Deformable Template for Tufted Curved Brush Heads
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Solution Overview
Problem
Manufacturing tufted brush heads with curved surfaces, such as hemispherical shapes, poses challenges due to size and shape constraints, which complicate bristle location and retention, especially as the brush head reduces in size and available surface area.
Innovation Solution
A deformable template with radially extending limbs and apertures that allows the tufts of bristles to project outward, transitioning from a flat to a curved shape, enabling secure bristle retention and forming a tufted curved surface like a hemispherical brush head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the brush head size is reduced, then the portability and compactness are improved, but the bristle retention and securing capability deteriorate
Solution Approach 1:
The substrate is divided into multiple radially extending limbs that can be independently formed and secured. Each limb can carry and secure tufts of bristles independently, allowing effective bristle retention even in a reduced-size brush head configuration.
Solution Approach 2:
The substrate is formed into a hemispherical or curved configuration with radially extending limbs. This curved geometry maximizes the use of available surface area within the compact brush head volume, improving bristle distribution and retention while maintaining a small overall size.
2Volume of moving object
If the brush head surface area is reduced, then the compactness is improved, but the available area for bristle projection and distribution deteriorates
Solution Approach 1:
The substrate is configured as a hemisphere or curved surface, which provides optimal surface area utilization within a compact volume. The curved geometry allows tufts of bristles to project radially outward from multiple limbs, maximizing the effective brushing surface area while keeping the overall brush head size small.
Solution Approach 2:
The substrate utilizes three-dimensional curved space with radially extending limbs instead of a flat two-dimensional surface. This dimensional transition allows efficient packing and distribution of bristle-bearing limbs throughout the available volume, increasing the effective surface area for bristle projection within the compact brush head.
3Shape
If the brush head shape is made curved, then the ergonomic and aesthetic properties are improved, but the complexity of inserting and retaining bristles deteriorates
Solution Approach 1:
The curved substrate is segmented into multiple discrete radially extending limbs. Each limb can be independently formed, positioned, and secured to the curved surface. Tufts of bristles are inserted into each limb separately, simplifying the manufacturing process compared to attempting to secure bristles directly to a continuous curved surface.
Solution Approach 2:
The substrate is formed into a hemispherical configuration with radially extending limbs that naturally conform to the curved surface. This geometry allows tufts of bristles to be inserted and secured in a radial pattern, simplifying the retention mechanism while maintaining the desired curved aesthetic and ergonomic properties.
Data Source
AI summary
The present invention provides a template for a tufted curved surface such as a hemispherical brush head for an electric toothbrush or the like, the template comprising a substrate having an upper surface adapted to carry one or more tufts of bristles such as to project outwardly from the upper surface, the substrate being shaped to be deformable between an expanded state in which the upper surface is substantially flat, and a collapsed state in which the upper surface is curved.