Hammer Tool Handle Coupling Flange Design
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Solution Overview
Problem
The existing hammer head fixing structure is not suitable for long-term use as it tends to wear and deform, leading to a reduction in the fixing effect and eventual disengagement of the hammer head from the handle, particularly when used with wooden handles.
Innovation Solution
The hammer tool design includes a hammer head with radial side holes and a handle with coupling flanges formed through deformation, such as squeezing, to create interlocking features that enhance the coupling strength and prevent disengagement, featuring disengagement prevention flanges and limiting flanges for improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional hammer head fixing structure with a wooden handle is used, then the initial coupling strength is sufficient, but the fixing effect deteriorates over time due to wear and deformation
Solution Approach 1:
The invention changes the material parameter of the handle from wood to metal (aluminum alloy), which fundamentally alters the wear resistance and deformation characteristics. The metal handle maintains its dimensional stability and coupling strength over time, resolving the deterioration issue while preserving the initial fixing effect.
Solution Approach 2:
The invention uses a composite structure combining metal handle with rubber grip material. The metal portion provides structural integrity and resistance to wear/deformation, while the rubber portion provides grip and comfort. This composite approach solves the durability problem of wooden handles.
2Strength
If the handle material is changed from wood to metal, then wear resistance and deformation resistance are improved, but the coupling mechanism must be redesigned
Solution Approach 1:
The invention divides the coupling interface into multiple functional segments: the insertion portion with flange for basic positioning, the disengagement prevention flange for preventing separation, and the limiting flange for depth control. This segmentation allows each element to perform its specific function simply, avoiding overall structural complexity.
Solution Approach 2:
Instead of making the hammer head complex to fit a simple handle, the invention inverts the approach by making the handle complex with multiple flanges that actively engage with the hammer head's insertion hole. The handle becomes the active coupling element with integrated fixing features.
3Reliability
If multiple flanges are added to the insertion portion, then disengagement prevention is improved, but manufacturing complexity increases
Solution Approach 1:
The flanges are pre-formed as integral features of the handle during the extrusion process, before assembly. The insertion portion with flange, disengagement prevention flange, and limiting flange are all created in one manufacturing step, eliminating the need for separate assembly operations and reducing overall manufacturing complexity.
Solution Approach 2:
The invention merges multiple fixing functions into a single integrated handle structure. The flange, disengagement prevention feature, and limiting feature are all combined in one extruded component, simplifying manufacturing compared to assembling separate parts.
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
This design provides an excellent coupling strength that prevents the hammer head from disengaging from the handle during use, allowing for effective hammering and potential swinging functions while maintaining structural integrity over time.
Implementation Method 1
the first coupling flange is formed by deforming the handle through squeezing
Implementation Method 2
The first coupling flange is formed by punching or squeezing the inner periphery of the hollow portion to form the first squeezing groove in the inner periphery of the hollow portion and to form the first coupling flange on the outer periphery of the insertion portion
Implementation Method 3
The disengagement prevention flange abuts against the second end of the hammer head
Data Source
AI summary
A hammer tool includes a hammer head and a handle. The hammer head includes an insertion hole and first and second side holes aligned with each other and located on two opposite sides of and intercommunicating with the insertion hole. The handle includes an insertion portion on an end thereof. The insertion portion is inserted into the insertion hole. A first coupling flange is integrally formed with the insertion portion and is inserted into the first side hole. The handle includes a hollow portion extending in a longitudinal direction thereof. The handle further includes a third side hole extending in a radial direction thereof. An end of the third side hole intercommunicates with the hollow portion. Another end of the third side hole extends to an outer periphery of the insertion portion. The third side hole is aligned with the second side hole.