Bristle Head Profile Formation via Non-Contact Heating
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Solution Overview
Problem
Existing methods for producing hairbrush bristles are limited in shape variability, particularly towards the tip, and often result in asymmetrical shapes due to gravity, leading to inefficiencies in mass production and potential for burrs which can be harmful and unhygienic.
Innovation Solution
A method involving non-contact heating of bristles on a carrier, aligned vertically, to form a head profile using electromagnetic radiation or heat from a metal object, allowing for various shapes and minimizing asymmetry, with optional rotation and precise chamber dimensions for efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If contact-free heating is used to form bristle heads, then manufacturing precision and symmetry are improved, but device complexity increases
Solution Approach 1:
The patent replaces mechanical contact heating systems with non-contact heating methods (infrared radiation, microwaves, or induction heating). This substitution eliminates the need for physical contact between heating elements and bristles, thereby improving head profile symmetry by preventing gravity-induced asymmetry while reducing the complexity of mechanical heating mechanisms.
Solution Approach 2:
The patent changes the heating method from conductive/convective contact heating to radiative or electromagnetic heating. This parameter change allows heating to occur without physical contact, enabling symmetrical head formation regardless of bristle orientation and simplifying the overall heating system design by eliminating complex contact mechanisms.
2Productivity
If bristles are molded in one piece with bristle head by injection molding, then productivity is improved, but manufacturing precision of head shape is limited
Solution Approach 1:
The patent separates the bristle shaft molding from the head profile formation. Bristles are first molded as shafts without heads, then individually or in groups receive head profiles through non-contact heating. This segmentation allows high-speed injection molding for productivity while enabling precise, flexible head shape formation through controlled heating, achieving both mass production efficiency and manufacturing precision.
3Device complexity
If conventional heating methods are used, then device complexity is reduced, but burrs are formed which create harmful factors
Solution Approach 1:
The patent replaces conventional contact-based mechanical heating with non-contact heating methods. This substitution prevents the mechanical stress and localized overheating that cause burr formation, thereby eliminating harmful factors while the simplified heating system maintains or even reduces device complexity through the use of standardized electromagnetic heating components.
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
Enables the production of bristles with gentle, symmetrical, and hygienic head profiles suitable for mass production, reducing waste and ensuring safety and ease of use, even with imperfect production standards.
Implementation Method 1
a non-contact heating acts at least on the bristle head
Implementation Method 2
Heating by any suitable electromagnetic radiation, in particular infrared light or also microwaves
Implementation Method 3
Heating by any suitable electromagnetic radiation, in particular infrared light or also microwaves
Implementation Method 4
The heating can be done by radiating heat from a metal object, such as a block of copper
Implementation Method 5
the bristles are guided in a vertical position. This means that the bristle head, to which the profile is to be formed, should either point upwards or downwards in the direction of fall. With this orientation, gravity appears to have a beneficial effect on head shape
Data Source
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AI summary
The invention relates to bristles, which can be used in brushes, particularly hair brushes, and to a method for producing such bristles. A method is disclosed for molding a head profile onto at least one bristle that can be used in a hair brush, wherein the at least one bristle is guided on a bristle carrier, wherein a contactless heater acts upon at least the bristle head.