Polymer Pen Holder with Flexure Joints for Cockpit Longevity
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Solution Overview
Problem
Existing pen holders for aircraft cockpits, particularly those with hybrid designs combining plastic and metal, tend to break prematurely, leading to reduced longevity.
Innovation Solution
A pen holder with a pen compartment and holding structure integrally formed as a single unitary member from polymer material, such as PA12, utilizing protruding holding members with flexure joints to securely hold pens by friction, manufactured via additive methods like selective laser sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a hybrid design combining plastic compartment wall and metal pen holding structure is used, then the pen holder can be manufactured with traditional methods, but the pen holder breaks earlier and has reduced longevity
Solution Approach 1:
The patent merges the plastic compartment wall and metal pen holding structure into a single integrated component made entirely of polymer material. The pen holding structure with spring elements is co-formed with the compartment wall through additive manufacturing, eliminating the hybrid design and creating a unified structure that resolves the reliability issues of premature breaking while maintaining manufacturability through modern 3D printing techniques.
Solution Approach 2:
The patent uses advanced polymer materials with elastic properties that combine the benefits of both traditional plastic and metal materials. The polymer material exhibits elastic deformation characteristics similar to metal springs while maintaining the corrosion resistance and fatigue resistance of polymers, creating a composite material solution that improves longevity without sacrificing manufacturability.
2Reliability
If a unitary member design is used, then the pen holder has increased longevity, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces traditional mechanical assembly processes with additive manufacturing technology. Instead of separately manufacturing the compartment wall and pen holding structure and assembling them through complex mechanical operations, the entire unitary structure is built layer-by-layer using selective laser sintering or similar 3D printing methods, simplifying the manufacturing process while enabling complex integrated geometries.
3Reliability
If holding members with flexure joints are used, then the pen holding structure can securely hold pens through friction, but the structural complexity increases
Solution Approach 1:
The patent incorporates flexure joints that enable dynamic movement of the holding members. These flexure joints allow the holding members to deflect and adapt to the inserted pen, creating a dynamic gripping mechanism that secures the pen through friction while accommodating variations in pen diameter and shape, thereby improving holding capability without requiring complex mechanical assemblies.
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 solution significantly increases the pen holder's usable life-span to at least 250,000 insertion-removal cycles, outperforming traditional designs and exceeding the lifespan of metallic holders, with minimal material bill and improved durability.
Implementation Method 1
each holding member comprises a first flexure joint portion that, when a pen is inserted into the engagement area, causes the holding member to press against the pen
Implementation Method 2
form an engagement area in which a pen is able to be held by friction between at least one of the holding members and the compartment wall
Data Source
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AI summary
In order to improve longevity of pen holders, the invention proposes to form a pen compartment (12) and a pen holding structure (30) by additive manufacturing of a polymer material, such as PA12. The pen is held by friction within the pen compartment (14) and can be easily inserted and removed. Such a pen holder has a usage life of at least 250.000 insertion-removal cycles.