Dart Board Number Ring Manufacturing via Sheet Metal Stamping
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Solution Overview
Problem
The traditional method of manufacturing a dart board number ring is costly, time-consuming, and prone to human error, with weak points forming due to individual attachment of numbers to a metal wire ring, which can lead to detachment under impact and requires complex tooling for design changes.
Innovation Solution
A method of processing a sheet of metal to create a single-piece segment with numbers and a ring portion, where the numbers extend away from the ring in the same direction, allowing for efficient joining of free ends to form a complete ring, using techniques like welding, adhesive, or mechanical connectors, and attaching the ring to the dart board using clips or other fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual numbers are manufactured and attached to a metal wire ring by gluing, welding, or brazing, then the number ring can be assembled, but weak points are formed that lead to disengagement of numbers under impact
Solution Approach 1:
The patent merges multiple individual numbers and the ring portion into a single integrated segment made from one continuous piece of metal. This eliminates the need for multiple attachment points between numbers and the ring, as they become structurally unified. The segment is formed by bending the metal sheet into a circular shape with numbers extending radially outward, creating a monolithic structure that prevents disengagement under impact.
2Adaptability or versatility
If hand-formed wire numbers are used, then flexibility in design is maintained, but the manufacturing process becomes time-consuming and prone to human error
Solution Approach 1:
The patent replaces manual wire forming with a mechanical stamping and bending process. A stamping tool cuts and forms numbers directly from a metal sheet, and then a bending tool forms the circular ring shape. This mechanical automation maintains design flexibility through programmable tooling while dramatically increasing production speed and eliminating human error in the forming process.
3Productivity
If multiple wire forming tools are used to produce numbers, then automated production is achieved, but the device complexity and cost increase
Solution Approach 1:
The patent combines multiple wire forming operations into a single stamping and bending process. Instead of using separate tools for each number, a single stamping tool cuts all numbers from the metal sheet in one operation, and a single bending tool forms the entire circular ring structure. This consolidation reduces tooling complexity while maintaining automated production capabilities.
4Ease of manufacture
If traditional press tooling methods are used to punch out individual numbers, then numbers can be manufactured, but 14 separate press tools are required increasing complexity and cost
Solution Approach 1:
The patent segments the manufacturing process into two simple stages: (1) stamping all numbers from a metal sheet in one operation using a single tool, and (2) bending the remaining metal into a circular ring. This segmentation eliminates the need for multiple press tools required by traditional methods, as the stamping tool creates both the numbers and the ring structure in sequence.
5Manufacturing precision
If numbers are positioned manually to correspond to scoring segments, then correct positioning can be achieved, but skill and experience are required and misplacement occurs
Solution Approach 1:
The patent incorporates positioning features directly into the stamping tooling before the manufacturing process begins. The stamping tool is pre-configured with templates or guides that automatically position numbers at the correct angular locations corresponding to dartboard scoring segments. This preliminary setup eliminates the need for manual positioning during production, ensuring consistent accuracy without requiring operator skill or experience.
Data Source
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AI summary
The present invention provides a method of manufacturing a dart board ring 10 for a dart board 30. The method comprises the processing of a sheet of metal to provide at least a segment of the dart board number ring 10. The segment comprises a ring portion 2, a plurality of numbers 1 laterally spaced along and extending away from the ring portion 2, and a free end. The method comprises the step of joining the free end to another free end.