Receiver Integral Housing Ultrasonic Welding Assembly
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Solution Overview
Problem
The conventional receiver assembly process requires two steps, increasing production costs and time due to separate components for the lower housing and yoke, necessitating a one-step integration for the rear cavity housing.
Innovation Solution
The receiver features an integral third housing with a magnetic conductive piece and plastic piece injection-molded together, forming a magnetic circuit system, allowing for one-step assembly via ultrasonic welding, simplifying the production process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the lower housing and yoke are separate components requiring two-step assembly, then the structural flexibility is improved, but the production complexity and time increase
Solution Approach 1:
The patent combines the lower housing and yoke into a single integrated component. The lower housing includes an integrated yoke structure that is formed as one piece, eliminating the need for separate assembly steps. This merging of components directly reduces assembly complexity while maintaining structural flexibility through the integrated design.
2Ease of manufacture
If the lower housing and yoke are separate components requiring two-step assembly, then the manufacturing flexibility is improved, but the productivity decreases
Solution Approach 1:
The lower housing and yoke are merged into a single integrated component manufactured in one step. The injection molding process creates both structures simultaneously, eliminating the need for separate manufacturing and assembly operations. This significantly improves productivity by reducing the number of assembly steps while maintaining manufacturing flexibility through the molding process.
Solution Approach 2:
The integrated design performs the function of both the lower housing and yoke in a single manufacturing action. The injection molding process simultaneously creates the housing structure and the magnetic yoke, performing multiple manufacturing functions in advance of what would traditionally require separate steps.
3Adaptability or versatility
If the lower housing and yoke are separate components requiring two-step assembly, then the structural adaptability is improved, but the production cost increases
Solution Approach 1:
The patent integrates the yoke structure into the lower housing as a single component. This eliminates the need for separate manufacturing processes and assembly operations, reducing labor costs, material handling costs, and production time. The integrated design maintains structural adaptability while significantly lowering production costs through process simplification.
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 integration simplifies the assembly process, saves production time, and reduces costs by combining the magnetic conductive piece and lower housing into a single component, enabling a more efficient manufacturing workflow.
Implementation Method 1
the third housing is fixed with the second housing by ultrasonic welding through the plastic piece
Data Source
AI summary
The present invention discloses a receiver comprising an outer housing that consists of a first housing, a second housing and a third housing fitting to each other from top to bottom. The third housing is an integral structure, and includes a magnetic conductive piece and a plastic piece integrally injection-molded therewith. The magnetic conductive piece is bonded and fixed with a magnet and a washer. The magnetic conductive piece, the magnet and the washer together form a magnetic circuit system of the receiver, and the third housing is fixed with the second housing by ultrasonic welding through the plastic piece. The receiver of the present invention can realize one-step assembly of the rear cavity housing of the product, simplify the production process of the product, save the production time, and further reduce the production cost of the product.