Flexible Connector with Rigid Insert for Hand Tool Assembly
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Solution Overview
Problem
Existing hand tool designs face challenges in providing a strong and durable connection between the handle and the tool head, especially when using fiberglass handles, which are difficult to machine and require additional compressive strength to prevent collapse under load.
Innovation Solution
A flexible connector is used to combine the handle and tool head, with a rigid tube insert for added strength, and grooves to allow bending and conforming to curved sockets, reducing material requirements and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid metal socket is used to connect the handle to the tool head, then connection strength is improved, but weight and material costs increase
Solution Approach 1:
The patent uses a composite structure combining a flexible connector (thermoplastic material) with a rigid tube insert (metal or rigid material) to achieve the necessary connection strength. The rigid insert provides structural support and strength at the connection point, while the flexible connector material reduces overall weight and allows for conformability to curved sockets. This composite approach resolves the contradiction by integrating both rigid and flexible materials in a single connection assembly.
2Strength
If fiberglass handle material is used, then strength to weight ratio is improved, but machining difficulty and manufacturing complexity increase
Solution Approach 1:
The patent replaces the traditional mechanical machining process with a molding process. The flexible connector is molded around the handle end and rigid tube insert, eliminating the need to machine grooves or shapes into the fiberglass handle. This substitution of molding for machining resolves the contradiction by enabling production of complex connector geometries without the difficulties associated with machining fiberglass materials.
3Adaptability or versatility
If the connector is made flexible to conform to curved sockets, then adaptability is improved, but structural strength may be reduced
Solution Approach 1:
The flexible connector achieves both conformability and strength through its composite construction. The thermoplastic flexible material allows the connector to bend and conform to curved or angled sockets, while the embedded rigid tube insert provides the necessary structural strength and resistance to bending forces. This composite design resolves the contradiction by allowing the flexible portion to adapt to socket geometry while the rigid insert maintains structural integrity.
4Strength
If a rigid tube insert is added to the handle end, then connection strength is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple components into a single integrated molded piece. The flexible connector is molded around the rigid tube insert and handle end in one manufacturing process, creating a unified connection assembly. This merging resolves the contradiction by reducing the number of separate parts that would need to be assembled, while still providing the strength benefits of the rigid insert. The molding process integrates what would otherwise be separate components into a single manufactured piece.
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 solution enhances resistance to bending and deformation, reduces weight and manufacturing costs, and simplifies the manufacturing process while providing increased strength and stability at the connection point.
Implementation Method 1
This wood filler helps to resist a compressive failure of the metal conical section when the tool is used as a pry in either digging or actually prying. This failure will occur on every quality tool at a relatively low load level if a core is not inserted which has adequate compressive strength to prevent the collapse of the conical tubing section
Implementation Method 2
The second end of the connector is flexible thereby allowing it to conform to the shape of the socket and contact the internal surface of the socket along its length regardless of whether the socket is straight or curved
Data Source
AI summary
A hand tool assembly generally comprising a handle and a tool head combined by a connector. The handle has a first end and a second end. The connector has a first end and a second end. The first end of the connector is combined with the second end of the handle. The second end of the connector is combined with the head of a tool by inserting the connector into a socket/opening in the tool's head. The second end of the connector is flexible thereby allowing it to conform to the shape of the socket regardless of whether the socket is straight or curved. A rigid tube insert is positioned a short distance into the handle second end and extends a short distance outward from the handle second end. Adhesives, fasteners, internal hooks, or other commonly known methods of securing an object within an outer sheath or covering may be used to help secure the components together.