Plastic Cantilevered Spring for Recyclable Dispenser Actuation
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Solution Overview
Problem
Existing dispensers with metal springs complicate recycling and require additional manufacturing and assembly due to the separate presence of metal springs, which are not integral to the plastic dispenser units.
Innovation Solution
A cantilevered spring mechanism is integrated into the dispenser, made entirely from plastic, acting as a unitary element with the support and actuator members, providing resiliency and eliminating the need for separate metal springs by using elongate cantilevered leaf spring members that are injection molded together with the dispenser components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal springs are used in plastic dispensers, then the dispenser provides reliable resiliency and long useful life, but the dispenser becomes harder to recycle and requires separate manufacturing and assembly processes
Solution Approach 1:
The spring member is merged with the actuator member to form a unitary plastic component. The spring arm and spring finger are integrally formed as single pieces with the actuator body, eliminating the need for separate metal springs and reducing assembly complexity while maintaining the dispensing function.
Solution Approach 2:
The invention uses plastic material for the spring member instead of traditional metal springs. The plastic spring arm and spring finger provide the necessary resiliency and elastic deformation capabilities while being compatible with plastic injection molding processes, creating a composite plastic assembly.
2Reliability
If metal springs are used in plastic dispensers, then the dispenser provides reliable resiliency, but the dispenser cannot be easily recycled as a single material stream
Solution Approach 1:
The spring member is made entirely of plastic material, matching the actuator member and dispenser body. This homogeneity of material composition allows the entire assembly to be processed together through injection molding and enables recycling as a single plastic material stream without requiring separation of metal components.
Solution Approach 2:
By combining the spring function into the plastic actuator member itself, the invention eliminates material heterogeneity. The unitary plastic construction means no metal parts need to be removed or separated during recycling, simplifying the recycling process to a single material type.
3Reliability
If separate metal springs are used, then the dispenser provides reliable actuator return, but additional manufacturing and inventory management are required
Solution Approach 1:
The spring arm and spring finger are integrally formed with the actuator member in a single injection molding process. This eliminates the need for separate manufacturing of metal springs, separate inventory management of multiple components, and multiple assembly steps, while still providing the necessary actuator return function through the plastic spring elements' elastic deformation.
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 recyclability, reduces manufacturing complexity, and maintains the dispenser's functionality while ensuring the spring members can endure the required number of cycles without failure, making the dispenser more cost-effective and environmentally friendly.
Implementation Method 1
The spring member has an unbiased condition and is resiliently deflectable generally normal to its longitudinal to assume deflected conditions from which the spring member inherently attempts to return to its unbiased condition
Data Source
AI summary
A spring mechanism comprising an elongate cantilevered spring member extending along a longitudinal coupled at a first end to a first member and with a distal, second end of the spring member engaging a second member such that the spring member biases the first and second members relative to each other. The spring member has an unbiased condition and being resiliently deflectable generally normal to its longitudinal to assume deflected conditions from which the spring member inherently attempts to return to its unbiased condition. The longitudinal of the spring member preferably remains disposed in a flat plane in deflecting of the spring member between the unbiased condition and the deflected conditions. The spring member preferably has, in cross-section normal to its longitudinal, a shape including two legs disposed to lie in planes parallel the flat plane and joined by a bight normal to the flat plane. Preferably, the spring member is provided with resiliency substantially by the resilient deflection of opposed portions of the two legs towards and/or away from each other normal to the flat plane. The spring member preferably consists of plastic material and may be formed as an integral element injection molded from plastic as a unitary element together with the first member to which it is coupled.