Display Assembly Using Structural Adhesive for Sealed Housings
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Solution Overview
Problem
The use of fasteners in ruggedized housings for electronic displays introduces potential leak points, requires additional parts and manufacturing time, and can cause optical distortion and uneven surfaces, while welding is labor-intensive and not suitable for all materials.
Innovation Solution
Employing structural adhesive to replace fasteners, particularly in display assemblies, which provides flatter surfaces, improved sealing, and enhanced structural integrity, and includes a thermal management substructure with heat exchangers using structural adhesive to manage heat and airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners are used to attach components in ruggedized housings, then structural strength is improved, but potential leak points increase and manufacturing time increases
Solution Approach 1:
The patent replaces the mechanical fastening system (screws, bolts, clips) with a chemical bonding system (structural adhesive). The adhesive forms continuous bonds between components, eliminating the discrete attachment points that create leak paths. This substitution maintains structural strength while improving sealing quality by creating a uniform, gap-free joint between housing components.
Solution Approach 2:
The patent merges the functions of mechanical attachment and sealing into a single adhesive bonding process. Instead of using fasteners for attachment and separate gaskets or seals for waterproofing, the structural adhesive simultaneously provides both structural strength and sealing, reducing the number of parts and potential failure points.
2Strength
If fasteners are used to attach components, then structural strength is improved, but the number of parts increases and manufacturing time increases
Solution Approach 1:
The patent combines multiple functions (attachment, sealing, structural support) into a single adhesive bonding operation. This eliminates the need for separate fastening operations, part insertion, and sealing applications, thereby reducing the total number of manufacturing steps and improving productivity.
Solution Approach 2:
The patent extracts and eliminates unnecessary fasteners and associated hardware from the assembly process. By using structural adhesive alone, the design removes screws, clips, rivets, and related components, simplifying the parts list and reducing assembly complexity and time.
3Strength
If fasteners are used to attach display components, then structural strength is improved, but optical quality deteriorates due to distortion and uneven surfaces
Solution Approach 1:
The patent replaces mechanical fastening with adhesive bonding to attach optical components such as diffusion panels, cover panels, and filters. The adhesive provides uniform surface contact without the protrusions, holes, or uneven surfaces created by fasteners, thereby maintaining optimal optical quality and display performance.
4Strength
If welding is used to join components, then structural strength is improved, but labor intensity increases and material versatility decreases
Solution Approach 1:
The patent replaces welding (a thermal/mechanical process) with adhesive bonding (a chemical process). This substitution eliminates the need for specialized welding equipment, reduces labor intensity, and expands material versatility since adhesives can bond dissimilar materials (metals, plastics, composites) that cannot be easily welded.
Solution Approach 2:
The patent changes the bonding mechanism from high-temperature thermal processing (welding) to ambient or controlled-cure chemical bonding (adhesive). This parameter change reduces energy input, simplifies manufacturing, and enables joining of materials with different thermal properties or melting points.
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 use of structural adhesive reduces the number of parts and manufacturing time, improves optical quality, enhances structural rigidity and thermal conduction, and decreases noise and power consumption, while ensuring consistent tolerancing and compliance with ingress protection standards.
Implementation Method 1
Display assemblies which comprise structural adhesive, and methods of manufacture related to the same
Implementation Method 2
enhances structural rigidity and thermal conduction
Data Source
AI summary
A display assembly is provided which includes a housing for an electronic display and a thermal management substructure. The thermal management substructure is located rearward of the electronic display and includes multiple components, which are secured to one another by a plurality of deposits of structural adhesive. Methods of manufacturing the thermal management substructure are also provided where structural adhesive is deposited between components of the thermal management substructure.