Hand-Held Tool Torque Connection and Plastic Molding
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Solution Overview
Problem
The production of hand-held tools with handles composed of multiple plastic components is time-consuming due to the need for multiple tool changes and long cycle times, making design changes and small series production costly.
Innovation Solution
A hand-held tool design featuring a torque-transmitting connection contour on the tool part, where an inner handle piece can be slid onto and connected to the contour, with casting channels allowing for the outer handle piece to be molded around both, eliminating the need for separate manufacturing steps and enabling varied designs without changing the molding tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a two-component injection-molding method is used to produce handles with different plastic components, then handles with different hardness levels and designs can be produced, but the production cycle time increases due to the necessity of changing the tool geometry between molding the first and second plastic components
Solution Approach 1:
The handle is divided into an inner handle piece and an outer handle piece that are molded separately and then assembled. The inner handle piece is molded first, removed from the tool, and then the outer handle piece is molded around it. This segmentation allows each component to be molded independently without requiring tool reconfiguration, thus reducing cycle time while maintaining design flexibility.
Solution Approach 2:
The inner handle piece is molded and prepared in advance before the outer handle piece is molded. By completing the inner component first and positioning it ready for assembly, the subsequent molding of the outer component can proceed without interruption or tool changes, streamlining the production process.
2Adaptability or versatility
If the tool geometry is changed to produce different handle shapes and designs, then handle adaptability improves, but new tools must be produced which increases cost and time
Solution Approach 1:
By segmenting the handle into inner and outer pieces that are molded separately, each component can be produced using the same basic tooling. Design variations are achieved by changing the inner handle piece, while the outer handle piece molding tool remains unchanged, significantly reducing the need for new tooling investments.
Solution Approach 2:
The outer handle piece molding tool serves multiple functions by accommodating different inner handle piece designs. The same tool cavity can produce various handle designs simply by changing the inner component, making the tooling system universal and adaptable to different product requirements without requiring dedicated tools for each design.
3Manufacturing precision
If multiple tool changes are performed to produce handles with different plastic components, then manufacturing precision can be maintained, but productivity decreases due to long cycle times
Solution Approach 1:
The inner handle piece is molded and prepared in advance with precise dimensions and features. By completing this component first and positioning it correctly before molding the outer piece, the precision requirements are met without requiring tool changes, thereby maintaining quality while improving production speed.
Solution Approach 2:
The inner handle piece is nested within the outer handle piece during the molding process. The inner piece acts as a core around which the outer piece is molded, ensuring proper alignment and precise fit between components without requiring additional positioning steps or tool changes, thus maintaining manufacturing precision while streamlining production.
Data Source
AI summary
A hand-held tool comprises a tool part and a handle surrounding a section of the tool part and connected to same in a torque-transmitting manner. The tool part comprises a connection contour used to connect the handle in a torque-transmitting manner at least in some areas, in a section surrounded by the handle. The handle comprises an inner handle piece which can be connected to the connection contour and surrounds same in a torque-transmitting manner. With the inner handle piece slid onto the connection contour, one or more outwardly-open casting channels are provided between the two parts. The handle further comprises an outer handle piece made of plastic, which during the course of a plastic moulding process is moulded around the unit comprising the tool part which has an inner handle piece connected to the connection contour thereof, wherein the at least one casting channel is at least partially filled with the plastic material which forms the outer handle piece. A method is also described for producing such a hand-held tool.