Vacuum cleaner ventilation grid, vacuum cleaner, and method for producing a vacuum cleaner ventilation grid
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Solution Overview
Problem
Existing vacuum cleaner ventilation grilles manufactured as injection-molded parts face challenges in achieving effective airflow redirection and undercuts, which are costly and time-consuming to produce.
Innovation Solution
A vacuum cleaner ventilation grille design comprising an injection-molded part with grid holes and a perforated film, where the film holes are offset and smaller than the grid holes, allowing for efficient airflow redirection without undercuts, using snap-fit elements and adhesives for attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an injection-molded part is used for the ventilation grille, then manufacturing cost and production time are reduced, but effective airflow redirection and undercuts cannot be achieved
Solution Approach 1:
The ventilation grille is divided into two separate components: an injection-molded base part and a perforated film. The injection-molded part provides the structural framework and initial hole pattern, while the separate perforated film adds the precise contouring and undercut features needed for effective airflow redirection. This segmentation allows each component to be optimized for its specific manufacturing process while working together to achieve the overall functional requirements.
Solution Approach 2:
The solution combines two different material forms - a rigid injection-molded plastic part and a flexible perforated film - into a composite structure. The injection-molded part provides structural integrity and cost-effective mass production, while the perforated film contributes precise geometric features for airflow control. This composite approach leverages the strengths of both manufacturing methods to overcome their individual limitations.
2Manufacturing precision
If undercuts and contours are added to the injection-molded part for effective airflow redirection, then manufacturing complexity and cost increase
Solution Approach 1:
The complex undercut and contour features are extracted from the injection-molded part and transferred to a separate perforated film. This allows the injection mold to remain simple and cost-effective, while the precise geometric features are achieved through a different manufacturing process (punching or laser cutting) that is better suited for creating complex hole patterns and contours without requiring complex molding operations.
Solution Approach 2:
The perforated film acts as an intermediary element that bridges the gap between the simple injection-molded structure and the complex airflow redirection requirements. The film is attached to the injection-molded part and provides the additional geometric complexity needed for effective airflow control, without requiring the injection mold itself to be complex.
3Area of stationary object
If the ventilation grille size is reduced, then footprint is minimized, but effective airflow redirection becomes more difficult
Solution Approach 1:
The solution adds a third dimension to the ventilation grille design by incorporating a perforated film layer attached to the injection-molded part. This multi-layer approach creates vertical stacking of functional features within a compact horizontal footprint. The film holes are positioned at different depths and angles relative to the base part holes, enabling effective airflow redirection in a smaller overall package by utilizing the depth dimension rather than requiring larger surface area.
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 achieves effective airflow redirection with a smaller footprint, lower manufacturing costs, and improved airflow turbulence for efficient exhaust air expulsion without disturbing users or stirring up dust.
Implementation Method 1
the film holes are preferably smaller, and in particular narrower, than the grid holes. This creates a tear-off edge at the upper edge of the overlapping holes, where the oncoming exhaust air becomes turbulent
Data Source
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AI summary
The invention relates to a vacuum cleaner ventilation grille comprising: - an injection-molded part (1) with a plurality of grid-like arranged grid holes (11), and - a perforated film (2) with a plurality of film holes (21), wherein the perforated film (2) is attached to the injection-molded part (1) such that the grid holes (11) and the film holes (12) are offset from one another and/or the film holes (21) are at least one dimension smaller than the grid holes (11). The invention further relates to a vacuum cleaner having such a vacuum cleaner ventilation grille, and to a corresponding method for manufacturing the vacuum cleaner ventilation grille.