Layer Electrode Back-Injection Molding With Sacrificial Tail Protection
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Solution Overview
Problem
The existing back-injection molding processes for touch screen layer electrodes are costly due to the need for precise positioning to avoid gluing the 'tail' area, which is not intended to be molded, requiring protective measures that are economically unattractive.
Innovation Solution
A sacrificial film is applied to the areas not to be back-injection molded, such as the 'tail', which can be easily removed after molding, either by remaining part of the molded body or being peeled off, using vacuum lines and adhesive methods to prevent the back-injection molding material from reaching these areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise positioning is used to protect the tail area during back-injection molding, then the tail remains free of molding material, but the positioning cost and process complexity increase significantly
Solution Approach 1:
A sacrificial film is introduced as an intermediary element between the tail area and the back-injection molding material. This film serves as a temporary barrier that prevents molding material from reaching the tail area, eliminating the need for complex positioning systems while ensuring complete protection during the molding process.
Solution Approach 2:
The sacrificial film is a low-cost, single-use component that is applied to the tail area before molding and then discarded after serving its protective function. This disposable approach replaces expensive, complex positioning mechanisms with a simple, economical solution that achieves the same protective effect without increasing process complexity.
2Ease of manufacture
If a sacrificial film is applied to protect the tail area, then the protection is simple and cost-effective, but additional steps are required in the molding process
Solution Approach 1:
The sacrificial film is applied to the tail area in advance, before the back-injection molding process begins. This preliminary protective measure ensures that the tail area is already protected when molding starts, allowing the main molding operation to proceed without interruption or additional protective steps during the actual molding cycle.
Solution Approach 2:
After the back-injection molding is complete, the sacrificial film is removed from the molded component. This removal step discards the temporary protective element that has served its purpose, allowing the final product to be obtained in its intended form without the sacrificial film. The process efficiently separates the temporary protective function from the final product.
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 cost-effective protection of the 'tail' area during back-injection molding, ensuring it remains free and easily removable without damage, reducing the complexity and cost of the process while maintaining the integrity of the touch-sensitive sensor.
Implementation Method 1
first vacuum lines for holding the layer electrode during the back-injection molding and second vacuum lines for holding a sacrificial film during the back-injection molding process
Data Source
AI summary
The invention relates to a film body, a method for the back-injection molding of a film body and a back-injection molding tool therefor. In particular, the invention relates to a method for the back-injection molding of layer electrodes (1) for producing touch-sensitive sensors for example for touch screens. Parts of the layer electrode (1), which after the back-injection molding should still be able to move freely, are covered by a sacrificial film (3) before and during the back-injection molding.