Brush Manufacturing Machine Segmented Injection Molding
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Solution Overview
Problem
Existing brush manufacturing machines face issues with excess plastic material overflowing during injection molding due to high pressure, making the brushes unusable, and require expensive, precisely constructed multi-compartment cartridges for injection-molding machines, leading to high costs and complexity.
Innovation Solution
A brush manufacturing machine design with a first injection-molding machine forming a thin-wall bristle carrier with shorter cycle times and a multi-compartment second injection-molding machine, using smaller cartridges and reducing the number of mold cavities, allowing for more economical production and easier handling, while optionally fusing bristle bundle ends to prevent overflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high injection-molding pressure is used to form the brush body, then the brush body can be properly formed, but excess plastic material overflows through the bristle bundles making the brush unusable
Solution Approach 1:
The injection molding process is divided into two separate stages: first forming the bristle carrier around individual bristle bundles, then forming the brush body around the carrier. This segmentation allows each stage to use appropriate pressure levels, preventing material overflow while ensuring proper formation.
Solution Approach 2:
The bristle carrier is formed in advance before the brush body injection molding. This preliminary action creates a protective structure around the bristle bundles that prevents plastic material from overflowing during the subsequent high-pressure brush body formation.
2Productivity
If multi-compartment cartridges are used to hold multiple bristle bundles, then production efficiency increases, but the cartridges become expensive and complex to manufacture with high precision requirements
Solution Approach 1:
The system separates the bristle bundle holding function (cartridges) from the injection molding function (multi-compartment mold). This allows simple, inexpensive cartridges to be used while achieving high productivity through the multi-compartment mold that can process multiple cartridges simultaneously.
Solution Approach 2:
Multiple simple cartridges are combined and processed together in a single multi-compartment mold cavity system, achieving high production efficiency without requiring each cartridge to be complex. The mold handles multiple cartridges in parallel.
3Productivity
If a multi-compartment injection-molding machine with multiple injection-molding assemblies is used to form both bristle carrier and brush body, then integrated production is achieved, but the machine becomes very complicated and expensive
Solution Approach 1:
The injection molding process is segmented into two separate machines: a first injection-molding machine for forming the bristle carrier and a second injection-molding machine for forming the brush body. This segmentation avoids the need for a complex multi-assembly machine while achieving integrated production through sequential processing.
Solution Approach 2:
The bristle carrier acts as an intermediary component between the bristle bundles and the brush body. It is formed by the first machine, then used as a mold insert in the second machine, enabling coordinated production without requiring a single complex machine with multiple assemblies.
4Object-generated harmful factors
If the bristle carrier is injection molded with low pressure to prevent overflow, then material overflow is avoided, but the production cycle time increases
Solution Approach 1:
The injection molding process is divided into two separate molding operations performed in parallel on different machines. The first machine forms the bristle carrier at low pressure to prevent overflow, while the second machine forms the brush body at high pressure. This segmentation allows each operation to use optimal pressure without compromising overall production efficiency.
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 design enables precise and economical injection molding of brush bodies with reduced processing time and costs, using smaller, less expensive cartridges, and allows for the production of different brush types with varying bristle patterns without significant time losses, while maintaining quality and reducing the need for complex multi-compartment machines.
Implementation Method 1
liquid plastic material is pressed upward through the individual filaments of the bristle bundle or at the edge of the bundles due to the high injection-molding pressure
Implementation Method 2
there is the option of fusing the brush bundles on their attachment side, connecting the individual fibers to each other in this way
Data Source
AI summary
A brush manufacturing machine (1) has a first injection-molding machine (18) for the region-by-region injection molding of material around the bristle bundles (7) held in cartridges (9) and for forming a bristle carrier (19) connecting the bristle bundles (7) and also a second injection-molding machine (24) in which the bristle carrier (19) can be inserted and material can be injection molded around this carrier for forming a brush body (25) or partial brush body. The first injection-molding machine (18) is constructed for forming a thin-walled plate as a bristle carrier (19) and has a shorter cycle time than the second injection-molding machine (24). At least the second injection-molding machine (24) is constructed as a multi-compartment injection-molding machine and has a multiple of the number of mold cavities of the first injection-molding machine (18).