Plastic Grip Element With Sawtooth Metal Insert
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Solution Overview
Problem
Existing handle elements with metal inserts face high production costs due to complex manufacturing and assembly processes, especially when producing small quantities, as they require costly injection molding and multiple components.
Innovation Solution
A fastening part with a sawtooth attachment at its upper end and a polygonal collar is used, allowing for a simple and cost-effective connection with the handle by being driven into its central recess, providing a secure and permanent attachment without the need for screws or adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If injection molding with metal inserts is used to connect handle elements, then a permanent connection is achieved, but production costs increase significantly due to complex preparation and set-up work
Solution Approach 1:
The connection system is divided into separate components: a handle element and a fastening part that can be manufactured independently and assembled later. This eliminates the need for complex injection molding with metal inserts, allowing each component to be produced using simpler, more cost-effective processes while maintaining a reliable permanent connection through the driven attachment mechanism.
2Reliability
If injection molding is used to connect the insert to the plastic handle, then a permanent connection is achieved, but the manufacturing process complexity increases
Solution Approach 1:
The metal insert is extracted from the injection molding process and becomes a separate fastening part. This eliminates the need for modified injection molds and complex preparation work, simplifying the manufacturing process while maintaining permanent connection reliability through the driven attachment with sawtooth engagement and polygonal collar.
3Adaptability or versatility
If multiple components with complicated shapes are used in the screwing tool, then functional requirements are met, but manufacturing and assembly difficulty increase
Solution Approach 1:
Multiple functional features are merged into the fastening part: the bolt-like body with threading, the sawtooth attachments for axial retention, and the polygonal collar for anti-rotation are all integrated into a single component. This reduces the number of separate parts from three to one, simplifying manufacturing and assembly while maintaining all necessary functional capabilities.
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 solution enables a reliable, inseparable connection between the plastic handle and the metal insert, reducing production costs and complexity by eliminating the need for injection molding and additional fastening means, while ensuring rotational security through the polygonal recess and collar engagement.
Implementation Method 1
the sawtooth attachments are barbed in the center hole of the handle and can no longer be pulled out
Implementation Method 2
the attachment part is driven into the central recess of the handle with its bolt-like end, which is designed as a sawtooth attachment, whereby the sawtooth attachments are barbed in the center hole of the handle
Implementation Method 3
The multi-edged collar, which engages in an associated polygonal recess on the underside of the handle and there positively engages in an associated polygonal recess, serves to prevent the fastening part from rotating in the handle
Data Source
Figure 1~4
AI summary
The device (1) has a fixing part that is anchored in the plastic part so as to turn with it and that is suitable for holding an optional screw-on part. The fixing part consists essentially of a bolt-like part with a saw tooth fitting on the upper end to which is joined a polygonal collar (7) with a transition to an optional screw-on part.