Plasma Jet Rounding of Thermoplastic Bristle Ends

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Solution Overview

Problem

Existing methods for rounding off bristle ends, such as using grinding wheels or laser beams, are time-consuming and expensive, and lack fine control, while plasma treatment methods for similar applications do not effectively address the need for a simple and inexpensive solution.

Innovation Solution

A method involving a plasma jet to thermally dissolve the outer edge of thermoplastic bristle ends, allowing for quick and precise rounding, and the simultaneous application of a fine-grained powder to enhance polishing properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If grinding wheels are used to round off bristle ends, then rounding can be achieved, but the process is time-consuming and expensive

Engineering Contradiction:

Improvebristle end rounding precisionVSAvoidrounding process speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the mechanical grinding wheel system with a plasma jet system. The plasma jet thermally dissolves the bristle ends through thermal energy, eliminating the need for mechanical contact and grinding wheels. This substitution enables faster processing while maintaining rounding precision, directly resolving the contradiction between manufacturing precision and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If laser beams are used to round off bristle ends, then rounding can be achieved quickly, but fine control is difficult due to excessive heat concentration

Engineering Contradiction:

Improverounding process speedVSAvoidrounding control precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the physical parameters of the energy delivery system by using plasma jet instead of laser beam. The plasma jet distributes thermal energy over a broader area with lower peak temperature concentration, enabling fine control of the rounding process while maintaining high processing speed. This parameter change resolves the contradiction between productivity and manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If conventional grinding methods are used, then rounding can be achieved, but the process is expensive

Engineering Contradiction:

Improvebristle end rounding qualityVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive mechanical grinding wheels that require frequent replacement and maintenance with a plasma jet system. The plasma jet delivers consistent rounding quality without the recurring costs of wheel replacement, directly reducing manufacturing costs while maintaining rounding quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If plasma jet is used to round off bristle ends, then processing speed increases, but additional equipment complexity is introduced

Engineering Contradiction:

Improverounding process speedVSAvoidplasma generation equipment

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical grinding systems with a plasma jet system that, while introducing new equipment, eliminates the need for mechanical contact, wheel replacement, and associated maintenance infrastructure. The plasma generation equipment provides faster processing with simplified operational complexity compared to mechanical grinding systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables rapid and cost-effective rounding of bristle ends with improved precision and the potential for enhanced polishing properties, such as antibacterial effects, while minimizing surface damage.

Implementation Method 1

the free ends of the bristles made of thermoplastic polymer materials are brought into contact with a plasma jet, whereby their outer edge is thermally dissolved

Methodology Applied

Scientific EffectThermal heating: Heating

Implementation Method 2

With the plasma jet directed onto the surface, such a total electrical power energy is applied to the bristle end surface that this rounding of the outer edges occurs

Methodology Applied

Scientific EffectElectrical energy to thermal energy conversion: Joule Heating

Data Source

PatentEP2403377B1Method for rounding off the bristle ends of a brush

Publication Date: 2014.10.08 REISHAUER AG

Figure 1
Figure 2

AI summary

A method is used to round off the free bristle ends of a brush, the bristles (5) of which are made of thermoplastic polymer materials. The free bristle ends (4) are brought into contact with a plasma beam (2), wherein the exterior edge (4b) of the free bristle ends is dissolved thermally or in a similar manner. The plasma beam (2) that is directed onto the surface (4a) produces a total electric power of such magnitude on said end surfaces (4a) of the bristles that the exterior edges (4b) of the bristles are rounded off. In this way, the rounding off can be performed in a substantially faster and easier manner compared to traditional grinding wheels.