Triple-Structure Coin Assembly via Outer Surface Recesses
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Solution Overview
Problem
Conventional bimetal coin and medal manufacturing methods face challenges in forming recesses and projections, leading to difficulties in processing small inner surfaces, unnatural metal flow during assembly, and requiring high energy for coupling, which affects the coherence and durability of the final product.
Innovation Solution
A method involving the formation of first and second recesses on the outer surfaces of an internal and external ring, respectively, with edges on the circumference, followed by annealing and acid-pickling, and simultaneous press-assembly to align and couple the rings, ensuring natural metal flow and improved coherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a recess or projection is formed in the inner surface of the external coin to couple the internal and external coins, then the coupling strength is improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
Instead of forming a recess in the external coin's inner surface (conventional approach), the invention inverts the approach by forming a protrusion on the internal coin's outer surface that inserts into a recess in the external coin's outer surface. This inversion simplifies manufacturing by allowing the external coin to be formed with a standard outer diameter press without requiring complex inner surface processing equipment.
Solution Approach 2:
The invention extracts the coupling feature formation from the external coin's inner surface (which requires exclusive processing equipment) and relocates it to the external coin's outer surface (which can be processed by standard equipment). This separation allows the use of conventional pressing equipment while achieving the same coupling function.
2Strength
If a recess or projection is formed in the inner surface of the external coin, then the coupling between internal and external coins is improved, but the ease of manufacture deteriorates due to requiring exclusive equipment
Solution Approach 1:
The invention inverts the location of the coupling feature from the external coin's inner surface to its outer surface. This allows the external coin to be manufactured using standard outer diameter pressing equipment rather than requiring exclusive inner surface processing equipment, significantly improving ease of manufacture while maintaining coupling strength.
Solution Approach 2:
By forming the coupling recess on the external coin's outer surface, the same pressing equipment used for forming the external coin's outer diameter can also form the coupling recess. This multi-functionality eliminates the need for exclusive processing equipment and simplifies the manufacturing process.
3Ease of manufacture
If the recess portion is formed in the center of the outer surface of the inner coin, then the processing of external coin inner surface is avoided, but the energy consumption increases due to unnatural metal flow
Solution Approach 1:
Instead of forming the recess on the internal coin's outer surface (which causes unnatural metal flow), the invention inverts the approach by forming the recess on the external coin's outer surface. This allows the metal to flow naturally during pressing, reducing the energy required for plastic transformation while maintaining ease of manufacture.
Solution Approach 2:
The coupling recess is formed on the external coin's outer surface during the initial pressing process, before the internal and external coins are assembled. This preliminary formation of the recess ensures that the metal flow during subsequent assembly follows a natural path, minimizing energy consumption.
4Ease of manufacture
If the recess portion is formed in the center of the outer surface of the inner coin, then the external coin inner surface processing is simplified, but the assembly coherence deteriorates due to unnatural metal flow
Solution Approach 1:
The invention inverts the location of the recess from the internal coin to the external coin's outer surface. This inversion allows the metal to flow naturally during assembly, improving the coherence between the internal and external coins while maintaining the simplicity of the manufacturing process.
Solution Approach 2:
The invention converts the potential harm of unnatural metal flow (which occurs when recess is on internal coin) into a benefit by relocating the recess to the external coin's outer surface. This relocation allows the metal flow to be natural, improving assembly coherence while maintaining manufacturing simplicity.
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 method enhances the assembly coherence between the external and internal rings, resulting in a structurally excellent triple-metal coin or medal with improved exterior surface appearance and stability.
Implementation Method 1
annealing and acid-pickling
Implementation Method 2
annealing and acid-pickling
Implementation Method 3
simultaneous press-assembly to align and couple the rings
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A coin assembly and a medal assembly which have triple-structures, respectively, and a method for fabricating the same are disclosed. The coin assembly includes an internal ring; an external ring coupled to an outside of the internal ring; an insert coupled to an inside the internal ring; a first recess formed in an outer surface of the internal ring, to have a predetermined portion of an outer surface of the external ring inserted therein, when the internal ring and the external ring are assembled with each other; and a second recess formed in an outer surface of the insert, to have a predetermined portion of an outer surface of the internal ring therein, when the insert and the internal ring are assembled with each other.