Custom Die-Cut Components in Digital Displays

Digital displays are an integral part of modern vehicle dashboards , household appliances, consumer electronics , and more. In applications like thermostats, cell phones, smart watches, and vehicles , displays allow a simplified, interactive experience for users. To make these digital display assemblies, manufacturers require a variety of die-cut components that, when combined, come together to make an impressive display that provides extreme clarity and a user-friendly experience, which we highlight below.

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1. Pressure Sensitive Adhesives (PSA)

Pressure sensitive adhesives (PSA) bond digital display components together. PSAs can be die-cut into many shapes and sizes to perform a variety of functions. Some of the PSAs primarily used in displays are acrylic foam tapes , optically clear adhesives (OCA) , and double coated tapes.

Acrylic foam tapes such as 3M? VHB? or tesa? ACXplus are used to create a high-strength and long-lasting bond, and optically clear adhesives provide a clear bond that maximizes optical clarity. Double coated tapes allow a thin yet strong bond of the many surface types in display assemblies.

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2. Gaskets/Seals

Digital displays use gaskets and seals to fill the space between surfaces. Gaskets and seals prevent light leakage while also protecting delicate internal components from water, dust, air, and other contaminants.

Rogers PORON polyurethane foam and BISCO silicone foam are extremely reliable, high-performance materials with excellent properties for sealing and gasketing, but rubber , acrylic foam tapes, and other elastomeric materials can also be used. The soft and damping cushions of gaskets also protect the sensitive display components from shock and vibration .

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3. Films/Plastics

Specialty films and plastics are essential for the function and longevity of digital displays. Display films, such as Micro Lens Array (MLA) films from BrightView Technologies , bring a brighter and enhanced display to users, while minimizing glare and increasing performance and uniformity.

Polyimide films, such as Kapton? , and polypropylene electrical insulation material, like ITW Formex? , provide a thin and durable protective barrier for display components. Both Kapton??and ITW Formex? can withstand high temperatures and offer great electrical insulation and flame-retardant properties.

Surface protection films temporarily protect display screens from scratching, marring, contamination, and damage during manufacturing, transportation, assembly, and initial use by the consumer. These films can be precisely cut to the exact dimensions of the screen and can include tabs for easy removal for assembly teams or the final customer.

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4. Thermal Management Materials

Thermal materials , such as thermally conductive pads, tape, and foam , transfer and spread heat generated by the digital display. Transferring and spreading heat helps keep the display functioning at a proper and safe operating temperature, ensuring the longevity of the device. Thermal materials can be die-cut to the size and shape needed by the digital display and are available in varying thicknesses if filling a gap or using a thin material are a concern.

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5. EMI/RFI Shielding, Grounding, Absorbing Materials

Digital displays contain sensitive components that require protection from electromagnetic interference (EMI) and radio frequency interference (RFI) . Aluminum and copper gaskets, foils, foams, films, and tapes can all be specially converted to minimize disruptions and malfunctions from EMI and RFI in display applications.

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Marian is a global converter with locations all around the world. Each of our manufacturing locations has the capacity and capabilities to produce custom parts for your display application as well as deliver those parts in a way that best fits into your existing processes (for automated placement , on rolls, in sheets, bulk packed, etc.). We produce billions of custom components for our customers globally every year.

Contact us and let us know today how we can be the die-cut solution for your digital display assembly.