Bristle Density Control in Brush Manufacturing via Compactor Plate
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Solution Overview
Problem
Existing methods for producing bristle areas for brushes using gas or air flow result in low packing density and visibility of injection material, leading to unappealing or unusable brushes due to limited fill level and filament misalignment during injection molding.
Innovation Solution
The use of movable hole pins to push bristle filaments offset in the axial direction into a compactor plate with smaller perforations, increasing bristle density and preventing injection material from being pushed through the bristles, along with a transportation apparatus using hollow lines and a vacuum system to ensure precise alignment and filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gas or air flow is used to transport bristle bundles into the central plate, then the transportation process is simplified and faster, but the fill level becomes limited and individual filaments may be left behind in the supply line
Solution Approach 1:
A compactor plate with perforations of smaller cross-section is introduced as an intermediary component between the central plate and the injection molding process. This compactor plate acts as a mediator that receives bristle bundles from the gas/air flow transport system and compacts them to achieve the desired fill level, thereby resolving the contradiction between fast transportation and precise filling.
Solution Approach 2:
The bristle bundles are pre-compacted in the compactor plate before being transferred to the injection molding process. This preliminary action of compacting the bundles ensures that they achieve the required density and fill level before the actual injection molding occurs, preventing the harm of low fill level while maintaining the efficiency of gas/air flow transport.
2Manufacturing precision
If the perforation cross-section is reduced to increase bristle density, then injection material cannot pass through the filaments, but the transportation of bristle bundles becomes more difficult
Solution Approach 1:
The system is segmented into two distinct functional components: a central plate with larger perforations optimized for receiving bristle bundles via gas/air flow transport, and a compactor plate with smaller perforations optimized for compacting the bundles to achieve high bristle density. This segmentation allows each component to be optimized for its specific function without compromise.
Solution Approach 2:
The solution transitions from a single-plate design to a two-plate three-dimensional arrangement. The compactor plate is positioned downstream from the central plate, creating a spatial sequence where bundles are first received and then compacted. This dimensional change enables the system to handle both transportation and compacting functions effectively.
3Ease of manufacture
If bristle bundles are loosely packed to facilitate transportation, then the injection molding process becomes problematic due to visible injection material, but tight packing complicates the transportation process
Solution Approach 1:
The compactor plate performs a preliminary compacting action on the bristle bundles before they undergo injection molding. This pre-compaction ensures that the bundles are tightly packed with high bristle density, preventing injection material from passing through and becoming visible on the brush surface, while the loose packing during transport is maintained for ease of transportation.
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 solution achieves higher bristle density and prevents injection material from being pushed through the bristles, even under high injection pressures, allowing for the creation of complex bristle patterns and reducing the risk of over-spraying during injection molding.
Implementation Method 1
transported via a gas or air flow and inserted into perforations of a central plate
Implementation Method 2
apparatus for removing individual bundles of bristles from the bristle supply as well as a transport apparatus for transporting the bundles of bristles
Data Source
AI summary
In a method for producing bristle areas for brushes, in particular toothbrushes, bundles of bristles (5) are divided off from a bristle supply (101), transported by a gas or air stream (Pf 1) and introduced into perforations (22) in a central plate (21). The bundles of bristles (5) are removed from the central plate (21) and transferred to a compactor plate (106) and, in the process, the density of the bundle of bristles (5) is increased. In the apparatus for producing bristle areas for brushes, in particular toothbrushes, having a bristle supply (101) and an apparatus (102) for removing individual bundles of bristles (5) from the bristle supply (101), and a transport apparatus (103) for transporting the bundles of bristles (5) into perforations (22) in a central plate (21) by a gas or air stream (Pf 1), a compactor plate (106) that has perforations (108) for receiving bundles of bristles (5) is arranged downstream of the central plate (21), with the cross-sections of the perforations being smaller than the cross-section of the bundle of bristles (5) supplied to the respective perforation (108). An apparatus is provided for forwarding the bundles of bristles (5) from the central plate (21) to the compactor plate (106).