Plastic Cover with Transparent Section and Display
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Solution Overview
Problem
Existing methods for producing plastic covers with transparent components, such as those used in vehicle displays, face challenges in achieving high manufacturing quality, process reliability, and mechanical stability, particularly due to the spatial setback of the transparent part, which hinders readability and is prone to environmental influences.
Innovation Solution
A method involving multi-component injection molding where a transparent film with an imprint is used, allowing the first transparent component to be injection-molded flush with the second component, concealing constructional and production traces, and providing enhanced mechanical stability and environmental resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the transparent part is spatially set back in the injection molding tool, then the manufacturing process is simplified, but the readability of the display is hindered and edges or shoulders arise
Solution Approach 1:
The patent transitions from a single-plane injection molding approach to a multi-layer dimensional structure. The transparent component is injection-molded in a first plane, then a print layer is applied, and finally a second component is injection-molded in a second plane that is offset relative to the first plane. This dimensional layering allows the transparent display area to remain flush and readable while accommodating manufacturing requirements in subsequent layers.
2Manufacturing precision
If the transparent component is made flush with the cover surface, then display readability is improved, but constructional means and production traces become visible
Solution Approach 1:
The patent applies a print layer selectively to specific regions of the transparent component. The print layer is applied to areas where constructional means and production traces are visible, while leaving the display area untouched and transparent. This local application of the print layer conceals defects only where necessary, maintaining display readability while hiding unwanted features.
Solution Approach 2:
The print layer serves as an intermediary element between the transparent component and the external environment. It acts as a visual mask that conceals constructional means and production traces on the transparent component without interfering with the display functionality. The print layer mediates between the need for a flush, readable display surface and the need to hide manufacturing artifacts.
3Manufacturing precision
If multiple separate components are used to achieve flush surfaces, then visual quality is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent combines multiple functional elements into a single integrated component structure. The transparent component, print layer, and second component are injection-molded as an integrated assembly where the transparent component and second component form a unified structure with a flush surface. This merging reduces the number of separate parts and assembly steps while achieving the desired visual quality.
Solution Approach 2:
The print layer is applied to the transparent component during the injection molding process itself, before final assembly is completed. This preliminary application of the print layer ensures that constructional means and production traces are concealed before the component undergoes subsequent manufacturing steps or assembly operations.
4Ease of manufacture
If the cover surface has protruding points or edges, then manufacturing is easier, but cleanability and aesthetic quality deteriorate
Solution Approach 1:
The patent uses multi-plane injection molding to create a flush surface topology. The second component is injection-molded in a second plane that is offset from the first plane, allowing the outer surface to be substantially flush while internal structural features remain in different planes. This dimensional arrangement eliminates protruding edges and corners that would trap dirt, improving cleanability while maintaining manufacturing feasibility.
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
This approach results in improved manufacturing quality, increased mechanical stability, easier cleanability, and enhanced durability against environmental factors, with reduced reject rates and increased production efficiency, enabling clear display visibility and robustness against dust, moisture, and contaminants.
Implementation Method 1
injection molding a first, transparent component onto the side of the film to which the imprint is applied
Data Source
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AI summary
The invention relates to a method for producing a plastic cover 100 with a transparent component 210 using a multi-component injection molding process. To reliably produce an improved plastic cover 100 with a transparent component 210 in large quantities and with high manufacturing quality, it is proposed to apply a print 220 to at least a partial area of a transparent film 230; to injection mold a first transparent component 240 onto the side of the film 230 on which the print 230 is applied, wherein the composite of the film 230 and the transparent component 240 forms a first component 200 of the plastic cover 100; and to injection mold a second component onto the first component 200 of the plastic cover, wherein the print 220 on the film 230 conceals any visually recognizable design features 250 and/or production traces that would disturb the appearance.