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INDEX

Object Selection

Introduction ��4

Interaction Map ��5

Object Interactions ��7

Product Choice ��9

Object Research

Photographic Study ��11

Vacuum Breakdown ��15

User Interaction Process ��16

Survey Results ��18

Concept Exploration

Initial Generation ��23

Design Feedback ��25

Model Making 1 ��26


Concept Definition

Mechanical Development ��30

Final Concept ��32


CAD Drawings ��34

Mechanism Development ��35

Prototype Manufacturing ��38

Final Prototype ��39

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Concept Presentation5

Final Concept ��41

Part Breakdown��42

Parts ��43

Materials ��44

SECTION:1

OBJECT SELECT ION

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Project Brief:Interaction design is the term given to the design of how users interact with or operate electronic devices such as computers or mobile phones. However interaction design is equally a part of the design of almost every product or service we use. The amount of things we interact with on a daily basis is incredible. For example you wake up in the morning and turn off your phone alarm. You open your bathroom door with the door handle. You turn the tap handle to brush your teeth and then you turn on the shower. You go downstairs and use the microwave to

make your breakfast. As you leave the house you set your heater timer and then you hop on your bike. This is just a tiny example of our daily interactions with products and services. In this project I have been tasked with redesigning the user interaction of a particular product and make it better. Better can mean lots of things, like easier, more pleasurable, safer, more aesthetically pleasing or may be more environmentally friendly. The following document highlights the process of doing this from the selection of this product to the final design.

INTRODUCTION

Mapping out my interactions during the day was a great way of discovering the different things I interact with on a daily basis. Using this method allowed me to see what interaction decisions I make and got me to think about how they could be improved. This type of interactions map using post-it notes is the most visual way of taking note of these interactions.

MY DAY: PRODUCT INTERACTIONS

INTERACTION MAP

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In a similar way to the previous map this digital interactions map was a way of thinking of how many products I interact with on a daily basis. This was beneficial in trying to choose which product I would like to improve for this project.

DAILY PRODUCT INTERACTION:

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Washing Machine

I interact with a washing machine at least once a week. A Washing machine is a device that requires little interaction, As long as you know how to set the required wash time then all thats done is the user puts there clothes into the drum, puts in their desired detergent and lets it run for a certain period of time until they take the washed clothes out to dry.

Toaster

In a similar way to the washing machine a toasters interaction is currently streamlined. There are issues around crumbs, cook time and potentially preservation of heat but overall this product is easy to use and requires little concentration. The main reason I would consider choosing this product is due to the fact that most toasters don’t keep toast warm as soon as it pops. This is an issue if you can’t get to the toast straight away.

Kettle

There are thousands of options you have when choosing a kettle. The kettle has been redesigned so many times. There are still obvious issues around overfilling and then wasting of energy and water but overall a kettle is an efficient way of heating water. If I was to redesign this products interaction the main consideration would be how much water people use when filling it.

OBJECT INTERACTIONS

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Bike

I use a bike every day. It is my main form of transportation for my daily commute. A Bike is a very mechanical object that while having a detailed interaction process it has been streamlined already. To undertake a redesign of this project would mean taking on a very mechanical based project. While a bike looks like it would make a good choice for this project, I however have reservations.

Coffee Pot

A coffee pot can be a gorgeously designed object or an eyesore. The issue with choosing this product is trying to maintain the balance between aesthetics and functionality. In terms of user interaction the coffee pot is flawed. It can be difficult to fill, pour and clean all of which take away from its purpose. Overall this product would make a good choice for this project.

Flask

A flask is an interesting object. Almost everyone has used them and everyone has the same complaints. It leaks, it drips from the lid, they break easily, the liquid doesn’t say warm. This product would make a good choice as the way the user interacts with it is flawed. As an object I am unaware of many variances in design being available. Most people tend to have the classic thermos style flask.

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Why A Flask?

PRODUCT CHOICE

I chose a flask as my object to redesign as I believe it has great potential to be improved. In regards to issues many people have the same problems. Flasks are known for leaking, losing temperature, dripping excess liquid when the cup is placed on top. These are all issues that I believe can be tackled and potentially solved through an innovative design solution. I also believe that in terms of user interaction a flask is flawed. The user firstly has to deal with all of the above problems but the way in which a flask is operated can be cumbersome. The user must drink from a cup that has threads on the lid, this is an unpleasant feeling and isn’t a great design choice. The user must also fill the flask via a narrow opening, This can lead to obvious problems. Finally the user must also clean the flask, given its design this makes it difficult to clean and as such means the user is less likely to use it creating many more issues around throwaway cardboard cups. Overall the flask is an object that should be a pleasure to use, not a chore.

SECTION:2

OBJECT RESEARCH

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Classic Flask:

PHOTOGRAPHIC STUDY

This is the standard thermos vacuum flask design. I spent 2 weeks using a flask every day to see what it was really like to use this classic flask. There are countless issues with it, the biggest being the fact that no matter how much you think you’ve emptied the cup there is always some left and will undoubtedly drip down the side of the flask once put back on top. The aesthetics of the flask are actually quite nice and when the lid is on top the flask looks quite nice. Its such a shame that the mechanics of the design fail drastically.

Goat Story The Goat Story mug is a horn shaped coffee container. While not technically a vacuum flask its a great example of good design in this field. The shape is ergonomic which is designed in a way that lets you drink the last sip of your coffee due to its incline. The mug comes with an easy to carry strap so it can be attached to your bag or across shoulder.s It is designed to be 100% leakproof and is also dishwasher safe. The mug is easy to open and can be closed with only one hand. In terms of temperature retention it can keep a drink hot for over 2 hours due to its material choice. The holder acts as a thermal insulator and also a stand for the mug.

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Generic Coffee FlaskThis is the coffee mug I use on a daily basis. I fill it before I leave home in the morning and often will refill it once or twice during the day. the main reason for purchasing was price over anything hence why It may not be the best product for my needs. The amount of temperature loss is amazing. This does not keep any liquid warm past 30 minutes. Logic dictates that this is mostly down to material choice given the mug has no vaccum.

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Reflection:

Photographic studies are important when researching a project as to really understand a product you need to interact with it and see its good and bad. While this photographic study may not be the most varied the understanding developed is very valuable. The most important thing I have taken from this study is the fact that the classic vacuum flask is greatly flawed in its design and

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1� Stopper

VACUUM FLASK BREAKDOWN

How It Works:Vacuum flasks do not allow heat transfer by any of the three ways that heat can travel. The silver coating on the inner bottle prevents heat transfer by radiation, and the vacuum between its double wall prevents heat moving by convection. The thinness of the glass walls stops heat entering or leaving the flask by conduction. The case surrounding the flask provides additional insulation. The mechanical solution of a vacuum to keep liquid temperature is more scientific than design and as such I feel that it would be a wasted effort to not use this current technology in some form or another in this project.

Usually made from a food safe plastic that won’t be affected by heat fluctuation. Works as a barrier to keep liquid and temperature inside. Mostly made from food safe nylon.

2� ContainerExternal, material selection is important as it can affect the heat retention. Material needs to be sealable to create a vacuum. Easily formed materials such as metal and plastic are common for range of designs.

3� Vacuum Space between external container and glass bulb is where the vacuum is created. The ratio between bulb thickness and vacuum spacing is important in order to maintain heat retention.

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4� BulbThe Glass bulb can be made with different materials. All will have some sort of metal element. Often this is a stainless steel coating on either the outside or inside

5� LiquidThe volume of flasks vary, for personal use 500ml to 1 litre flasks are popular. Flasks store a variety of different liquids. Tea, Coffee, Stew and soup. Many people store hot water in flasks.

6� SupportsSupports are only found in some flasks. They are used to keep the glass bulb in place in the event the user drops the flask. Often supports do little to save the bulb and often can affect the temperature retention.

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How Is It Used?Flask:

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USER INTERACTION PROCESS

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Process:

Classic vacuum flask. capacity of 1 litre, quite large yet thin.

Twisting the top off. Requires some effort depending on type of threads. This can be hard if twisted on too tight.

Lifting the cup off. lifting the cup off reveals the ugly white plastic top and vacuum release mechanism. Not visually appealing whatsoever.

The user must press this button to release the vacuum pressure. Hard to press if the flask has not been opened in a while.

Pouring. Quite possibly the worst part of the entire experience. The liquid comes out of all sides of the mechanism which means there is no concentrated flow.

Twisting the stopper mechanism off. This is on quite tight given the vacuum it is housing. this can be difficult depending on strength.

Removing. Due to condensation the stopper will undoubtedly drip water and as such create a mess.

Transferring liquid to flask. Not user friendly at all. Spillage bound to occur.

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Reasoning:

The problem with studying user interaction of a product is that you can become consumed with your own interaction and not take into consideration the experience of the mass user group. To get some sort of Idea what issues other people have when using a flask I created and ran a survey over two weeks. I gained over 100 responses which I feel is a large enough sample to justify the validity of the results.

1: Have you ever used a flask?

This question is important to start with as it eliminates those who have not used a flask before and as such are of very little value to me in terms of understanding user experience. 82% of people said yes while 18% said no.

Yes 82%No 18%

2: What have you stored? 3: What issues have you had?

Tea 61�4%Coffee 37�3%Soup 48�2%Stew 4�8%Other 14�5%

Trying to determine what people store in a flask lets me know what type of materials I should be looking into. Different liquids can have different reactions with certain materials and as such it is important to catch this early.

Leaks 50�7%Spillage 36�7%Pouring 25�3%Filling17�7%Other 22�8%

This is probably the most important question in the survey. The fact that over 50% of people who have used a flask have experienced some kind of leak or spillage proves the point that this is a product worth redesigning.

SURVEY RESULTS

4: Aesthetic Comparison

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Vinnebago Flask

The Winnebago flask is made by Corkcicle. It has a 750ml capacity. This flask can keep and cold beverage ice cold for over 24 hours. In relation to hot drinks this flask can keep a drink hot for up to 12 hours (that is incredible!). The design is targeted at those who wish to transport colder liquids more so than hot.

Aquavo Flask

The Aquaovo is primarily made of glass which means the user can display their liquid in a nice way. It only weighs 567 grams which is a perfect weight for carrying around. It has a double skinned glass and a removable tea strainer. The flask does not contain Bisphenol-A or BPA and has a capacity of 25 cl.

Non -Brand Flask

The non-brand flask is made of stainless steel and is eco-friendly. The design is minimalist and echoes that of the classic thermos vacuum flask. In terms of functionality it uses the same internal mechanism as the classic thermos flask. As a result while this might be the most visually appealing of the 3 flasks it is by far the weakest in terms of functionality.

4: Aesthetic Comparison

Vinnebego 16%Aquavo 40�7%Non-Brand 43�2%

In terms of aesthetics it is important to develop an understanding of what design elements a user likes in their product. To get an idea of this I inserted images of the top 3 best selling flasks of 2015 into the survey and asked the responders to pick their favourite one. Its interesting to me that the most popular was the non-brand flask. I wonder if this is due to its minimalist shape and form?

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5: Key Features?

In a similar way to finding out what issues people have had, determining what they believe are key features is vitally important. An easy to use product makes sense. From my research up to this point I can see flasks are not easy to use.

6: Age Demographic: 7: Gender Ratio:

10-20 8�4%20-30 34�9%30-40 16�9%40-50 22�9%50-60 9�6%60+ 7�2%

Targeting certain age demographics is important if we look at the marketing aspect of a product for a second. From this survey its interesting to see that the largest section of people are between 20-30 years old.

Male 37�3%Female 62�7%

Gender ratio isn’t a vital figure to get but it is interesting to see if men or women use flasks more. Of the 100 people that answered the survey 63 were female and 37 male. Why could it be that more women use flasks than men?

Ease of UseTemperatureAestheticsCustomizationOther

8: Any other feedback:

The last section box in my survey asked the responder to leave any other feedback or issues they have had. The amount of problems people have had is staggering. It took me over an hour to read through all of the feedback. I collated the core points at each response and tried to determine what were the main common problems. I found that the 3 most common issues for flask users were leakage, pouring and temperature loss.

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Leakage - from lid, seal and o-ring

Pouring - Dribble from cup

Temp Loss - Vaccum, material choice

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Survey: Reflection

I gained great insight into the problems people face when using flasks from conducting this survey. The results I have got are invaluable in terms of progressing. From my own personal experience and feedback from the surveys I have determined how I am moving forward with this project.

I plan to design a flask that is not only functional but is aesthetically pleasing. The flask itself will be beautifully designed and done in a way that users will find visually pleasing. In regards to functionality I plan to tackle 3 big areas. Firstly I plan to solve the issue of leakage through some kind of mechanical design solution. Secondly I want to develop a design that makes pouring the liquid easy with little to no clean up involved. Finally I plan to tackle the issue of temperature loss. I plan to design a flask that can preserve temperature for a much longer time than the current flasks on the market.

ANALYSIS

SECTION:3

CONCEPT EXPLORAT ION

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INITIAL GENERATION

Initial concept

generation is more

inspired by

functionality and

solving specific

problems.

Sketches here use a minimalist approach and are more based around 1 specific concept

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Simplistic and

minimalistic is an

interesting direction to

consider for this project

Asymmetrical designs could have great potential as they also act as a design pice similar to that of a sculpture.

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Concept Exploration: Feedback

After starting initial concept exploration I showed my designs to my peers, friends and family in order to get some feedback. I focused in on talking to people who I knew used flasks frequently. I received great feedback ranging from comments on my potential leakage and temperature loss solutions to the aesthetics of some of my designs. The best feedback I got was on one specific design which my peers agreed if excecuted well could look beautiful. the design pictured below shows a rough idea of what this minimalist flask could look like. I personally like this concept the most out of all my designs and think that developing it further is the right idea. I plan to develop some quick models of it first in order to get an idea of the relationship between the body and flask bottom.

FEEDBACK

Cardboard Sketch ModelThis sketch model was made using an old cardboard case for some colouring pencils. It gave me an initial idea of how the design could be applied to reality. The sketch model itself is way too thin in terms of diameter and would not hold enough liquid to warrant a mouthful. It is beneficial to get your hands dirty and start trying to make this product a reality through iteration.

MODEL MAKING 1

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MODEL MAKING 2

Model Making: Detailed Sketch Model

After playing around with some sketch models I wanted to develop something more solid. I did this in conjunction with my development of the design. This model was turned on a lathe out of wood and was cut in 3 places to highlight where the top would open and how the bottom cup could twist off. The benefit of doing this was that I got an idea of how ergonomic the design should be. Getting the user interaction in terms of height to diameter ratio is vitally important if this project is to be deemed a success. This model was too wide and made the cup difficult to use as the hand didn’t sit comfortably on it. The diameter of the body was too wide also. It made pouring from the flask difficult as once again the hand would not wrap around properly. these are all big considerations to bring forward as the design develops.

SECTION:4

CONCEPT DEF IN IT ION

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MECHANICAL DEVELOPMENT

The goal while doing

this development was

to develop practical

solutions to the

determined problems.

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The way in which the

cup goes on is very

important to this

product. Leakage is not

an option!

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Concept Definition: Final Concept

After making sketch models, getting design feedback and developing my design I feel I have reached a final design concept. The flask will have 3 key features. Firstly its minimalism, the choice of materials is important but overall the flask will look minimal in design yet be noteworthy due to this. Secondly the flask will have a removable cup at the bottom that houses a special “Drip tray”. This drip tray seals in any remaining liquid in the cup when the cup is screwed back on. Finally the design will employ the use of “Titanium Pillow Plates” in an effort to reduce temperature loss. The next step is to begin developing a working drawing of the final design and then develop the CAD, however I plan to do one last quick model to determine the final dimensions in order to make sure they are perfect for the user interaction.

FINAL CONCEPT

Model Making: Ergonomics Development

This final model was turned using a lathe and cut into 3 pieces in a similar fashion to the last sketch model. This model was then partially wrapped in titanium sheets in order to see what a different finish would look like. The wood was also partially sprayed in an effort to see what it would look like in a different colour. While this looks well I don’t see it fitting in with the minimalist clean design I have in mind for this project. In terms of ergonomics and dimensions the size of the flask has now been adjusted so that if fits better in a persons hand. The new diameter and size feel better and overall give the object a nice presence.

MODEL MAKING 3

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Working DrawingThe working drawing shown was developed after the last model was made. The last model provided accurate dimensions for many of the pieces of the design. The working drawing was made in AutoCAd and will be used to develop the final 3D Cad in Solidworks. The design is 250mm in height. The cup is approximately 70mm in height while the diameter of the entire flask is 80mm. The bottom of the cup has rubber supports and has a 5mm fillet for user comfort. The opening mechanism is housed down 10mm from the top.

CAD DRAWINGS

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Rubber Liquid SealThis render shows how the rubber seal works. The cup has a recess at its bottom where liquid collects after use. Once the user is finished and they twist the cup back on to the main body and a rubber seal the opposite shape of the recess comes into contact with the recess and seals off any liquid from escaping down the sides. If for some reason there is some liquid that escaped the recess there is also a rubber 0-ring placed above the threads that once the cup is in place acts as an extra barrier to leakage. This design solution eliminates the possibility of the cup leaking liquid down the sides.

MECHANISM DEVELOPMENT

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1� Vacuum BulbThis is the container in which the liquid is housed. The bulb is made from glass with a stainless steel coating.

2� Rubber Liquid SealThis is the rubber part that comes into contact with the cup to seal in any liquid left in the recess at the bottom.

3� Flask CupThe cup has a recess which collects any liquid left in the bottom of the cup and is sealed in when the rubber seal comes down.

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Temperature Retention: Titanium Pillow Plates

The vacuum in a flask does have weak points. Primarily at the top near the opening. This is where temperature is primarily lost. In order to combat this Issue I have developed a circular version of titanium pillow plates. There are 12 pillow plates that essentially insulate the bulb while also removing the possibility of heat loss at the top of the flask.

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Initial Renders

Once the 3d model was complete I brought it into Cinema4D for some test renders with different materials. I wanted this to look as realistic as possible and bringing it into a software like this would give me an idea of how it could potentially look. While this was just an initial rendering session I was disappointed with the results and as such decided that extensive work will need to be done to define the materials properly.

CONCEPT RENDERS

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Protoype:Manufacturing

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PROTOTYPE MANUFACTURING

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FINAL PROTOTYPE

SECTION:5

CONCEPT PRESENTAT ION

Titanium Lid

Glass Bulb

Titanium Pillow Plates

Flask Main BodyThe main body’s diameter is designed in a way that the user feels comfortable while opening, filling and pouring from the flask.

Rubber O-Ring

FLVSK Cup

The glass bulb holds a capacity of 600ml or 20oz� It is made from glass but has a stainless steel coating on the inside to working in conjunction with the heat retention of the pillow plates�

The Cup is designed to fit the users hand perfectly� The material is a pleasure to touch and the lip is made of a nylon that reacts with the users lip well�

The rubber O-ring acts as an extra barrier for the liquid seal mechanism� Any liquid on the side of the cup will not drip down sue to this barrier�

Titanium pillow plates wrap around the body of the bulb to add extra insulation and to reduce the heat loss points of the Vacuum�

The user twists the lid off to access the flask. The size is ergonomically designed to fit the users hand comfortably.

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Functional Design

The flask breaks into several components. The main body, the cup and the lid� The cup twists off at the bottom and the user fills it with liquid. The top twists off so the user can

fill the flask with their desired liquid.

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Titanium:These parts are all constructed of titanium sourced from China� This is an expensive option but provides an extremely high quality function, it is lightweight, tough and food safe� Unlike Stainless Steel and especially aluminium, hazardous coatings are not needed to ensure it is food safe� Titanium provides a component with longevity, it will not let the user down� The components can be produced through deep drawing, and although titanium is not the most sustainable material to produce it will give the product longer functional use�

Nylon (PA):The Lip of the cup and slider on the top are both constructed of injection moulded nylon� This is an extremely tough food safe, water proof material� It again will make the product very tough and long lasting� It is a high quality polymer that would be produced through injection moulding with retractable cores to create the detailed elements� The Nylon components can be manufactured in the UK�

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© Darragh Hughes Design 2016Bloomfield Ave. 36 Apt 4 Portobello, Dublin 8

T +353 85 739 4435 /// www�darraghhughes�com /// darraghhughes@mail�com

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