Co-molding Mobile Device Display with Internal Die Assembly
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Solution Overview
Problem
Traditional methods for assembling mobile device bodies with multiple materials, such as glass displays and molded plastic, result in aesthetically unappealing seams that can capture dust and moisture, leading to corrosion and weakness in the device.
Innovation Solution
The method involves co-molding the body using an external and internal die assembly, where the internal die holds the display component in place during injection molding of the plastic body, ensuring direct contact and integration of materials, and allows for the removal of the die without disturbing the formed body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the display portion is assembled to the molded body during the assembly process using gaskets, then the display can be attached to the body, but seams are created that capture dust and dirt, loosen the seal, and allow moisture entry
Solution Approach 1:
The patent combines the display assembly and body molding operations into a single co-molding process. The display portion is integrated directly into the molded body during the molding operation itself, eliminating the need for separate assembly with gaskets. This merging of operations creates a seamless structure that prevents dust and moisture ingress while maintaining manufacturing efficiency.
Solution Approach 2:
The patent extracts and eliminates the gasket component from the traditional assembly process. By using co-molding, the sealing function that was previously performed by separate gasket components is integrated directly into the molded body structure, removing the source of seams and potential failure points.
2Adaptability or versatility
If multiple materials are used for the body (glass display and molded plastic), then the device achieves desired aesthetic and functional properties, but multiple seams are created where materials meet
Solution Approach 1:
The patent merges the display portion and body into a single integrated structure through co-molding. The display is embedded directly into the molded body material, creating a unified structure that eliminates weak seam points while preserving the benefits of using multiple materials (glass display with plastic body) for aesthetic and functional properties.
3Ease of operation
If gaskets are used to mate the display portion to other components, then the components can be assembled, but aesthetically unappealing seams are created
Solution Approach 1:
The patent removes the gasket component entirely from the design. The co-molding process creates a seamless integration between the display and body, eliminating the visible seams that would otherwise be required to mate the components. This achieves both easy component integration and superior aesthetic appearance.
4Productivity
If traditional assembly methods are used with multiple seams, then the device can be manufactured, but the seams create weak portions where the body is most likely to break when dropped
Solution Approach 1:
The patent combines the display and body into a single integrated molded structure, eliminating the multiple seams that create weak points in traditional assembly methods. The co-molding process maintains manufacturing productivity while creating a unified structure that distributes stress more evenly and resists breaking during drops.
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 eliminates seams, enhances material integration, reduces dust and moisture ingress, and strengthens the device by ensuring a seamless and robust connection between the display and the body.
Implementation Method 1
The molding can be accomplished by injection molding
Data Source
AI summary
Tooling and methods for co-molding a body with two different materials. An internal die assembly comprising at least two parts allows for placement of a component and co-molding of the body around the component and then removal of the internal die assembly without disturbing the body.