Integrally Molded Drumhead Resin Frame and Membrane
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Solution Overview
Problem
Conventional drumhead manufacturing processes are complex and costly due to the need for swaging or adhesive fixation of the striking face member to a metal head frame, increasing production costs and complexity.
Innovation Solution
A drumhead with a membrane and frame integrally formed by molding, where the outer periphery of the membrane is fixed within a mold and resin material is injected to create the frame, simplifying the manufacturing process and reducing costs by eliminating the need for additional components and complex fixation methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the outer circumferential portion of the striking face member is fixed on the head frame by swaging or adhesive, then the striking face member is securely attached, but the manufacturing process becomes complicated and manufacturing costs increase
Solution Approach 1:
The patent combines the striking face member and head frame into a single integrally molded drumhead component. The resin material is injected to simultaneously form both the striking face member and head frame, eliminating the need for separate fixation processes such as swaging or adhesive application. This merging of components resolves the technical contradiction by maintaining secure attachment (through integral formation) while dramatically simplifying the manufacturing process.
2Strength
If the outer circumferential portion of the striking face member is fixed on the head frame by swaging or adhesive, then the striking face member is securely attached, but manufacturing costs of the drumhead increase
Solution Approach 1:
The patent combines the striking face member and head frame into a single integrally molded drumhead component. The resin material is injected to simultaneously form both the striking face member and head frame, eliminating the need for separate fixation processes such as swaging or adhesive application. This merging of components resolves the technical contradiction by maintaining secure attachment (through integral formation) while dramatically simplifying the manufacturing process.
3Manufacturing precision
If the outer periphery of the membrane protrudes from the outer side surface of the molded frame, then the membrane is fully formed, but additional cutting steps are required and appearance is degraded
Solution Approach 1:
The patent applies local quality control by designing the mold cavity and injection parameters to ensure the resin material precisely fills only the intended volume. The head frame's outer peripheral surface is formed at the exact boundary where the membrane should end, preventing protrusion. This localized precision in the molding process eliminates the need for post-molding cutting operations while maintaining complete membrane formation.
4Productivity
If gate traces are formed on the inner wall surface, then the resin material is properly injected, but the appearance of the drumhead is degraded
Solution Approach 1:
The patent extracts or removes the gate trace from the visible outer surface of the drumhead by positioning the injection gate on the inner wall surface. The gate trace is deliberately placed on the inner peripheral surface where it is hidden from external view. This extraction of the necessary injection feature to a hidden location maintains efficient resin injection while preserving the aesthetic appearance of the drumhead's outer surface.
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 integrated molding process reduces manufacturing steps, lowers costs, and improves the appearance of the drumhead by eliminating protruding edges and gate traces, while enhancing fixation strength and reducing weight.
Implementation Method 1
After the outer periphery of the membrane is disposed within a cavity of a mold, a resin material is injected into the cavity of the mold, thereby the frame to which the outer periphery is fixed is molded.
Data Source
AI summary
A percussion instrument includes: a cylindrical shell portion having an open upper surface side; and a drumhead stretched to be installed on the upper surface side of the shell portion, wherein the drumhead includes: a membrane formed of a membranous material, having a struck head portion configured as a striking face to be struck by a performer and an outer periphery located on an outer circumferential side of the struck head portion; and an annular frame formed of a resin material and having the outer periphery of the membrane fixed thereto, and the drumhead is integrally formed by the membrane and the frame by injection molding.