Contact Probe Assembly Using a C-Shaped Pipe Member
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Solution Overview
Problem
The existing methods for manufacturing contact probes, such as those described in Japanese Patent No. 6751249, are inefficient due to the complexity of processing and assembly, particularly for small-sized members, which complicates the work efficiency.
Innovation Solution
A method involving an external shape forming step, protrusion forming step, curling step, probe assembling step, and cutting step to create a contact probe with a C-shaped pipe member, where plungers and a coil spring are inserted, and a cutting step to separate the connection parts, enhancing assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the plate member is bent and formed into a cylindrical shape with plungers and coil spring inserted separately, then the contact probe can be assembled, but the processing becomes complex and work efficiency is reduced
Solution Approach 1:
The patent merges the pipe member and connection part into a single integrated structure formed from one plate material. The pipe member is formed by bending the plate material into a cylindrical shape, and the connection part is formed by cutting and bending portions of the same plate, eliminating the need for separate assembly steps and reducing processing complexity
Solution Approach 2:
The protrusions are formed on the plate material before bending into the cylindrical shape. This preliminary formation of locking features allows the plungers to be securely locked into position during the assembly process, simplifying the overall manufacturing workflow
2Productivity
If small-sized members such as contact probes are assembled separately, then the contact probe can be manufactured, but work efficiency is more reduced
Solution Approach 1:
The patent combines multiple components (pipe member, connection part, and protrusions) into a single integrated plate structure that is formed and assembled in fewer steps, significantly improving work efficiency for small-sized contact probes
Solution Approach 2:
The plate material is segmented into distinct functional regions (pipe member portion, connection part, protrusions) that are formed through cutting and bending operations, allowing for efficient assembly while maintaining structural integrity
Data Source
AI summary
A method of manufacturing a contact probe includes: forming external shapes of a plurality of main body part base materials on a plate material, each of the plurality of main body part base materials being connected to a base part via a connection part and used for forming a main body part of a pipe member; forming a plurality of protrusions on each of the plurality of main body part base materials; forming the pipe member by bending each of the plurality of main body part base materials into a C-shape such that the protrusions protrude toward an inner side of the pipe member; assembling the contact probe by inserting first and second plungers and a coil spring into the pipe member connected to the connection part; and cutting the pipe member from the connection part.