Brush Mat Production with Bundled Fiber Casting

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Solution Overview

Problem

Existing methods for producing brush mats with fiber trims are inefficient and costly, lacking a cost-effective process for creating a carrier mat with individually secured fibers.

Innovation Solution

A method involving providing a fiber-covered brush body, encapsulating the brush surface in a casting compound, curing it to form a carrier mat, and severing the fibers to separate the base body, allowing for a cost-effective production of brush mats with individually secured fibers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional methods are used to produce brush mats with fiber trims, then production cost is high and efficiency is low, but the process lacks a cost-effective solution for creating carrier mats with individually secured fibers

Engineering Contradiction:

Improveproduction costVSAvoidproduction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The invention segments the fiber attachment process by first creating fiber bundles that are punched into the base body, then later separating them into individual fibers through a cutting process. This segmentation allows for more efficient production compared to attempting to attach individual fibers one by one, while still achieving the desired individual fiber appearance in the final product.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention applies preliminary action by pre-attaching fibers in bundle form to the base body before the final product completion. The fibers are punched into the base body in bundled configuration, allowing for faster initial attachment, and then separated in a subsequent step to achieve the individual fiber appearance needed for the final brush mat product.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If fibers are attached individually to the carrier mat, then the fiber trim quality is high with individual fiber appearance, but the manufacturing process becomes complex and costly

Engineering Contradiction:

Improvefiber trim qualityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The manufacturing process is segmented into distinct phases: bundle attachment phase followed by individual fiber separation phase. This allows the complex task of individual fiber attachment to be replaced with simpler bundle attachment, followed by a cutting operation that achieves the individual fiber appearance without requiring complex individual fiber placement machinery.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of attaching individual fibers directly to the base body in the traditional manner, the invention inverts the approach by first attaching fibers in bundles and then separating them. This reverse sequence simplifies the attachment process while still achieving the desired individual fiber appearance in the final product.

Inventive Principle:

Principle #13The other way round (Inversion)

3Productivity

If fiber bundles are punched into the base body, then production speed increases, but the base body must be separated from the brush body requiring additional processing steps

Engineering Contradiction:

Improveproduction speedVSAvoidadditional processing steps

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The invention extracts the base body from the brush body assembly as a separate component through a cutting process. This extraction is necessary to complete the manufacturing process, allowing the carrier mat with attached fibers to be separated from the base body, with the understanding that this additional step enables the overall production efficiency gains from the bundle punching method.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Enables the production of brush mats with individually secured fibers at a lower cost, facilitating their use in conveyor systems with optimized fiber arrangement and density for enhanced conveying efficiency.

Implementation Method 1

curing the casting compound to form the carrier mat

Methodology Applied

Scientific EffectCuring:

Data Source

PatentEP4623752A1Method for producing a brush mat and brush mat

Publication Date: 2025.10.01 AUGUST MINK GMBH & CO KG

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Figure 5~6

AI summary

The invention relates to a method for producing a brush mat (1) comprising a carrier mat (10) with a fiber trim (12), comprising the steps of: providing a fiber-covered brush body (2), wherein the brush body (2) has a base body (20) with bundled bristles (22) comprising a number of fiber bundles (220), each with a plurality of fibers (120) projecting from the base body (2), and wherein free ends of the fiber bundles (220) form a brush surface (24), potting the brush surface (24) in a potting compound (4), curing the potting compound (4) to form the carrier mat (10), and severing the fibers (120) to separate the base body (20) from the carrier mat (10). The invention further relates to a correspondingly produced brush mat, an intermediate product, and the use of an intermediate product for producing a brush mat with a fiber trim.