Two-Material Handle Injection Molding with Embedded Branding
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Solution Overview
Problem
Current handle manufacturing processes are complex, time-consuming, and expensive, and branding on handles tends to fade quickly due to wear, making them impractical and costly to produce.
Innovation Solution
A method involving injection molding of a handle with a rigid inner body and a flexible outer layer, where branding is created using the inner material and filled with a second material through a single injection point, ensuring durability and ease of use without additional production steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If branding is applied by printing or painting on the handle surface, then the handle can display product information, but the brand/signs gradually fade due to wear and friction, making them illegible after short use
Solution Approach 1:
The branding elements are pre-formed as integral parts of the handle structure during the injection molding process, rather than being applied subsequently. The cavities corresponding to brand letters and symbols are created in the mold itself, ensuring the branding is built-in from the start and cannot fade or wear off like surface-applied marks
Solution Approach 2:
The handle is manufactured using two different materials: a harder, more wear-resistant material for the inner body that contains the branding cavities, and a softer, more flexible material for the outer grip layer. This composite construction protects the branding cavities from wear while maintaining grip comfort, solving the contradiction between branding durability and handle performance
2Reliability
If branding is created by embossment or recess in the handle, then the brand information is permanently embedded, but the handle surface becomes non-smooth, making it difficult to turn and uncomfortable to use
Solution Approach 1:
The branding cavities are nested within the inner body of the handle, below the surface level. The outer grip layer is molded to cover these cavities completely, creating a smooth external surface while preserving the embedded branding elements underneath. This nested structure allows the brand information to be permanently embedded without compromising handle smoothness or usability
Solution Approach 2:
The two-material construction allows the harder inner material to contain the embossed branding cavities while the softer outer material provides a smooth, comfortable grip surface that covers the cavities, resolving the contradiction between permanent branding and handle smoothness
3Reliability
If handles are manufactured with two materials (harder inner material and flexible outer material), then the handle provides greater robustness and secure grip, but the manufacturing process becomes complicated, time-consuming and expensive
Solution Approach 1:
The manufacturing process merges multiple operations into a single injection molding cycle. The harder inner material is first injected to form the core structure with branding cavities, then the softer outer material is injected in the same mold without removing or repositioning the inner material. This combined process eliminates the need for separate manufacturing steps, reducing complexity despite the two-material construction
Solution Approach 2:
The inner body with branding cavities is formed first as a preliminary step within the same molding cycle, preparing the structure for the outer material injection. This preliminary formation of the inner core with integrated branding elements simplifies the overall process compared to post-manufacturing branding operations
4Reliability
If handles are manufactured with two materials using traditional methods, then the handle provides robustness and secure grip, but the manufacturing process is time-consuming, increasing production time and cost
Solution Approach 1:
The injection molding process combines the formation of both the harder inner material and the softer outer material into a single continuous operation. The inner material is injected first, then the outer material is injected in the same mold cycle without removing the inner material, eliminating the time required for separate manufacturing steps and reducing overall production time
Solution Approach 2:
The manufacturing process maintains continuity by keeping the mold closed and the injection system active throughout the formation of both material layers. The transition from inner to outer material injection occurs without interrupting the molding cycle, ensuring continuous useful action and minimizing production time while maintaining the two-material robust construction
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 approach simplifies and speeds up the manufacturing process, enhances handle durability, and maintains branding clarity, reducing costs and production time while providing a comfortable grip.
Implementation Method 1
injection molding an inner body or first body by injecting a first material using a first mold
Implementation Method 2
injection molding an outer body or second body by injecting a second material over the inner body
Data Source
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AI summary
The present invention relates to a handle formed by at least a first material and a second material, and to a method, system and apparatus for manufacturing same. The present invention provides a handle formed by two different materials, a body made of a first more rigid material (for example, a polymer such as polypropylene) and a covering made of a second more flexible material (rubber). The body will include signs (formed by letters, numbers, logos, drawings or any other type of symbol) made in said first material. The covering may have two independent portions separated by a strip of the first material. The proposed invention will allow the covering made of the second material to fill up the inner cavities and cover the two separate portions with a single injection point.