Light-emitting display sheet, light-emitting display member, light-emitting display device, and method for producing light-emitting display member
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Solution Overview
Problem
Light-emitting display sheets with printed patterns face deformation issues during in-mold decorative injection molding due to contact with molten resin, leading to obscure outlines and reduced contrast in light emission displays.
Innovation Solution
A light-emitting display sheet design featuring a first fiber base material layer and a surface material layer with a print portion sandwiched between them, preventing direct contact with molten resin and maintaining print outline clarity, while also enhancing bonding strength and reducing color variation through light diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a print portion is formed on a fiber base material by printing with ink, then it is possible to easily produce a light-emitting display sheet, but the print portion may come into contact with molten resin during in-mold decorative injection molding, causing the print outline to deform
Solution Approach 1:
The patent embeds the print portion within a sandwich structure consisting of the fiber base material layer and the surface material layer. The print portion is positioned between these two layers, effectively nesting it within the composite structure. This nesting approach protects the print portion from direct contact with molten resin during injection molding while maintaining the ease of production through simple lamination processes.
Solution Approach 2:
The surface material layer acts as an intermediary protective layer between the print portion and the molten resin during injection molding. This intermediary structure prevents direct contact between the heat-sensitive print portion and the hot molten resin, thereby preventing deformation while allowing the injection molding process to proceed normally.
2Productivity
If the print portion is exposed during injection molding, then the molding process can proceed easily, but the outline of the print portion becomes obscure and contrast is reduced
Solution Approach 1:
The print portion is nested within the sandwich structure of the fiber base material layer and surface material layer. This nesting allows the injection molding process to proceed efficiently without exposing the print portion to molten resin, thereby maintaining both high productivity and high display quality with clear outlines and contrast.
Solution Approach 2:
The patent converts the potential harm of the injection molding process (heat and pressure affecting the print) into a benefit by using the surface material layer as a protective barrier. The same injection molding process that could have damaged the print now serves to integrate the surface material layer, which in turn protects the print and enhances the overall display quality.
3Manufacturing precision
If a surface material layer is added to protect the print portion, then print outline clarity is maintained, but the structure becomes more complex
Solution Approach 1:
The print portion is nested within the sandwich structure formed by the fiber base material layer and surface material layer. This nesting approach maintains print outline clarity while integrating the protective layer as an inherent part of the display sheet structure, rather than adding it as a separate complex component.
Solution Approach 2:
The protective surface material layer is merged with the fiber base material layer to form an integrated sandwich structure. This merging combines the protective function with the structural function in a single unified component, avoiding the need for separate protective elements and reducing overall structural 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
The solution effectively prevents print portion deformation during injection molding, maintains clear outlines, increases contrast between emitting and non-emitting portions, and improves bonding strength, resulting in a stable and high-quality light-emitting display.
Implementation Method 1
the first fiber base material layer diffuses the transmitted light, and thus reduces color variation of light emission
Data Source
AI summary
A light-emitting display sheet includes a first fiber base material layer and a surface material layer stacked on the first fiber base material layer. The first fiber base material layer includes a first surface facing the surface material layer, and a second surface opposite to the first surface. The light-emitting display sheet further includes a print portion having an outline and sandwiched between the first surface of the first fiber base material layer and the surface material layer.