Viewing Screen Insert Holding via Single Suction Nozzle
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Solution Overview
Problem
Existing methods for manufacturing viewing screens with injection-overmolded inserts face challenges in maintaining optical quality due to mechanical tension caused by holding systems that are difficult to set up and can introduce stress during the injection process.
Innovation Solution
A method involving an injection mold with a single suction nozzle positioned at the nose cutout portion, using a low-porosity metal insert to hold the insert in place, reducing mechanical tension and ensuring accurate conformation to the mold cavity without introducing stress, thereby improving optical quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple suction nozzles are used to hold the insert around the periphery, then the insert is securely held in place, but mechanical tension is introduced into the insert affecting optical quality
Solution Approach 1:
The patent extracts the holding function from multiple peripheral suction nozzles and concentrates it into a single suction nozzle located at the nose cutout portion. This single nozzle holds the insert through the nose cutout area during injection molding, eliminating the need for multiple nozzles and preventing mechanical tension from being introduced into the insert, thus preserving optical quality while maintaining reliable holding.
Solution Approach 2:
The nose cutout portion acts as an intermediary zone for holding the insert. By positioning the suction nozzle at this specific location rather than at the periphery, the holding action is mediated through an area that does not compromise the optical quality of the viewing screen, resolving the contradiction between secure holding and optical precision.
2Area of stationary object
If the insert size is reduced to save material, then surface area is reduced, but holding stability may be compromised
Solution Approach 1:
The patent applies local quality by concentrating the holding function at a specific local zone (the nose cutout portion) rather than distributing it across the entire periphery. This allows the insert to be held stably through a localized area, enabling reduction of overall insert surface area while maintaining sufficient holding stability through the strategically positioned single suction nozzle.
3Reliability
If a mechanical holding system is used to secure the insert, then the insert is held in place, but the system becomes difficult to set up and introduces stress
Solution Approach 1:
The patent extracts the essential holding function from a complex mechanical holding system with multiple components and reduces it to a single suction nozzle. This simplified system maintains reliable holding stability while being easier to set up and less prone to introducing stress into the insert during the molding process.
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 method effectively reduces mechanical tension and maintains optical quality by concentrating tension in the zone that will be cut out, allowing for precise conformation and minimizing defects such as lines or deformations, while also saving surface area by using a smaller insert size.
Implementation Method 1
holding the insert using at least one suction nozzle incorporated into the injection mold
Implementation Method 2
the suction nozzle comprises a low-porosity metal insert preventing the injected thermoplastics material from being sucked up
Data Source
AI summary
The invention relates to a method for creating a viewing screen (3) having an injection overmolded insert (9). Said method includes the steps of: placing an insert (9), to be overmolded, into an injection mold (1); holding the insert (9) by at least one suction nozzle (21) built into the injection mold (1); injecting, into the mold (1), a thermoplastic material for forming a mechanical substrate layer for the viewing screen; and removing the thus-formed viewing screen (3) from the mold.