Glass Insert Molding Die for Housing Case Hardness
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Solution Overview
Problem
Existing housing cases for small electric and communication devices, particularly those covering LCD or display screens, lack sufficient hardness to withstand impacts and scratches, leading to potential warping and damage during use.
Innovation Solution
A housing case design featuring a glass plate with a resin frame integrated to support the backside periphery, using a glass insert molding die that includes a sliding core for positioning and resin injection, ensuring the front portion covering the display screen is adequately hardened and resistant to impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thin coated film hard coat layer is applied on the plastic substrate, then the manufacturing process is simple and cost-effective, but the hardness is insufficient to withstand impacts and scratches on the display screen portion
Solution Approach 1:
The invention uses a composite structure combining glass plate and resin frame materials. The glass plate provides high hardness (9H) to withstand scratches and impacts on the display screen, while the resin frame provides structural support and integration. This composite approach achieves the required hardness without excessive manufacturing complexity by integrating materials with complementary properties.
Solution Approach 2:
The housing case front portion is segmented into distinct functional components: a glass plate for hardness and scratch resistance, and a resin frame for structural support and integration. This segmentation allows each component to be optimized for its specific function while simplifying the overall manufacturing process through modular assembly.
2Strength
If a glass plate is used to enhance hardness, then scratch resistance is improved, but the manufacturing process becomes more complex requiring precise positioning and integration
Solution Approach 1:
The glass insert molding die performs multiple functions: it positions the glass plate precisely, forms the resin frame structure, and integrates both materials into a single housing case component. This multi-functionality reduces overall manufacturing complexity despite using glass, as one die accomplishes what would otherwise require multiple separate processes.
Solution Approach 2:
The resin frame acts as an intermediary material that bridges the glass plate and the housing structure. It provides a bonding interface between the glass plate and the housing case body, enabling integration while maintaining the glass plate's hardness properties. The resin frame absorbs the complexity of integration, allowing the glass plate to be positioned and secured effectively.
3Ease of manufacture
If a thin coated film is used for the hard coat layer, then the manufacturing cost is low, but the protection against impacts and scratches is insufficient
Solution Approach 1:
The invention replaces the thin coated film with a glass plate-resin frame composite structure. The glass plate provides superior impact and scratch protection (9H hardness) compared to thin coated films, while the resin frame provides additional structural protection and integration. This composite approach maintains cost-effectiveness by using standard manufacturing processes while dramatically improving protection reliability.
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 provides enhanced hardness and resistance to scratches and impacts for the housing case, preventing warping and ensuring the display screen remains intact, while also allowing for cost-effective manufacturing.
Implementation Method 1
integrated with the flat plate to support a backside periphery of the flat plate
Implementation Method 2
integrated with the flat plate using a glass insert molding die
Implementation Method 3
a sliding core (5) having a bottom portion (5b) that comes into contact with the periphery of the flat plate (2) facing the stationary die (15)
Implementation Method 4
injecting a molten resin into the cavity to integrate a resin frame (3) with the flat plate (2)
Data Source
Figure 1(a)~4
Figure 5~7
Figure 8~9
AI summary
A housing case (1) for a small electric device and communication device includes a flat plate (2) having a dimension substantially the same as that of the front portion of the housing case and comprising at least a glass plate, and a resin frame (3) integrated with the flat plate (2) to support the backside periphery of the flat plate (2).