Earplug Dispenser with Haptic Feedback to Reduce Jamming
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Solution Overview
Problem
Conventional rotary-type dispensing mechanisms for disposable earplugs, which are compressible and tacky, often fail to accurately and consistently dispense a single earplug due to jamming issues and malfunctions, as they are not designed to handle the unique physical characteristics of these materials.
Innovation Solution
A manually operable dispenser with a dispensing mechanism that includes a separator assembly and an index assembly, where the interaction between the first and second dispensing mechanism portions provides varying rotational resistance, allowing for haptic feedback and improved alignment of the dispensing aperture with individual bores, reducing jamming and enhancing dispensing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional rotary-type dispensing mechanism is used for earplugs, then the device can store and dispense small objects, but the compressible and tacky earplugs become lodged between moving components causing jamming and malfunction
Solution Approach 1:
The dispensing mechanism is segmented into discrete functional zones: a storage well, individual bores for each earplug, a dispensing aperture, and a rotary index assembly. This segmentation isolates each earplug in its own bore, preventing them from interacting and causing jams, while the indexed rotation ensures controlled, one-at-a-time dispensing.
Solution Approach 2:
The patent introduces an intermediary indexing mechanism with a handle and aperture that mediates between the user's rotational input and the earplug dispensing. This intermediary controls the rotation in discrete steps, allowing the user to advance the mechanism without directly forcing compressible earplugs through tight clearances, thereby reducing jamming.
2Productivity
If a rotary dispensing mechanism is used, then individual earplugs can be dispensed, but the compressible material makes it difficult to accurately and consistently dispense only a single earplug
Solution Approach 1:
Each earplug is preliminarily positioned and held within its own dedicated bore in the separator assembly before dispensing. The bore acts as a pre-positioning fixture that maintains the earplug in a ready state, ensuring that when the index aperture aligns with the bore, exactly one earplug is available for dispensing without variation or jamming.
Solution Approach 2:
The separator assembly provides local quality by giving each earplug its own dedicated bore with specific dimensions and orientation. This localized structure ensures that each earplug is handled independently with consistent geometry, improving dispensing accuracy while accommodating the compressible nature of the material.
3Ease of operation
If a manually operable mechanism is used, then the user can control dispensing, but the lack of haptic feedback makes it difficult to know when proper alignment is achieved
Solution Approach 1:
The index assembly provides mechanical haptic feedback to the user during rotation. As the index aperture passes by each bore, the user feels discrete tactile cues or resistance changes that indicate alignment positions. This feedback loop allows the user to know when proper alignment is achieved without visual confirmation, maintaining manual control while restoring information about system state.
Data Source
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AI summary
A manually operable dispenser for dispensing earplugs is provided. An exemplary dispenser includes a first dispensing mechanism portion and a second dispensing mechanism portion that interacts with the first dispensing mechanism portion during rotation of the handle. Interaction between the first dispensing mechanism portion and the second dispensing mechanism affects a rotational resistance (τ) at the handle such that rotational resistance (τ) varies between a maximum rotational resistance (τmax) and a minimum rotational resistance (τmin) as the handle is rotated by a user.