Cosmetic Brush Assembly Machines for Disc Stacking and Wire Twisting
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Solution Overview
Problem
Existing mascara brushes face challenges in achieving desired bristle arrangements and maintaining angular offsets without a keyed system, which can be complex and require precise alignment.
Innovation Solution
A cosmetic applicator brush design featuring discs with projections and indentations that maintain angular relationships independently, using wire passages to link discs and define the angular offsets through wire twists.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a keyed system with disc-specific keying elements is used to achieve angular offset, then the angular relationship between discs can be maintained, but the device complexity and manufacturing precision requirements increase
Solution Approach 1:
The patent removes the complex keyed system with disc-specific keying elements from the traditional brush construction. Instead of using keys on both the rod and discs to achieve angular offset, the invention uses a simplified approach where the rod has a single key feature that interacts with corresponding features on the discs to maintain angular relationships without requiring multiple disc-specific keys.
Solution Approach 2:
The rod is designed with a universal keying mechanism that can work with multiple discs having different angular offset requirements. The single key feature on the rod can engage with corresponding features on different discs to maintain various angular relationships, eliminating the need for disc-specific keying elements and simplifying the overall system.
2Manufacturing precision
If disc-specific keying elements are used for each disc, then angular offset can be achieved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The invention extracts and removes the complex disc-specific keying elements from the assembly process. By using a simplified rod keying mechanism that works with standard features on the discs, the patent eliminates the need for multiple disc-specific keys, thereby reducing assembly steps and improving productivity while maintaining angular relationship consistency.
Solution Approach 2:
The rod is pre-formed with the keying features and angular offset geometry before assembly. This preliminary preparation of the rod with its keying mechanism allows for faster assembly operations, as the angular relationships are already established in the rod structure rather than requiring complex alignment procedures during assembly.
3Shape
If a keyed system is used to maintain angular offset, then bristle arrangement can be controlled, but the device complexity increases
Solution Approach 1:
The patent extracts and eliminates the complex keyed system structure from the brush design. Instead of using multiple disc-specific keys and complex keyways, the invention uses a simplified rod keying mechanism that maintains bristle arrangement control through a more straightforward structural approach, reducing device complexity while preserving the desired bristle configuration.
Solution Approach 2:
Instead of having the discs with complex keying features to achieve angular offset, the invention inverts the approach by having the rod with the keying features. This inversion simplifies the overall system by placing the complexity in the rod rather than in each disc, thereby reducing the device complexity while maintaining control over bristle arrangement.
Data Source
AI summary
A manufacturing method for producing a cosmetic applicator brush is disclosed. The method comprises a first step of cutting and bending a plurality of wires, a second step of stacking a plurality of discs along the plurality of wires, a third step of twisting the plurality of wires to form a desired angle, and a fourth step of coining and cutting the plurality of wires to produce the cosmetic applicator brush. The movement among the first step, the second step, the third step, and the fourth step is done via a conveyer belt system. All of the first step, the second step, the third step, and the fourth step are performed by a single machine or system.