Spring-Buffered Case Corner Structure for Slim Drop Protection
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Solution Overview
Problem
Existing electronic product case designs that use foam, rubber, or silicone to absorb impact forces result in thick and heavy corners, compromising the product's appearance and requiring thicker materials for higher drops or heavier products.
Innovation Solution
A case structure incorporating an inner case base, a buffer outer case, and a torsional spring, where the buffer outer case moves relative to the inner case base upon impact, utilizing the torsional spring's elastic potential energy to absorb and redistribute impact forces, maintaining a slim appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thicker foam, rubber or silicone is used to protect against higher drops or heavier products, then the impact resistance is improved, but the corners of the product look thick and heavy, affecting the overall appearance
Solution Approach 1:
The buffer outer case is designed to move dynamically relative to the inner case base when impact force is applied. The torsional spring enables the buffer outer case to rotate and deform under impact, absorbing energy through controlled movement rather than relying on static thick material. This dynamic response allows thin-profile corners to provide equivalent or superior impact protection while maintaining sleek appearance.
Solution Approach 2:
The invention changes the protective mechanism from material thickness to elastic deformation parameters. The torsional spring's elasticity coefficient and the buffer outer case's moment of inertia are optimized to provide appropriate impact resistance. By adjusting these parameters, the system achieves effective protection with minimal protrusion, resolving the contradiction between protection level and appearance.
2Strength
If thicker foam, rubber or silicone is used to absorb impact force, then the protection level is improved, but the device becomes heavier and bulkier
Solution Approach 1:
The buffer outer case functions as a flexible shell that can deform under impact. Instead of using thick rigid or semi-rigid materials like foam or rubber, the invention employs a thin-walled structure supported by a torsional spring. This flexible shell approach provides effective impact absorption through controlled deformation and elastic recovery, significantly reducing weight and bulk while maintaining protection level.
Solution Approach 2:
The invention replaces the traditional mechanical cushioning system (thick foam/rubber layers) with a spring-based elastic system. The torsional spring stores and releases energy during impact events, providing protection without the weight and volume penalties of thick dissipative materials. This mechanical substitution achieves equivalent protection with reduced mass.
3Reliability
If a buffer structure is added to resist collision, then the impact resistance is improved, but the device complexity increases
Solution Approach 1:
The case is segmented into two functional parts: the inner case base and the buffer outer case. The torsional spring is positioned at corner areas where impact is most likely to occur. This segmentation allows the buffer function to be localized to specific high-risk areas rather than requiring comprehensive protection throughout the entire device, reducing overall structural complexity while maintaining effective collision resistance.
Solution Approach 2:
The buffer outer case serves multiple functions: it provides impact protection, maintains aesthetic appearance, and can be integrated with the overall case design. The torsional spring mechanism is a simple, universal component that can be applied to various device types and corner configurations. This multi-functionality reduces the need for additional specialized components, keeping the overall device complexity low.
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 case structure effectively resists collisions while maintaining a compact appearance, passing military-level drop tests and ensuring the product's functionality even after repeated impacts, without the need for thick protrusions.
Implementation Method 1
The torsional spring correspondingly deforms and stores elastic potential energy
Implementation Method 2
the torsional spring releases the elastic potential energy to reposition the buffer outer case
Data Source
AI summary
A case structure includes an inner case base, a buffer outer case and a torsional spring. The inner case base has a corner area and a fixing column located at the corner area. The buffer outer case is movably overlapped on an outer side of the corner area. The torsional spring is sleeved on the fixing column and located between the buffer outer case and the inner case base. A first end and a second end of the torsional spring are respectively connected to the buffer outer case. When the force exerted on the buffer outer case causes the buffer outer case to move relative to the inner case base, the torsional spring correspondingly deforms and stores elastic potential energy. When the force exerted on the buffer outer case disappears, the torsional spring releases the elastic potential energy to reposition the buffer outer case.