Telescopic Baton Lever Locking for Thin-Tube Reliability
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Solution Overview
Problem
Existing expandable telescopic batons are complex, material-intensive, and heavy, with locking mechanisms that are prone to wear and difficult to manufacture, leading to reliability issues and inability to produce lightweight batons with thinner tubes.
Innovation Solution
The design features a tubular handle and central tube with internal radial grooves, lever segments with tilting arms and elastic elements for secure locking and easy assembly, and a one-piece release rod that ensures reliable extension and folding, allowing for the production of a lightweight baton with high strength and small locking mechanism size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If locking means with balls and grooves are used, then the baton can be locked in extended position, but the construction becomes complex and material-intensive
Solution Approach 1:
The locking member is divided into multiple lever segments (first tilting arm and second tilting arm) that can independently tilt and engage with the grooves. This segmentation allows the locking function to be distributed across multiple simple components rather than requiring a complex integrated mechanism.
Solution Approach 2:
Instead of using balls that passively fit into grooves, the invention uses lever segments with radial projections that actively engage with the grooves through tilting motion. The release mechanism works by tilting the levers to disengage projections from grooves, reversing the conventional approach where balls are pushed out radially.
2Reliability
If locking means with balls and deep grooves are used, then the baton can be locked securely, but the tube walls become thin and strength is reduced
Solution Approach 1:
The locking function is segmented into multiple radial projections on different lever segments, allowing the grooves to be shallower and more distributed along the tube length. This eliminates the need for deep grooves that would weaken the tube walls.
Solution Approach 2:
The lever segments are pre-positioned with radial projections that automatically engage with the grooves when the tube is extended. The elastic element pre-loads the lever segments to ensure reliable engagement without requiring deep grooves for ball retention.
3Ease of operation
If semi-circular segments with springs are used for locking, then the baton can be folded easily, but wear occurs on the release rod and manufacturing becomes difficult
Solution Approach 1:
Instead of using springs to push semi-circular segments out of grooves, the invention uses lever segments that tilt to engage and disengage radial projections from grooves. The release rod simply tilts the levers rather than forcing segments against spring pressure, reducing wear and simplifying manufacturing.
Solution Approach 2:
The lever segments are designed to automatically engage with the grooves through their own tilting motion without requiring complex spring mechanisms. The elastic element provides self-loading to ensure engagement, eliminating the need for separate spring components and complex assembly.
4Reliability
If conical enlargement on release rod is used, then the baton can be locked in extended position, but the locking mechanism size increases and thin tubes cannot be produced
Solution Approach 1:
The locking mechanism is segmented into multiple small lever segments distributed around the tube perimeter rather than requiring a single large conical mechanism. This allows the locking function to be achieved with minimal volume, enabling thin-walled tube construction.
Solution Approach 2:
Instead of using axial conical enlargement that increases length, the invention uses radial tilting of lever segments to achieve locking. This dimensional change from axial to radial operation allows compact locking mechanism volume while maintaining reliability.
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 solution results in a baton that is easy to manufacture, lightweight, and reliable, with high strength and resistance to shock, enabling reliable extension and folding even under severe conditions, and allowing for the production of batons with smaller diameters.
Implementation Method 1
the segments are provided with an elastic element pushing the radial projections into the internal radial grooves
Implementation Method 2
the lever segments of the first order tilt over the tilting edge, wherein the radial projections extend from the internal radial groove
Data Source
Figure 1
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AI summary
The expandable telescopic baton (1) consists of the handle (2), the central tube (5) with secondary locking member, of the end tube (6) with terminal locking member, of the button (4) and of the release rod (8). The locking member comprises at least two lever segments of the first order (9, 9'), whose first tilting arms (11) bear the radial projections (10) securing the tubes (5, 6) in the extended position, the second tilting arms (12) extend inside the tubes (5, 6), and the tilting means comprising the tilting edge (15) ensures the tilting of the segments (9, 9') against the inner wall of the tube (5, 6). The segments (9, 9') on the inner side are dimensionally adjusted so that the smallest internal clear distance (L1) between the second tilting arms (12) is smaller than the smallest internal clear distance (L2) between the first tilting arms (11) and at the same time smaller than the diameter (d) of the release rod (8). The release rod (8) passing through the locking tilts over the segments (9, 9'), thus extending radial projections (10) from the internal radial grooves (7, 7').