Molded Article Shade Structure Suppresses Light Leakage

The patent applies preliminary action by forming a shade structure (rib) in advance during the injection molding process, before the actual molding of the decorative sheet. This pre-formed rib creates a physical barrier that compensates for potential misalignment, ensuring that even if the decorative sheet shifts during molding, light leakage is prevented. The shade structure is created as part of the mold cavity preparation, allowing the molding process to proceed efficiently without requiring post-processing alignment adjustments.

The patent introduces an intermediary element - the shade structure (rib) - that is disposed between the light source and the potential leakage path at the edge of the decorative sheet. This rib acts as a mediator that blocks excess light from escaping through gaps or misalignments at the edges, while allowing the decorative sheet to maintain its maximum display area. The intermediary structure resolves the conflict by providing light control without restricting the spatial arrangement of the decorative components.

The patent merges the shade structure with the existing molded article body by forming the rib as an integrated feature during the injection molding process. Rather than adding a separate, discrete shade component that would increase assembly steps and device complexity, the shade structure is combined with the housing or frame structure in a single molding operation. This integration maintains manufacturing efficiency and simplifies the overall device structure while still providing effective light leakage suppression.