Brush Fiber Bundle Anchoring via Preliminary Cutting

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Solution Overview

Problem

Existing methods for manufacturing brushes face challenges when dealing with varying fiber bundle thickness and material, as the melting process can be inefficient, leading to inadequate anchoring of smaller bundles due to uneven protrusion and material distribution.

Innovation Solution

Fiber bundles are cut to length and profile-matched before anchoring, using adjustable pens and a heat-conducting stamp to ensure uniform melting and anchoring, regardless of bundle thickness or material differences.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If fiber bundles are pushed through openings in holder with varying thickness and material, then brush manufacturing can handle diverse fiber bundle specifications, but smaller fiber bundles will not protrude far enough through openings to melt sufficiently for proper anchoring

Engineering Contradiction:

Improveability to handle varying fiber bundle thickness and materialVSAvoidquality of anchoring of fiber bundles

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies preliminary action by cutting fiber bundles to predetermined lengths before they are pushed through the holder openings. This ensures that smaller fiber bundles protrude far enough through the openings to be properly melted and anchored, while larger bundles are cut to appropriate lengths. The cutting step is performed in advance of the pushing and melting operations, guaranteeing adequate protrusion for all bundle sizes regardless of their initial thickness or material properties.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If contact time between hot stamp and fiber bundles is prolonged to ensure sufficient melting, then anchoring quality improves, but production capacity decreases

Engineering Contradiction:

Improvequality of anchoring of fiber bundlesVSAvoidproduction capacity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent resolves this contradiction by performing the cutting operation beforehand to establish optimal protrusion lengths. This preliminary action ensures that when the hot stamp contacts the fiber bundles, they are already positioned at the correct distances from the holder surface, allowing for rapid and uniform melting. The process eliminates the need for prolonged contact times because the geometry of protrusion is controlled in advance, thus maintaining high production capacity while ensuring reliable anchoring.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If custom stamps with exact profiles are developed for each brush type, then anchoring precision improves, but manufacturing cost and method flexibility worsen due to need for separate stamps

Engineering Contradiction:

Improveprecision of anchoring profileVSAvoidcost and flexibility of manufacturing method

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces the need for custom stamps by performing preliminary cutting of fiber bundles to precise lengths. This preliminary action establishes the correct profile and positioning of fiber bundles before they are pushed through the holder and melted. The cutting step, performed using appropriate cutting tools or devices, creates the necessary geometric precision without requiring expensive, custom-molded stamps for each brush type, thereby maintaining manufacturing precision while improving ease of manufacture and flexibility.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent substitutes the mechanical stamping system with a cutting-based system. Instead of using a hot stamp to define the profile and position of fiber bundles, the invention uses cutting operations to predetermined lengths to achieve the same effect. This substitution eliminates the need for complex, custom-molded stamps while maintaining or improving precision, and allows for easier adaptation to different brush types by simply adjusting cutting parameters rather than manufacturing new stamps.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 ensures consistent and high-quality anchoring of fiber bundles in the brush body, improving production efficiency and flexibility by eliminating the need for custom stamps and reducing production time.

Implementation Method 1

use is made of a heat-conducting stamp to ensure uniform melting and anchoring

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP1878355B1Method for manufacturing brushes and device applied trereby

Publication Date: 2012.10.10 GB BOUCHERIE NV

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Figure 4~6

AI summary

Method for manufacturing brushes which consists in providing fiber bundles (4) in a support (2); in moving the fiber bundles (4) according to a desired profile until they protrude through openings (21) in a holder (10) with one far end; in anchoring the fiber bundles (4) in the holder (10), characterized in that the method comprises the following operational steps: moving the fiber bundles (4) in the support (2) according to an intermediary profile; shortening the fiber bundles (4) to a desired length; and moving the fiber bundles (4) further until they have been provided through the openings (21) in the holder (10) according to the desired profile.