Power Tool Cord Protector Labyrinth Friction Design
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Solution Overview
Problem
Heavier portable power tools often experience cord separation due to impulse loads or jerks, particularly when dropped or maneuvered, leading to connection failures.
Innovation Solution
A power tool design featuring a cord set load protector with a labyrinthine internal structure and radially extending bosses within the housing, combined with a crimp-on device and cord clamp system, which absorbs forces and distributes stress along the power cord to prevent separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a power cord is directly connected to the motor without protection, then the device complexity is reduced, but the reliability deteriorates due to cord separation from impulse loads
Solution Approach 1:
The cord protector is nested within the housing structure, with the labyrinthine internal features integrated into the housing wall itself. The cord protector passage is formed as an internal cavity within the housing, allowing the protection mechanism to be embedded rather than added as a separate external component.
Solution Approach 2:
The labyrinthine structure creates localized friction zones at specific positions along the cord protector passage. The first and second bosses are positioned at different locations within the housing to create distributed friction points that engage with the cord protector at different stages of cord movement.
2Reliability
If a labyrinthine structure with multiple bosses is added to the housing, then the cord protection capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The cord protector passage and the labyrinthine friction features are merged into a single integrated housing structure. The first and second bosses are formed as integral parts of the housing wall, eliminating the need for separate manufacturing steps for these protection features.
3Reliability
If the first boss extends farther radially inward than the second boss, then the frictional force distribution is optimized, but the manufacturing precision requirements increase
Solution Approach 1:
The first and second bosses are designed with asymmetric extension distances from the housing interior surface. The first boss extends farther radially inward than the second boss, creating an intentional asymmetric friction force distribution that optimizes cord protection while providing built-in alignment features.
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 effectively absorbs and distributes applied forces, reducing the likelihood of cord separation and enhancing the durability and flexibility of the power cord connections.
Implementation Method 1
a frictional force occurs between the cord protector and the cord jacket in response to a load being applied to the power cord
Data Source
Figure 1
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AI summary
A power tool having a housing, a motor disposed in the housing, a power cord connected to the motor, and a cord protector operably engaging the power cord. The housing includes a labyrinth that engages the cord protector providing an additional frictional force on the power cord.