# US 12,766,821 B2 · Compound curve component lamination method and product > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,766,821 B2 - Document ID: US12766821B2 - Status: Granted - Kind: B2 - Application number: 18/200,824 - Filed: 2023-05-23 - Published: 2024-11-28 - Granted: 2026-10-20 - Earliest claimed: 2023-05-23 - Assignees: Rockwell Collins, Inc. - Applicants: Rockwell Collins, Inc. - Inventors: Cameron T McCalley; James D Sampica - Web page: https://patentgrep.com/patent/US12766821B2 ## CPC - B32B 37/12: characterised by using adhesives - B32B 1/00: Layered products having a non-planar shape - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 37/1009: {using vacuum and fluid pressure} - B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)} - B32B 2250/03: 3 layers - B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA - B32B 2307/412: Transparent - B32B 2309/68: Vacuum - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract A direct dry film (DDF) lamination method includes providing a chamber including a bladder, positioning a frame in the chamber, positioning a compound curve substrate in an interior space within the frame, and suspending, by the frame, an optically clear adhesive (OCA) sheet over the compound curve substrate. In embodiments, a top liner of the OCA sheet is scored or cut to introduce weakness imparting flexibility in the sheet corresponding to the curvature of the compound curve substrate. The method continues with evacuating the chamber, deploying the bladder, retracting the bladder, and venting the chamber. Additional steps prepare the product for further boding with a flexible film or rigid part having a matched curvature profile. ## Claims ### Claim 1 A method of direct dry film (DDF) laminating a compound curve substrate, comprising: providing a chamber including a bladder; positioning a frame in the chamber, the frame forming an interior space; positioning a compound curve substrate in the interior space; suspending, by the frame, an optically clear adhesive (OCA) sheet over the compound curve substrate, the OCA sheet including a top liner; structurally altering the top liner at one or more locations corresponding to curvature of the compound curve substrate, wherein the structural altering introduces a localized weakness in the top liner to facilitate stretching of the OCA sheet; evacuating the chamber to induce a vacuum; deploying, with the compound curve substrate held stationary, the bladder into contact with the OCA sheet to move the OCA sheet into conformed contact with a surface of the compound curve substrate to bond the OCA sheet to the surface; retracting the bladder; and venting the chamber. ### Claim 2 (depends on 1) The method according to claim 1, wherein the OCA sheet further includes a bottom liner, and the method further comprises removing the bottom liner prior to evacuating the chamber. ### Claim 3 (depends on 1) The method according to claim 1, wherein structurally altering the top liner comprises scoring the top liner. ### Claim 4 (depends on 1) The method according to claim 1, wherein structurally altering the top liner comprises cutting the top liner. ### Claim 5 (depends on 1) The method according to claim 1, further comprising: positioning a second substrate in the chamber; evacuating the chamber to induce a vacuum; deploying the bladder into contact with the second substrate to move the second substrate into conformed contact with the OCA sheet; retracting the bladder; and venting the chamber. ### Claim 6 (depends on 1) The method according to claim 1, wherein the second substrate is a flexible film or a rigid compound curve substrate having a curvature profile matching a curvature profile of the compound curve substrate. ### Claim 7 (depends on 1) The method according to claim 1, further comprising, after venting the chamber: trimming the OCA sheet bonded to the surface of the compound curve substrate; and removing the top liner. ### Claim 8 (depends on 1) The method according to claim 1, wherein the OCA sheet is maintained in conformed contact with the compound curve substrate for a predetermined time period. ### Claim 9 (depends on 1) The method according to claim 1, wherein the method further comprises heating at least one of the chamber, the OCA sheet, and the compound curve substrate. ### Claim 10 (depends on 1) The method according to claim 1, wherein the OCA sheet is coupled to the frame by a plurality of elastic members. ### Claim 11 A laminated compound curve product, comprising: a compound curve substrate and a second substrate bonded together by an intermediate optically clear adhesive (OCA) sheet, wherein the laminated compound curve product is produced according to a method of direct dry film (DDF) lamination comprising: providing a chamber including a bladder; positioning a frame in the chamber, the frame forming an interior space; positioning the compound curve substrate in the interior space; suspending, by the frame, the OCA sheet over the compound curve substrate, the OCA sheet including a top liner structurally altered at one or more locations corresponding to curvature of the compound curve substrate, wherein the structural altering introduces a localized weakness in the top liner to facilitate stretching of the OCA sheet; evacuating the chamber to induce a vacuum; deploying, with the compound curve substrate held stationary, the bladder to move the bladder into contact with the OCA sheet to move the OCA sheet into conformed contact with a surface of the compound curve substrate; retracting the bladder; venting the chamber; and bonding the second substrate to the OCA sheet bonded to the surface of the compound curve substrate. ### Claim 12 (depends on 11) The product according to claim 11, wherein the OCA sheet further includes a bottom liner, and the method further comprises removing the bottom liner prior to evacuating the chamber. ### Claim 13 (depends on 11) The product according to claim 11, wherein the structurally altered top liner is scored. ### Claim 14 (depends on 11) The product according to claim 11, wherein the structurally altered top liner is cut. ### Claim 15 (depends on 11) The product according to claim 11, wherein the method further comprises: positioning the second substrate in the chamber; evacuating the chamber to induce a vacuum; deploying the bladder into contact with the second substrate to bring the second substrate into conformed contact with the OCA sheet; retracting the bladder; and venting the chamber. ### Claim 16 (depends on 11) The product according to claim 11, wherein the second substrate is a flexible film or a rigid compound curve substrate having a curvature profile matching a curvature profile of the compound curve substrate. ### Claim 17 (depends on 11) The product according to claim 11, further comprising, after venting the chamber: trimming the OCA sheet; and removing the top liner. ### Claim 18 (depends on 11) The product according to claim 11, wherein the OCA sheet is maintained in conformed contact with the compound curve substrate for a predetermined time period. ### Claim 19 (depends on 11) The product according to claim 11, wherein the method further comprises heating at least one of the chamber, the OCA sheet, and the compound curve substrate. ### Claim 20 (depends on 11) The product according to claim 11, wherein the OCA sheet is coupled to the frame by a plurality of elastic members.