U.S. patent number 3,798,699 [Application Number 05/154,055] was granted by the patent office on 1974-03-26 for synthetic tufted constructions.
This patent grant is currently assigned to Tucel Industries, Inc.. Invention is credited to John C. Lewis, Jr..
United States Patent |
3,798,699 |
Lewis, Jr. |
March 26, 1974 |
SYNTHETIC TUFTED CONSTRUCTIONS
Abstract
Tufted brush construction comprising pretrimmed synthetic
filament tufts fused at one end and attached to adjacent tufts by a
connector means. The base of each tuft and the connector means are
embedded into a foam composition to support the tufted mat
construction.
Inventors: |
Lewis, Jr.; John C.
(Middlebury, VT) |
Assignee: |
Tucel Industries, Inc.
(Middlebury, VT)
|
Family
ID: |
22549808 |
Appl.
No.: |
05/154,055 |
Filed: |
June 17, 1971 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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20624 |
Mar 18, 1970 |
3633974 |
|
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Current U.S.
Class: |
15/179; 15/201;
300/21; 15/182; 15/217 |
Current CPC
Class: |
A46B
3/00 (20130101) |
Current International
Class: |
A46B
3/00 (20060101); A46b 001/00 () |
Field of
Search: |
;15/179,180,181,182,161,159,202,215,216,217,201,203 ;300/21 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Feldman; Peter
Attorney, Agent or Firm: LeBlanc and Shur
Parent Case Text
This application is a division of my patent application Ser. No.
20,624, filed Mar. 18, 1970, now U.S. Pat. No. 3,633,974, and a
continuation-in-part of my copending patent application Ser. No.
841,160, now U.S. Pat. No. 3,596,999, a divisional application of
parent application Ser. No. 578,840, now U.S. Pat. No. 3,471,202;
and a continuation-in-part of my copending application Ser. No.
800,330, now U.S. Pat. No. 3,604,043 a divisional application of
parent application Ser. No. 578,840, now U.S. Pat. No. 3,471,202.
Claims
What is claimed and desired to be secured by United States letters
Patent is:
1. A tufted modular brush construction comprising: a plurality of
mutually spaced, synthetic filament tufts, each tuft comprising a
plurality of synthetic filaments extending from a prefused
homogeneous mass of said filamentary material;
a flexible filamentary connector embedded in and extending
laterally through said prefused masses to interconnect said
mutually spaced tufts;
a cured synthetic foam base surrounding said connector and at least
a portion of said prefused masses, said base supporting said tufts
in a preselected configuration.
2. The tufted modular brush construction of claim 1 wherein said
connector is a synthetic filament web.
3. The brush construction of claim 2 wherein said web filaments are
polypropylene.
4. The tufted modular brush construction of claim 1 wherein the
base is a material selected from the group consisting of
polyester-based polyurethane foam and polyether-based polyurethane
foam.
5. The brush construction of claim 1 wherein the cured foam base is
flexible.
6. The tufted brush construction of claim 1 wherein the cured foam
base is rigid.
7. The tufted brush construction of claim 1 wherein the foam base
is cured in a contoured configuration to support said tufts in a
circular brush construction.
8. The tufted modular brush construction of claim 1 wherein the
foam base is cured to support said tufts in a flat brush mat
configuration.
Description
This invention relates to new and useful brush-type articles. More
specifically, it is concerned with fabrication of tufted synthetic
filament whereby said filament is supported by foamed
substrates.
The brush and carpet industry for many years have been limited in
design due to the conventional substrates and methods employed for
joining tufts of filaments to the substrates. In most instances,
the filaments forming the tuft are doubled over in a U-shape and
held to a somewhat thick substrate by means of a staple in the case
of a brush and a cord-like rope in the case of a carpet. In both
cases, the tufts are held fast by the anchoring means. Also, the
method of making tufts and joining them to the substrate does not
allow for multiple tuft formation.
The picking and formation of multiple tufts from synthetic filament
have been described in U.S. Pat. No. 3,471,202 by Lewis, and allow
pre-trimmed synthetic filament tufts to be assembled from filament
having a length nearly the same as the finished desired tuft. By
employing the method of forming tufts in accordance with the Lewis
patent, it becomes possible to construct tufted articles having
thin foamed substrates, i.e., 1 inch tufts supported by
poly-urethane foam having a thickness of 1/8 inch.
It will be apparent in the discussion which follows wherein the
novel constructions of this invention differ from conventional
constructions and it should be apparent also that there are many
economical factors to be gained by such methods of
construction.
Objects and advantages of this invention will be set forth in part
hereinafter and in part will be obvious herefrom, or may be learned
by practice with the invention, the same being realized and
attained by means of the steps, methods, combinations and
improvements pointed out in the appended claims.
The objects of this invention will now be described. While this
invention is primarily concerned with new and novel brush
constructions and tufted modular components, it should be realized
that the principles of this invention are attained only through the
novel combination of retaining cut-to-length parallel synthetic
filament and dispensing those filaments in situations wherein (1)
single filament tufts are formed, (2) multiple filament tufts are
formed, (3) complete tufted brush-type constructions are
simultaneously formed, and (4) continuous modular tufted strip-type
constructions are formed. Any of these described situations can be
supported by foamed substrate.
An object of this invention is to provide a tufted brush-type
construction comprising pre-trimmed synthetic filament tufts
arranged in a tuft pattern and self-supported by a thin foamed
substrate. Another object of this invention is to provide a tufted
construction comprising synthetic filament tufts supported by
lightweight flexible foam.
Further objects of this invention are to provide novel methods for
the production of tufted constructions employing the features set
forth in the foregoing objects. These objects are attained by the
procedure particularly described hereinafter, as well as in my
hereinabove-mentioned U.S. Pat. No. 3,471,202, which procedure
comprises, in its broader aspects, joining filament tufts at their
fused base by employing a substrate or connector, said substrate
employed for aligning tuft formations prior to supporting said
tufts in foam. The more usually preferred connectors are those of
extruded thermoplastic monofilament whereby the unset fused tuft
end is brought into contact with said connector prior to cooling
and then allowed to cool, providing a tuft base secured by the
monofilament. This construction is then subsequently set in foam in
one of the ways designated hereinafter.
Brushes have been prepared as described in U.S. Pat. No. 2,576,546
wherein plastic filaments, i.e., Nylon, have fused ends. The fused
ends are set in rubber and cured until the filaments are held
securely. Unlike the instant invention, tufts are not held together
at their bases prior to insertion into rubber, nor are the tufts
capable of being arranged in tuft formations, i.e., 48 tufted scrub
brush. It should be noted that the prior constructions could not be
supported prior to being secured in the rubber. The rubber had to
be supported on a core, thus not allowing for self-supporting tuft
formations.
In the discussion which follows, for convenience sake, the term
"synthetic" filament applies to those synthetic monofilaments which
are formed from linear thermoplastic polymers from the group
consisting of polystyrene and polystyrene copolymers, polyvinyl
chloride and polyvinyl chloride acetate copolymers, polyfluorides,
polyethylene, polypropylene, polyethylene-polypropylene copolymers,
polyamides, polyimides, polyesters and polyurethane. Both oriented
and unoriented monofilaments may be employed. Also, various
cross-sectional shapes may be imparted to the monofilaments, such
as for instances, i.e., circular, lobular, trifoil, "X" and "Y"
cross-sections, triangular, polygonal, star, etc. Mixtures of
synthetic monofilaments may be employed in cases where the
compositions of the filaments are compatible during any fusing
operations, i.e., heat-sealing. Such filaments may have suitable
crimp imparted to all or some portion of their length.
The term "picking" as used in the specification refers to the
formation of a filament tuft wherein the tuft is formed by engaging
more than one cut-to-length filament by its end and removing same
from a parallel disposed bundle of filaments. The picking device
employed is of the type disclosed in the aforementioned U.S. Pat.
No. 3,471,202.
The term "substrate" refers to the foamed composition surrounding
the filament tufts and can be either flexible or rigid. The foam
acts as the handle or back in conventional brush constructions.
As indicated above, the foam substrate of this invention is made
from a polyurethane foam. The term "polyurethane foam" as used
herein includes both polyester-based polyurethane foam and
polyether based-polyurethane foam. Any conventional polyester
based-polyurethane foam or polyether based-polyurethane foam may be
employed for the substrate. As is well known, polyester
based-polyurethane foams are conventionally made by reacting an
organic polyisocyanate, i.e., toluene diisocyanate, with a
polyester containing free hydroxyl and/or carboxyl groups, i.e.,
the polyester resin reacting product of ethylene glycol and adipic
acid. When reacting a polyisocyanate with a hydroxy-polyester, a
small amount of water is added to bring about carbon dioxide
formation with polyisocyanate and the reaction is accelerated in
known manner by the addition of catalysts, i.e., a tertiary amine
catalyst such as triethylamine and N-methylmorphaline.
Polyether based-polyurethane foams are conventionally made in a
manner similar to that described above except that in place of a
polyester, polyether is employed for the reaction with
polyisocyanate. U.S. Pat. Nos. 2,727,219, 2,814,606 and 3,029,209
disclose polyurethane foam compositions that may be used as the
substrate in accordance with this invention. Specific foam examples
will be set forth hereinafter.
The term "connector" refers to any material, for example, a
monofilament, which is employed for attaching tufts thereon in
order to arrange and support tufts prior to foaming. The connector
can be in the form of a screen knit or other similar
constructions.
In the drawings:
FIG. 1 is a front view of a fibre tuft of this invention;
FIG. 2 is a front view of the tufts of this invention attached to
another at their base by a connecting means;
FIG. 3 is a bottom view of the tufts of FIG. 2;
FIG. 4 is a side cross-sectional view taken along line IV--IV of
FIG. 2;
FIG. 5 is a front view in cross section of the tufts of FIG. 2
supported in rigid foam;
FIG. 6 is a side cross-sectional view along line VI--VI of FIG.
5;
FIG. 7 is a front view in cross section of the tufts of FIG. 2
supported in flexible foam;
FIG. 8 is a sectional view in cross section of the tufts of FIG. 2
being set in foam to form a foam-supported tuft construction;
FIG. 9 is a longitudinal sectional view of the foam-supported tufts
as formed in FIG. 8;
FIG. 10 is a fragmentary bottom view of a group of tufts held
together by a web-like means;
FIG. 11 is a side cross-sectional view of the tufts of FIG. 10;
FIG. 12 is a detailed fragmentary view of a mat in perspective and
partly in section showing one arrangement of the tufts from FIGS.
10 and 11 supported in foam;
FIGS. 13-17 illustrate a method of assembling a brush employing the
sections of FIG. 5. FIG. 13 is a front view of a section comprising
a multiplicity of filament tufts joined together and supported by
rigid foam. FIG. 14 is an end view of FIG. 13. FIG. 15 is an end
view of four sections aligned side by side. FIG. 16 is an end view
of a cap adapted to be placed over the aligned segments of FIG. 15
in the manner shown in end view FIG. 17 which shows a finished
brush construction with the sections held by the cap;
FIG. 18 is a front view of the tufts of this invention attached to
each other by polypropylene monofilament;
FIG. 19 is a fragmentary view of a group of tufts as shown in FIG.
18;
FIG. 20 is a side view, partially in cross section, of a shoe brush
from the tuft formation of FIG. 19;
FIG. 21 is an end view of the shoe brush of FIG. 20; and
FIG. 22 is a fragmentary side view of a flexible continuous
belt-of-tufts supported in flexible foam.
In order to describe the invention more fully, reference is now
made to specific embodiments illustrated in the drawings. The
invention is directed to brush making wherein tufted brushes and
tufted constructions result by first forming modular tufted
arrangements, said tufted arrangements comprising cut-to-length
synthetic filament fused at one end and attached to adjacent tufts
by means of a connector, then setting the arrangement in a foamed
substrate whereby the resultant construction is self-supporting and
said tufts are held securely within the foam support. Such a tuft
employed for these constructions is shown in FIG. 1. The tuft of
FIG. 1 is formed from cut-to-length filament 100 by picking said
filament from one end and heating to fuse the opposite end portion
101 to a temperature of approximately that of the melting point of
the particular type of synthetic filament employed. Most
thermoplastic filaments have softening points which make them
pliable and capable of fusing together under slight pressure.
Consequently, as the heated ends of the filaments soften, they are
brought into contact with a connecting material, i.e.,
polypropylene monofilament, and subsequently pressed around the
connectors thus resulting in the filament tuft being supported in a
web-like structure whereby the fused base end 104 of FIG. 2 of each
tuft is attached to an adjacent tuft. The tufts in FIG. 2 show one
such tuft construction where the base 103 is attached to an
adjacent tuft 102 by means of connector 104. This construction can
be likened to a "string-of-pearls." The fused base 103 for purposes
of illustration is shown much larger than necessary, and does not
have to extend beyond the filament in the tuft. The base 401 of
FIG. 18 shows another embodiment of the fused section where the
base does not extend beyond the width of the filament diameter.
In order to form a single length of self-supporting tufts as
illustrated in FIGS. 5 and 6, it is necessary to first prepare a
continuous length of attached synthetic tufts as shown in FIG. 2.
The tufts are then brought into contact with a polyurethane
foam-producing mix which, within seconds, begins to react and a
foam structure results. Within a relatively short period of time,
i.e., 90 seconds, the foaming action will reach a peak or rise
point, and then gel. Within another few minutes, i.e., 120 seconds,
the foam substrate will be tack free and for all practical purposes
will be considered set. The tufts are, at this point, securely held
and of a self-supporting nature.
To illustrate the aforedescribed procedure more specifically, the
following specific example is now given:
EXAMPLE I
A batch of 9 pounds per cubic foot rigid polyurethane foam was made
by the following recipe (all reactants were at room
temperature):
100 grams of Mistafoam 850-S urethane foam base (material
manufactured by M-R Plastics and Coatings, Inc.) was blended with
100 grams of Mistafoam 801-H urethane foam prepolymer in an
electric mixer for 60 seconds (cream time) and then poured to a
depth of 1/16 inch onto a metal tray measuring 3/8 inch wide, 36
inches long and 3/16 inch deep. Immediately, a "string-of-tufts"
was placed into the foam composition and within 30 seconds the
foaming reaction started. At the end of 120 seconds, the tufts were
held fast within the foam substrate. A strip of self-supporting
tufts as shown in FIG. 5 resulted wherein the foam substrate 105
supports tufts 102, the thickness of the substrate being on the
order of 1/8 inch.
The invention in its broader aspects is not limited to rigid foam
compositions. In order to fully describe the flexible strip of
tufts shown in FIG. 7, reference is now made to the flexible
substrate 106 in FIG. 7.
EXAMPLE II
A batch of 2 pounds per cubic foot polyurethane foam was made by
the following recipe (all reactants were at room temperature):
50 grams of Formez-50 (a polyester-resin) was blended with 2 grams
of N-ethyl morpholine in an electric mixer for 45 seconds and then
3.6 grams of distilled water added and the mixture allowed to mix
for another 30 seconds. To this resin pre-mix, 105 grams of
Nacconate 80 (80:20 mixture of 2,4 and 2,6-toluene diisocyanate)
was added and mixed for approximately 10 seconds, then poured onto
the same metal tray as cited in Example I. Immediately after, a
"string-of-tufts" was immersed in the pre-mix and foaming allowed
to continue. Soon after, 5-10 seconds, the foaming action started
and the cell structure formed. Within 240 seconds, the tufts were
self-supported in the substrate and a strip of tufts as shown in
FIG. 7 resulted. The substrate portion 106 was approximately 3/16
inch in thickness.
While the invention is susceptible of embodiment in many different
forms, there is shown now in FIGS. 8 and 9 specific embodiments
with the understanding that the present disclosure is to be
considered as an exemplification of the principle of the invention
and is not intended in any way to limit the invention to the
embodiment illustrated.
Particular attention is now given to the cylindrical brush
construction and method of forming as shown in FIGS. 8 and 9. The
method consists of wrapping a "string-of-tufts" 102 around a rigid
supporting means 109 while simultaneously applying a foamed
polyurethane pre-mix from supply 108 through nozzle 107 in order
that the fused ends 103 of tufts 102, said tufts attached by
connector 104, can become securely held in the substrate 110. The
foaming support means 109 is rotated in direction B while the tufts
102 come from direction A. As the foaming begins and cell structure
takes place, substrate 110 is formed. After the foam composition is
set, it is removed from support means 109 in direction C, thereby
resulting in a tufted cylindrical brush 111. The method can be
carried out whereby the brush 111 is simultaneously removed during
the foaming operation by allowing enough time between removal and
curing of the foam. This only requires a sufficient distance
between the wrapping and foaming section and the cured section of
the brush. Although not shown, it is possible to form an inverted
cylindrical tufted unit wherein the tufts project inward.
EXAMPLE III
A tufted cylindrical brush (polypropylene tufts) having a 1 inch
diameter and a 3 inch brush face comprising 108 synthetic tufts
having a trim length of 1 inch and a tuft diameter of 3/16 inch,
supported in rigid polyurethane foam, was constructed in the
following manner:
A batch of 9 pounds per cubic foot rigid polyurethane foam was made
according to the same procedures as cited in Example I. The pre-mix
was then applied in liquid form to a paper mandrel (5 inches long
and having a diameter of 1 inch, the thickness being 0.050 inch)
and a continuous "string-of-tufts" was wrapped around, taking care
to embed to base of the filament tufts in the foam pre-mix. When
the tufts had been wrapped, foaming started and within 120 seconds,
the whole mass had set. A few more minutes and the mass was tack
free. The paper core was twisted from the brush unit leaving a
completely self-supporting tufted polypropylene cylindrical brush
having a substrate of rigid polyurethane foam. The substrate had an
average thickness of 3/16 inch. The excess foam was removed at each
end leaving a 3 inch brush face.
It is apparent that the tufted mat construction illustrated in FIG.
12 is a complicated construction, and could not be produced by any
technique other than by practicing the method disclosed in the
instant invention. In addition, the invention in its broader aspect
is not limited to individual tufts having a base area greater than
the area of the filament comprising the tuft whereby a bead is
employed to anchor the tuft. Tufts so formed in accordance with
this invention can have fused base portions wherein there is no
significant portion of fused area, but more important is the fact
that the fused portion is held to and attached thereto an adjacent
fused portion by means of a finite substance. This connector acts
as an alignment means for tufts, and arrangement control and a
reinforcing medium for the foam composition, and contributes to the
stability of the tuft with the foam support.
More specifically, referring now to the ski mat construction of
FIG. 12, the tufts 199 are supported in flexible foam 202. The tuft
bases 200 are attached to each other by means of connectors 201 as
shown in FIGS. 10 and 11. The connector is formed from an oriented
polypropylene monofilament whose diameter is in the order of 0.025
inch.
A ski mat in FIG. 12 is made by the following example:
EXAMPLE IV
A tufted arrangement consisting of polyamide synthetic filaments
was produced by first picking filament at its non-working end to
form tufts, and subsequently, adfixing the heated ends to a network
of polypropylene monofilament in order to produce the construction
shown in FIG. 10. A pre-mix of flexible foam was prepared according
to the method cited in Example II and poured onto a flat sheet of
wax paper. Immediately afterwards, foaming started and continued
for approximately 240 seconds. At that time the foam set and there
resulted a flexible tufted mat comprising polyamide filament tufts.
This tufted mat can be employed as artificial snow for skiing.
FIGS. 13-17 show how foam segments with synthetic tufts illustrated
in FIG. 5 may be assembled into a finished brush. More
particularly, as shown in FIGS. 13 and 14, filament tufts 300 of
this invention protrude from a common foam segment 301. The common
segment 301 can contain holes or other means for attaching it to
another similar segment, but in the instant invention reference is
made to the use of an adhesive. An end view of this segment is
shown in FIG. 14. In FIG. 15, four similar segments 301, 301', 301"
and 301'" are placed so that they are aligned with each other. As
shown in FIG. 16, there is provided a molded cap 302. When cap 302
is placed over segments 301, 301', 301" and 301'" as shown in FIG.
17, with adhesive, a finished brush emerges as shown in FIG.
17.
By employing synthetic filament tufts attached through their base
401 with connector 402 as shown in FIGS. 18 and 19, a rigid or
semi-rigid foam supported shoe brush may be constructed. The shoe
brush shown in FIGS. 20 and 21 clearly demonstrates the simplicity
in forming brushes. Employing tuft picking machinery as disclosed
in U.S. Pat. No. 3,471,202, it is possible to form continuous
modular strips of thermoplastic pre-trimmed brush constructions as
shown in FIG. 19. By simply cutting the construction every 12
tufts, 48 tufted shoe brushes can be formed. The interconnected
tufts can be supported in either rigid or semi-rigid foam
substrates, depending upon the physical shape and flexibility
desired.
As shown in FIG. 22, a belt of tufts 501 may be made from the
flexible strip construction shown in FIG. 7. By placing a
continuously connected flexible foam supported belt of tufts 501
onto a shaft 502 and rotating in direction D, a tufted brushing
tool 500 is formed.
The filament tufts of this invention may best be tufted by use of
heat-sealing technique and preferably by bringing the heated
non-working ends of the synthetic filament tuft into contact with a
suitable source of heated air and subsequently pressing the heated
mass into a connector means. An inert atmosphere, such as nitrogen,
carbon dioxide, or vacuum, can be employed when discoloration and
degradation through oxidation of the thermoplastic filament is
critical.
There is no restriction on the trim length, tuft diameter and tuft
arrangement when manufacturing such foam-supported brush-type
constructions.
The foregoing considerations conclusively demonstrate the
advantages to be gained by providing self-supporting tufted
arrangements of the type hereinbefore described. When such
constructions are incorporated into brushes, mats and the like,
there is attained new and novel constructions heretofore not
known.
The invention in its broader aspects is not limited to the specific
steps, methods, compositions, combinations and improvements
described but departures may be made therefrom in the scope of the
accompanying claims without departing from the principles of the
invention and without sacrificing its chief advantages.
* * * * *