Surface Panel Resin Layer Sensor Film Molding
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Solution Overview
Problem
Existing surface panels for mobile devices have limited transmissive and sensing regions, leading to complex manufacturing processes and restricted display and input capabilities due to the placement of touch sensors and decorative layers.
Innovation Solution
A surface panel design featuring a transmissive resin layer and a sensor film with a transmissive electrode layer and wiring layer, where the sensor film is stacked on the resin layer and the electrode layer is positioned on the back surface, allowing for a larger sensing region and simplified manufacturing through a two-step molding process with molds, ensuring accurate positioning and minimizing creasing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a frame-shaped decorative portion made of synthetic resin is attached to the periphery of the glass substrate, then the transmission quality of display light is favorable, but the area of the light transmissive region and sensing region becomes very small
Solution Approach 1:
The patent moves the decorative function from the front surface (2D plane) to the side surface (3D extension) of the panel. The side surface decorative portion extends vertically along the periphery, allowing the front surface to be fully utilized for light transmission and sensing while maintaining aesthetic appearance through the side decorative elements.
Solution Approach 2:
The decorative portion is segmented into two distinct parts: a front surface decorative portion and a side surface decorative portion. This segmentation allows each part to serve its specific function - the front surface portion maintains minimal obstruction to light, while the side surface portion provides the primary decorative function, thereby increasing the overall light transmissive area.
2Ease of manufacture
If injection molding is performed by positioning an assembly of the glass substrate and touch sensor inside the mold, then the decorative portion is fixedly attached, but the manufacturing process becomes complex
Solution Approach 1:
The patent combines the glass substrate, touch sensor assembly, and decorative portions into a single integrated molding process. The mold cavity is designed to accommodate all components simultaneously, and the resin is injected to bond them together in one operation, eliminating the need for separate positioning and attachment steps.
Solution Approach 2:
The glass substrate and touch sensor are pre-assembled into a configured unit before being placed in the mold. This preliminary assembly ensures proper positioning and alignment, simplifying the subsequent injection molding process and reducing the complexity of in-mold positioning operations.
3Device complexity
If the touch sensor is disposed on a region different from the light transmissive portion, then the structure is simplified, but the user cannot perform input operation by directly touching the display portion
Solution Approach 1:
The patent extends the touch sensor functionality to the side surface of the panel, creating a three-dimensional sensing area. While the front surface maintains full light transmission for display, the touch sensing capability is distributed to the side surface decorative portion, allowing users to perform input operations by touching the side surface rather than requiring separate sensor regions on the front surface.
4Volume of moving object
If the light transmissive portion is disposed in a limited space on the upper side of the outer casing, then the structure is compact, but a large screen cannot be displayed
Solution Approach 1:
The patent utilizes the vertical dimension by extending the light transmissive portion and display area to the side surface of the panel. This three-dimensional configuration allows the display to wrap around or extend along the periphery, significantly increasing the effective display area without proportionally increasing the footprint area, thereby achieving large screen display in a compact form factor.
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 design enables a larger transmissive region for display and sensing, improving user interaction and manufacturing efficiency by allowing a wider display area and accurate sensor placement without creasing issues.
Implementation Method 1
a melted resin is injected into the mold
Data Source
AI summary
A method manufactures a front panel including a front panel body formed of a single transmissive resin layer and a sensor film attached thereto, using a first mold having a molding recessed portion and a second mold having a molding projecting portion. The first and second molds are joined together such that a cavity is formed between the molding recessed portion and the molding projecting portion, by placing the sensor film between the first mold and the second mold, on the molding projecting portion in the cavity. A melted resin is injected into the cavity to form the single transmissive resin layer having a front surface formed in a shape of the molding recessed portion, and a back surface formed along the sensor film in a shape of the molding projecting portion, thereby laminating the sensor film to the back surface of the transmissive resin layer.