Two-Mold System for High-Speed Bristle Tuft Compression
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Solution Overview
Problem
At high conveying speeds, individual bristles in brush tufts can become compressed and fail to fully enter mold perforations, leading to reduced or insufficient bristle filling in brushes.
Innovation Solution
A two-mold system where bristles are initially filled into a first mold with larger perforations, allowing loose filling and easy gas flow, then transferred to a second mold with narrower openings for compression, ensuring complete tuft insertion and preventing bristle loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high conveying speed is used to increase productivity, then the bristles become compressed and fail to fully enter mold perforations, but if low conveying speed is used, then productivity decreases
Solution Approach 1:
The mold is divided into two separate molds: a first mold with larger perforations for receiving bristle tufts at high speed, and a second mold with narrower perforations for compacting the tufts. This segmentation allows each mold to perform its specific function optimally without compromise.
Solution Approach 2:
The first mold performs preliminary action by receiving and temporarily holding the bristle tufts in a loose state before compaction. This preliminary reception at larger perforations enables high-speed conveying without compromising filling completeness.
2Manufacturing precision
If narrow perforations are used to compact bristles, then filling density improves, but conveying gas flow is blocked and bristle delivery is impeded
Solution Approach 1:
The compaction function is separated from the reception function by using two distinct molds. The first mold with larger perforations maintains open gas flow for high-speed conveying, while the second mold with narrower perforations provides compaction density.
Solution Approach 2:
The two-mold system enables continuous useful action by maintaining gas flow continuity through the first mold while achieving compaction in the second mold. The process flows continuously from reception to compaction without interruption.
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
Significantly increases the degree of bristle filling in brushes to about 70%, ensuring complete tuft delivery and preventing bristle protrusion, as demonstrated by the method and device described.
Implementation Method 1
with the aid of a gas or air stream, transported through supply lines leading to each perforation to be filled and introduced into the perforations of the form
Data Source
Figure 1
Figure 2~5
Figure 3~6
AI summary
The method involves forming bristle bunch (4) with multiple bristles. The bristle bunch is filled in holes (2) of a mold (3), where cross-section of the mold is greater than the cross-section of the bunch. Gas or is passed in the mold between the bristles until all the bristles are filled in the mold. The bunch is transferred from the mold to another mold (7) with narrow receiving openings to bring the bunch into a desired compressed form. The molds have hole patterns, which correspond to each other, at sides of the molds, where the sides face each other. An independent claim is also included for a device for making bristle zones for brush or bristle bundles of brush.