Two-Step Injection Moulding Teat Cleaner Eliminates Assembly Gaps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing teat cleaning cups face issues with high manufacturing costs due to expensive drilling of nozzle holes and gaps between parts that can harbor germs and bacteria, making them difficult to assemble and disassemble, and inefficient in cleaning dirty teats, especially for free-range animals.
Innovation Solution
A teat cleaner system produced through two-step injection moulding, where an inner body and exterior part are fused together, eliminating gaps and reducing parts, with channels and apertures designed for efficient cleaning liquid distribution and drainage, enhancing hygiene and assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple separate parts (inner tube and outer sleeve) are used in the teat cleaning cup, then assembly flexibility is improved, but gaps between parts are created that can harbor germs and bacteria
Solution Approach 1:
The patent merges the inner tube and outer sleeve into a single integrated component formed by injection molding. The inner body and outer wall are molded as one piece, eliminating the gap between separate parts while maintaining the functional structure of a teat cleaning cup. This integration prevents germ harboring while preserving assembly functionality.
2Ease of manufacture
If nozzle holes are drilled in the inner tube, then cleaning function is achieved, but manufacturing cost increases due to expensive drilling operations
Solution Approach 1:
The patent incorporates the nozzle holes directly into the injection molding process itself, rather than drilling them separately after manufacturing. The mold includes ejector pins or specialized cavities that form the nozzle holes during the molding operation, eliminating the need for costly post-manufacturing drilling while ensuring precise hole placement and consistent cleaning function.
3Ease of operation
If the teat cleaning cup is designed with multiple separate components, then ease of assembly is improved, but assembly and disassembly becomes difficult and time-consuming
Solution Approach 1:
The patent combines multiple components into a single injection-molded unit, eliminating the need for complex assembly and disassembly operations. The integrated design allows the entire teat cleaning cup to be manufactured as one piece, drastically reducing assembly time while maintaining the functional benefits of having distinct internal regions for cleaning and drainage.
4Ease of manufacture
If the teat cleaning cup structure is simplified, then manufacturing cost is reduced, but cleaning efficiency for very dirty teats deteriorates
Solution Approach 1:
The injection molding process is used to directly form the nozzle holes and internal channels during manufacturing, eliminating costly post-processing drilling operations. The molded structure includes optimized hole patterns and channel configurations that maintain effective cleaning performance for heavily soiled teats while significantly reducing manufacturing complexity and cost.
Data Source
AI summary
A method and teat cleaner for producing, by injection moulding, a teat cleaner of a teat cleaning cup that includes an inner body forming a central cavity for enclosing a teat, an exterior part, and channels therebetween for injection moulding the inner body in a first tool having a core, sliders that each include a protrusion for forming an aperture in the inner body, and channel walls, and an outer casting mould; separating the inner body from the first tool; placing the inner body in a second tool that includes a casting mould and rods; inserting the rods for forming the channels; fixating the rods; and injection moulding the exterior part in the second tool; separating the second tool from the fused teat cleaner; and removing the rods.