Shape-Shifting Toothbrush Tuft with Variable Cross-Sectional Geometry
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Solution Overview
Problem
Existing toothbrush designs lack versatility in their tuft shapes, which limits their ability to meet advanced cleaning needs, and there is a need for a method to manufacture such advanced tufts.
Innovation Solution
A toothbrush head or brush carrier featuring a shape-shifting tuft with distinct first and second cross-sectional areas and shapes, where the planes of these cross-sections are parallel, and a method of manufacturing this tuft using a mold insert with corresponding cavities, fiber introduction, and connection techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional tuft with uniform cross-section is used, then the manufacturing process is simple, but the cleaning versatility and adaptation to different tooth surfaces is limited
Solution Approach 1:
The tuft is divided into multiple sections along its length, with each section having a different cross-sectional shape. The first cross-section has a first shape and the second cross-section has a second shape that does not match the first when overlaid, allowing different parts of the tuft to perform different cleaning functions
Solution Approach 2:
Different sections of the tuft are given different local geometries to optimize performance for specific cleaning tasks. The varying cross-sectional shapes create different fiber arrangements at different heights, enabling the tuft to adapt to various tooth surface geometries and provide enhanced cleaning versatility
2Shape
If the cross-sectional area changes along the tuft length, then the tuft shape can be varied, but the structural consistency and mounting stability may be compromised
Solution Approach 1:
The tuft employs asymmetric cross-sectional shapes where the first cross-sectional shape and second cross-sectional shape do not match when overlaid. This asymmetric design allows shape variation while maintaining structural integrity through careful design of the fiber arrangement and binding structure
Solution Approach 2:
The invention changes the geometric parameters of the cross-section along the tuft length while maintaining the cross-sectional area substantially constant. By varying the shape parameters (such as orientation, eccentricity, or boundary definition) rather than the area parameter, the tuft achieves shape diversity while preserving structural consistency and mounting stability
3Adaptability or versatility
If advanced tuft shapes are implemented, then cleaning performance is enhanced, but the manufacturing complexity increases
Solution Approach 1:
The mold insert is pre-configured with cavities that define the complex shape-shifting tuft geometry before the molding process. By preparing the mold insert in advance with the precise cavity shapes, the complex tuft geometry can be manufactured efficiently through a single molding operation, reducing overall manufacturing complexity
Solution Approach 2:
The mold insert cavities serve as negative copies of the desired tuft shapes. By creating precise inverse molds of the complex cross-sectional shapes, the manufacturing process can replicate the advanced tuft geometry accurately without requiring complex forming operations or multiple assembly steps
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The present disclosure is concerned with a toothbrush head or a brush carrier having at least one carrier element, at least one shape-shifting tuft mounted on the carrier element such that the shape-shifting tuft raises from a mounting end on a mounting surface of the carrier element generally along an extension direction towards a free end of the shape-shifting tuft, the shape-shifting tuft having a length from the mounting base to the free end, the shape-shifting tuft comprising a plurality of fibers, and the shape-shifting tuft having a first cross-section having a first cross sectional area and shape at a first length along the extension direction, and a second cross-section having a second cross-sectional area and shape at a second length along the extension direction, wherein the first cross-sectional area and the second cross-sectional area are substantially identical and the first cross-sectional shape and the second cross-sectional shape are different so that the first cross-sectional shape does not match the second cross-sectional shape independent from an angle by which the first cross-sectional shape is rotated and independent from a displacement of the first cross-sectional shape.