Resin Frame Joint Design for Strength and Appearance
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Solution Overview
Problem
Existing resin frame manufacturing methods either compromise on joining strength or appearance, as high joining strength often requires a removing process that deteriorates the outer surface appearance, while improved appearance comes at the cost of reduced joining strength.
Innovation Solution
A resin frame design incorporating both entire-surface and partial welded portions at different locations on the joint, allowing for harmonized joining strength and appearance, achieved through a manufacturing method involving cutting, melting, and welding processes that optimize the placement and removal of welding margins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the removing process is applied to eliminate protruding welding margins, then the outer surface appearance is improved, but the joining strength is reduced
Solution Approach 1:
The welding margin is divided into two functional zones: a first portion that protrudes outward to ensure strong joining through increased welding area, and a second portion that is recessed to maintain smooth outer surface appearance. This segmentation allows both appearance and strength requirements to be satisfied simultaneously.
Solution Approach 2:
Different portions of the welding margin are given different geometric qualities: the first portion is designed with protruding geometry to maximize welding contact area and strength, while the second portion is designed with recessed geometry to preserve the aesthetic appearance of the outer surface. Each portion serves its specific local function optimally.
2Strength
If the welding margin is increased to improve joining strength, then the structural integrity is enhanced, but the outer surface appearance deteriorates due to protruding portions
Solution Approach 1:
The welding margin structure is segmented into a strength-providing first portion and an appearance-providing second portion, allowing the welding margin to be sufficiently large for strength while preventing outward protrusion that would harm appearance.
Solution Approach 2:
The solution moves from a two-dimensional surface consideration to a three-dimensional volumetric structure, where the welding margin extends inward (recessed) rather than outward (protruding), utilizing the depth dimension to resolve the appearance-strength conflict.
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 resin frame achieves balanced joining strength and appearance by strategically placing entire-surface and partial welded portions, enhancing both the structural integrity and visual appeal.
Implementation Method 1
a melting process, in which end surfaces of two frame members are heated, and end portions of the frame members are melted as welding margins
Implementation Method 2
a welding process, in which the welding margins are abutted against each other and welded
Data Source
AI summary
A resin frame includes frame members combined into a frame shape that includes a corner portion, and a joint portion joining a pair of the frame members which are adjacent to each other at the corner portion. The joint portion includes an entire-surface welded portion, in which end surfaces of the pair of the frame members are welded to each other over an entire surface in a thickness direction of a plate portion of the frame members, and a partial welded portion, in which the end surfaces of the pair of the frame members are welded to each other on one side of the entire surface in the thickness direction while another side of the entire surface in the thickness direction is not welded. The entire-surface welded portion and the partial welded portion are present at different portions on an outer periphery of the joint portion.