3D Printed Chassis for Large Displays
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Solution Overview
Problem
The high manufacturing costs and time-consuming processes associated with producing display apparatus chassis, particularly for large displays, due to the need for press molds, numerical control turret punch presses, and injection molding, limit design freedom and increase costs.
Innovation Solution
The use of 3D printing to directly mold structures onto metal plates, eliminating the need for press molds and allowing for the integration of different materials, such as metal and resin, with coupling parts featuring undercut designs and reinforcing elements to enhance coupling and rigidity, thereby reducing manufacturing costs and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If press molds are used to manufacture the rear chassis, then the manufacturing precision and strength are improved, but the manufacturing cost and device complexity increase due to the high cost of press molds and the time-consuming process
Solution Approach 1:
The patent combines the rear chassis and fastening member into a single integrated component manufactured by 3D printing. This eliminates the need for separate press molds for the chassis and separate fastening members, reducing manufacturing process complexity while maintaining structural precision and strength through additive manufacturing techniques.
Solution Approach 2:
The patent uses 3D printing to create a digital replica or copy of the chassis design directly from CAD models, eliminating the need for physical press molds. This digital copying approach allows for rapid iteration and modification without the high costs associated with creating and modifying traditional press molds.
2Strength
If the rear chassis is manufactured by processing a metal plate using NCT and combining separate aluminum extrusion components, then the strength and rigidity are improved, but the manufacturing time and cost increase due to the combining process
Solution Approach 1:
The patent merges the rear chassis and fastening member into a single 3D printed component, eliminating the need for separate aluminum extrusion components and the time-consuming combining process. This integrated approach maintains structural strength while significantly improving manufacturing efficiency by producing the entire assembly in one operation.
Solution Approach 2:
The patent employs composite materials in the 3D printing process, combining metal powders or resins with varying properties to create different regions of the chassis with optimized strength characteristics. This allows for complex geometries and internal structures that provide high strength-to-weight ratio without requiring multiple separate components.
3Strength
If surface treatment and injection molding are used to mold the fastening member directly onto the metal plate, then the coupling strength is improved, but the manufacturing cost increases due to the requirement of insert-injecting molds and large injection molding machines
Solution Approach 1:
The patent combines the fastening member and rear chassis into a single monolithic component manufactured by 3D printing. This eliminates the need for separate fastening members and the complex surface treatment and injection molding processes, achieving strong coupling through integrated design while reducing manufacturing complexity and cost.
Solution Approach 2:
The patent uses 3D printing to directly copy the fastening member geometry as part of the rear chassis structure, eliminating the need for separate mold-based injection processes. This approach achieves the same coupling function through additive manufacturing, reducing the need for specialized insert-injecting molds and large injection molding equipment.
4Strength
If aluminum extrusion molding is used to manufacture the front chassis, then the strength and luxurious appearance are improved, but the design freedom and material selection are restricted
Solution Approach 1:
The patent changes the manufacturing parameters from traditional aluminum extrusion to 3D printing, enabling continuous variation of geometric parameters and complex shapes that were previously impossible with extrusion molding. This allows for optimized structural designs and aesthetic variations while maintaining strength requirements, significantly expanding design freedom and material options.
5Adaptability or versatility
If injection molding with plastic resin is used to manufacture the front chassis, then the design freedom and cost are improved, but the luxurious appearance and structural rigidity are reduced
Solution Approach 1:
The patent uses composite materials in 3D printing, combining metal powders or high-strength resins with reinforcing structures to achieve both design freedom and structural rigidity. This allows for complex geometries and cost-effective manufacturing while maintaining the luxurious appearance and strength properties previously only achievable with metal extrusion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing costs and time by eliminating the need for press molds and enabling more design freedom for metal chassis, while enhancing the rigidity and coupling strength of the display apparatus.
Implementation Method 1
stacked structures 3D printed on the plate
Implementation Method 2
The structure may be melted pelletized resin
Implementation Method 3
The concave/convex surface may be finely formed on a surface of the plate by electric discharge machining
Data Source
AI summary
A display apparatus including an improved chassis and a manufacturing method thereof. The display apparatus includes a display panel, a chassis including a plate provided to cover the display panel and a coupling part on the plate, and stacked structures 3D printed on the plate coupled to the coupling art.