Brush Bristle Bundle Carrier and Cutting Mechanism
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Solution Overview
Problem
Current brush manufacturing methods are inefficient in attaching bristle bundles to the holding section without anchors, leading to complexities in bristle feeding and handling, especially for producing brushes with varied colors and thicknesses.
Innovation Solution
A method and device that utilize a bundle carrier with through openings to unroll and cut bristle material directly into the carrier, allowing for simultaneous feeding and cutting of strands from multiple coils, which are then fused or encapsulated to secure the bundle, enabling efficient attachment to the brush body without anchors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If bristle bundles are attached without anchors using traditional methods, then the brush structure is simplified, but the bristle feeding and handling process becomes complex and inefficient
Solution Approach 1:
The device is divided into distinct functional modules: a magazine for storing multiple bristle bundles, a bundle remover for extracting individual bundles, and a feeding mechanism for delivering bundles to the attachment point. This segmentation allows each component to be optimized independently, resolving the contradiction by maintaining structural simplicity while improving feeding efficiency through specialized sub-components.
Solution Approach 2:
A bundle carrier is introduced as an intermediary component that temporarily holds and transports bristle bundles from the magazine to the attachment location. This mediator simplifies the overall process by providing a dedicated handling mechanism, eliminating the need for complex direct feeding systems while maintaining high productivity.
2Speed
If bristle bundles are stored under lateral tension in a magazine, then the bundles are ready for quick removal, but the feeding mechanism becomes more complex
Solution Approach 1:
Bristle bundles are pre-positioned in the magazine under lateral tension before the attachment process begins. This preliminary arrangement ensures that bundles are immediately accessible and can be removed quickly without requiring complex real-time positioning mechanisms, thereby achieving high speed while minimizing feeding mechanism complexity.
Solution Approach 2:
The lateral tension storage system in the magazine allows bundles to self-align and present themselves for removal without requiring additional actuators or complex control mechanisms. The elastic energy stored in the tensioned bundles automatically facilitates their extraction and feeding, reducing the complexity of the feeding mechanism while maintaining high removal speed.
3Productivity
If multiple bristle bundles are attached simultaneously, then productivity increases, but the attachment device becomes more complex
Solution Approach 1:
Multiple bristle bundles are attached to the same support portion simultaneously by combining their rear ends into a single integrated attachment operation. This merging approach increases productivity by processing multiple bundles in one attachment cycle while avoiding the need for separate attachment mechanisms for each bundle, thereby limiting the increase in device complexity.
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
Simplifies the bristle feeding process, allows for easy production of brushes with varied bristle colors and thicknesses, and improves the application performance, such as in nail polish brushes by maintaining an arcuate bristle bundle shape for better paint application.
Implementation Method 1
A feeding device which unwinds the strand from at least one spool and introduces it into the opening in the bundle carrier
Implementation Method 2
a melting device for melting the rear ends of the bristle bundle, by which the rear ends are fixed in the bundle carrier
Implementation Method 3
an ultrasonic welding device for welding the rear ends of the bristle bundle, by which the rear ends are fixed in the bundle carrier
Data Source
Figure 1~3
Figure 4~4a
Figure 5~6
AI summary
According to a method and a device for producing a brush or a paint brush at least one bundle of bristles is secured to a mounting section of the brush without anchoring. For producing the bundles of bristles fibers which form a strand (30) are wound off from a bobbin (24) and are inserted into a bundle carrier (14). A bundle (16) is then cut off from the strand (30) by means of a cutting device (52). The bundle carrier can form the holding section of the brush or paint brush.