Power Adapter Case Welding Strength Enhancement
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Solution Overview
Problem
Conventional power adapter case housings face challenges in enhancing the strength of the combination between two half cases due to the limited welding surface area, making them prone to separation under external forces.
Innovation Solution
The electrical apparatus employs a resin case with a box-shape design, where the two half cases are not only ultrasonically welded but also feature engaging and engaged portions that restrict relative movement, enhancing the combination strength by providing additional structural support through interlocking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If only welding is used to combine half cases, then the manufacturing process is simple, but the combination strength is insufficient due to limited welding surface area
Solution Approach 1:
The case combination mechanism is segmented into multiple independent components: welding portions for thermal bonding and engaging portions for mechanical interlocking. This segmentation allows each portion to perform its specific function optimally, with the engaging portion providing additional strength through geometric interlocking rather than relying solely on welding surface area
Solution Approach 2:
The patent employs a composite connection approach combining thermal welding (molecular-level bonding) with mechanical engagement (geometric interlocking). This composite method integrates two different bonding mechanisms to achieve superior combination strength that neither method could provide alone, overcoming the limitation of limited welding surface area
2Strength
If welding surface area is increased to improve strength, then combination strength improves, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The engaging portions are pre-formed during the injection molding process of the half cases, creating the mechanical interlocking geometry before assembly. This preliminary formation eliminates the need for additional machining or forming operations to create engagement features, maintaining manufacturing simplicity while enabling enhanced strength
Solution Approach 2:
The engaging portions are designed to automatically align and interlock when the half cases are brought together during assembly. The geometric features self-align without requiring precise external positioning or complex fixtures, making the manufacturing process as simple as bringing the two molded halves together
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 approach significantly improves the strength of the case combination by ensuring that the two half cases are securely locked together, reducing the likelihood of separation and enhancing durability against external forces.
Implementation Method 1
a welding step of melting the melting protrusion formed on the end surface of the first case half and thereby welding the end surface of the first case half and the end surface of the second case half to each other
Implementation Method 2
end surfaces facing each other are formed at an edge of the first case half and an edge of the second case half. The end surface of the first case half has a melting protrusion formed thereon
Data Source
AI summary
An electrical apparatus includes a first half case and a second half case. An end surface at an edge of the first half case and an end surface of the second half case are welded to each other. The first half case has an engaged portion inside thereof. The second half case has, inside thereof, an engaging portion which engages with the engaged portion so as to restrain relative movement of the first half case and the second half case in a direction in which the first half case and the second half case are separated. With this structure, strength of combination of the two half cases can be improved.