Conductor Plate Folding Layout for Higher Yield and Less Scrap
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Solution Overview
Problem
The existing method for manufacturing conductor plates, as described in PTL 1, requires improvement in terms of efficiency and yield.
Innovation Solution
A method involving a press process to form a closed region and separate a bent region from the periphery, while maintaining a connection portion, followed by a bending process to laminate the bent region with another region in the closed area, thereby developing the bent region outside the closed area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conventional manufacturing method is used, then the conductor plate can be manufactured with simple process, but the material utilization efficiency is low
Solution Approach 1:
The conductor plate is divided into a closed region and a bent region that is separated from the periphery while maintaining a connection portion. This segmentation allows the bent region to be formed from a smaller material area, improving yield without compromising structural integrity.
Solution Approach 2:
The bent region is folded back and laminated onto itself, creating a nested structure where the bent region is positioned within or adjacent to the closed region. This nesting approach maximizes material utilization by reusing the bent region's material rather than discarding it.
2Device complexity
If the bent region is completely separated from the periphery, then the conductor plate structure is simplified, but the structural integrity is compromised
Solution Approach 1:
The bent region is extracted from the periphery of the closed region, creating a distinct separate component. This extraction simplifies the overall structure by clearly defining the bent region as a separate element that can be independently formed and positioned.
Solution Approach 2:
A connection portion is introduced as an intermediary element between the bent region and the closed region. This connection portion maintains structural integrity by providing a physical link while allowing the bent region to be formed from a smaller material area, thus resolving the contradiction between simplification and strength.
3Manufacturing precision
If more material is used for manufacturing, then the conductor plate quality is improved, but the production cost increases
Solution Approach 1:
The bent region is folded back in the third dimension (thickness direction) and laminated onto the closed region. This dimensional transformation allows the conductor plate to achieve improved quality and structural complexity without consuming additional material, as the bent region is reused in a different spatial configuration.
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 improves the yield of conductor plates by allowing them to be manufactured using a smaller area of material, resulting in a more efficient production process.
Implementation Method 1
a press process of forming a predetermined closed region by press molding
Implementation Method 2
a bending process of bending the bent region at the connection portion to laminate the bent region with a laminated region that is another region in the closed region
Data Source
AI summary
A method for manufacturing a conductor plate includes: a press process of forming a predetermined closed region by press molding and separating a predetermined bent region from the periphery of the closed region while leaving only a connection portion that is a part of the bent region; and a bending process of bending the bent region at the connection portion to laminate the bent region with the laminated region that is another region in the closed region, and developing a part of the bent region to the outside of the closed region.