Toy Brick Electrical Contacts via Nested Conductor Wires
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing plastic toy building blocks face challenges in maintaining a secure mechanical clamping force and reliable electrical connections over time, especially after repeated assembly and disassembly, while also requiring cost-effective production methods and minimal components.
Innovation Solution
The design incorporates nubs on the upper side of the building blocks with resilient conductor wires guided through the block's interior for electronic position determination, using a contact interface to ensure permanent clamping and electrical connections, with a minimal component count and efficient mechanical assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resilient conductor wires are guided through the building block interior, then electrical connection reliability is improved, but device complexity increases
Solution Approach 1:
The conductor wires are nested within channels formed in the plastic basic body, with the wires positioned inside hollow cylindrical structures that are integral parts of the building block. This nesting approach allows the electrical connection elements to be integrated within the structural body rather than added as separate external components, reducing overall complexity while maintaining connection reliability.
Solution Approach 2:
The electrical connection function is merged with the structural body by integrating conductor wires directly into the plastic basic body through channels and hollow cylindrical structures. The contact interface is combined with the nubs and basic body geometry, creating a unified structure where mechanical connection and electrical connection are achieved through the same assembly action.
2Force
If contact interface with nubs is designed, then mechanical clamping force is improved, but manufacturing precision requirements increase
Solution Approach 1:
The contact interface utilizes the elastic resilience of the plastic material to create a dynamic clamping mechanism. When building blocks are assembled, the plastic deforms elastically to engage the nubs and maintain clamping force, allowing for tolerance compensation. This dynamic response enables reliable mechanical connection without requiring extremely tight manufacturing tolerances.
Solution Approach 2:
The design changes the physical state of the plastic material from rigid to elastic during assembly, allowing the material to deform and absorb dimensional variations. The elastic deformation parameter enables the building blocks to accommodate manufacturing tolerances while still achieving sufficient clamping force through the contact interface.
3Reliability
If electrical contacts are protected from mechanical stress, then contact reliability is improved, but device complexity increases
Solution Approach 1:
The conductor wires are nested within hollow cylindrical structures formed in the plastic basic body, providing inherent protection from external mechanical stress. This nested arrangement shields the electrical contacts from damage while avoiding the need for separate protective components.
Solution Approach 2:
The plastic basic body acts as a protective shell that encloses and protects the conductor wires from mechanical stress, throwing, falling, and other external forces. The plastic material provides a cushioning effect that prevents direct contact between external objects and the electrical connection elements.
4Ease of manufacture
If minimal components are used, then ease of manufacture is improved, but assembly precision requirements increase
Solution Approach 1:
Multiple functions are merged into the plastic basic body: structural support, electrical insulation, wire protection, and mechanical connection. The basic body integrates channels for conductor wires, hollow cylindrical structures for additional protection, and contact interfaces with nubs, eliminating the need for separate components for each function.
Solution Approach 2:
The plastic basic body serves multiple purposes simultaneously: it provides the structural framework, guides and protects the electrical conductor wires, creates the contact interface for mechanical connection, and provides electrical insulation. This multi-functionality reduces the total component count while maintaining assembly precision through integrated design features.
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
This solution provides a durable and cost-effective plastic toy building block system with reliable mechanical and electrical connections, capable of withstanding repeated use and manufacturing in large series, while reducing manufacturing costs and ensuring robustness against mechanical stress.
Implementation Method 1
resilient conductor wires guided from the underside of the plastic toy building block through its interior via a contact interface to its top side
Data Source
AI summary
The plastic toy building block is provided with electrical contacts to determine its position. The block has a basic body having recesses extending from top to bottom in its interior. In these are each inserted, combined into packets, several discrete elastically resilient conductor wires clamped between plastic strips. Elastically resilient conductor wires protrude downward into the recess. Contact points protrude from the plastic strips at the top. Several electrical cables are led from each nub to the underside of a nub plate to discrete contact points. Except for the nub surfaces, the nub plate can be covered by a cover plate and hereafter can be placed with the nub plate on the basic body of the toy building block. The lower contact points on the film then make electrical contact with the upper stubs and thus with contact points of the conductor wires.