Display assembly using structural adhesive

A display assembly comprising:

• a housing;
• a cover layer supported by the housing;
• an electronic display layer located rearward of the cover layer and supported by the housing;
• one or more airflow pathways extending through the housing rearward of the electronic display layer;
• a heat exchanger for dissipating heat from said display assembly during use, wherein said heat exchanger is secured within said housing rearward of the electronic display layer, said heat exchanger comprising multiple layers of at least one material, said layers defining one or more channels forming at least part of at least one of said one or more airflow pathways;
• and
• a plurality of deposits of structural adhesive, at least some of which are provided at said layers, to secure said layers to each other or to another structure within said housing, said structural adhesive comprises a pressure sensitive adhesive comprising methyl methacrylate and a spacing material comprising glass beads, each having a diameter between about 1/1000ths and about 100/1000ths of an inch;
• wherein the heat exchanger forms part of a thermal management substructure of the display assembly.

A method for manufacturing a heat exchanger including layers of at least one material and a plurality of deposits of structural adhesive, at least some of which are provided at said layers, to secure said layers to each other or to another structure within a housing of a display assembly, when completed, said method comprising:

• moving, by way of a robot, a first layer of the heat exchanger to a work surface;
• securing said first layer to said work surface, where said first layer is devoid of said sections of alternating height;
• mixing, by way of a computer-controlled system, multiple components of the structural adhesive;
• depositing, by way of a robotic system, said structural adhesive along portions of said first layer corresponding to planned locations of subset of the sections of alternating height of a second layer of the heat exchanger;
• placing, by way of the robot, the second layer atop the first panel such that the structural adhesive deposited at the first layer contacts the subset of the sections of alternating height of the second layer;
• depositing, by way of the robotic system, additional amounts of the structural adhesive along remaining ones of the sections of alternating height of said second layer;
• and
• placing, by way of the robot, a third layer of heat exchanger atop the second layer such that the additional amounts of the structural adhesive deposited at the second layer are interposed between the remaining ones of the sections of alternating height of the second layer.