Identical Shaft Coupler Structure for Secure Tool Segment Alignment
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Solution Overview
Problem
Existing shaft couplers for tools require unique coupling members and specialized tooling, leading to increased manufacturing costs and complexity in connecting and disconnecting shaft segments for tools like outdoor and power tools.
Innovation Solution
A shaft coupler design featuring identical coupling members with spaced-apart coupling flanges and projections, allowing for alignment and secure connection of shaft segments using a bolt and nut system, which reduces manufacturing costs and simplifies assembly by enabling interchangeable parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unique coupling members are used in existing shaft couplers, then the connection can be secured, but manufacturing costs and device complexity increase
Solution Approach 1:
The patent applies universality by making the first and second coupling members identical in structure and function. Both coupling members have the same body configuration, opening, coupling flanges, and projection features, allowing either coupling member to connect to either shaft segment interchangeably. This eliminates the need for unique or asymmetric coupling members while maintaining secure connection through the standardized interface design.
2Reliability
If unique coupling members with specialized tooling are used, then secure connection is achieved, but manufacturing costs increase
Solution Approach 1:
The patent reduces manufacturing costs by standardizing the coupling members so that the first and second coupling members are identical. This allows for economies of scale in production, as the same coupling member design can be manufactured in larger quantities using the same tooling and processes, eliminating the need for specialized tooling for different coupling member types.
Solution Approach 2:
The patent changes the design parameters of the coupling members from unique/asymmetric to identical/symmetric. This parameter change standardizes the geometry, materials, and manufacturing specifications across all coupling members, simplifying the manufacturing process and reducing costs associated with maintaining multiple unique part specifications.
3Device complexity
If identical coupling members are used, then manufacturing complexity is reduced, but connection security must be maintained
Solution Approach 1:
The patent maintains connection security in identical coupling members through the composite structure of multiple functional elements: the coupling flanges provide clamping surfaces, the projection provides positioning and engagement features, the ribs on locating surfaces provide alignment, and the tapered stop surfaces limit insertion. This composite design ensures that simplification through identical components does not compromise connection reliability.
Solution Approach 2:
The patent uses tapered stop surfaces on the coupling flanges that provide a curved or angled geometry to guide and limit the insertion of shaft segments. This geometric feature ensures proper alignment and secure engagement while maintaining the identical design of the coupling members, preventing over-insertion and ensuring consistent connection security.
Data Source
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AI summary
A shaft coupler with substantially identical coupling members operable to couple two shaft segments of a tool. The shaft coupler includes a first coupling member including a first body having a first coupling end and an opposite first shaft end defining a first opening configured to receive a first shaft segment; and a second coupling member including a second body having a second coupling end and an opposite second shaft end defining a second opening configured to receive a second shaft segment. The first coupling member and the second coupling member are identical. The first coupling end is configured to engage the second coupling end to selectively couple the first coupling member to the second coupling member and, thereby, the first shaft segment to the second shaft segment.