Modular Safety Handle Assembly to Reduce Manufacturing Time and Cost
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Solution Overview
Problem
The existing safety handle devices for bathrooms, typically made by metal casting, incur high manufacturing costs due to time-consuming surface polishing processes and bulky sizes, which increases production costs.
Innovation Solution
A safety handle device comprising a handle tube unit, joint members, and support tube units, where the handle tube unit has a tube channel with openings and mounting holes, and the support tube units are detachably coupled to the handle tube unit using fastening members, allowing for easier assembly and reduced processing time, with components that can be made from tubing or sheet metal through techniques like stamping and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tubing is integrally formed by metal casting to ensure structural strength, then the safety handle has sufficient load-bearing capacity, but the surface polishing process becomes time-consuming and manufacturing costs increase
Solution Approach 1:
The patent divides the integral tubing into multiple separate components (handle tube, support tubes, joint members) that can be manufactured independently through simpler processes like stamping and bending, then assembled together. This segmentation eliminates the need for time-consuming surface polishing of large cast components while maintaining structural strength through proper connection design.
Solution Approach 2:
The patent changes the manufacturing parameters from integral casting to separate component fabrication using stamping, bending, and welding processes. This parameter change reduces manufacturing time and complexity while achieving the same structural strength through engineered connections and material selection.
2Strength
If the tubing is integrally formed by metal casting to ensure structural strength, then the safety handle has sufficient load-bearing capacity, but the manufacturing costs become relatively high
Solution Approach 1:
By segmenting the integral structure into separate components, each piece can be manufactured using less expensive processes like stamping and bending instead of costly metal casting. The assembly of these simpler components reduces overall manufacturing cost while maintaining load-bearing capacity through proper connection design.
Solution Approach 2:
The patent employs cheaper manufacturing processes (stamping, bending, welding) for individual components instead of expensive integral casting. While the components are separate rather than integral, their combined assembly achieves the required strength at lower cost.
3Ease of manufacture
If the safety handle uses a modular design with detachable components to reduce manufacturing time and cost, then the processing becomes easier, but the device complexity increases
Solution Approach 1:
The patent merges multiple simple components (handle tube, support tubes, joint members, fastening members) into a unified modular assembly. While each component is simple to manufacture, their combination creates a functional system that balances manufacturing ease with controlled complexity through standardized connection interfaces.
Solution Approach 2:
The joint members and fastening members serve multiple functions: structural connection, load transfer, and detachable assembly. This multi-functionality reduces the need for specialized complex components, simplifying manufacturing while achieving the required structural performance.
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 reduces manufacturing time and costs by allowing for easier processing of smaller components, while maintaining structural strength and load-bearing capacity, and provides an aesthetically pleasing appearance by concealing welding positions.
Implementation Method 1
The handle tube unit (2), the support tube units (5) and the joint members (3, 4) are made from metal materials, and the surfaces of the handle tube unit (2), the support tube units (5) and the joint members (3, 4) are free from welds
Data Source
Figure 1
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AI summary
A safety handle device includes a handle tube unit (2), a plurality of joint members (3, 4), and a plurality of support tube units (5). The handle tube unit (2) is formed with a tube channel (20) that has two openings (201), and has a plurality of mounting holes (24). Each joint member (3, 4) is detachably disposed in the tube channel (20) and has an engaging bore (311, 411). Each support tube unit (5) includes a support tube subunit (51) detachably coupled to the handle tube unit (2), a fastening member (52) passing through the respective mounting hole (24) and engaged detachably with the engaging bore (311) of the respective joint member (3, 4), a securing seat (54) adapted to be fixed to a wall (9), and a securing member (55) extending into the support tube subunit (51) and connected to the securing seat (54).