Electric Contact Base Material Deformation Control
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Solution Overview
Problem
Press working or roll working on a contact material to embed it into a base material causes deformation of the base material, leading to overflow from the surrounding area, which is not effectively managed in existing methods.
Innovation Solution
Forming absorption holes around the welding position on the base material to absorb deformation caused by the crushing of the contact material, allowing for controlled embedding and maintaining the base material's thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If press working or roll working is performed on contact material to embed it into base material, then the contact material is successfully embedded into the base material, but deformation occurs in the base material causing overflow from the surrounding area
Solution Approach 1:
Absorption holes are formed around the welding position before the crushing step. This preliminary action creates predetermined spaces that will absorb the deformation occurring during subsequent crushing, preventing overflow and maintaining base material integrity
Solution Approach 2:
The base material is segmented by creating multiple absorption holes at specific positions around the welding area. These holes divide and distribute the deformation stress across multiple locations, preventing concentrated overflow and maintaining overall shape integrity
2Ease of manufacture
If conventional crushing methods are used to embed contact material, then the contact material is crushed and embedded, but the base material deforms and overflows requiring additional processing
Solution Approach 1:
Absorption holes are formed in advance before crushing, preparing the base material to accommodate deformation. This eliminates the need for subsequent corrective processing steps, maintaining manufacturing simplicity while preventing overflow problems
3Shape
If absorption holes are formed around welding position, then deformation in thickness direction is absorbed preventing overflow, but additional process steps are required
Solution Approach 1:
Absorption holes are formed as a preliminary step before crushing, creating predetermined spaces that will accommodate deformation. This single additional step prevents overflow and maintains shape stability throughout the subsequent crushing and embedding processes
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 effectively absorbs deformation in the thickness direction of the base material, preventing overflow and ensuring reliable and cost-effective manufacturing of electric contacts with reduced material loss and simplified processes.
Implementation Method 1
one or more absorption holes that absorb deformation of the base material in a thickness direction caused by the crushing of the contact material are formed around the welding position of the contact material on the base material
Implementation Method 2
a welding step of welding a contact material to a base material
Data Source
AI summary
A method of manufacturing an electric contact includes a welding step of welding a contact material (12) to a base material (11), and a crushing step of crushing the contact material (12), wherein one or more absorption holes (11a and 11b) that absorb deformation of the base material (11) in a thickness direction (Z direction) caused by the crushing of the contact material (12) are formed around the welding position of the contact material (12) on the base material (11).