

[0032] Figure 12B is a side view of an exemplary embodiment where a container is transferring the adhesive to a first glass component and frame.

[0033] Figure 13 is a side view of an exemplary embodiment for applying a second glass component.

[0034] Figure 14A is a side view of an exemplary embodiment of a bonded glass assembly. [0035] Figure 14B is a side view of an exemplary embodiment where the mixture has not yet been exposed to UV light and the UV light source is moved across a stationary assembly.

[0036] Figure 14C is a side view of an exemplary embodiment where the mixture has not yet been exposed to UV light and the assembly is moved under a stationary UV light source.

[0037] Figure 15 is a top view of an exemplary embodiment of a bonded glass product.

[0038] Figure 15A is a magnified cross-sectional view of an embodiment of a bonded glass product in Figure 15 taken along line 15A-15A as indicated in Figure 15.

[0039] Figure 16 is a side view of an exemplary embodiment of a bonded glass product.

[0040] Figure 17 is a top view of an exemplary embodiment of a bonded glass product.

[0041] Figure 17A is a magnified cross-sectional view of an embodiment of a bonded glass product in Figure 17 taken along line 17A-17A as indicated in Figure 17.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

[0042] Figure 1 illustrates an exemplary embodiment of a mixture 2 comprising capsules 4. The capsules 4 may contain either a resin portion 6 or a catalyst portion 8. The capsules 4 may also contain any other material or additive necessary to facilitate adhesive formation between the resin portions 6 and the catalyst portions 8. The capsules 4 prevent the resin portions 6 and the catalyst portions 8 from coming into direct contact with one another. The use of the capsules 4 allows the resins portions 6 and the catalyst portions 8 to be premixed eliminating the need to mix multi-part adhesives during the bonding process.

[0043] Figures 2 and 3 illustrate other exemplary embodiments of the mixture 2. Figure 2 illustrates a mixture 2 wherein only part B 8 is encapsulated. Figure 3 illustrates a mixture 2 wherein only part A 6 is encapsulated. By providing a capsule 4 (encapsulating element) around either part A 6 or part B 8, the components remain isolated from one another. An advantage of encapsulating only one component may be to decrease the overall weight of the mixture 2 and decrease the material needed to encapsulate the components 6 and 8. Encapsulating only one component 6 or 8 may also increase adhesive formation. It should be understood by those skilled in the art, that the mixture 2 illustrated in Figure 2 may include at least some encapsulated resin portions 6, and that the mixture 2 illustrated in Figure 3 may include at least some encapsulated catalyst portions 8.

[0044] In other exemplary embodiments, the resin 6 and catalyst 8 may be replaced by any materials, when combined, form an adhesive or bonding material. An example of an adhesive that may be used in the exemplary embodiments is manufactured by Momentive Performance Materials Incorporated of Albany, New York (hereinafter "Momentive"). www.momentive.com. Momentive manufactures an encapsulated photo-initiated multi-part optically clear adhesive that may be used with some of the exemplary embodiments herein.

[0045] The mixture 2 may then be applied to the glass component 9 to be bonded. The mixture 2 is applied in amounts sufficient to prevent defects such as the halo effect or window framing. The glass component 9 may be any display component including, but not limited to: LCD stacks, front plates, touch panels, or any other glass components found in a display.

[0046] Although the mixture 2, as shown in Figure 4 is alternating pattern of parts A 6 and parts B 8, this is merely a representation of the mixture 2 not of the actual dispersion of components 6 and 8. Although the components 6 and 8 are shown in a 1 :1 ratio, it is should be understood that different ratios may be used depending on the components 6 and 8 used in the mixture 2.

[0047] Figures 5 and 6 illustrate other exemplary embodiments of the claimed invention. Figure 5 illustrates a mixture 2 applied to the glass component 9 to be bonded wherein the mixture 2 includes encapsulated resin portions 6 and catalyst portions 8. Figure 6 illustrates a mixture 2 applied to the glass component 9 to be bonded wherein the mixture 2 includes resin portions 6 and encapsulated catalyst portions 8.

[0048] Figures 7A through 7F show several methods for releasing the encapsulated portions of the mixture so that they can combine to form an adhesive. As shown in Figure 7A, a mixture 2 comprising resin portions 6 and encapsulated catalyst portions 8 is applied to a first glass component 9. As the encapsulated catalyst portions 8 are exposed to the UV light 70, the capsules 4 may begin to allow the release of the catalyst portions 8 and permit them to come into contact with the resin portions 6 in the mixture 2 (as indicated by the dashed lines). In this embodiment, the first glass component 9 is moved underneath the stationary UV light source 70. Upon contact with one anther, the resin portions 6 and the catalyst portions 8 begin to form an adhesive 80 (as shown in Figure 8). In exemplary embodiments, to ensure that substantially all of the resin portions 6 and the catalyst portions 8 are in contact; the adhesive 80 may be able to penetrate the capsules 4 not exposed to the UV light and contact the resin portion 6 or catalyst portion 8 contained therein. After the adhesive is formed, it may begin the curing process.

[0049] Figure 7B shows an alternative embodiment where the first glass component 9 and the mixture 2 remain stationary while the UV light source 70 is moved across the assembly. Figures 7C through 7F show an alternative embodiment where a numeric dispenser 150 is used to apply the mixture 2 to the first glass component 9. The numeric dispenser 150 may contain a first container 175 for housing the resin and a second container for housing the catalyst 170. A vacuum may be used in each container to remove any air bubbles and a pump may be used with each container 175 and 170 in order to send the desired amount of resin or catalyst to a mixing tip 160. The resin and catalyst can be mixed in any desired ratios and can be precisely controlled. Figure 7C shows a first embodiment where the mixture 2 is exposed to a UV light source 70 upon exiting the mixing tip 160. In this embodiment, it may be preferable to ensure that the containers 175 and 170 and mixing tip 160 cannot be penetrated by the UV light to ensure that the mixture does not begin to prematurely form an adhesive. Figure 7D shows a second embodiment where the mixture 2 is exposed to a UV light source 70 while still present within the mixing tip 160. Here, it may be preferable to allow UV to penetrate the mixing tip 160 but not the containers 175 and 170. FIGURE 7E shows a third embodiment where the mixture 2 is applied to the first glass component 9 and the UV light source 70 applies UV light after the mixture 2 is applied to the first glass component 9. FIGURE 7F provides an illustration of how the mixture may be applied to the first glass component 9 by moving the numeric dispenser 150 across the surface of the first glass component 9. By using the numeric dispenser 150, the precise amount of mixture that is applied as well as the location on the first glass component 9 can be tightly controlled. This can help insure that the mixture is applied in a very uniform manner. Further, in some embodiments it may be desirable to apply the mixture in a non-uniform manner. Thus, in some embodiments it may be preferable to apply more (or less) of the mixture towards the outside edges of the first glass component 9.

[0050] As shown in Figure 8, once the capsules have released their contents, the resin portion 6 and catalyst portion 8 may mix to create an adhesive 80. In an exemplary embodiment, the adhesive 80 would not require UV to cure, but would only require UV to release the encapsulated portions. In other embodiments, the adhesive 80 may be UV light cured, visible light cured, or cured by a moisture condensation method. In still other embodiments, the adhesive 80 may be dual curing and capable of cross-linking when subjected to UV light or visible light and/or by a moisture condensation method. In still other embodiments, the adhesive may be a RTV silicon.

[0051] As shown in Figure 9, after the adhesive 80 has formed on the first glass component 9, a second glass component 90 may be placed on the adhesive 80 so as to interpose the adhesive 80 between the first and second glass components 9 and 90. The adhesive 80 is then allowed to fully cure. Once the adhesive has cured, the remnants of the capsule 4 (encapsulating element) may be present. It is to be understood, that exemplary embodiments may be used with any type of display where bonded glass components may be used.

[0052] Although the mixture and resulting adhesive described above can be applied in many different ways, an exemplary method has been discovered which may eliminate even more defects in the final bonded glass. Although this method could be practiced with many types of adhesives, practicing the method with the encapsulated mixture and adhesive disclosed above can provide a very low failure rate during the bonding process.

[0053] Figure 10 is an elevated top view of a first glass component 10 having defined outside edges 12. The first glass component may have a first surface 14. The first glass component may have a frame 20 positioned around the outside edges 12. Figure 10A is a cross-sectional view of the frame 20 by itself. The frame 20 may have an L-shaped cross section having a top portion 22, side portion 24, and a top surface 25. The top portion 22 of the frame 20 having an inside edge 26 and an outside edge 28. The top portion 22 of the frame 20 is designed to overlap the first surface 14 of the first glass component 10, such that the outside edges 12 of the first glass component 10 contact the side portion 24 of the frame 20, as illustrated in Figure 11. The frame 20 may be a rigid material, including, but not limited to: metal, plastic, or composite materials. The frame 20 may have a unitary body design. In other embodiments, the frame 20 may be constructed from multiple sections.

[0054] In exemplary embodiments, the first glass component 10 may be a LCD stack or any other LCD component. In still other embodiments, the first glass component 10 may be any glass feature found in a LCD, LED, OLED, or light emitting polymer display.

[0055] To begin an exemplary bonding process a frame seal adhesive is applied to inside edge 26 of the frame 20 overlapping the first glass component 10 on its first surface 12, forming a frame seal. The width and thickness of the frame seal may be sufficient to form a complete seal between the inside edge 26 of the frame 20 and the first surface 14 of the first glass component 10. This frame seal may prevent particulate from entering any space between the top portion 22 of the frame 20 and the first surface 14 of the first glass component 10. The frame seal adhesive may then be allowed to cure at room temperature. A variety of frame seal adhesives may be used to seal the frame 20 to the first surface 12. One example of a frame seal adhesive that may be used is Dow Corning® brand product 3145 RTV Adhesive/Sealant (hereinafter "the 3145 adhesive"). [0056] After the frame seal adhesive has had sufficient time to cure, a barrier coat may be applied over the frame seal. The barrier coat may be applied over the frame seal with a brush. In other exemplary embodiments, the barrier coat may be applied using any suitable application method. The adhesive used for the barrier coat may be an optical adhesive. In some embodiments, the optical adhesive may be index matched. One example of an adhesive that may be used for the barrier coat is Dow Corning® brand Product, Sylgard® 527 A&B Silicone Dielectric Gel (hereinafter "the 527 adhesive"). The 527 adhesive may comprise 1 part resin to 3 parts catalyst. However, to maximize adhesion and optical performance, the 527 adhesive may comprise 1 part resin to 1 part catalyst. After the barrier coat is applied, it is allowed to cure.

[0057] After the barrier coat has had sufficient time to cure, skirting tape (not shown in the figures) may be applied to the side portion 24 of the frame 20. The skirting tape may be aligned such that is covers the side portion 24 of the frame 20 without contacting the top portion 22 of the frame 20. The skirting tape may be any self adhesive tape. More preferably, the skirting tape may be any self adhesive tape that is easily removable. In other embodiments, a skirting tape may not be used.

[0058] For one embodiment, the next step in the bonding process might be to place a desired amount of a mixture 30 within a container 100, as illustrated in Figure 12A. The mixture 30 may be any type of optical adhesive or may be the encapsulated adhesive as described above. If the encapsulated adhesive is being used, a UV light source 70 may apply UV light to the mixture 30 while it is within container 100 in order to release the encapsulated portions to create an adhesive. As shown in Figure 12B, the mixture 30 may be transferred from the container 100 to the first surface 14 of the first glass component 10 and frame 20. The mixture 30 may be poured so as to flood the entire first surface 14 of the first glass component 10 and cover the frame 20. The mixture 30 may continue to be poured over the first surface 14 of the first glass component 10 and frame 20 until the mixture 30 runs over the top portion 22 of the frame 20 and down the side portion 24. Any excess mixture may be recovered from underneath the first glass component 10. In some embodiments, the mixture 30 may be poured from above at approximately the center of the first surface 14 and then spread to the edges (either permitted to spread naturally or manually). In other embodiments, the mixture 30 may be poured from multiple positions above the first surface 14 or frame 20.

[0059] As shown in Figure 13, after the mixture 30 has been allowed to flood the first surface 14, a second glass component 40 having opposing edges (first edge 42 and second edge 44), may be positioned for bonding. If using the encapsulated adhesive and the UV was not applied to the mixture 30 while present in the container 100, a UV source may be exposed to the mixture 30 prior to positioning the second glass component 40.

[0060] The second glass component 40 may be positioned so that the first edge 42 is in contact with the top surface 25 (see Figure 10A) of the frame 20. The second edge 44 may be elevated above the first surface 14 of the first glass component 10. The second edge 44 may then be slowly lowered so as to create a wave of mixture 30 (or adhesive, if already released from the capsules). As the second edge 44 of the second glass component 40 is lowered, the mixture 30 wave moves across the first surface 14. By lowering the second glass component 40 in this manner, the defects associated with bonded glass components may be substantially eliminated. As shown in Figure 14A, after the second edge 44 of the second glass component 40 is lowered such that the second edge 44 contacts the top surface of the frame 25, and is substantially parallel to the first glass component 10, it is allowed to cure. After curing is complete the skirting tape is removed, thus removing any excess mixture 30 from the frame 20.

[0061] If using the encapsulated adhesive described above, and the mixture 30 has not yet been exposed to UV light, once the second glass component 40 has been placed, the mixture may now be exposed to UV where the encapsulated component may be released in order to create the adhesive and begin the curing process. As shown in Figure 14B, the UV light source 70 may be moved across a stationary assembly 500. Alternatively, as shown in Figure 14C, the assembly 500 may be moved across a stationary UV light source 70. As discussed at length above, in exemplary embodiments the adhesive may be able to dissolve adjacent capsules so that only a portion of the mixture would require exposure to UV radiation. In this case, the adhesive could spread throughout the mixture, dissolving capsules and forming the adhesive in a uniform and complete manner. [0062] The finished product is illustrated in Figures 14A, 15, and 15A. Figure 14A is a side view of the of the bonded glass components 10 and 40. Figure 15 is a top perspective view of the bonded glass. Figure 15A is a magnified cross-sectional view of the bonded glass. The second glass component 40 may be in contact with the top surface 25 of the frame 20. A layer of mixture 30 is interposed between the second glass components 40 and the first glass component 10 and the frame 20. The depth of the mixture 30 may be substantially equal to that of the thickness of the top portion 22 of the frame 20. In this manner, the depth of the mixture 30 may be controlled by varying the thickness of the top portion 22 of the frame 20.

[0063] In the embodiment shown in Figures 14A, 15, and 15A, the length and width of the first glass component 10 and the second glass component 40 are substantially equal (or the second glass component 40 may be slightly larger). In other embodiments, the second glass component 40 may have length and/or width dimensions less than that of the first glass component 10. This is illustrated in Figure 16. To bond the second glass component 40 to the first glass component 10 the first edge 42 of the second glass component 40 is positioned at the inside edge 26 of the frame 20. The second edge 44 is elevated above the first surface 14 of the first glass component 10. The second edge 44 is slowly lowered so as to create a wave of mixture 30. As the second edge 44 of lowered, the mixture 30 wave moves across the first surface 14. The second edge 44 is lowered so that it may come to rest near the inside edge 26 of the frame 20. Figure 17 provides a top view of the bonded glass. Figure 17A is a cross-sectional view of the bonded glass. In this embodiment, the second glass component 40 rests on the mixture 30 layer rather than the top surface 25 of the frame 20 as in the embodiment illustrated in Figure 15A.

[0064] In other exemplary embodiments, the skirting tape may be applied to both the top and side portions 22 and 24 of the frame 20. This allows for the removal of any excess adhesive 30 from the all portions of the frame 20.

[0065] In still other embodiments, the 3145 adhesive used for the frame seal is replaced by an adhesive having a lower viscosity. One example of an adhesive that may be used is Dow Corning® brand product 3140 RTV Adhesive/Sealant (hereinafter "the 3145 adhesive"). The use of an adhesive having a lower viscosity than that of the 3145 adhesive may eliminate the need for a barrier coat. In exemplary embodiments, where the barrier is no longer applied, the mixture 30 may be poured onto the first surface 14 after the frame seal is cured.

[0066] Having shown and described exemplary embodiments of the invention, those skilled in the art will realize that many variations and modifications may be made to affect the described invention and still be within the scope of the claimed invention. Thus, many elements indicated above may be altered or replaced by different elements which will provide the same result and fall within the spirit of the claimed invention. It is the intention, therefore, to limit the invention only as indicated by the scope of the claims.

Claims

WHAT IS CLAIMED IS:

1 . A method of bonding glass components, comprising:

providing a mixture comprising two portions which can be combined to produce an adhesive, where at least one of the portions is encapsulated;

applying the mixture to a first glass component;

exposing the mixture to an ultraviolet light source to release the encapsulated portion and form an adhesive;

placing a second glass component on the adhesive so as to interpose the adhesive between the first and second glass components; and allowing the adhesive to cure.

2. The method of claim 1 wherein:

the step of exposing the mixture to an ultraviolet light source is performed by moving the first glass component under a stationary ultraviolet light source.

3. The method of claim 1 wherein:

the step of exposing the mixture to an ultraviolet light source is performed by moving the ultraviolet light source over a stationary first glass component.

4. The method of claim 1 wherein: the step of applying the mixture to a first glass component is performed by a numeric dispenser.

The method of claim 1 wherein:

the step of applying the mixture to a first glass component is performed by a numeric dispenser; and

the step of exposing the mixture to an ultraviolet light source is performed after the mixture has exited the numeric dispenser but prior to contacting the first glass component.

The method of claim 1 wherein:

the step of applying the mixture to a first glass component is performed by a numeric dispenser having a mixing tip; and

the step of exposing the mixture to an ultraviolet light source is performed while the mixture is present within the mixing tip of the numeric dispenser.

The method of claim 1 wherein:

the step of applying the mixture to a first glass component is performed by:

placing a certain amount of mixture within a container; and pouring the mixture from the container onto the first glass component.

8. The method of claim 1 wherein:

the step of applying the mixture to a first glass component and exposing the mixture to an ultraviolet light source is performed by:

placing a certain amount of mixture within a container; exposing the mixture within the container to ultraviolet light; and pouring the mixture from the container onto the first glass component.

9. The method of claim 1 wherein:

the steps of exposing the mixture to an ultraviolet light source to release the encapsulated portion and allowing the portions to mix and create an adhesive are performed after the step of placing the second glass component.

10. A method for bonding glass components comprising the steps of:

providing a first glass component having a top surface and a perimeter; placing a frame around the perimeter of the top surface of the first glass component, the frame having a top surface, inside edge, and outside edge;

applying a sealant to the interface between the top surface of the first glass component and the inside edge of the frame;

allowing the sealant to cure; applying an adhesive to the top surfaces of the first glass component and the frame;

placing a second glass component, having first and second opposing edges, such that the first edge is in contact with the top surface of the frame and the second edge is elevated above the frame; and holding the first edge in place while lowering the second edge of the

second glass component until the second opposing edge contacts the top surface of the frame.

1 1 . The method from claim 10 further comprising the steps of:

applying a barrier coat to the top surfaces of the first glass component and the frame prior to applying the adhesive; and

allowing the barrier coat to cure prior to applying the adhesive.

12. The method from claim 10 wherein:

the adhesive is an encapsulated adhesive comprising a resin and a

catalyst where either the resin, the catalyst, or the resin and the catalyst are encapsulated.

13. The method of claim 12 further comprising the step of:

exposing the encapsulated adhesive to an ultraviolet light source

14. The method from claim 10 further comprising the steps of: applying skirting tape around the outside edge of the frame prior to performing the step of applying the adhesive; and

removing the skirting tape once the adhesive has cured.

15. A method of bonding glass components, comprising:

providing a first glass component having a top surface and a perimeter; providing a mixture comprising a resin and a catalyst, where either the resin, catalyst, or both resin and catalyst are encapsulated;

placing a frame around the perimeter of the top surface of the first glass component, the frame having a top surface and inside edge;

allowing the sealant to cure;

exposing the mixture to an ultraviolet light source to release the

encapsulated portion and form an adhesive;

applying the adhesive to the top surfaces of the first glass component and the frame;

placing a second glass component, having first and second opposing

edges, such that the first edge is in contact with the top surface of the frame and the second edge is elevated above the frame; and holding the first edge in place while lowering the second edge of the

second glass component until the second opposing edge contacts the top surface of the frame. placing a second glass component on the adhesive so as to interpose the adhesive between the first and second glass components; and allowing the adhesive to cure.

16. The method of claim 15 wherein:

17. The method of claim 15 wherein:

18. The method of claim 15 wherein:

the step of applying the adhesive to a first glass component is performed by a numeric dispenser having a mixing tip.

19. The method of claim 18 wherein:

the step of exposing the mixture to an ultraviolet light source is performed while the mixture is present within the mixing tip of the numeric dispenser The method of claim 15 wherein:

the step of exposing the mixture to an ultraviolet light source and applying the adhesive to a first glass component is performed by:

placing a certain amount of mixture within a container;

exposing the mixture within the container to ultraviolet light to create an adhesive; and

pouring the adhesive from the container onto the first glass component.