Paintbrush Bristle Carrier Plate Grid Design
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Solution Overview
Problem
Existing brush manufacturing techniques face challenges in achieving a dense bristle pack with reliable attachment while minimizing costs, particularly with natural bristles, as current methods either result in low density or high production costs due to the need for longer bristles and extensive spacing of attachment points.
Innovation Solution
A brush design featuring a grid-like bristle carrier plate with a high proportion of receiving openings, allowing bristle bundles to be inserted and secured through these openings, eliminating the need for clips and enabling a dense bristle pack, with options for mechanical or adhesive attachment to the handle, and varying opening sizes for optimized paint distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If bristles are attached using a dense bundle in a sleeve with gluing, then bristle density is improved, but individual bristle attachment reliability deteriorates
Solution Approach 1:
The bristle pack is divided into multiple smaller bristle bundles, each inserted through its own receiving opening in the grid-like bristle carrier plate. This segmentation allows each bundle to be individually secured while maintaining high overall density, resolving the contradiction between density and attachment reliability.
Solution Approach 2:
A grid-like bristle carrier plate with receiving openings serves as an intermediary structure between the bristle bundles and the handle. This plate provides multiple attachment points that securely hold individual bundles while maintaining high bristle density, eliminating the need for sleeve gluing.
2Reliability
If clips are used to attach bristles in holes, then bristle attachment reliability is improved, but bristle density deteriorates due to required spacing
Solution Approach 1:
The clips traditionally used to secure bristles are completely removed from the design. Instead, bristle bundles are inserted directly through receiving openings in the grid-like bristle carrier plate and secured without any additional clipping elements, simplifying the structure and increasing density.
Solution Approach 2:
The structure of the bristle carrier plate is changed from a solid body with spaced holes to a grid-like structure with numerous receiving openings. This parameter change in the carrier plate geometry allows for much higher bristle density while maintaining secure attachment through the openings themselves.
3Reliability
If natural bristles are used with clips, then attachment security is improved, but production cost deteriorates due to longer bristle requirements
Solution Approach 1:
The clipping mechanism is removed entirely, eliminating the need for extended bristle lengths that would otherwise be required to bend over and secure under clips. Natural bristles can be used at optimal lengths, reducing material cost while maintaining secure attachment through the grid carrier plate.
4Strength
If holes are spaced far apart to hold clips, then attachment strength is improved, but bristle pack density deteriorates
Solution Approach 1:
The bristle carrier plate is designed with a grid-like structure where the spacing between receiving openings is optimized for both structural strength and bristle density. This parameter optimization allows closely spaced openings that maintain body strength while maximizing bristle pack density.
Data Source
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AI summary
A paint brush has a handle, a bristle carrier plate fixed directly to the handle, and a plurality of bundles of bristles inserted into the bristle carrier plate through receiving openings.