U-Shaped Motion Converter for Coreless Plastic Molding
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Solution Overview
Problem
Existing motion converters for personal care devices that convert rotary motion into linear reciprocating motion are complex to manufacture and require intricate gear mechanisms, making them costly and difficult to produce using plastic injection molding.
Innovation Solution
A motion converter design featuring a deformable unit, mounting unit, coupling unit, and connector unit with U-shaped receivers and a bracing element, allowing for the conversion of rotary motion from a motor shaft into linear reciprocating motion of a drive shaft, where the U-shaped receivers are manufactured using plastic injection molding without the need for additional cores, simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional gear mechanisms are used to convert rotary motion into linear reciprocating motion, then the motion conversion function is achieved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple functional components (mounting unit, connector unit, deformable unit, and motion converter) into a single integrated plastic injection molded part. This eliminates the need for separate gear mechanisms and reduces assembly steps, directly resolving the contradiction between ease of manufacture and device complexity.
Solution Approach 2:
The patent replaces traditional mechanical gear mechanisms with a deformable unit that uses elastic deformation to achieve motion conversion. This substitution eliminates complex gear trains while maintaining the rotary-to-linear motion conversion function, thereby simplifying manufacturing and reducing device complexity.
2Productivity
If plastic injection molding is used for manufacturing motion converters, then production efficiency increases, but intricate gear mechanisms are difficult to produce
Solution Approach 1:
The patent segments the motion converter into distinct functional units (mounting unit with U-shaped receivers, connector unit, deformable unit) that can be independently designed and molded. This segmentation allows each unit to be optimized for injection molding, avoiding the difficulty of molding intricate gear mechanisms as a single complex part while maintaining high production efficiency.
Solution Approach 2:
The patent changes the design parameters of the motion converter to be compatible with plastic injection molding processes. By designing U-shaped receivers and simple geometric features instead of intricate gear teeth, the part becomes moldable while maintaining functionality, thus resolving the contradiction between productivity and ease of manufacture.
3Ease of manufacture
If U-shaped receivers with elongated holes are manufactured without additional cores, then manufacturing complexity reduces, but the structural integrity may be compromised
Solution Approach 1:
The patent uses the deformable unit's elastic properties to compensate for the open-ended U-shaped receivers. The deformable unit acts as a flexible element that maintains structural integrity while allowing the receivers to be molded without cores, resolving the contradiction between molding simplicity and structural strength.
Solution Approach 2:
The bracing element is designed to provide preemptive structural support to the U-shaped receivers. By incorporating this bracing feature into the molded part, the design ensures structural integrity is maintained before any potential failure, allowing core-less molding while preserving strength.
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
The proposed motion converter effectively converts rotary motion into linear reciprocating motion while being easier and more cost-effective to produce, utilizing standard off-the-shelf components and reducing manufacturing complexity, thus enhancing the efficiency and affordability of personal care devices.
Implementation Method 1
the periodic deformation means a periodic deformation in a z direction and a 180 degrees phase-shifted periodic deformation in a y direction being perpendicular to the z direction
Data Source
AI summary
The present disclosure is concerned with a motion converter structured for converting a rotational motion provided by a motor shaft into a linear reciprocating motion of a drive shaft. The motion converter has a deformable unit, a mounting unit connected with the deformable unit, a coupling unit connected with the deformable unit, the coupling unit being structured to receive the drive shaft or the coupling unit comprising the drive shaft, a connector unit connected with the deformable unit, the connector unit comprising at least a first essentially U-shaped receiver being structured for receiving a first eccentric shaft element of the motor shaft and having a U-base and two U-legs together defining a first elongated hole having a length, a width and a height, and a first bracing element that connects the two U-legs of the first essentially U-shaped receiver on their free ends such that access into the first elongated hole across the width and the height of the first elongated hole is provided, preferably where the first bracing element is bar-shaped or U-shaped or O-shaped, and where the length is measured from an inner surface of the U-base to the free ends of the U-legs.