Spaced Bristle Tuft Structure for Fast-Clean Brush Rollers
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Solution Overview
Problem
Existing brush rollers used for forming three-dimensional wood grain textures on wood-plastic flooring 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 with a spacing structure comprising a general root segment, a general head segment, and a spacing segment that separates bristles, along with a brush roller design using a suspension groove system for quick disassembly, reducing adhesion of slow-curing substances and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If brush rollers are used continuously for removing slow-curing substance, then production efficiency is maintained, but residue adhesion to bristle head segments increases causing functionality degradation
Solution Approach 1:
The bristle assembly is divided into modular components: bristle tufts with spacing structures that can be independently replaced. The roller body, bristle tufts, and spacing structures form separable modules, allowing only the contaminated bristle tufts to be replaced while the roller body and spacing structures remain in use, thus maintaining productivity while restoring functionality.
Solution Approach 2:
The invention enables selective discarding of only the contaminated bristle tufts (not the entire brush roller) and recovery/reuse of the roller body and spacing structures. This partial replacement approach minimizes waste while restoring the brush roller's functionality, addressing both productivity and reliability concerns.
2Reliability
If brush rollers are disassembled frequently for cleaning, then residue adhesion is removed, but production downtime increases
Solution Approach 1:
The bristle tufts are designed as separable modules from the roller body through the spacing structure mechanism. This segmentation allows rapid removal and replacement of only the contaminated bristle tufts without disassembling the entire roller body or stopping production for extended periods, thus minimizing time loss while restoring functionality.
Solution Approach 2:
The brush roller system transitions from a static, fixed-bristle design to a dynamic, easily replaceable bristle tuft system. The spacing structures enable bristle tufts to be quickly installed and removed, allowing the system to adapt rapidly to contamination issues without requiring full disassembly or prolonged production stoppages.
3Area of stationary object
If bristles are arranged densely on the roller surface, then coverage area increases, but residue adhesion between adjacent bristles increases
Solution Approach 1:
The bristle arrangement is segmented into discrete tufts separated by spacing structures. This segmentation creates physical barriers between adjacent bristle tufts, preventing residue from bridging between them, while still maintaining high overall coverage through optimized tuft distribution across the roller surface.
Solution Approach 2:
Different regions of the roller surface have different bristle tuft densities optimized for their specific functions. The spacing structures create local variations in bristle arrangement, with tighter spacing where coverage is needed and greater separation where residue adhesion is a concern, achieving both high coverage and reduced adhesion.
4Reliability
If entire brush roller is disassembled for bristle replacement, then complete cleaning is achieved, but device complexity and disassembly time increase
Solution Approach 1:
The brush roller is segmented into independently replaceable bristle tufts and a permanent roller body. This segmentation simplifies the replacement procedure to only the necessary component (bristle tufts), eliminating the need to disassemble the entire roller body, thus reducing device complexity and disassembly time while restoring functionality.
Solution Approach 2:
The contaminated bristle tufts are extracted and removed from the roller body without removing the roller body itself. This selective extraction approach simplifies the maintenance procedure by focusing only on the problematic components, reducing the overall complexity of the disassembly and cleaning process.
Data Source
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.