Extruded Plastic Laminate Structure for Touch Sensing Devices
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Solution Overview
Problem
Conventional plastic laminate structures experience peeling of layers due to mold shrinkage and foreign substance intrusion during injection molding, especially in high-temperature/high-humidity environments, leading to structural integrity issues and contamination.
Innovation Solution
A plastic laminate structure composed of extruded plastic layers laminated in a specific direction with an adhesive layer, ensuring uniform thermal expansion and reduced shrinkage, and eliminating the need for injection molding to prevent foreign substance intrusion, with optional electrode and rib features for enhanced functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used to form the plastic laminate structure, then manufacturing efficiency is improved, but mold shrinkage causes peeling between layers
Solution Approach 1:
The patent changes the molding method from injection molding to extrusion molding, which fundamentally alters the thermal processing parameters and eliminates mold shrinkage. This parameter change resolves the contradiction by maintaining layer bonding stability while preserving manufacturing efficiency through the extrusion process.
Solution Approach 2:
The patent extracts the problematic injection molding step that causes mold shrinkage and peeling. By removing this specific process and replacing it with extrusion molding, the harmful effect is eliminated while the beneficial manufacturing efficiency is maintained.
2Productivity
If injection molding is used, then production speed is improved, but foreign substances intrude between the molding die and sheets
Solution Approach 1:
The patent removes the injection molding die from the process, eliminating the source of foreign substance intrusion. By extracting this problematic component and replacing it with an extrusion molding system, production speed is maintained while foreign substance contamination is prevented.
3Adaptability or versatility
If multiple laminated layers are used, then functional complexity is improved, but peeling between layers occurs more likely
Solution Approach 1:
The patent changes the thermal processing parameters by using extrusion molding instead of injection molding, which eliminates mold shrinkage. This allows multiple laminated layers to be bonded stably without peeling, enabling functional complexity while maintaining layer bonding stability.
Solution Approach 2:
The patent uses multiple different plastic materials (first plastic material and second plastic material) with potentially different thermal properties. The extrusion molding process ensures these composite layers bond stably without the peeling issues that would occur with injection molding.
4Adaptability or versatility
If the plastic laminate structure is curved, then design flexibility is improved, but peeling occurs more likely
Solution Approach 1:
The patent changes the molding method to extrusion molding, which eliminates mold shrinkage. This allows the plastic laminate structure to be curved or bent after formation without causing peeling, as the layers are not under residual stress from injection molding cooling.
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
The solution significantly reduces the likelihood of peeling between layers and foreign substance intrusion, maintaining structural integrity and cleanliness, even in challenging environmental conditions, while allowing for secure electrode placement and rib bonding for improved performance.
Implementation Method 1
an adhesive layer, which affixes adjacent plastic layers to one another
Implementation Method 2
the plastic layers have relatively smaller thermal shrinkage ratios
Data Source
AI summary
A plastic laminate structure including a plurality of, or a plurality of kinds of, plastic layers and an adhesive layer. The plastic layers are laminated together in a first direction. All the plastic layers are comprised exclusively of extruded plastic layers. The adhesive layer affixes together two of the plastic layers that are adjacent to each other in the first direction.