3D Printed Guide Element for Complex Bristle Geometry
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Solution Overview
Problem
Existing devices for producing bristle arrays for brushes, such as toothbrushes, face challenges in creating complex bristle field geometries with non-circular cross-sections due to the limited availability and high cost of geometry hoses, which are complex and expensive to manufacture.
Innovation Solution
A device utilizing an additive manufacturing process to produce guide elements and continuous guide channels with varied cross-sectional geometries, allowing for the efficient and cost-effective production of bristle fields with complex geometries, where the guide element is attached to a bundle-retaining plate and bristle bundles are transported through a gas or air stream, enabling the creation of diverse bristle field designs without the need for complex molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If geometry hoses are used to produce non-circular bristle bundles, then complex bristle field geometries can be achieved, but manufacturing complexity and costs increase significantly
Solution Approach 1:
The patent changes the cross-sectional parameters of the guide channel from circular to non-circular shapes (rectangular, triangular, polygonal) to produce corresponding non-circular bristle bundles. This allows the same transport system to create varied geometries by simply changing the guide channel cross-section parameters rather than using different complex geometry hoses for each shape.
Solution Approach 2:
The guide element serves multiple functions: it guides the bristle bundles through the transport system, defines the final cross-sectional geometry, and can be configured with different channel shapes to produce various bundle geometries. This single component replaces the need for multiple specialized geometry hoses with different cross-sections.
2Ease of manufacture
If geometry hoses with limited cross-sectional geometries are used, then manufacturing is simpler, but design flexibility and variety of bristle field geometries are restricted
Solution Approach 1:
The guide channel cross-sectional parameters (shape, size, orientation) can be varied to produce different bristle bundle geometries. The patent specifically mentions rectangular, triangular, and polygonal cross-sections that can be achieved by modifying the guide channel geometry while using the same basic transport infrastructure.
Solution Approach 2:
The patent introduces a new dimension of geometric control through the guide element's cross-sectional profile. Instead of relying on the hollow line geometry alone, the guide channel provides an additional geometric dimension that defines the bristle bundle cross-section, enabling greater design flexibility without complicating the transport system.
3Ease of manufacture
If conventional manufacturing processes like casting or injection molding are used for guide elements, then production is established, but complex geometries require complex molds and increase costs
Solution Approach 1:
The additive manufacturing process enables local variation in the guide element geometry without requiring corresponding variations in tooling. Complex internal channels and cross-sectional shapes can be directly fabricated layer-by-layer, eliminating the need for complex molds and cores that would be required with conventional injection molding or casting processes.
Solution Approach 2:
The desired guide element geometry can be directly copied from a digital 3D model through additive manufacturing, eliminating the need for physical mold-making. This digital-to-physical copying process allows rapid prototyping and production of complex geometries without the expensive tooling development required by conventional manufacturing methods.
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 approach allows for the production of bristle fields with complex geometries in a simpler, more cost-effective manner, reducing manufacturing complexity and costs by using 3D printing processes, enabling a wide range of cross-sectional geometries and designs that were previously difficult or expensive to achieve with conventional methods.
Implementation Method 1
transport device for transporting bristle bundles through at least one hollow conduit of the transport device by means of a gas or air stream
Data Source
Figure 1~2
Figure 3~6
AI summary
A device (1) for producing sets of bristles for brushes, in particular toothbrushes, comprises a transport device (2) for transporting bristle bundles through at least one hollow line (3) of the transport device (2) by means of a gas or air stream into perforations (4) of an bundle-retaining plate (5) that is held ready. In addition, the transport device (2) also comprises a guide element (6), inside which at least one continuous guide channel (10, 10a, 10b, 10c, 10d) is formed, via which bristle bundles can be fed to the perforations (4) of the bundle-retaining plate (5). The guide element (6) and the at least one continuous guide channel (10, 10a, 10b, 10c, 10d) are produced by means of an additive production method. In order to produce the device (1) according to the invention, first the guide element (6) and the at least one continuous guide channel (10, 10a, 10b, 10c, 10d) are produced by means of an additive production method, in particular printed by means of a 3D printing method, and then installed on a fastening interface (7) of the device (1).