Light Emitting Metal Knob Anodizing Defect Reduction
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Solution Overview
Problem
Conventional methods for manufacturing light emitting metal knobs result in high defect rates due to separation of letters from the light blocking metal plate during the display window formation process, especially when anodizing is applied, which prevents the realization of surface colors for island parts.
Innovation Solution
A novel manufacturing process involving a display groove forming step, first resin layer coupling, upper surface plane-cutting, anodizing, and second resin layer coupling, along with surface treatment and sandblasting, to ensure letters remain coupled to the resin layer and allow for anodizing processing, thereby reducing defect rates and enabling surface color realization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If letters are formed by carving the upper surface of the light blocking metal plate, then the display window can be formed, but the letters become island parts that separate from the metal plate during anodizing
Solution Approach 1:
The patent applies preliminary action by forming recesses in the metal plate before creating the display window, and by pre-attaching the resin layer to these recesses. This preliminary structural preparation ensures that letters remain connected to the metal plate through the resin layer during subsequent anodizing processes, preventing separation while maintaining display window functionality
2Productivity
If the upper surface is plane-cut to form the display window, then light emission is enabled, but letters separate from the resin layer increasing defect rate
Solution Approach 1:
The patent implements the nested doll principle by creating a multi-layer nested structure where letters are embedded within the resin layer, which itself is attached to the metal plate. The recesses in the metal plate are nested with the resin layer, and letters are nested within the resin layer structure. This nested configuration ensures that when the upper surface is plane-cut for light emission, the letters remain securely bonded to the resin layer through the nested structural relationship
3Shape
If anodizing is applied to the metal plate, then surface color is achieved, but island parts (letters) cannot be colored
Solution Approach 1:
The patent uses the resin layer as an intermediary element that bridges the metal plate and the letters. The resin layer is selectively attached to recesses in the metal plate, creating a structure where the metal plate can undergo anodizing for surface coloring while the letters, attached through the resin intermediary, remain connected and can also receive color treatment. This intermediary structure enables versatile color application to all 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
The process significantly reduces defect rates by maintaining the coupling of letters and side surfaces with the resin layers, allowing for effective anodizing and surface color realization, enhancing the manufacturing efficiency and aesthetic appeal of light emitting metal knobs.
Implementation Method 1
anodizing treatment is required to realize a surface color of the light blocking metal plate 10
Implementation Method 2
applying an anodic oxidation treatment to the surface of the light blocking metal plate and then absorbing an organic dye to realize color
Implementation Method 3
The resin layer 20 is coupled to the lower part of the light blocking metal plate 10 by bonding or by insert injection molding
Implementation Method 4
The resin layer 20 is coupled to the lower part of the light blocking metal plate 10 by bonding or by insert injection molding
Data Source
Figure 1
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AI summary
The present invention relates to a method for manufacturing a light emitting knob based on a novel process that is capable of preventing a letter that is separated from a light blocking metal plate at a display window forming step from being separated from a resin layer irrespective of the shape or the type of the letter, which constitutes a light emitting display window, thereby considerably reducing a defect rate, and in particular, to provide a method for manufacturing a light emitting metal knob that introduces a new process so as to realize a surface color through anodizing processing from letters separated from a light blocking metal plate.