Fluorescent Tool Supports in Dual-Shell Container for FOD Detection
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Solution Overview
Problem
Current tool containers lack visibility of stored tools, particularly fluorescent tool supports, which can lead to Foreign Object Damage (FOD) in sensitive environments like aero-engine maintenance, where the absence of tools is difficult to detect.
Innovation Solution
A tool container designed with shells made of two plastics materials, one rigid and one soft, featuring fluorescent tool supports that provide visibility through windows, allowing users to easily detect the presence or absence of tools and minimizing FOD by alerting users to missing tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional opaque tool containers are used, then manufacturing cost and simplicity are maintained, but visibility of tool supports and detection of missing tools is poor
Solution Approach 1:
The patent applies fluorescent coloration to the tool supports, causing them to glow under UV or blacklight illumination. This color change technique transforms ordinary invisible plastic supports into highly visible fluorescent indicators, allowing users to easily detect missing tools without adding complex mechanical or electronic components to the container structure.
2Strength
If rigid plastics material is used for shells, then structural strength is improved, but cushioning and stability of tools is reduced
Solution Approach 1:
The patent employs a composite construction where rigid plastic shells provide structural strength and protection, while separate soft plastic cushions or foam inserts provide tool stabilization and shock absorption. This composite approach allows each material to perform its optimal function - the rigid shell maintains container integrity while the soft interior materials prevent tool movement and damage during transport.
3Stability of the object's composition
If soft plastics material is added to shells, then tool cushioning and stability are improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the container into separate functional segments: rigid plastic shells for structural support and separate soft plastic cushions or foam inserts for tool stabilization. This segmentation allows each component to be manufactured independently using optimized processes, then assembled together, reducing overall manufacturing complexity compared to creating a single complex multi-material shell.
4Loss of information
If fluorescent tool supports are implemented, then detection of missing tools is improved, but manufacturing cost increases
Solution Approach 1:
The patent incorporates fluorescent dyes or pigments into the plastic material used for tool supports during the injection molding process. This color change technique is integrated into the existing manufacturing workflow, requiring only minor adjustments to the molding process rather than adding separate assembly steps or expensive electronic detection systems, thereby keeping manufacturing costs relatively low while achieving excellent visibility.
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 tool container effectively reduces FOD by allowing easy detection of missing tools through fluorescent markings, provides cushioning and stability for tools, and reduces rattling noises with its soft closure mechanism, enhancing user experience and safety.
Implementation Method 1
the or each tool support comprises second material of one of the first shell or second shell pigmented with a fluorescent colour visible through a respective window
Implementation Method 2
The soft material deforms elastically and its resilience ejects the socket from the holding means
Data Source
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AI summary
A tool container (10) comprising: a first shell comprising a shell body of a first plastics material and a second plastics material different to the first material; and a second shell comprising a shell body of the first material and the second material. The first shell is coupled to the second shell by means of a hinge (60) to rotate between open and closed positions. The tool container comprises tool supports (202, 204, 212, 213, 214, 215, 223, 224, 233, 234) each arranged to support a respective hand tool inside the tool container. The first shell and/or second shell comprises a window to the or each tool support inside the tool container. The tool supports comprise material of the first shell or second shell pigmented with a fluorescent colour visible through a respective window.