Toy Track Connector With Living Hinge for Easy Assembly
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Solution Overview
Problem
Existing toy vehicle track systems face challenges in manufacturing cost and ease of assembly, particularly for larger vehicles, as they require more complex and material-intensive connectors that complicate the separation of track sections while providing improved alignment and securement.
Innovation Solution
The design of a track connector with a central portion and end portions, including a third post with a living hinge or descending/ascending parts, allows for increased vertical displacement and frictional engagement, enabling easier assembly and disassembly of track sections while maintaining alignment and securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple flanges and joined connectors are used to improve strength and alignment, then the track sections are held more firmly together, but it becomes more difficult for children to break down the connected sections
Solution Approach 1:
The connector incorporates a flexible central portion that can dynamically deform under applied force. When a child presses on the third post, the flexible central portion bends, allowing the posts to move vertically and disengage from the track section holes. This dynamic flexibility enables easy separation while maintaining strong connection during normal use.
2Manufacturing precision
If multiple flanges and joined connectors are used to improve alignment, then the alignment of abutting track sections is improved, but the height of connectors elevates the connected ends of track sections from the surface
Solution Approach 1:
The connector uses a flexible central portion that operates in the vertical dimension to achieve alignment in the horizontal plane. By allowing vertical displacement of the posts through flexing, the connector self-aligns the track sections horizontally without requiring the posts to be elevated, thus maintaining a low profile.
3Reliability
If synthetic resin material is used to provide durability and flexibility, then the track system can withstand abuse and allow twisting and curving, but the manufacturing cost and complexity increase
Solution Approach 1:
The connector is divided into distinct functional portions: rigid end portions for connection, a flexible central portion for deformation, and posts for engagement. This segmentation allows each part to be optimized for its specific function and manufactured using appropriate processes, reducing overall manufacturing complexity while maintaining durability.
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 reduces manufacturing costs and complexity by allowing for easier separation of track sections while maintaining secure and aligned connections, improving usability and efficiency.
Implementation Method 1
the third post includes a living hinge to allow for increased vertical displacement of the first, second, and/or third posts when a downward force is applied to the third post
Implementation Method 2
The connectors include a plurality of bumps to increase frictional engagement between the connector and the track sections
Data Source
AI summary
Toy vehicle track systems and connectors for those systems are disclosed. The connectors include a central portion, first and second end portions, and first and second side portions. The central portion includes first and second posts, and a third larger post disposed between the first and second posts. In some embodiments, the third post includes a living hinge to allow for increased vertical displacement of the first, second, and/or third posts when a downward force is applied to the third post. In some embodiments, the central portion includes descending and ascending parts to allow for increased vertical displacement of the first, second, and/or third posts when a downward force is applied to the third post. In some embodiments, the connectors include a plurality of bumps to increase frictional engagement between the connector and the track sections.