U.S. patent application number 11/118182 was filed with the patent office on 2006-11-02 for brush with stapled tufts.
This patent application is currently assigned to Accurate Wire, Inc.. Invention is credited to Douglas J. Milheim, Michael J. O'Keeffe.
Application Number | 20060242779 11/118182 |
Document ID | / |
Family ID | 37215254 |
Filed Date | 2006-11-02 |
United States Patent
Application |
20060242779 |
Kind Code |
A1 |
Milheim; Douglas J. ; et
al. |
November 2, 2006 |
Brush with stapled tufts
Abstract
A bristle brush has a head with a multiplicity of closely spaced
recesses in one surface thereof and in which are disposed bristle
tufts of U-shaped configuration which extend outwardly thereof. The
tufts are comprised of multiple bristles and have a bight portion
disposed adjacent the bottom of the recesses and vertically
extending leg portions. Staples are disposed between the leg
portions of the tufts and pressing the bight portions downwardly in
the recesses. The staples have a body portion of generally
rectangular cross section and of greater length than the diameter
of the recesses. A multiplicity of ribs are provided on at least
one side surface and extend transversely thereof. The ribs are
spaced apart in the vertical direction a distance at least three
times the width of the ribs, and the ribs are of substantially
lesser height than the thickness of the body portion. At least some
of the ribs are embedded in the material of the head about the
recesses.
Inventors: |
Milheim; Douglas J.;
(Guilford, CT) ; O'Keeffe; Michael J.; (Windsor,
CT) |
Correspondence
Address: |
PEPE & HAZARD, LLP
225 ASYLUM ST.
HARTFORD
CT
06103
US
|
Assignee: |
Accurate Wire, Inc.
|
Family ID: |
37215254 |
Appl. No.: |
11/118182 |
Filed: |
April 28, 2005 |
Current U.S.
Class: |
15/195 ; 15/190;
300/21 |
Current CPC
Class: |
A46B 3/16 20130101 |
Class at
Publication: |
015/195 ;
300/021; 015/190 |
International
Class: |
A46B 3/16 20060101
A46B003/16 |
Claims
1. A bristle brush comprising: (a) a head having a multiplicity of
closely spaced recesses in one surface thereof; (b) bristle tufts
of U-shaped configuration disposed in said recesses and extending
outwardly thereof, each of said tufts being comprised of multiple
bristles having a bight portion disposed adjacent the bottom of the
recesses and vertically extending leg portions; and (c) staples
disposed between the leg portions of the tufts and pressing said
bight portions downwardly in said recesses, said staples having a
body portion of generally rectangular cross section of greater
length than the diameter of said recesses and having a multiplicity
of ribs on at least one side surface which extend transversely
thereof, said ribs being spaced apart in the vertical direction a
distance at least three times the width of said ribs, said ribs
being of substantially lesser height than the thickness of said
body portion, at least some of said ribs being embedded in the
material of said head about said recesses.
2. The bristle brush in accordance with claim 1 wherein said ribs
are provided on both side surfaces of said staples.
3. The bristle brush in accordance with claim 1 wherein said ribs
are of generally arcuate cross section.
4. The bristle brush in accordance with claim 3 wherein said
arcuate cross section of said ribs is semicylindrical.
5. The bristle brush in accordance with claim 1 wherein said
recesses are of circular cross section.
6. A bristle brush comprising: (a) a head having a multiplicity of
closely spaced circular recesses in one surface thereof; (b)
bristle tufts of U-shaped configuration disposed in said recesses
and extending outwardly thereof, each of said tufts being comprised
of multiple bristles having a bight portion disposed adjacent the
bottom of the recesses and vertically extending leg portions; and
(c) staples disposed between the leg portions of the tufts and
pressing said bight portions downwardly in said recesses, said
staples having a body portion of generally rectangular cross
section and of greater length than the diameter of said recesses
and having a multiplicity of ribs of generally arcuate cross
section which extend transversely thereof on both side surfaces
thereof, said ribs being spaced apart in the vertical direction a
distance at least three times the width of said ribs, said ribs
being of substantially lesser height than the thickness of said
body portion, at least some of said ribs being embedded in the
material of said head about said recesses.
7. In a method for making a bristle brush, the steps comprising:
(a) forming a brush head with a multiplicity of closely spaced
recesses in one surface thereof; (b) inserting bristle tufts of a
U-shaped configuration into said recesses, said tufts each being
comprised of multiple bristles having a bight portion and
vertically extending leg portions; and (c) driving staples between
said tuft leg portions against said bight portions to press said
bight portions of said tufts against the bottom of said recesses,
said staples having a body portion of generally rectangular cross
section and of greater length than the diameter of said recesses
and having a multiplicity of ribs extending transversely of at
least one side surface thereof, said ribs being spaced apart in the
vertical direction a distance at least three times the width of
said ribs, said ribs being of substantially lesser height than the
thickness of said body portion, at least some of said ribs being
embedded in the material of said head about said recesses.
8. The method for making bristle brushes in accordance with claim 7
wherein said tufts and staples are assembled prior to insertion
into said recesses.
9. The method for making bristle brushes in accordance with claim 7
wherein said ribs are provided on both side surfaces of said
staples.
10. The method for making bristle brushes in accordance with claim
7 wherein said ribs are of generally arcuate cross section.
11. The method for making bristle brushes in accordance with claim
10 wherein said arcuate cross section of said ribs is
semicylindrical.
12. The method for making bristle brushes in accordance with claim
7 wherein said recesses are of circular cross section.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to brushes and, more
particularly, to brushes using an improved staple to secure the
bristle tufts in recesses in the head of the brush.
[0002] Brushes are used in many applications for seemingly
countless tasks. In come cases, brushes are designed for specific
applications, such as toothbrushes for dental hygiene. Other
brushes have more generic uses, such as a typical scrub brush.
Brushes typically utilize a multiplicity of bristles bunched
together to form a tuft. The tufts are anchored in tuft holes
located in the brush head. Typically, numerous tufts/tuft holes are
located on the brush head and the number and locations vary
depending upon the design. In many cases, a staple is used to
anchor the tuft into the tuft holes on the brush head.
[0003] A common practice is to use a flat or rectangular piece of
wire cut to a specified length as the staple. The tuft is wrapped
around the staple in a U-shape, and then the staple and tuft are
driven into the tuft hole. They are held in place by the mechanical
resistance between the staple and brush head and the staples are
typically made slightly longer than the tuft hole to ensure that
the staple can be anchored in the brush head securely. The flat or
rectangular wire used to produce these staples is typically
provided in long lengths, packaged on spools, and cut to the
desired lengths during the manufacture of the brushes. Exemplary of
such staples are those illustrated in Leigh U.S. Pat. No.
3,871,048, Klee U.S. Pat. No. 5,724,697 and Fassler U.S. Pat. No.
5,740,579.
[0004] Generally, the staples have a relatively large surface area
and thereby cost because of the amount of metal employed.
[0005] It is an object of the present invention to provide a brush
with a novel staple having a cross section of relatively small
cross area and which exhibits good holding power.
[0006] It is also an object to provide a method for making brushes
using staples with the novel cross section.
[0007] Another object is to provide such a brush and method in
which the staple is of relatively lower cost and easy to
fabricate.
SUMMARY OF THE INVENTION
[0008] It has now been found that the foregoing and related objects
may be readily attained in a bristle brush comprising a head having
a multiplicity of closely spaced recesses in one surface thereof,
and bristle tufts of U-shaped configuration disposed in the
recesses and extending outwardly thereof. Each of the tufts is
comprised of multiple bristles and has a bight portion disposed
adjacent the bottom of the recesses and vertically extending leg
portions. Staples are disposed between the leg portions of the
tufts and press the bight portions downwardly in the recesses. The
staples have a body portion of generally rectangular cross section
and of greater length than the diameter of the recesses and a
multiplicity of ribs on at least one side surface. The ribs extend
transversely of the side surface and are spaced apart in the
vertical direction a distance at least three times the width of the
ribs. The ribs are of substantially lesser height than the
thickness of the body portion and at least some of the ribs are
embedded in the material of the head about the recesses.
[0009] Preferably, the ribs are provided on both side surfaces of
the staples, the ribs are of generally arcuate cross section, and
desirably semicylindrical. The recesses in the brush head are of
generally circular cross section.
[0010] In making the bristle brush, a brush head is formed with a
multiplicity of closely spaced recesses, in one surface thereof,
and bristle tufts of a U-shaped configuration are inserted into the
recesses, the tufts are comprised of multiple bristles and having a
bight portion and vertically extending leg portions. Staples are
disposed between the tuft leg portions and driven against the bight
portions to press the bight portions of the tufts against the
bottom of the recesses. The staples have a body portion of
generally rectangular cross section and of greater length than the
diameter of the recesses, and a multiplicity of ribs extend
transversely thereof. The ribs are spaced apart in the vertical
direction a distance at least three times the width of the ribs,
and the ribs are of substantially lesser height than the thickness
of the body portion. At least some of the ribs are embedded in the
material of the head about the recesses.
[0011] Desirably the tufts and staples are assembled prior to
insertion into the recesses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a brush embodying the
present invention;
[0013] FIG. 2 is a perspective view of a coil of staple wire
employed in the present invention with the free end projecting
therefrom to an enlarged size;
[0014] FIG. 3 is an enlarged plan view of the staple used in the
brushes of the present invention;
[0015] FIG. 4 is a schematic view of the staple being inserted into
the folded tuft of bristles;
[0016] FIG. 5 is a schematic view of the staple and bristle tufts
being pushed into the circular recesses in the brush head to lock
the tufts in the recesses; and
[0017] FIG. 6 is a cross sectional view of the staple drawn to an
enlarged scale.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Turning first to FIG. 1, therein shown is a tooth brush
employing the present invention and comprising a head 10 and a
handle or grip 12. Seated in recesses (seen in FIGS. 4 and 5) in
the head 10 are tufts generally designated by the numeral 14 and
comprised of a multiplicity of bristles 16.
[0019] Turning next to FIGS. 2-4, therein illustrated is a staple
embodying the present invention and generally designated by the
numeral 18. The coil 20 of staple wire is cut into short segments
to provide the staple 18 which has a body portion 22 of generally
rectangular cross section with semi-cylindrical ribs 24 on both
side surfaces thereof. The semi-cylindrical ribs 24 are spaced
apart on centers a distance X and have a diameter Y at their base
which is less than the thickness Z of the body portion as best seen
in FIG. 6.
[0020] FIGS. 4 and 5 illustrate diagrammatically the method of
assembling the tufts and staple into the brush head 10 which has a
multiplicity of cylindrical recesses 26 formed therein with a
diameter A. A staple 18 having a length B (dimension shown in FIG.
6) which is slightly greater than the diameter A of the recess 26
is inserted into a bundle or tuft 14 to fold the tuft into a
generally U-shaped configuration with a pair of leg portions 28 and
a bight portion 30. The assembly of tuft 14 and staple 18 is moved
by a mandrel (not shown) into the recess 26 to press the bight
portion 30 of the tufts towards the base of the recess 26. Because
the staple 18 has a length greater than the diameter of the recess
26, the staple 18 is pressed into the material of the head 10, and
the tuft 14 and staple 18 are thus firmly secured in the recess
26.
[0021] As will be readily appreciated, the staple may have ribs on
one or both side surfaces and the ribs may have a cross section
other than semi-cylindrical such as triangular or rectangular. At
least two ribs, and preferably four, are provided on each side
surface, and they are spaced apart a distance much greater (than at
least three times) the thickness of the body portion of the staple
so as to add only a small amount to the cross sectional area of the
body portion. Although the recesses in the head may have a cross
section other than circular, generally cylindrical recesses are
easy to form and firmly seat the tufts and staples.
[0022] The brush heads are typically made of synthetic resin and
the recesses can be formed in the molding operation or in a
subsequent drilling operation. Although wood may also be employed,
synthetic resin provides more secure retention of the tufts.
[0023] A staple of approximately 0.010''.times.0.060'' is typical
for most toothbrush applications. The ribbed wire design shown in
FIGS. 2-4 has an overall thickness (including the ridges) of
0.0100'', and a width of 0.060''. There are four ribs extending
longitudinally on each side surface of the body portion of the
wire. Each rib has a height (Z) of 0.001'' and a width (Y) of
0.002''--essentially a half round shape with a radius of
0.001''.
[0024] In the ribbed staple shown in FIGS. 2-6, there is a 17.9%
decrease in cross sectional area as compared to the standard
rectangular flat wire staple with dimensions of
0.010''.times.0.060'' as seen from the following calculations:
[0025] Standard 0.010''.times.0.060'' flat staple area:
0.010''.times.0.060''=0.0006 sq in. [0026] Ribbed staple example
base dimensions: 0.008''.times.0.060''=0.00048 sq in. [0027] Rib
area: 4.times.(3.14159.times.((0.001'') 2))=0.0000126 sq in. [0028]
Total area: 0.00048 sq in+0.0000126 sq in=0.0004926 sq in. [0029] %
reduction in area: ((0.0006 sq in)-(0.0004926 sq. in))/0.0006 sq
in=0.179 sq in. [0030] 17.9%
[0031] For any individual brush application, the same length of
wire staple would be needed when producing staples from both the
standard flat wire and the ribbed wire. The advantage lies in the
ribbed wire having a smaller cross sectional area. Based on the
example 0.010''.times.0.060'' wire listed above, using ribbed wire
would yield a savings in staple wire cross sectional area of
17.9%.
[0032] The staples of the present invention are easily formed from
round wire stock which is flattened and then drawn through roller
dies which form the ribs. The formed staple wire is then cut to the
desired length in a tufting machine and automatically assembled
with the bristle tufts and driven into the tuft holes in the brush
by an anvil or platen.
[0033] The metal utilized for the staples will depend upon factors
such as cost, use of fabrication, corrosion resistance, etc. Widely
employed alloys are those of copper, nickel and zinc.
[0034] Thus, it can be seen from the foregoing detailed
specification and attached drawings that brushes can be readily
fabricated with bristle tufts being firmly secured in holes in the
brush head by relatively low cost staples which can be readily
fabricated.
* * * * *