Light Emitting Wheel Hub Internal Wire Routing
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Solution Overview
Problem
Existing light emitting wheels suffer from frequent lead wire breakage during manufacturing and operation due to exposure to stress and shock, leading to electrical failures, and air bubbles form during cast molding, reducing quality and production efficiency.
Innovation Solution
The improved armature assembly secures lead wires internally within the coil bobbin, and a specially designed wheel hub rim portion prevents air bubble formation, allowing for automated assembly and reliable electrical contact, with diametrically opposed light emitting devices to maintain continuous light output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If lead wires are drawn out and manually connected to light emitting devices, then connection flexibility is improved, but lead wire breakage frequency increases
Solution Approach 1:
The patent merges the lead wire connection process into the injection molding operation by integrating lead wire positioning features directly into the mold. The lead wires are secured within the hub assembly during molding, eliminating separate manual connection steps while maintaining reliable electrical contact between the coil bobbin and light emitting devices.
Solution Approach 2:
The patent implements preliminary positioning of lead wires through molded-in features such as recesses, channels, or guide structures formed in the hub during the injection molding process. This preliminary action secures the lead wires before final assembly, preventing breakage during subsequent handling and installation while maintaining connection flexibility.
2Manufacturing precision
If manual manipulation is used to connect lead wires, then connection precision is improved, but manufacturing time increases
Solution Approach 1:
The patent enables the hub assembly to self-position and self-secure the lead wires through integrated molded features. The injection molding process automatically forms recesses, channels, or guide structures that hold the lead wires in precise positions without requiring manual manipulation, achieving both connection precision and high manufacturing speed through automated production.
Solution Approach 2:
The patent replaces manual mechanical manipulation with an automated injection molding process. The mold incorporates features that automatically position and secure lead wires through plastic deformation and mechanical interlocking during molding, substituting human-operated precision assembly with automated mold-driven positioning that maintains precision while dramatically increasing productivity.
3Device complexity
If conventional hub design is used, then manufacturing simplicity is improved, but air bubble formation occurs
Solution Approach 1:
The patent segments the hub structure into functional zones with optimized gate positioning and venting features. By dividing the molding cavity into regions with controlled fill sequences and incorporating strategic vent channels, the design prevents air trap formation while maintaining overall structural simplicity. The segmentation allows air to escape through designated paths rather than becoming trapped in the final part.
Solution Approach 2:
The patent introduces intermediary features such as vent channels, air escape paths, and optimized gate designs that act as mediators between the injecting molten plastic and the hub cavity. These intermediary structures facilitate controlled air evacuation during molding, preventing air bubble formation in the final product while adding minimal complexity to the overall hub design.
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 solution enhances the reliability and durability of light emitting wheels, simplifies manufacturing, and prevents air bubbles during molding, ensuring consistent electrical contact and improved production efficiency.
Implementation Method 1
The coil bobbin or spool of the armature assembly of the compact generator is shown in FIG. 2
Implementation Method 2
A conductive plate or printed circuit board bearing light emitting device such as a LED (light emitting diode) is connected to the wheel hub
Data Source
AI summary
The present inventive compact generator, light emitting wheel hub has an improved light and armature assembly that simplifies manufacturing, improves function and durability of the light emitting wheel hub. The inventive wheel hub is useful for such wheels used in skate board, roller skate, in-line roller skate, wheel chair, and like apparatus.