CN116887720A

CN116887720A - Brush manufacturing machine

Info

Publication number: CN116887720A
Application number: CN202280014068.8A
Authority: CN
Inventors: 李福源
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-03-17
Filing date: 2022-03-11
Publication date: 2023-10-13
Also published as: JP2024511403A; GB2618260A; WO2022197176A1; GB202311854D0

Abstract

Embodiments of the present invention provide a brush making machine (100) that includes a rotary transport mechanism (160); a bristle carrier loading station (110); one or more bristle dispensing stations (120 a-d) comprising a bristle feeding mechanism (200), bristle tuft pickers (240), bristle planting feeders (250) for planting high density and short length bristle tufts on bristle carriers (170) having fine-pitch openings; an ultrasound fusion station (130); a heating station (140); an unloading station (150); and a logic control system for providing programming instructions, controlling the process sequence, and monitoring feedback of the operating conditions at each station through a network of sensors and actuators.

Description

Brush manufacturing machine

Technical Field

The present invention relates generally to brush manufacture.

Background

This section is merely intended to provide background information in the general field of the invention and is merely used to enhance the understanding of the invention and is not an admission that it is prior art.

Currently, there is a continuing need to produce unique types of brushes for specific cleaning purposes. These brushes are required to have different shapes and sizes for different and specific applications. There is a need for a special clean production modular brush for filter screens. The filter screen may be made of metal, plastic or fabric.

Because of the unique shape of these filters, the brushes need to be modular pieces that fit together to form a single brush product. The size of each brush module is generally less than 20mm in length and width. The brush module is square or rectangular. The modules are arcuate for effective contact with the filter surface.

In order to effectively clean the interstices of the filter mesh, it is necessary to implant the bristle tufts in a matrix configuration. Multiple product families require different arrays. For example, there are product specifications having 5 rows and 4 columns of bristle tufts with spacing between them of less than 5mm.

Based on the above-mentioned requirements, there is a need for manufacturing brush products in a cost-effective and feasible manner. The manufacturing process must produce rated brush modules on delivery days with short turn-around times, minimal raw material waste in production, and reduced defects. However, there is no commercially available machine for producing this particular series of brush products.

Accordingly, in view of the foregoing discussion, there is a need to overcome the limitations in brush manufacture described above.

Disclosure of Invention

The limitations of existing brush makers in view of the above increase throughput by reducing waiting time between processes, reducing raw material wastage, and minimizing process defects.

In one aspect, embodiments of the present invention provide a brush making machine that includes a rotary transport mechanism; a bristle carrier loading station; one or more bristle dispensing stations comprising a bristle feeding mechanism, a bristle tuft pick-up, and a bristle planting dispenser for planting high density and short length bristle tufts on bristle carriers having closely spaced openings; an ultrasonic fusion station; a heating station; an unloading station; and a logic control system for providing programming instructions, controlling the process sequence, and monitoring feedback of the operating conditions at each station through a network of sensors and actuators.

In another aspect, embodiments of the present invention provide a system for manufacturing a brush, comprising: a rotary conveying mechanism; a bristle carrier loading station; one or more bristle dispensing stations; an ultrasonic fusion station; a heating station; an unloading station; and a logic control system for providing programming instructions, controlling the process sequence, and monitoring feedback of the operating conditions at each station through a network of sensors and actuators.

Drawings

The views mentioned herein disclose example embodiments of the claimed invention. Detailed descriptions and preparations of well-known components/substances/elements are omitted so as not to unnecessarily obscure the embodiments herein. Other objects, features and advantages of the present invention will become apparent from the following description when read in conjunction with the accompanying drawings.

FIG. 1A shows a schematic diagram of the present invention according to an embodiment of the present invention;

fig. 1B illustrates an example of a bristle carrier according to an exemplary embodiment of the present invention;

fig. 2A shows an example of a bristle feeding mechanism according to an example implementation of the present invention;

FIG. 2B illustrates an example of a bristle tuft pickup according to an example embodiment of the invention;

FIG. 2C illustrates an example of a nozzle in accordance with an example implementation of the present invention;

FIG. 2D illustrates an example of a cross-sectional view of a blowing and suction system in accordance with an example implementation of the present invention;

fig. 3 shows an example of an ultrasound device according to an example implementation of the invention.

Detailed Description

This section is intended to provide an illustration and description of various possible embodiments of the invention. The embodiments used herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. The examples used herein are intended merely to aid in understanding the manner in which the embodiments may be practiced and to enable those of skill in the art to practice the embodiments used herein. Furthermore, the examples/embodiments described herein should not be construed as limiting the scope of the embodiments herein.

Referring to fig. 1, an embodiment of the present invention provides a brush maker 100 that includes a rotary transport mechanism 160; a bristle carrier loading station 110; one or more bristle dispensing stations 120a-d including a bristle feeding mechanism 200, a bristle tuft picker 240, and a bristle planting dispenser 250 for planting high density and short length bristle tufts on bristle carriers 170 having fine-spaced openings; an ultrasound fusion station 130; a heating station 140; an unloading station 150; and a logic control system for providing programming instructions, controlling the process sequence, and monitoring feedback of the operating conditions at each station through a network of sensors and actuators.

The brush maker 100 also includes a network of sensors and actuators controlled by a logic control system that implements a preprogrammed sequence of process steps.

The stations 110, 120a-d, 130-150 of the brush making machine 100 are connected by a rotary conveyor 160 that stops at each station. The rotary transport mechanism 160 is preferably a turntable.

The movement of the rotary transport mechanism 160 is guided by a servo motor. Where station 1 is a bristle carrier loading station 110, station 2 is a bristle dispensing station 120a-d, station 3 is an ultrasonic welding station 130 for sealing bristle carrier openings 172, station 4 is a heating station 140 for securely securing bristle tufts to bristle carriers 170, and station 5 is an unloading station 150.

In addition, there may be multiple bristle dispensing stations 120a-d that dispense bristles into multiple rows and columns of bristle carrier openings 172. The number of bristle dispensing stations 120a-d is based on the configuration of the rows and columns of bristle carrier openings 172. In the exemplary embodiment of the machine, there are four bristle dispensing stations 120a-d.

The bristle carrier loading station 110 includes a vibratory hopper, a direction check device, a gripper arm with a presence sensor that controls movement of the gripper arm. Vibration of the vibratory hopper is provided by a rotational vibration exciter. The bristle carrier 170 is loaded into a vibratory hopper. The vibration causes the bristle carrier 170 to move in a spiral upward motion until the bristle carrier 170 is properly oriented and transported along the track to the bristle carrier loading station 110 for pick-up. The orientation checking means ensures that the bristle carrier is properly oriented for the pick-and-place unit. Once the presence sensor detects the bristle carrier 170, the clamp arm delivers the bristle carrier 170 to the rotating turntable. The second presence sensor drives rotation of the rotary transport mechanism 160.

Referring to fig. 2A-2D, the bristle dispensing stations 120a-D include a bristle feeding mechanism 200 with a bristle tuft picker 240, and a bristle planting dispenser 250. In addition, the bristle feeding mechanism 200 includes a magazine 210 for bristle tufts having a vertical platen 230 and a horizontal platen 220 controlled by solenoid valves and reed switches.

The bristle tufts are manually loaded into the cartridge 210. The vertical platen 230 is designed to move in a vertical direction to ensure that the bristles are flattened to the same height. The horizontal platen 220 pushes the bristles in a horizontal direction toward the bristle tuft picker 240. The synchronized dual compression motion is used to continuously supply the same number of bristle tufts into the bristle tuft picker 240. To minimize waste in production, bristles are precut to specific lengths and supplied at a desired density.

The bristle tuft picker 240 includes a pick plate 241, the pick plate 241 having a pick face 242, the pick face 242 having one or more through holes 244 sized to correspond with the through holes of the bristle holder openings 172. Preferably, the shape of the through hole 244 is semicircular, but is not limited thereto. In addition, a sensor is used to detect bristle tufts in all of the through holes 244 of the pick-up plate. Further, the control mechanism slides the pickup plate 241 and the horizontal platen 220 to the clamping position. The bristle tufts are clamped at the top and bottom to prevent the bristle tufts from entering the conveyor line 270.

In addition, as shown in fig. 2C, the bristle planting dispenser 250 includes a tapered nozzle 252. The tapered nozzle 252 includes a first opening 254 and a second opening 256, wherein the diameter of the first opening 254 is greater than the diameter of the second opening 256. The first opening 254 of the tapered nozzle 252 receives the distal end of the delivery wire 270. The tapered nozzle 252 receives bristle tufts through the first opening 254 to the second opening 256 via the blowing and suction system 260 via a conveyor line 270. Wherein the diameter of the second opening 256 is smaller than the diameter of the throughbore of the bristle holder opening 172.

The tapered nozzle 252 achieves a fine pitch distribution of bristle tufts that allows for an acute angle due to the arcuate profile of the bristle carrier 170. When the bristle carrier 170 is detected, the stop at the distal end of the tapered nozzle 252 retracts. The tapered nozzle 252 moves in a vertical motion toward the bristle carrier 170. Which is configured to stop directly above each bristle holder opening 172. In an exemplary embodiment, the distance between the tapered nozzle 252 and the bristle holder opening 172 can be less than 5mm. Each tapered nozzle 252 is uniquely positioned and oriented at a particular angle to the target bristle bearing opening 172. The activation of the high pressure blower and vacuum pump delivers bristle tufts through delivery line 270 into bristle planting dispenser 250. Within the bristle planting dispenser 250, the pushing of the high pressure blower and pulling of the vacuum pump planted bristle tufts in each bristle carrier opening 172. Once bristle tuft ejection is detected, the bristle planting dispenser 250 moves away from the bristle carrier in a vertical motion. The low pressure blower is activated before the bristle planting dispenser 250 is retracted. Suction from the vacuum chamber pulls the bristle tufts downward while a second pressure is applied by the bristle planting dispenser 250. The second pressure is less than the first pressure. This pressure holds the bristle tufts at the bristle carrier opening 172 and prevents the bristle tufts from clogging the cone feeder as they retract.

As shown in fig. 2D, the blower and suction system 260 includes a high pressure blower, a low pressure blower, a vacuum pump, a delivery line 270 having a tapered nozzle 252 at a distal end, and a stopper. In the illustrated embodiment, there are 4 conveyor lines 270 at the bristle dispensing stations 120a-d. The placement of the bristle carrier 170 at the bristle planting dispenser 250 triggers the presence sensor. When the bristle carrier 170 is detected, the stop is removed and the bristle planting dispenser 250 is moved vertically toward the bristle carrier 170. This creates a clear path from the bristle tufts at the bristle tuft picker 240 to the bristle carrier 170 at the end of the transfer line 270. The bristle tufts advance toward the bristle carrier 170 as a result of the activation of the high pressure blower and vacuum. Once the bristle tufts are discharged into the bristle carrier opening 172, the bristle planting dispenser 250 will move vertically upward toward its zero or rest position. To ensure that the bristle tufts remain in the bristle holder openings 172, the high pressure blower is turned off and the low pressure blower is turned on. When the bristle planting dispenser 250 is in the zero position, the high pressure blower, the low pressure blower, and the vacuum pump are turned off. The stop then protrudes at the distal end of the delivery wire 270. The timing and pressure settings of the high pressure blower, low pressure blower, and vacuum ensure that the bristle tufts are delivered and held within the openings of the bristle holder openings 172.

The blowing and suction system 260 is controlled by a logic control system. The logic control system varies the pressure differential applied to the bristle tufts. The pressure differential is varied by monitoring and varying the blowing and suction pressures. In addition, the monitoring and timing of the activation and deactivation sequence between the blower and extractor is controlled by the logic control system to supply bristle tufts through the tapered nozzle 252 and the delivery line 270 and to provide a desired pressure differential to retain the bristle tufts in the bristle carrier openings 172 after implantation when the blower and extractor system 260 is deactivated. With the bristle tufts held in the bristle holder openings 172, the bristle holders 170 are transported to the next station.

Referring to fig. 3, the ultrasonic fusion station 130 includes a power source, vibrator, transducer, and ultrasonic horn 132. The ultrasonic horn 132 is preferably shaped to match the contour and size of the bristle carrier 170. When the ultrasonic horn 132 is compressed against the bristle carrier 170, it delivers energy to the energy director 174 on the bristle carrier 170. The concentrated energy can cause the material of the energy directors 174 to melt and flow into the bristle holder openings 172. The material of the energy director 174 will completely fill the bristle holder opening 172 when the process is optimized. The desired result of this process is to seal the bristle holder opening 172 from the distal end and retain the bristle tufts in the bristle holder 170.

The heating station 140 includes a heating controller and a heating element having a heating plate shaped to match the contour and size of the bristle carrier 170. The purpose of the heating station is to increase bristle holding strength. This is accomplished by melting the distal end of the bristle tufts to form a thickened end of the bristle tuft material. This allows the bristle tufts to be securely embedded within the sealed bristle carrier opening 172. Post-heated bristle tufts in the bristle carrier 170 have a high holding strength.

The unloading station 150 includes a presence sensor and a pick-and-place gripper. When the bristle carrier 170 is detected at the unloading station 150 by the presence sensor, the bristle carrier 170 filled with bristles is removed for assembly.

In another embodiment, a system 100 for manufacturing brushes includes a rotary transport mechanism 160; a bristle carrier loading station 110; one or more bristle dispensing stations 120a-d; an ultrasound fusion station 130; a heating station 140; an unloading station 150; and a logic control system for providing programming instructions, controlling the process sequence, and monitoring feedback of the operating conditions at each station through a network of sensors and actuators. The system 100 for manufacturing brushes also includes a network of sensors and actuators controlled by a logic control system that implements a preprogrammed sequence of process steps.

It will be apparent to those skilled in the art that the present invention may be readily produced in other specific forms without departing from its essential ingredients and characteristics. The present embodiments are to be considered as merely illustrative and not restrictive, and the scope of the invention is indicated by the claims rather than by the foregoing description, and all changes which come within the range are therefore intended to be embraced therein.

Claims

1. A brush making machine, comprising:

a rotary conveying mechanism (160);

a bristle carrier loading station (110);

one or more bristle dispensing stations (120 a-d) comprising a bristle feeding mechanism (200), bristle tuft pickers (240), bristle planting feeders (250) for planting high density and short length bristle tufts on bristle carriers (170) having fine-pitch openings;

an ultrasound fusion station (130);

a heating station (140);

an unloading station (150); and

a logic control system for providing programming instructions, controlling the process sequence, and monitoring feedback of the operating conditions at each station through a network of sensors and actuators.

2. The brush making machine of claim 1, wherein the bristle carrier loading station (110) includes a vibratory hopper, a direction checking device, a gripping arm having a presence sensor that controls movement of the gripping arm.

3. The brush making machine of claim 1, wherein the bristle feed mechanism (200) includes a magazine (210) for the bristle tufts having a vertical platen (230) and a horizontal platen (220) controlled by solenoid valves and reed switches.

4. A brush making machine according to claims 1 and 3, wherein the bristle tuft picker (240) includes a pick-up plate (241), the pick-up plate (241) having a pick-up face (242), the pick-up face (242) having one or more through holes (244) of a size consistent with the through holes of the bristle carrier openings (172), the through holes (244) may be semi-circular in shape, but are not limited thereto.

5. A brush making machine according to claim 3, wherein the bristle planting dispenser (250) includes a conical nozzle (252).

6. The brush making machine according to claims 1 and 5, wherein the tapered nozzle (252) includes a first opening (254) and a second opening (256), wherein the first opening (254) has a diameter greater than a diameter of the second opening (256).

7. The brush making machine according to claims 1, 5 and 6, wherein the tapered nozzle (252) receives a distal end of a delivery wire (270) at the first opening (254).

8. The brush making machine according to claims 1, 5, 6 and 7, wherein the tapered nozzle (252) receives the bristle tufts through the first opening (254) to the second opening (256) via a blowing and suction system (260) through the conveyor line (270).

9. The brush making machine of claim 1, wherein the ultrasonic fusion station (130) includes an ultrasonic horn (132) shaped to match the contour and size of the bristle carrier (170).

10. The brush making machine of claim 1, wherein the heating station (140) comprises a heating element having a heating plate shaped to match the contour and dimensions of the bristle carrier (170).

11. The brush making machine of claim 1, wherein the unloading station (150) includes a presence sensor and a pick-and-place gripper.

12. The brush making machine according to any one of claims 1-11, comprising a network of sensors and actuators controlled by the logic control system implementing a preprogrammed sequence of process steps.

13. A system for manufacturing brushes, comprising:

a rotary conveying mechanism (160);

a bristle carrier loading station (110);

an ultrasound fusion station (130);

a heating station (140);

an unloading station (150); and

14. The system for manufacturing brushes of claim 13, comprising a network of sensors and actuators controlled by the logic control system implementing a preprogrammed sequence of process steps.