Ultrasonically Sealed Mop Edges for Stitch-Free Reinforcement
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Solution Overview
Problem
Conventional cleaning mops face issues with edge reinforcement, manufacturing complexity, and compatibility with mop bases, leading to increased costs, material tensions, and reduced productivity, especially when producing curved profiles or symmetrical designs.
Innovation Solution
The use of ultrasonic sealing for the perimeter edges of a cleaning mop, allowing for continuous or spot sealing of a single, sealable material that eliminates the need for stitching and enables precise, repeatable production of curved profiles and symmetrical designs, while ensuring compatibility with standard equipment and mop bases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stitching is used to reinforce the edges of the mop, then the edge strength is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The patent replaces the mechanical stitching system with an ultrasonic welding system. The ultrasonic welding device uses high-frequency vibrations to melt and fuse the thermoplastic elastomer material at the edges, creating a strong bond without needles or threads. This substitution eliminates the complexity of stitching operations while maintaining or improving edge strength.
Solution Approach 2:
The patent changes the material parameter by using thermoplastic elastomer material that can be ultrasonic-welded. This material property enables the transition from mechanical stitching to ultrasonic welding, as the material's thermoplastic nature allows it to be softened by ultrasonic energy and formed into reinforced edges through heat and pressure application.
2Strength
If stitching is used to reinforce the edges of the mop, then the edge strength is improved, but the manufacturing time and productivity decrease
Solution Approach 1:
The ultrasonic welding system replaces the manual or machine stitching process, enabling continuous operation without the need to thread needles or handle individual stitches. The process can be automated and run continuously, significantly increasing production speed and productivity while maintaining strong edge reinforcement.
Solution Approach 2:
The ultrasonic welding process allows for continuous operation along the entire edge of the mop without interruption. The welding head can move continuously along the edge, applying ultrasonic energy and forming the reinforced structure in one continuous motion, eliminating the stop-and-start nature of stitching operations.
3Adaptability or versatility
If different materials are used for the mop body and stitching thread, then the functional requirements are met, but material tensions and shrinkage differences occur during washing
Solution Approach 1:
The patent uses the same thermoplastic elastomer material for both the mop body and the reinforced edges. This homogeneity ensures that both parts expand and contract at the same rate during washing and drying, eliminating the material tension and shrinkage differences that occur when dissimilar materials are combined. The uniform material composition maintains structural stability throughout the washing process.
4Adaptability or versatility
If curved profiles or angled indents are required in the mop edges, then the design versatility is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The ultrasonic welding system is designed with a movable welding head that can dynamically adjust its position and angle during operation. This dynamic capability allows the system to create curved profiles and angled indents by varying the motion path of the welding head, enabling complex geometries without requiring complex tooling or multiple operations.
Solution Approach 2:
The ultrasonic welding device serves multiple functions: it can create straight edges, curved profiles, and angled indents all with the same basic equipment. The system's ability to adapt to different geometric requirements through programming and motion control makes it a universal solution for various mop designs, eliminating the need for specialized equipment for each profile type.
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 enhances productivity and reduces costs by avoiding thread breakages and material tensions, allowing for uniform absorption and complete waterproofing, and facilitates easy attachment to mop bases, maintaining structural integrity and flexibility.
Implementation Method 1
The use of ultrasonic sealing for the perimeter edges of a cleaning mop
Data Source
Figure 1~2
Figure 3~4
AI summary
This invention is a cleaning mop that is made differently to mops currently on the market, and in particular, part of this invention is the structure of the edges and the way they are made for this mop; and the invention has an appearance and a method for being used that is similar to traditional cleaning cloths, except that advantageously it has no stitching along the perimeter edges.