Blow Molded Toy Cycle Integrated Fork and Handlebar Assembly
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Solution Overview
Problem
Existing toy tricycles face challenges in assembly complexity, durability, and supply chain management due to numerous small parts, which can lead to incorrect assembly, reduced consumer satisfaction, and increased manufacturing costs. Additionally, they often require multiple manufacturing lines and suppliers, resulting in aesthetic issues and reduced durability.
Innovation Solution
A blow molded toy cycle design featuring a body with a seating surface and arm with integrated tapered and annular sections for secure fork attachment, along with a handlebar system that ensures correct assembly through protrusions and recesses, and a pedal with ribs for traction, all aimed at reducing the number of parts and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple small parts are used in toy tricycle assembly, then the functionality and structural completeness of the toy is improved, but the assembly complexity and difficulty increase significantly
Solution Approach 1:
The patent combines multiple separate small parts into a single integrated injection-molded component. Specifically, the handlebar assembly integrates the handlebar, grips, brake levers, and connecting elements into one unified part that attaches to the fork, eliminating the need for multiple separate fasteners and connection pieces while maintaining all necessary functional elements.
Solution Approach 2:
The integrated handlebar assembly serves multiple functions simultaneously: it provides steering control, hand grips for the child, brake activation mechanisms, and structural connection to the fork. This multi-functional design consolidates what would traditionally require multiple separate components into a single universal part.
2Manufacturing precision
If multiple manufacturing lines and suppliers are used to produce all parts, then the variety and quality of individual parts is improved, but the supply chain complexity and manufacturing costs increase
Solution Approach 1:
The patent consolidates manufacturing by integrating multiple parts into a single injection-molded component. This allows one manufacturing line to produce the entire handlebar assembly, eliminating the need for coordination between multiple suppliers and manufacturing lines while maintaining high part quality through precision injection molding technology.
Solution Approach 2:
The single integrated handlebar assembly performs multiple functions that would traditionally require separate components from different suppliers. By designing this universal part to incorporate handlebars, grips, brakes, and connection elements, the patent reduces supply chain complexity while maintaining functional completeness and quality.
3Manufacturing precision
If traditional injection molded parts are used for small components, then the precision and detail of small parts is improved, but the number of molds and machines required increases
Solution Approach 1:
The patent merges multiple small parts into a single injection-molded handlebar assembly, allowing one mold and one machine to produce what would traditionally require multiple molds and multiple machines. This significantly improves manufacturing efficiency while maintaining the precision and detail expected of injection-molded parts.
4Ease of operation
If the fork interface is designed for easy assembly, then the ease of assembly is improved, but the durability and resistance to wear may be reduced
Solution Approach 1:
The patent employs asymmetric design in the fork interface, where the handlebar assembly has a specific non-symmetric shape that fits into a corresponding asymmetric receptacle on the fork. This asymmetric geometry provides inherent alignment and positioning features that guide correct assembly without requiring complex instructions, while the asymmetric contact surfaces distribute loads optimally to enhance durability and resist wear over time.
Data Source
AI summary
A blow molded toy cycle has a female bearing area with tapered and recess sections. A fork has a corresponding male bearing area that includes a tapered section and an annular protrusion section. A protrusion spaced at a distance from the annular protrusion extends from the shaft and has a surface to contact a top surface of the body to secure the fork when the male and female bearing areas are in contact. The fork has integrally formed tabs that to bend around an axle to form a bearing area for the axle that allows the axle to rotate within the fork. A blow molded pedal attaches to a section of the axle and has a series of ribs disposed between side sections to form a bearing area that allows the pedal to rotate around the axle. Two rear and one front wheels attach to the body and fork respectively.