Brush Bristle Profiling Without Cutting Waste
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Solution Overview
Problem
Existing brush manufacturing processes face challenges in producing profiled bristles without generating cutting waste, which contaminates equipment and complicates production.
Innovation Solution
A brush manufacturing device with a profiling device that axially displaces bristle filaments to create profiles on the cleaning side of the bristle arrangement, using profiling and counter-profiling tools to generate desired shapes without cutting, followed by heat bonding to a bristle carrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bristles are trimmed using a heated tool, then the desired profile is achieved on the cleaning side, but cutting waste is generated that contaminates equipment and complicates production
Solution Approach 1:
The patent replaces the mechanical cutting process with a thermal process. Instead of mechanically trimming bristles with a heated tool that generates cutting waste, the invention uses a heating device to melt the bristle material and a cooling device to solidify it, forming the desired profile without mechanical cutting waste
Solution Approach 2:
The patent utilizes phase transitions of the bristle material (from solid to liquid through heating, then back to solid through cooling) to create the profile. The heating device melts the bristle material and the cooling device solidifies it, allowing the bristles to be shaped without mechanical cutting
2Productivity
If bristles are trimmed to create profile, then cleaning performance is improved, but equipment contamination and production complexity increase
Solution Approach 1:
The patent replaces complex mechanical trimming operations with a simpler thermal process system consisting of a heating device and a cooling device, reducing equipment complexity while maintaining profile quality
Solution Approach 2:
The patent uses phase transitions (melting and solidifying) to create the bristle profile, which is a simpler and cleaner process compared to mechanical trimming, reducing equipment contamination and production complexity
3Object-generated harmful factors
If cutting waste is removed using suction devices or shielded areas, then equipment contamination is reduced, but production time and effort increase
Solution Approach 1:
The patent converts the potential harm of material removal into a benefit by using a thermal process that shapes the bristles without generating cutting waste in the first place, eliminating the need for suction devices or shielded areas
Solution Approach 2:
The patent uses phase transitions to shape bristles without mechanical cutting, thereby eliminating cutting waste and the need for additional waste removal operations that would consume production time
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 method eliminates cutting waste and simplifies the manufacturing process by creating precise profiles on bristles, ensuring efficient and clean production of brushes.
Implementation Method 1
a heating device (19) for heating the bristle filaments (4) and the bristle carrier (2)
Implementation Method 2
a cooling device (31) for cooling the melted bristle filaments (4)
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
The invention relates to improvements in the technical field of brush manufacturing. In particular, a profiling device (25) for profiling a bristle arrangement (3) of a brush (1) to be manufactured is proposed as a technical improvement. This device is configured to profile a cleaning side (27) of the bristle arrangement by axially displacing bristle filaments (4) of the bristle arrangement (3) with respect to their longitudinal axes.