Spaced Bristle Tuft Structure for Low-Residue Brush Rollers
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Solution Overview
Problem
Existing brush rollers used for forming three-dimensional wood grain textures on flooring materials face issues with slow-curing substance residues adhering to bristle head segments, leading to reduced functionality and necessitating frequent disassembly for cleaning, which decreases production efficiency.
Innovation Solution
A bristle tuft design with a spacing segment between bristles, featuring a bending or enlarged structure, and a quick-disassembly mechanism for the brush roller, allowing easy detachment from the production line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a brush roller with radially arranged bristles is used to remove slow-curing substance, then the surface structure edges become sharp and resemble natural wood grain, but the bristle head segments accumulate residues and lose functionality requiring frequent disassembly
Solution Approach 1:
The bristle is divided into multiple segments: a root segment for mounting, a spacing segment with spacing structures (protrusions or grooves) between adjacent bristles, and a head segment for wire drawing. This segmentation prevents residue accumulation by maintaining spacing between bristle head segments while preserving the sharp edge effect.
2Productivity
If the brush roller operates continuously for production, then productivity is maintained, but residue adhesion on bristles increases over time reducing effectiveness
Solution Approach 1:
The spacing structures on the spacing segment create automatic spacing between adjacent bristles during rotation, preventing residue accumulation without requiring external intervention or frequent disassembly for cleaning, thus maintaining continuous production capability.
3Reliability
If frequent disassembly for cleaning is performed, then bristle functionality is restored, but production downtime increases
Solution Approach 1:
The spacing structures are pre-designed into the bristle structure during manufacturing, creating built-in residue prevention capabilities that eliminate the need for frequent disassembly and cleaning operations during production.
4Manufacturing precision
If bristles are closely arranged for complete surface coverage, then wire drawing completeness improves, but residue accumulation between bristles increases
Solution Approach 1:
Different segments of the bristle have different functions: the root segment provides mounting, the spacing segment with spacing structures prevents residue accumulation locally between bristles, and the head segment performs wire drawing. This local differentiation allows close arrangement for complete coverage while preventing residue buildup.
Data Source
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AI summary
A bristle tuft, a brush roller with the bristle tuft, and a disassembly method of the brush roller, used in flooring production, particularly in the manufacture of printed flooring with three-dimensional wood grain textures on the surface. The bristle tuft comprises a plurality of bristles gathered into a tuft, wherein at least one bristle includes: a general root segment for mounting on a roller body, a general head segment extending in a direction perpendicular to the rotation axis of the roller body, and a spacing segment disposed between the general root segment and the general head segment, used to space apart at least one adjacent bristle to form a separated state except for the general root segment, the spacing segment having a spacing structure. The brush roller with the bristle tuft comprises: a roller body having a rotation axis; a roller sleeve for rotatably mounting the rotation axis and provided with an outer fixing member; and a suspension component for slidably mounting the roller sleeve, configured with an inner fixing member for fixing the outer fixing member.