A toothbrush bristle planting forming process for forming a circular arc bristle tip

Abstract

The present application relates to toothbrush bristle planting technical field, specifically relates to a kind of toothbrush bristle planting forming process of forming arc hair tip, comprising the following steps: S1: injection moulding integrated brush head, and the end face of brush head is formed with multiple bristle planting holes, and the bottom of bristle planting hole is formed with convex arc support surface;S2: preform brush hair bundle, and preform bundle is correspondingly configured with copper sheet;S3: the preform bundle is folded, and copper sheet is clamped in the middle of bundle, and bundle is pressed into bristle planting hole, and the finished product toothbrush is obtained;The present application can make the top surface of bristle semispherical arc surface with middle hump and both sides gentle transition, reduce the possibility of cutting bristle edge to scratch gum, adapt to sensitive gum population, while it can reduce the possibility of quality undesirable phenomena such as shedding and delamination of brush head, reduce the manufacturing cost of toothbrush.

Description

Technical Field

[0001] This invention relates to the field of toothbrush bristle implantation technology, specifically to a toothbrush bristle implantation molding process for forming rounded bristle tips. Background Technology

[0002] Toothbrushes are the core tool for daily oral care. They primarily use the brush head and bristles, along with toothpaste, to rub the tooth surface, removing plaque and food residue. They are essential household items for maintaining oral hygiene and preventing oral diseases. Currently, the mainstream toothbrush bristle implantation processes in the industry mainly include copper sheet implantation and hot-melt implantation.

[0003] In the copper bristle implantation process, a copper sheet is clamped from the middle of the bristles during implantation, and the roots of the bristles are evenly attached to the bottom of the flat implantation hole. The bristle ends can only form a horizontal and flat outline. Even if the outline is later modified into an arc shape, if the rounding rate is not up to standard, the tips of the bristles will have sharp edges. When brushing, the sharp edges will repeatedly rub against the gums, which can easily irritate and scratch the gums. People with sensitive teeth will experience strong discomfort.

[0004] Toothbrushes produced by the hot-melt bristle implantation process have bristle heads that are bonded to the handle. However, under long-term stress, the bristles are prone to delamination and detachment, resulting in a high product scrap rate. At the same time, the import of specialized equipment and bristle molds makes mass production difficult, and the price of curved bristle products is relatively high, making it difficult to cover the mass market. Therefore, there is an urgent need in this field to develop a toothbrush bristle implantation process that combines the effect of curved bristles, low cost, and structural stability. Summary of the Invention

[0005] To address the aforementioned shortcomings in the existing technology, this invention provides a toothbrush bristle implantation process for forming rounded bristle tips, thereby solving the above problems.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A toothbrush bristle implantation process for forming rounded bristle tips includes the following steps: S1: The brush head is injection molded in one piece. Multiple hair implantation holes are formed on the end face of the brush head, and a convex arc-shaped support surface is formed at the bottom of the hair implantation holes. S2: Pre-made brush filament bundles, each pre-made filament bundle is equipped with a corresponding copper sheet; S3: Fold the pre-made filament bundle in half, clamp the middle of the filament bundle with a copper sheet, and press the filament bundle into the bristle implantation hole to obtain the finished toothbrush.

[0007] In this way, the surface of the brush head of the finished toothbrush is evenly opened with multiple bristle implantation holes. The bottom surface of each bristle implantation hole is provided with a convex arc-shaped base. The bristle bundles are clamped and fixed on the base by copper sheets to form bristles. The top surface of the bristles is a hemispherical arc surface with a raised middle and a smooth transition on both sides. By setting a convex arc-shaped base, hemispherical arc-shaped bristles are naturally formed. Unlike existing technologies that trim the bristles into an arc shape, this eliminates the need for extensive trimming and reduces the requirements for rounding. The brush head and handle are injection molded as a single piece, unlike existing technologies that first prepare the brush head and then connect it to the handle. This solves the problem of brush head detachment at its source.

[0008] This structure reduces the possibility of the flat bristles scratching the gums, making it suitable for people with sensitive gums. At the same time, the brush head and handle are injection molded as a single piece, which reduces the possibility of the brush head falling off or delaminating, thus reducing the manufacturing cost of the toothbrush.

[0009] Furthermore, the brush bristles in step S2 are made of straight monofilaments, and the step also includes the following steps: S4: Trim and heighten the bristles of the finished toothbrush; S5: Grind and polish the finished toothbrush; S6: Airflow blows to remove residual hair and injection molding burrs from the brush head.

[0010] Furthermore, the bristles in step S2 are double-pointed, and the method further includes the following steps: S4': Trim the bristles of the finished toothbrush; S5': Airflow sweeps away residual hair and injection molding burrs from the brush head.

[0011] Furthermore, the double-pointed bristles are made of PBT material, which reduces the need for subsequent processes such as flat-cutting the bristles and then physically rounding them, thereby reducing the possibility of the sharp edges of the flat-cut bristles scratching the gums and lowering manufacturing costs.

[0012] Furthermore, the bottom of the bristle implantation hole of the brush head made in S1 is provided with a convex arc-shaped curved surface. The surface of the arc-shaped curved surface can smoothly transition to the side wall of the bristle implantation hole, thereby making the top surface of the bristles a hemispherical arc surface with a raised middle and a gentle transition on both sides, reducing the possibility of the flat bristle edges scratching the gums and making it suitable for people with sensitive gums.

[0013] Furthermore, the arc height of the curved surface is 0.15-0.4mm, which facilitates the formation of a hemispherical arc surface and improves the gingival protection effect.

[0014] Furthermore, the radius of the arc of the curved surface is 1.2-2.5mm, which can form an effective height difference and facilitate the formation of a hemispherical arc surface.

[0015] Furthermore, the total exposed height of the bristles is 8-12mm, and the height difference at the root caused by the arc-shaped surface is directly converted into the height difference at the tip of the bristles, which facilitates the formation of a hemispherical arc surface.

[0016] In summary, the advantages of this invention are: 1. Low modification cost, compatible with existing copper sheet bristle implantation production lines, no new production processes, significantly reducing product development and mass production costs, enabling affordable mass production of curved gum-protecting toothbrushes; 2. Reduces the possibility of the sharp edges of the flat-cut bristles scratching the gums, making it suitable for people with sensitive gums; 3. Reduce the possibility of brush head defects such as detachment, delamination, and glue separation from the source, thereby reducing after-sales scrap costs; 4. Wide range of applications: The toothbrush prepared by this invention can be adapted to a variety of needs. Attached Figure Description

[0017] Figure 1 This is a three-dimensional structural diagram of the finished toothbrush obtained by the present invention; Figure 2 This is a cross-sectional view of the toothbrush head obtained by the present invention. Figure 3 This is a cross-sectional view of a toothbrush head in the prior art. Figure 4 The outline of the top of the monofilament is unqualified (the end face has sharp edges). Figure 5 A qualified monofilament tip profile (without sharp edges on the end face); Figure 6 This is a magnified view of a defective toothbrush bristle (with sharp edges on the end face). Reference numerals in the accompanying drawings: Brush head 1; Hair grafting hole 2, base 201; 3. Brush bristles. Detailed Implementation

[0018] To enable those skilled in the art to better understand the present invention, the technical solution of the present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0019] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this patent. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0020] Example 1: The present invention provides a toothbrush bristle implantation process for forming rounded bristle tips, comprising the following steps: S1: The brush head is injection molded in one piece. Multiple hair implantation holes are formed on the end face of the brush head, and a convex arc-shaped support surface is formed at the bottom of the hair implantation holes. S2: Uses straight monofilament pre-made brush filament bundles, and each pre-made filament bundle is equipped with a corresponding copper sheet; S3: Fold the pre-made filament bundle in half, clamp the middle of the filament bundle with a copper sheet, and press the filament bundle into the bristle implantation hole to obtain the finished toothbrush; S4: Trim and heighten the bristles of the finished toothbrush; S5: Grind and polish the finished toothbrush; S6: Airflow blows to remove residual hair and injection molding burrs from the brush head.

[0021] like Figure 1-2 As shown, the toothbrush head 1 prepared in this embodiment has multiple bristle implantation holes 2 evenly opened on its surface. Each bristle implantation hole 2 has a convex arc-shaped base 201 on its inner bottom surface. The bristle bundles are clamped and fixed on the base by copper sheets to form bristles 3. Specifically, the surface of the base 201 can smoothly transition to the sidewall of the bristle implantation hole 2, avoiding right-angle bends on the surface of the base 201, thereby reducing the possibility of bristle root jamming and incomplete bristle implantation.

[0022] The arch height of the base 201 is 0.15-0.4mm, and the radius of the arc of the base 201 is 1.2-2.5mm. Specifically, when the arch height is <0.15mm, the height difference of the base 201 is insufficient, the effect of the bristles forming an arc is weak, and the improvement of the gum protection effect is not obvious. When the height of the arc is greater than 0.4mm, the support at the base of the bristles on both sides of the base 201 is too low, which makes it easy for bristles to get stuck and fall off during bristle implantation, and the yield rate drops to below 92%. When the radius of the arc R is less than 1.2 mm, the bottom arc of the hole in the base 201 is steep, the root of the brush bristles is bent and damaged, and the bristles are easy to break; when the radius of the arc R is greater than 2.5 mm, the curved surface of the base 201 tends to be flat, and it cannot form an effective height difference, thus losing the arc-shaped shaping effect.

[0023] In S4, the total exposed height of the bristles 3 is controlled to be 8-12mm. After uniform cutting, the height difference at the root brought by the base 201 is directly converted into the height difference at the tip of the bristles 3. The middle bristles are longer and the sides are shorter, naturally forming a bristle tuft outline that is high in the middle and low on both sides.

[0024] The grinding process in S5 eliminates sharp cut surfaces, increases the rounding rate of the bristles 3, and reduces the possibility of the bristles 3 scratching the gums and causing gum bleeding during brushing.

[0025] Example 2: The other features of this embodiment are the same as those of Embodiment 1, except that: The arch height of the base 201 is 0.25mm, and the radius of the arc of the base 201 is 1.8mm. Specifically, when the arch height of the base 201 is 0.25mm and the radius of the arc is 1.8mm, the pass rate of the bristle implantation process is 99.7%, which is no different from the pass rate of traditional flat-bottom bristle implantation. After the bristles 3 are rounded, the bristle bundles have a uniform arc transition without local protrusions or depressions. In the durability test, there is no bristle loss or brush head cracking.

[0026] Example 3: S1: The brush head is injection molded in one piece. Multiple hair implantation holes are formed on the end face of the brush head, and a convex arc-shaped support surface is formed at the bottom of the hair implantation holes. S2: The pre-made brush filament bundles are made of PBT material with double-pointed wires, and each pre-made filament bundle is equipped with a corresponding copper sheet; S3: Fold the pre-made filament bundle in half, clamp the middle of the filament bundle with a copper sheet, and press the filament bundle into the bristle implantation hole to obtain the finished toothbrush; S4: Airflow blows to remove residual hair and injection molding burrs from the brush head.

[0027] In this way, the double-pointed filaments have fine and soft tips, and the tips of the filaments naturally form a smooth arc transition. The tips are delicate and soft, and combined with the arc-shaped contour formed by the height difference at the root, the finished product has no sharp edges and corners, and no additional rounding is required.

[0028] Example 4: The other features of this embodiment are the same as those of embodiment 3, except that: S4': Trim the bristles of the finished toothbrush; S5': Airflow sweeps away residual hair and injection molding burrs from the brush head.

[0029] Specifically, by trimming the bristles to a fixed height, the height of the exposed bristles is controlled, the cut end face is kept horizontal, and the differences are reduced, thereby reducing the possibility of toothbrush bristles being of random lengths and unable to form a regular arc shape.

[0030] Example 5: The other features of this embodiment are the same as those of embodiment 4, except that: S4”: Trim the bristles of the finished toothbrush; S5”: Grind and polish the finished toothbrush to a rounded shape; S6”: Airflow sweeps away residual hair and injection molding burrs from the brush head.

[0031] Specifically, by rounding and polishing, the toothbrush undergoes a secondary fine softening process, which can improve the gum protection effect of the finished toothbrush.

[0032] Comparative Example 1: like Figures 3-6As shown, the existing flat-bottomed tufting hole copper sheet tufting process is used. The bottom of the tufting hole 2 is a flat plane, and the other injection molding, tufting, and rounding parameters are the same as in Example 5. Experimental results: All bristles had the same height at the base. After rounding, the tips of bristles 3 had flat cut surfaces. When the rounding rate was not up to standard, there were sharp edges on the end faces. When simulating brushing and rubbing the gums, it was easy to cause redness of the gums. If the rounding rate is to be guaranteed, the preparation time and cost will be greatly increased, making it less practical. At the same time, bristles 3 could not form arc-shaped gradient bristle bundles, which could not improve the gum protection effect.

[0033] Comparative Example 2: The existing AFT copper-free hot-melt bristle implantation process requires the use of independent plastic head pieces to hot-melt fix the bristles, the head pieces to be bonded to the brush handle, and specialized imported AFT equipment and million-level head piece molds. This is compared with Example 3.

[0034] Test results: In terms of usage effect, the curved end face of the bristles is basically the same as the finished product of this application in terms of feel and gum protection performance; In terms of cost, the AFT process mold development cost is about RMB 1 million, and the manufacturing cost of a single product is more than 35% higher than that of this application; this application only requires modification of the injection mold cavity, the mold modification cost is less than RMB 10,000, it is compatible with existing production lines, and there is no additional equipment investment. Regarding product reliability, after cold and hot cycling and repeated brushing durability tests, 12% of AFT's split toothbrush products showed defects such as glue separation and detachment. The toothbrush prepared by this invention is integrally molded and does not show defects such as detachment or delamination.

[0035] In summary, the advantages of this invention are: 1. Low modification cost, compatible with existing copper sheet bristle implantation production lines, no new production processes, significantly reducing product development and mass production costs, enabling affordable mass production of curved gum-protecting toothbrushes; 2. Reduces the possibility of the sharp edges of the flat-cut bristles scratching the gums, making it suitable for people with sensitive gums; 3. Reduce the possibility of brush head defects such as detachment, delamination, and glue separation from the source, thereby reducing after-sales scrap costs; 4. Wide range of applications: The toothbrush prepared by this invention can be adapted to various needs.

[0036] The above are merely embodiments of the present invention. Commonly known structures and characteristics are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, and are capable of using conventional experimental methods prior to that date. They can improve and implement the present invention based on the guidance provided in this application and their own capabilities. Typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the structure of the present invention. These modifications and improvements should also be considered within the scope of protection of the present invention, and will not affect the effectiveness of the invention or the practicality of the patent.

Claims

1. A toothbrush bristle implantation process for forming rounded bristle tips, characterized in that, Includes the following steps: S1: The brush head is injection molded in one piece. Multiple hair implantation holes are formed on the end face of the brush head, and a convex arc-shaped support surface is formed at the bottom of the hair implantation holes. S2: Pre-made brush filament bundles, each pre-made filament bundle is equipped with a corresponding copper sheet; S3: Fold the pre-made filament bundle in half, clamp the middle of the filament bundle with a copper sheet, and press the filament bundle into the bristle implantation hole to obtain the finished toothbrush.

2. The toothbrush bristle implantation process for forming rounded bristle tips according to claim 1, characterized in that, The brush bristles in S2 are straight monofilaments, and the process also includes the following steps: S4: Trim and heighten the bristles of the finished toothbrush; S5: Grind and polish the finished toothbrush; S6: Airflow blows to remove residual hair and injection molding burrs from the brush head.

3. The toothbrush bristle implantation process for forming rounded bristle tips according to claim 1, characterized in that: The brush bristles in S2 are double-pointed bristles, and the process also includes the following steps: S4': Trim the bristles of the finished toothbrush; S5': Airflow sweeps away residual hair and injection molding burrs from the brush head.

4. The toothbrush bristle implantation process for forming rounded bristle tips according to claim 3, characterized in that: The double-pointed wire is made of PBT material.

5. The toothbrush bristle implantation process for forming rounded bristle tips according to any one of claims 2-4, characterized in that: The bottom of the hair-planting hole of the brush head produced in S1 is provided with a convex arc-shaped curved surface, and the surface of the arc-shaped curved surface can smoothly transition to the side wall of the hair-planting hole.

6. The toothbrush bristle implantation process for forming rounded bristle tips according to claim 5, characterized in that: The arc height of the curved surface is 0.15-0.4mm.

7. The toothbrush bristle implantation process for forming rounded bristle tips according to claim 6, characterized in that: The radius of the arc of the curved surface is 1.2-2.5 mm.

8. The toothbrush bristle implantation process for forming rounded bristle tips according to any one of claims 2 or 3, characterized in that: The total exposed height of the bristles is 8-12mm.

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