Insert Molding 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 ultra-thin designs that have narrow or no borders, where traditional bonding methods fail to provide reliable attachment and structural integrity.
Innovation Solution
A display cover panel design featuring a molding tab with co-molded insert molding, using a carbon-fiber-filled poly(butylene terephthalate) resin, which increases bonding strength and stiffness by forming a seamless bond with the outer panel, even at small dimensions, and includes cutout portions for enhanced bonding and reduced thickness.
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:
The insert molding process merges the bonding function with the manufacturing process itself. The polymer material is molded directly onto the outer panel in a single operation, combining attachment and formation into one integrated process that eliminates separate bonding steps while achieving superior bonding strength
Solution Approach 2:
The solution uses composite materials by incorporating carbon-fiber-filled poly(butylene terephthalate) resin into the insert molding. This composite material provides both the necessary bonding strength and stiffness while maintaining the ultra-thin profile, overcoming the limitations of traditional bonding methods
2Shape
If the display cover panel is made ultra-thin with narrow borders, then sleek appearance is achieved, but stiffness and structural integrity deteriorate
Solution Approach 1:
The insert molding is strategically positioned at specific locations on the display cover panel where additional stiffness is most needed. This localized reinforcement approach maintains the overall ultra-thin sleek appearance while providing targeted structural support exactly where required by the design
Solution Approach 2:
The use of carbon-fiber-filled poly(butylene terephthalate) resin provides high stiffness-to-thickness ratio, enabling the panel to maintain ultra-thin dimensions while achieving the necessary structural integrity and resistance to deformation
3Length of stationary object
If the molding tab dimensions are reduced for ultra-thin design, then sleek appearance is maintained, but bonding strength becomes insufficient
Solution Approach 1:
The carbon-fiber-filled polymer material compensates for the reduced molding tab dimensions by providing superior mechanical properties. The composite material's inherent strength and stiffness allow the bonding tab to maintain adequate bonding capability even at reduced thicknesses required for ultra-thin design
Solution Approach 2:
The insert molding process changes the bonding interface parameters by creating a larger bonded surface area and optimizing the bonding geometry during molding. This allows the bonding tab to achieve sufficient bonding strength despite reduced overall dimensions through optimized dimensional parameters
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 a display cover panel with exceptional bonding strength, capable of withstanding forces up to 45 Newtons and increased stiffness, while maintaining a sleek appearance, effectively addressing the structural integrity issues in ultra-thin portable device designs.
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.