In-Vehicle Display Device Protective Layer Injection Molding
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Solution Overview
Problem
Display devices in vehicles are prone to damage during the injection process of plastic frames due to exposure to high temperatures, limiting the efficient arrangement of components within the limited vehicle space.
Innovation Solution
A display device structure featuring a semiconductor light emitting unit with a transparent substrate, a protective layer, and a back cover, where the protective layer covers the lower surface of the display unit and the fixing portion, preventing damage during injection molding by buffering thermal expansion and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the display device is injected together with the plastic frame, then the inner space utilization is improved and assembly process is simplified, but the display device is exposed to high temperature and may be damaged
Solution Approach 1:
A protective layer is introduced as an intermediary component between the display device and the plastic frame during injection molding. This protective layer absorbs the thermal and mechanical stress of the injection process, allowing the display device to be integrated with the frame while preventing damage. The protective layer serves as a buffer that mediates the harmful effects of high-temperature injection on the sensitive display components.
Solution Approach 2:
The protective layer is positioned beforehand to cover and protect the display device before the injection molding process begins. This pre-positioned protective structure cushions the display device against the high temperature and pressure of the incoming plastic material, enabling safe integration of heat-sensitive components with the plastic frame in a single manufacturing step.
2Volume of moving object
If the display device is placed inside the plastic frame, then space utilization is improved, but the display device is exposed to high temperature during injection
Solution Approach 1:
The protective layer acts as a thermal barrier and intermediary structure that allows the display device to be positioned inside the plastic frame while shielding it from thermal exposure during injection molding. This enables efficient space utilization through integration while the protective layer mediates the harmful thermal effects.
Solution Approach 2:
The protective layer is implemented as a thin film or flexible protective structure that can be positioned between the display device and the plastic frame. This thin protective barrier provides thermal protection during injection while maintaining the compact integrated structure, allowing space-efficient design without exposing the display to harmful temperatures.
3Reliability
If separate assembly process is used for display device and plastic frame, then display device is protected from injection damage, but manufacturing complexity increases
Solution Approach 1:
The protective layer is designed to be integrated with either the display device or the plastic frame, allowing the protective function to be combined with existing components. This merging approach enables single-step injection molding that protects the display device while simplifying the overall manufacturing process, avoiding the need for separate assembly operations.
Solution Approach 2:
The protective layer serves multiple functions: it protects the display device from thermal damage during injection, provides structural support, and enables integration with the plastic frame. This multi-functionality allows a single component to address both protection needs and manufacturing simplification, eliminating the need for separate protective measures and assembly steps.
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
Enables the display unit and back cover to be injected together without damage, optimizing space utilization and maintaining the display device's slimness while preventing breakage and thermal stress.
Implementation Method 1
preventing damage during injection molding by buffering thermal expansion and pressure
Implementation Method 2
a display unit having a plurality of semiconductor light emitting devices and outputting light to an upper surface thereof
Data Source
AI summary
The present invention provides a display device, including a display unit having a plurality of semiconductor light emitting devices and outputting light to an upper surface thereof, a transparent substrate located on an upper side of the display unit and having a fixing portion protruding from one surface thereof to surround a side surface of the display unit, a protective layer formed to cover a lower surface of the display unit, and a back cover coupled to a part of the transparent substrate and the protective layer in an injection manner, wherein the protective layer is located to cover the fixing portion.