U.S. patent application number 11/509916 was filed with the patent office on 2008-02-28 for twisted-in-wire brush and method of manufacturing same.
This patent application is currently assigned to Brushtech, Inc.. Invention is credited to Armen G. Gunjian.
Application Number | 20080047086 11/509916 |
Document ID | / |
Family ID | 39111985 |
Filed Date | 2008-02-28 |
United States Patent
Application |
20080047086 |
Kind Code |
A1 |
Gunjian; Armen G. |
February 28, 2008 |
Twisted-in-wire brush and method of manufacturing same
Abstract
A bristle structure including at least two stem wires spirally
wound together to form a longitudinally extending core of the
bristle structure and a plurality of bristles extending outwardly
from the longitudinally extending core. Each of the bristles has a
first end and an opposed second end, and each of the bristles is
clamped between the stem wires such that the second end of each
bristle extends a greater distance from the longitudinally
extending core than the first end of the each bristle.
Inventors: |
Gunjian; Armen G.;
(Plattsburgh, NY) |
Correspondence
Address: |
BURR & BROWN
PO BOX 7068
SYRACUSE
NY
13261-7068
US
|
Assignee: |
Brushtech, Inc.
Plattsburgh
NY
|
Family ID: |
39111985 |
Appl. No.: |
11/509916 |
Filed: |
August 25, 2006 |
Current U.S.
Class: |
15/206 |
Current CPC
Class: |
A46B 3/18 20130101; A46B
2200/3073 20130101; A46B 2200/3093 20130101 |
Class at
Publication: |
15/206 |
International
Class: |
A46B 3/18 20060101
A46B003/18 |
Claims
1. A bristle structure comprising: at least two stem wires spirally
wound together to form a longitudinally extending core of said
bristle structure; and a plurality of bristles extending outwardly
from said longitudinally extending core, each of said bristles
having a first end and an opposed second end and being clamped
between said stem wires such that said second end of each bristle
extends a greater distance from said longitudinally extending core
than said first end of said each bristle.
2. The bristle structure of claim 1, wherein all of said bristles
have substantially the same length.
3. The bristle structure of claim 2, wherein said second end of
each bristle extends from said longitudinally extending core a
distance that is at least 10% greater than the distance that said
first end of said each bristle extends from said longitudinally
extending core.
4. The bristle structure of claim 2, wherein said first ends of
said bristles collectively form a first helical pattern extending
along said longitudinally extending core, and said second ends of
said bristles collectively form a second helical pattern extending
along said longitudinally extending core.
5. The bristle structure of claim 4, wherein the diameter of said
first helical pattern is less than the diameter of said second
helical pattern.
6. The bristle structure of claim 2, wherein said second ends of
said bristles collectively form a second helical pattern extending
along said longitudinally extending core, and said second helical
pattern has a diameter that is greater than the length of said
bristles.
7. A bristle brush comprising: at least two stem wires spirally
wound together to form a longitudinally extending core having a
first end and an opposed second end; first and second support arms
respectively extending from said first and second ends of said
longitudinally extending core; a plurality of bristles extending
outward from said longitudinally extending core, each of said
bristles having a first end and an opposed second end, and being
clamped between said stem wires such that said second end of each
bristle extends a greater distance from said longitudinally
extending core than said first end of said each bristle; and a
handle coupled to at least one of said first and second support
arms.
8. The bristle brush of claim 7, wherein said first and second
support arms are integral extensions of the stem wires that form
said longitudinally extending core.
9. The bristle brush of claim 8, wherein said first and second
support arms extend along said longitudinally extending core, and
said handle is coupled to only one of said support arms such that
said handle also extends in substantially the same direction as
said longitudinally extending core.
10. A lint brush for cleaning the exhaust duct of a clothes dryer
comprising the bristle brush of claim 9.
11. The bristle brush of claim 8, wherein at least a portion of
each of said first and second support arms extends in a direction
substantially perpendicular to said longitudinally extending core,
and said handle is coupled to both of said support arms such that
said handle also extends in a direction substantially perpendicular
to said longitudinally extending core.
12. A grill brush for cleaning the grill rods of a barbeque grill
comprising the bristle brush of claim 11.
13. The bristle brush of claim 7, wherein all of said bristles have
substantially the same length.
14. The bristle brush of claim 13, wherein said second end of each
bristle extends from said longitudinally extending core a distance
that is at least 10% greater than the distance that said first end
of said each bristle extends from said longitudinally extending
core.
15. The bristle brush of claim 13, wherein said first ends of said
bristles collectively form a first helical pattern extending along
said longitudinally extending core, and said second ends of said
bristles collectively form a second helical pattern extending along
said longitudinally extending core.
16. The bristle brush of claim 15, wherein the diameter of said
first helical pattern is less than the diameter of said second
helical pattern.
17. The bristle brush of claim 13, wherein said second ends of said
bristles collectively form a second helical pattern extending along
said longitudinally extending core, and said second helical pattern
has a diameter that is greater than the length of said
bristles.
18. A method of manufacturing a bristle structure, comprising the
steps of: positioning a plurality of bristles between at least two
stem wires such that a first end of each bristle extends outward
from the stem wires a first distance and a second end of each
bristle extends outward from the stem wires a second distance
greater than the first distance; and spirally winding the stem
wires together to form a longitudinally extending core of the
bristle structure and to clamp the bristles between the stem wires,
whereby the first ends of the bristles collectively form a first
helical pattern extending along the longitudinally extending core,
and the second ends of the bristles collectively form a second
helical pattern extending along the longitudinally extending
core.
19. The method of claim 18, wherein all of the bristles have
substantially the same length.
20. The method of claim 19, wherein the second end of each bristle
extends from the longitudinally extending core a distance that is
at least 10% greater than the distance that the first end of said
each bristle extends from the longitudinally extending core.
21. The method of claim 19, wherein the diameter of the first
helical pattern is less than the diameter of the second helical
pattern.
22. The method of claim 19, wherein the diameter of the second
helical pattern is greater than the length of the bristles.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a twisted-in-wire brush
having an offset helical bristle pattern, and a method of making
the brush.
BACKGROUND OF THE INVENTION
[0002] Twisted-in-wire (TIW) brushes are well known in the art.
These brushes mechanically retain bristles between two or four stem
wires. Traditionally, the bristles are centered lengthwise between
the stem wires, which are then twisted to lock the bristles in
place and to create a generally cylindrical brush having an outside
diameter equal to the length of the bristles used.
[0003] As shown in FIGS. 6 and 7, a typical TIW brush 10 of the
prior art is made by first centering individual bristles 20 between
two stem wires 30. The individual bristles all have substantially
the same length varying only by normal manufacturing tolerances.
Stem wires 30 are then twisted about an axis 40 centered between
the two stem wires 30 and centered along a longitudinal axis 50 of
the individual bristle 20. The twisting results in a pinching force
between the two stem wires that holds the bristles 20 in
position.
[0004] The resulting brush 10 has bristles 20 spirally revolving to
form two helixes extending centered along the axis 40. Outer ends
of the bristles 20 revolve to form an outside diameter 60 which is
equal to the length of the bristles 20.
[0005] The stem wires 30 can extend beyond the brush portion
containing bristles 20. This extension portion can be covered with
a handle 70, as shown in FIG. 6. The handle 70 can be attached to
extending portions (not shown) of the stem wires 30, which do not
contain bristles.
[0006] As shown in FIGS. 6 and 7 typical TIW brushes have a
consistent outer surface where all of the ends of the bristles
terminate along a uniform outside diameter of the brush. While
these bristles may bend during use to take on the shape of a work
surface, the bristles themselves terminate at the same
diameter.
[0007] The uniform outer diameter functions well when the brush is
used against surfaces that have a correspondingly continuous or
uniform surface (e.g., the inside of a round pipe or tube, or the
flat surface of a metal plate). Problems arise, however, when such
a brush is tasked with performing a cleaning function on an
irregular surface. One such problem begins when a user attempts to
force a typical TIW brush into recess portions of a surface such as
in corners or along a grate, which often collect dirt and grime to
be removed. For the typical TIW brush to reach these locations,
many of the bristles must be bent or otherwise deformed to allow
some of the bristles to reach the recessed surface. If such
bristles are metallic in nature, the bristles may become
permanently deformed, thus effectively ruining those portions of
the brush for future use.
[0008] Another problem with traditional TIW brushes is their lack
of space available to accept larger or bulky residue. Residue such
as grease chunks, soil, or lint must be forced through the outside
diameter of the TIW brush and then be lodged near the stem wire
intermixed between the individual bristles. While this may seem
like an advantage, any such residue is very difficult to remove
allowing the TIW brush to be reused in the future.
[0009] Another disadvantage of traditional TIW brushes becomes
apparent when the brushes are made having a relatively large
outside diameter. Material costs for all metals and plastics have
skyrocketed from historic levels. Traditional TIW brushes would
require the bristles in such a brush having a large outside
diameter to be the same length as the diameter of the brush itself.
The cost of the bristles may then become a significant factor
requiring a consumer to purchase a brush which is shorter than
required or smaller in outside diameter than required. Either
concession may reduce the cleaning effect desired by the
consumer.
[0010] To avoid some of these pitfalls normally seen in traditional
TIW brushes, designers have resorted to trimming selective bristles
of a traditional TIW brush to form a contoured design. For example,
TIW brushes used in the mascara industry often have bristles
trimmed in a helical or arcuate shape to better allow the transfer
of mascara from the TIW brush to a user's eyelash. The economy of
such trimming is, however, questionable. The trimming process adds
an additional, time consuming step to the process of manufacturing
a TIW brush, and the raw materials that are trimmed from the brush
during manufacture are typically wasted. While it is possible that
the trimmed bristle material may be recycled, that material would
need to be completely remanufactured before the material could be
used again as a bristle.
[0011] For at least the reasons explained above, it is clear that a
new TIW brush and method of manufacture is required to solve the
above problems, while, at the same time decreasing the amount of
waste created during the manufacturing process.
SUMMARY OF THE INVENTION
[0012] It is an object of the present invention to overcome the
problems with prior art brush designs, as discussed above. In
accordance with one embodiment of the present invention, a bristle
structure is provided that includes at least two stem wires
spirally wound together to form a longitudinally extending core of
the bristle structure. A plurality of bristles extend outwardly
from the longitudinally extending core, and each of the bristles
has a first end and opposed second end. The bristles are clamped
between the stem wires such that the second end of each bristle
extends a greater distance from the longitudinally extending core
than the first end of each bristle.
[0013] The resultant bristle structure includes two helical
patterns extending along the length of the brush, which provides a
contoured outer brush surface that is more effective at cleaning
irregular work surfaces.
[0014] In accordance with a second embodiment of the present
invention, a bristle brush is provided that includes at least two
stem wires spirally wound together to form a longitudinally
extending core having a first end and an opposed second end. The
bristle brush further comprises first and second support arms
respectively extending from the first and second ends of the
longitudinally extending core, and a plurality of bristles
extending outward from the longitudinally extending core. Each of
the bristles has a first end and an opposed second end, and is
clamped between the stem wires such that the second end of each
bristle extends a greater distance from the longitudinally
extending core than the first end of the bristle. A handle is
coupled to at least one of the first and second support arms.
[0015] Preferably, the first and second support arms are integral
extensions of the stem wires that form the longitudinally extending
core. According to one embodiment of the present invention, the
first and second support arms extend along the longitudinally
extending core, and a handle is coupled to only one of the support
arms such that the handle also extends in substantially the same
direction as the longitudinally extending core. In accordance with
another embodiment, at least a portion of each of the first and
second support arms extend in a direction substantially
perpendicular to the longitudinally extending core, and a handle is
coupled to both of the support arms such that the handle also
extends in a direction substantially perpendicular to the
longitudinally extending core.
[0016] In accordance with another embodiment of the present
invention, a method of manufacturing a bristle structure includes
the steps of positioning a plurality of bristles between at least
two stem wires such that a first end of each bristle extends
outward from the stem wires a first distance and a second end of
each bristle extends outward from the stem wires a second distance
greater than the first distance. The method further includes the
step of spirally winding the stem wires together to form a
longitudinally extending core of the bristle structure and to clamp
the bristles between the stem wires. The first ends of the bristles
collectively forming a first helical pattern extending along the
longitudinally extending core and the second ends of the bristles
collectively form a second helical pattern extending along the
longitudinally extending core.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] For a fuller understanding of the nature and objects of the
invention, reference should be made to the following detailed
description of a preferred mode of practicing the invention, read
in connection with the accompanying drawings in which:
[0018] FIG. 1 is a top view of a twisted-in-wire brush made in
accordance with one embodiment of the present invention;
[0019] FIG. 2 is a partial sectional view of the twisted-in-wire
brush shown in FIG. 1;
[0020] FIG. 3 is a top view of an intermediate manufacturing step
according to an embodiment of the present invention;
[0021] FIG. 4 is a side view of the intermediate manufacturing step
depicted in FIG. 3;
[0022] FIG. 5 is a top view of a second embodiment of the present
invention;
[0023] FIG. 6 is a top view of a prior art twisted-in-wire brush;
and
[0024] FIG. 7 is a partial sectional view of the twisted-in-wire
brush shown in FIG. 6.
[0025] FIG. 8 is a perspective view of the second embodiment shown
in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIGS. 1 and 2 show a TIW brush in accordance with one
embodiment according to the present invention. The size, shape, and
number of bristles 120 in any given brush is a function of customer
preference. The brush 100 shown in FIG. 1 contains many relatively
fine bristles 120 held between two stem wires 130, which are shown
in FIG. 1 partially obscured by the bristles 120. The location of
the stem wires 130 can be seen covered with a cap 190 at one end
and covered with a handle 170 at the other.
[0027] For the sake of clarity, FIG. 2 is provided as a section of
the brush 100 taken through the brush area. Only two bristles are
shown, but it should be understood that different numbers, size,
and shapes of bristles can be used in accordance with the present
invention. Bristles 120 are retained between the two stem wires 130
at a point along the center axis 140 of the completed brush. The
bristles 120 are mounted such that one end of each bristle 120
extends further beyond the stem wires 130 than the other end. This
arrangement allows the more distant ends of the bristle 120 to
define a larger brush diameter 180, and the ends of the bristles
120 closer to the stem wires 130 to define a smaller brush diameter
160.
[0028] The brush 100 takes on an auger-like appearance where the
larger diameter 180 and the smaller diameter 160 helically extend
along the length of the brush 100. Debris and other residue can
easily reside in the brush 100 between the smaller diameter 160 and
the larger diameter 180 helixes. Furthermore, the bristles 120
forming the larger diameter helix 180 can more easily reach into
surface discontinuities and around rises, such as ribs of a grate
(e.g., BBQ grill).
[0029] Referring now to FIGS. 3 and 4, the manufacturing process
according to one embodiment of the present invention includes
aligning the bristles 120 between the two stem wires 130 in a novel
manner. Preferably, all of the bristles have substantially the same
length. It should be noted, however, that the bristles will vary in
length by normal manufacturing tolerances. The bristles 120 are
arranged such that one end of each of the bristles 120 extends
beyond the stem wire 130 a distance that corresponds to the larger
diameter helix 180 of the finished brush 100. The other end of each
of the bristles 120 extending a shorter distance from the stem
wires corresponds to the desired smaller diameter helix 160 of the
finished brush.
[0030] The process of aligning the bristles between the stem wires
and subsequently twisting the stem wires can be accomplished
through manual means. However, for the quantities and efficiency
required with a larger scale production, an automatic machine can
be selected. For example, a TIW brush 100 in accordance with the
present invention can be made using a modified Borghi AB4
continuous cycle twisting machine. In the Borghi twisting machine,
guides are typically arranged to center the bristles between two
converging stem wires. The method of making a brush 100 in
accordance with the present invention involves shifting the bristle
guides to one side of their normal location so that the bristles
120 are no longer centered lengthwise between the two stem wires.
It should be understood that other continuous cycle twisting
machines can be used to create the brush 100 in accordance with the
present invention.
[0031] The larger outer diameter helix 180 can be easily determined
based on the distance between the bristle guides (not shown in
FIGS. 3-4) on the twisting machine. For every unit of measure the
bristle is moved to one side, the larger diameter helix 180
increases by twice that amount. Accordingly, the smaller diameter
helix 160 is likewise decreased by the same amount that the larger
diameter helix 180 is increased. Preferably, the bristles 120 are
offset such that one end of each bristle 120 extends from the
center axis 140 a distance that is 10% greater than the distance
that the other end of bristle 120 extends from the center axis 140.
The longer ends of the bristles 120 collectively form the larger
diameter helix 180 extending along the center axis 140, and the
shorter ends of the bristles 120 collectively form the smaller
diameter helix 160 extending along the center axis 140.
[0032] It should be understood that the present invention can be
made with various different characteristics relating to the desired
brush type. For example, the bristles 120 can be made from any
known bristle material such as plastic, carbon steel, stainless
steel, brass, aluminum, etc. Additionally, the stem wires 130 can
be made out of similar materials such as carbon steel, stainless
steel, brass, aluminum, etc. The number of bristles can also be
varied according to the desired function of the brush. For example,
the embodiment disclosed in FIG. 1 of the present application
discloses the use of a large number of fine individual bristles
allowing the brush to be used for smaller, lighter products. On the
other hand, larger, more dispersed fibers, such as those shown in
FIGS. 3 and 4, for example, can also be used.
[0033] Stem wires 130 perform various functions. Stem wires 130
must be strong enough to generate sufficient grip between the two
stem wires 130 to reliably retain the bristles 120. Additionally,
certain uses require that the brush 100 have sufficient bending and
buckling strength to allow the brush to be held in various
directions and pushed into locations to be cleaned. Aside from the
strength requirements, the diameter of the wire is important as the
diameter sets the pitch of the helix to be formed by setting the
space held between the individual bristles or groups of bristles.
As is well known in the art, more stem wires 130 can be utilized to
nearly double the distance between the bristles and nearly double
the length of one pitch of the helix.
[0034] One application of the novel brush design according to the
present invention is a grill cleaning brush, as shown in FIG. 5.
The grill cleaning brush 200 includes low carbon soft steel stem
wires 130 holding a plurality of fine brass bristles 120. The
individual bristles 120 are held within the stem wires 130 such
that a double helix is created, one helix having a larger diameter,
the other having a smaller diameter. Stem wires 130 extending
beyond the bristles 120 are arranged and bent such that they come
together and extend to be mounted within a handle 270. The handle
can be made out of plastic, wood, brass, etc.
[0035] FIG. 8 shows the brush structure of FIG. 5 being used to
clean a barbeque grill. FIG. 8 shows that the bristles 120 of the
larger diameter helix 280 are able to extend through the grill 290
in such a way that sides of the grill rods 310 can be cleaned. FIG.
8 also shows that bristles 120 of the smaller diameter helix 260
effectively clean top sides of the grill rods 310. Accordingly, the
grill cleaning brush 200 is able to clean more surfaces of the
grill 290 than a typical grill brush.
[0036] Another application is a lint brush for cleaning dryer
vents, as shown in FIG. 1, the structure of which has already been
described.
[0037] While the present invention has been particularly shown and
described with reference to the preferred mode as illustrated in
the drawings, it will be understood by one skilled in the art that
various changes may be effected therein without departing from the
spirit and the scope of the invention as defined by the claims.
* * * * *