Compact Brush Head Bonding Without Separate Bristle Fasteners
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Solution Overview
Problem
Existing brushes, particularly toothbrushes, have bulky brush heads that are uncomfortable in the oral cavity and are difficult to recycle, with manufacturing processes that require separate fastening means for bristle attachment, leading to inefficiencies and environmental impact.
Innovation Solution
A brush design with a bristle carrier where the bristle filaments are attached using molten filament material to fill the receiving recess, creating a compact and stable structure without separate fastening means, and using biodegradable materials for easy recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate fastening means are used to attach bristles to the bristle carrier, then the bristle attachment is secure, but the device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent merges the bristle and bristle carrier into a single integrated component made of thermoplastic material. The bristles are inserted into receptacles in the bristle carrier, and then the entire assembly is heated and molded as one piece, eliminating the need for separate fastening means. This combining approach maintains secure attachment while reducing device complexity and manufacturing steps.
Solution Approach 2:
The thermoplastic bristle carrier serves multiple functions: it holds the bristles in receptacles, provides structural support, and acts as the bonding medium itself through heating and molding. This multi-functionality eliminates the need for separate fastening components, reducing both complexity and manufacturing cost while maintaining attachment reliability.
2Ease of operation
If the brush head is made compact with minimal lateral overhang, then comfort in oral cavity improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses parameter changes in the thermoplastic material through heating and molding processes to achieve the desired compact brush head shape. By controlling temperature and pressure parameters during the molding process, the bristle carrier can be precisely formed with minimal lateral overhang while maintaining structural integrity and comfort characteristics.
Solution Approach 2:
The bristles are inserted into the receptacles before the final molding process. This preliminary arrangement allows the bristle carrier to be pre-shaped with the bristles in position, and then the entire assembly is heated and molded as one piece. This preliminary action simplifies the final molding process and reduces precision requirements for achieving the compact shape.
3Ease of manufacture
If traditional manufacturing methods are used with separate fastening means, then manufacturing flexibility is maintained, but productivity decreases and cost increases
Solution Approach 1:
The patent combines multiple manufacturing steps into a single integrated process. The bristles are inserted into receptacles, and then the entire bristle carrier assembly is heated and molded as one piece. This merging of steps eliminates the need for separate fastening operations, significantly improving productivity while maintaining manufacturing flexibility through the thermoplastic material's versatility.
Solution Approach 2:
The patent replaces mechanical fastening systems with a thermal-molding process. Instead of using separate mechanical fasteners or adhesive bonds, the thermoplastic material is heated to a pliable state and then molded to create an integrated structure. This substitution of mechanical systems with a thermal process improves productivity and simplifies manufacturing while maintaining flexibility in design.
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
The design results in a compact, comfortable, and stable brush head with reduced material waste, facilitating easy recycling and cost-effective manufacturing through a metallurgical bond between bristle filaments and the carrier.
Implementation Method 1
the receiving recess is filled with filament material melted onto the attachment-side ends of the bristle filaments
Implementation Method 2
attachment-side ends of the bristle filaments are heated to connect the bristle filaments to the bristle carrier
Implementation Method 3
the receiving recess is filled with filament material melted onto the attachment-side ends of the bristle filaments
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
The invention relates to improvements in the technical field of brush manufacturing and relates, among other things, to a brush (1) which has a bristle carrier (2) with a receiving recess (5) which, when bristle filaments (4) are attached to the bristle carrier (2), is completely or partially filled by melted filament material from the attachment-side ends (6) of the bristle filaments (4) of the brush (1) to be manufactured.