Mascara Brush Assembly With Post-Assembly Trimming and Bending
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Solution Overview
Problem
Existing mascara brushes, whether twisted-in-wire or stacked-disc array, lack the ability to vary bristle characteristics along the brush length or are difficult to customize post-assembly, limiting their shape and functionality.
Innovation Solution
A brush design featuring a twisted wire core with an integral tip and stacked-disc configuration, allowing for post-assembly trimming and shaping, including a core wire section with a helical configuration and bristles that inhibit disc rotation, combined with molded or additively manufactured elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If brushes are manually made by inserting bristles one by one into a board, then the brush can be manufactured with simple tools, but the manufacturing time and labor cost are excessively high
Solution Approach 1:
The invention divides the brush manufacturing process into distinct segments: preparing individual bristle pieces with notches, preparing the board with corresponding recesses, and then assembling them using adhesive. This segmentation allows each component to be prepared independently and efficiently, then quickly assembled, replacing the slow manual insertion process while maintaining manufacturing simplicity.
Solution Approach 2:
The invention applies preliminary action by pre-notching the bristles and pre-forming recesses in the board before assembly. The bristles are cut to length, notched at the end, and the board has recesses formed in advance. This preliminary preparation enables rapid assembly using simple adhesive application, dramatically increasing productivity without requiring complex manufacturing tools.
2Stability of the object's composition
If conventional brush manufacturing methods are used, then the structure remains traditional, but the production time per brush is excessively long
Solution Approach 1:
The invention maintains the traditional brush structure of bristles set in a board while applying preliminary actions: notching bristles in advance and forming recesses in the board before assembly. This allows the familiar brush composition to be assembled rapidly using adhesive, reducing production time from minutes per brush to seconds per brush while preserving the stable traditional structure.
Solution Approach 2:
The invention replaces the mechanical insertion process (physically forcing bristles into the board one by one) with a chemical bonding system using adhesive. The adhesive is applied to the notched bristles or board recesses, allowing quick bonding without manual insertion tools. This substitution dramatically reduces production time while maintaining the structural integrity of the traditional brush design.
3Device complexity
If brushes are made by inserting bristles into a board using traditional methods, then no special equipment is needed, but the manufacturing cost per unit is very high due to labor intensity
Solution Approach 1:
The invention segments the brush into pre-notched bristle pieces and a board with pre-formed recesses. This segmentation allows each component to be manufactured independently using simple tools, then assembled with minimal equipment. The notching and recess formation can be done with basic cutting and shaping tools, and assembly requires only adhesive application, dramatically reducing both equipment complexity and per-unit manufacturing cost.
Solution Approach 2:
The invention replaces the labor-intensive mechanical insertion process with a simplified system using adhesive bonding. Instead of requiring workers to manually insert and secure each bristle with tools, the adhesive system allows quick bonding of pre-prepared bristles to the board. This substitution eliminates the need for complex insertion equipment and dramatically reduces labor costs while maintaining simple manufacturing requirements.
Data Source
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AI summary
A brush includes a core wire section having a proximal end and a distal end and a plurality of discs received on the core wire section, the plurality of discs defining a brush head. The brush head is shaped by at least one of trimming the plurality of discs of the brush head and/or bending a portion of the core wire section.