LED Display Housing Manufacturing via Spin Double Injection
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Solution Overview
Problem
The conventional manufacturing process for LED display device housings is time-consuming and cost-ineffective due to manual handling between mold assemblies and difficulties in recycling defective products, especially since the display side is already printed with ink during the second injection molding process.
Innovation Solution
The use of a spin double injection machine with first and second mold assemblies allows for simultaneous injection molding of the cover and transparent members, enabling easy recycling of defective products and separating the ink process from the molding steps, thereby reducing manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual disposition of the cover from one mold assembly to another is used, then the housing can be manufactured with multiple components, but the manufacturing time increases and productivity decreases
Solution Approach 1:
The patent combines multiple mold assemblies (first mold assembly for cover, second mold assembly for transparent members) into a single integrated mold system. This allows simultaneous formation of multiple housing components in one injection cycle, eliminating manual transfer operations and significantly reducing manufacturing time while maintaining the ability to manufacture complex multi-component housings
2Ease of manufacture
If the second injection molding process is performed before ink printing, then the transparent members can be formed, but defective housing becomes difficult to recycle since the display side is already printed with ink
Solution Approach 1:
The patent reverses the conventional sequence by performing ink printing on the cover after the second injection molding process completes successfully. This preliminary action sequencing ensures that if defects are detected after molding, the cover can be easily removed and recycled without ink contamination, while still achieving the final printed appearance in the successful product
3Ease of manufacture
If the conventional sequential process is used, then each component can be manufactured separately, but the overall manufacturing cost increases due to multiple separate operations
Solution Approach 1:
The patent merges the manufacturing of the cover and transparent members into a single integrated injection molding process using multiple mold assemblies. This combining of previously separate manufacturing operations reduces the total number of process steps, minimizes handling and setup time, and significantly lowers overall manufacturing cost while still producing distinct, separately-functional components
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 significantly reduces manufacturing time and costs by allowing for efficient recycling of defective products and preventing ink from covering the transparent members, while also enhancing production efficiency through the use of a spin double injection machine and laser engraving for pattern formation.
Implementation Method 1
spin double injection machine with first and second mold assemblies
Data Source
AI summary
A method for manufacturing a housing of an LED display device includes the steps of: (a) filling a first material into a first mold assembly at a first place to form a cover with a plurality of first display holes, followed by moving the cover to a second place, filling a second material into a second mold assembly and the cover to seal one of the plurality of the first display holes via a plurality of first transparent members; and (b) disposing an ink layer on a display side of the cover in such a manner that the ink layer covers the display side of the cover and that the first transparent member in each of the first display holes is exposed from the ink layer.