Die Head Shim Design for Resin Joining Uneven Display Panels
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Solution Overview
Problem
Existing methods for joining a light-permeable member to an image display panel fail to effectively address unevenness on the joint surface, leading to incomplete wetting and bubble formation due to the large level difference portions between the frame and the main surface of the panel.
Innovation Solution
A method involving a die head with interchangeable shims that adjust the dispensing port dimensions to match the image display panel's dimensions, allowing for precise application of light-permeable resin across both the frame and main surface, ensuring complete coverage and stability of the resin layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a die head with a fixed dispensing port is used to apply resin to an image display panel with level difference portions, then the resin application process is simple, but the resin cannot properly fill the uneven surfaces resulting in poor joining quality
Solution Approach 1:
The die head structure is made dynamic by allowing the shim to move relative to the die blocks. The shim can be positioned at different locations along the supply path, enabling the dispensing port to adapt to different levels and positions on the image display panel surface. This dynamic adjustment capability allows the resin to properly fill uneven surfaces while maintaining a relatively simple overall structure.
Solution Approach 2:
The die head is segmented into multiple components: die blocks, a shim, and a cap. The shim acts as a separate, adjustable element that can be positioned independently to control resin flow. This segmentation allows the dispensing system to adapt to surface unevenness without redesigning the entire die head structure.
2Area of stationary object
If the dispensing port length is increased to cover the entire image display panel surface, then complete coverage is achieved, but resin is wasted in areas where joining is not performed
Solution Approach 1:
The shim can be dynamically positioned along the supply path to align the dispensing port only with the specific area where joining is required. This dynamic positioning ensures resin is applied only to the necessary region, preventing waste while maintaining complete coverage of the joining area.
Solution Approach 2:
The dispensing port is designed to provide localized resin application rather than uniform coverage across the entire panel. The shim allows the resin to be directed precisely to the joining area, ensuring adequate coverage where needed while avoiding waste in non-joining regions.
3Strength
If a thick-walled shim is used for the dispensing port, then structural strength is improved, but the resin flow and filling capability is reduced
Solution Approach 1:
The shim design incorporates local quality by having different wall thicknesses in different regions. The shim has sufficient overall strength to maintain structural integrity, while the region around the dispensing port has optimized thickness to ensure proper resin flow and filling capability. This localized differentiation allows both strength and productivity requirements to be met.
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 enables successful joining of a light-permeable member to an image display panel with uneven surfaces, preventing bubble formation and ensuring a stable resin application, thereby improving the yield and quality of the joining process.
Implementation Method 1
a light-permeable resin 4 for joining an image display panel 3 with level difference portions 7 formed thereon and a light-permeable member 2
Data Source
Figure 1~2
Figure 3
Figure 4A~4D
AI summary
An apparatus for manufacturing a joined member of the present invention includes a die head 10 for applying a light-permeable resin 4 for joining an image display panel 3 with level difference portions 7 formed thereon and a light-permeable member 2 to a surface of the image display panel 3. The die head 10 includes a pair of die blocks 20a, 20b having a supply path 22 formed therein for the light-permeable resin 4, and a first and second shims 30 and 40 detachably interposed between the die blocks 20a and 20b and defining an dispensing port 11 of the die head 10. The first shim 30 has a slit-like first dispensing port 31 corresponding to a length of a main surface portion 5a of the image display panel 3, and the second shim 40 has a slit-like second dispensing port 41 having a length greater than the length of the main surface portion 5a of the image display panel 3. The first shim 30 has a wall thickness D1 that is smaller than a wall thickness D2 of the second shim 40. By employing such a configuration, it is possible to provide an apparatus and a method for manufacturing a joined member capable of successfully joining a light-permeable member to an image display panel having unevenness formed on its joint surface.