CHALLENGE
What goes into making a product? Understand why why the Grand Wall Phone was such a successful product.
SOLUTION
Use forensic analysis skills and knowledge of materials and manufacturing processes to tear down an existing manufactured product, analyze its components, materials and construction and apply those findings in the development of a new product.
HOW I HELPED
Design Researcher
Tear Down/Disassembly
Concept Development
Grand Wall Phone
PROCESS
Can we disassemble a product to learn more about it?
The grand wall phone was used for communication and connection. It was made of good quality materials that withstood a busy kitchen environment.
70 years after its original introduction and in a society that has long surpassed the need for a wall phone, the grand wall phone is still a statement product due to its organic shapes and bulbous form giving the viewer joy.
Bell Telephone Magazine Ad
Bell Telephone Magazine Ad
Phone Disassembly
Phone Disassembly Label Parts
The entire grand wall phone is made with high quality and durable material. There are numerous parts that go into making this project function well.
BUTTONS
The buttons of the grand wall phone are primarily made from ABS and manufactured using injection molding. The rubber keypad is made using silicone while the PCB has multiple materials and layers.
Button Components
Individual button components
Individual button components
Individual button components
Back housing and some internal parts
Front Housing Outside
Front Housing Inside
Back Housing Outside
Back Housing Inside
HOUSING
The housing is also made from ABS plastic and made using injection molding. This is made evident from parting lines and ejector pins. Also, there are swirls on the inside the the plastic, an impression from the mold used to make the housing.
INTERNAL COMPONENTS
Some internal comments include the PCB and the ringer assembly. The PCB is made from rigid laminate with a glossy epoxy substrate. Conductive layers are made of thin copper foil.
The ringer housing is also made from ABS. Copper is the dominant metal in the manufacturing of bells.
Phone PCB
Phone Ringer
Phone Handset
Phone Receiver
Phone Handle
Phone Speaker and Microphone
HANDSET
The handset is also made from ABS plastic while the cord of the handset has polypropylene insulation and a polyvinyl chloride cover.
Interestingly, the phone has a weight in the handle of the handset to give the phone a hefty feeling.
HOOK SWITCH
The plastic portions of the hook switch are made using ABS and manufacturing using injection molding. It is easy to see the ejector pin and gate marks on these smaller pieces.
The handset hanger is likely made from some type of cast steel.
Hook Switch
Hook Switch
Hook Switch
This project created the foundation for the Grand Kitchen Timer. Make sure to check it out!
