Level Vial Fixing via Merged Aperture and Magnet
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Solution Overview
Problem
Traditional level manufacturing methods involve multiple drill holes and costly plug production, as well as adhesive sealing, leading to increased costs and a less aesthetically pleasing appearance due to the complexity of material adhesion and plug shapes.
Innovation Solution
Combining vial-receiving and magnet-locating apertures allows for a single-step drilling process, eliminating the need for traditional plugs and adhesive sealing, with magnets used to fix the vials after positioning, reducing material and labor costs while enhancing the level's appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional plug insertion or glue sealing methods are used to fix the vial, then the vial can be securely fixed in the hole, but the manufacturing cost increases and the appearance becomes less aesthetic
Solution Approach 1:
The patent combines the vial-receiving aperture and magnet-locating aperture into a single integrated hole structure. The magnet is positioned at one end of the hole while the vial is received in the same hole, eliminating the need for separate plug components or adhesive sealing operations. This merging of functions reduces manufacturing steps, eliminates the need for additional materials (plugs, adhesives), and improves appearance by creating a cleaner, more integrated look.
Solution Approach 2:
The single hole structure serves multiple functions simultaneously: it acts as both the vial-receiving aperture and the magnet-locating aperture. The magnet positioned at one end of the hole provides magnetic fixation, while the same hole accommodates the vial, eliminating the need for separate fixation mechanisms and reducing overall device complexity.
2Ease of operation
If multiple drill holes are created for separate vial-receiving and magnet-locating apertures, then the vial and magnet can be independently positioned, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent merges two separate aperture-drilling operations into a single drilling operation. By creating one hole that serves both as the vial-receiving aperture and magnet-locating aperture, the manufacturing process is simplified, reducing the number of drilling steps, tool changes, and positioning operations required, thereby lowering manufacturing complexity and cost.
Solution Approach 2:
The patent utilizes the longitudinal dimension of a single hole to accommodate both the vial and magnet at different positions along the same axis. The vial is received in the main portion of the hole while the magnet is positioned at one end, effectively using spatial arrangement along the hole's length to achieve independent positioning without requiring separate holes.
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 approach decreases manufacturing costs and improves the level's appearance by simplifying the drilling process and eliminating the need for plugs and adhesive sealing, resulting in a more cost-effective and visually appealing product.
Implementation Method 1
a side of the opened-ended locating hole is mounted with a locating aperture so that a magnet is positioned in the locating aperture so as to fix the vial
Data Source
AI summary
A level includes a top surface, a bottom surface parallel with the top surface, and a body accommodating at least one vial. The body has at least one through hole, at least one portion of the vial is exposed through the through hole, a close-ended locating hole is mounted at a side of the through hole, an opened-ended locating hole is mounted at another side of the through hole, and two sides of the vial are accommodated in the two locating holes respectively. A side of the opened-ended locating hole is mounted with a locating aperture so that a magnet is positioned in the locating aperture so as to fix the vial.