Anchor-Free Brush Tufting Device Using Axial Compression
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Solution Overview
Problem
Existing brush manufacturing methods are inefficient and require significant maintenance, adaptation, and production costs due to the use of anchors or carriers with precise hole patterns, limiting flexibility and speed in producing different tuft patterns.
Innovation Solution
A method and device for anchor-free tufting where tufts of bristles are sequentially inserted into a base part with a guide-free gap, using a programmable positioning device to align and push the tufts into openings, allowing for easy adaptation to various patterns and reducing wear and tear, with axial pressure and optional thermal cutting and fastening methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If anchors or carriers with precise hole patterns are used to attach bristle tufts, then the bristles are securely anchored to the base part, but the device complexity increases and maintenance requirements increase
Solution Approach 1:
The patent extracts and eliminates the anchor or carrier component from the brush manufacturing process. Instead of using traditional anchors or carriers with precise hole patterns to attach bristle tufts, the invention directly inserts and secures tufts into the base part through simple openings, removing the intermediate component that caused complexity and maintenance issues.
Solution Approach 2:
The patent replaces expensive, complex anchors and carriers with simple, disposable-like openings in the base part. The base part itself serves as the anchoring structure, eliminating the need for reusable precision components that require maintenance and replacement.
2Manufacturing precision
If carriers with precise hole patterns are used to hold tufts during transport and insertion, then the tufts are precisely positioned, but the manufacturing cost increases and adaptability to new patterns decreases
Solution Approach 1:
The patent removes the carrier component entirely from the process. Instead of manufacturing and transporting carriers with precise hole patterns, the invention uses direct insertion of tufts into openings in the base part, eliminating carrier manufacturing costs while maintaining positioning precision through the base part's opening pattern.
Solution Approach 2:
The base part serves multiple functions: it provides the structural foundation of the brush, contains the openings for tuft insertion, and acts as the anchoring structure. This multi-functionality eliminates the need for separate carriers, reducing manufacturing costs and improving adaptability to different tuft patterns.
3Ease of operation
If device-side carriers are used to transport tufts to the base part, then the tufts are organized and positioned correctly, but the device requires significant adaptation for different base parts
Solution Approach 1:
The base part is designed to be universal, serving as both the structural component and the tuft-attachment component. The openings in the base part directly receive tufts without requiring adaptation of separate carriers, making the system adaptable to different brush configurations by simply changing the base part's opening pattern.
Solution Approach 2:
The patent eliminates the carrier component that would require adaptation for different base parts. By directly inserting tufts into the base part's openings, the system achieves ease of operation without sacrificing versatility, as the base part itself can be easily modified or replaced to accommodate different patterns.
4Strength
If radial clamping force is applied during tuft insertion, then the tufts are securely held in the device, but the bristles expand in the gap making insertion difficult
Solution Approach 1:
Instead of applying radial clamping force to hold tufts in the device, the patent inverts the approach by using axial compression force. The tufts are compressed axially during insertion and then expand radially after insertion to secure themselves in the openings, eliminating the problem of bristle expansion during the insertion process.
5Stability of the object's composition
If fusion of bristle ends within carriers is performed, then the tufts are stabilized, but the production of carriers becomes expensive
Solution Approach 1:
The patent removes the carrier component that would require expensive production and fusion processes. Instead, tuft stabilization is achieved directly in the base part through the opening structure and axial compression during insertion, eliminating carrier production costs entirely.
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 method significantly reduces production costs and maintenance by eliminating the need for anchors and carriers, enabling quick adaptation to new tuft patterns and improving cycle times, while maintaining precise bristle alignment and length adjustment.
Implementation Method 1
The bristles are melted and fused together in tufts or as a whole in a fastening station
Implementation Method 2
with a heated tool, in particular a so-called hot knife. There is contact between the hot tool and the individual tufts
Implementation Method 3
the fitted base part is then inserted from a bristle-covering station into a cavity of a mold half of an injection molding tool
Data Source
AI summary
The invention relates to a method and device for producing brushes (10), wherein bunches (16) of bristles are removed sequentially from a store (44) of bristles, in which the bristles are packed parallel to each other. The bunches (16) of bristles removed are transported to a base part (12) of the brush (10) by means of a transport device (18). The bunches (16) of bristles are pushed sequentially into associated openings (14) in the base part from the rear of the base part (12). A gap is provided between the transport device (18) and the opening (14), through which gap the bunches (16) of bristles are pushed into the opening (14). Then the bunches (16) of bristles are fastened to the base part (12) without anchoring.