Refillable Sunscreen Stick Coupling Structure for Simple Reuse
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Solution Overview
Problem
Existing stick-type containers for products like sunscreens and deodorants are non-refillable, leading to waste and increased manufacturing costs due to their complex structure, which requires precise assembly and high material usage.
Innovation Solution
A refillable stick container system with a refill unit that includes an elevation shell and holder, featuring coupler parts for secure attachment, allowing easy refilling and maintaining strong coupling strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a stick container is designed with a complicated structure to enable stick movement and exposure, then the functionality of exposing and using the stick material is improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
The container is divided into a reusable container assembly and a replaceable refill unit. The refill unit contains the stick material and holder, while the container assembly provides the coupling mechanism. This segmentation allows the complex functionality to be maintained while simplifying the overall device structure for manufacturing.
Solution Approach 2:
The holder is nested within the elevation shell, which itself is coupled to the container assembly. The holder can move vertically within the shell space, and the entire refill unit couples to the container assembly through coupler parts. This nested arrangement enables complex functionality within a simplified modular structure.
2Ease of operation
If a stick container is made in small size for portability, then the ease of carrying is improved, but the amount of usable content and manufacturing precision requirements decrease
Solution Approach 1:
The separation of the refill unit from the container assembly allows the refill unit to be manufactured in small sizes for portability while the container assembly can be reused multiple times. This enables users to carry only the necessary amount of product in the refill unit.
Solution Approach 2:
The refill unit containing the stick material is designed to be replaceable, while the container assembly is recovered and reused. This allows the small refill unit to be easily replaced when empty, maintaining portability while enabling refilling of the same small container multiple times.
3Strength
If a refill unit is designed to be firmly secured over the entire width of the stick material, then the coupling strength is improved, but the ease of manufacture and assembly simplicity decrease
Solution Approach 1:
The coupling mechanism is segmented into discrete coupler parts on the refill unit and corresponding connector parts on the container assembly. This segmentation allows for simple manufacturing of individual components that assemble to provide strong coupling, avoiding complex monolithic designs.
Solution Approach 2:
The coupler parts are designed with asymmetric features including ledges and alignment protrusions that engage with corresponding structures on the container assembly. This asymmetric design provides strong coupling while maintaining simple manufacturing, as the asymmetric features naturally guide alignment during assembly.
4Manufacturing precision
If a refillable stick container is designed with precise manufacturing requirements, then the coupling precision is improved, but the manufacturing cost increases
Solution Approach 1:
The precise coupling features are concentrated in the refill unit and container assembly interfaces rather than throughout the entire structure. This segmentation allows for precise manufacturing only where needed at the coupling interfaces, while other parts can be manufactured with standard tolerances, reducing overall manufacturing cost.
Solution Approach 2:
The asymmetric coupler parts with ledges and alignment protrusions provide self-alignment during assembly. This self-alignment feature reduces the need for extremely precise manufacturing across the entire component, as the asymmetric geometry naturally guides proper positioning, thereby reducing manufacturing costs while maintaining coupling precision.
Data Source
AI summary
A refill unit and a refillable stick container that allow a refilling of a stick type sunscreen product are disclosed. The refill unit includes: an elevation shell that extends a particular length along a left-right direction, extends a particular length along a vertical direction, and forms a shell space on its inside; and a holder that is arranged within the shell space and to be movable along a vertical direction. The elevation shell includes: a shell body that forms the shell space and in a lower surface of which an insertion hole is formed; and a shell-side coupler part, at a lower portion of which is formed a shell ledge protruding in a horizontal direction. The holder may include: a holder body arranged within the shell space; and a holder-side coupler part that extends down at a position corresponding to a center of the insertion hole.