Break Resistant Joint for Portable Misting Fan
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Solution Overview
Problem
Portable misting fan devices have a weak joint between the upper and lower body portions, making them prone to breakage when dropped, and existing solutions like adhesives and ultrasonic welds are costly and not universally applicable.
Innovation Solution
A non-circular neck configuration with grooves and rails, combined with flanges and a sleeve structure, secures the upper body portion to the lower body portion, preventing rotation and enhancing break resistance without the need for adhesives or expensive techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a threaded neck with screw cap is used to join the upper and lower body portions, then the device can be easily assembled and disassembled, but the joint becomes weak and prone to breakage when dropped
Solution Approach 1:
The collar body is divided into two separate half-collars that are joined together, allowing the assembly to be disassembled for cleaning and maintenance while maintaining a strong joint structure when assembled. The segmentation allows for easier manufacturing and assembly of the components.
Solution Approach 2:
The neck portion is designed with an asymmetric non-circular configuration featuring flat spots, which corresponds to matching flat spots on the collar body. This asymmetric design prevents rotation during assembly and creates a more robust joint compared to a symmetric circular design, while still allowing for easy alignment and assembly.
2Strength
If adhesives or ultrasonic welds are used to strengthen the joint, then break resistance improves, but manufacturing cost increases
Solution Approach 1:
The collar body is designed as a single integrated piece that combines the support ledge, neck engagement features, and sealing surfaces into one component. This merging eliminates the need for separate adhesive applications or complex welding procedures, reducing manufacturing cost while maintaining joint strength through the integrated structural design.
Solution Approach 2:
The joint structure is designed to be self-securing through the interaction between the non-circular neck portion and the collar body with matching geometry. The design inherently provides alignment features, rotation prevention, and structural interlocking without requiring external fastening methods like adhesives or welds, thereby simplifying manufacturing.
3Strength
If a non-circular neck configuration with grooves and rails is used, then rotation is prevented and joint strength increases, but device complexity increases
Solution Approach 1:
The non-circular neck portion with flat spots creates an asymmetric geometry that naturally prevents rotation when assembled with the collar body. This asymmetric design achieves the rotational prevention function through simple geometric constraints rather than complex mechanical locking mechanisms, maintaining relatively low device complexity while significantly improving joint strength.
Solution Approach 2:
The collar body is designed with a curved support ledge that provides a bearing surface for the upper body portion. This curved geometry distributes loads more effectively and complements the non-circular neck configuration, enhancing joint strength through smooth geometric transitions rather than sharp angles or complex features.
Data Source
AI summary
There is disclosed a portable misting fan formed by upper and lower body portions which are joined together along a joint. The joint is improved by providing the lower body portion with a non-circular neck portion along its top end, and wherein the upper body portion includes two halves which terminate in lower body collar sections, intended to be joined together in overlying relationship relative to the neck portion. A rail and groove system is employed as between the upper first and second body portions, and the neck portion, so that the rails will slidingly engage the grooves in the neck portion rendering the joint resistant to rotation. The neck portion includes an aperture into which a sleeve is press fitted, the sleeve includes upper and lower lips, and the lower body collar sections include inwardly extending flanges which overlie and engage the upper and lower lips formed in the sleeve, thereby brace and secure the pump assembly within the device.