Flexible Electronic Device Manufacturing via Continuous Strip Overmolding
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Solution Overview
Problem
Current methods for manufacturing flexible portable electronic devices are limited by their inability to scale up for mass production while allowing for shape, thickness, and decoration variability, making them unsuitable for large-scale manufacturing.
Innovation Solution
A method involving the use of two impermeable plastic strips, where one is overmoulded with flexible material and the other decorated and assembled with electronic components, then joined and cut to produce flexible devices with varied shapes, thicknesses, and decorations, enabling mass production with real-time adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If piece-by-piece manufacturing method is used, then flexibility and customization are improved, but productivity deteriorates
Solution Approach 1:
The manufacturing process is divided into separate functional zones along a continuous strip: overmoulding station for creating device bodies, printing station for decoration, assembling station for electronic components, and joining/cutting stations for final assembly. This segmentation allows each station to operate independently and simultaneously, enabling mass production while maintaining customization capabilities through modular process design.
Solution Approach 2:
The patent implements a continuous manufacturing process where impermeable plastic strips move continuously through multiple processing stations without interruption. The strip passes sequentially through overmoulding, printing, assembling, joining, and cutting stations in an unbroken workflow, maximizing productivity by eliminating idle time between operations while maintaining the flexibility to customize each device along the production line.
2Manufacturing precision
If piece-by-piece manufacturing method is used, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The impermeable plastic strip undergoes preliminary processing at the overmoulding station where device bodies are formed with precise dimensions and shapes before subsequent operations. The printing station applies decorations with exact positioning, and the assembling station pre-positions electronic components according to precise specifications. These preliminary actions ensure manufacturing precision is established early in the continuous process, maintaining consistency across all produced devices.
Solution Approach 2:
The patent replaces traditional manual or batch mechanical assembly operations with automated processing stations that use controlled mechanical systems. The overmoulding station uses injection molding machinery for precise body formation, the printing station employs automated printing mechanisms for accurate decoration application, and the assembling station utilizes automated component placement systems. This substitution of automated mechanical systems maintains high precision while enabling continuous high-speed production.
3Productivity
If mass production method is implemented, then productivity is improved, but adaptability deteriorates
Solution Approach 1:
The manufacturing system is designed to be dynamic and adaptable rather than fixed. The printing station can dynamically change decoration patterns and colors on different sections of the strip, the overmoulding station can adjust body shapes and thicknesses, and the assembling station can vary electronic component configurations. This dynamic capability allows the continuous production line to produce diverse device variants with different shapes, decorations, and specifications while maintaining high productivity through uninterrupted manufacturing.
Solution Approach 2:
Different sections or zones of the impermeable plastic strip can receive different treatments and properties along its length. The overmoulding station can create devices with varying thicknesses and shapes at different locations, the printing station can apply different decorative patterns to different sections, and the assembling station can place different electronic components in different positions. This local quality approach enables customization and variety within the continuous mass production process.
4Productivity
If continuous strip processing is used, then productivity is improved, but device complexity increases
Solution Approach 1:
The complex manufacturing process is segmented into distinct, specialized stations: overmoulding for body formation, printing for decoration, assembling for component integration, joining for securing components, and cutting for individual device separation. Each station performs a specific function with dedicated equipment and processes, which simplifies the overall system architecture while enabling continuous high-productivity manufacturing. The segmentation allows independent optimization of each station without increasing overall process complexity.
Solution Approach 2:
The impermeable plastic strip serves multiple functions throughout the manufacturing process: it acts as the base material for device bodies, as a substrate for printing decorations, as a structural element during assembly, as a medium for joining operations, and as the final product form after cutting. This multi-functionality of a single continuous strip reduces the need for multiple different materials and processes, thereby managing complexity while maintaining high productivity across all manufacturing stages.
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 allows for the mass production of flexible portable electronic devices with diverse shapes, thicknesses, and decorations, facilitating real-time model adaptation and enabling efficient production of customizable devices.
Implementation Method 1
overmoulding a layer of flexible plastic material, which forms the body of the portable electronic device, on an external face of a first impermeable plastic film
Implementation Method 2
securing a second impermeable plastic film onto the first impermeable plastic film, so as to delimit, between the first and second impermeable plastic films, an impermeable capsule or cavity which houses the electronic assembly
Data Source
AI summary
Method of mass producing a flexible portable electronic device capable of at least processing information, the method including the steps consisting in passing a first impermeable plastic strip through an overmolding station in which the first impermeable plastic strip is overmolded using a plastic material,the method further including the steps consisting in passing a second impermeable plastic strip with a bottom surface facing upwards, in succession:through a printing station in which the second impermeable plastic strip receives, on the bottom surface thereof, at least one decorative ink;through an assembly station in which the second impermeable plastic strip receives, in various places on the bottom surface thereof, the electronic assemblies for processing information,joining and welding the first overmolded impermeable plastic strip to the second decorated impermeable plastic strip, and then in cutting out and releasing the portable electronic devices.