Mold System for Display Resin Structural Integrity

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Solution Overview

Problem

The existing display apparatus technologies face challenges in enhancing the quality of resin structures, particularly in the manufacturing process, which affects the durability and integration of display modules in electronic devices, especially with the increasing miniaturization of components and the need for flexible, bendable display solutions.

Innovation Solution

The proposed solution involves a manufacturing apparatus comprising a first mold with a groove structure, a second mold with a higher modulus material, and a third mold for encapsulating the display module, where resins are injected and cured to form a resin structure with a circumferential member and protrusions, enhancing the structural integrity and flexibility of the display apparatus.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a single rigid mold is used for manufacturing the resin structure, then the structural strength is improved, but the manufacturing precision of the resin structure deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing precision of resin structure

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The mold is divided into two segments: a first mold made of rigid material (metal or ceramic) for providing structural strength, and a second mold made of flexible material (silicone rubber) for achieving manufacturing precision. The flexible second mold can elastically deform to match the precise contours of the display module, while the rigid first mold provides overall structural support.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mold system uses composite materials by combining rigid material (metal or ceramic) for the first mold and flexible material (silicone rubber) for the second mold. This composite approach allows the rigid portion to provide strength while the flexible portion provides precision fitting and elastic recovery.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If the mold tightly fits the display module, then the manufacturing precision is improved, but the stress concentration on the display module increases

Engineering Contradiction:

Improvemanufacturing precisionVSAvoidstress concentration

Core Design Contradiction:

Manufacturing precisionVSStress or pressure

Solution Approach 1:

Different regions of the mold have different properties: the first mold provides general structural support with lower local stress, while the second mold provides localized precise fitting at critical interfaces. The flexible second mold distributes stress through its elastic deformation rather than creating stress concentrations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The mold design changes the physical parameters of the molding system by using materials with different elastic moduli. The flexible second mold has lower stiffness, allowing it to adapt to the display module's shape without transmitting excessive stress, while maintaining precise dimensional control.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20240224725A1Display apparatus and apparatus for manufacturing display apparatus

Publication Date: 2024.07.04 SAMSUNG DISPLAY CO LTD

AI summary

An apparatus for manufacturing the display apparatus includes a first mold that includes an open surface that accommodates a display module, a second mold that surrounds the first mold and accommodates the first mold, and a third mold coupled to the second mold to cover the accommodated display module, wherein a modulus of the first mold is lower than a modulus of the second mold.