Abrasive Brush Having Bristles With Fused Abrasive Globules

Abstract

The specification discloses an article of manufacture comprising an abrasive brush and the abrasive bristles comprising same, and a method for producing or manufacturing same. Each abrasive bristle is of a resilient type and has a free outer bristle end carrying an enlarged abrasive globule of relatively fused bonding material and particulate abrasive material which may be mounted on a bristle end directly by a fused-in-place junction between the bristle end and the globule or by auxiliary mounting or attachment means taking the form of an auxiliary bristle end member having said bonding material and particulate material fused thereto and with said auxiliary bristle end member being further provided with attachment means for attaching same to a corresponding free outer bristle member end. Said attachment means may comprise brazed junction means, mechanical engagement means, or any other suitable attachment means. The specification discloses several methods of manufacturing the abrasive bristles, and basically said method comprises applying to the end of a heat-resistant bristle member a particulate abrasive material and a fusible type of bonding material (which is either liquefied before such application, during such application, or subsequent to such application) in one or more applicatory and subsequent hardening steps until a substantial deposit of same has been applied to and condensed upon each free outer bristle member end so treated, to an extent such as to comprise and define one or more corresponding fused-in-place, enlarged abrasive globules.

Description

Generally speaking, the present invention comprises an abrasive brush having a plurality of resiliently deflectable bristle members, at least certain of which have mounted at free outer bristle member ends thereof corresponding enlarged abrasive globules of relatively fused bonding material and particulate abrasive material, with said enlarged abrasive globules being effectively provided with means for mounting each such abrasive globule with respect to a corresponding free outer bristle member end and comprising, in one form of the invention, a fused-in-place junction of said bonding material and the corresponding surface portion of the corresponding bristle member end whereby to positively and firmly fasten each such enlarged abrasive globule made up of such an abrasive outer coating means to the corresponding bristle member end in a manner such as to virtually entirely prevent chipping and flaking away, or other types of detachment, of all or portions of the abrasive globule from the bristle member end during even very heavy abrasive use of the brush for abrading a workpiece. In another form of the invention, the means for mounting each such abrasive globule with respect to a corresponding free outer bristle member end comprises an auxiliary bristle end member for each such bristle member end having said outer coating means comprising said fusible bonding material and said particulate abrasive material fused in place with respect to the auxiliary bristle end member which is then effectively provided with attachment means for attaching said auxiliary bristle end member to a corresponding free outer bristle member end. Such attachment means may take the form of brazed, welded, soldered, or other adhesive or cohesive junction means, or may take the form of various types of mechanical attachment or engagement means. In any case, the effective end result is to provide a brush having a plurality of resilient bristles each firmly carrying at an outer end thereof such an enlarged abrasive globule having maximum abrading efficiency by reason of the provision of the maximum quantity of particulate abrasive material at the precise location where it is needed for abrading purposes. In one preferred form, the abrasive brush may have the bristle members arranged in a generally similar, longitudinally divergingly directed relationship with respect to a brush-holding base means and a longitudinal axis of the complete device so as to define and comprise what might be termed an end brush or a flare brush of an effectively resiliently expansible type capable of abrading inside, concave workpiece surfaces of various different diameters. However, it should be clearly noted that this is merely exemplary of one advantageous form of the invention, and it should be understood that the invention is not limited to this particular type of brush but may be employed in a greater variety of different types of brushes and, indeed, wherever the mounting of one or more such abrasive bristle members is desired.

It should also be noted that, in one preferred form of the invention, the bristle members are preferably made of resilient, metallic, heat-resistant material which, in certain forms, may be of a composite form such as is commonly known as metallic cable, which usually comprises a plurality of twisted metallic wire portions, with each of the wire portions, in certain forms thereof, in turn comprising a plurality of twisted, metallic, individual wire strand portions. However, it should be understood that the invention is not specifically so limited and that various different types of metallic bristle construction may be employed other than multiple-strand cable constructions of the type just referred to and that, indeed, in certain forms of the invention it is even possible that the bristle members may be made of a heat-resistant, resilient material other than metal.

However, for purposes of illustration only, I have elected to primarily describe and illustrate the above-mentioned end brush or flare brush form of the invention in a version thereof wherein each of the bristle members is made of the multi-twisted-strand, metallic cable form referred to above and which, in one exemplary form, may be made of stainless steel which is corrosion-resistant, relatively heat-resistance, and has a desired degree of lateral resiliency (or, conversely, compliancy) whereby to be well adapted for use in the above-mentioned exemplary type of end brush or flare brush which is of the above-mentioned expansible, variable-diameter type and which furthermore is commercially available at moderate cost. While this form of the inventions has been chosen for the purpose of describing the invention in detail hereinafter, it should be clearly understood that it is exemplary only and is not to be construed as specifically limiting the invention.

In one preferred form of the invention, the plurality of bristle members have corresponding rear end portions mounted within a receiving cup member which firmly holds same and which, in one version, may have the bristle member rear ends firmly potted in place with a potting compound or other hardened matrix material to enhance the engagement thereof.

It should be clearly understood in the remainder of this application that reference to either the article-of-manufacture aspect of the invention or to the method aspect of the invention is to be broadly construed and interpreted as being applicable to, and providing a corresponding disclosure of, the other method or article-of-manufacture aspect thereof, respectively.

It should be noted in connection with the use of the expression "two-phase" with reference to the material in the abrasive globules, that this refers primarily to the outer coating means and the free outer end of the bristle member itself in one aspect and, in another aspect, refers to at least two of the major different constituents of the outer coating material itself and, thus, it can be seen that in actuality, if all of these materials are taken into account, more than two materials are involved in certain forms of the invention, and the composite is actually a multi-phase material. Therefore, the expression, "two-phase" material as used herein is intended to be broadly interpreted in the light of the foregoing statement as inclusive of any of the meanings or material combinations referred to herein. This is also true of the expression, "multiphase."

It will be understood from the foregoing summary of the invention that the improved design of the present invention will function as a very effective and size-adjustable, resiliently deflectable grinding brush capable of operating for a very substantial period of time by reason of the fact that a very large amount of the extremely hard, particulate abrasive material is carried at the free outer bristle member ends or bristle member tip ends in a manner adapted to attain full abrasive efficiency by reason of the fact that the metallic bonding material is softer than the particulate abrasive material (and in certain forms of the invention may be softer than the material of a workpiece which is to be abraded, although not specifically so limited) so that the bonding material will be abraded away somewhat more rapidly than the particulate abrasive material, which will thus always cause the harder particulate, abrasive material to project outwardly from the bonding material and to thus continually outwardly present a very effective abrasive surface adapted to contact the adjacent surface of a workpiece which is to be abraded--this latter function actually occurring during abrading operation of the device.

With the above points in mind, it is an object of the present invention to provide an improved abrasive brush having abrasively tipped bristles of the type referred to herein, which is adaptable for use as a resiliently deflectable grinding, honing, and/or polishing brush and which, in one exemplary but non-specifically-limiting form, may comprise an end or flare brush having bristle means of a metallic (preferably stainless steel cable) type provided with and carrying in a fused-in-place manner a plurality of enlarged abrasive globules.

It is a further object of the present invention to provide a novel abrasively tipped bristle construction and method of manufacturing same, having any or all of the advantages referred to herein and including any or all of the features referred to herein, generically and/or specifically and individually or in combination, and which is of relatively simple, inexpensive, easily manufactured construction, both as to initial capital costs (including tooling costs, etc.) and as to the cost of production per item or unit, such as to facilitate widespread, large-scale manufacturing, sale, and use of the invention for the purposes outlined herein or for any substantial functional equivalents thereof. This is also true with respect to the method aspect of the invention.

Further objects are implicit in the detailed description which follows hereinafter (which is to be considered as exemplary of, but not specifically limiting, the present invention), and said objects will be apparent to persons skilled in the art after a careful study of the detailed description which follows hereinafter, and all such implicit objects are intended to be included and comprehended herein as fully as if particularly defined and pointed out herein.

For the purpose of clarifying the nature of the present invention, several exemplary embodiments of the article-of-manufacture aspect of the invention and several exemplary combinations of method steps for producing same are illustrated in the hereinbelow-described figures of the accompanying drawings and are described in detail hereinafter.

FIG. 1 is a side elevational view of one exemplary embodiment of the invention wherein the device takes the form of what might be termed an end brush having a plurality of laterally deflectable bristle members made of twisted wire portions and twisted individual wire strands, and normally positioned in similarly longitudinally divergingly directed relationship with respect to the bristle-mounting brush base means mounting the rear ends of the bristle members. Each of the bristle members is shown as carrying on the free outer end thereof a fused-in-place sintered-on, enlarged abrasive globule of the novel type provided by the present invention.

FIG. 2 is a front elevational view of the exemplary form of the invention shown in FIG. 1 and shows each of the bristle members in the forwardly outwardly diverging relationship referred to in the description of FIG. 1.

FIG. 3 is a front elevational view generally similar to FIG. 2 but shows each of the bristle members in inwardly laterally deflected relationship so that all of the abrasive globules fused in place or sintered on the free outer ends of the bristle members are in closely adjacent relationship. It should be understood that it is necessary for some surrounding structure to restrain the normally diverging free outer bristle ends and the abrasive globules fused-in-place and sintered on said free bristle ends in order to cause them to assume the inwardly laterally deflected relationship shown in FIG. 3 and thus a surrounding flue pipe or tubing is also shown in cross section in this view and functions for this restraining purpose--it being understood that a variety of different sizes of tubing or flue pipes having different interior diameters may be placed in a relationship such as is shown in FIG. 3 for interior abrading, honing, or polishing thereof by the fused-in-place, sintered-on, enlarged abrasive globules of the end brush when it is power rotated.

FIG. 4 is a cross-sectional view taken substantially on the plane and in the direction indicated by the arrows 4--4 of FIG. 1 and clearly illustrates the interior cross-sectional construction of the exemplary bristle mounting brush base means.

FIG. 5 is an enlarged, fragmentary view taken substantially along the plane and in the direction indicated by the arrows 5--5 of FIG. 1 and also of FIG. 4, and further illustrates the detail of the detailed construction of the exemplary bristle mounting brush base means. This view also shows fragmentarily in phantom a forward collet or chuck portion of a power driving unit adapted to engage the rearwardly positioned tool-engageable shaft portion of the bristle-mounting brush base means, it being understood that said fragmentarily shown chuck or collet may be a portion of any type of power driving unit, such as that provided as a major portion of a conventional electric hand drill, for example, although not specifically so limited.

FIG. 6 is a greatly enlarged, fragmentary, perspective, partly broken away and partly sectional view of an exemplary one of the forward end portions of any of the bristle members and including the free outer or tipe end thereof and the fused-in-place and sintered-on, enlarged, abrasive globule carried thereby. This view clearly illustrates the exemplary construction of the bristle member of the exemplary first form of the invention and the construction of the exemplary fused-in-place, sintered-on, abrasive globule and also the strong mechanical junction therebetween provided by the novel construction and novel method of the present invention.

FIG. 7 is a reduced-size view of a somewhat diagrammatic and schematic nature illustrating one exemplary method for producing the type of fused-in-place, sintered-on, enlarged abrasive globule illustrated fragmentarily in FIG. 6, and shown in multiple form in other figures as being carried by the free outer bristle ends of the plurality of bristle members. In this view, certain portions of the powder torch or flame-spraying apparatus are shown partially broken away in order to clarify important portions of the exemplary method of the present invention illustrated in FIG. 7.

FIG. 8 is a fragmentary, somewhat diagrammatic and schematic view, similar to at least a portion of FIG. 7, but illustrates a slight modification of the exemplary method for producing the article of manufacture of the present invention as shown somewhat diagrammatically and schematically in FIG. 7. The difference lies in the different type and location of introduction of the powdered applicatory material which is to form the fused-in-place, sintered-on, enlarged, abrasive globule than is disclosed somewhat diagrammatically and schematically in the FIG. 7 showing of the first method of the present invention.

FIG. 9 is a view of a somewhat diagrammatic and schematic nature similar in certain respects to FIG. 7, but illustrates a slightly different method for producing each of the fused-in-place, sintered-on, enlarged, abrasive globules which results in a final enlarged abrasive globule of somewhat different interior construction, as illustrated fragmentarily in partially broken away and sectional form in FIG. 10.

FIG. 10 is an enlarged, fragmentary, partially broken away and partially sectional view, similar to FIG. 6, but illustrates a very slightly modified form of the fused-in-place, enlarged, abrasive globule of the present invention.

FIG. 11 is a view similar in many respects to FIG. 6, but illustrates a very slight modification of the invention wherein the bristle member shown fragmentarily is of different construction from the exemplary first form of the invention as best shown in FIG. 6.

FIG. 12 is a somewhat diagrammatic view illustrating a modified method of fusing in place the outer coating means comprising the particulate abrasive material and fusible bonding material so as to form the enlarged abrasive globule. This view illustrating this method step is shown with respect to one bristle only for purposes of simplification and illustrates the process in a form wherein the particulate abrasive material is contained in the melted bonding material so that the application thereof to the bristle member end can be accomplished by puddle dipping either in a single step or in multiple steps.

FIG. 13 is a view very similar to FIG. 12 but illustrates a slight modification wherein the material applied by puddle dipping comprises the melted bonding material only, it being understood that immediately after removal of the bristle member end from the crucible containing the melted bonding material, it will be inserted into a container carrying the particulate abrasive material as illustrated in FIG. 14. This may be done as many times as desired in order to build up the coating means into an enlarged abrasive globule of any desired size.

FIG. 14 is a fragmentary, somewhat diagrammatic view illustrating the step following that shown in FIG. 13.

FIG. 15 is a view illustrating the initial step in another method which comprises the initial heating of the bristle member end followed by the step illustrated in FIG. 16.

FIG. 16 is a fragmentary, somewhat diagrammatic view illustrating the next step following that shown in FIG. 15, comprising the insertion of the extremely hot bristle member end into the coating means in powdered metal form and comprising both the particulate abrasive material and the fusible bonding material.

FIG. 17 illustrates fragmentarily the next step following that shown in FIG. 16--it being understood that the series of steps shown in FIGS. 15 through 17 may be repeated as many times as desired in order to build up an enlarged abrasive globule of any desired size.

FIG. 18 is a fragmentary, sectional view similar in certain respects to FIG. 6, but illustrates a further modification of the invention wherein the abrasive globule is fused in place by any of the various methods of the present invention on the surface of an auxiliary bristle end member which then is attached onto a main bristle member end by any suitable means, which is shown in this example as comprising a brazed junction, although the invention is not specifically so limited.

FIG. 19 is a fragmentary view similar to FIG. 18 but illustrates a different type of attachment means for the auxiliary bristle end member.

Generally speaking, the exemplary first form of the invention illustrated comprises what might be termed an end brush means or device, such as is generally designated by the reference numeral 20, which includes a plurality of similarly longitudinally and normally divergingly directed, laterally resiliently deflectable, normally metallic bristle members, each of which is generally designated by the reference numeral 22 and each having a rear end 24 provided with and carried by a bristle-member-mounting brush base means, such as is generally designated by the reference numeral 26. The mounting of the rear ends 24 of the exemplary five bristle members 22 by the bristle-member-mounting brush base means 26, in the exemplary first form of the invention illustrated, is such that all portions of each of said bristle members 22 forwardly of the mounted rear end 24 thereof are unsupported and free for movement--the only support being provided by the fixedly mounted rear end 24 thereof. Each of the forwardly extending bristle member shaft portions is designated by the reference numeral 28 and, initially before the mounting of the abrasive globules referred to hereinafter, terminates in a free outer end or tip end 30 such as can be seen in phantom in FIG. 1.

Each of the three outer bristle ends or tip ends 30 is provided with a fused-in-place, sintered-on, enlarged abrasive globule, such as is generally designated by the reference numeral 32. In the exemplary form of the invention illustrated, each of the fused-in-place enlarged abrasive globule 32 comprises a desired type of outer abrasive coating means, such as is generally designated by the reference numeral 34, firmly mechanically joined to and mounted on the free outer bristle end 30 in a manner which positively prevents inadvertent or undesired separation of the abrasive outer coating means 34 of the abrasive globule 32 from the free outer bristle end 30, such as by flaking away, chipping away, or otherwise becoming separated therefrom as a result of mechanical impact, vibration, or other stresses or shocks, either mechanically produced or thermally produced, or any combination thereof.

In the exemplary first form of the invention illustrated, the outer abrasive coating means 34 of each of the enlarged abrasive globules 32 comprises two major constituents or components, a first one of which is particulate, abrasive material of an extremely hard type, such as particles of tungsten carbide or the like, and a metallic bonding material which usually has a lower melting temperature than the particulate abrasive material and is not as hard and which is adapted to effectively hold the particles of the abrasive material in a surrounding relationship with respect to the corresponding free outer bristle end 30 and to function as a joining material adapted to provide a very strong mechanical junction of the various particles of abrasive material with respect to each other and of all of the particles of abrasive material with respect to the corresponding free outer bristle end 30. The junction is usually of what might be termed a fused-in-place or sintered-on type, involving the melting, or partial melting, of the metallic bonding material while the particulate abrasive material remains in solid, unmelted condition, and the flowing of the inner portion of the melted, or partially melted, metallic bonding material into engagement with the effectively porous outer surface of the free outer bristle end 30 and the subsequent condensing and hardening of the previously liquified, melted, or partially melted metallic bonding material so that upon hardening, it provides a very strong and virtually non-removable junction of the type best illustrated at the junction interface designated by the reference numeral 36 in FIG. 6.

In the exemplary first form of the invention illustrated, the particulate abrasive material is designated by the reference numeral 38 and, as previously mentioned, may comprise tungsten carbide or particles of any other suitable extremely hard abrasive material, and also in the exemplary first form of the invention illustrated, the above-mentioned metallic bonding material may comprise a nickel-base alloy or any other substantial functional equivalent, designated by the reference numeral 40, and having a lower melting temperature than the tungsten carbide particles of abrasive material 38 and also being softer than the extremely hard particles of abrasive material 38. However, such a nickel-base alloy metallic bonding material 40 may have a sufficiently high melting temperature and may have sufficient hardness as to provide a very strong, hard, wear-resistant and heat-resistant characteristic to the portions of the complete abrasive globule 32 formed thereby so as to maximize the strength of the junction interface 36 and further minimize any likelihood of the abrasive outer coating means 34 of the abrasive globule 32 to flake or chip away as a result of shock mechanically produced, or of thermally produced stresses, etc. In other words, this type of metallic bonding material provides a very long lasting abrasive globule 32 and is particularly advantageous, although it should be noted that the invention is not specifically limited thereto, and various other functional equivalents may be employed in lieu thereof. This is also true with respect to the particulate abrasive material 38.

It should be noted that the metallic bonding material 40 referred to above may be said to comprise a braze-weld type of metallic bonding material, since its function when heated to a sufficiently high temperature, as will be described in greater detail hereinafter, is to effectively provide a brazed or welded junction at the junction interface 36 between the metallic bonding material 40 and the metallic free outer bristle end 30, which is of dissimilar metal. It is also true that a similar type junction effectively occurs between the melted, or partially melted, and subsequently condensed and/or hardened metallic bonding material 40 and each of the particles of tungsten carbide abrasive material 38 and, thus, the description of the metallic bonding material 40 as being a braze-weld type of metallic bonding material is believed to be functionally correct and will be employed at various locations throughout this application in describing or referring to said metallic bonding material 40.

It should be noted that, as pointed out hereinbefore, each of the bristle members 22 is made of metallic material and, therefore, each free outer bristle end 30 is, for course, of this same metallic material and is adapted to provide the type of braze-weld or fused-in-place, sintered-on junction interface 36 between the metallic material of the free outer bristle end 30 and the braze-weld type of metallic bonding material 40 as described hereinbefore. In the first example illustrated, the metallic material of each of the bristle members 22 may comprise stainless steel which has certain advantages in that it is substantially non-corrodible, in mechanically strong and capable of providing the desired degree of lateral resiliency to each of the bristle members 22, and is relatively resistant to the effect of heat and, therefore, is substantially unaffected by the heat applied to the corresponding free outer bristle end 30 for a very short time when the fused-in-place, sintered-on, enlarged, abrasive globule 32 is effectively mounted thereon by flame-spraying or flame-coating, as is best illustrated in FIG. 7 and as will be described in greater detail hereinafter.

Also, it should be noted that, in the exemplary first form of the invention illustrated, each of the stainless steel bristle members 22 comprises a stainless steel cable having a plurality of twisted stainless steel wire portions 22P, each of which, in turn, comprises a plurality of twisted stainless steel individual wire strands 22S. Such stainless steel cable provides a very effective material for each of the bristle members 22, since it is commercially available at moderate cost and has the desired mechanical, thermal, and chemical properties for the purposes of the bristle members 22.

Additionally, it should be noted that the free outer end 30 of each such stainless steel cable type of bristle member 22 has a very porous, roughened, penetrable surface, and thus allows the melted or partially melted braze-weld type of metallic bonding material 40 of the outer coating means 34 of the abrasive globule 32 to penetrate the surface of the free outer bristle end 30 to a substantial degree and thus form the corresponding junction interface 36 in a manner having a substantial thickness or depth, which greatly enhances the mechanical and thermal properties of said junction interface 36 and correspondingly of the firm and substantially non-removable mounting of the entire abrasive globule 32 on the free, outer bristle end 30 of the stainless steel cable type of bristle member 22. Indeed, said mounting is so mechanically and thermally superior as to make it virtually impossible for the abrasive globule 32 to flake or chip away under virtually any condition of normal operating use even when subjected to very high speed, high impact, and high vibration operating conditions and/or when subjected to very high temperature operating conditions. This feature is superior to the mounting of any type of abrasive means on any type of bristle of any prior art abrasive brush known to me and provides a major advantage of the present invention.

In the exemplary first form of the invention illustrated, the previously generically mentioned bristle-member-mounting brush base means, generally designated at 26, comprises a receiving cup member 42 which is usually substantially cylindrically shaped, although not specifically so limited in all forms of the invention, which has an open forward end 44 and a closed rear end 46 which is provided with a tool-engageable portion which, in the example illustrated, comprises a centrally axially positioned, rearwardly projecting, tool-engageable shaft portion 48 which is adapted to be received within a chuck or collet, such as is shown fragmentarily in phantom at 50 in FIG. 5, of any type of power driving unit such as that provided as a major portion of a conventional electric hand drill, for example, although not specifically so limited. The arrangement is such that the tool-engagement shaft portion 48 allows the entire end brush 20 to be power rotated for effective abrading, grinding, honing, or polishing operation, usually within a tubular or cylindrical hole in a work piece, such as the hole in tubing, flue pipe, or the like, although not specifically so limited. One such work piece is generally designated by the reference numeral 52 in FIG. 3 and is merely representative of any of a variety of different types of work pieces.

In the exemplary first form of the invention illustrated, the receiving cup member 42 receives, engages, and firmly holds therein the rear ends 24 of the bristle members 22. This may be done mechanically, such as by press-fit engagement therein, by various clamping structures or devices, or may be done by adhesive or cohesive junction means adapted to bond or embed the rear ends 24 of the bristle members 22 within the recess formed within the receiving cup member 42. While any of these arrangements, or any other functional equivalents, may be employed for firmly fastening the rear bristle ends 24 within the receiving cup member 42, the arrangement shown in the exemplary first form of the invention as best seen in FIGS. 4 and 5 comprises a combination of a press-fit mechanical engagement and the provision of adhesive bonding means 54 comprising an initially effectively liquefied material at the time of mounting of the rear bristle ends 24 therein and adapted to subsequently harden into an effectively hard retaining potting material 54 as clearly shown in FIGS. 4 and 5. The hardening may be of a thermosetting type induced by catalytic action or by curing at an elevated temperature, or both, and, in one form of the invention, may comprise a synthetic plastic resin of the so-called epoxy resin type, although not specifically so limited.

It should be noted that the enlarged abrasive globule 32 carried by the free outer bristle end 30 of each metallic bristle member 22 may be said to comprise a two-phase or multi-phase material (usually a largely metallic material) which effectively alters the physical characteristics of the free outer bristle end 30, and it should further be noted that the coating means 34, comprising the abrasive globule 32, does not extend along the rest of the laterally resilient stainless steel cable shaft portion 28 of the corresponding bristle member 22 and thus does not alter the lateral resiliency or compliancy characteristics thereof in any manner whatsoever. This is important because it is desired to have the shaft portion 28 retain certain resiliency and compliancy characteristics which provide for the normal diverging thereof in a manner such as is clearly shown in FIGS. 1 and 2 and yet which allows the bristle members to be laterally inwardly resiliently deflected into a configuration such as is illustrated in FIG. 3, and also allows the bristle members to assume any configuration therebetween as determined by the outer surrounding restraint, such as the flue pipe shown at 52 in FIG. 3, for example. This makes it possible for the end brush 20 to effectively abrade, grind, hone, or polish an inside cylindrical surface of a number of different diamters of pipe, tubing or the like, without changing the end brush size.

In other words, one end brush can operate effectively for removing scale or other deposits from the interior surface of a flue pipe or the like, such as that shown at 52 in FIG. 3 when it is of an extremely small diameter, and can function just as effectively with any size of flue pipe ranging between that shown in FIG. 3 and that shown fragmentarily in phantom at 52' in FIG. 1. This portion of the total range of permissible diameter variation in the flue pipe, or the like, which is to have its inner surface abraded (usually for cleaning purposes) results from the lateral resiliency and compliancy characteristics of the uncoated bristle shaft portions 28. However, this feature is even further enhanced and increased by reason of the fact that the end brush 20 is adapted to be power-rotated by power-driving means engaged with the tool-engageable portion 48 in a manner such as has been previously described herein, and this will effectively produce substantial centrifugal force on each of the enlarged abrasive globules 32, which have substantial mass, and will cause them to move even further outwardly toward a position such as that shown in dotted lines at 32" in FIGS. 1 and 2 under the action of such centrifugal force. This is permitted by reason of the lateral resiliency and compliancy characteristics of the shaft portion 28 of each of the bristle members 22, and thus it can be seen that the lateral resiliency and compliancy characteristics of the uncoated shaft portion 28 of each of the bristle members 22 is quite important since it makes possible the very wide range of pipe or tubing sizes, or diameters of other cylindrical work piece surfaces, which can be effectively abraded by one single size of end brush.

Additionally, in connection with the above, it should be noted that the dotted line outside position of the bristle members 22 shown in FIGS. 1 and 2 at 32" can be increased to even a greater diameter by increasing the rate of rotation of the entire end brush 20.

One exemplary method for producing the type of abrasively tipped bristle members of the novel end brush 20 of the first form of the invention is illustrated somewhat diagrammatically and schematically in FIG. 7 wherein the plurality of bristle members 22 are shown as having their rear ends 24 or adjacent shaft portions 28 initially clamped or held by a vise-like structure, such as is generally designated by the reference numeral 56, and which may be mounted at a fixed location or may be mounted on a conveyor belt or other moving structure, as desired, for facilitating rapid production of abrasively tipped bristle members. The mounting aspects of the holder means 56 and, indeed, the detailed structure thereof are not important to the basic concept of the present invention and therefore are not shown in detail. The initially uncoated free outer ends 30 of the bristle members 22 are effectively held by the holder means 56 in adjacent, upwardly extending positions (although this is not to be construed as a limiting factor, and they might be held in other directional relationships).

Apparatus of the type known in the art as a powder torch or flame spray attachment or gun is shown in FIG. 7 and is generally designated by the reference numeral 58. It will be noted that it is adapted to be engaged at a rear end 60 thereof with respect to a forward portion 62 of a conventional oxygen-acetylene welding torch or the like, such as it generally designated by the reference numeral 64 and which normally has two feed tubes, pipes, or hoses 66 and 68, respectively, which connect to corresponding oxygen and acetylene supply tanks 70 and 72, respectively, usually through appropriate control valves 74 and 76, respectively.

The two feed ducts 66 and 68 containing oxygen and acetylene, respectively, are normally effectively combined in the conventional torch 64 and would normally feed through a conventional torch tip and provide a very hot flame for welding, cutting, brazing, or other purposes in an entirely conventional manner.

However, since the torch body portion 64 is connected, as indicated at 60, to the outer torch or flame spray gun attachment generally designated at 58, the two gases are fed therethrough to an output torch tip 78 where the flame is produced but in so doing the gases pass through an aspirating mixing chamber portion 80 into which a quantity of powdered applicatory material such as is generally designated at 82, is adapted to be fed from an upper supply chamber or hopper 84 which normally carries same.

The downward feeding of the powdered applicatory material 82 normally occurs when the spring-biased, thumb-operable lever 86 is depressed, and at all other times only the two combustible gases, oxygen and acetylene in the example illustrated, are fed through the lower portion of the mixing chamber 80 and to the output torch tip 78.

The entire assembled device illustrated in FIG. 7 may be said to be a flame-spraying means, since the temperatures produced by the burning oxygen and acetylene gases at the torch tip 78 are sufficient to feed, melt, and effectively braze-weld a metallic bonding material, such as that previously mentioned and shown at 40 in FIG. 6 after it has been solidified on the corresponding free outer bristle end 30.

At the same time that the above-described action is occurring, the other constituent of the powdered applicatory material 82, which comprises the previously mentioned particles of extremely hard, abrasive material 38 is or are also fed by the output flame shown at 88 in FIG. 7, produced at the torch tip 78, onto each of the free outer bristle ends 30, when directed thereupon so that the melted, or at least partially melted (or, in some cases, vaporized) metallic bonding material 40 of the applicatory powder 82 and the unmelted abrasive particles 38 of the applicatory powder 82, are fed together onto the rough outer surface of each of the free outer bristle ends 30 and allowed to deposit thereon and to effectively condense out so that the metallic bonding material or liquid 40 will effectively harden and solidify with the unmelted tungsten carbide abrasive particles 38 held in disseminated relationship therethrough and over the outer surface thereof, thus resulting, after such a cooling and hardening has occurred, in a fused-in-place, sintered-on enlarged abrasive globule such as best shown at 32 in FIG. 6.

It will be noted that the size of the abrasive globule 32 produced is a function of how long the applicatory powder 82 is allowed to be deposited on the free outer bristle tip or end 30 by holding the applicatory powder-dispensing lever 86 in a depressed position.

FIG. 8 illustrates a slight modification of the FIG. 7 showing, wherein corresponding parts are designated by similar reference numerals, followed by the letter a, however. In this slight modification, it will be noted that the main difference is that the two gas ducts or jets 66a and 68a do not combine prior to entering the mixing chamber 80a but remain separate and the powdered applicatory material 82a is fed into one or the other of said still separate gas streams which are subsequently combined before reaching, or at, the output torch tip 78a. This arrangement may be employed in certain cases where the different flow rate of one or the other of the two gas jets is such as to result in a superior feeding and mixing of the powdered applicatory material 82a as compared to the direct feeding of same into the combined two jets as shown in the first form of the invention illustrated diagrammatically in FIG. 7.

FIG. 9 is a view quite similar to FIG. 7 and shows a slight modification thereof and because it is a modification, similar parts are designated by similar reference numerals, followed by the letter b, however. In this modification, it will be noted that there are two different storage chambers 84b for two different types of powdered applicatory material 82b, and each can be controllably dispensed by operation of a different dispensing lever 86b into the combined gas jet flow path of the oxygen and acetylene flowing to the torch tip 78b. The purpose of this type of arrangement is primarily to allow the initial application of just the powdered metallic bonding material 40b which, as previously mentioned, may comprise a nickel-base alloy or the like, until a substantial coating thereof has been built up on the corresponding free outer bristle end 30b as is best shown in FIG. 10, after which the other dispensing lever 86b is operated and a combination powdered applicatory material 82b of substantially the same type as that described above in connection with FIG. 7, is dispensed into the flowing combined gas stream. This results in the abrasive outer coating means 34b having an effectively outer layer which consists of a large amount of the particulate abrasive material 38b (and some of the metallic bonding material 40b) and having an effectively inner joining layer which consists almost entirely of metallic bonding material 40b, as is best shown in FIG. 10. This modified version of the invention has certain significant features arising from the fact that virtually all of the particulate abrasive material 38b is positioned for maximum abrasive efficiency, while most of the metallic bonding material 40b is positioned for maximum bonding and joining efficiency. Otherwise, this modification of the invention is similar to the first version of the invention, and no further detailed description thereof is thought necessary or desirable.

FIG. 11 illustrates fragmentarily a further slight modification of the invention and, therefore, similar parts are designated by similar reference numerals, followed by the letter c, however. In this modification, the major difference is the fact that each bristle member 22c is no longer made of twisted wire cable, but may be made of various other physical constructions, of metallic material, of course, and, if desired, the free outer bristle end 30c may be appropriately treated mechanically, chemically, or otherwise, so as to provide an effectively roughened outer surface such as is indicated at 90, which will enhance the strength of the junction interface 36c or, if desired, such roughening treatment may be eliminated in certain forms of the invention. Otherwise, the FIG. 11 modification of the invention is similar to the previously described forms of the invention, and no further detailed description thereof is thought necessary or desirable.

FIG. 12 illustrates diagrammatically a modified method of fusing in place the outer coating means comprising the particulate abrasive material and the fusible bonding material with respect to a bristle member end. Therefore, parts which are structurally or functionally substantially equivalent or similar to corresponding parts of the previously described forms of the invention are designated by similar reference numerals, followed by the letter d, however. In this modification, it will be noted that a container, which may be a crucible or any other appropriate heat-resistant container or vessel such as is indicated by the reference numeral 90, is adapted to contain the melted or liquefied coating material or means generally designated by the reference numeral 34d and comprising both the liquefied bonding material 40d and the particulate abrasive material 38d. In one preferred form of the invention, the metallic bonding material may comprise a cobalt-based alloy containing substantial quantities of cobalt and lesser quantities of nickel and chromium in addition to other alloying elements such as molybdenum, silicon, boron, iron, carbon or the like, although not specifically so limited. The particulate abrasive material 38d may comprise particles of silicon carbide, tungsten carbide, or any other suitable, extremely hard, abrasive material. However, it should be clearly understood that the invention is not limited to either the exemplary bonding material or the exemplary particulate abrasive material just referred to, which merely exemplify certain advantageous compositions thereof.

In any event, it will be noted that the complete coating means 34d is in substantially liquefied or semi-liquefied form by reason of having been heated until such condition has been reached and, thus, one or more bristle members, such as the exemplary bristle member 22d can be dipped therein by a process which is often called "puddle-dipping," and, upon removal, it will be found that a layer of the coating material 34d of a substantial thickness has adhered to the free outer end 30d of the bristle member 22d. It will be found that, immediately upon removal of the bristle end 30d from the liquefied coating material 34d, it will begin to condense or harden in place so as to effectively produce a fused-in-place abrasive globule similar to that shown at 32 in FIG. 6, for example, although perhaps of lesser diameter. However, the diameter can be increased to any desired extent by merely repeating the dipping and condensing operation as many times as is desired.

FIG. 13 illustrates a very slight modification of the method illustrated fragmentarily in FIG. 12 and, therefore, parts which are structurally or functionally substantially equivalent or similar are designated by similar reference numerals, followed by the letter e, however. In the FIG. 13 modification, it will be noted that the crucible or container 90e contains only the liquefied or melted bonding material 40e which does not contain particles of the abrasive material similar to that shown at 38d in FIG. 12. Thus, in this modification, each bristle member, such as that shown fragmentarily at 22e, has its free outer end 30e dipped into the liquefied or melted bonding material 40e, which then forms a junction with the free end 30e of the bristle member 22e and, immediately after removal from the quantity of liquefied bonding material 40e in the crucible 90e, said coated bristle member end 30e is dipped into another crucible 92, such as is shown in FIG. 14, which contains the powdered particulate abrasive material 38e, which then immediately adheres to the still semiliquid outer surface of the coating material 34e which has just been applied to the bristle end 30e by puddle-dipping in the crucible 90e of FIG. 13. This process can be repeated as many times as possible to produce an enlarged abrasive globule similar to that shown at 32 in FIG. 6, for example, of any desired size.

FIGS. 15 through 17 illustrate, in sequence, the steps involved in a slightly modified form of the method for producing a bristle member having an enlarged abrasive globule fused in place on the free outer end thereof, and, therefore, parts which are structurally or functionally substantially similar or equivalent to those of previously described forms of the invention are designated in said figures by the same reference numerals, followed by the letter f, however. In this modification of the invention, it will be noted that the initial step shown in FIG. 15 comprises the heating of the bristle member free outer end 30f, which is done in the example illustrated by mounting same in a thermally insulated but movable holder such as that shown fragmentarily at 94, and holding the bristle member end 30f in the flame 95 of a blow torch 97 (or otherwise heating same) followed by the dipping of the heated bristle member end 30f into the powdered coating material 34f carried in the container 93 shown in FIG. 16. The heat of the bristle member tip end or free end 30f will partially liquefy or partially melt the bonding material constituent of the coating means 34f and cause a fused junction thereof with respect to the effectively roughened outer surface of the heated bristle member end 30f so as to effectively produce an at least partially fused-in-place junction therebetween. This step is illustrated in FIG. 16.

FIG. 17 illustrates the next step, which comprises, again, heating the bristle member free end 30f and the relatively small, abrasive globule 32f, partially formed thereon in the manner described above, until an effectively fused-in-place junction of the bonding material thereof with respect to the bristle member end 30f is achieved. As illustrated in FIG. 17, this second heating step again comprises subjecting the bristle member end 30f and the coating material 34f comprising the relatively small abrasive globule means 34f to the flame 95 of the blowtorch 97 or the like. However, it should be noted that both the heating step shown in FIG. 15 and the heating step shown in FIG. 17 may be accomplished by means other than a blowtorch, and all such arrangements are intended to be included and comprehended herein.

It should also be noted that the sequence of steps illustrated in FIGS. 15 through 17 inclusive can be repeated as many times as desired and with any desired form of suitable heating means so as to effectively apply multiple coats of the coating means 34f to the bristle member end 30f so as to produce an enlarged abrasive globule 32f of any desired size.

FIG. 18 is a fragmentary view, somewhat similar to FIG. 6, but illustrates a modification of the invention, and, therefore, parts which are structurally or functionally substantially similar or equivalent to those previously described forms of the invention are designated by similar reference numerals, followed by the letter g, however. In this modification it will be noted that the abrasive globule 32g is effectively mounted on the free outer bristle end 30g by the provision of mounting means taking the form of an auxiliary bristle end member, generally designated by the reference numeral 96, which comprises a member made of a material such as any of the types of bonding material previously described or other appropriate material, designated by the reference numeral 40g, and carrying in a fused-in-place relationship with respect thereto the particulate abrasive material 38g, but with the auxiliary bristle end member 96 being effectively provided with attachment means, which may be of any of a variety of different types, for attaching same to the bristle member end 30g. In the example, said attachment means comprises the brazed junction indicated at 98, although it might take the form of a soldered junction, a welded junction, a junction fastened by any type of adhesive or cohesive means, whether of metallic material, plastic material, or otherwise, or any suitable type of mechanical attachment means. It will be noted that the over-all effect is to produce a composite bristle member 22g, having the auxiliary bristle end member 96 firmly attached to the bristle member end 30g and, therefore, being fully functionally equivalent to the abrasive, fused-in-place globule form of the invention in any of its different aspects as previously described and as illustrated in other figures of the drawings.

FIG. 19 illustrates a very slight modification of the form of the invention shown in FIG. 18, and, therefore, parts which are structurally or functionally substantially similar or equivalent to those of the FIG. 18 form of the invention are designated by similar reference numerals, followed by the letter h, however. In this modification all of the parts are similar to those illustrated in the FIG. 18 form of the invention, with the exception of the attachment means functionally equivalent to the brazed attachment means 98 of the FIG. 18 form of the invention and, therefore, designated by the reference numeral 98h in the FIG. 19 form of the invention, wherein it is shown as comprising a mechanical type of attachment means. Incidentally, it should be noted that, in certain forms of the invention, if desired, the attachment means may be of a removable type. Also, the auxiliary bristle end members such as shown at 96 in FIG. 18 and shown at 96h in FIG. 19, may be of any desired configuration and/or composition suitable for various different abrasive purposes.

It should also be noted that, in certain forms of the invention, the bristle members may be made of heat-resistant material other than metal, and this may also be true of the bonding material of which the abrasive globules are made, and all such arrangements are intended to be included and comprehended within the broad scope of the present invention.

While the present invention has been shown primarily in connection with an end brush and has been shown primarily with the bristle members being made of twisted wire cable, preferably stainless steel cable, it should be clearly understood that the invention is of sufficiently broad scope to include and comprehend various other types of brushes and various other types of bristle members, provided that the construction of the abrasive globules and the methods for producing same fall within the scope of the broad teachings of the present invention. For example, and not to be construed in a limiting sense, one such type of modified brush employing the novel type of bristle of the present invention comprises what might be termed a wheel brush wherein a plurality of bristle members of the novel type of the present invention are carried by a bristle-mounting brush base means in radially outwardly directed fashion so that the wheel brush will cause the radially outwardly directed bristle members to simulate in appearance the multiple spokes of a wheel radiating outwardly from the central wheel hub simulated in appearance by the bristle-mounting brush base means in such a modified brush. This type of construction would have the inner ends of the bristles fixed to the bristle-mounting brush base means in the form of a hub with all of the abrasive globules being positioned at the extreme outer circumference of the wheel brush, and it will be found that this type of brush is very effective for use in abrading, cleaning, and polishing the inner surfaces of welded junctions along an inner, cylindrical surface, such as that provided by a plurality of lengths of pipe which have been end-to-end welded together. This is merely illustrative of one of the many other forms which the brush may take within the broad scope of the present invention which is directed primarily to the novel bristle and the method of producing same rather than to any particular brush configuration.

It should be noted that in the FIGS. 18 and 19 form of the invention, the auxiliary bristle end member, such as the one generally designated by the reference numeral 96 in FIG. 18, for example, or the one generally designated by the reference numeral 96h in FIG. 19, for example, may have the particles of abrasive material 38g and 38h, respectively, disseminated throughout the entire body of the auxiliary bristle end member, such as shown at 96 and 96h, respectively, and the complete so-called abrasive globule such as shown at 32g and 32h, respectively. Indeed, these may be of a unitary structure made of a common material comprising the bonding material, such as shown at 40g and 40h, respectively, having the particulate abrasive material 38g and 38h, respectively, disseminated therethrough or on the surface thereof or carried in any other manner previously disclosed in this application, with the entire device then being adapted to be brazed onto the bristle end in the manner illustrated in FIG. 18 or attached thereto in any other functionally equivalent manner, or to be mechanically fastened onto the bristle end in the manner illustrated in FIG. 19 or in any other functionally equivalent manner. In other words, the invention is not limited to an arrangement wherein the auxiliary bristle end member, such as generally designated by the reference numerals 96 and 96h, respectively, be distinct from, or in any way different from, the rest of the corresponding abrasive globule, such as shown at 32g and 32h, respectively. Also, it should be noted that the mounting recess may be modified or eliminated entirely in certain forms of the invention, and the brazed or mechanical attachment may be direct to the end of the bristle, and all such arrangements, or functionally equivalent arrangements, are intended to be included and comprehended within the broad scope of the present invention.

It should be understood that the figures and the specific description thereof set forth in this application are for the purpose of illustrating the present invention and are not to be construed as limiting the present invention to the precise and detailed specific structure shown in the figures and specifically described hereinbefore. Rather, the real invention is intended to include substantially equivalent constructions embodying the basic teachings and inventive concept of the present invention.

Claims

I claim:

1. A compliantly mounted abrasive means in the form of a brush device, comprising: a brush means including a plurality of bristle members, each having a rear end provided with and carried by a bristle-member-mounting brush base means, each bristle member being made of a heat-resistant flexible compliant material and including a corresponding resiliently deflectable, compliant shaft portion provided with a corresponding free outer end carrying and effectively defining an enlarged abrasive globule including a desired type of outer abrasive coating means comprising a fusible bonding material and an extremely hard, particulate, abrasive material fused in place relative to said bonding material, with the fusible bonding material providing a strong, fused-in-place junction thereof with respect to the particulate abrasive material and being provided with bridging, interengaging, and effectively penetrating means effectively firmly mounting said enlarged abrasive globule with respect to said bristle member free outer end in a manner projecting outwardly therefrom, said bridging, interengaging, and effectively penetrating means for mounting each such abrasive globule with respect to a corresponding free outer bristle member end comprising a fused-in-place junction of said bonding material and the corresponding surface portion of each corresponding bristle member end positively and firmly fastening said abrasive outer coating means to said bristle member end in said manner projecting outwardly therefrom, each bristle member comprising a plurality of adjacent metal strand portions, together forming a metallic cable provided with multiple effectively porous, penetrable junction interface means comprising the surface portions of the cable having openings between the cable strand portions extending thereinto and receiving therein portions of said bonding material when fused thereon whereby to maximize the junction strength and the bridging, interengaging, and effectively penetrating relationship of said bonding material relative to the rest of the abrasive globule and the effectively porous, penetrable junction interface means of said bristle member free outer end.

2. A device as defined in claim 1, wherein said particulate abrasive material and said bonding material are effectively intermixed and fused to each other whereby to cause said particulate abrasive material to be firmly held in place and dispersed throughout said bonding material of each of said abrasive globules.

3. A device as defined in claim 1, wherein said abrasive outer coating means comprises an effective outer layer of said particulate abrasive material and an effective inner layer of said bonding material providing said strong junction of said particulate abrasive material with respect to said bonding material whereby to firmly fasten them together.

4. A device as defined in claim 1, wherein said bonding material comprises a braze-weld-type of metallic material capable of forming a braze-weld-type of junction with the particulate abrasive material when fused thereto.

5. A device as defined in claim 1, wherein the metallic material of which each bristle member is made comprises a metallic, stainless steel cable and wherein said bonding material comprises a braze-weld-type of metallic material capable of forming a braze-weld-type of junction with the particulate abrasive material when fused thereto, each bristle member having a major portion of the length thereof positioned inwardly of the abrasive globule at the free outer end thereof substantially free of said particulate abrasive material and said braze-weld-type of metallic bonding material whereby to have substantially unaltered lateral compliance characteristics and whereby to position substantially all of said particulate abrasive material in said abrasive globules carried at the free outer ends of said compliant bristle members in optimum locations for abrading contact with a surface of a workpiece.

6. A device as defined in claim 1, wherein said bristle-mounting brush base means comprises a receiving cup member having an open forward end and a closed rear end provided with a longitudinally centrally axially positioned rearwardly projecting tool-engageable shaft portion.

7. A device as defined in claim 1, wherein said bristle-mounting brush base means comprises a receiving cup member having an open forward end and a closed rear end provided with a longitudinally centrally axially positioned rearwardly projecting tool-engageable shaft portion, said receiving cup member receiving, engaging, and firmly holding therein rear ends of corresponding ones of said plurality of bristle members.

8. A device as defined in claim 1, wherein said bristle-mounting brush base means comprises a receiving cup member having an open forward end and a closed rear end provided with a longitudinally centrally axially positioned rearwardly projecting tool-engageable shaft portion, said receiving cup member receiving, engaging, and firmly holding therein rear ends of corresponding ones of said plurality of bristle members and being provided with effectively adhesive potting means initially comprising an effectively liquefied material at the time of mounting thereof and subsequently comprising an effectively hard retaining potting material.

9. A device as defined in claim 1, wherein said plurality of metal strand portions comprises an assembly of twisted, stainless steel wire portions, each in turn comprising a plurality of twisted, stainless steel, individual wire strands and together causing said cable to comprise a stainless steel cable having said effectively porous, penetrable junction interface means formed by the openings between the stainless steel wire portions and stainless steel wire strands of a corresponding free bristle end; said bristle-mounting brush base means comprising a substantially cylindrically shaped receiving cup member having an open forward end and a closed rear end provided with a longitudinally centrally axially positioned rearwardly projecting tool-engageable shaft portion, said receiving cup member receiving, engaging, and firmly holding therein rear ends of corresponding ones of said plurality of stainless steel cable bristle members and being provided with effectively adhesive potting means initially comprising an effectively liquefied material at the time of mounting thereof and subsequently comprising an effectively hard retaining potting material taking the form of a synthetic plastic resin of the epoxy resin type.

10. A device as defined in claim 1, wherein said brush means comprises an end brush with said plurality of bristle members being similarly longitudinally but divergingly directed and being laterally and inwardly resiliently deflectable.