Ultrasonic Welding Bristled Component for Cosmetic Applicator
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Solution Overview
Problem
Current manufacturing methods for personal-care applicators, such as cosmetic brushes, are limited in flexibility and functionality, with restricted patterns and fiber densities due to material constraints, leading to high production costs and complexity, particularly in batch processing.
Innovation Solution
The use of ultrasonic welding to attach bristles to a carrier with varying angles and shapes, allowing for a wide range of functional configurations and patterns, including crisscross and tufted arrangements, enabling more flexible and efficient production of cosmetic applicators with diverse functionalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If twisted-wire brushes are used with limited fiber density variations, then the manufacturing process is simple, but the functional versatility and pattern variety are restricted
Solution Approach 1:
The brush is divided into discrete tufted bristle units that can be independently positioned and secured to the carrier, allowing varied fiber density patterns without complex wire twisting processes. Each tuft acts as an independent element that can be arranged in different configurations.
Solution Approach 2:
The traditional mechanical wire twisting and trimming process is replaced with a ultrasonic welding process that secures bristles directly to a carrier. This substitution eliminates the need for complex mechanical wire manipulation while achieving the desired bristle arrangement and density variations.
2Adaptability or versatility
If molding processes are used to create various brush patterns, then pattern variety is achieved, but manufacturing cost and prototyping difficulty increase
Solution Approach 1:
Instead of creating entire brush patterns through complex molding processes, the invention uses discrete bristle tufts that can be individually or in groups attached to a carrier. This segmentation allows for pattern variety through simple arrangement changes rather than expensive mold creation.
Solution Approach 2:
The carrier serves as a simple, inexpensive support structure that can be easily manufactured and modified. The bristle tufts act as replaceable elements that can be rearranged to create different brush patterns without requiring expensive mold investment, making prototyping cost-effective.
3Reliability
If batch processing is used for brush manufacturing, then quality control is easier, but production time and cost increase
Solution Approach 1:
The ultrasonic welding process enables continuous attachment of bristle tufts to the carrier as they pass through the welding zone, eliminating the need for stopping and starting between operations. This continuous processing maintains consistent quality while significantly increasing production speed compared to traditional batch methods.
Solution Approach 2:
The ultrasonic welding process inherently provides consistent welding results through controlled mechanical vibration and pressure, eliminating the need for extensive manual inspection and adjustment. The process self-regulates to maintain quality standards while operating at high speed, combining quality control with productivity.
4Strength
If traditional welding methods are used to attach bristles to carrier, then the attachment is secure, but the bristle angle and pattern flexibility are limited
Solution Approach 1:
The ultrasonic welding process dynamically adjusts welding parameters during the attachment process, allowing bristles to be secured at various angles and positions while maintaining strong attachment. The process can adapt to different bristle orientations and carrier configurations without compromising weld strength.
Solution Approach 2:
The ultrasonic welding process can change parameters such as vibration amplitude, pressure, and welding time to optimize attachment strength for different bristle angles and material combinations. This parameter flexibility enables secure attachment of bristles at any angle while maintaining pattern versatility.
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
This approach enhances the flexibility in producing various applicator designs and functionalities, reduces production costs, and improves product quality by enabling continuous manufacturing processes, allowing for a greater variety of bristle patterns and densities without the limitations of traditional methods.
Implementation Method 1
The bristles are ultrasonically welded to the carrier throughout the carrier's length so that a direct ultrasonic bond is formed between a surface of the carrier and a portion of each of the bristles
Data Source
AI summary
A bristled component for a cosmetic applicator comprising: an elongated carrier having a longitudinal axis; and at least a first plurality of bristles including at least one array of bristles ultrasonically welded to the carrier and outwardly extending therefrom according to a first pre-determined pattern, wherein the carrier and the bristles comprise ultrasonically compatible materials, and wherein the bristles are ultrasonically bonded to the carrier through a direct ultrasonic bond between a surface of the carrier and a lengthwise portion of each of the bristles. A process comprises wrapping a yarn around a moving endless band, juxtaposing a support strip with the band's edge, ultrasonically welding the yarn to the first support strip, removing the welded yarn and support strip from the band, and cutting the strip into a plurality of bristled components.