Optical Module Injection Molding for Display Adhesion
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Solution Overview
Problem
Conventional optical modules in display devices face issues with contamination particles like dust during the adhesive process, leading to dark spots and potential detachment of the adhesive interface between the light guide plate and the cover lens, reducing the reliability of the display device.
Innovation Solution
An optical module is manufactured using an injection molding process, where a decoration layer is formed on the light guide plate, specifically on the second light-extracting surface, to address contamination issues and improve adhesion, utilizing materials like polycarbonate, polymethyl methacrylate, or their combinations, and including a flange that forms a housing space to enhance the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive process is used to join light guide plate and cover lens, then assembly is achieved, but contamination particles attach to surfaces causing dark spots and potential detachment
Solution Approach 1:
The patent extracts and removes the adhesive from the assembly process entirely. Instead of using adhesive to join the light guide plate and cover lens, the invention uses a mechanical snap-fit structure where the cover lens is directly attached to the light guide plate through integrated structural features, eliminating the adhesive layer and thus the contamination risk associated with it.
Solution Approach 2:
The patent merges the covering function and the fastening function into a single integrated structure. The cover lens is designed with integrated attachment features that combine the protective covering role with the mechanical fastening role, eliminating the need for separate adhesive application and creating a more reliable contamination-free joint.
2Manufacturing precision
If contamination particles are present on adhesive or surfaces, then dark spots appear on display surface, but manufacturing precision is compromised
Solution Approach 1:
The invention extracts and eliminates the adhesive layer from the assembly, which is the primary source of contamination particles. By removing the adhesive and its application process, the patent inherently prevents dust and particles from attaching to adhesive surfaces, thus maintaining surface cleanliness without requiring additional cleaning steps.
Solution Approach 2:
The patent incorporates preliminary cleaning and protection measures into the mold design itself. The mold includes features that prevent particle generation and attachment during the injection molding process, and the assembly structure is designed to minimize exposure to contamination risks before final assembly, ensuring surface cleanliness is maintained throughout manufacturing.
Data Source
AI summary
The present disclosure provides an optical module. The optical module includes a light guide plate and a decorative layer. The light guide plate includes at least one light-entering inclined surface, a first light-emitting inclined surface adjacent to the light-entering inclined surface and a second light-emitting inclined surface opposite to the first light-emitting inclined surface. The decorative layer is covered the second light-emitting inclined surface of the light guide plate by an injection molding process. A display device containing the optical module and a method for manufacturing the optical module are also provided herein.