Reinforced Key Device Stud Riveting and Injection Molding
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Solution Overview
Problem
The existing key device manufacturing process is complicated and costly due to the difficulty in forming desired hook members through multiple stamping processes, leading to increased production expenses.
Innovation Solution
A key device with a reinforced structure comprising a plastic key cap and a metal base plate unit, where the base plate is riveted to the key cap using studs that change shape from straight tubular to rivet form upon heating, and engaging members are injection molded to anchor members for secure pivot connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple stamping processes are used to form hook members, then the desired shape can be achieved, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The patent changes the material parameter from plastic to metal for the base plate, enabling single-stamping formation of hook members with desired shapes. This material parameter change allows achieving complex hook shapes in one stamping operation rather than multiple stamping processes, thereby reducing manufacturing process complexity while maintaining shape accuracy
Solution Approach 2:
The patent employs composite material construction by combining metal base plate with plastic key cap and plastic engaging members. The metal base plate provides structural strength and enables precise single-stamping formation, while plastic components provide other functional benefits, creating a composite structure that resolves the manufacturing complexity issue
2Manufacturing precision
If multiple stamping processes are used to form hook members, then the desired shape can be achieved, but manufacturing costs increase
Solution Approach 1:
Changing the material parameter to metal allows single-stamping formation of hook members, eliminating the need for multiple stamping processes. This reduces manufacturing steps, decreases production time, and lowers manufacturing costs while maintaining the desired shape accuracy of hook members
Solution Approach 2:
The patent extracts the hook member formation process from the complex multi-stamping sequence by using metal material properties to achieve the desired shape in a single stamping operation, thereby removing unnecessary manufacturing steps and reducing costs
3Stability of the object's composition
If a reinforced structure is implemented with metal base plate and riveting, then structural stability is improved, but assembly complexity increases
Solution Approach 1:
The patent merges multiple components (base plate, engaging members, key cap) into an integrated assembled structure where the metal base plate is riveted to the plastic key cap, and engaging members are injection-molded to anchor members. This merging creates a reinforced unified structure that improves stability while the modular design keeps assembly manageable
Solution Approach 2:
The reinforced structure uses composite materials (metal base plate + plastic key cap + plastic engaging members) joined through riveting and injection molding. This composite construction provides enhanced structural stability and strength while maintaining reasonable assembly complexity through standardized joining methods
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 solution simplifies the assembly process, reduces manufacturing costs, and provides a stable, easy-to-assemble key device with a reinforced structure, enhancing production efficiency.
Implementation Method 1
heating and melting one end of each stud such that the shape of each stud is changed from the straight tubular shape to a rivet shape
Data Source
AI summary
A key device includes a key cap and a base plate unit. The key cap includes a top wall and a peripheral wall cooperatively defining a receiving space. The top wall has a plurality of spaced-apart studs protruding into the receiving space. The base plate unit is disposed in the receiving space and is riveted to the top wall through the studs. The base plate unit includes a base plate, and a plurality of engaging members secured to the base plate. The base plate includes a plurality of stud holes for extension of the studs respectively therethrough, and a plurality of spaced-apart anchor members. The engaging members are injection molded to the anchor members, respectively.