Classifications

• • A—HUMAN NECESSITIES
  • A46—BRUSHWARE
  • A46D—MANUFACTURE OF BRUSHES
  • A46D3/00—Preparing, i.e. Manufacturing brush bodies
  • A46D3/04—Machines for inserting or fixing bristles in bodies
  • A46D3/045—Machines for inserting or fixing bristles in bodies for fixing bristles by fusing or gluing to a body
• • A—HUMAN NECESSITIES
  • A46—BRUSHWARE
  • A46D—MANUFACTURE OF BRUSHES
  • A46D1/00—Bristles; Selection of materials for bristles
  • A46D1/04—Preparing bristles
  • A46D1/055—Combing; Mixing; Sorting
• • A—HUMAN NECESSITIES
  • A46—BRUSHWARE
  • A46D—MANUFACTURE OF BRUSHES
  • A46D1/00—Bristles; Selection of materials for bristles
  • A46D1/10—Vibrating devices for arranging bristles
• • A—HUMAN NECESSITIES
  • A46—BRUSHWARE
  • A46D—MANUFACTURE OF BRUSHES
  • A46D3/00—Preparing, i.e. Manufacturing brush bodies
  • A46D3/04—Machines for inserting or fixing bristles in bodies
• • A—HUMAN NECESSITIES
  • A46—BRUSHWARE
  • A46D—MANUFACTURE OF BRUSHES
  • A46D3/00—Preparing, i.e. Manufacturing brush bodies
  • A46D3/08—Parts of brush-making machines
  • A46D3/082—Magazines for bristles; Feeding bristles to magazines; Knot picking

Definitions

• the present invention generally relates to brush manufacturing.
• each brush module is generally smaller than 20 mm in length and width.
• the brush modules are either square or rectangular shaped. To effectively make contact with the filter surfaces, the modules are curved.
• the bristle tufts are required to be implanted in a matrix configuration.
• the various product families required different arrays. For example, there was a specification for a product with 5 rows and 4 columns with the pitch between bristle tufts less than 5 mm.
• the embodiments of the present disclosure provides a brush manufacturing machine comprising a rotary transportation mechanism; a bristle carrier loading station; one or more bristle dispensing station comprising a bristle feed mechanism, a bristle tuft picker, and a bristle plant feeder, that plants high-density and short length bristle tufts on a bristle carrier with fine pitch openings; an ultrasonic fusion station; a heating station; an unloading station; and a logic controller system for providing programmed commands, controlling the machine sequence and monitoring the feedback of operating conditions at every station through a network of sensors and actuators.
• embodiments of the present disclosure provides a system for manufacturing brushes comprising a rotary transportation mechanism; a bristle carrier loading station; one or more bristle dispensing station ; an ultrasonic fusion station; a heating station; an unloading station; a logic controller system for providing programmed commands, controlling the machine sequence and monitoring the feedback of operating conditions at every station through a network of sensors and actuators.
• FIG. 1A illustrates a schematic illustration of the present invention in accordance with an embodiment of the present disclosure
• FIG. IB illustrates an example of a bristle carrier in accordance with an exemplary implementation of the present disclosure
• FIG. 2A illustrates an example of a bristle feed mechanism in accordance with an exemplary implementation of the present disclosure
• FIG. 2B illustrates an example of a bristle turf picker in accordance with an exemplary implementation of the present disclosure
• FIG. 2C illustrates an example of a nozzle in accordance with an exemplary implementation of the present disclosure
• FIG. 2D illustrates an example of a cross-sectional view of a blower and suction system in accordance with an exemplary implementation of the present disclosure
• FIG. 3 illustrates an example of an ultrasonic device in accordance with an exemplary implementation of the present disclosure.
• the embodiment of the present disclosure provides a brush manufacturing machine (100) comprising a rotary transportation mechanism (160); a bristle carrier loading station (110); one or more bristle dispensing station (120a-d) comprising a bristle feed mechanism (200), a bristle tuft picker (240), and a bristle plant feeder (250), that plants high- density and short length bristle tufts on a bristle carrier (170) with fine pitch openings; an ultrasonic fusion station (130); a heating station (140); an unloading station (150); and a logic controller system for providing programmed commands, controlling the machine sequence and monitoring the feedback of operating conditions at every station through a network of sensors and actuators.
• a brush manufacturing machine comprising a rotary transportation mechanism (160); a bristle carrier loading station (110); one or more bristle dispensing station (120a-d) comprising a bristle feed mechanism (200), a bristle tuft picker (240), and a bristle
• the brush manufacturing machine (100) further comprising a network of sensors and actuators controlled by the logic controller system that enables a pre-programmed sequence of processing steps.
• the stations (110, 120a-d, 130-150) of the brush manufacturing machine (100) are linked by a rotary transportation mechanism (160) that stops at each station.
• the rotary transportation mechanism (160) is preferably a turntable.
• station 1 is the bristle carrier loading station (110)
• station 2 is the bristle dispensing station (120a-d)
• station 3 is the ultrasonic welding station (130) to seal the bristle carrier openings (172)
• station 4 is the heating station (140) to securely fasten the bristle tuft to the bristle carrier (170)
• station 5 is the unloading station (150).
• a plurality of bristle dispensing stations (120a-d) can be present to dispense bristles to the various rows and columns of the bristle carrier openings (172).
• the number of bristle dispensing stations ( 120a-d) is based on the configuration of rows and columns of the bristle carrier openings (172). In an exemplary embodiment of this machine, there are four bristle dispensing stations (120a-d).
• the bristle carrier loading station (110) comprises a vibrating feeder bowl, an orientation check feature, a gripper arm having a presence sensor that controls the movement of the gripper arm.
• the vibration of the vibrating feeder bowl is provided by a rotary vibrating exciter.
• Bristle carriers (170) are loaded into the vibrating feeder bowl.
• the vibration causes the bristle carriers (170) to move in an upward spiral until the bristle carriers (170) are oriented correctly and transported along a track to the bristle carrier loading station (110) for pick-up.
• An orientation check feature ensures the bristle carrier is oriented correctly for the pick-and-place unit.
• the bristle dispensing station (120a-d) comprises a bristle feed mechanism (200) together with a bristle tuft picker (240), and a bristle plant feeder (250). Further, the bristle feed mechanism (200) comprises a magazine (210) for the bristle tufts, having a vertical compression plate (230) and a horizontal compression plate (220) controlled by a solenoid valve and reed switch.
• the bristle tufts are manually loaded into a magazine (210).
• the vertical compression plate (230) is designed to move in a vertical direction, to ensure the bristles are levelled to the same height.
• the horizontal compression plate (220) pushes the bristles in a horizontal direction towards the bristle tuft picker (240).
• the simultaneous dual compression motion is to continuously feed an equal number of bristle tufts into the bristle tuft picker (240).
• the bristles were pre-cut to a specific length and supplied in the required density.
• the bristle tuft picker (240) comprises a picker plate (241) with a picker face (242) with one or more through holes (244) with dimensions consistent with the through holes of the bristle carrier openings (172).
• the shape of the through holes (244) are semi-circular, but are not limited to such.
• a sensor is used to detect the bristle tufts in all the through holes (244) of the picker plate.
• a control mechanism slides the picker plate (241) and the horizontal compression plate (220) into a clamping position. The bristle tufts are clamped at the top and bottom to prevent the bristle tuft from entering into the transport line (270).
• the bristle plant feeder (250) comprises a conically shaped nozzle (252).
• the conically shaped nozzle (252) embodies a first opening (254), and a second opening (256), where the diameter of the first opening (254) is larger than the diameter of the second opening (256).
• the first opening (254) of the conically shaped nozzle (252) receives a distal end of a transport line (270).
• the conically shaped nozzle (252) receives the bristle tufts through the transport line (270) through the first opening (254) to the second opening (256) via a blower and suction system (260). Where the diameter of the second opening (256) is smaller than the diameter of the through holes of the bristle carrier openings (172).
• the conically shaped nozzle (252) enables fine pitch dispensing of the bristle tufts allowing for acute angles due to the curved profile of the bristle carrier (170).
• the stopper at the distal end of the conically shaped nozzle (252) is retracted.
• the conically shaped nozzle (252) moves in a vertical motion towards the bristle carrier (170). It is set to stop just above each bristle carrier opening (172).
• the distance between the conically shaped nozzle (252) and the bristle carrier opening (172) can be less than 5 mm.
• Each conically shaped nozzle (252) is uniquely placed and directed at specific angles of the targeted bristle carrier opening (172).
• the activation of the high-pressure blower and the vacuum suction transports the bristle tufts through the transport line (270) into the bristle plant feeder (250).
• the bristle plant feeder (250) Within the bristle plant feeder (250), the push of the high-pressure blower, and the pull of the vacuum suction, plants the bristle tufts in each bristle carrier opening (172).
• the bristle plant feeder (250) moves in a vertical motion away from the bristle carrier.
• the low-pressure blower is activated.
• the suction from the vacuum chamber pulls down the bristle tufts, while a second pressure is applied through the bristle plant feeder (250).
• the second pressure is lower than the first pressure. This pressure maintains the bristle tufts at the bristle carrier openings (172) and prevents the bristle tufts from plugging the cone feeder as it is retracted.
• the blower and suction system (260) comprises a high-pressure blower, a low-pressure blower, a vacuum suction, transport lines (270) with the conically shaped nozzle (252) at the distal end, and a stopper.
• transport lines (270) with the conically shaped nozzle (252) at the distal end, and a stopper.
• the placement of the bristle carrier (170) at the bristle plant feeder (250) triggers a presence sensor. When the bristle carrier (170) is detected, the stopper is removed and the bristle plant feeder (250) moves vertically towards the bristle carrier (170).
• the high-pressure blower, the low-pressure blower and the vacuum suction are deactivated.
• the stopper is then extended at the distal end of the transport line (270). The timing and pressure settings for the high-pressure blower, low-pressure blower and the vacuum suction ensures the bristle tufts are transported and retained within the openings of the bristle carrier opening (172).
• the blower and suction system (260) is managed by the logic controller system.
• the logic controller system varies the pressure difference applied on the bristle tuffs.
• the pressure difference is varied by monitoring and varying the blower and suction pressure.
• the monitoring and timing of the sequence of activation and deactivation between the blower and suction is managed by the logic controller system to feed the bristle tufts through the conically shaped nozzle (252) and transport line (270), and to provide the required pressure difference to hold the bristle turfs in the bristle carrier openings (172) after planting, when deactivating the blower and suction system (260). With the bristle turfs retained in the bristle carrier openings (172), the bristle carrier (170) is transported to the next station.
• the ultrasonic fusion station (130) comprises a power supply, a vibrator, a transducer, and an ultrasonic horn (132).
• the ultrasonic horn (132) is preferably shaped to match the bristle carrier (170) profile and dimensions.
• the ultrasonic horn (132) When the ultrasonic horn (132) is pressed against the bristle carrier (170), it transfers energy to the energy director (174) features on the bristle carriers (170).
• the concentrated energy enables the material of the energy director (174) to melt and flow into the bristle carrier openings (172).
• the material of the energy director (174) will completely fill the bristle carrier openings (172) when the process is optimised.
• the desired outcome from this process is to seal the bristle carrier openings (172) from the distal end and retain the bristle tufts in the bristle carrier (170).
• the heating station (140) comprises a heating controller, and a heating element having a heating plate shaped to match the bristle carrier (170) profile and dimensions.
• the objective of the heating station is to increase the bristle retention strength. This is achieved by melting the distal end of the bristle tufts, resulting in the bristle tuft material forming a thickened end. This enables the bristle tufts to be securely embedded within the sealed bristle carrier openings (172).
• the post- heated bristle tuft in the bristle carrier (170) has high retention strength.
• the unloading station (150) comprises a presence sensor and a pick-and-place gripper.
• the bristle carrier (170) is detected by the presence sensor at the unloading station (150), the bristle carrier (170) filled with bristles are taken out for assembly.
• a system for manufacturing brushes comprising a rotary transportation mechanism (160); a bristle carrier loading station (110); one or more bristle dispensing station (120a-d); an ultrasonic fusion station (130); a heating station (140); an unloading station (150); a logic controller system for providing programmed commands, controlling the machine sequence and monitoring the feedback of operating conditions at every station through a network of sensors and actuators.
• the system for manufacturing brushes (100) further comprising a network of sensors and actuators controlled by the logic controller system that enables a pre-programmed sequence of processing steps.

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• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Brushes (AREA)
• Manufacture Of Motors, Generators (AREA)

Priority Applications (4)

Applications Claiming Priority (2)

Publications (1)

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Citations (6)

• 2022
  • 2022-03-11 CN CN202280014068.8A patent/CN116887720A/zh active Pending
  • 2022-03-11 JP JP2023557759A patent/JP2024511403A/ja active Pending
  • 2022-03-11 WO PCT/MY2022/050016 patent/WO2022197176A1/en active Application Filing
  • 2022-03-11 GB GB2311854.0A patent/GB2618260A/en active Pending
  • 2022-03-11 US US18/278,815 patent/US20240130515A1/en active Pending

Patent Citations (6)

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