Triangular Pry Bar Handle With Elastomeric Overmold Grip
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Solution Overview
Problem
Existing pry bars have cumbersome metal handles that lack ergonomic design, particularly for large or commercial use, and previous improvements in grip technology have not adequately addressed the need for a secure and practical grip for elongate pry bars.
Innovation Solution
A pry bar handle with a transversely disposed triangular cross-section featuring rounded soft thermoplastic surfaces and spaced oval thermoplastic grip elements, combined with a metal end cap having radially outward serrated elements, provides a secure ergonomic grip. The handle's centerline is vertically displaced from the end cap axis, and the number of grip elements is proportioned to the handle's length for improved grip functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal handle is used for the pry bar, then the structural strength is improved, but the ease of operation deteriorates due to cumbersome grip
Solution Approach 1:
The handle is constructed as a composite structure combining a metal core (for strength) with an overmolded elastomeric material (for grip). The elastomeric layer provides a non-slip, comfortable grip surface while the metal core maintains the structural integrity and strength required for pry bar operations.
2Ease of manufacture
If a symmetric grip design is used, then the manufacturing simplicity is improved, but the ergonomic performance deteriorates for elongate pry bars
Solution Approach 1:
The grip surface features non-uniform spacing of oval grip elements that are denser toward the distal end of the handle. This local variation in element distribution provides enhanced ergonomic performance for elongate pry bars by concentrating grip points where the user's hand naturally positions itself during operation.
3Reliability
If the number of grip elements is increased, then the grip security is improved, but the device complexity increases
Solution Approach 1:
The grip element configuration uses varying parameters including non-uniform spacing, different orientations, and varying sizes of oval elements. This parameter variation creates multiple grip points for enhanced security without requiring a simple repetitive pattern, thus improving grip reliability while keeping the manufacturing process relatively straightforward.
Data Source
AI summary
A pry bar has a transversely disposed generally triangular cross-section handle grip portion having surfaces formed of a soft elastomeric over-molded material. The handle is formed with an inner hard thermoplastic core and molded over outer elastomeric cover. A metal tether receiving element and impact cap are fixedly secured at the handle proximate end.