Hand Tool Handle Variable Thickness Elastomer Comfort
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Solution Overview
Problem
Existing hand tool handles, particularly those made from thermoplastic materials, often fail to provide sufficient comfort during prolonged use, leading to blisters and discomfort due to friction, and previous attempts to improve comfort, such as using flexible elastomer coatings or gel cushions, have been complex and expensive to produce or ineffective.
Innovation Solution
A hand tool handle design featuring a rigid support core with a hollow structure and a flexible elastomer envelope that varies in thickness from the periphery to the center, reducing the cutting effect and enhancing comfort during handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid thermoplastic handle is used, then the handle provides structural strength and support, but it causes discomfort and blisters during prolonged use due to friction and lack of flexibility
Solution Approach 1:
The handle combines rigid thermoplastic material for structural strength with flexible elastomer material for comfort. The elastomer coating is applied over the rigid core, creating a composite structure that provides both mechanical support and tactile comfort during prolonged use.
Solution Approach 2:
The elastomer coating is applied selectively to specific regions of the handle where user contact occurs, while maintaining the rigid core structure throughout. This local application of different material properties optimizes both strength and comfort without compromising overall structural integrity.
2Ease of operation
If a flexible elastomer coating is applied over the rigid core, then handling comfort is improved, but the production process becomes more complex and expensive
Solution Approach 1:
A thin elastomer coating is applied over the rigid handle core, providing flexibility and comfort without requiring complex internal structures. This thin-film approach simplifies manufacturing compared to fully flexible handles while maintaining comfort benefits.
3Ease of manufacture
If the elastomer envelope has uniform thickness, then manufacturing is simplified, but the user experiences cutting effects from the light edge and reduced comfort
Solution Approach 1:
The elastomer envelope thickness varies locally: thicker at the periphery to prevent cutting effects from the light edge, and thinner at the center to provide tactile feedback and comfort. This non-uniform thickness distribution optimizes both safety and user experience.
Solution Approach 2:
The solution moves from a one-dimensional uniform thickness approach to a two-dimensional variable thickness profile, where thickness is optimized at different locations (periphery vs. center) to achieve multiple functional goals simultaneously.
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 variable thickness of the flexible envelope provides improved comfort and reduces fatigue during prolonged use, while maintaining sufficient resistance and preventing injury from the handle's edge.
Implementation Method 1
a flexible material envelope (30) made of a more flexible material such as an elastomer
Implementation Method 2
generate blisters or blisters on the user's hand due to prolonged friction
Data Source
Figure 1~4
Figure 5~11
Figure 12~13
AI summary
The handle (10) has a hollow structure support core (20) with an internal chamber (22) that is opened at an interior by a hole (24), where the core is made of material chosen from metal, coated metal, thermoplastic material e.g. polypropylene and PVC, or wood. The hole is covered by a flexible case material (30), so that the flexible case material does not have an internal support formed by the support core at the level of the hole. The flexible case material defines a rim at interior of a tank.