Abstract:
The present disclosure is directed to a substrate lamination system and method. 
     A substrate lamination apparatus may comprise: (a) a vacuum chamber; (b) a flexible membrane; and (c) a substrate support. 
     A system for laminating substrates may comprise: (a) a vacuum chamber; (b) a flexible membrane; (c) a substrate support; (d) a vacuum pump; (e) a compressor; and (f) a control unit, wherein the control unit is configured to carry out the steps: (i) evacuating the vacuum chamber; and (ii) applying pressure to at least one of a first substrate and a second substrate.

Description:
[0001]    The present application constitutes a continuation-in-part of U.S. patent application Ser. No. 11/214,518, entitled PROCESS FOR GLASS-TO-GLASS SEALING OLEDS WITH DRY FILM ADHESIVE, naming James D. Sampica, Paul R. Nemeth and Vincent P. Marzen as inventors, filed Aug. 30, 2005, which is currently co-pending, or is an application of which a currently co-pending application is entitled to the benefit of the filing date. 
         [0002]    The present application constitutes a continuation-in-part of U.S. patent application Ser. No. 11/215,683, entitled PANEL-TO-PANEL LAMINATION METHOD FOR IMPROVED UNIFORMITY, naming Vincent P. Marzen, Paul R. Nemeth and James D. Sampica as inventors, filed Aug. 30, 2005, which is currently co-pending, or is an application of which a currently co-pending application is entitled to the benefit of the filing date. 
         [0003]    The present application constitutes a continuation-in-part of U.S. patent application having the United States Postal Service Express Mailing Label No. EM117518596US, entitled SUBSTRATE LAMINATION SYSTEM AND METHOD, naming Tracy J. Barnidge, Vincent P. Marzen, Paul R. Nemeth, and James D. Sampica as inventors, filed Jan. 18, 2008, which is currently co-pending, or is an application of which a currently co-pending application is entitled to the benefit of the filing date. 
         [0004]    The present application constitutes a continuation-in-part of U.S. patent application having the United States Postal Service Express Mailing Label No. EM117518675US, entitled SYSTEM AND METHOD FOR DISASSEMBLING LAMINATED SUBSTRATES, naming Tracy J. Barnidge, Vincent P. Marzen, Paul R. Nemeth, and James D. Sampica as inventors, filed Jan. 18, 2008, which is currently co-pending, or is an application of which a currently co-pending application is entitled to the benefit of the filing date. 
         [0005]    The present application constitutes a continuation-in-part of U.S. patent application having the United States Postal Service Express Mailing Label No. EM117518640US, entitled SYSTEM AND METHOD FOR COMPLETING LAMINATION OF RIGID-TO-RIGID SUBSTRATES BY THE CONTROLLED APPLICATION OF PRESSURE naming Tracy J. Barnidge, Vincent P. Marzen, Paul R. Nemeth, and James D. Sampica as inventors, filed Jan. 18, 2008, which is currently co-pending, or is an application of which a currently co-pending application is entitled to the benefit of the filing date. 
         [0006]    The present application constitutes a continuation-in-part of U.S. patent application having the United States Postal Service Express Mailing Label No. EM117518667US, entitled ALIGNMENT SYSTEM AND METHOD THEREOF, naming Tracy J. Barnidge, Vincent P. Marzen, Paul R. Nemeth, and James D. Sampica as inventors, filed Jan. 18, 2008, which is currently co-pending, or is an application of which a currently co-pending application is entitled to the benefit of the filing date. 
         [0007]    The present application constitutes a continuation-in-part of U.S. patent application having the United States Postal Service Express Mailing Label No. EM117518653US, entitled PLANARIZATION TREATMENT OF PRESSURE SENSITIVE ADHESIVE FOR RIGID-TO-RIGID SUBSTRATE LAMINATION naming Tracy J. Barnidge, Vincent P. Marzen, Paul R. Nemeth, and James D. Sampica as inventors, filed Jan. 18, 2008, which is currently co-pending, or is an application of which a currently co-pending application is entitled to the benefit of the filing date. 
         [0008]    All subject matter of the Related Applications and of any and all parent, grandparent, great-grandparent, etc. applications of the Related Applications is incorporated herein by reference to the extent such subject matter is not inconsistent herewith. 
     
    
     BACKGROUND 
       [0009]    Liquid crystal display (LCD) screens and other monitors may require rigid or semi-rigid substrates to be coupled to the display. These substrates may serve many purposes including optical enhancements, protection from impact, or environmental concerns, or sometimes to improve thermal operating range, such as heating elements. As such, robust lamination of multiple substrates, such as a rigid glass substrate to an LCD screen, may be desirable. 
       SUMMARY 
       [0010]    The present disclosure is directed to a substrate lamination system and method. 
         [0011]    A substrate lamination apparatus may comprise: (a) a vacuum chamber; (b) a flexible membrane; and (c) a substrate support. 
         [0012]    A system for laminating substrates may comprise: (a) a vacuum chamber; (b) a flexible membrane; (c) a substrate support; (d) a vacuum pump; (e) a compressor; and (f) a control unit, wherein the control unit is configured to carry out the steps: (i) evacuating the vacuum chamber; and (ii) applying pressure to at least one of a first substrate and a second substrate. 
         [0013]    It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not necessarily restrictive of the claims. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate examples and together with the general description, serve to explain the principles of the disclosure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The numerous advantages of the disclosure may be better understood by those skilled in the art by reference to the accompanying figures in which: 
           [0015]      FIG. 1  is an isometric view of a substrate lamination system. 
           [0016]      FIG. 2  is an cross-sectional view of a substrate lamination system. 
           [0017]      FIG. 3  top view of a substrate lamination system. 
           [0018]      FIG. 4  is an isometric view of a substrate lamination system. 
           [0019]      FIG. 5  is an isometric view of a substrate alignment insert. 
           [0020]      FIG. 6  is a top view of a substrate mask. 
           [0021]      FIG. 7  an schematic view of a substrate lamination system. 
           [0022]      FIG. 8  is a high-level logic flowchart of a process. 
           [0023]      FIG. 9  is a high-level logic flowchart of a process depicting alternate implementations of  FIG. 8 . 
           [0024]      FIG. 10  is a high-level logic flowchart of a process depicting alternate implementations of  FIG. 8 . 
           [0025]      FIG. 11  is a high-level logic flowchart of a process depicting alternate implementations of  FIG. 8 . 
           [0026]      FIG. 12  is a high-level logic flowchart of a process depicting alternate implementations of  FIG. 8 . 
           [0027]      FIG. 13  is a high-level logic flowchart of a process depicting alternate implementations of  FIG. 8 . 
           [0028]      FIG. 14  is a high-level logic flowchart of a process depicting alternate implementations of  FIG. 8 . 
           [0029]      FIG. 15  is a high-level logic flowchart of a process depicting alternate implementations of  FIG. 8 . 
           [0030]      FIG. 16  is a high-level logic flowchart of a process. 
           [0031]      FIG. 17  is a high-level logic flowchart of a process. 
           [0032]      FIG. 18  is a cross-sectional view of a substrate lamination system. 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. 
         [0034]      FIGS. 1 and 18  illustrate example systems in which one or more technologies may be implemented. A lamination system  100  may comprise a vacuum chamber  110 , at least one flexible membrane  120 , and a substrate support  130 . 
         [0035]    The vacuum chamber  110  may be any container which is capable of being sealed so as to separate a space interior to the vacuum chamber  110  from a space exterior to the vacuum chamber  110 . For example, the vacuum chamber  110  may be a generally rectangular structure having a vacuum chamber body  111  and a vacuum chamber lid  112 . The vacuum chamber  110  may be constructed of any number of materials having sufficient strength so as to maintain a vacuum such as aluminum, steel, carbon fiber, plastics, and the like. 
         [0036]    Referring now to  FIG. 2 , the flexible membrane  120  may be disposed within the vacuum chamber  110  so as to partition the vacuum chamber  110  into at least a first compartment  121  and a second compartment  122 . For example, the flexible membrane  120  may be affixed to an underside of the vacuum chamber lid  112  by sealing the flexible membrane  120  about the periphery of the vacuum chamber lid  112  so as to partition the vacuum chamber  110  into a first compartment  121  formed by the flexible membrane  120  and the vacuum chamber body  111  and a second compartment  122  formed by the flexible membrane  120  and the vacuum chamber lid  112 . 
         [0037]    The second compartment  122  may comprise an expansion portion  122 A and a plenum portion  122 B separated by a perforated plenum diffuser screen  123 . The perforated plenum diffuser screen  123  may serve to provide uniform distribution of airflow from the plenum portion  122 B into the expansion portion  122 A. 
         [0038]    The flexible membrane  120  may be constructed from any flexible material capable of partitioning two compartments into separate pressure zones. For example, the flexible membrane  120  may be constructed of silicone rubber. The flexible membrane  120  may have one or more of the following physical characteristics: an elongation capacity of at least 100%; a tear strength of at least 30 psi; anti-static properties and/or an anti-static liner (e.g. polyester or polyethylene) disposed on one or more surfaces of the flexible membrane  120 . 
         [0039]    In other exemplary embodiments, the lamination system  100  may comprise at least one lid positioning mechanism  113 . The lid positioning mechanism  113  may serve to maintain the vacuum chamber lid  112  in an open position with respect to the vacuum chamber body  111 . The lid positioning mechanism  113  may comprise a gas cylinder mechanism as depicted in  FIG. 1 . In still further exemplary embodiments, the lid positioning mechanism  113  may comprise an actuated mechanism (e.g. a pneumatically actuated system, [not shown]) which may be extended or retracted manually or as part of an automated system controlled by a processing unit. 
         [0040]    Referring now to  FIGS. 3-18 , the substrate support  130  may be any device/structure capable of maintaining a first substrate  101  and a second substrate  102  in spatial separation when disposed within the vacuum chamber  110 . The substrate support  130  may maintain the first substrate  101  and/or the second substrate  102  in semi-horizontal positions as in  FIG. 2  or in semi-vertical positions as in  FIG. 18 . For example, the substrate support  130  may comprise at least one retractable support pin  131 . The retractable support pin  131  may be disposed within and project from a wall of the vacuum chamber body  111 . The retractable support pin  131  may be operably coupled to an actuating mechanism  132 . Further, the use of any number of substrate supports  130  supporting any number of substrates is fully contemplated by the presently described embodiments. 
         [0041]    The cross-geometry of the tip of the retractable support pin  131  may be selected from any number of geometries including, but not limited to: cylindrical, square, hemispherical, trapezoidal, and the like. The geometry may be selected so as to minimize contact with a substrate while providing adequate substrate support. 
         [0042]    The actuating mechanism  132  may comprise a motor  133  configured to translate the retractable support pin  131  in and out of the vacuum chamber  110 . The operation of the motor  133  and the corresponding insertion or retraction of the retractable support pin  131  may be controlled by a control unit  160 , as shown in  FIG. 7 . 
         [0043]    In other exemplary embodiments, the substrate support  130  may comprise a deformable support (e.g. a foam or putty structure; a spring structure) an electromagnetic support (e.g. an electromagnet operably couplable to a metallic element), retractable air cylinder or solenoid. 
         [0044]    The first substrate  101  and/or second substrate  102  may be rigid or semi-rigid in nature such that, when supported by the substrate support  130 , the first substrate  101  and/or second substrate  102  do not deform to a degree such that they contact a layer disposed in a horizontal plane beneath the first substrate  101  and/or second substrate  102 , such as a pressure-sensitive adhesive layer  103 . For example, the first substrate  101  may comprise a display monitor (e.g. an LCD, LCOS, or LED screen). The second substrate  102  may comprise an opaque rigid or semi-rigid reinforcing layer (e.g. glass, plastic). The pressure-sensitive adhesive layer  103  may comprise commonly known acrylic or silicone based polymers. 
         [0045]    Referring to  FIG. 4 , the vacuum chamber  110  may further comprise a vacuum port  113  so as to provide a connection for a vacuum line (not shown) operably coupled to a vacuum pump  170 . The vacuum port  113  may be operably coupled to the vacuum chamber body  111  to provide a conduit between the first compartment  121  and the vacuum pump  170 . 
         [0046]    The vacuum chamber  110  may further comprise a vacuum/pressurization port  114  so as to provide a connection for a vacuum/compressor line (not shown) operably coupled to a vacuum pump/compressor  180 . The vacuum/pressurization port  114  may be operably coupled to the vacuum chamber lid  112  to provide a conduit between the second compartment  122  and the vacuum pump/compressor  180 . 
         [0047]    In still another exemplary embodiment, the lamination system  100  may comprise at least one locking mechanism  190 . The locking mechanism  190  may serve to secure the vacuum chamber lid  112  to the vacuum chamber body  111  so that the interior of the vacuum chamber  110  may be evacuated. For example, locking mechanism  190  may comprise an electromagnetic lock having an electromagnet  191  and a metal element  192  operably couplable to the electromagnet so as to maintain the vacuum chamber lid  112  and the vacuum chamber body  111  in a locked position, thereby creating an adequate seal via the flexible membrane  120 . 
         [0048]    Referring again to  FIG. 5 , the lamination system  100  may further comprise a substrate alignment insert  140 . The substrate alignment insert  140  may serve to align at least one the first substrate  101  and the second substrate  102  within the vacuum chamber  110 . The substrate alignment insert  140  may comprise a base portion  141  (e.g. the floor of the vacuum chamber body  111  or a separate base layer) and at least one substrate alignment guide  142 . For example, the substrate alignment guide  142  may comprise two substantially adjacent wall portions configured at a 90° angle with respect to one another and projecting from the base portion  141  so as to receive at least one substrate within the space defined by the angle of the wall portions. 
         [0049]    In alternate exemplary embodiments, the substrate alignment guide  142  may be selected from brackets, pegs, grooves, bumps, slots, a recessed space within a body, and/or any other suitable mechanism for specifically positioning a substrate within the vacuum chamber  110 . 
         [0050]    In an alternate exemplary embodiment, the base portion  141  of the substrate alignment insert  140  may further comprise a recessed region  145  suitable for receiving at least one of the first substrate  101  and the second substrate  102 . 
         [0051]    Referring to  FIG. 6 , the lamination system  100  may further comprise a carriage or substrate mask  150 . The substrate mask  150  may comprise a substantially planar mask body  151  defining a mask aperture  152 . The mask aperture  152  may be configured so as to fit around at least one substrate alignment guide  142 . For example, the mask aperture  152  may comprise alignment guide aperture portions  153  may be which allow the substrate mask  150  to be secured around at least one substrate alignment guide  142 . The substrate mask  150  may serve to protect portions of or the second substrate  102  which are outside the periphery of the mask aperture  152 , such as flexible circuitry  104  coupled to the first substrate  101 . 
         [0052]    Referring again to  FIG. 5 , in an alternate exemplary embodiment, the at least one substrate alignment guide  142  may comprise a substrate mask support portion  143 . The substrate mask support portion  143  may allow the substrate alignment guide  142  to support the substrate mask  150  in spatial separation from the base portion  141  when the substrate mask  150  is disposed atop the substrate alignment insert  140 . 
         [0053]    In still another exemplary embodiment, the substrate alignment insert  140  and/or the substrate mask  150  may be removable from the lamination system  100  so as to allow for the lamination of different sizes of substrates. To effectuate the removal of the substrate alignment insert  140  and/or the substrate mask  150 , at least one handle member  144  may be provided. 
         [0054]    In still further exemplary embodiments, lamination system  100  components may incorporate electrostatic discharge (ESD) prevention technologies. For example, the substrate alignment insert  140  and/or the substrate mask  150  may be constructed from materials having desirable ESD properties. Further, the substrate alignment insert  140 , the substrate mask  150  and/or any other lamination system  100  component may be connected to electrical ground via ground lines. Further, the lamination system  100  components may be subjected to ionization such that charged surfaces will dissipate that charge through controlled methods. Such ionization may be conducted prior to bringing sensitive substrates, such as sensitive electronic substrates into close proximity with the lamination system  100 . 
         [0055]    Referring to  FIG. 7 , the lamination system  100  may further comprise a control unit  160 . The control unit  160  unit may comprise vacuum control logic  161 , vacuum/pressurization control logic  162  and/or substrate support control logic  163 . The vacuum control logic  161 , vacuum/pressurization control logic  162 , and/or substrate support control logic  163  may comprise integrated logic (e.g. application specific integrated circuitry (ASIC), field programmable gate arrays (FPGA), digital signal processors (DSP)), a programmable logic controller (PLC) or one or more programs (e.g. firmware or software) configured to run on one or more processors (e.g. processors marketed by Intel® and AMD® integrated into personal computers (PCs)). 
         [0056]    The vacuum control logic  161  may be configured to provide control signals to a vacuum pump  170  operably coupled to the vacuum chamber  110  via vacuum port  113  to create a vacuum within the first compartment  121 . 
         [0057]    The vacuum/pressurization control logic  162  may be configured to provide control signals to vacuum pump/compressor  180  operably coupled to the vacuum chamber  110  via vacuum/pressurization port  114  to create a vacuum or pressurization within the second compartment  122 . 
         [0058]    The substrate support control logic  163  may be configured to provide control signals to the actuating mechanism  132  to either insert or retract the retractable support pin  131 . 
         [0059]      FIG. 8  illustrates an operational flow  800  representing example operations related to lamination of one or more substrates with a pressure sensitive adhesive. In  FIG. 8  and in following figures that include various examples of operational flows, discussion and explanation may be provided with respect to the above-described examples of  FIGS. 1 through 7 , and/or with respect to other examples and contexts. However, it should be understood that the operational flows may be executed in a number of other environments and contexts, and/or in modified versions of  FIGS. 1 through 7 . Also, although the various operational flows are presented in the sequence(s) illustrated, it should be understood that the various operations may be performed in other orders than those which are illustrated, or may be performed concurrently. 
         [0060]    After a start operation, the operational flow  800  moves to a disposing operation  810 , where disposing a pressure-sensitive adhesive layer between a substantially planar surface of a first substrate and a substantially planar surface of a second substrate may occur. For example, as shown in  FIGS. 1 through 7 , the pressure-sensitive adhesive layer  103  may be disposed between the first substrate  101  and the second substrate  102 . Disposing operation  810  may be conducted in either a manual fashion (e.g. by an operator) or an automated fashion whereby an automated disposing apparatus (e.g. a robotic arm configured to dispose the pressure-sensitive adhesive layer  103  between the first substrate  101  and the second substrate  102 ) such as those commonly found in the manufacturing arts may be employed. 
         [0061]    Then, in a disposing operation  820 , disposing the first substrate, pressure-sensitive adhesive layer and second substrate within a vacuum chamber may occur. For example, as shown in  FIGS. 1 through 7 , the first substrate  101 , the second substrate  102 , and the pressure-sensitive adhesive layer  103  may be disposed within the vacuum chamber  110 . Disposing operation  820  may be conducted in either a manual fashion (e.g. by an operator) or an automated fashion whereby an automated disposing apparatus (e.g. a robot arm configured to dispose the pressure-sensitive adhesive layer  103  between the first substrate  101  and the second substrate  102 ) such as those commonly found in the manufacturing arts may be employed. 
         [0062]    Then, in an evacuation operation  830 , evacuating the vacuum chamber may occur. For example, as shown in  FIGS. 1 through 7 , the vacuum control logic  161  may cause the vacuum pump  170  to evacuate the first compartment  121  of the vacuum chamber  110  via vacuum port  113 . During vacuum operation  830 , the vacuum/pressurization port  114  or the inlet of the vacuum pump/compressor  180  may be sealed so as to limit any deformation of the flexible membrane  120  during the evacuation of the vacuum chamber  110 . 
         [0063]    Then, in a pressure application operation  840 , applying pressure to at least one of a first substrate and a second substrate may occur. For example, as shown in  FIGS. 1 through 7 , the vacuum/pressurization control logic  162  may cause the vacuum pump/compressor  180  to pressurize the second compartment  122  of the vacuum chamber  110  via vacuum/pressurization port  114 . The pressurization of the second compartment  122  may induce a deformation of the flexible membrane  120  in at least the general direction of the first substrate  101 , the second substrate  102 , and the pressure-sensitive adhesive layer  103 . Such a deformation may press the first substrate  101 , the second substrate  102 , and the pressure-sensitive adhesive layer  103  together, thereby attaching the pressure-sensitive adhesive layer  103  so as to laminate the first substrate  101  and the second substrate  102  to one another. 
         [0064]    In other exemplary embodiments, the flexible membrane  120  may comprise a vacuum bag (not shown) which may be disposed within the vacuum chamber  110 , there by defining the first compartment  121  inside the vacuum bag and the second compartment  122  outside the bag. The vacuum bag may at least substantially surround the first substrate  101 , the second substrate  102 , and the pressure-sensitive adhesive layer  103  within the first compartment  121 . 
         [0065]      FIG. 9  illustrates alternative embodiments of the example operational flow  800  of  FIG. 8 .  FIG. 9  illustrates example embodiments where the disposing operation  810  may include at least one additional operation. Additional operations may include an operation  902 , and/or an operation  904 . 
         [0066]    At the operation  902 , disposing a sheet of pressure-sensitive adhesive between a substantially planar surface of a first substrate and a substantially planar surface of a second substrate may occur. For example, as shown in  FIGS. 1 through 7 , the pressure-sensitive adhesive layer  103  may be a preformed adhesive sheet which may be mechanically disposed between the first substrate  101  and the second substrate  102 . 
         [0067]    At the operation  904 , coating at least a portion of at least one of the substantially planar surface of the first substrate and the substantially planar surface of the second substrate with a pressure-sensitive adhesive may occur. For example, as shown in  FIGS. 1 through 7 , the pressure-sensitive adhesive layer  103  may be a cured-state polymer-based pressure sensitive adhesive composition which may be coated on a surface of at least one of the first substrate  101  and the second substrate  102 . 
         [0068]      FIG. 10  illustrates alternative embodiments of the example operational flow  800  of  FIG. 8 .  FIG. 10  illustrates example embodiments where the disposing operation  820  may include at least one additional operation. Additional operations may include an operation  1002 . 
         [0069]    At the operation  1002 , co-aligning a portion of the first substrate with a portion of the second substrate may occur. For example, as shown in  FIGS. 1 through 7 , the at least one of the first substrate  101  and the second substrate  102  may be placed within the substrate alignment insert  140  so as to maintain the substrate in a substantially static position during the vacuum creation operation  830  or the pressure application operation  840 . Such alignment may ensure that desired portions of at least one of the first substrate  101  and the second substrate  102  are contacted with the pressure-sensitive adhesive layer  103  while minimizing contact with undesired portions of the first substrate  101  and/or the second substrate  102 . 
         [0070]      FIG. 11  illustrates alternative embodiments of the example operational flow  800  of  FIG. 8 .  FIG. 11  illustrates example embodiments where the disposing operation  820  may include at least one additional operation. Additional operations may include an operation  1102 , an operation  1104 , and/or an operation  1106 . 
         [0071]    At the operation  1102 , maintaining at least a portion of at least one of the first substrate and second substrate in spatial separation from the pressure-sensitive adhesive layer may occur. For example, as shown in  FIGS. 1 through 7 , during the vacuum creation operation  830 , portions of at least one of the first substrate  101  and the second substrate  102  are maintained in spatial separation from the pressure-sensitive adhesive layer  103  by the substrate support  130  so as to allow for a substantially complete evacuation of air between the substrate and the pressure-sensitive adhesive, thereby limiting the entrainment of air between the first substrate  101  and the second substrate  102 . Further, at the operations  1104  and  1106 , supporting at least one of the first substrate and the second substrate on a support pin may occur. For example, as shown in  FIGS. 1 through 7 , a retractable support pin  131  may maintain at least one of the first substrate  101  and the second substrate  102  in spatial separation from the pressure-sensitive adhesive layer  103 . 
         [0072]      FIG. 12  illustrates alternative embodiments of the example operational flow  800  of  FIG. 8 .  FIG. 12  illustrates example embodiments where the disposing operation  820  may include at least one additional operation. Additional operations may include an operation  1202 , and/or an operation  1204 . Further, at the operation  1202 , supporting at least one of the first substrate and the second substrate a deformable support may occur. For example, as shown in  FIGS. 1 through 7 , the substrate support  130  may include a deformable support such as a foam, putty structure or a spring having sufficient spring forces such that the substrate support  130  remains in an expanded configuration until a pressure is applied to at least one of the first substrate  101  and the second substrate  102 , such as by the expansion of the flexible membrane  120 . Further, at the operation  1204 , supporting at least one of the first substrate and the second substrate on at least one electromagnetic support may occur. For example, as shown in  FIGS. 1 through 7 , the at least one of the first substrate  101  and the second substrate  102  may be operably coupled to a metal element which may be contacted to an electromagnet disposed within the vacuum chamber  110 , such as to the vacuum chamber lid  112 . Upon the application of power to the electromagnet, the metal element operably coupled to the at least one of the first substrate  101  and the second substrate  102  may be magnetically attracted to the electromagnet, thereby supporting the at least one of the first substrate  101  and the second substrate  102  is spatial separation from the pressure-sensitive adhesive layer  103 . 
         [0073]      FIG. 13  illustrates alternative embodiments of the example operational flow  800  of  FIG. 8 .  FIG. 13  illustrates example embodiments where the evacuation operation  830  may include at least one additional operation. Additional operations may include an operation  1302 , and/or an operation  1304 . 
         [0074]    At the operation  1302 , evacuating a first portion of the vacuum chamber to a first pressure may occur. For example, as shown in  FIGS. 1-7 , the second compartment  122  may be evacuated via vacuum/pressurization port  114 . The evacuation of the second compartment  122  may occur prior to closing the vacuum chamber lid  112  atop the vacuum chamber body  111  so as to maintain the flexible membrane  120  in close proximity to the vacuum chamber lid  112  and avoid contact between the flexible membrane  120  and at least one of the first substrate  101  and the second substrate  102  prior to pressure application operation  840 . 
         [0075]    At the operation  1304 , evacuating a second portion of the vacuum chamber to a second pressure may occur. For example, as shown in  FIGS. 1-7 , the first compartment  121  may be evacuated via vacuum port  113 . The evacuation of the first compartment  121  may occur after closing the vacuum chamber lid  112  atop the vacuum chamber body  111  so as to remove substantially all air from the interior of the first compartment  121 . During evacuation operation  1304 , a pressure differential may be maintained between the first compartment  121  and the second compartment  122  where the first pressure in the second compartment  122  is lower than the second pressure than the first compartment  121 . 
         [0076]    During evacuation operation  1304 , a pressure differential may be maintained between the first compartment  121  and the second compartment  122  where the first pressure in the second compartment  122  is lower than the second pressure than the first compartment  121 . 
         [0077]      FIG. 14  illustrates alternative embodiments of the example operational flow  800  of  FIG. 8 .  FIG. 14  illustrates example embodiments where the pressure application operation  840  may include at least one additional operation. Additional operations may include an operation  1402 , and/or an operation  1404 . 
         [0078]    At the operation  1402 , expanding a flexible membrane by the application of pressure to a surface of the flexible membrane may occur. For example, as shown in  FIGS. 1 through 7 , a pressure may be exerted on the surface of the flexible membrane  120  facing the second compartment  122 . Further, at the operation  1404 , expanding a flexible membrane by the application of air pressure to a surface of the flexible membrane may occur. For example, as shown in  FIGS. 1 through 7 , the vacuum/pressurization control logic  162  of the control unit  160  may cause the vacuum pump/compressor  180  to pressurize the second compartment  122  of the vacuum chamber  110  via the vacuum/pressurization port  114 . Pressurization of the second compartment  122  may cause the flexible membrane  120  to expand, thereby contacting at least one of the first substrate  101  and the second substrate  102  and pressing the first substrate  101 , the pressure-sensitive adhesive layer  103  and the second substrate  102  together to attach to the pressure-sensitive adhesive layer  103  and laminate the first substrate  101  to the second substrate  102 . 
         [0079]    In particular applications, a differential pressure between an evacuated first compartment  121  and a pressurized second compartment  122  of from about 20 to 7600 torr and, more particularly, about 760 torr may be desirable. However, the amount of pressure applied to the second compartment  122  and the corresponding expansion of the flexible membrane  120  may be a function of the pressure required to effectively attach a selected pressure-sensitive adhesive layer  103  or the sensitivity of the first substrate  101  and the second substrate  102 , as would be determinable by one of skill in the art. As such, any range of differential pressures between the first compartment  121  and the second compartment  122  is fully contemplated by this disclosure. 
         [0080]      FIG. 15  illustrates alternative embodiments of the example operational flow  800  of  FIG. 8 .  FIG. 15  illustrates example embodiments where the pressure application operation  840  may include at least one additional operation. Additional operations may include an operation  1502 . Further, at the operation  1502 , masking a portion of at least one of the first substrate and second substrate from contact with the flexible membrane may occur. For example, as shown in  FIGS. 1 through 7 , the substrate mask  150  may be affixed to the substrate alignment insert  140  such that it provides a barrier between the flexible membrane  120  and at least one of the first substrate  101  and the second substrate  102 . Such a configuration may limit the contact area of the flexible membrane  120  to particular portions of at least one of the first substrate  101  and the second substrate  102  within the area defined by the mask aperture  152  during flexible membrane  120  expansion. 
         [0081]      FIG. 16  illustrates an operational flow  1600  representing example operations related to lamination of one or more substrates with a pressure sensitive adhesive.  FIG. 16  illustrates an example embodiment where the example operational flow  800  of  FIG. 8  may include at least one additional operation. Additional operations may include an operation  1610 , and/or an operation  1612 . 
         [0082]    After a start operation, a disposing operation  810 , a disposing operation  820 , and a vacuum creation operation  830 , the operational flow  1600  moves to a contacting operation  1610 , where contacting at least one of the substantially planar surface of the first substrate and the substantially planar surface of the second substrate to the pressure-sensitive adhesive layer may occur. For example, as shown in  FIGS. 1 through 7 , at least one of the first substrate  101  and the second substrate  102  may be moved from a supported position where at least one of the first substrate  101  and the second substrate  102  is maintained in spatial separation from the pressure-sensitive adhesive layer  103  to a contacted position where at least one of the first substrate  101  and the second substrate  102  is brought into physical contact with the pressure-sensitive adhesive layer  103 . Further, at the operation  1612 , retracting a support pin may occur. For example, as shown in  FIGS. 1 through 7 , the retractable support pin  131  of the substrate support  130  which may support at least one of the first substrate  101  and the second substrate  102  in spatial separation from the pressure-sensitive adhesive layer  103  may be retracted so as to allow at least one of the first substrate  101  and the second substrate  102  to be brought into physical contact with the pressure-sensitive adhesive layer  103 . 
         [0083]      FIG. 17  illustrates an operational flow  1700  representing example operations related to lamination of one or more substrates with a pressure sensitive adhesive.  FIG. 16  illustrates an example embodiment where the example operational flow  800  of  FIG. 8  may include at least one additional operation. Additional operations may include an operation  1710  and/or an operation  1720 . 
         [0084]    After a start operation, a disposing operation  810 , a disposing operation  820 , a vacuum creation operation  830 , and a pressure application operation  840 , the operational flow  1700  moves to a heating operation  1710 , where heating at least one of the first substrate, pressure-sensitive adhesive layer, and second substrate may occur. For example, as shown in  FIGS. 1 through 7 , the first substrate  101 , the second substrate  102  and the pressure-sensitive adhesive layer  103  may be heated by a heating element internal to the vacuum chamber  110  or disposed within an external heating apparatus, such as an autoclave. Such heating may serve to further set the pressure-sensitive adhesive layer  103 . In particular applications, the heating may occur in an environment having a temperature of from about ambient to 200° C. and, more particularly, about 80° C. 
         [0085]    Further, at operation  1720 , pressurizing an environment containing the first substrate, pressure-sensitive adhesive layer, and second substrate may occur. For example, the first substrate  101 , pressure-sensitive adhesive layer  103  and the second substrate  102  may be disposed in a pressure vessel in which the pressure may be elevated above ambient pressures. The elevated pressure may be from about 760 torr to about 7600 torr and, more particularly about 1520 torr. 
         [0086]    Operations  1710  and  1720  may be conducted over a period of time of from about 2 to 5 hours. However, the amount of heat and pressure applied and the timing therefore may be a function of the heat and pressure required to effectively attach a selected pressure-sensitive adhesive layer  103  or the sensitivity of the first substrate  101  and the second substrate  102  to heat and/or pressure, as would be determinable by one of skill in the art. As such, any range of temperatures and pressures is fully contemplated by this disclosure. 
         [0087]    It is believed that the lamination systems and methods and many of their attendant advantages will be understood by the foregoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages, the form herein before described being merely an explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.