Wearable Audio Hinge Cable Routing and Stress Management
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Solution Overview
Problem
Designing a hinge for wearable audio devices, such as audio eyeglasses, that accommodates cables while maintaining the hinge mechanism's functionality is challenging due to the need for cable management and minimizing cable stress.
Innovation Solution
The implementation of a hinge with an insert to manage the minimum bend radius of cables and a cable management feature, including a metal ledge and adhesive strips, to secure and route the cables efficiently through the hinge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cables are routed through the hinge, then connectivity between device sections is achieved, but cable stress and damage risk increase
Solution Approach 1:
A cable management feature acts as an intermediary structure between the hinge mechanism and the cable. This feature includes a cable retention opening that guides and secures the cable through the hinge assembly, preventing direct stress on the cable from hinge movement while maintaining electrical connectivity between device sections.
Solution Approach 2:
The hinge assembly is segmented into distinct functional zones: a hinge mechanism portion for movement, a cable management feature for cable routing, and a hinge cover for protection. The cable retention opening is specifically positioned to separate the cable path from the primary hinge articulation point, reducing mechanical stress on the cable.
2Reliability
If cable management features are added to the hinge, then cable stress is reduced, but device complexity increases
Solution Approach 1:
The cable management feature is merged with the hinge cover assembly rather than being a separate independent component. The cable retention opening is integrated into the hinge cover structure, allowing the cable to be routed through the same assembly that provides structural protection and hinge functionality, thereby minimizing additional complexity.
3Ease of operation
If the hinge is designed for smooth movement, then device functionality is maintained, but cable stress increases
Solution Approach 1:
The cable management feature serves as a mediator that decouples the hinge movement from cable stress. The cable retention opening is positioned and configured to allow the hinge to move smoothly while the cable remains secured in a stress-free path, preventing force transmission from the hinge mechanism to the cable.
Data Source
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AI summary
Various aspects include wearable audio devices with through-hinge wiring configurations. In particular aspects, a wearable audio device includes a hinge coupling a first section and one additional section; and a cable extending through the hinge. In various implementations, the hinge is overmolded on the cable and includes: a body defining a cavity accommodating the cable with a first opening to a pathway in the first section, and a second opening to an additional pathway in the one additional section; an insert within the body and adjacent the first opening, the insert defining a minimum radius of a bend in the cable within the cavity; a hinge mechanism contained within the body; and a cable management feature contained within the body, wherein the hinge mechanism, cable management feature and cable are all located in a common plane that is radially oriented relative to the primary axis of the hinge mechanism.