Thermoplastic Elastomer Handle Microstructure for Power Tools
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power tool handles made of plastics are prone to dirt accumulation, lack robustness, do not fit comfortably in the hand, and can slip easily, posing safety risks and discomfort to users.
Innovation Solution
A material comprising thermoplastic elastomers with a texture depth ranging from 250 to 400 μm, produced using injection molding with laser-structured molds, which creates a microstructure that enhances grip and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic handles are used for power tools, then manufacturing is simple and cost-effective, but the handles become dirty easily, lack robustness, and slip easily out of the hand
Solution Approach 1:
The patent applies parameter changes by modifying the surface texture depth of the handle material. By controlling the texture depth to be between 250-400 μm, the handle gains improved grip and robustness while maintaining the simplicity of injection molding manufacturing. This parameter optimization resolves the contradiction between ease of manufacture and reliability.
Solution Approach 2:
The patent uses composite materials by combining thermoplastic elastomers with specific surface texture characteristics. The composite structure integrates the manufacturability of plastic materials with the enhanced grip and robustness provided by the controlled microstructure, achieving both ease of manufacture and improved reliability.
2Ease of operation
If the texture depth of the material is increased to improve grip, then the microstructure becomes more pronounced, but the material becomes more difficult to remove from the injection mold
Solution Approach 1:
The patent optimizes the texture depth parameter to a specific range of 250-400 μm, which provides sufficient grip quality while avoiding excessive depth that would cause demolding difficulties. This precise parameter control resolves the contradiction between ease of operation and ease of manufacture.
Solution Approach 2:
The patent applies partial action by using a moderate texture depth that is sufficient for improving grip but not so excessive as to cause manufacturing problems. The texture depth is optimized to provide the necessary functional benefit without the harmful side effects of excessive protrusion.
3Shape
If the hills and dales of the injection mold are made deeper to create pronounced microstructure, then the surface texture is more defined, but the objects cannot be removed from the mold without damage
Solution Approach 1:
The patent controls the height and depth parameters of the injection mold features to create a well-defined microstructure while maintaining object integrity during demolding. The optimized parameters ensure sufficient shape definition without excessive protrusion that would cause damage.
Solution Approach 2:
The patent applies beforehand cushioning by designing the injection mold with appropriate clearance and rounded transitions that prevent damage during demolding. The mold design anticipates the demolding process and incorporates features that protect the object from damage while still achieving the desired microstructure definition.
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 material provides a safe, pleasant, and user-friendly surface for power tool handles, offering improved grip, reduced risk of slipping, and increased operational safety, while maintaining robustness and ease of cleaning.
Implementation Method 1
the hills and dales in the injection mold, which later form the microstructure on the surface of the objects produced, are produced by laser structuring
Data Source
AI summary
A method for producing an object having a microstructure. In the production of the objects, use is made of injection molds which have a counterstructure to the desired microstructure of the object, wherein the counterstructure of the injection mold can be obtained by laser structuring. The material and the objects produced therefrom have proven to be surprisingly robust, hard-wearing and slip-resistant, making them particularly suitable for the production of handles for power tools. A material which includes at least one thermoplastic elastomer material, wherein a texture depth of the material is in a range of from 250 to 400 μm, preferably in a range of from 300 to 380 μm, and more preferably about 325 μm. In yet another aspect, the invention relates to use of the material as a surface material for power tools.