Bristle Bundle Transport Using Positive Gas Pressure

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Solution Overview

Problem

Existing methods for producing bristle fields for brushes using negative pressure in feed lines often cause individual bristles to separate, making it difficult to maintain a cluster orientation during transport, and alternative methods that fuse bristles are time and energy consuming.

Innovation Solution

A method and apparatus that use a gas cushion with pressure above atmospheric pressure in the feed line to keep bristles together, eliminating the need for fusing by maintaining a gas cushion on either side of the bundle during transport, using inlet and outlet valves to control gas flow and pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If negative pressure is applied in the feed line to transport bristle clusters, then the bristles can be conveyed through the feed line, but the clusters separate into individual bristles and lose their defined orientation

Engineering Contradiction:

Improvetransport speedVSAvoidcluster integrity

Core Design Contradiction:

SpeedVSStability of the object's composition

Solution Approach 1:

Instead of using negative pressure (suction) to transport the bristle clusters as in prior art, the invention uses positive gas pressure to push the clusters through the feed line. This inversion of the pressure approach prevents cluster separation while maintaining transport functionality, as the positive pressure gently propels the clusters without the separating effect of suction forces.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention employs a gas cushion (pneumatic field) between the bristle clusters and the feed line walls to reduce friction and prevent adhesion during transport. This pneumatic approach allows smooth conveyance of the clusters without mechanical contact that could cause separation, resolving the contradiction between transport capability and cluster integrity.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Stability of the object's composition

If bristles are fused to form a fixed cluster to maintain orientation during transport, then the cluster stability is improved, but the process becomes time consuming and energy consuming

Engineering Contradiction:

Improvecluster stabilityVSAvoidprocess time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The invention replaces the mechanical/thermal process of fusing bristles with a pneumatic transport system using positive pressure and gas cushion. This substitution eliminates the need for heating, melting, or bonding operations, thereby maintaining cluster stability during transport without the time and energy costs associated with fusing processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention extracts and eliminates the fusing step from the overall process by using positive gas pressure transport. By removing this unnecessary intermediate step, the process becomes more efficient while still achieving the goal of stable cluster transport and precise insertion into mold perforations.

Inventive Principle:

Principle #2Taking out (Extraction)

3Speed

If positive gas pressure is applied above atmospheric pressure in the feed line, then the bundle of bristles can be moved towards the mold form, but the pressure must be maintained to prevent bristle separation

Engineering Contradiction:

Improvemovement speedVSAvoidpressure control complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The invention employs feedback control through sensors that detect the position and state of bristle bundles during transport. This feedback information is used by the control system to dynamically adjust the positive gas pressure, maintaining optimal pressure levels to prevent bundle separation while enabling efficient transport. The feedback mechanism simplifies pressure control by automating adjustments based on real-time conditions.

Inventive Principle:

Principle #23Feedback

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

Effectively prevents bristle separation during transport without the need for fusing, ensuring accurate insertion into mold perforations while maintaining process efficiency and reducing energy consumption.

Implementation Method 1

providing a gas cushion on either side of the bundle during transport

Methodology Applied

Scientific EffectGas cushion: Air Lubrication

Implementation Method 2

applying a predefined gas pressure above atmospheric pressure in the feed line between the inlet valve and the outlet valve

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentUS10722024B2Method and apparatus for producing bristle fields for brushes

Publication Date: 2020.07.28 BRAUN GMBH

AI summary

A method and an apparatus for producing bristle fields for brushes. The bristles are filled into a hole of a mold form by a feed line having an upstream end with an inlet valve and a downstream end with an outlet valve. The method includes steps of forming a bundle of bristles; applying a predefined gas pressure above atmospheric pressure in the feed line the inlet and outlet valves; inserting the bundle into the feed line at an insertion station between the inlet and outlet valves; and maintaining the predefined pressure between said valves; draining off a first volume of gas from the feed line via the outlet valve while feeding a second volume of gas into the feed line via the inlet valve, thereby moving the bundle of bristles in the feed line towards the mold form, wherein the pressure in the feed line upstream and downstream of the bundle of bristles is kept above atmospheric pressure.