Handle Core with Flat Material Layer via Injection Molding
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Solution Overview
Problem
Existing handle manufacturing processes for sports equipment and tools are cumbersome, requiring precise cutting and trimming of materials for coating, which is time-consuming and inefficient, especially when aiming for a secure and easy-to-grip surface.
Innovation Solution
A handle design featuring a core covered with a layer of flat material, such as fabric or leather, which is securely attached using a plastic film or injection molding, allowing for easy production and adaptation to specific purposes while ensuring a pleasant grip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flat material layer is coated on the handle core using traditional methods, then the grip comfort is improved, but the manufacturing complexity and time increase due to precise cutting and trimming requirements
Solution Approach 1:
The patent combines the flat material layer and core into a single integrated handle structure through injection molding. The flat material is placed in the mold cavity before injecting the core material, merging two separate components into one unified part that requires no separate attachment, cutting, or trimming operations.
Solution Approach 2:
The flat material layer is positioned and secured in the mold cavity before the core material is injected. This preliminary placement ensures the flat material is already in its final position and orientation, eliminating the need for post-manufacturing cutting and trimming operations.
2Ease of operation
If traditional coating methods are used with sheet material, then the grip surface is improved, but the production time and efficiency decrease due to tedious cutting and trimming work
Solution Approach 1:
The injection molding process merges the flat material layer and core into a single integrated component, eliminating multiple separate manufacturing steps such as cutting, trimming, and assembly, thereby dramatically improving production efficiency.
Solution Approach 2:
The patent replaces traditional mechanical coating methods (which require manual or machine cutting and trimming) with an injection molding process that forms the complete handle in one operation, substituting complex mechanical operations with a streamlined molding process.
3Strength
If the flat material is securely attached to the core, then the structural integrity is improved, but the manufacturing process becomes more complex requiring precise alignment and fixation
Solution Approach 1:
The injection molding process merges the flat material layer and core into a single integrated structure where the core material flows around and bonds to the flat material, creating inherent structural integrity without requiring separate alignment or fixation operations.
Solution Approach 2:
The flat material is positioned in the mold cavity before core injection, preliminarily establishing its final position. The subsequent injection process automatically secures it through material bonding, eliminating the need for separate alignment and fixation steps.
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 method simplifies handle production by securely attaching a flat material layer to a core, providing a comfortable grip and allowing for customizable hardness and attachment of components, reducing manufacturing complexity and time.
Implementation Method 1
The pressure with which the layer of sheet material is pressed against the inner surface of the mold can be the injection pressure of the material (particularly plastic, preferably thermoplastic plastic or thermosetting plastic) with which it is injected into the mold
Implementation Method 2
Alternatively or additionally, the pressure can also arise because the plastic foams in the mold and the layer of flat material is pressed against the inner surface of the mold by the foaming pressure
Data Source
AI summary
A part intended to be gripped manually, for example a handle (2), in particular for sports sticks, comprises a core (14) of soft or hard foam and a sheath (12) of leather or textile material or an imitation of such sheet-like materials. Provided in the core (14) is a blind hole (20) which is open towards the lower end (5) of the handle (2) and which, if the core (14) consists of soft foam, is formed by a sleeve (16) which is closed at the upper end and which is embedded in the core (14).