Abstract: An improved nonrecoil or deadblow hammer and related production method are provided, wherein the hammer has a tool head of hardened steel or the like formed with a hollow socket containing a filler material adapted to shift in the direction of an impact blow struck by the hammer to absorb or dissipate shock forces and thereby substantially reduce or eliminate tool head rebound. The tool head comprises a central body having, for example, a conventional impact member and a nail removal claw formed at opposite ends thereof. The hollow socket is formed in the central body and is upwardly open for seated reception of a hollow canister containing the filler material, such as a flowable and relatively high mass filler material in the form of small steel pellets. In a preferred configuration, the canister is preassembled with a tool handle which extends downwardly from the tool head through a handle port formed at the base or lower end of the socket.

Abstract: An improved nonrecoil or deadblow hammer and related production method are provided, wherein the hammer has a tool head of hardened steel or the like formed with a hollow socket containing a flowable filler material adapted to absorb or dissipate shock forces and thereby substantially reduce or eliminate rebound when an impact blow is struck by the hammer. The tool head comprises a central body having, for example, a conventional impact member and a nail removal claw formed at opposite ends thereof. The hollow socket is formed in the central body and is upwardly open for seated reception of a hollow canister containing the flowable filler material, such as small steel pellets. In the preferred form, the canister is preassembled with a tool handle which extends downwardly from the tool head through a handle port formed at the base or lower end of the socket.

Abstract: An improved impact tool of the nonrecoil type is provided, to include a molded thermoplastic jacket encasing a hollow core canister having a flowable filler material such as small steel pellets or the like disposed therein and adapted to shift about within the canister for absorbing and dissipating impact shock forces. The hollow canister, which may be lightweight in construction, is partially filled with a selected quantity of the flowable filler material and the residual canister volume is occupied by at least one pulverable slug prior to placement of the canister into a mold for formation of the jacket thereon under heat and pressure. The pulverable slug has sufficient structural integrity to withstand molding temperatures and pressures, so that the slug and filler material cooperatively define a rigid structural backstop to prevent deformation of the hollow canister during the jacket molding step.

Abstract: A process for releasably attaching a tool handle to a tool head includes the steps of (1) inserting an end of the tool handle into the tool head through a tool head aperture, (2) turning the end of the tool handle relative to the tool head to engage a pair of lands therein which prevent withdrawal of the end of the tool handle from the tool head, and (3) threading a nut onto the tool handle so as to engage a portion of the tool head adjacent to the aperture. The process is accomplished by providing the handle a connecting stud at one end thereof, wherein the connecting stud includes a pair of oppositely disposed flanges which extend generally perpendicularly outwardly therefrom. The tool head has a central cavity into which the connecting stud is inserted through the aperture. The pair of lands are capable of selectively engaging the connecting stud flanges to prevent withdrawal of the connecting stud from the tool head.

Abstract: An improved impact tool of the nonrecoil type is provided, to include a molded thermoplastic jacket encasing a hollow core canister having a flowable filler material such as small steel pellets or the like disposed therein and adapted to shift about within the canister for absorbing and dissipating impact shock forces. The hollow canister, which may be lightweight in construction, is partially filled with a selected quantity of the flowable filler material and the residual canister volume is occupied by at least one pulverable slug prior to placement of the canister into a mold for formation of the jacket thereon under heat and pressure. The pulverable slug has sufficient structural integrity to withstand molding temperatures and pressures, so that the slug and filler material cooperatively define a rigid structural backstop to prevent deformation of the hollow canister during the jacket molding step.

Abstract: In a process for manufacturing a handle for a hand tool, resin-coated fibers are pultruded to form an elongate, substantially hollow fiber-resin composite rod having a first end for attachment to a tool head. A glass filament is wound about a longitudinal axis of the composite rod adjacent to the rod's first end, after which an encasement over the filament is molded onto the rod. For increased strength, the filament may be first coated with a thermo-setting resin and, after wrapping the filament about the rod, the resin is cured prior to the molding step. The resultant tool handle, particularly useful in applications with, for example, lopping shears, may be very lightweight and yet exhibit superior strength characteristics in comparison with standard composite handles manufactured in a pultrusion manufacturing process.

Abstract: A hollow composite rod manufactured in a pultrusion manufacturing process includes a hollow interior space that may be filled with a liquid, such as water or oil, and subsequently sealed to greatly increase the strength of a resultant rod assembly. The composite rod includes a high strength, pultruded fiber-resin jacket that, at each end, is molded about a reinforced insert to create a fluid-tight seal therebetween. Threaded access apertures are provided through either the reinforced inserts or the jacket itself, to permit the filling or draining of fluid relative to the hollow interior space. Reinforcing sleeves or caps may be molded over a portion of the jacket's exterior to improve the composite rod's resistance to cutting and chipping-type damage.

Abstract: A process for manufacturing a hand tool includes the steps of assembling a tool handle to a molded composite handle adapter to form a tool handle assembly, and attaching the assembly to a tool head utilizing removable fasteners. The tool handle assembly is formed by utilizing a portion of the tool handle as an insert in the mold for the handle adapter. A handle receiving socket is formed during the molding process around the inserted end of the tool handle shaft, to securely fasten the tool handle to the handle adapter. The handle adapter has an enlarged base that is seated on a platform of the tool head. Threaded fasteners, such as machine screws, are received within the handle adapter and locked in place to attach a tool handle assembly to the tool head. A shim may be disposed between the tool head and the handle adapter to facilitate use of the tool handle assembly with a number of different tool heads.

Abstract: A process for manufacturing a shovel includes the steps of stamping a substantially flat shovel blade from sheet metal stock, attaching a molded composite handle adapter to the shovel blade, and fastening a tool handle to the handle adapter. The resultant shovel includes a shovel blade having a platform on an upper surface thereof and a foot tread extending the width of a rear edge of the blade, and a handle securely fixed to the blade via the handle adapter. The handle adapter has an enlarged base at a first end thereof seated on the platform of the blade, a handle receiving socket at a second end thereof, and an angular intermediate portion. A connecting stud has a first end embedded in the intermediate portion of the handle adapter, and a second end which extends into the handle receiving socket. The tool handle has an end secured within the handle receiving socket such that the second end of the connecting stud is embedded therein.

Abstract: A tool handle assembly includes a molded adapter bonded to the end of a handle shaft, which adapter includes a generally cylindrical cap portion and a generally tapered frustoconical portion that surrounds the handle shaft adjacent to the cap portion. The handle assembly is inserted into a lower entrance of a tapered eyehole of a tool head such that the frustoconical portion of the adapter engages a portion of the eyehole. In one preferred form, the cap portion of the adapter includes external barbs. A pair of arcuate wedges having interior teeth are inserted between the cap portion of the adapter and the tool head and bear on the major axis of the tool head. The teeth of the wedge cooperate with the barbs of the adapter to secure the wedges in place. In another preferred form, the adapter includes a pair of slots into which wedge inserts are driven to expand the cap portion of the adapter and thus secure the tool head to the handle assembly.

Abstract: In a process for manufacturing a bow rake, an outer plastic encasement is molded over a structural skeleton to form a cross-head including a handle-receiving socket and a plurality of spaced-apart tines. An elongated claw is pressed into an end of each tine, and an end of a handle is securing within the handle-receiving socket. In manufacturing the cross-head, one or more voids in the structural skeleton are filled with a selected flowable filler material which provides a structural backstop to maintain the shape integrity of the hollow skeleton during the molding step. Some or all of the filler material is removed from the skeleton subsequent to the molding step. Prior to pressing the claws into the tines, the claws are heated and then secured on a ram. The cross head is placed in a stationary jig in alignment with the ram, and the heated claw is then pressed into the selected tine. A similar process is utilized to connect the handle to the cross-head.

Abstract: An adapter for connecting a tool head to a fiberglass tool handle or shaft. The adapter includes a cap having greater compressive strength than the handle. The cap fits over the end of the handle to prevent damage during assembly, use or storage of the tool. A pair of adapter sections fit around the cap and the adjacent end of the handle. The adapter sections have recesses which receive the ends of the cap. A pair of pins carried by the adapter sections extend into openings in the handle. The cap also acts as a guide to provide proper alignment of the adapter sections and tool head with respect to the handle.

Abstract: A combined insert and end plug for aligning fiberglass tool handles for attachment to tool heads and for concealing the ends of the handles. The resilient molded plastic insert has a center portion and a plurality of integral outwardly directed legs. The insert is mounted within a tool head opening so that the legs are disposed between the handle and the walls of the opening. The insert holds the handle in proper position for attachment to the tool head. The insert has a plurality of outwardly directed resilient membranes which flex inwardly during insertion and then flex outwardly by their own resilience to combine with the center portion to form a cover for the outer end of the opening.

Abstract: An assembly tool for use in attaching fiberglass handles to tools and the like. A tape applicator is mounted for reciprocal vertical movement by a double-acting hydraulic cylinder. A tool head is mounted beneath the applicator with masking tape overlying one end of the tool head opening. The applicator comprises a hollowed resilient pad which draws the masking tape tightly across the top of the opening and then presses it into sealing engagement with the entire periphery of the opening. The opening is thereby sealed against leakage of potting compound inserted into the opening to bond a handle to the tool head.