Powered Tool Brush with Integral Injection Molded Head
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Solution Overview
Problem
Existing powered tool brushes, typically made of plastic, suffer from poor integrity, leading to damage, bristle loss, and inadequate dirt removal due to insufficient friction and easy disengagement from surfaces.
Innovation Solution
A powered tool brush with a brush head formed integrally on a structural support member via injection moulding, which encloses the support member to enhance integrity and prevent disengagement, combined with anti-skid features to improve torque transfer and prevent bristle loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic brush head is implanted in an electric drill bit, then the brush head can be easily manufactured and replaced, but the integrity is poor and the brush head is easily damaged and pressed to be crooked
Solution Approach 1:
The brush head and structural support member are merged into a single integrated component through integral injection moulding, eliminating the separate implantation process. This merging ensures that the brush head and support member form an unified structure that cannot be easily damaged or pressed crooked, while maintaining manufacturing efficiency through single-step production.
Solution Approach 2:
The brush head is designed to wrap and enclose the structural support member, creating a nested structure where the brush head forms an outer shell around the support member. This nesting provides structural protection and prevents disengagement, while the support member reinforces the brush head against damage.
2Ease of manufacture
If a plastic brush head is used, then the manufacturing is simple, but the brush head is easily disengaged and causes bristle loss
Solution Approach 1:
The brush head and structural support member are merged into a single integrated component through integral injection moulding, eliminating the separate implantation process. This merging ensures that the brush head and support member form an unified structure that cannot be easily damaged or pressed crooked, while maintaining manufacturing efficiency through single-step production.
Solution Approach 2:
The anti-skid groove is pre-formed on the structural support member during the injection moulding process, before the brush head is assembled. This preliminary action ensures that when the brush head wraps around the support member, the anti-skid features are already in place to prevent rotation and bristle loss, eliminating the need for post-assembly adjustments.
3Ease of operation
If manual brushing is used, then the operation is simple, but insufficient friction is generated and dirt is not completely brushed away
Solution Approach 1:
The powered tool brush utilizes rotational motion generated by the electric drill to create mechanical vibration and high-speed movement of the brush bristles. This mechanical action generates sufficient friction between the brush and the surface being cleaned, enabling complete dirt removal that cannot be achieved through static manual brushing.
4Ease of operation
If the brush head is located outermost, then it is easily accessible for cleaning, but it is easily stuck in slits and results in bristle loss
Solution Approach 1:
The brush head is designed as a flexible wrapping structure that encloses the structural support member. This flexible shell design allows the brush head to conform to surfaces and resist getting stuck in slits, while maintaining accessibility for cleaning. The flexible material can deform to avoid rigid entrapment points.
Solution Approach 2:
The structural support member is positioned inside the brush head to provide beforehand cushioning and structural reinforcement. When the brush head encounters resistance or attempts to enter narrow slits, the internal support member prevents excessive deformation and stress concentration that would otherwise cause bristle loss.
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 solution provides a durable and effective dirt removal tool with enhanced surface protection, improved bristle retention, and increased applicability for various cleaning tasks without damaging surfaces.
Implementation Method 1
a brush head, which is directly formed on the structural support member by integral injection moulding
Implementation Method 2
a surface of the structural support member inwardly recesses to form an anti-skid groove, the brush head is provided with an anti-skid contour, which is fitted to the anti-skid groove
Implementation Method 3
the brush body is directly formed on the bottom wall by integral injection moulding, and the brush body includes a plurality of bristle structures formed by the bottom wall extending in the direction away from the support member
Data Source
AI summary
A powered tool brush includes: a connecting member, one end of which is a free end, at least part of the connecting member close to the free end is used for being connected to a rotation drive end of a powered tool; a structural support member, which is fixedly connected to another end of the connecting member; and an integrally formed brush head, the head having a bottom wall, a brush body and a side wall, the bottom wall is used for covering a surface position of the support member that is away from the connecting member, the body is formed by the bottom wall and/or the side wall extending in a direction away from the support member, and the side wall is formed by the bottom wall extending in a direction approaching the support member, and is used for wrapping and covering the periphery of the support member.