Brush Seal Tuft Bonding and Cutting for Faster Bristle Assembly

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Solution Overview

Problem

Existing methods for manufacturing brush seals are inefficient due to long cycle times associated with thermal processes, and they often require bristles to be held together along their entire length, necessitating skilled labor and complex assembly procedures.

Innovation Solution

An apparatus that forms multi-filament tufts by using a support and an adhesive reservoir to retain and cut aligned wires or fibers, allowing for improved filament retention and automated manufacturing, where the support and adhesive reservoir are movable relative to each other to apply adhesive to the end of the skein, and a cutter adjusts the skein length.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermal processes (heating, melting, injection moulding, cooling) are used to manufacture bristle carriers, then the bristles can be held together, but the cycle time becomes extremely long

Engineering Contradiction:

Improvebristle holdingVSAvoidcycle time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces thermal processes with a mechanical system consisting of a support that moves on a closed path and clamping devices that transfer bristles to the support. This mechanical approach eliminates heating, melting, injection moulding, and cooling cycles, dramatically reducing manufacturing cycle time while maintaining bristle holding capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The support structure is designed to automatically receive bristles from clamping devices, move them through the manufacturing process, and release them at the appropriate station. This self-service mechanism eliminates the need for manual intervention and complex assembly procedures, reducing both cycle time and skilled labor requirements

Inventive Principle:

Principle #25Self-service

2Stability of the object's composition

If bristles are held together along their entire length, then the tuft structure is maintained, but skilled labor and complex assembly procedures are required

Engineering Contradiction:

Improvetuft structureVSAvoidassembly complexity

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent applies segmentation by holding bristles together only at specific locations (the base portion) rather than along their entire length. The support structure includes positioning elements that maintain tuft structure at critical points while leaving other portions free, thereby simplifying the manufacturing process and reducing assembly complexity without compromising tuft integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support acts as an intermediary device that temporarily holds bristles in the correct configuration during manufacturing. This intermediary structure enables automated handling and positioning of tufts, eliminating the need for skilled manual assembly while maintaining the required tuft structure

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If automated manufacturing is implemented, then productivity increases, but manufacturing precision may be compromised

Engineering Contradiction:

Improveproduction efficiencyVSAvoidtuft formation accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent incorporates feedback mechanisms through precisely engineered support structures with positioning elements that ensure consistent tuft formation. The support geometry and movement parameters are designed to automatically compensate for variations, maintaining high manufacturing precision while enabling automated high-speed production

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The support structure is designed with dynamic characteristics that allow it to adapt to slight variations in bristle properties during automated handling. The movable support on a closed path can adjust its position and orientation to maintain optimal tuft formation, ensuring consistent precision across high-volume production

Inventive Principle:

Principle #15Dynamics

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 reduces cycle time, improves tuft filament retention, and reduces reliance on skilled operators by enabling controlled and repeatable bonding of fibers, resulting in efficient and automated production of brush seals with improved tuft formation.

Implementation Method 1

relative movement of the support and the adhesive reservoir inserts the end of the skein retained by the support in the adhesive reservoir so that adhesive adheres to the end of the skein to form the tuft

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentEP2919615B1Tuft forming apparatus

Publication Date: 2023.11.22 CROSS MANUFACTURING CO (1938) LTD

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AI summary

An apparatus (10) for forming multi-filament tufts for use in a brush seal includes a support (14) for retaining an end of a skein (16) of aligned wires or fibres and a glue reservoir (15) dimensioned to receive the skein end. The support (14) and the reservoir (15) being relatively movable whereby the end can be inserted in the glue reservoir (15) so that the adhesive can adhere the wires or fibres at the end to form the tuft. A cutter (13) is also provided for cutting the wires or fibres to length after the wires and fibres are retained by the support (14).