Plate Spring Fixing Structure with Embedded Resin
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Solution Overview
Problem
Conventional methods for assembling plate spring fixing structures and electric contact structures, such as those used in coin type cells and piezo buzzers, require complex processes and large components, leading to increased production costs and variability in product quality due to the need for complex metal molds and precise positioning of bent metal terminals.
Innovation Solution
A method involving a flat plate with a spring property that is temporarily fixed, molded with resin, and then bent to form plate springs, allowing for adjustment and simplification of the assembly process without the need for complex molds, reducing production costs and component size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods use complex metal molds and bent metal terminals for assembling plate spring fixing structures, then the assembly process requires precise positioning and complex manufacturing, but this leads to increased production costs and device complexity
Solution Approach 1:
The invention divides the plate spring into two functional segments: a fixed portion embedded in the molded resin part and a spring portion extending outward. This segmentation allows the fixed portion to be precisely positioned during molding while the spring portion maintains manufacturing flexibility, resolving the contradiction between positioning precision and device complexity
Solution Approach 2:
The plate spring is temporarily fixed to a temporary fixation member before the resin molding process. This preliminary action ensures precise positioning of the plate spring during molding without requiring complex metal molds or post-assembly bending operations, thereby reducing both manufacturing complexity and device complexity
2Force
If conventional methods use bent metal terminals with complex metal molds, then the structure can provide elastic force, but the production cost increases due to complex manufacturing processes
Solution Approach 1:
The invention merges the plate spring fixing process with the resin molding process into a single integrated operation. The plate spring is temporarily fixed to a fixation member, which is then embedded in the resin during molding. This merging eliminates the need for separate complex metal molding and bending operations, reducing production cost while maintaining the elastic force function through the spring portion
Solution Approach 2:
The plate spring is temporarily fixed to a temporary fixation member before molding. This preliminary action enables the plate spring to be positioned and secured during the resin molding process without requiring complex metal molds or subsequent bending operations, thereby reducing manufacturing complexity and production cost while preserving the elastic force function
3Reliability
If conventional methods require precise positioning of bent metal terminals, then the electric contact function can be achieved, but the component size and assembly complexity increase
Solution Approach 1:
The plate spring is segmented into a fixed portion embedded in the molded resin part and a spring portion extending outward to make contact. This segmentation allows the fixed portion to be compactly integrated into the molded resin part while the spring portion provides the necessary contact length, thereby maintaining electric contact reliability without increasing overall component size or assembly complexity
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 simplifies the assembly process, reduces production costs, and allows for adjustable plate spring bending, resulting in a more stable and cost-effective plate spring fixing and electric contact structure.
Implementation Method 1
the metal terminal 240, serving as a plate spring, which has been formed together with the outer case 230 through insert molding. The metal terminal 240 is bent up from the bottom of the outer case 230, and is arranged to press one end portion thereof against the piezoelectric element 210 using the elastic force caused by the spring property
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(f)
Figure 3(a)~3(b)
AI summary
Provided is a plate spring fixing structure and the like which do not necessitate complex assembling processes and thus can reduce production cost and can be reduced in size, and which enable adjustment, during a production process, of the extent to which the plate spring is bent. A holding structure (1A) includes a first plate spring (12) that has: a fixed portion (12a) embedded in and fixed to a first molded resin part (11); and a spring portion (12b) which is not fixed and which has a spring property. The fixed portion (12a) has a face that is not in contact with the first molded resin part (11).