Brush Head Plate Attachment Methods for Void Elimination
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Solution Overview
Problem
Current methods for attaching brush head plates to handles, such as ultrasonic welding and overmoulding, face issues like voids between parts, deformation, and risk of leakage or contamination, particularly when using hot resin against cold surfaces.
Innovation Solution
The use of friction welding, mechanical connections, gluing, or overmoulding techniques, including the application of expanding adhesives or fillers to seal voids and enhance bonding, while also considering methods like in-mould assembly and laser welding to ensure a strong and contamination-resistant attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to attach head plate to handle, then attachment speed and reliability are improved, but voids are created between the back part of head plate and front face of recess
Solution Approach 1:
The harmful void space is extracted and removed from the assembly by designing the handle recess to exactly match the head plate back surface, eliminating the void creation problem while maintaining the benefits of ultrasonic welding
Solution Approach 2:
A filler material is introduced as an intermediary substance to occupy and seal the void space between the head plate and handle, preventing contamination and improving the overall attachment quality
2Object-affected harmful factors
If filler material is placed in recess to fill void, then void elimination is achieved, but additional manufacturing steps and material cost are required
Solution Approach 1:
The filler material step is extracted and eliminated by redesigning the handle recess geometry to perfectly match the head plate back surface, achieving void elimination without adding manufacturing complexity
Solution Approach 2:
The recess dimensions and geometry parameters are adjusted to precisely match the head plate specifications, allowing void-free assembly through dimensional optimization rather than additional filling operations
3Strength
If hot resin is overmoulded against cold head plate, then strong bonding is achieved, but deformation and shrinkage occur after cooling
Solution Approach 1:
The head plate is pre-heated before overmoulding to counteract the thermal shock that would otherwise cause deformation and shrinkage during cooling, maintaining dimensional stability while achieving strong bonding
Solution Approach 2:
The temperature parameter of the head plate is changed from cold to heated state before the overmoulding process, preventing thermal shock and subsequent deformation while maintaining bonding strength
4Strength
If pressure is applied during overmoulding, then bonding strength is improved, but risk of resin leakage between filaments increases
Solution Approach 1:
The pressure application is localized to specific areas away from the filament junctions during overmoulding, maintaining bonding strength in the handle-head plate interface while preventing resin leakage between filaments through selective pressure distribution
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
These methods provide a robust and contamination-resistant attachment of brush head plates to handles, minimizing voids and deformation risks, and ensuring a secure bond that prevents bacterial growth and leakage.
Implementation Method 1
The brush handle and the head plate are joined to each other in a friction welding process
Implementation Method 2
ultrasonically weld both parts together
Implementation Method 3
the tufted head plate is placed into a mould cavity, after which the handle is overmoulded against the head plate, bonding solidly
Implementation Method 4
laser welding to ensure a strong and contamination-resistant attachment
Data Source
Figure 1~3
Figure 4~6
Figure 7~8B
AI summary
A method of combining a brush head plate with a brush handle or part of brush handle is disclosed which makes use of any of a mechanical, friction, welding, gluing and molding technique or of a combination of these techniques.