LED Display Module Molding Coating for Fast Waterproof Protection
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Solution Overview
Problem
LED displays face durability issues due to environmental damage and static, with conventional coating methods being time-consuming and inefficient.
Innovation Solution
A method involving a die-based molding process using a first and second die to form a cavity, fill it with a coating material, cure and separate the coating material to create a molding part that covers LEDs, improving manufacturing efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional dispensing or spraying method is used to coat LEDs, then waterproofing protection is achieved, but coating time and coating solution consumption increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-forming a cavity structure on the PCB board before LED mounting, and then injecting coating material into this cavity in advance. This allows the coating to be applied efficiently before final assembly, reducing the time needed during production while ensuring comprehensive waterproofing protection of the LEDs.
Solution Approach 2:
The patent utilizes hydraulic injection to fill the cavity with coating material. The injection system uses fluid pressure to deliver the coating material efficiently into the predetermined cavity, enabling rapid and uniform coating application that reduces both coating time and material consumption compared to conventional spraying methods.
2Reliability
If conventional dispensing or spraying method is used to coat LEDs, then waterproofing protection is achieved, but coating solution consumption increases
Solution Approach 1:
The cavity is designed and prepared in advance on the PCB board, defining the exact volume and shape needed for coating material. This preliminary structuring ensures that coating material is injected only where needed, eliminating waste from overspray or excessive dispensing, thus reducing coating solution consumption while maintaining effective waterproofing protection.
Solution Approach 2:
The hydraulic injection system provides precise control over coating material delivery, filling the cavity to the exact required amount. This controlled injection method prevents material waste compared to spraying, reducing coating solution consumption while ensuring complete coverage for waterproofing protection.
3Productivity
If molding process with die plate and side surface dies is used, then manufacturing efficiency and contrast ratio are improved, but device complexity increases
Solution Approach 1:
The molding process is segmented into distinct functional components: a die plate for forming the base cavity, multiple side surface dies for shaping the cavity walls, and a coupling body for securing the display module. This segmentation allows each component to perform its specific function efficiently, improving overall manufacturing productivity while making the complex molding process more manageable and modular.
Solution Approach 2:
The die plate and side surface dies are designed as multi-functional tools that not only form the coating cavity but also provide structural support and positioning for the display module during the coating process. This multi-functionality reduces the need for additional separate fixtures or tools, improving manufacturing efficiency without proportionally increasing device complexity.
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
Enhances manufacturing efficiency and durability by reducing coating time, protecting LEDs from environmental damage, and improving contrast ratio through a uniform and seamless display screen.
Implementation Method 1
the first light transmittance of the first portion is higher than a second light transmittance of the second portion
Implementation Method 2
the coating material includes a heat-curable resin having a light-transmissivity
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A method for molding a display module includes forming a cavity using a die plate of a first die and a plurality of side surface dies; filling the cavity with a coating material; fixing the display module to a second die using a coupling body disposed on a second surface of the display module, opposite of a first surface of the display module disposed with a plurality of LEDs; soaking the display module in the coating material filled in the cavity; curing the coating material; and separating the cured coating material of the display module from the die plate.