Tool Container with Composite Cushioning for Impact Protection
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Solution Overview
Problem
Existing tool containers fail to effectively cushion and stabilize metal hand tools against impacts, reduce rattling noises, and provide tactile feedback during closure, while also being sensitive to Foreign Object Damage (FOD) due to lack of adequate cushioning and frictional support.
Innovation Solution
A tool container made of two injection-molded plastics materials, where a relatively soft material is used for cushioning and friction, combined with a rigid material for strength, featuring tool supports with cushions that protrude from the shell bodies to provide three-axis stability and visibility through windows, and a locking mechanism that prevents accidental damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid plastics material is used for the shell body, then strength and durability are improved, but cushioning capability and frictional contact are insufficient
Solution Approach 1:
The patent applies composite materials by combining a rigid first plastics material for the shell body with a soft second plastics material for the tool support cushion. This composite structure allows the rigid material to provide structural strength while the soft material provides impact cushioning and frictional contact, resolving the contradiction between strength and cushioning capability.
2Object-affected harmful factors
If a soft plastics material is used for cushioning, then impact protection is improved, but structural strength and stability are reduced
Solution Approach 1:
The patent uses a composite material structure where the soft second plastics material forms the tool support cushion embedded in the rigid first plastics material shell. This allows the soft material to provide impact protection while the rigid composite structure maintains overall structural strength and stability.
3Stability of the object's composition
If tool supports are added to hold tools, then tool stability is improved, but rattling noises and impact risks increase
Solution Approach 1:
The patent applies local quality by making the tool support cushion specifically soft and compliant at the contact points with tools, while the rest of the shell remains rigid. This localized softness provides cushioning and reduces rattling noises exactly where tools contact the container, without compromising overall structural integrity.
4Reliability
If the container is made to close tightly, then tool security is improved, but tactile feedback during closure is insufficient
Solution Approach 1:
The patent incorporates feedback by designing the soft second plastics material tool support cushion to provide tactile feedback during the closure process. As the lid closes, the soft cushion deforms and provides sensory feedback to the user, allowing them to feel when full closure is approaching, thus improving ease of operation while maintaining reliable tool security.
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 tool container effectively cushions hand tools against impacts, reduces rattling noises, provides tactile feedback during closure, and enhances visibility and stability, while minimizing Foreign Object Damage by using fluorescent markings and a secure locking mechanism.
Implementation Method 1
Natural resilience of the tool supports' second material cushions the hand tools against impacts caused by accidental collisions with the tool container
Implementation Method 2
A second relatively soft plastics material, attached externally to the first material, may be used to provide a softer touch and improves frictional contact and stability of the tool container when rested on a surface
Implementation Method 3
Natural resilience of the second material may provide a soft closure of the first shell against the second shell as the hand tools are clasped between the tool supports
Data Source
Figure 1
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AI summary
A tool container (10) comprising: a first shell (20) comprising a shell body (22) of a first plastics material; a second shell (40) comprising a shell body (42) of the first material; and a locking mechanism (70, 72, 74). The first shell is coupled to the second shell by means of a hinge (60) to rotate between open and closed positions. The tool container comprises tool supports (202, 204, 212, 213, 214, 215, 222, 223, 224, 232, 233, 234, 242, 243, 248, 249) arranged to clasp a respective hand tool between the first and second shells of the tool container in the closed position. The supports comprise a cushion (202b, 204c, 212b, 213b, 222b, 223b, 232b, 233b, 242b, 243b, 248b, 249b) of second plastics material of one of the first shell or the second shell. The second material is relatively soft in relation to the first material.