From my explosive view drawings I wanted to realise my design in a 3D Model. Modelling is an important process as it allows me to create a 3D prototype using inexpensive material such as cardboard. From this model I can test how the hinge mechanism works and rectify any errors to improve my final design which will be used for manufacture.
Above: Firstly I designed the shape of the USB case around the inlay for the USB circuit
Above: Next I increased the space in the lid that will be cut out to house the USB chassis.
Above: As in my earlier drawings, I increased the width of the casing on the left-hand side to allow room for the pin-hinge. The USB now measures 35mm, although I said in my specification the width should be no more than 25mm, this design shouldn't cause problems for the user because they can still allow access to a secondary USB port by simply placing the wider side of my USB on the opposite side to the secondary USB port.
Above: Next I drew the hinge, it will be an extension of the lid and the body will have a cavity in which this will sit. This section will be be the middle layer of my case which will be sandwiched between two outer layers.
Final Design for Card Mode (Attempt 1)
- Lid of bottom layer
- Lid of top layer
- Body of bottom layer
- Body of top layer
- Cut out within the middle section which will allow room for the USB circuit board to sit
- Lid of the middle layer - this hold the extension hinge which will connect the lid to the body
- These two rectangles are placed within the cavities - this area will be removed on the laser cutter so from this wastage I will cut two rectangles which should fit within the holes on the USB circuit board - these will then be attached to the bottom layer to secure the circuit in place.
- The body of the middle layer
- Cut hole - these are aligned to the same positions on all 3 layers so that the pin can be positioned in line to attach the lid and the body through the 3 layers.
- This was my initial drawing from which I developed my model. It shows where the USB chassis and circuit are positioned.
Card Model - Design 1
I have developed my card model further...
The 3rd sketch shows the middle layer which will be sandwiched between the top and bottom layers.
It is this layer I have developed...
- I have made an alteration to the shape of the hinge - I have made it smaller to allow it more room to turn.
- I have also made the hinged layer of the lid open ended to allow for a larger turning circle so that it does not catch on the USB chassis.
- I have changed the inner shape of the hook so that it is more rounded. This is more for design aesthetic rather than to aid the functioning of the product.
The images below show my first card model, I have numbered them with an explanation below.
Click on the image to enlarge...
1. The laser cut pieces for my card model; hopefully this shows how the card model fits together.
2. The lid - this is made up of 3 layers, the middle layer holds the extended leg which has a hole for the pin
3. Here
I have glued the top and middle layers and have inserted the template
for the USB circuit. The circuit is quite lose - I can reduce the recess
(and hence the overall width of the USB casing) to produce a more snug
fit. You can also see how the pin will be held for the opening
mechanism.
4. The completed card model - this photograph shows how the top and bottom fit together.
5. I
used 3mm acrylic rod to represent the pin. Unfortunately the lid does
not turn enough. I realised this is due to the way the leg extension and
recess in the body fit together (shown in image 3)
Card Model - Design 2
This is my second card model which has a different shaped hinge.
Click on the image to enlarge...
1. The newly designed middle section of my card model
2. The constructed model with hinge mechanism
3. The lid could not function correctly as it became stuck on the corner of the body casing.
4. This image shows an exploded view of the constructed model with hinge mechanism.
5. In order to hold in my USB circuit I will include a tight fitting peg that secures in the circuit via the rectangular hole.
Card Model - Design 3
After
manufacturing my card model I returned to my Corel Draw design to make
adjustments in order to develop my card model further. I have decided to
use the shorter version of the USB circuit in order to keep my USB
dimensions compact. I also added my logo.
The 1st and 2nd sketches above show the top and bottom layers of my model.
The 3rd sketch shows the middle layer which will be sandwiched between the top and bottom layers.
1. The central layer of my card model
2. I
used 3mm acrylic rod to represent the pin. Again the lid does not turn
enough. I realised this is due to the way the leg extension and recess
in the body fit together.
3. To rectify this I rounded the bottom of the leg extension and the corner on the body.
4. Testing my model - I found that the lid didn't turn enough to allow the USB to be inserted into the port.
5. In order for the USB to be inserted into the port, the lid must be able to turn 180ยบ.
6. To achieve this I must make a recess in the body of the casing.
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