Refillable Wiper Blade Segmentation and Coupler Attachment
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Solution Overview
Problem
Conventional wiper blades deteriorate over time due to wear and exposure to environmental factors, leading to inconsistent wiping performance and high replacement costs, with consumers often replacing them only when performance significantly decreases.
Innovation Solution
A refillable wiper blade design featuring a refill subassembly with a wiping element, elongated spline, and retention clip that securely attaches to a coupler, allowing for easy replacement without removing the wiper blade from the arm, reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wiper blades are used with complete replacement, then wiping performance is maintained, but manufacturing cost and consumer expense increase
Solution Approach 1:
The wiper blade is divided into two main segments: a reusable coupler assembly and a replaceable refill subassembly. This segmentation allows consumers to replace only the wear-prone refill portion while retaining the expensive coupler, thereby maintaining consistent wiping performance over time while reducing manufacturing costs and consumer expenses.
Solution Approach 2:
The design enables discarding of the consumable refill subassembly (wiping element and spline) while recovering and reusing the durable coupler assembly. This approach eliminates the need to manufacture and purchase complete new wiper blades, reducing both manufacturing complexity and consumer cost while ensuring consistent performance through regular refill replacement.
2Reliability
If complete wiper blade replacement is required, then performance is restored, but time and complexity of replacement increase
Solution Approach 1:
By segmenting the wiper blade into a permanent coupler and a removable refill subassembly, the replacement process is simplified to involve only the refill portion. Consumers can quickly detach and replace the refill subassembly without removing the entire wiper blade from the wiper arm, significantly reducing replacement time while restoring wiping performance.
Solution Approach 2:
The coupler assembly is pre-configured with attachment mechanisms (retention clips, splines, and engagement features) that enable quick connection and disconnection of refill subassemblies. This preliminary design of the coupling system allows for rapid replacement without complex tools or procedures, maintaining performance while minimizing time loss.
3Strength
If traditional wiper blade design is used, then structural integrity is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The wiper blade is segmented into a coupler assembly and a refill subassembly, where the coupler maintains structural integrity through its robust construction with retention clips and engagement features, while the refill subassembly is designed for easy replacement. This segmentation reduces overall device complexity by allowing independent optimization of each component's function and manufacturing process.
Solution Approach 2:
The design separates the durable structural components (coupler, retention clips) from the consumable components (refill subassembly, wiping element). The structural integrity is maintained in the reusable coupler portion, while the simpler refill portion can be easily manufactured and replaced, reducing overall device complexity and manufacturing cost.
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 provides consistent wiping performance, simplifies replacement, and reduces consumer costs by allowing for quick and efficient swapping of refill subassemblies, maintaining effective cleaning quality without the need for frequent full wiper blade replacements.
Implementation Method 1
an upwardly-biased cantilevered finger extending from the clip body. The coupler has a first end shaped to receive the clip body of the retention clip, and a relief defined adjacent to the first end and shaped to accommodate the cantilevered finger of the retention clip. The refill subassembly and the coupler cooperate such that predetermined movement of the coupler with respect to the spline of the refill subassembly brings the clip body into engagement with the first end of the coupler such that the cantilevered finger deflects downwardly until subsequent movement of the coupler along the spline releases the cantilevered finger upwardly and into the relief of the coupler thereby securing the refill subassembly to the coupler.
Data Source
AI summary
A refillable wiper blade (36) including a refill subassembly (38) and a coupler (48) adapted for releasable attachment thereto. The refill subassembly includes a wiping element (42), an elongated spline (44) supporting the element, and a retention clip (46) operatively attached to the spline. The clip has a body (58) and an upwardly-biased cantilevered finger (60) extending from the body. The coupler has a first end (62A) shaped to receive the body of the clip, and a relief (64) defined adjacent to the first end and shaped to accommodate the finger of the clip. The refill subassembly and the coupler cooperate such that predetermined movement of the coupler with respect to the refill subassembly brings the body into engagement with the first end of the coupler such that the finger deflects downwardly until subsequent movement of the coupler along the spline releases the finger upwardly and into the relief of the coupler thereby securing the refill subassembly to the coupler.