Fastener Component for Cable and IC Module Assembly
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Solution Overview
Problem
Conventional power adapter assembly processes require multiple irreversible ultrasonic welding steps, leading to complex manufacturing, low yield, and potential quality control issues, which complicates achieving a seamless and safe design.
Innovation Solution
An electronic apparatus with a fastener component that secures the cable and integrated circuit module separately, allowing for simplified assembly using ultrasonic welding on one side of the case, with guiding rails and limiting racks to position the fastener component accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple ultrasonic welding processes are used to join housing and side covers, then the housing structure is securely assembled, but the manufacturing process becomes complex and yield rate decreases
Solution Approach 1:
The patent integrates the cable securing function and circuit board fixation into a single cable assembly structure that is ultrasonic-welded to the housing in one operation. This combines multiple functions (cable retention, electrical connection support, and structural assembly) into one welding process, reducing the number of separate ultrasonic welding steps from multiple to one, thereby simplifying the manufacturing process and improving yield rate while maintaining assembly strength
2Stability of the object's composition
If ultrasonic welding is used to join housing and side covers, then the assembly is securely fixed, but the process becomes irreversible and quality control becomes difficult
Solution Approach 1:
The patent incorporates cable routing guides and positioning features directly into the cable assembly before the ultrasonic welding process. This preliminary arrangement of cable paths and connection points ensures proper alignment and positioning is achieved prior to welding, reducing the risk of welding defects and enabling better quality control through pre-verification of component placement
3Device complexity
If circuit board is assembled in housing before side covers are attached, then the integrated design is achieved, but the manufacturing process time increases
Solution Approach 1:
The patent divides the assembly into modular components: the cable assembly with integrated circuit board connections is prepared as a separate unit, then quickly attached to the housing via a single ultrasonic welding operation. This segmentation allows parallel preparation of components and reduces sequential assembly steps, maintaining integrated design while shortening total manufacturing time
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 approach enhances product reliability and yield by ensuring the integrated circuit module is securely fixed before assembly, simplifying the manufacturing process, and meeting safety requirements by preventing detachment during impacts.
Implementation Method 1
combining the at least one side cover with the main housing by ultrasonic welding for forming a closed configuration
Data Source
AI summary
An electronic apparatus includes a case, an integrated circuit module, a cable and a fastener component. The case includes an opening and an accommodating space for the integrated circuit module and the fastener component installed therein. The cable is passed through the opening to be electrically connected with the integrated circuit module. The fastener component is adjacent to the opening and includes a first fastening portion and a second fastening portion for fastening the conducting cable and the circuit module respectively. Thereby, the cable and the integrated circuit module will be fastened simultaneously through the fastener component, and a one-time ultrasonic welding process is applied for assembly, thus the process will be simplified as to improve the yield rate.