Chamfered Brush Bristle Anchoring Without Mechanical Fasteners
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Solution Overview
Problem
Existing methods for attaching bristle tufts to brush holders without anchors require additional effort and equipment, and may compromise hygiene due to gaps between layers, especially in toothbrushes.
Innovation Solution
A method involving a bristle carrier with beveled anchoring openings, where the bristle carrier is heated and compressed to embed the bristle tufts without an anchor, using a tool part to deform the carrier and secure the bristles within the opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bristle carrier is heated and compressed to embed bristle tufts without an anchor, then the anchoring strength is improved, but the risk of material protrusion and hygiene issues increases
Solution Approach 1:
The invention applies local quality by creating a chamfered transition edge at the specific location where the bristle carrier meets the anchoring opening. This localized geometric feature ensures that material flows smoothly during compression without protruding, while maintaining anchoring strength. The chamfer is precisely positioned at the transition zone to control material behavior only where needed.
Solution Approach 2:
The invention changes the geometric parameter of the transition edge by introducing a chamfer with specific angles and dimensions. This parameter modification alters how the thermoplastic material deforms during heating and compression, preventing protrusion while ensuring proper anchoring. The chamfer dimensions are optimized to balance material flow control with anchoring effectiveness.
2Device complexity
If traditional anchorless methods are used to attach bristle tufts, then the procedural complexity is reduced, but the manufacturing precision and hygiene quality deteriorate
Solution Approach 1:
The invention applies preliminary action by pre-forming the chamfered transition edge on the bristle carrier before the bristle insertion process. This pre-prepared geometric feature ensures that when the bristle carrier is later heated and compressed, the material flows predictably without protruding, achieving gap-free interfaces without requiring complex real-time control during assembly.
3Manufacturing precision
If the transition edge is sharply defined without chamfer, then the manufacturing precision of the anchoring opening is improved, but the material behavior during compression becomes unpredictable causing protrusion
Solution Approach 1:
The chamfer introduces a localized geometric variation at the transition edge that specifically addresses material flow behavior. The rest of the anchoring opening maintains its precise dimensions and sharp definition, while only the transition zone is modified with the chamfer to control material deformation during compression.
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 material at the transition edge, allowing for larger tolerances during tool assembly and preventing material protrusion, enhancing the hygiene and quality of the brush by ensuring a gap-free interface.
Implementation Method 1
the bristle carrier is heated and compressed to embed the bristle tufts
Implementation Method 2
The thermoplastic material of the bristles melts, causing the bristles to merge
Implementation Method 3
the tool part exerts a compressive force on the heated bristle carrier and deforms the bristle carrier
Implementation Method 4
material of the bristle carrier in the area of the edge and the inside is pressed laterally into the anchoring opening
Data Source
Figure 1a~1g
Figure 2
Figure 3~5A
AI summary
The invention relates to a method or a device for securing bristles in a bristle carrier (10) without anchors, in which once the bristles have been inserted into anchoring openings (12) in the bristle carrier (10), these openings are closed by the application of pressure and heat. A transition edge (320) surrounding the anchoring opening (12) has a chamfered edge (322).