Broom Body Foam Insert Fastening Without Dovetail Undercuts
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Solution Overview
Problem
Existing broom designs with foam material bodies for fine debris removal are costly to manufacture due to complex fastening mechanisms, such as dovetail joints, which require undercuts and are expensive to produce.
Innovation Solution
The broom body incorporates various simple and cost-effective fastening means like rectangular or V-shaped sockets, dovetail pins with interruptions, headless pins, bulged pins, straps with snap hinges, and tooth-shaped elevations to securely attach the foam material body without the need for complex manufacturing processes, allowing for easy replacement and force transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dovetail joint is used to fasten the foam material body, then the foam material body can be securely fastened to the broom body, but the manufacturing cost increases due to undercuts
Solution Approach 1:
Instead of using a traditional dovetail joint where the socket is formed in the broom body requiring expensive undercut machining, the patent inverts the design by placing the dovetail profile on the foam material body itself. This allows the socket to be a simple rectangular or V-shaped cavity that can be easily manufactured in injection molding, while the dovetail pin on the foam body provides the secure mechanical interlock.
Solution Approach 2:
The patent replaces the complex mechanical undercutting process with a simpler injection molding approach. The socket geometry is redesigned to be compatible with mold cavities, eliminating the need for expensive secondary machining operations while maintaining the structural integrity of the fastening connection.
2Reliability
If a complex fastening mechanism is used, then the foam material body can be securely attached, but the manufacturing process becomes complicated and expensive
Solution Approach 1:
The fastening system is segmented into distinct functional elements: a simplified socket in the broom body and a dovetail pin integrated with the foam material body. This segmentation allows each component to be optimized independently - the socket for easy molding and the pin for secure engagement - reducing overall system complexity while maintaining attachment security.
Solution Approach 2:
The foam material body serves multiple functions: it provides the cleaning surface, contains the fastening mechanism, and transmits forces to the broom body. By integrating the dovetail pin directly into the foam body design, the patent eliminates separate fastening components, reducing part count and assembly complexity while maintaining secure attachment.
3Ease of operation
If the foam material body is positively fastened for easy replacement, then the foam material body can be easily replaced, but the fastening mechanism becomes more complex
Solution Approach 1:
The fastening system is designed with asymmetric dovetail geometry that provides stable engagement in the insertion direction but allows easy release in the opposite direction. The foam material body can be firmly attached during use but can be quickly removed by applying force in the release direction, providing dynamic functionality that adapts to different operational states.
Solution Approach 2:
The broom body is pre-formed with the socket geometry during injection molding, and the foam material body is pre-formed with the dovetail pin integration. This preliminary preparation of complementary geometries allows for tool-free assembly and replacement, eliminating the need for additional fastening components or complex assembly procedures.
Data Source
AI summary
The invention relates to a broom body (1) having, on its underside facing the surface to be cleaned, at least two cleaning bodies (3, 4) made of different materials. One cleaning body (3) is forted by a foam material body (5), which is non-positively and/or positively joined to the broom body (1). This foam material body (1) can be inserted into the broom body (1) in a manner that is perpendicular to the longitudinal axis (6) of the broom body (1), and the foam material body (5) has at least one fastening means (7) for positively fastening it to the broom body.