Tilted Mold for Uniform Display Panel Windows
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Solution Overview
Problem
Existing methods for manufacturing display panel windows struggle to produce windows with curved surfaces of equal width and are inefficient in terms of manufacturing time, as they often result in uneven widths and require lengthy heating and cooling processes.
Innovation Solution
An apparatus featuring a mold tilted at a predetermined angle, with sequential heating and cooling modules, and a transfer part that moves the mold through heating, forming, and cooling stages, allowing for the formation of windows with both sides having the same width by controlling temperature gradients and using multiple heating and cooling parts to reduce processing times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional heating and cooling methods are used, then the window can be formed, but the manufacturing time is lengthy
Solution Approach 1:
The heating and cooling processes are divided into multiple independent modules (first heating module, second heating module, first cooling module, second cooling module) that can operate simultaneously on different portions of the mold, enabling parallel processing and reducing total manufacturing time
Solution Approach 2:
The mold is tilted at a predetermined angle relative to the horizontal plane, creating a dimensional change that allows gravitational force to assist in uniform heat and cold distribution across the plate, accelerating the thermal processing while maintaining formation precision
2Manufacturing precision
If the mold is positioned horizontally, then the equipment is simple, but the curved surfaces have unequal widths
Solution Approach 1:
The mold is deliberately positioned at an asymmetric tilt angle rather than horizontally, creating an intentional asymmetric configuration that compensates for thermal distribution variations and ensures uniform curved surface widths on both sides of the formed window
Solution Approach 2:
By tilting the mold at a specific angle, the gravitational field is utilized to create equipotential thermal distribution across the plate surface during heating and cooling, ensuring uniform temperature gradients that produce consistent curved surface dimensions
3Productivity
If single heating and cooling modules are used, then the equipment is simple, but the processing time is long
Solution Approach 1:
The heating and cooling systems are segmented into multiple independent modules positioned at different locations on the mold, allowing simultaneous thermal processing of different regions and significantly reducing the time required to achieve uniform temperature distribution and phase change
Solution Approach 2:
Multiple heating and cooling modules operate continuously and simultaneously throughout the formation process, maintaining constant thermal action on the plate from multiple zones, which eliminates idle time and accelerates the overall manufacturing cycle
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 apparatus enables the efficient production of windows with both sides having the same width and reduces manufacturing time by optimizing temperature control and processing stages, simplifying equipment and improving production efficiency.
Implementation Method 1
the first and second heating modules are configured to apply heat to the top and bottom portions of the mold so as to heat the plate
Implementation Method 2
The first heating module may include a first heater positioned above the mold for heating the mold
Implementation Method 3
the forming part is configured to jet a high-temperature gas onto the heated plate, so as to form the heated plate into the predetermined shape
Implementation Method 4
the first and second cooling modules are configured to cool the top and bottom portions of the mold, so as to cool the heated plate and thereby form the window having the predetermined shape
Data Source
AI summary
An apparatus for forming a window of a display panel includes a mold configured to hold a plate in a concave portion, wherein the concave portion has a predetermined shape, and a transfer part configured to sequentially transfer the mold to a heating part, a forming part, and a cooling part. The heating part includes first and second heating modules respectively positioned on top and bottom portions of the mold and configured to apply heat to the top and bottom portions of the mold. The forming part is positioned above the mold and configured to jet a high-temperature gas onto the heated plate. The cooling part includes first and second cooling modules respectively positioned on the top and bottom portions of the mold and configured to cool the top and bottom portions of the heated plate. The mold is tilted at a predetermined angle relative to a horizontal plane.