3D Conductive Wire Embedding to Prevent Insert-Molding Displacement
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Solution Overview
Problem
The conventional method of manufacturing three-dimensional structures can result in undesirable displacement of the conductive wire due to the pressure exerted by molten plastic during the insert-molding process.
Innovation Solution
A method involving the preparation of a first structure with a fixing face, fixing a plastic layer to this face, and using an ultrasonic head to apply ultrasonic waves and embed a conductive wire partly into the plastic layer, thereby reducing the likelihood of displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the rear substrate is insert-molded using molten plastic to cover the heater, then the substrate can be securely formed and joined, but the molten plastic presses the heater causing undesirable displacement
Solution Approach 1:
The heater is fixed to the front substrate before the insert-molding process begins. This preliminary fixation ensures the heater is securely positioned before molten plastic is injected, preventing displacement during the molding process while maintaining bonding strength.
Solution Approach 2:
The patent applies a counteracting measure by pre-fixing the heater in place before the harmful action (molten plastic pressure) occurs. This preliminary anti-action counterbalances the pressing force during insert-molding, preventing the heater from displacing while still allowing the molding process to create strong bonds.
2Manufacturing precision
If the heater is fixed before insert-molding, then displacement is reduced, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent combines multiple operations into an integrated process where the heater fixation and insert-molding are performed in a coordinated sequence within the same manufacturing system. This merging reduces the need for separate handling steps and minimizes overall process complexity despite adding a fixation step.
Solution Approach 2:
By performing the heater fixation as a preliminary action that integrates with the subsequent insert-molding process, the patent avoids the need for separate post-processing steps to correct displacement. This preliminary positioning simplifies the overall manufacturing flow compared to methods requiring multiple adjustment stages.
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 effectively reduces the possibility of undesirable displacement of the conductive wire, ensuring a stable integration within the three-dimensional structure.
Implementation Method 1
operating an ultrasonic head to apply ultrasonic waves to the conductive wire and to press the conductive wire against the plastic layer
Implementation Method 2
injecting molten plastic onto the fixing face of the first structure in the cavity of the first molding die, and solidifying the molten plastic to mold the plastic layer
Data Source
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AI summary
The invention reduces a possibility of undesirable displacement of a conductive wire of a three-dimensional structure. A method for manufacturing a three-dimensional structure S1 includes: preparing a first structure 100 including a fixing face 101; fixing a plastic layer 200 to the fixing face 101 of the first structure 100; preparing a conductive wire 300; and operating an ultrasonic head U to apply ultrasonic waves to the conductive wire 300 and to press the conductive wire 300 against the plastic layer 200, and thereby partly embedding the conductive wire 300 into the plastic layer 200.