Double Overmolded Display Housing Assembly for Compact Tools
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Solution Overview
Problem
Display assemblies in hand tools, such as motorized ratchet wrenches, require additional space for buttons and flat displays, resulting in a bulkier housing that is cumbersome for use in tight spaces.
Innovation Solution
A display housing assembly with a molded lens, base, and integrated buttons that correspond to the external geometry of the tool housing, allowing for a more compact design by eliminating the need for separate button structures and accommodating the display unit within the tool's shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate buttons and flat displays are used in the display assembly, then the display function is achieved, but the housing becomes bulkier and harder to operate in tight spaces
Solution Approach 1:
The patent combines the buttons and display into a single integrated display housing assembly that is molded as one piece. The buttons are formed as integral portions of the housing structure, eliminating the need for separate button components and reducing overall housing volume while maintaining full display and control functionality.
Solution Approach 2:
The display unit is nested within the molded housing structure, with the buttons and display elements integrated into the housing walls. This nesting approach allows the display assembly to fit within the existing housing geometry without requiring additional external space.
2Adaptability or versatility
If additional structure for buttons is added to accommodate the display assembly, then the display functionality is achieved, but the housing shape becomes more complex and bulkier
Solution Approach 1:
The buttons and housing are merged into a single molded component, where the button structures are formed directly as part of the housing walls. This integration eliminates the need for separate button housings or mounting structures, maintaining simple housing geometry while providing full display and button functionality.
3Ease of manufacture
If separate components are used for the display assembly, then manufacturing flexibility is improved, but assembly complexity and time increase
Solution Approach 1:
The display housing, buttons, and button features are all merged into a single molded part. This eliminates the need for separate assembly steps for attaching buttons to the housing, reducing assembly time to virtually zero for these components while maintaining manufacturing flexibility through mold design options.
Solution Approach 2:
The buttons and housing features are pre-formed during the molding process itself, rather than being added in subsequent assembly steps. This preliminary formation of all button structures and display housing features during molding eliminates post-molding assembly operations.
4Ease of manufacture
If a flat display structure is used, then the display is easy to manufacture, but it requires additional space that creates a bulkier housing
Solution Approach 1:
The flat display unit is nested within the molded housing structure, utilizing the housing walls and internal cavities to accommodate the display without adding external bulk. The display is integrated into the housing geometry, allowing it to be housed within the existing volume constraints.
Data Source
AI summary
A display housing assembly has a base, a lens, and buttons. The base, lens, and buttons may be shaped to correspond with an external geometry of a tool housing, such as, for example, curved, arcuate or cylindrically shaped. The display housing assembly may also be assembled by molding the lens, molding the base over the lens, and molding the buttons over the base.