IC Card Cover Joining Structure with Ultrasonic Weld and Locking Mechanism

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Solution Overview

Problem

Existing component joining structures for IC cards and connectors require separate manufacturing facilities and molds for ultrasonic welding and mechanical locking systems, leading to increased costs and complexity due to the need for two distinct types of components and production controls.

Innovation Solution

A component joining structure that integrates both ultrasonic welds and a locking mechanism, allowing for either ultrasonic welding or mechanical locking, using a single type of component, with the ultrasonic welds and locking mechanism aligned inwards to save space and improve joining strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate manufacturing facilities and molds are prepared for ultrasonic welding and mechanical locking systems, then both joining systems can be provided to satisfy different user needs, but the number of components, equipment costs, and production control costs increase

Engineering Contradiction:

Improveability to provide different joining systemsVSAvoidnumber of components and manufacturing facilities

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cover component is designed with both ultrasonic welding portions and locking mechanism portions integrated into a single structure. This allows the same component to serve multiple joining functions, eliminating the need for separate components for different joining systems. The cover component can be joined to the resin body component through either ultrasonic welding or mechanical locking, providing versatility while reducing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The ultrasonic welding portions and locking mechanism portions are merged into a single cover component structure. By combining these previously separate joining mechanisms into one integrated component, the patent reduces the number of parts and simplifies manufacturing while maintaining the ability to support both joining methods.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If two types of components with different joining systems are fabricated, then user-specific requirements can be met, but manufacturing costs and production control complexity increase

Engineering Contradiction:

Improvecustomization for different joining systemsVSAvoidmanufacturing cost and production control

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single cover component design incorporates both ultrasonic welding portions and locking mechanism portions, allowing it to be used with either joining system. This universal design eliminates the need to manufacture separate component types, reducing manufacturing costs and simplifying production control while still meeting different user requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If ultrasonic welds and locking mechanism are aligned inwards, then space is saved and joining strength is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvejoining strengthVSAvoidalignment precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The ultrasonic welds and locking mechanism portions are merged and aligned in the same inward direction within the cover component. This integrated alignment optimizes the use of space and ensures that both joining mechanisms work together to improve overall joining strength, while the design accommodates standard manufacturing precision capabilities.

Inventive Principle:

Principle #5Merging (Combining)

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 configuration reduces the number of components and production costs by enabling the use of either joining system with a single component, improving joining strength and efficiency while minimizing space requirements.

Implementation Method 1

at least one ultrasonic weld that is provided in the cover component, and is formed protruding from the cover component, and that can join the cover component and the body component together by being fixed to the body component with ultrasonic welding

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS8243456B2Component joining structure, IC card, and connector

Publication Date: 2012.08.14 JST MFG CO LTD

AI summary

An ultrasonic weld is provided in a cover component, is formed protruding from the cover component, and is provided so that it can join the cover component and the body component together by being fixed to the body component with ultrasonic welding. A locking mechanism is provided so that it can join the cover component and the body component together via engaging portions that engage with each other. The locking mechanism includes a first engaging portion provided in the cover component, and a second engaging portion that is provided in another component fixed to the body component, and that can engage with the first engaging portion. Thus, it is possible to decrease the number of components, and also reduce equipment costs and production control costs.