Reverse-Molded Grip Component for Hand Tools
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Solution Overview
Problem
Conventional grip component manufacturing processes can deform the inner portion due to contracting pressure from the external portion, limiting the use of softer materials for vibration isolation and shock absorption, and often require complex adhesive application and compression steps that increase assembly time and cost.
Innovation Solution
A reverse-molded grip component process where the external portion is molded first, followed by the inner portion, allowing the inner portion to be formed without resisting contracting pressure, using softer materials for improved vibration isolation and simplifying assembly by eliminating the need for strong adhesives and compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the external portion is molded first in conventional processes, then the structural integrity and durability are improved, but the inner portion deforms due to contracting pressure limiting vibration isolation capability
Solution Approach 1:
The patent inverts the conventional molding sequence by molding the external portion first, then the inner portion. This reversal allows the outer shell to set without being deformed by subsequent material contraction, while still enabling the inner portion to provide vibration isolation. The inversion resolves the contradiction by changing the temporal sequence of operations.
Solution Approach 2:
The grip component is segmented into two distinct portions with different material properties: an external portion for structural integrity and durability, and an inner portion for vibration isolation. The segmentation allows each portion to be optimized for its specific function without compromising the other, resolving the contradiction between durability and vibration isolation.
2Object-affected harmful factors
If softer materials are used for the inner portion to improve vibration isolation, then vibration damping is improved, but the inner portion deforms under contracting pressure from the external portion
Solution Approach 1:
By inverting the molding sequence and molding the external portion first, the patent eliminates the contracting pressure problem that would deform soft inner materials. The outer shell is already set and constrained when the inner material is molded, allowing soft materials to be used without deformation while maintaining shape stability.
Solution Approach 2:
The patent changes the material parameter (hardness) of the inner portion to be softer for vibration isolation, and resolves the resulting deformation issue by changing the process parameter (molding sequence) rather than compromising the material selection.
3Ease of manufacture
If conventional molding processes are used, then manufacturing capability is maintained, but complex adhesive application and compression steps are required increasing assembly time and cost
Solution Approach 1:
The patent merges the molding and assembly operations by creating a self-aligning, self-bonding structure. The reverse-molded geometry and material properties enable the inner and outer portions to bond automatically during molding without requiring separate adhesive application and compression steps, reducing assembly time while maintaining manufacturing capability.
Solution Approach 2:
The grip component structure is designed to be self-assembling through the reverse molding process. The outer portion and inner portion automatically bond through the molding process itself, eliminating the need for external adhesive application and compression operations. The structure serves its own assembly function.
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 reverse-molded grip component enhances vibration isolation, reduces user fatigue, and simplifies the assembly process by using softer materials for the inner portion and relying on mechanical fasteners, while maintaining durability and abrasion resistance with a harder external layer.
Implementation Method 1
forming an external portion of the grip component by molding a first thermoplastic elastomer (TPE) material or thermoplastic urethane (TPU) material into a shell
Implementation Method 2
forming an inner portion of the grip component by filling the first cavity with a second TPE material or TPU material
Implementation Method 3
using softer materials for improved vibration isolation and shock absorption
Implementation Method 4
maintaining durability and abrasion resistance with a harder external layer
Data Source
AI summary
A hand tool comprising a head portion, a shaft, and a grip component is provided. The shaft is attached to or integral with the head portion, and the grip component is disposed around the shaft. The grip component and the shaft form a handle of the hand tool. The grip component comprises an external portion molded from a first thermoplastic elastomer (TPE) material or thermoplastic urethane (TPU) material, and an inner portion molded from a second TPE material or TPU material. The first TPE or TPU material has a first level of hardness, and the second TPE or TPU material has a lower level of hardness. The inner portion is disposed around the shaft, and the external portion forms a shell around the inner portion and is an exposed user contact surface. The grip component is attached to the shaft via at least a mechanical fastener.