Coaxial Line Support Disk Injection Molding
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Solution Overview
Problem
Conventional coaxial lines with small dimensions are difficult to manufacture precisely and inexpensively due to complex assembly processes, which increase costs and tolerance issues.
Innovation Solution
The inner conductor-supporting disk assembly is produced using micro-spraying technology to apply support discs directly onto a one-piece inner conductor, eliminating the need for additional assembly and adjustment, and is then integrated into an outer conductor using injection molding and adhesive techniques for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional assembly methods with multiple turned parts and plugged tube parts are used, then the coaxial line can be manufactured with traditional techniques, but the manufacturing cost increases and manufacturing precision deteriorates for small dimensions
Solution Approach 1:
The patent combines multiple separate components (inner conductor, support disks, outer conductor) into an integrated assembly where support disks are directly mounted on the inner conductor as a single unit. This merging eliminates the need for separate assembly operations and reduces tolerance accumulation, thereby improving manufacturing precision while maintaining ease of manufacture.
Solution Approach 2:
The patent segments the manufacturing process into distinct stages: first producing the inner conductor with mounted support disks as a complete assembly, then integrating this assembly into the outer conductor. This segmentation allows each stage to be optimized independently, improving overall manufacturing precision without increasing complexity.
2Ease of manufacture
If multiple tube parts are plugged into the outer conductor to assemble the inner conductor-supporting disk assembly, then the assembly can be constructed using conventional techniques, but the device complexity increases
Solution Approach 1:
The patent merges the inner conductor and support disks into a single integrated assembly that is inserted as one unit into the outer conductor. This eliminates the need for multiple separate tube parts to be plugged together, reducing device complexity while maintaining manufacturing feasibility.
3Ease of manufacture
If conventional assembly methods are used, then traditional manufacturing processes can be applied, but tolerance summation issues arise and adjustment work is required
Solution Approach 1:
The patent performs preliminary mounting of support disks onto the inner conductor during the inner conductor production stage, before the final assembly into the outer conductor. This preliminary action ensures precise positioning and eliminates tolerance summation issues that would arise from subsequent assembly operations, while keeping the overall process simple.
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 allows for high-precision, cost-effective production of coaxial lines with exact adjustments, reducing manufacturing complexity and tolerance issues, especially suitable for high-frequency applications with small dimensions.
Implementation Method 1
By spraying the support discs directly onto the one-piece inner conductor using known micro-spraying technology, the inner conductor-support disc assembly can be manufactured with high precision and stability.
Data Source
Figure 1~3
AI summary
The invention relates to a coaxial line in which the support disks (2) are moulded directly onto the inner line (1) according to the plastic injection technique. Also, a surrounding adhesive channel (3) is formed on the outer periphery of the support disk (2), said adhesive channel enabling the support disk (2) to be stuck in the outer conductor (5) by filling with an adhesive.