Integrally Molded Elastomeric Hair Brush with Cavity Cushioning
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Solution Overview
Problem
Existing hair brushes face issues of non-durability, complex construction leading to high manufacturing costs, and inefficiencies due to multiple separate parts and precise assembly requirements, which compromise their performance and comfort during use.
Innovation Solution
A hair brush design featuring a base member with connection means for a sheet material with spikes, integrally formed by injection molding of thermoplastics such as TPE-E, TPE-A, TPU, or PU, allowing the sheet material to secure to the base member and create a convex curvature with a cavity for cushioning, eliminating the need for separate bristles and supporting membranes, and enhancing durability and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional hair brushes use multiple separate parts (bristles, supporting membranes, base structures), then they can provide basic brushing function, but they become complex in construction leading to high manufacturing costs and assembly inefficiency
Solution Approach 1:
The patent combines multiple traditional brush components (bristles, supporting membrane, and base structure) into a single integrally molded body made of thermoplastic elastomer material. This merging eliminates the need for separate parts and complex assembly processes, directly reducing manufacturing cost and improving production efficiency while maintaining the functional benefits of traditional multi-component designs
2Reliability
If traditional hair brushes use rigid structures, then they provide structural stability, but they become non-durable due to inherent physical structure and cause discomfort during use
Solution Approach 1:
The patent changes the material parameter from rigid plastics to thermoplastic elastomer with specific hardness (Shore D50-D65) and flexural modulus (30,000-40,000 PSI) ranges. This parameter change enables the brush to simultaneously achieve durability through material resilience and user comfort through flexible, cushioning contact during brushing operations
Solution Approach 2:
The patent introduces dynamic flexibility into the brush structure through the elastomeric material and cavity design that allows movement and deformation under pressure. This dynamic characteristic enables the brush to adapt to different hair types and brushing forces, improving both durability through stress absorption and comfort through flexible contact
3Ease of operation
If traditional hair brushes lack cushioning mechanisms, then they are simpler in construction, but they cause discomfort and damage during use
Solution Approach 1:
The patent merges the cushioning function with the main brush body structure by integrating a cavity within the molded elastomeric material. This eliminates the need for separate cushioning components or complex multi-layer constructions, providing comfort through the inherent flexibility and movement capability of the unified elastomeric structure
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 more durable, cost-effective, and comfortable hair brush that provides effective cushioning and detangling, addressing the challenges of durability, manufacturing complexity, and user comfort.
Implementation Method 1
the sheet material and the spikes being integrally formed by injection molding of a plastic(s) material selected from the group of thermoplastics polyester elastomer (TPE-E), polyether block amide copolymer (TPE-A), thermoplastic polyurethane (TPU) and polyurethane (PU)
Implementation Method 2
when the spikes are under pressure the spikes are movable in response to the pressure, causing corresponding movement to the sheet material, the movement creating a cushioning effect
Data Source
AI summary
One aspect of the present invention is concerned with a method of manufacture of a hair brush. The method has the steps of providing a base member having connection means at circumferential region thereof, providing a sheet material having a plurality of spikes extending from outwardly facing surface of the sheet material, the sheet material and the spikes are integrally formed by injection molding of a plastic(s) material selected from the group consisting of thermoplastics polyester elastomer (TPE-E), polyether block amide copolymer (TPE-A), thermoplastic polyurethane (TPU) and polyurethane (PU), with a hardness from substantially Shore D50 to D65, and with a flexural modulus from 30,000 PSI to 40,000 PSI, assembling the sheet material by fitting perimeter thereof to the circumferential region of the base member, the base member and the connection means are configured to allow the sheet material to secure to the base member. The outwardly facing surface assumes a convex curvature. In an assembled configuration, a cavity is defined between the sheet material and the base member. In use, when the spikes are under pressure the spikes are movable in response to the pressure, causing corresponding movement to the sheet material, the movement creating a cushioning effect.