Toothbrush Head Tuft Anchoring With Multi-Level Fuse Balls
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Solution Overview
Problem
Existing toothbrush manufacturing methods lack flexibility in integrating different types of cleaning elements and bristle tufts, limiting the ability to meet diverse consumer requirements such as deep cleaning, sensitive cleaning, and gum massage while ensuring a comfortable brushing experience.
Innovation Solution
A method for producing a brush head that involves arranging bristle tufts with different properties in a hole perforation plate, adjusting their positions and distances to an energy source for contactless fusing, forming fuse balls at varying levels within a cleaning element carrier, and embedding these fuse balls to secure the tufts in the carrier, allowing for high design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fuse balls are made larger than bristle tufts to anchor them securely in the brush head, then the anchoring reliability is improved, but the manufacturing precision deteriorates because homogenous size, form and shape of fuse balls are not important in AFT method
Solution Approach 1:
The invention changes the parameter of fuse ball size from variable (in AFT method) to controlled and homogeneous (in hot tufting method with mold bar). By using a mold bar with precisely defined holes, the fuse balls are formed with consistent dimensions that are larger than the bristle tufts, ensuring reliable anchoring while maintaining manufacturing precision through the mold's geometric constraints
Solution Approach 2:
The mold bar serves as an intermediary tool that mediates between the bristle tufts and the final brush head structure. It provides a standardized interface through which bristle tufts are inserted and fuse balls are formed, ensuring both homogeneity of fuse balls and secure anchoring without requiring variable sizing
2Adaptability or versatility
If different types of cleaning elements and bristle tufts are integrated into one brush head, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The mold bar serves as a universal fixture that can accommodate multiple types of bristle tufts and cleaning elements through its array of standardized holes. Different tuft types can be positioned in different holes according to the desired brush head design, allowing one mold bar to produce multiple configurations without requiring different tooling for each type
Solution Approach 2:
The brush head is segmented into multiple independent positions on the mold bar, each capable of holding different types of cleaning elements. This segmentation allows for modular assembly where various tuft types can be independently positioned and secured, simplifying the integration of diverse components into a unified brush head structure
3Adaptability or versatility
If fuse balls are formed at different levels in the cleaning element carrier, then the adaptability is improved for securing different tuft types, but the manufacturing precision deteriorates
Solution Approach 1:
The invention utilizes the vertical dimension (depth) in addition to horizontal positioning on the mold bar. By forming fuse balls at different levels (depths) within the cleaning element carrier material, the system gains an additional degree of freedom for securing different tuft types while the mold bar's structured holes maintain precise horizontal positioning and depth control
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 secure integration of diverse cleaning elements and bristle tufts with standardized fusing, enhancing the brush head's design flexibility to meet various consumer needs and ensure effective cleaning and comfort.
Implementation Method 1
forming fuse balls at the ends of the tufts by application of thermal energy from an energy source arranged at a predefined distance to the front surface
Implementation Method 2
the one or more fuse ball(s) of the one or more bristle tuft(s), are embedded in the material of the cleaning element carrier
Data Source
Figure 1A~1D
Figure 2A~2E
Figure 3a~3i
AI summary
A part (10) of a brush head, in particular a toothbrush head (12, 16) is disclosed comprising one or more bristle tuft(s) (20) each consisting of a plurality of bristle filaments (22) which are connected to each other via a fuse ball (24) and a cleaning element carrier (30), wherein the fuse ball(s) (24) are embedded in the material of the cleaning element carrier (30) in such that the one or more fuse ball(s) (24) are completely enclosed and the bristle filaments (22) protrude from the front surface (31) of the cleaning element carrier (30); wherein at least two fuse balls (24) are located at different levels in the cleaning element carrier (30). Further a brush head, in particular a toothbrush head (12, 16) is disclosed comprising a part (10) as disclosed herein.