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Team Q-451 complete product design process of an innovative pocket key holder and organizer.

Team Q-451 complete product design process of an innovative pocket key holder and organizer.



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  • … Bettering life through the best designs. A company founded by four Saint Louis University graduates in 2008 with the sole purpose of making superior devices for a better lifestyle. innovation creation style David Smart Tyler Smith Jake Ahearn Mathew Janda
    • The goal of this project is to develop an innovative, key design which will revolutionize the current key carrying industry. The project included research and design of the product, manufacture of prototypes, and costs as well as introducing the product into the market which are continuing goals of our product design.
    • The major constraints of the design are its’ size, price, and number of keys to hold. Through our analysis of the customer we would like to incorporate approximately four keys into a “sleek candy bar” sized holder in a retail cost range of $20-30 . Other added features to the key holder from our research could include a light beacon, a way of holding oblong nik-naks or tags. This device would also address quality and problems in durability, ease of use, and the scratching of other items in the customers pocket. Also, this design must be aesthetically pleasing and represent a status symbol to the customer.
    The Idea Style Functional Keys http://artfiles.art.com/images/-/Sean-Connery---James-Bond-Photograph-C12150975.jpeg http://www.armyknife.ch/images/swiss_army_knife.jpg
  • Customer
    • The NEW customer is used to highly functional, attractive and stylish products. While innovations have occurred at the individual key level (laser cut, remote access, etc.), the current key chain design does not fit this paradigm . The key chain designs are mundane, bulky, awkward and not functional. The keys also scratch cell phones, rip pockets, and jab legs. As pocket devices (wallets, cell phones, etc.) become more common, an opportunity exists for an innovative key chain which is functional and meets today’s fashion standards.
    • The target customer for this product is fashion-conscious, outgoing younger generation between the ages of 19-24 . This trendy group enjoys new gadgets. Since the skin-tight is the fashion trend, there is a need for compact pocket devices (wallets, keys, cell phones). On an average, this age group carries 4 keys, making the first-generation product design task manageable. The sleek, cool key chain appeals to this market segment.
  • Survey Results
  • Key Scope
    • Main Goal(s) of Product
    • (by graduation):
    • Create and produce a functional, innovative, key carrying product
    • Secondary Goals:
    • Research sales and marketing avenues
    • Manufacturing device and introducing product to market
    • Age Range: 19-24
    • Retail Price: $20-30
    • Performance Specifications:
    • Size: slim candy bar
    • Number of Keys: 4
    • Possible Customer Needs:
    • Missing/losing keys
    • Avoid scratching
    • Durable
    • Ease of use
    • Flashy
    • Conversion capabilities
    • (tags, nic-naks, automatic car opener)
  • Evolutionary Design Initial Concepts Narrowed Renderings Fall Design Prototype Alternate Designs
  • Design Features; Prototype Ergonomic Handling Easily interchangeable Keys & Parts Ease of Use: 2-movements Ejection Deployment (Four Keys) Sleek Styling Carabineer for Add-ons Dimensions: 3.2” x 1.8” x 1.3” Initial Position of Key Deployment Aligned with Most Locks Personalized Faceplates Play Factor Push Buttons Deployment
  • Design; Mechanical Features
  • Design; Continued
    • Prototype components:
    • Rack & pinion system gives a mechanical advantage of the retraction length
    • that the customer must pull.
    • Spring loaded system ejects the key instantaneously.
    • Symmetry to reduce bending moments on arm bar retraction apparatus.
    • Exchange keys: Easily removed interlocking faceplate (non-fastened) coupled
    • with easily removed key blanks adapted to key holder.
    • Push button engagement. Flat springs incorporated to reduce size and ease
    • of use.
    • Ramp effect on arm bar which enables ejected keys to restrict both pulling
    • pushing forces against the key.
    • Ergonomic advantages with thumb movements.
    Spring Forces Dove Tail Slide Release Buttons Key Interchangeability Rack & Pinion System Mechanical Advantage Tolerances/Interferences Arm- Bar Position Reduction in Moment
    • Rack & Pinion (Mechanical Advantage 2:1):
    • Length moved by sliding half is also the length moved
    • by the arm-bar due to rack-pinion engagement.
    • Pinion (critical component)
    • Diameter: 0.22”
    • Rack (2)
    • Fixed to sliding half & arm-bar
    • Springs:
    • Buttons / Retraction
    • Flat springs incorporated into button
    • Ejection system springs
    • (Five identical compressive springs in series)
    • Specifications (per spring)
    • Mean coil diameter: 3/16”
    • Free Length: 39/64”
    • Shut height: 3/16”
    • Spring constant: 3.54 lb/inch (0.71 lb/inch total)
    • Forces
    • Retraction spring load: (five compressive springs in series with extension spring (~1 lb/inch) in parallel)
    • ~2 lbs
    • Worst case (all four keys are retracted at once):
    • ~6 lbs
    Design; Continued
    • Stress Analysis
    • Analysis was conducted on two critical stainless steel and nylon parts. More specifically, the arm-bar and push button mechanisms.
    • The worst case was ran using loads of 8 lbs and all other scenarios used spring loads of 2 lbs. All photos are of Nylon material.
    Design; Continued Arm-bar under the loading of one key being retracted. Concentrations occur at hinge point. Smoothing and movement of guide Can be made to reduce stress and redirect loads. Reduction in stress using middle keys rather than end keys due to bending moment. Arm-bar under worst case scenario (all keys ejected). Same Stress concentrations at end points. Push button stresses. Maximum stresses At top of button primarily due to moment due To placement of support structure.
  • Materials
    • Stainless Steel/Steel
    • Cover material & critical components
    • Gives appealing nature and needed strength
    • to critical parts.
    • Gear, Arm-bar, retraction bar
    • Brushed Aluminum
    • Cover material
    • Appealing and gives structural
    • integrity to device.
    • Internal Parts (non-critical components)
    • Plastic ejection molded parts
    • Reduction in cost/weight
    • Must maintain strength, reliability
    • Polyoxymethylene (POM)
    • Tough (7-10 ksi yield strength)
    • Naturally lubricating
    • Adaptable and better fatigue resistance
    • Higher price
    • Good for moving parts (retraction bar/buttons)
    • Acrylonitrile-Butadiene-Styrene (ABS)
    • Allows for higher strength components
    • (2.7-7.4 ksi yield strength)
    • Can be cast easily
    • Polypropylene (PP)
    • 3-5 ksi yield strength
    • Lower cost
    • Non-structural components
    Skin/Cover Components
  • Estimated Manufacturing Costs Manufacturing costs were estimated using materials of steel and ejection molded plastic parts. The analysis incorporates start-up fees, labor, operations, etc. From the graph below the cost per device is drastically reduced to our goal price twenty devices are manufactured and then continues to decrease in cost. $24.72
  • Future Design Advancements/Improvements
    • Reduction in Stress Concentrations
    • Radii changes
    • Material/design changes
    • Reduction in Size & Shape
    • Shape consideration & reduction in mechanism size
    • Styling & ergonomics
    • Testing
    • Durability, Quality, Ergonomics
    • Improvements to design
    • Manufacturing & Materials
    • Material strength considerations
    • Quotes
    • Creating Multiple Marketing Devices
    • Different lifestyle configurations
    • Faceplates, accessories, etc.
  • Marketing Expanding…
    • Interchangeability
      • Key Blades
      • Tools
        • Screwdriver
        • Knife
        • Light
        • USB
      • Faceplates
        • School Spirit
        • Sports Teams
        • Family Pictures
    • Lifestyle
      • Athlete
      • Businessman
      • Fisherman/Hunter
      • Sailor
      • Grade School Student
    • Next Generation
      • Flashlight
      • Lost Key Alarm
      • Safety Lock-Down
    • Other Usages
    • (due to easy to deploy and retract)
      • Space
      • Skiing
  • Patent Currently holding conversations with the Saint Louis University Patent Attorney Business Plan Currently holding conversations with the Saint Louis University Entrepreneur Center Near Future Plans
  • Questions… Acknowledgments Mechanical Engineering Professor Sridhar Condoor Industrial Engineer Health Doty Mechanical Engineering Technician Frank Coffey