Insert Molding for Display Cover Panel Bonding
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Solution Overview
Problem
Existing display cover panels for portable information handling systems face challenges in achieving sufficient bonding strength and stiffness, especially with the increasing trend towards ultra-thin designs with narrow or no borders, where traditional bonding methods fail to provide reliable adhesion and structural integrity.
Innovation Solution
The implementation of an insert molding process using a polymer, such as carbon-fiber-filled poly(butylene terephthalate) resin, co-molded with a metal outer panel featuring molding tabs and cutout portions, which increases bonding strength and stiffness by forming a seamless and strong joint, capable of withstanding forces perpendicular to the edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional bonding methods are used for ultra-thin display cover panels, then manufacturing simplicity is maintained, but bonding strength and structural integrity are insufficient
Solution Approach 1:
Molding tabs are pre-formed on the outer panel before the insert molding process. These tabs extend towards the display surface and provide predetermined bonding locations, ensuring strong adhesion areas are established in advance before the insert molding is applied
Solution Approach 2:
The solution combines a metal outer panel with a polymer insert molding (such as carbon-fiber-filled poly(butylene terephthalate) resin). This composite construction integrates the strength of metal with the bonding capabilities of polymer, achieving superior bonding strength and stiffness while maintaining ultra-thin design
2Shape
If the display cover panel is made ultra-thin with narrow borders, then aesthetic appearance and modern design are improved, but structural integrity and stiffness deteriorate
Solution Approach 1:
The insert molding process creates a composite structure where polymer material is bonded to the metal outer panel. This combination provides enhanced stiffness and structural integrity while maintaining the ultra-thin profile, as the polymer layer adds structural reinforcement without significant thickness increase
Solution Approach 2:
The insert molding is strategically positioned at specific locations on the outer panel, such as along edges or at critical structural points. This localized reinforcement provides enhanced stiffness where needed most, while keeping other areas thin and aesthetically pleasing
3Strength
If the bonding area is increased to improve adhesion, then bonding strength improves, but the available space on ultra-thin panels is reduced
Solution Approach 1:
The bonding structure is segmented into discrete molding tabs rather than a continuous bonding layer. These tabs are strategically positioned at critical locations, concentrating bonding strength at specific points while leaving the rest of the panel area available for display or other functions
Solution Approach 2:
Molding tabs are pre-formed on the outer panel before the insert molding process. These tabs extend towards the display surface and provide predetermined bonding locations, ensuring strong adhesion areas are established in advance before the insert molding is applied
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 solution enhances the bonding strength and stiffness of the display cover panel, ensuring durability and structural integrity while maintaining a sleek, thin design, capable of withstanding forces up to 45 Newtons and providing a high-quality external appearance.
Implementation Method 1
the insert molding may include a polymer that is bonded with the outer panel by co-molding with the outer panel
Data Source
AI summary
A display in a portable information handling system may have a narrow or no border. A display panel cover included with the display may be formed with an insert molding that is co-molded with an outer panel for high bonding strength and high stiffness, as well as providing a desired high quality external appearance to information handling system. Additionally, an exterior insert molding may be formed to include an exterior surface of the information handling system.