Composite Press Forming With 180° Hemming for Hidden Cut Edges
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Solution Overview
Problem
The existing manufacturing processes for OLED displays require a separate cabinet to prevent side surfaces from being exposed, increasing costs and complexity, while also lacking efficient methods for finishing and hemming composite materials.
Innovation Solution
A press forming method using an upper metal member, a resin member, and a lower metal member, where the lower metal member is folded by 180 degrees using a hemming die to prevent exposure, eliminating the need for a separate cabinet and enabling both inward and outward hemming, with easy removal of hot melt films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a separate cabinet is used to prevent side surfaces from being exposed, then the side surfaces are protected, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent merges the protective function previously performed by a separate cabinet into the composite material structure itself. The metal plate is integrated with the resin layer to form a unified composite material that inherently protects the side surfaces, eliminating the need for additional separate components.
Solution Approach 2:
The metal plate in the composite material serves multiple functions: it provides structural support, acts as a barrier to prevent exposure of side surfaces, and enables hemming operations. This multi-functionality replaces what previously required separate dedicated components.
2Object-affected harmful factors
If a separate cabinet is used to prevent side surfaces from being exposed, then the side surfaces are protected, but manufacturing cost increases
Solution Approach 1:
The protective function is merged into the composite material structure itself. The metal plate and resin layer form an integrated unit that protects side surfaces without requiring separate protective components, thereby reducing material costs and assembly complexity.
3Object-affected harmful factors
If the lower metal member is folded by 180 degrees using a hemming die, then side surfaces are prevented from being exposed, but the process complexity increases
Solution Approach 1:
The metal plate is prepared in advance with appropriate dimensions and bonding surfaces before the hemming operation. The coating films are applied beforehand to ensure proper bonding, and the stacking sequence is predetermined to facilitate the subsequent folding and hemming operations.
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 method reduces manufacturing costs, achieves excellent flatness and stiffness, and simplifies the finishing process by preventing exposure of composite material surfaces without a separate middle cabinet, while allowing for both inward and outward hemming.
Implementation Method 1
producing the composite material including the upper metal member, a first hot melt member, the resin member, a second hot melt member, and the lower metal member sequentially layered and bonded together
Data Source
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AI summary
Disclosed is a press forming method for a composite material including an upper metal member (102), a resin member (104), and a lower metal member (106), the method including: producing the lower metal member having first and second coating films respectively bonded to upper and lower surfaces thereof; producing the composite material including the upper metal member, a first hot melt member, the resin member, a second hot melt member, and the lower metal member; cutting an area spaced inward a predetermined distance from a lengthwise edge of the composite material by using a T-cutter, such that only the lower metal member remains; removing the upper metal member, the first hot melt member, the resin member, and the second hot melt member that are located outside the cut area; and folding the lower metal member by an angle of 180 degrees by using a hemming die.