Die Casting Radio-Frequency Member With Artificial Magnetic Conductors
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Solution Overview
Problem
The existing manufacturing methods for radio-frequency members with artificial magnetic conductors are challenging for mass production due to the complexity of cutting conductive rods, which hinders scalability and efficiency.
Innovation Solution
A die casting method is employed using a plurality of dies to form internal cavities, injecting a metal material in a fluid state, and allowing it to solidify, resulting in radio-frequency members with integrated artificial magnetic conductors, enabling mass production by defining precise functional regions within the cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cutting method is used to form artificial magnetic conductor, then manufacturing precision can be achieved, but productivity is low and mass production is difficult
Solution Approach 1:
The patent changes the manufacturing parameter from mechanical cutting to die-casting process, injecting metal material in fluid state into a cavity to form the artificial magnetic conductor structure. This parameter change enables mass production while maintaining structural precision through proper gate and overflow design
Solution Approach 2:
The patent replaces the mechanical cutting system with a die-casting system that uses fluid injection and solidification. The gate and overflow structures guide the metal flow to form precise rod structures without mechanical contact, eliminating cutting operations and enabling high-volume production
2Productivity
If die casting method is used to enable mass production, then productivity is improved, but manufacturing precision of functional regions must be carefully controlled
Solution Approach 1:
The patent introduces a gate structure as an intermediary element that controls metal flow into the functional-region section. The gate acts as a mediator between the metal material and the cavity, ensuring precise filling of rod forming holes while enabling mass production through controlled injection
Solution Approach 2:
The patent extracts the functional-region section design from the overall cavity structure, creating a dedicated zone with specific rod forming holes. This separation allows independent optimization of the functional region for precision while the rest of the cavity supports mass production requirements
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 allows for the industrial-scale production of radio-frequency members with integrated artificial magnetic conductors, enhancing scalability and reducing manufacturing complexities, thereby improving the efficiency of producing radio-frequency components.
Implementation Method 1
injecting a metal material in a fluid state into the cavity, and separating the first die and the second die after the metal material solidifies
Data Source
AI summary
In a manufacturing method of a radio-frequency member in which an inner peripheral surface of a cavity in a die includes a functional-region section that provides the radio-frequency member, a gate opens in a first wall surface of the inner peripheral surface of the cavity, an overflow expands in a direction in which a second wall surface of the inner peripheral surface extends is opened in the second wall surface, the functional-region section is located in a main flow region, the functional-region section includes a plurality of rod forming holes, a distance between edges of openings of at least two rod forming holes is smaller than depths of both of the two rod forming holes, a metal material in a fluid state is injected into the cavity through the gate, and a portion of the metal material flows outside of the cavity from the overflow.