Powder Container Intermediate Cap Mesh Fixing via Coupling Ring
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Solution Overview
Problem
Conventional powder container manufacturing processes for intermediate caps with meshes are complex, requiring large workspaces and many workers, leading to low productivity and high costs due to ultrasonic welding and intricate assembly steps, and the assembled intermediate caps can suffer from mesh decoupling or uneven assembly.
Innovation Solution
An intermediate cap design for a powder container that uses a coupling ring and lower cover to securely fix a mesh between the cap body and the coupling ring, with a coupling protrusion wheel and toothed protrusions for secure engagement, simplifying the manufacturing process and improving assembly stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding and intricate assembly steps are used to manufacture intermediate caps with meshes, then the mesh is securely fixed, but the manufacturing process becomes complex requiring large workspaces and many workers, leading to low productivity and high costs
Solution Approach 1:
The patent replaces the ultrasonic welding process with a mechanical coupling system consisting of a coupling ring, coupling protrusions, and coupling grooves. The mesh is secured through mechanical interlocking rather than thermal welding, eliminating the need for complex welding equipment and skilled operators while maintaining secure fixation.
Solution Approach 2:
The intermediate cap is divided into separate modular components: cap body, coupling ring, mesh, and lower cover. These segments can be manufactured independently using simple processes and then assembled through straightforward coupling mechanisms, reducing manufacturing complexity and enabling parallel production.
2Reliability
If ultrasonic welding and intricate assembly steps are used to manufacture intermediate caps with meshes, then the mesh is securely fixed, but the manufacturing process becomes complex requiring large workspaces and many workers, leading to high costs
Solution Approach 1:
The complex ultrasonic welding process is replaced with simple mechanical coupling operations. The coupling ring with protrusions fits into grooves on the cap body, providing secure mesh fixation through basic mechanical interlocking that can be performed with simple tools and minimal skill.
Solution Approach 2:
The coupling structure is designed to be self-aligning and self-securing. The coupling protrusions automatically engage with the coupling grooves when components are assembled, eliminating the need for complex alignment procedures or specialized welding operations.
3Ease of manufacture
If conventional assembly methods are used, then the mesh can be fixed, but the mesh may be pushed to one side or decoupled during assembly, leading to uneven assembly
Solution Approach 1:
The coupling ring features asymmetric coupling protrusions that correspond to asymmetric coupling grooves on the cap body. This asymmetric design ensures proper orientation and positioning of the mesh during assembly, preventing the mesh from being pushed to one side and ensuring uniform assembly throughout.
Solution Approach 2:
The coupling structure provides mechanical feedback through the interlocking protrusions and grooves. When components are assembled correctly, the coupling elements engage smoothly and securely, providing immediate feedback that ensures proper positioning and prevents decoupling during the assembly process.
Data Source
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AI summary
The present invention relates to an intermediate cap of a powder container to which a mesh is coupled by a coupling ring and a lower cover, and a method of manufacturing the same and, more particularly, to an intermediate cap of a powder container to which a mesh is coupled by a coupling ring and a lower cover, wherein the intermediate cap is mounted on the inside of the powder container; the intermediate cap comprises a cap body, a mesh, a coupling ring and a lower cover; a coupling protrusion wheel is formed in the lower part of the cap body; the coupling ring is forcedly fitted into the outside of the coupling protrusion wheel of the cap body in a state where the mesh is positioned between the cap body and the coupling ring to fix the mesh between the cap body and the coupling ring; and the lower cover is coupled to the lower part of the cap body to assemble the intermediate cap, so that the mesh is strongly coupled between the cap body and the coupling ring, thereby preventing the mesh from being decoupled therefrom, and preventing the mesh from being assembled while being pushed to one side.