Composite Socket Frame Structure for Fast, Precise Manufacturing
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Solution Overview
Problem
Machining methods for manufacturing socket frames are time-consuming, leading to prolonged manufacturing times and lead times compared to other methods like pressing, which hinders mass production efficiency.
Innovation Solution
A frame for a contact unit comprising a metal frame and a resin frame, where the metal frame is formed by pressing multiple plates to reduce processing time, and the resin frame provides high positional accuracy and heat resistance, allowing for faster assembly and maintaining quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining is used to manufacture the frame, then manufacturing accuracy is improved, but manufacturing time is prolonged
Solution Approach 1:
The frame is divided into two separate components: a metal frame portion and a resin frame portion. The metal frame is manufactured by pressing (fast) while the resin frame is manufactured by molding (accurate). This segmentation allows each portion to be optimized for its specific manufacturing requirements, resolving the contradiction between speed and precision.
Solution Approach 2:
The frame combines two different materials (metal and resin) into a composite structure. The metal portion provides structural strength and is quickly formed by pressing, while the resin portion provides precise dimensional accuracy through molding. This composite approach allows simultaneous optimization of manufacturing speed and precision for different functional requirements.
2Reliability
If machining is used to manufacture the frame, then frame quality is improved, but lead time is prolonged
Solution Approach 1:
The frame is segmented into metal and resin portions that can be manufactured independently through optimized processes. The metal frame is produced by pressing (quick) and the resin frame by molding (precise), then assembled together. This eliminates the sequential machining steps that prolonged lead time while maintaining overall frame quality.
Solution Approach 2:
The invention changes the manufacturing parameters and methods for different portions of the frame. Instead of using the same machining process for the entire frame, it applies pressing (different parameters) for the metal portion and molding for the resin portion, optimizing both quality and lead time for each segment.
3Productivity
If pressing is used to manufacture the frame, then manufacturing time is reduced, but manufacturing accuracy deteriorates
Solution Approach 1:
The frame is divided so that the metal portion is manufactured by pressing (high speed) and the resin portion by molding (high precision). This segmentation allows the pressing process to achieve its speed advantage without compromising overall frame accuracy, as the resin portion compensates for any dimensional variations.
Solution Approach 2:
By using composite materials (metal and resin), the invention leverages the advantages of each material's manufacturing process. The metal frame portion benefits from the speed of pressing, while the resin frame portion provides the precision that compensates for any limitations of the pressing process, achieving both high productivity and high accuracy.
Data Source
AI summary
A frame for a contact unit includes: a resin frame made of resin and a metal frame made of metal. The metal frame has a bottom plate on which the resin plate is disposed, an inner peripheral plate and an outer peripheral plate. Each of the resin frame and the bottom plate has a front side, a rear side, a left side and a right side at front, rear, left and right positions to surround a housing portion of the contact unit. The inner peripheral plate and an outer peripheral plate stand in a first direction from an inner peripheral edge and an outer peripheral edge of the bottom plate respectively to cover at least partially an inner part and an outer part of the resin frame on the bottom plate.