PTt: a revolution in anchorless brushmaking [30/09/2016]
PTt: a revolution in anchorless brushmaking
In the spring of this year, 16 years after the AFT technology, Boucherie presented the PTt technology at the occasion of the Interbrush show in Freiburg. So many years ago, AFT was the first commercially available anchorless technology on the market, and it successfully opened up a multitude of options for new toothbrush designs.
With the new PTt technology, the manufacturing of anchorless toothbrushes becomes simpler, and offers an even wider range of design options and manufacturing advantages. The way the technology fixes the tufts in the brush head is totally different from anything else :
1./ filaments are end-rounded and arranged in a tuft pattern
2./ the individual filaments are melted together to form tufts that have a mushroom shaped end
3./ the tufts are inserted in pre-cored holes of a toothbrush handle.
4./ By applying pressure ( P) and heat ( T) during a certain time ( t), the surface of the brush head shapes itself to enclose the mushroom-shaped ends of the tufts, holding them firmly.
The MANUFACTURING advantages are important :
Just like a conventional toothbrush machine, the PTt works with standard toothbrush handles with precored holes. There is only one mold, and there is only one handle component to process.
There is no welding, clicking or assembly as is the case with head plate technology
PTt works with pre-cut filament pucks. A fibrebox with in-line end rounding feature ensures excellent product quality for each filament type.
Any kind of filament, with no special coatings, and in any packaging, can be processed with the AFT style tuft picking technology, using integrated pre-endrounding.
Tuft fusing is possible by means of radiation heat, with no contact between die and filaments.
The PTt is available as a manually loaded machine, or with all possible automation to reduce operator labour to a minimum. Depending on the number of stations and the exact configuration, there are PTt machines available with outputs from 22 up to 48 brushes per minute.
The product DESIGN advantages are more than substantial :
Next to simplifying the manufacturing process, the revolutionary PTt anchorless technology brings entirely new design possibilities :
Because there are no head plates and no anchors, the PTt technology allows a very narrow space between the tufts and the edge of the head
TPE ( “rubber”) cleaning elements between the tufts, on the outside or on the back of the head ( tongue cleaner), are possible.
The widest range of handle materials can be used, including transparent materials.
Angled tufts are possible, in length-, width or a combined direction
The toothbrush head can be very thin, typically at least one millimeter thinner than a conventional toothbrush, which makes for a very ergonomic toothbrush head.
The tuft topography can be complex, with extreme length differences, without any additional complexity or cost. There are no hard to maintain profiled trimming devices, there are no spreading systems.
Tufts of the most varied sizes and shapes can be combined.
The product QUALITY advantages are convincing :
Excellent and consistent tuft retention
No voids in the head, the handle material is tightly hugging the filaments, with no voids as in the case of plate technology.
Pre-endrounding system integrated in the fibrebox, just like on the well-known and proven AFT machine : pre-cut filaments are put in the fibrebox of the machine, automatically or manually, after which they are end-rounded before being picked and tufted.
A 5-colour fibrebox allows to use a wide variety of bristle types in the product, and each filament type has its own end-rounding device. In other words, the end-rounding process can be optimized depending upon thickness, texture and/or colour of the filaments. All bristles of the same type are end-rounded in the same conditions, so that all bristle tips will later show an identical end-rounding quality, no matter where they are inserted in the brush.
Innovation Award at the 58th FEIBP Congress in Edinburgh, Scotland : Presented as Boucherie’s most recent technological innovation for the production of anchorless brushes, the participants to the congress elected the PTt technology as the winner of the Innovation Award.
When it comes to top quality products of the highest sophistication, there is simply no comparison. There is only Boucherie PTt.