Brush Head Assembly Bristle Retention via Elastomeric Matrix Molding
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Solution Overview
Problem
Existing brush head assemblies often fail to securely retain bristle tufts, leading to loose bristles and suboptimal positioning during toothbrush operation, and the manufacturing process is time-consuming and costly.
Innovation Solution
A method involving a tuft plate, profile plate, and die plate to position and shape bristle tufts within an elastomeric matrix, where the bristle ends are heated and molded to adopt specific shapes, ensuring secure retention and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bristle tufts are inserted into retention rings and heated to fuse them, then bristle retention is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent eliminates retention rings from the brush head assembly, extracting this component entirely. Bristle tufts are directly inserted into cavities formed in the elastomeric matrix material itself, which is then molded to secure the bristles without requiring separate retention structures or post-insertion heating steps.
Solution Approach 2:
The patent combines the retention function and the structural matrix into a single integrated elastomeric component. The cavities for holding bristle tufts are formed directly within the elastomeric matrix material, merging what were previously separate elements (retention rings and matrix) into one unified structure that secures bristles during the molding process itself.
2Ease of operation
If bristle tufts are organized into desired shapes and fused with heat, then brushing performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent pre-forms the elastomeric matrix material to include cavities with the desired final shape and orientation before bristle insertion. This preliminary shaping of the matrix cavities eliminates the need for subsequent heating and shaping operations on the bristles themselves, as they are molded into their final configuration during the initial molding process.
Solution Approach 2:
The patent replaces the thermal field (heating) used in conventional processes with a mechanical field approach. Instead of heating bristles to melt and shape them, the elastomeric matrix is mechanically molded around the bristle tufts in their desired configuration, using mechanical pressure and shape during the molding process to achieve the final bristle arrangement.
3Manufacturing precision
If retention rings are used to secure bristle tufts, then bristle positioning is improved, but bristle security deteriorates under dynamic motion
Solution Approach 1:
The patent uses the elastomeric matrix material with specific viscoelastic properties that provide both precise positioning and secure retention. The composite nature of the molded elastomeric material, which can be formulated with specific mechanical properties, allows it to firmly hold bristle tufts in precise positions while withstanding dynamic stresses during brush operation, overcoming the limitations of rigid retention rings.
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
The method effectively secures bristle tufts within the brush head, improving retention and reducing manufacturing time and costs, while allowing for optimal bristle positioning and enhanced brushing performance.
Implementation Method 1
applying heat to each of the first ends of the plurality of bristle tufts, via a die plate comprising at least one cavity configured to receive at least one of the plurality of the first ends, at a temperature sufficient to at least partially melt each of the first ends into the cavity
Implementation Method 2
at a temperature sufficient to at least partially melt each of the first ends into the cavity, wherein each first end of the plurality of bristle tufts adopts the shape of the cavity
Implementation Method 3
applying a force, via a profile plate, to a second end of each of the plurality of bristle tufts, wherein the profile plate comprises a predetermined shape complementary to a desired profile configuration of the bristle tufts
Data Source
AI summary
A method (200) for manufacturing a brush head (10) includes: (i) positioning (210) a first end (23) of each of a plurality of bristle tufts (21) into a tuft plate (110) comprising a plurality of cavities (120) each configured to receive at least one of the plurality of bristle tufts; (ii) applying (220) a force, via a profile plate (300), to a second end (25) of the plurality of bristle tufts, wherein the profile plate comprises a predetermined shape complementary to a desired profile configuration of the bristle tufts; and (iii) applying (230) heat to each of the first ends of the plurality of bristle tufts, via a die plate (400) comprising at least one cavity (410) configured to receive at least one of the plurality of the first ends, at a temperature sufficient to at least partially melt each of the first ends into the cavity.