Integral Pre-Structure for Embedded Members

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Solution Overview

Problem

Conventional methods for forming embedded members require separate punching molds for each type, leading to high manpower costs, waste material, and inefficient production due to the inability to reuse positioning scraps for different terminal configurations.

Innovation Solution

A method that modifies the first punching mold to produce two kinds of embedded members, allowing for the formation of integral pre-structures with connecting segments and bridges, which can be cut to create separate embedded members and positioning scraps, enabling the use of a single process to produce multiple types suitable for different insert molding processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate punching molds are used for each type of embedded member, then each embedded member can be formed with its specific terminal configuration, but the punching mold requires frequent adjustment which increases manpower cost and reduces productivity

Engineering Contradiction:

Improveembedded member type varietyVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent applies universality by designing a single punching mold that can produce multiple types of embedded members with different terminal configurations. The mold includes a positioning scrap with multiple positioning holes that can accommodate different terminal arrangements, allowing one mold to replace multiple specialized molds and eliminate frequent mold adjustments while maintaining the ability to produce various embedded member types

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If separate punching molds are used for each type of embedded member, then each embedded member can be formed with its specific terminal configuration, but the frequent mold adjustment increases manpower cost

Engineering Contradiction:

Improveembedded member type varietyVSAvoidmanpower cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If conventional punching method is used with separate molds, then each embedded member can be formed accurately, but too much waste material is produced increasing production cost

Engineering Contradiction:

Improveembedded member formation accuracyVSAvoidwaste material

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent applies merging by combining multiple embedded members and their positioning scraps into a single integral pre-structure that is punched from one metallic strip. This integrated approach allows the positioning scrap to serve multiple embedded members simultaneously, reducing the total amount of waste material compared to producing each embedded member separately with individual positioning scraps

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If conventional punching method is used with separate molds, then each embedded member can be formed accurately, but the production cost is high due to waste material

Engineering Contradiction:

Improveembedded member formation accuracyVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10622776B2Method for forming embedded members, pre-structure prepared therefrom, and positioning scrap

Publication Date: 2020.04.14 STARCONN ELECTRONIC (SU ZHOU) CO LTD

AI summary

A method includes the steps: providing a pre-structure comprising a first pre-embedded member and a second pre-embedded member, wherein the first pre-embedded member has a first positioning segment, a connecting segment connected to the first positioning segment, a first piece, and a bridge; the second pre-embedded member has a second positioning segment, a hanging segment connected to the second positioning segment, and a second piece, wherein the bridge is connected to the connecting segment and the second piece; fixing the bridge onto the hanging segment; segmenting the connecting portion of the bridge and the connecting segment to form a first embedded member, which is defined by the first positioning segment, the connecting segment and the first piece, and a second embedded member, which is defined by the second positioning segment, the hanging segment, the second piece and the bridge; separating the second embedded member from the first embedded member.