Ultrasonically Welded Lint Roller Holder With Material-Saving Cutouts
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Solution Overview
Problem
Existing lint roller holders are costly to manufacture due to the need for additional raw material for pins and recesses, and a continuous circumferential surface required for structural support, which increases material consumption and production costs.
Innovation Solution
A lint roller holder design featuring elongated housing parts with ultrasonic welding of outer peripheral edges, including channels and ridges for secure attachment, and cut-outs to reduce material usage, allowing for a more efficient manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pins and recesses are molded into both housing parts to secure them together, then the structural integrity and reliability of the holder is improved, but the manufacturing cost and material consumption increase
Solution Approach 1:
The holder is divided into two separate housing parts that are joined together, allowing each part to be optimized independently. The pins are integrated into only one housing part rather than both, reducing redundant material while maintaining the segmented structure for reliability.
Solution Approach 2:
The pins and housing parts are combined into an integrated structure where the pins are molded as part of one housing piece. This merging eliminates the need for separate pin components and reduces material consumption compared to having pins and recesses in both housing parts.
2Strength
If a continuous circumferential surface is provided on the lint roller support for structural support, then the strength and reliability of the holder is improved, but the raw material consumption increases
Solution Approach 1:
The continuous circumferential surface is segmented into discrete reinforcement regions where pins are integrated. Instead of providing continuous material around the entire circumference, the structure is divided into specific zones that provide necessary structural support while reducing overall material consumption.
Solution Approach 2:
The housing part has non-uniform material distribution with localized reinforcement at the pin integration zones. The material density and structural properties are optimized locally where pins are integrated to provide structural support, while other areas use less material, achieving strength without continuous circumferential material.
3Ease of operation
If pins and recesses are molded on both housing parts, then the ease of assembly and operation is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The assembly process is simplified by segmenting the joining mechanism so that pins are integrated into one housing part and recesses are provided in the other. This asymmetric segmentation reduces the number of components and steps compared to having matching pins and recesses in both parts, lowering device complexity while maintaining ease of assembly.
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 design results in a cost-effective and high-quality lint roller holder with reduced material requirements without compromising structural integrity or operational effectiveness.
Implementation Method 1
These outer peripheral edges are then secured together by an ultrasonic weld
Data Source
AI summary
A lint roller holder having a pair of elongated housing parts which are substantially identical to each other. Each housing part includes an elongated handle section and semi-cylindrical lint roller support section which is longitudinally adjacent the handle section. The housing parts are secured together in a facing relationship, such that an outer peripheral edge of both of said semi-cylindrical lint roller support and said handle sections abut against each other to form both a cylindrical lint roller support and a handle. The outer peripheral edges of the housing parts are then secured together by ultrasonic welding. Each housing part also includes at least one cut-out in the semi-cylindrical lint roller support section to reduce raw material usage requirements.