Toothbrush Brush-Head Grooves for Reliable Bristle Anchoring
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Solution Overview
Problem
Conventional toothbrush manufacturing methods using metal anchor plates are complex and unreliable for securing bristle bundles, leading to inconsistent anchoring and potential material separation issues.
Innovation Solution
A toothbrush design featuring a plastic brush head with U-shaped grooves in the hole cross-section for receiving folded bristle bundles, where plastic anchor plates are welded into these grooves to ensure secure anchoring, utilizing a combination and tapering section for symmetrical insertion and friction welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal anchor plates are used to secure bristle bundles, then the anchoring strength is improved, but the manufacturing complexity and reliability issues arise
Solution Approach 1:
The patent replaces expensive metal anchor plates with inexpensive plastic anchor plates that are integrated into the brush head during injection molding. These plastic anchors are disposable and eliminate the need for separate metal components, reducing manufacturing complexity while maintaining adequate anchoring strength for the application.
Solution Approach 2:
The patent merges the anchor plate and brush head into a single integrated component. The plastic anchor plates are formed as part of the brush head structure during injection molding, eliminating the need for separate metal anchor plates and reducing assembly steps. This integration simplifies manufacturing while maintaining anchoring functionality.
2Strength
If metal anchor plates are used to secure bristle bundles, then the anchoring strength is improved, but the reliability of securing bristle bundles deteriorates
Solution Approach 1:
The patent uses homogeneous plastic material for both the brush head and anchor plates, eliminating the metal-plastic interface that causes reliability issues. The plastic anchor plates are made from the same thermoplastic material as the brush head, ensuring consistent thermal and mechanical properties throughout the assembly, which improves welding reliability and overall securing consistency.
Solution Approach 2:
The plastic anchor plates are designed as disposable components that are integrated during injection molding. This eliminates the need for reusable metal anchors and their associated reliability problems, providing consistent and reliable anchoring through the disposable plastic components that are replaced with the brush head.
3Object-affected harmful factors
If plastic anchor plates are used instead of metal, then environmental sustainability is improved, but the anchoring reliability deteriorates
Solution Approach 1:
The patent changes the material parameters by using thermoplastic materials with specific melting points and welding characteristics. The plastic anchor plates are made from the same thermoplastic material as the brush head, allowing for reliable thermal welding that ensures consistent anchoring reliability while maintaining environmental sustainability through recyclable plastic materials.
Solution Approach 2:
The patent achieves homogeneity by using the same plastic material for both the brush head and anchor plates. This eliminates the material interface problems that reduce reliability, while maintaining environmental sustainability through the use of recyclable thermoplastic materials throughout the entire component system.
4Ease of manufacture
If the grooves do not have the combination section with centering and tapering, then the manufacturing simplicity is improved, but the anchoring reliability deteriorates
Solution Approach 1:
The patent incorporates the combination section with centering and tapering features directly into the mold during injection molding. This preliminary action ensures proper alignment and positioning of the anchor plates before welding, eliminating the need for separate alignment operations while ensuring reliable anchoring through the pre-formed geometric features.
Solution Approach 2:
The patent uses parameter changes in the groove geometry, specifically the combination section with centering and tapering features. These geometric parameter variations guide the anchor plates into proper alignment during insertion, ensuring reliable welding surfaces are achieved while maintaining manufacturing simplicity through integration into the molding process.
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 more reliable and efficient anchoring method, ensuring high pull-out forces and environmental sustainability by using recyclable plastic materials, while simplifying the production process.
Implementation Method 1
The anchor plate is fixed in the two grooves in the U-shaped profile by welding
Data Source
AI summary
A toothbrush has a brush head, at least one folded bristle bundle and at least one plastic anchor plate, wherein the brush head has a hole with a longitudinal axis for the at least one bristle bundle, wherein an anchor plate is fixed in the hole to anchor the respective bristle bundle, the anchor plate being held in two grooves running parallel to the longitudinal axis, which are formed in the hole by injection molding, the grooves having a centering section which, when viewed in a direction perpendicular to the longitudinal axis, has a depth that successively decreases with increasing distance from an entrance of the hole.