Dispenser Shuttle Switch for Accurate Sheet Removal Detection
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Solution Overview
Problem
Existing product dispensers face challenges in accurately determining product removal and providing feedback to users, particularly due to component cost constraints, manufacturing inconsistencies, and the risk of switch damage from excessive force, as well as the lack of tactile feedback with capacitive sensors.
Innovation Solution
A shuttle mechanism is positioned between the tear bar and a switch on a printed circuit board, using the force of the paper product to move and actuate the switch, reducing component count, managing force, and providing feedback through motor operation for capacitive sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a direct switch connection to the tear bar is used, then the structure is simple, but the switch is exposed to excessive force that may damage it
Solution Approach 1:
A shuttle member is introduced as an intermediary between the tear bar and the switch. The shuttle receives force from the tear bar during product removal and transmits a controlled portion of this force to the switch, preventing direct exposure to excessive force while maintaining the simple overall structure
2Speed
If the switch is positioned close to the tear bar, then the response is immediate, but the switch is exposed to dust and excessive force from the tearing process
Solution Approach 1:
The shuttle acts as a mediator that transmits the tearing motion to the switch from a distance. The switch can be positioned on the PCB away from the tear bar, reducing exposure to dust and excessive force, while the shuttle bridges the gap to transmit the removal detection signal
Solution Approach 2:
The shuttle converts the linear tearing motion into rotational or angular motion of the PCB assembly, allowing the switch to be actuated from a different spatial dimension and location, away from the harsh environment near the tear bar
3Device complexity
If capacitive sensors are used for user input, then the design is sleek and modern, but there is no tactile feedback to confirm user interaction
Solution Approach 1:
When a capacitive sensor detects user input, the system provides tactile feedback by actuating the shuttle mechanism. This causes the PCB to rotate or move, creating a physical sensation that confirms to the user their input was registered, while maintaining the sleek capacitive sensor design
4Reliability
If multiple components are used for tear detection, then the reliability is high, but the component cost and manufacturing complexity increase
Solution Approach 1:
The shuttle member serves multiple functions: it acts as a force transmitter, a motion amplifier, a positional translator, and a mechanical linkage. This multi-functionality reduces the need for separate components for each function, lowering component count and manufacturing cost while maintaining reliable tear detection
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 solution enhances the accuracy of product removal detection, reduces component and manufacturing costs, and provides user feedback, ensuring reliable operation and user interaction with capacitive sensors.
Implementation Method 1
The shuttle uses the force of the paper towel to move to an actuated position to interact with a switch
Data Source
AI summary
An example sheet product dispenser includes a dispensing mechanism operable to dispense sheet product to provide the dispensed portion within a dispensing chute. A tear bar is provided for separating the dispensed portion from a remainder of the sheet product. A shuttle is positioned between a switch and the dispensed portion. The shuttle is movable between an unactuated position and an actuated position. When the shuttle is in the unactuated position, the switch is in the unactuated configuration. The shuttle and the switch are positioned within the sheet product dispenser such that as the user pulls on the dispensed portion the shuttle moves to the actuated position so that the shuttle applies a force on the switch sufficient enough to transition the switch to an actuated configuration to indicate removal of the dispensed portion. Other example improvements include providing feedback for user inputs to a product dispenser.