Description:METHOD OF RUGGEDIZATION OF A COMMERCIAL OFF-THE-SHELF DISPLAY MODULE

BACKGROUND

TECHNICAL FIELD
[0001] The present disclosure relates to display ruggedization technologies and, more particularly, to structural integration techniques for enhancing mechanical durability and environmental resilience of commercial off-the-shelf (COTS) display modules while preserving the original assembly and functional integrity of the display cell and associated components.

DESCRIPTION OF THE RELATED ART
[0002] Commercial off-the-shelf (COTS) display modules are widely used in industrial equipment, transportation systems, outdoor installations, and defense support platforms due to their availability, cost efficiency, and standardized performance characteristics. Such display modules typically include a display cell retained within a mechanical frame, along with associated optical and electronic components that are factory-assembled and calibrated to ensure proper visual performance.
[0003] In many deployment environments, displays are subjected to mechanical loads, vibration, thermal cycling, and environmental exposure. To address these conditions, protective and functional layers such as cover glass, touch interfaces, optical conditioning elements, thermal management components, and electromagnetic shielding layers may be incorporated into display assemblies.
[0004] Conventional approaches for integrating additional layers into display assemblies often involve structural modifications to the original display module, replacement of frame components, or reconfiguration of the display stack. Such processes may alter load paths, affect alignment of optical components, or require recalibration of the display module. Additionally, certain integration techniques may introduce mechanical stresses into the display cell or modify the structural role of the original mechanical frame.
[0005] As display modules continue to be deployed in applications requiring improved durability and environmental resistance, considerations remain regarding how additional layers interact with the structural features of pre-assembled display modules, including the mechanical frame, the display cell, and the active display region.
[0006] Accordingly, there exists a need for techniques that enable integration of protective and functional layers with Commercial Off-The-Shelf (COTS) display modules while maintaining structural integrity of the original mechanical frame, preserving alignment of the display cell, and managing mechanical loads arising from environmental and operational conditions.
[0007] The reference to any prior art in this specification is not an acknowledgment or suggestion that such prior art forms part of the common general knowledge in any jurisdiction or that a person, skilled in the art, could reasonably expect such prior art to be understood, regarded as relevant, or combined with other aspects of prior art.

BRIEF SUMMARY
[0008] One or more embodiments relate to a method of ruggedization of a commercial off-the-shelf display module. The ruggedized commercial off-the-shelf (COTS) display module is designed to improve durability and functionality without altering the original factory-assembled display. Many display modules are widely available and cost-effective, but they may require additional protective or functional layers to operate reliably in demanding environments such as industrial settings, transportation systems, outdoor installations, or defense support applications.
[0009] Further, additional functional layers, such as protective glass, touch interfaces, optical filters, or heating elements, are integrated onto an existing display module in a manner that preserves the original structure and alignment of the display. Instead of modifying or rebuilding the internal components, the added layers are supported by the display’s existing mechanical frame. This approach allows the display cell to remain protected from direct mechanical stress while maintaining visual performance.
[0010] The integration method ensures that any mechanical forces applied to the added layers are transferred to the display’s frame rather than the display cell itself. This helps maintain alignment and reduces the risk of damage caused by vibration, shock, or temperature changes. Optional spacer elements may be used to maintain proper positioning and alignment of the added layers, ensuring consistent performance and appearance.
[0011] By retaining the factory-assembled configuration, including the original backlight, the ruggedized display module preserves calibration and reduces the time and cost associated with rebuilding or redesigning the display. This enables faster deployment and improved reliability in applications where enhanced durability and additional functionality are required.
[0012] In an embodiment, the present disclosure provides a ruggedized commercial off-the-shelf (COTS) display module that enhances mechanical durability and functional integration while preserving the structural integrity of a pre-assembled display module. The ruggedized COTS display module includes a pre-assembled COTS display module comprising a display cell and an original mechanical frame surrounding the display cell. The original mechanical frame retains the display cell in a factory-assembled configuration.
[0013] In an embodiment, a double-sided adhesive tape is disposed on a surface region of the original mechanical frame and confined to a perimeter region corresponding to the original mechanical frame. The adhesive tape forms a bonding interface positioned outside an active display region of the display cell. By confining the bonding interface to the perimeter region, the active display region remains free from structural bonding, thereby preserving optical performance and preventing direct mechanical loading of the display cell.
[0014] In an embodiment, one or more functional layers are bonded to the bonding interface. The one or more functional layers may include optical conditioning layers, electrically functional layers, thermally active layers, or touch-sensitive layers, depending on application requirements. The functional layers are mechanically supported by the original mechanical frame through the bonding interface, such that structural support is provided by the frame rather than the display cell.
[0015] In an embodiment, mechanical loads applied to the one or more functional layers are transmitted through the bonding interface to the original mechanical frame. This load transfer path enables the original mechanical frame to function as a primary load-bearing structure, thereby reducing stress concentration on the display cell and preserving alignment of the display cell within the frame. In an embodiment, the double-sided adhesive tape includes an acrylic foam adhesive tape, and/or a very high-bond adhesive tape.
[0016] In an embodiment, one or more spacer elements are positioned between the original mechanical frame and the one or more functional layers to maintain controlled positioning of the functional layers relative to the display cell. The spacer elements maintain a defined separation distance, promote uniform load distribution, and preserve optical alignment between the functional layers and the active display region. In an embodiment, the elements define a space between the one or more functional layers and the display cell. The space comprises a transparent medium, air, an optically transparent gel, and a transparent glass sheet.
[0017] In an embodiment, the pre-assembled COTS display module includes a factory-integrated backlight that remains unmodified during formation of the ruggedized COTS display module. Maintaining the factory-integrated backlight and pre-assembled configuration preserves factory alignment and calibration while enabling integration of additional functional layers.
[0018] In an embodiment, the bonding interface forms a continuous load-distributing structure along at least a portion of the perimeter region, thereby enhancing structural integrity and improving resistance to vibration and mechanical shock.
[0019] In an embodiment, the ruggedized COTS display module is suitable for deployment in commercial applications, including industrial displays, transportation displays, outdoor equipment displays, and defense support systems, where improved durability and functional integration are required.
[0020] In an embodiment, the present disclosure provides a method for ruggedizing a commercial off-the-shelf (COTS) display module while preserving the factory-assembled configuration of the display cell and associated structural components. The method begins with providing a pre-assembled COTS display module comprising a display cell and an original mechanical frame surrounding the display cell. Further, the method includes disposing a double-sided adhesive tape onto a surface region of the original mechanical frame within a perimeter region corresponding to the original mechanical frame. The adhesive tape forms a bonding interface positioned outside an active display region of the display cell. By positioning the bonding interface outside the active display region, the optical performance of the display cell is preserved while enabling structural integration of additional layers. In an embodiment, the double-sided adhesive tape includes an acrylic foam adhesive tape, and/or a very high-bond adhesive tape.
[0021] In an embodiment, the method includes bonding one or more functional layers to the bonding interface such that the one or more functional layers are mechanically supported by the original mechanical frame. The functional layers may include optical conditioning layers, electrically functional layers, thermally active layers, or touch-sensitive layers, depending on operational requirements. Mechanical support through the original mechanical frame enables integration of additional functionality without imposing direct structural loads on the display cell.
[0022] In an embodiment, mechanical loads applied to the one or more functional layers are transmitted through the bonding interface to the original mechanical frame. This load transfer path allows the original mechanical frame to function as a primary load-bearing structure, thereby reducing stress on the display cell and maintaining alignment of the display cell within the frame. In an embodiment, the bonding interface forms a continuous load-distributing structure along at least a portion of the perimeter region, enhancing structural integrity and improving resistance to vibration and mechanical shock encountered during operation.
[0023] The features and advantages of the subject matter here will become more apparent in light of the following detailed description of selected embodiments, as illustrated in the accompanying FIGUREs. As will be realized, the subject matter disclosed is capable of modifications in various respects, all without departing from the scope of the subject matter. Accordingly, the drawings and the description are to be regarded as illustrative in nature.

BRIEF DESCRIPTION OF THE DRAWING
[0024] In the figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description applies to any one of the similar components having the same first reference label, irrespective of the second reference label.
[0025] FIGURE 1 illustrates a side view of a Commercial Off-The-Shelf (COTS) display module, in accordance with an embodiment of the present disclosure.
[0026] FIGURE 2 illustrates a side view of a ruggedized COTS display module, in accordance with an embodiment of the present disclosure.
[0027] FIGURE 3 illustrates a perspective view of a ruggedized COTS display module, in accordance with an embodiment of the present disclosure.
[0028] FIGURE 4 illustrates a flowchart of a method for ruggedizing the COTS display module, in accordance with an embodiment of the present disclosure.
[0029]
[0030] Other features of embodiments of the present disclosure will be apparent from accompanying drawings and detailed description that follows. 
DETAILED DESCRIPTION
[0031] Terminology
[0032] Brief definitions of terms used throughout this application are given below.
[0033] The terms “connected” or “coupled” and related terms are used in an operational sense and are not necessarily limited to a direct connection or coupling. Thus, for example, two devices may be coupled directly, or via one or more intermediary media or devices. As another example, devices may be coupled in such a way that information can be passed there between them, while not sharing any physical connection with one another. Based on the disclosure provided herein, one of ordinary skill in the art will appreciate a variety of ways in which connection or coupling exists in accordance with the aforementioned definition.
[0034] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0035] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context dictates otherwise.
[0036] The phrases “in an embodiment,” “according to one embodiment,” and the like generally mean the particular feature, structure, or characteristic following the phrase is included in at least one embodiment of the present disclosure and may be included in more than one embodiment of the present disclosure. Importantly, such phrases do not necessarily refer to the same embodiment.
[0037] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the disclosure, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).
[0038] Certain exemplary embodiments of the present invention are described below and illustrated in the accompanying figures. The embodiments described are only for purposes of illustrating the present invention and should not be interpreted as limiting the scope of the invention, which, of course, is limited only by the claims below. Other embodiments of the invention and certain modifications and improvements of the embodiments described will occur to those skilled in the art, and all such alternate embodiments, modifications, and improvements are within the scope of the present invention.
[0039] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the invention.
[0040] FIGURE 1 illustrates a side view of a Commercial Off-The-Shelf (COTS) display module 100, in accordance with an embodiment of the present disclosure. In an embodiment, the COTS display module 100 may include a display cell 102 retained within an original mechanical frame 104. The COTS display module 100 may be a factory-assembled unit configured for integration into a display system without modification of internal components.
[0041] In an embodiment, the display cell 102 may comprise a liquid crystal display (LCD) cell, an organic light-emitting diode (OLED) display cell, a microLED display cell, or any other flat-panel display technology. The display cell 102 may include an active display region configured to present visual information and a peripheral region configured for structural retention within the original mechanical frame 104. In an embodiment, the display cell 102 may include multiple internal layers such as a substrate, pixel matrix, thin-film transistor (TFT) layer, color filters, polarizers, and protective coatings. These layers may be factory-aligned to ensure proper optical performance. The present disclosure does not require disassembly, modification, or recalibration of these internal layers. In another embodiment, the display cell 102 may include protective edge seals or encapsulation layers configured to protect internal display components from moisture and contaminants. The ruggedization process described herein does not disturb such protective features.
[0042] In an embodiment, the original mechanical frame 104 may surround and retain the display cell 102, providing structural support and maintaining positional alignment of the display cell 102. The original mechanical frame 104 may be formed from metal, polymer, composite material, or combinations thereof, and may include features such as retaining edges, mounting surfaces, and structural ribs. In an embodiment, the original mechanical frame 104 may define a perimeter region surrounding the display cell 102, wherein the perimeter region is distinct from the active display region. In another embodiment, the original mechanical frame 104 may include stepped surfaces, recesses, or ledges configured to retain the display cell 102 and provide additional structural interfaces. Such features may facilitate alignment and load transfer when additional functional layers are integrated.
[0043] In an alternate embodiment, the original mechanical frame 104 may include surface treatments such as anodization, coatings, or texturing to improve adhesion, corrosion resistance, or environmental durability.
[0044] In an embodiment, the COTS display module 100 may further include factory-integrated components such as a backlight unit, driver electronics, flexible interconnects, and mounting interfaces (not shown in any of the FIGURES). These components may remain in a pre-assembled and calibrated state during formation of the ruggedized COTS display module 200.
[0045] In an alternate embodiment, the COTS display module 100 may be configured in various sizes and aspect ratios, including rectangular, square, circular, or custom geometries, depending on application requirements. The original mechanical frame 104 may correspondingly define a perimeter region suitable for integration of additional layers.
[0046] In an embodiment, the COTS display module 100 illustrated in FIGURE 1 serves as a baseline structure upon which ruggedization is performed. The structural integrity, factory alignment, and pre-assembled configuration of the display cell 102 and the original mechanical frame 104 are preserved during formation of the ruggedized COTS display module 200.
[0047] In an embodiment, preserving the pre-assembled configuration of the COTS display module 100 reduces the risk of misalignment, contamination, and damage associated with disassembly or reconstruction of display components. This preservation enables integration of additional functional layers while maintaining optical performance and calibration.
[0048] FIGURE 2 illustrates a side view of a ruggedized COTS display module 200, in accordance with an embodiment of the present disclosure. FIGURE 3 illustrates a perspective view of a ruggedized COTS display module 200, in accordance with an embodiment of the present disclosure. For the sake of brevity, FIGURE 2 and FIGURE 3 have been explained together. The ruggedized COTS display module 200 may include the COTS display module 100 described with reference to FIGURE 1, along with additional structural elements configured to enhance durability, functionality, and environmental resilience.
[0049] In an embodiment, the ruggedized COTS display module 200 may include a double-sided adhesive tape disposed on a surface region of the original mechanical frame 104 and confined to a perimeter region corresponding to the original mechanical frame 104. The double-sided adhesive tape forms a bonding interface positioned outside an active display region of the display cell 102, such that no portion of the adhesive tape overlaps the active display region of the display cell 102. The adhesive tape enables bonding of one or more functional layers 202 to the original mechanical frame 104 while maintaining separation between the functional layers 202 and the active display region of the display cell 102. In an embodiment, the double-sided adhesive tape may be provided as a pre-formed tape layer having adhesive surfaces on opposing sides to facilitate attachment between the original mechanical frame 104 and the one or more functional layers 202.
[0050] In an alternate embodiment, the double-sided adhesive tape may comprise a pressure-sensitive adhesive tape configured to provide structural bonding, mechanical compliance, and environmental sealing. The adhesive tape may be selected to accommodate stresses arising from vibration, mechanical shock, and thermal expansion mismatch between the original mechanical frame 104 and the one or more functional layers 202. In certain embodiments, the adhesive tape may further provide resistance to moisture ingress, dust contamination, ultraviolet exposure, or chemical exposure, depending on environmental requirements. In certain embodiments, the double-sided adhesive tape may be applied as a continuous strip, segmented strips, or patterned segments along the perimeter region of the original mechanical frame.
[0051] In an embodiment, one or more functional layers 202 may be bonded to the bonding interface formed by the adhesive tape. The one or more functional layers 202 may include optical conditioning layers, electrically functional layers, thermally active layers, or touch-sensitive layers. In an embodiment, the one or more functional layers 202 may include protective cover glass, anti-reflective coatings, electromagnetic interference shielding layers, infrared or ultraviolet filters, transparent heater elements, capacitive touch panels, or combinations thereof. In an embodiment, the one or more functional layers 202 are mechanically supported by the original mechanical frame 104 through the bonding interface formed by the adhesive, such that structural support is provided by the frame 104 rather than the display cell 102.
[0052] In an alternate embodiment, the one or more functional layers 202 may be pre-assembled into a stack prior to bonding, or may be individually bonded to the bonding interface, depending on assembly requirements.
[0053] In an embodiment, mechanical loads applied to the one or more functional layers 202 may be transmitted through the adhesive tape to the original mechanical frame 104. The original mechanical frame 104 may function as a primary load-bearing structure, thereby reducing direct structural loading on the display cell 102 and preserving alignment of the display cell 102 within the frame 104.
[0054] In an embodiment, the bonding interface formed by the adhesive tape may define a continuous load-distributing structure along at least a portion of the perimeter region, thereby enhancing structural integrity and improving resistance to vibration and mechanical shock. In an alternate embodiment, the bonding interface may be discontinuous or segmented while still enabling load transfer through the original mechanical frame 104, depending on design requirements.
[0055] In an embodiment, one or more spacer elements 204 may be positioned between the original mechanical frame 104 and the one or more functional layers 202 to maintain controlled positioning of the functional layers 202 relative to the display cell 102. In an embodiment, the spacer elements 204 may define a separation distance between the one or more functional layers 202 and the display cell 102, thereby promoting uniform load distribution, and maintaining optical alignment. In an embodiment, the spacer elements 204 may be formed from polymeric materials, elastomeric materials, metallic materials, composite materials, or combinations thereof. The spacer elements 204 may be configured as discrete pads, continuous rings, ribs, posts, or other geometries suitable for alignment and spacing.
[0056] In an alternate embodiment, the spacer elements 204 may be positioned at perimeter locations, corner regions, or distributed locations along the original mechanical frame 104 to achieve desired alignment and load distribution characteristics. In certain configurations, the spacer elements 204 may be arranged in alignment with the perimeter region corresponding to the adhesive tape, such that the spacer elements 204 follow a bonding path defined for the adhesive tape. In further embodiments, the spacer elements 204 may occupy selected portions of the perimeter region where the adhesive tape is absent, thereby providing positional control and load support without application of adhesive tape at those locations.
[0057] In an embodiment, the one or more spacer elements 204 positioned between the original mechanical frame 104 and the one or more functional layers 202 may define a space between the one or more functional layers 202 and the display cell 102. The spacer elements 204 maintain a controlled separation distance that prevents direct contact between the functional layers 202 and the display cell 102, thereby preserving optical alignment and reducing the transfer of mechanical stresses to the display cell 102. In certain embodiments, the space between the one or more functional layers 202 and the display cell 102 may contain a transparent medium that permits transmission of light from the display cell 102 through the one or more functional layers 202. The transparent medium may comprise, for example, air, an optically transparent gel, or a transparent glass sheet positioned between the display cell 102 and the one or more functional layers 202. In certain implementations, an air gap may provide optical separation and structural isolation between the display cell 102 and the functional layers 202, while an optically transparent gel may improve optical coupling and absorb mechanical stresses arising from vibration, mechanical shock, or thermal expansion mismatch. In alternate embodiments, a transparent glass sheet may be positioned within the defined space to provide additional structural protection and optical stability while maintaining optical transmission from the display cell 102 through the functional layers 202. The selection of the medium occupying the defined space may depend on optical, mechanical, and environmental requirements of the ruggedized COTS display module 200.
[0058] In an embodiment, the ruggedized COTS display module 200 is formed while maintaining the pre-assembled configuration of the COTS display module 100, including the display cell 102, original mechanical frame 104, and any factory-integrated components such as a backlight unit. Preserving the pre-assembled configuration maintains factory alignment and calibration while enabling integration of additional functional layers. In an alternate embodiment, the ruggedized COTS display module 200 may be formed without disassembly, replacement, or modification of internal components of the COTS display module 100, thereby reducing manufacturing complexity and risk of damage.
[0059] In an embodiment, FIGURE 2 and FIGURE 3 collectively illustrate the structural arrangement of a ruggedized commercial off-the-shelf (COTS) display module 200, in which one or more functional layers 202 are integrated onto a pre-assembled COTS display module 100 by means of the double-sided adhesive tape disposed along a perimeter region of the original mechanical frame 104. The adhesive tape forms a bonding interface positioned outside an active display region of the display cell 102, thereby enabling the functional layers 202 to be mechanically supported by the original mechanical frame 104 rather than the display cell 102. In certain embodiments, one or more spacer elements 204 may be positioned between the original mechanical frame 104 and the functional layers 202 to maintain controlled positioning and alignment.
[0060] FIGURE 4 illustrates a flowchart 400 of a method for ruggedizing a Commercial Off-The-Shelf (COTS) display module, in accordance with an embodiment of the present disclosure. The method begins at step 402 and proceeds through a sequence of steps for integrating one or more functional layers with a pre-assembled COTS display module while preserving the structural integrity and alignment of the display cell.
[0061] At step 404, the method includes providing a pre-assembled COTS display module, wherein the pre-assembled COTS display module comprises a display cell and an original mechanical frame surrounding the display cell. In an embodiment, the pre-assembled COTS display module may include factory-integrated components such as a backlight unit, driver electronics, and optical layers that remain in an assembled and calibrated state.
[0062] In an embodiment, the display cell may comprise a Liquid Crystal Display (LCD), Organic Light-Emitting Diode (OLED) Display, microLED display, or other flat-panel display technologies. The original mechanical frame may provide structural support and alignment features that retain the display cell within a perimeter region distinct from an active display region.
[0063] In another embodiment, the pre-assembled COTS display module may be selected based on size, resolution, aspect ratio, or application-specific requirements, and the method may be applied without disassembly or modification of internal display components.
[0064] At step 406, the method includes disposing a double-sided adhesive tape on a surface region of the original mechanical frame within a perimeter region corresponding to the original mechanical frame. The double-sided adhesive tape forms a bonding interface positioned outside an active display region of the display cell, such that the adhesive tape is confined to the perimeter region and is not applied over the active display region of the display cell. In an embodiment, the double-sided adhesive tape may be provided as a pre-formed tape layer having adhesive surfaces on opposing sides to facilitate bonding between the original mechanical frame and one or more functional layers. The double-sided adhesive tape may comprise a pressure-sensitive adhesive tape configured to provide structural bonding between the original mechanical frame and the one or more functional layers. The adhesive tape may further provide mechanical compliance to accommodate stresses arising from vibration, mechanical shock, and thermal expansion mismatch between the original mechanical frame and the one or more functional layers, while also contributing to environmental sealing of the display assembly.
[0065] In an alternate embodiment, the adhesive tape may provide resistance to moisture ingress, dust contamination, ultraviolet radiation, or chemical exposure, depending on environmental requirements.
[0066] At step 408, the method includes bonding one or more functional layers to the bonding interface formed by the double-sided adhesive tape, such that the one or more functional layers are mechanically supported by the original mechanical frame. In an embodiment, the one or more functional layers may comprise optical conditioning layers, electrically functional layers, thermally active layers, or touch-sensitive layers. Examples include protective cover glass, anti-reflective coatings, electromagnetic interference shielding layers, infrared or ultraviolet filters, transparent heaters, capacitive touch panels, or combinations thereof. In an embodiment, the one or more functional layers may include combinations of optical, electrical, and thermal functionalities integrated into a single layer or multiple layers.
[0067] In an embodiment, the one or more functional layers may be bonded individually or as a pre-assembled stack. The bonding interface may provide structural support through the original mechanical frame, thereby reducing direct mechanical loading on the display cell.
[0068] In an embodiment, mechanical loads applied to the one or more functional layers are transmitted through the bonding interface to the original mechanical frame, enabling the frame to function as a primary load-bearing structure while preserving alignment of the display cell.
[0069] In an embodiment, the bonding interface may form a continuous load-distributing structure along at least a portion of the perimeter region. The continuous bonding interface may enhance structural integrity and improve resistance to vibration and mechanical shock. In another embodiment, the bonding interface may be segmented or discontinuous while still enabling effective load transfer to the original mechanical frame, depending on design and manufacturing requirements.
[0070] In an embodiment, the method further comprises positioning one or more spacer elements between the original mechanical frame and the one or more functional layers to maintain controlled positioning of the functional layers relative to the display cell. The spacer elements may define a separation distance and a space between the one or more functional layers and the display cell, thereby preventing direct contact between the functional layers and the display cell while promoting uniform load distribution and maintaining optical alignment. In certain embodiments, the defined space between the one or more functional layers and the display cell may contain a transparent medium that allows transmission of light from the display cell through the functional layers. The transparent medium may comprise, for example, air, an optically transparent gel, or a transparent glass sheet positioned between the display cell and the one or more functional layers. In an embodiment, the spacer elements may be formed from polymeric, elastomeric, metallic, or composite materials and may be configured as pads, rings, posts, ribs, or other geometries suitable for alignment and spacing.
[0071] In an alternate embodiment, the spacer elements may be positioned at perimeter locations, corner regions, or distributed positions along the original mechanical frame to achieve desired alignment and load distribution. In certain configurations, the spacer elements maintain the defined space between the display cell and the functional layers while allowing the bonding interface formed by the double-sided adhesive tape to secure the functional layers to the original mechanical frame.
[0072] At step 410, the method concludes with formation of the ruggedized COTS display module, wherein the pre-assembled configuration of the COTS display module is maintained. In an embodiment, factory-integrated components such as a backlight unit remain unmodified, preserving factory alignment and calibration while enabling integration of additional functional layers. In an embodiment, the method may be implemented using automated dispensing systems, manual assembly processes, or hybrid manufacturing techniques, depending on production volume and application requirements.
[0073] Embodiments of the present disclosure provide significant advantages over conventional techniques used to ruggedize commercial off-the-shelf (COTS) display modules. Conventional ruggedization approaches often involve dismantling the original display assembly, removing factory-installed components, and reconstructing the display stack using custom structural elements. Such procedures increase manufacturing complexity and may introduce risks including contamination of optical surfaces, misalignment of internal display layers, and potential damage to sensitive electronic or optical components. In contrast, the disclosed approach enables ruggedization of the display module while preserving the original factory-assembled configuration of the display cell and associated components, thereby maintaining factory calibration and reducing the risks associated with invasive modification of the display assembly.
[0074] Another advantage arises from the structural configuration in which the bonding interface is confined to a perimeter region of the original mechanical frame. By locating the bonding interface outside the active display region, the disclosed technique avoids introducing bonding materials within the optical viewing area of the display cell. This arrangement preserves optical clarity and prevents distortion or optical artifacts that may occur when structural bonding materials are applied directly within the display region. As a result, the display module retains its intended visual performance while still allowing additional functional layers to be securely integrated.
[0075] The disclosed configuration also establishes an efficient load transfer path through the original mechanical frame. Mechanical loads applied to the functional layers, such as those arising from vibration, impact, or environmental stresses, are transferred through the bonding interface to the mechanical frame rather than being transmitted directly to the display cell. Because the mechanical frame is structurally designed to support such loads, this load distribution significantly reduces the likelihood of stress-induced damage to the display cell. Consequently, the ruggedized display module demonstrates improved durability and reliability in operational environments where mechanical stresses are present.
[0076] Additional advantages are achieved through the use of spacer elements that maintain a controlled separation between the functional layers and the display cell. The spacer elements define a space between these components, thereby preventing direct contact that could otherwise introduce localized stress or optical distortion. This defined space may contain air, an optically transparent gel, or a transparent glass sheet depending on optical and environmental requirements. The presence of this controlled space allows the display assembly to accommodate dimensional tolerances and environmental variations while maintaining proper optical transmission from the display cell through the functional layers.
[0077] The disclosed approach further enables flexible integration of a variety of functional layers without requiring modification of the underlying display module. Such layers may include protective glass, optical conditioning elements, touch interfaces, thermal management components, or other functional elements required for specific applications. Because these layers are integrated through the perimeter-based bonding architecture, the display module can be adapted for different operational environments without redesigning the internal structure of the display assembly.
[0078] Another advantage of the disclosed ruggedization technique is the ability to preserve factory-integrated components such as backlight units, driver electronics, and optical stacks. Maintaining these components in their original calibrated configuration eliminates the need for requalification or recalibration that might otherwise be required when a display module is disassembled and rebuilt. This preservation of the original assembly significantly reduces manufacturing effort and enables faster deployment of ruggedized display modules.
[0079] Overall, the disclosed ruggedization technique provides a structurally efficient and non-intrusive approach for enhancing durability and functionality of commercial off-the-shelf display modules. By enabling integration of additional functional layers while preserving the integrity and alignment of the pre-assembled display module, the technique offers a practical and scalable solution for deploying display systems in industrial equipment, transportation platforms, outdoor installations, and defense-support environments where enhanced durability and operational reliability are required.
[0080] While embodiments of the present disclosure have been illustrated and described, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the disclosure, as described in the claims.
[0081] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C,…, and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
[0082] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
, C , Claims:CLAIMS
We Claim:
1. A ruggedized Commercial Off-The-Shelf (COTS) display module, the ruggedized COTS display module comprising:
a pre-assembled COTS display module, the pre-assembled COTS display module comprising:
a display cell; and
an original mechanical frame surrounding the display cell;
a double-sided adhesive tape disposed on a surface region of the original mechanical frame and confined to a perimeter region corresponding to the original mechanical frame, wherein the double-sided adhesive tape forms a bonding interface outside an active display region of the display cell; and
one or more functional layers bonded to the bonding interface;
wherein the one or more functional layers are mechanically supported by the original mechanical frame through the bonding interface; and
wherein mechanical loads applied to the one or more functional layers are transmitted through the bonding interface to the original mechanical frame.
2. The ruggedized COTS display module as claimed in claim 1, wherein the bonding interface forms a continuous load-distributing structure along at least a portion of the perimeter region.
3. The ruggedized COTS display module as claimed in claim 1, wherein the one or more functional layers comprise at least one of: optical conditioning layers, electrically functional layers, thermally active layers, and touch-sensitive layers.
4. The ruggedized COTS display module as claimed in claim 1, wherein the double-sided adhesive tape comprises at least one of: an acrylic foam adhesive tape, and a very high-bond adhesive tape.
5. The ruggedized COTS display module as claimed in claim 1, further comprising one or more spacer elements positioned between the original mechanical frame and the one or more functional layers to maintain controlled positioning of the one or more functional layers relative to the display cell, wherein the one or more spacer elements define a space between the one or more functional layers and the display cell.
6. The ruggedized COTS display module as claimed in claim 5, wherein the space comprises at least one of: a transparent medium, air, an optically transparent gel, and a transparent glass sheet.
7. The ruggedized COTS display module as claimed in claim 1, wherein the pre-assembled COTS display module comprises a factory-integrated backlight that remains unmodified during formation of the ruggedized COTS display module.
8. A method for ruggedizing a commercial off-the-shelf (COTS) display module, the method comprising:
providing a pre-assembled COTS display module, wherein the pre-assembled COTS display module comprises a display cell and an original mechanical frame surrounding the display cell;
disposing a double-sided adhesive tape on a surface region of the original mechanical frame within a perimeter region corresponding to the original mechanical frame, wherein the double-sided adhesive tape forms a bonding interface outside an active display region of the display cell; and
bonding one or more functional layers to the bonding interface, wherein the one or more functional layers are mechanically supported by the original mechanical frame;
wherein mechanical loads applied to the one or more functional layers are transmitted through the bonding interface to the original mechanical frame.
9. The method as claimed in claim 8, comprising forming, via the bonding interface, a continuous load-distributing structure along at least a portion of the perimeter region.
10. The method as claimed in claim 8,
wherein the one or more functional layers comprise at least one of: optical conditioning layers, electrically functional layers, thermally active layers, and touch-sensitive layers; and
wherein the double-sided adhesive tape comprises at least one of: an acrylic foam adhesive tape, and a very high-bond adhesive tape.
11. The method as claimed in claim 8, further comprising positioning one or more spacer elements between the original mechanical frame and the one or more functional layers to maintain controlled positioning of the one or more functional layers, wherein the one or more spacer elements define a space between the one or more functional layers and the display cell, wherein the space comprises at least one of: a transparent medium, air, an optically transparent gel, and a transparent glass sheet.