Resin Housing Fixing by Thermal Embedding for Precise Positioning
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Solution Overview
Problem
Conventional housing fixing methods rely on protrusions and grooves for positioning, limiting accuracy and requiring costly bonding materials like solder or adhesive, which increase material and management costs.
Innovation Solution
A method involving pre-adjustment of a resin housing on a base plate, followed by heating and pressing to embed a contact portion into a groove or hole, eliminating the need for bonding materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a protrusion and groove engagement method is used to fix the housing, then the housing position is determined, but the positional accuracy is limited by the processing accuracy of the protrusion and groove
Solution Approach 1:
The invention extracts the positioning function from the mechanical engagement structure (protrusion and groove) and separates it from the fixing function. The housing bottom surface is made flat for positioning, while a separate contact portion is melted and embedded into the base plate for fixing, eliminating the need for complex engagement structures and achieving higher positional accuracy.
Solution Approach 2:
The invention changes the physical state of the contact portion from solid to melted state through heating, allowing it to flow and embed into the base plate. After cooling, it solidifies to provide strong fixation. This parameter change (temperature) enables a simpler and more accurate positioning method compared to mechanical engagement.
2Reliability
If solder or adhesive is used to fix the housing position, then the position is fixed, but material cost and material management cost are generated
Solution Approach 1:
The housing's own contact portion serves as the bonding material. By melting and embedding the contact portion of the housing itself into the base plate, the invention eliminates the need for external solder or adhesive materials, thereby reducing material costs and management costs while maintaining reliable fixation.
Solution Approach 2:
The invention discards the concept of using separate bonding materials and instead recovers/utilizes the housing material itself (contact portion) for the bonding purpose. The contact portion is melted and embedded into the base plate, transforming the housing material into the bonding medium.
3Reliability
If solder or adhesive is used for fixing, then bonding is achieved, but printing work or coating work and bonding time are required
Solution Approach 1:
The invention replaces the mechanical processes of printing, coating, and bonding with a thermal process. By heating the contact portion to melt it and then embedding it into the base plate, the method eliminates multiple sequential steps (printing, coating, bonding) and achieves fixation in a more efficient integrated process.
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
Improves positional accuracy and reduces material and management costs by eliminating the need for bonding materials, while simplifying the bonding process.
Implementation Method 1
a step of heating the base plate or the contact portion of the housing with the base plate while pressing the housing against the base plate, to thereby deform the flat contact portion of the housing so that the contact portion is partially embedded in the hole
Implementation Method 2
a step of cooling the thus-heated base plate or contact portion of the housing with the base plate
Data Source
AI summary
There are included: a step of adjusting, on a surface of a base plate, the position of a housing which is made of a resin and is placed on the base plate so as to partially cover that base plate, to an extent that a contact portion of the housing with the base plate is kept straddling a groove that is formed on the surface of the base plate and has a width smaller than a width of the contact portion; a step of heating the base plate or the contact portion of the housing with the base plate while pressing the housing against the base plate; and a step of cooling the thus-heated base plate or contact portion of the housing with the base plate. This makes it possible to significantly improve the accuracy of the position adjustment.