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Producing Built-in Electroluminescent Lamps by Introducing In-mould Inkjet Printing in Injection Moulding: Theory and Approach

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feasl ahmeri

on 3 September 2010

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Transcript of Producing Built-in Electroluminescent Lamps by Introducing In-mould Inkjet Printing in Injection Moulding: Theory and Approach

Producing Built-in Electroluminescent Lamps by Introducing In-mould Inkjet Printing in Injection Moulding: Theory and Approach Presented By
F A I S A L A L A H M A R I
OUTLINE Current State of Commercial Electroluminescent (EL) Devices


EL Advantages


Aim of the Current Project


Objectives of the Current Project
Less power
Thin cross sections
Negligible heat emissions ... is to find a new process that can produce built-in EL panel in massive quantities Understanding several electroluminescent devices and their structures.
Understanding current state of the art in the manufacturing of electroluminescent devices.
Evaluation of the current manufacturing processes.
Suggests innovative solutions.
Evaluate the solutions.
Select and evaluate the best solution. Materials of the Structure Introduction

Electroluminescence in Commercial Use: Theory and Manufacturing Methods

Basic Rationale & Justification

Alternative Designs for the New Concept

The Conclusion 78% of plastic processing is done by injection molding, extrusion and blow molding Injection molding
Large batch size
Forming complex geometries
Automated process
Producing a product in one single setup
(Anatoli Dashchenko 2003) stated that “It is well known that, even in highly automated manufacturing, almost all products spend 80 to 90% of their “time of becoming a product” in an idle state”
Intermediate storage, quality inspection, cleaning, transportation and clamping
Advantages of the new process

High production rate.


Negligible time between printing and injection molding processes.


The process will combine the EL panel with the EL device cover.


No assembly required to assemble the EL panel with the EL device cover.


Lower requirements of labor.


Improved quality.


Reduce inventories Main Printer Frame Design The main contributions of this research are as follows:
Identified the problems and disadvantages of using the current manufacturing methods of producing the EL devices.
Eliminated these disadvantages by illustrating a new manufacturing process.
Provided six designs that can be studied and used in future manufacturing processes.
SUMMARY AND CONCLUSIONS
The new process integrates and combined injection moulding process with inkjet printing process.
The bond between the EL layers and plastic part can be strengthened by coating adhesive substance.
When utilizing the new process, no assembly line is required to assemble the EL panel with device covering.
Design# 6 offers several machines and tools can be used during printing process.
The new process can adapt any further development in EL structures or materials as design# 6 has high degree of flexibility.
The materials of EL layers should cure quickly to gain the benefit of having the new process with higher production rate.
Several types of EL panels can produced in the same batch using the same printer since it has resolution of more than 1400dpi.
Complicated printed profiles could be done by utilizing the robotic arm in design# 3.
The new process benefits the field of manufacturing EL devices by having low operational cost, low labour and improved quality manufacturing process. AlternativeDesigns:

Design#1

Design#2

Design#3

Design#4

Design#5

Design#6 Best Design Selection Criteria
Cost
Easy to design
Easy to manufacture
Easy to assemble
Life
Precision
Flexibility
Easy to maintenance
Rigidity
Satisfy the purpose
Noise
Process speed. Best Design Selection Methods
One is to nominate the best design.
The other is used to check the evaluation.
Best Design for the New Concept
High resolution of 1440 dpi and pixel diameter of 28 micrometers
high flexibility
high speed printing
Less waste
3D print
high production rate
More than one printer or tool
Adhesive layer can be coated on the printed
Considering Other Designs Printing at different angles Less power

Thin cross sections

Negligible heat emmissions ... is to find a new process that can produce built-in EL panels in massive quantities Understanding several electroluminescent devices and their structures.

Understanding current state of the art in the manufacturing of electroluminescent devices.

Evaluation of the current manufacturing processes.

Suggests innovative solutions.

Evaluate the solutions.

Select and evaluate the best solution.
Materials for Structures FURTHER WORK
To develop this research by building prototype for this process and test it in the field.
To perform feasibility study of in-mould inkjet printing that includes marketing, technical and financial (cost) areas.
To study utilizing design# 6 in other technologies, such as in-mould painting, instead of printing technology.
Studying the in-mould inkjet printing to produce electrical circuits, sensors, conductors… etc.
To study the use of more than printing head or tools at the same time.







Process description Thank You
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