Synthetic Resin Clip Structure to Contain Spring Breakage
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Solution Overview
Problem
Synthetic resin clips with elastic composite springs made of high-density carbonate resin often break during repetitive use, leading to safety hazards due to flying debris and complications in mold design and production, which increases costs and safety concerns when interacting with metal detectors.
Innovation Solution
A synthetic resin clip design featuring a pair of clip members with a U-shaped synthetic resin spring mounted between them, secured by a pivot shaft and fly-apart preventing bars, allowing the clip members to remain intact and prevent debris from dispersing upon spring breakage, while also being cost-effective to produce.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a synthetic resin spring made of composite material including high-density carbonate resin is used, then the clip can be made non-metallic to avoid metal detector response, but the spring breaks during repetitive use causing safety hazards
Solution Approach 1:
The spring is divided into multiple segments along its length, with groove portions created at regular intervals. These grooves act as stress relief zones that prevent crack propagation throughout the entire spring, allowing the spring to maintain durability while retaining its non-metallic composite material composition that avoids metal detector response.
Solution Approach 2:
Groove portions are pre-formed in the spring at locations where stress concentration is most likely to occur during repetitive use. These grooves serve as predetermined stress relief zones that cushion and distribute mechanical stresses before they can cause catastrophic failure, thereby preventing spring breakage while maintaining the non-metallic composition.
2Reliability
If the synthetic resin spring is covered at the time of molding the clip members, then the spring is protected, but the mold structure becomes complicated and production costs increase
Solution Approach 1:
The spring is extracted from the molding process as a separate component. Instead of being covered during clip member molding, the spring is formed independently with integrated groove portions, then assembled into the finished clip product. This separation simplifies the molding process and reduces mold complexity while still providing spring protection through its own structural design.
Solution Approach 2:
The groove portions are preliminarily formed in the spring during spring manufacturing, before the spring is assembled into the final clip product. This preliminary structuring of the spring with built-in stress relief grooves eliminates the need for complex mold structures to cover or protect the spring during molding, as the protection is already inherent in the spring's design.
3Device complexity
If window holes are opened over the entire width for mold removal, then mold complexity is reduced, but broken spring pieces can fly out into the surroundings
Solution Approach 1:
The spring is segmented with groove portions that create natural containment zones. When the spring breaks, these grooves limit the projection distance of broken pieces and prevent them from flying out through the window holes, allowing full-width window holes to be used for simple mold removal without creating safety hazards.
Solution Approach 2:
The groove portions act as predetermined barriers that cushion and contain broken spring pieces before they can be projected outward. This beforehand structural feature prevents debris from reaching the window holes, allowing the mold to have simple full-width openings for easy removal while maintaining safety.
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 design ensures safety by keeping clip members and broken spring pieces from flying apart, allowing for secure handling and detection of metal contaminants without increasing production costs or mold complexity.
Implementation Method 1
a synthetic resin spring, which is bent back at a middle and formed in a "U" shape, is mounted in straddle position between both of the clip members. The clip members are elastically urged in the direction in which clamping portions of the clip members press against each other due to the synthetic resin spring.
Data Source
AI summary
A very safe synthetic resin clip is composed of a pair of synthetic resin clip members, and a hanger includes two synthetic resin clips. Each synthetic resin clip member has at least one bracket bearing portion projecting inwardly from an interior portion on a rear face thereof which is provided with a bearing space therein. A pivot shaft is interposed into the bearing spaces of the clip members in use. If a synthetic resin spring has broken and the respective clip members are subjected to a reaction to the spring breakage, the pair of clip members is held by the pivot shaft, secured in position, without flying apart in pieces.