Rainbow Stick Toy Manufacturing via Segmented Sheet Slits
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Solution Overview
Problem
The conventional method of manufacturing rainbow stick toys is labor-intensive and costly, with low productivity, resulting in inconsistent quality and shape issues due to manual bonding of strip members to bonding members, leading to difficulties in mass production and sales promotion.
Innovation Solution
A method involving the formation of coupling slits and protrusions on continuous regions of a flexible sheet, allowing for automated production of ornament strips that can be easily coupled into rings, improving productivity and reducing costs, and incorporating stopper plates and snag-proof plates for better shape control and entanglement prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual bonding method is used to attach strip members to bonding members, then flexibility and simplicity of structure are maintained, but productivity is very low and manufacturing cost is high
Solution Approach 1:
The continuous flexible sheet is segmented into multiple strip members by forming coupling slits between them, allowing automated processing while maintaining the flexibility of the overall structure. This segmentation enables machine processing instead of manual bonding, significantly improving productivity.
Solution Approach 2:
The coupling slits are formed in advance during the sheet processing stage, before the strip members are assembled into the final product. This preliminary action of creating the slits allows for automated coupling later, eliminating the need for manual bonding operations during final assembly.
2Ease of manufacture
If manual bonding method is used to attach strip members to bonding members, then结构简单性 is maintained, but manufacturing cost increases
Solution Approach 1:
The continuous flexible sheet is segmented into multiple strip members by forming coupling slits between them, allowing automated processing while maintaining the flexibility of the overall structure. This segmentation enables machine processing instead of manual bonding, significantly improving productivity.
Solution Approach 2:
The coupling slits are formed in advance during the sheet processing stage, before the strip members are assembled into the final product. This preliminary action of creating the slits allows for automated coupling later, eliminating the need for manual bonding operations during final assembly.
3Ease of operation
If hand work is used for cutting and bonding strip members, then flexibility in handling is maintained, but quality consistency deteriorates due to varying strip member lengths
Solution Approach 1:
The continuous flexible sheet is segmented into multiple strip members by forming coupling slits between them, allowing automated processing while maintaining the flexibility of the overall structure. This segmentation enables machine processing instead of manual bonding, significantly improving productivity.
Solution Approach 2:
The manufacturing process transitions from manual cutting and bonding to automated slit formation and coupling, changing the operational parameters from hand-controlled variations to machine-controlled precision. This parameter change ensures consistent strip member lengths and uniform quality across all products.
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3C
AI summary
A method of manufacturing an ornament includes: providing a pair of continuous regions (11) facing one another in a flexible sheet (1); forming a plurality of slits (10) between the pair of continuous regions (11) to form a plurality of ornament strips (13), wherein the plurality of ornament strips (13) are separated from each other while both ends of the plurality of ornament strips (13) are integrally formed with the pair of continuous regions (11); and reversing the plurality of ornament strips (13) with respect to the pair of continuous regions (11) such that the plurality of ornament strips (13) radiate to form into an arc between the pair of continuous regions (11), while coupling each of the pair of continuous regions (11) to be formed into a ring.