Transparent Panel Wall Member Formation Using Flat Plate Pressing
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Solution Overview
Problem
The challenge lies in manufacturing a transparent panel with a wall member that has uniform height and smoothness for bonding to an optical member, which is difficult to achieve with high precision and at a low cost, especially for curved panels, due to the complexity of maintaining high positional and dimensional accuracy.
Innovation Solution
A method involving the formation of a mask layer on the transparent panel, application of a curable resin material, pressing with a flat plate to define the wall member's height and smoothness, curing, and then removing the mask layer to create a wall member along the panel's periphery, ensuring precise bonding with the optical member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a wall member is formed on the periphery of a curved transparent panel using a dispenser, then resin protrusion is prevented, but the visibility is impaired and high positional accuracy and dimensional accuracy are required
Solution Approach 1:
A flat plate is introduced as an intermediary tool to press the curable resin material during curing. This flat plate serves as a mediator that transfers pressure uniformly across the resin material, enabling the formation of wall members with high positional and dimensional accuracy without requiring complex direct formation processes on the curved panel surface.
Solution Approach 2:
The conventional dispenser-based mechanical formation method is replaced with a pressing mechanism using a flat plate. This substitution allows for more precise control over the wall member formation by applying uniform pressure during curing, thereby achieving high positional and dimensional accuracy while maintaining ease of manufacture.
2Object-affected harmful factors
If the height and smoothness of the wall member upper surface are increased, then resin protrusion is prevented, but manufacturing difficulty increases and mass production becomes difficult
Solution Approach 1:
Complex machining processes are replaced with a simple pressing operation using a flat plate. The flat plate applies uniform pressure to the curable resin material during curing, automatically forming wall members with uniform height and smoothness without requiring difficult machining operations, thereby enabling easy manufacture and mass production.
Solution Approach 2:
The formation process parameters are changed from mechanical machining to pressure application during curing. By controlling the pressing force and duration of the flat plate during the curing process, uniform wall member height and smoothness are achieved without complex machining, simplifying the manufacturing process for mass production.
3Manufacturing precision
If high positional accuracy and dimensional accuracy are required for the wall member, then resin protrusion is prevented, but manufacturing time increases and cost increases
Solution Approach 1:
Time-consuming precision machining processes are replaced with a quick pressing operation using a flat plate during curing. This mechanical substitution achieves high positional and dimensional accuracy in a single step without requiring multiple machining operations, thereby reducing manufacturing time and enabling efficient mass production.
Solution Approach 2:
The wall member formation is performed as a preliminary action during the curing process itself, rather than as a separate post-processing step. By applying pressure with the flat plate during curing, the wall members are formed with high accuracy while the resin is still pliable, eliminating the need for subsequent machining operations and improving productivity.
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 method enables the production of transparent panels with wall members that provide precise bonding to optical members, preventing resin protrusion and maintaining visibility, while allowing for efficient mass production.
Implementation Method 1
a curable resin composition is applied to a transparent panel to form a curable resin layer, an optical member such as a liquid crystal display panel or an organic EL panel is laminated via the curable resin layer, and then the curable resin layer is cured
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5
AI summary
Provided are a method for manufacturing a transparent panel formed with a wall member having high accuracy, a uniform height from a surface to adhere to an optical member, and smoothness. This method comprises: a step of preparing a transparent panel 4 for an optical device 1 to be bonded to an optical member 2; a step of forming a mask layer 15 so as to form an opening 6 along a periphery of an outer shape of the transparent panel 4; a step of applying a curable resin material 7 to the opening 6 and the mask layer 15; a step of pressing a flat plate 10 against the curable resin material 7; a step of curing the resin composition 7 to form a cured resin layer 11; a step of detaching the flat plate 10; and a step of removing the mask layer 15 together with the cured resin layer 11 formed on the mask layer 15 to obtain a wall member 12 along the periphery of the outer shape of the transparent panel 4.