Toothbrush Head Bristle Tuft Overmolding for Flexible Cleaning Designs
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Solution Overview
Problem
Existing toothbrush manufacturing methods lack flexibility in integrating different types of cleaning elements and bristle tufts, limiting design options to meet diverse consumer needs such as deep cleaning, sensitive cleaning, and gum massage.
Innovation Solution
A method involving the use of a hole perforation plate to arrange bristle tufts with varying properties, applying energy to form fuse balls at different distances, and over-molding with plastic to create a cleaning element carrier, which is then integrated into a brush head mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different types of cleaning elements and bristle tufts are integrated into one brush head, then design flexibility and versatility are improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is divided into distinct segments: providing multiple filament containers with different bristle properties, picking and arranging bristle tufts in a hole perforation plate, fusing tuft ends to form fuse balls, and overmolding with plastic material. This segmentation allows each step to be optimized independently while maintaining overall flexibility.
Solution Approach 2:
The hole perforation plate serves multiple functions: it holds and arranges various types of bristle tufts, positions them according to the desired bristle field pattern, and facilitates the fusing process. The fuse balls formed from different bristle types all serve the universal function of anchoring tufts securely in the overmolded brush head.
2Manufacturing precision
If fuse balls are formed at different distances from the energy source according to tuft properties, then manufacturing precision is improved, but process complexity increases
Solution Approach 1:
The energy source is positioned at a predefined distance from the hole perforation plate, creating a controlled thermal field. Bristle tufts with different properties (diameter, material, cross-section) are arranged at different distances from the energy source, allowing each tuft to receive appropriate thermal energy for consistent fuse ball formation despite variations in tuft characteristics.
Solution Approach 2:
The distance between bristle tufts and the energy source is varied as a controllable parameter based on tuft properties such as diameter, material composition, and cross-section. This parameter adjustment ensures that each tuft type receives the optimal amount of thermal energy for fuse ball formation, maintaining manufacturing precision across diverse bristle types.
3Reliability
If fuse balls are made larger than bristle tufts for secure anchoring, then reliability is improved, but loss of substance increases
Solution Approach 1:
The fuse balls are formed as molten copies of the bristle tuft material through controlled heating. The plastic material is melted and reshaped into fuse balls that replicate the tuft's material properties, ensuring compatibility and secure anchoring while minimizing waste through precise material transformation rather than addition.
Solution Approach 2:
The bristle tuft ends undergo a phase transition from solid to molten state when exposed to thermal energy from the energy source. This melting process transforms the tuft material into fuse balls that can be molded into anchoring shapes, securing the tufts in the brush head while utilizing the existing material rather than adding excessive amounts.
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 high design flexibility in toothbrush heads by securely incorporating diverse cleaning elements and bristle tufts, ensuring secure anchoring and consistent fuse ball formation despite varying tuft properties.
Implementation Method 1
applying energy from the energy source to the ends of the one or more bristle tufts until fuse balls are formed
Implementation Method 2
applying energy from the energy source to the ends of the one or more bristle tufts until fuse balls are formed
Implementation Method 3
injecting molten plastic material into the brush head mold forming a toothbrush head
Data Source
AI summary
A method of making a cleaning element carrier for a toothbrush comprises: providing at least two pluralities of loose filaments of a predefined length and different from one another in at least one of filament material, filament diameter, filament cross-section, filament shape, presence or absence of additives, presence or absence of a coating, and any combination thereof; providing a hole-perforation plate having a front surface, a back surface, a thickness therebetween, and a plurality of holes shaped and arranged according to a predetermined pattern; picking filaments from the pluralities of loose filaments; providing an energy source; arranging a plurality of bristle tufts in a fusing position in the hole-perforation plate so that ends of the bristle tufts are disposed at different distances from the energy source, wherein the distances are adjustable according to the at least one property, wherein the plurality of bristle tufts includes bristle tufts comprising an inner portion bristle tufts comprising a peripheral portion, and wherein a distance between the energy source and the ends of the bristle tufts comprising the inner portion is shorter than a distance between the energy source and the ends of the bristle tufts comprising the peripheral portion; applying energy from the energy source to the ends of the tufts until fuse balls are formed at the ends of the tufts; transferring the tufts to a molding position in the hole-perforation plate so that a distance between a bottom edge of at least one fuse ball of at least one bristle tuft and the front surface of the hole-perforation plate is different from a distance between the bottom edge of the fuse ball of said tuft and the front surface of the hole-perforation plate in the fusing position; over-molding the fuse balls with molten plastic material thereby forming a cleaning element carrier.