Diaphragm Manufacturing via Segmented Base and Suspended Edge
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Solution Overview
Problem
Current diaphragm manufacturing methods lack automation, leading to decreased production yield and efficiency.
Innovation Solution
A diaphragm manufacturing method involving a base with a through hole, a membrane, and a molding step to form a suspending edge, followed by a cutting step to form the diaphragm, enabling automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If adhesive method or injection molded method is used to form diaphragm, then diaphragm can be assembled or formed, but production cannot be automated leading to decreased yield and efficiency
Solution Approach 1:
The base is divided into a main body portion and multiple connecting portions that can be separately formed and then assembled. The suspending edge is also segmented with distinct joining portions for connecting to the membrane and base. This segmentation enables automated assembly operations while maintaining production efficiency.
Solution Approach 2:
The connecting portions are pre-formed on the base with connecting grooves, and the suspending edge is pre-formed with extended portions that correspond to these grooves. This preliminary preparation of connection features enables automated assembly without manual intervention, resolving the contradiction between automation and productivity.
2Ease of manufacture
If adhesive method is used to assemble membrane and spring arms, then diaphragm can be formed, but production yield and efficiency are poor due to lack of automation
Solution Approach 1:
The traditional adhesive bonding method is replaced with a mechanical connection system using connecting portions, connecting grooves, and extended portions. This mechanical substitution enables automated assembly operations while maintaining ease of manufacture, resolving the contradiction between ease of assembly and production efficiency.
3Manufacturing precision
If injection molded method is used to form spring arms on membrane, then diaphragm can be formed, but production cannot be automated leading to decreased yield
Solution Approach 1:
The diaphragm components are segmented into the base with connecting portions and the suspending edge with extended portions. This segmentation allows each component to be manufactured with high precision using injection molding, while the overall assembly can be automated, resolving the contradiction between manufacturing precision and automation.
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
The method significantly increases production yield and efficiency by allowing automated processing with machines like mechanical arms, improving recognition and effectiveness of the diaphragm production process.
Implementation Method 1
the suspending edge further comprises a first joining portion that connects to the membrane, a second joining portion that connects to the main body portion, and an elastic portion positioned between the first joining portion and the second joining portion
Data Source
AI summary
The present invention provides a diaphragm manufacturing method, including: a base, a membrane, a molding step, and a cutting preparation step. The membrane is fitted at a central location of a through hole and forms an interspace a main body portion. A molding step further consists of forming a suspending edge between the main body portion and the membrane, whereby the suspending edge is formed with extended portions that extend into corresponding connecting grooves. A cutting step comprises cutting the connecting portions and the extended portions, to form a diaphragm fabricated from the main body portion, the membrane, and the suspending edge. The base can be gripped by mechanical arms by means of the external portions, thus achieving the effectiveness of automated production, as well as increasing production yield and efficiency.