Method for producing a cleaning roller, cleaning roller and vacuum cleaner nozzle
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Solution Overview
Problem
The production of cleaning rollers using plastic injection molding faces challenges with mechanical loads causing deformations, stress cracks, and imbalances due to uneven cooling, leading to structural integrity issues and operational inefficiencies.
Innovation Solution
A multi-stage injection molding process is employed, where a core and jacket are produced using different polymer materials, allowing for controlled cooling and solidification, reducing temperature differences and enabling the production of dimensionally stable roller bodies with improved cohesion and weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large-volume plastic roller body is produced using a single-stage injection molding process, then the structural integrity and mass required for mechanical strength are achieved, but excessive rapid and uneven cooling causes stress, deformation, and dimensional inaccuracy
Solution Approach 1:
The roller body is divided into two separate manufacturing stages: a core component and a shell component. The core is first injection-molded with sufficient mass for structural integrity, then the shell is overmolded around it. This segmentation allows the core to be produced with controlled cooling to avoid deformation, while the shell adds the necessary mass without subjecting the entire large volume to rapid cooling, thus maintaining dimensional accuracy.
Solution Approach 2:
The core is pre-formed through the first injection molding process with optimized cooling to ensure dimensional stability and minimize internal stresses. This preliminary action creates a stable foundation that prevents deformation before the shell is added, allowing the final roller body to achieve both required mass and high dimensional accuracy.
2Strength
If the roller body is made larger and more massive to withstand mechanical stresses, then the required strength and durability are achieved, but the production complexity and difficulty of manufacturing increase
Solution Approach 1:
The manufacturing process is segmented into two injection molding operations: forming the core and then overmolding the shell. This approach allows each stage to be optimized independently - the core for dimensional stability and the shell for mass and strength - thereby reducing the overall manufacturing complexity compared to producing a single large component.
Solution Approach 2:
The roller body is constructed as a composite of two polymer materials: the core material optimized for dimensional stability and the shell material optimized for mass and mechanical strength. This composite structure enables the roller to achieve high mechanical strength while maintaining ease of manufacture through standardized injection molding processes applied in sequence.
3Manufacturing precision
If uniform slow cooling is applied to large-volume injection molded parts to avoid temperature-related distortion, then dimensional accuracy is improved, but the production cycle time increases and productivity decreases
Solution Approach 1:
The roller body production is segmented into two injection molding stages. The core is manufactured first with controlled slow cooling to ensure dimensional accuracy. The shell is then overmolded around the cooled core, allowing the majority of the polymer mass to be added without requiring equally prolonged cooling time for the entire component. This segmentation maintains dimensional accuracy while reducing total cycle time compared to cooling a single large-volume part.
Solution Approach 2:
The core is pre-formed and fully cooled before the shell is added. This preliminary action ensures the critical dimensional features are established during the core formation with controlled cooling, while the subsequent shell addition does not require proportional cooling time, thereby maintaining productivity.
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
This method results in a more stable and accurately dimensioned cleaning roller with reduced vibrations and improved operational balance, suitable for heavy use and long periods of operation, while maintaining the quality and efficiency of the injection molding process.
Implementation Method 1
the mass of plastic melt used can be reduced in each case. This allows for faster solidification/cooling without excessive temperature differences occurring within the component
Implementation Method 2
This allows for faster solidification/cooling without excessive temperature differences occurring within the component
Data Source
Figure 1A~1B
Figure 2A~2B
AI summary
The invention relates to a method for manufacturing a cleaning roller, in particular for a floor cleaning device, comprising a roller body (1) and a cleaning arrangement mounted on the roller body (1). According to the invention, the roller body (1) has a core (3) and a shell (6) arranged around the core (3). The roller body (1) is manufactured in a multi-stage injection molding process, wherein the core (3) is produced in a first injection mold (2) with a first polymer material, and wherein the shell (6) is produced by at least one subsequent overmolding of the core (3) in a second injection mold (5) with a second polymer material.