EP1121877A2

EP1121877A2 - Cleaning device and method of construction

Info

Publication number: EP1121877A2
Application number: EP01300883A
Authority: EP
Inventors: George Koregelos
Original assignee: Individual
Current assignee: Individual
Priority date: 2000-01-31
Filing date: 2001-01-31
Publication date: 2001-08-08
Also published as: JP2001246340A; EP1121877A3

Abstract

A cleaning device 1 and method for making which is constructed from a thermoplastic material 2 to which a plurality of fibers 3 are fused and protrude therefrom, and formed into a curvilinear configuration such as a helix-like, or U-shape-like configuration. The method includes the steps of heating the base 2 until it is softened and bent to a U-shape like configuration and then cooling the base member 2, or helically winding the base 2 onto a rotating mandrel 11; stopping the mandrel 11 and severing an end of the base member 2; and cooling the base member 2 so that it retains its U-shape or helical configuration.

Description

This invention is specifically constructed for cleaning the slide valves of all brass section musical instruments, but may also be used in cleaning all types of tubular devices from the glassware in chemistry labs and other industrial and commercial uses to kitchenware used in food preparation.
Musical instruments in the brass section such as the trumpet, French horn, flugelhorn, coronet, mellophone, baritone horn, euphonium, tuba, sousaphone and trombone , all of which have removable slides, must be cleaned periodically. Brushes have been developed and are available commercially for this task. All of these brushes are constructed from straight fibers or bristles which are mechanically bound to a pair of twisted metal wires which are flexible to some extent. The problem with such metal wires is the fact that if the plastic or rubber caps are separated from the ends of the wires, the sharp edged wire ends can scratch or actually punch through the soft brass , thin wall metal tubes of the musical instruments, particularly those which have sharp, small diameter turns. Twisted wire brushes are not particularly flexible and this further exacerbates the scraping and scratching of the interior walls of the instruments. Many slides in musical instruments are formed with 180° turns and damage to the geometry of the slide can take place in the hands of a careless or young amateur musician.
Musical instruments are constructed with a wide range of lengths and diameters. A universal brush made from twisted wire is simply not available, to handle the different diameters and different lengths. Many brushes in an attempt to accommodate different lengths merely have fibers at the end of a very long handle. If the brush needs to be pushed through a sharp bend which occurs at the mid portion of the slide, the portion of the brush not covered with fibers must be covered with a soft flexible sheath to protect the inner wall of the brass tube from the much harder surface of the twisted wire brush.
The present invention provides, in a first aspect a cleaning device comprising:
an elongated flexible base member formed from a thermoplastic material having fibers protruding from at least one side of a portion thereof and said base member having a characteristic permitting memory reset from a first configuration to a second configuration.
In a second aspect, the present invention provides a method for forming a cleaning device which comprises the steps of:
selecting an elongated flexible base member formed from a thermoplastic material having a plurality of memory states and having a plurality of fibers integrally connected to and protruding from at least one side of a portion thereof;
bending said base member having a first memory state from a first position to a second position; and
applying heat to said base member to reset said first memory state to a second memory state.
In a third aspect, the present invention provides a method for forming a cleaning device which comprises the steps of:
selecting an elongated base member formed from a thermoplastic material and having a plurality of fibers integrally connected thereto and protruding therefrom;
attaching a first portion of said base member to a rotatable mandrel member at a starting point on said mandrel;
simultaneously rotating said mandrel, and progressively feeding said base member onto said mandrel at an ever increasing distance from said starting point on said mandrel;
applying sufficient heat to said base member to soften said thermoplastic material so that it will conform to the outer surface of said mandrel;
continuing said rotating and feeding until a selected end point away from said starting point on said mandrel is reached;
applying a cooling medium to said base member until said base member hardens and remains conformed to the outer surface of said mandrel; and
removing said base member from said mandrel.
In a fourth aspect, the present invention provides a cleaning device comprising:
a holder member having an end portion configured to provide angularly related sides;
a base member formed from a thermoplastic material;
a plurality of fibers integrally connected to said base member and protruding therefrom; and wherein
said base member is configured to overlap said end portion and to register with said angularly related sides so that said fibers protrude outwardly from said base member and said holder member.
In a fifth aspect, the present invention provides a method for forming a cleaning device which comprises the steps of:
selecting an elongated base member formed from a thermoplastic material and having a plurality of fibers integrally connected thereto and protruding therefrom;
bending said elongated base member in a U-shape- like configuration forming a head portion and depending leg portions;
heating said thermoplastic material sufficiently to reset the memory of said thermoplastic material to said U-shape-like configuration; and
attaching said leg portions to a holder member.
In a sixth aspect, the present invention provides a method for forming a cleaning device which comprises the steps of:
selecting a holder member having an end portion formed from a thermoplastic material;
selecting an elongated base member formed from a thermoplastic material and having a plurality of fibers integrally connected thereto and protruding therefrom;
bending said elongated base member in a U-shape- like configuration forming a head portion and depending leg portions; and
heating said thermoplastic portion of said holder portion and elongated base member sufficiently to reset the memory of said thermoplastic base member to said U-shape-like configuration and to fuse at least a portion of said elongated base member to at least a portion of said thermoplastic portion of said holder member.
In a seventh aspect, the present invention provides a method of use of a cleaning device according to any one of claims 1 to 10 or as formed according to a method as claimed in any one of claims 12 to 24, the method including use of the cleaning device to clean an inside surface of a curved pipe in a musical instrument or in glassware.
The gist of the present invention is a cleaning device which has no part with a hardness greater than the object being cleaned. Thus scratching, abrading or otherwise damaging materials in the cleaning device are eliminated to protect the musical instruments, laboratory glass ware , housewares or other objects being cleaned.
An object of the present invention is to provide an inexpensive, easy to use cleaning device which is inexpensive to manufacture, can be used to clean objects having internal passageways of varying lengths, opening sizes and angular turns, yet can be easily modified and manufactured in different shapes, lengths and diameters to accommodate an even wider variety of objects to be cleaned.
A further object is to provide a cleaning device which has no core or shaft so that the basic structure can be easily modified so that cleaning devices can be made to clean the internal walls of a tube as well as the outer circumference of the tube.
Still a further object is to provide a cleaning device which has the inherent ability to stretch automatically to reduce its diameter when inserted through a constricted opening or pulled through a sharp bend in a tubular member. This feature enables the diameter of the cleaning device to be reduced without bending the fibers of the cleaning device under some situations and bending the fibers less in other situations.
Yet another object is to provide a cleaning device with the inherent ability to increase its diameter when moving from a constricted portion of a tube to a wider portion of the tube yet maintain the cleaning fibers in a relatively right angular relationship to the inside wall of the tube being cleaned.
Still another object is to provide a method for constructing a cleaning device which can be manufactured in a variety of shapes, a variety of configurations, and sizes from the same base element.
The present invention will now be described by way of example only with reference to the accompanying drawings, in which:
Fig. 1 is a schematic perspective view of an apparatus illustrating a method of constructing a cleaning device according to the present invention.
Fig. 2 is a schematic perspective view of a portion of the apparatus of Fig. 1 illustrating one of the steps in a method according to the present invention.
Fig. 3 is a schematic perspective view illustrating another position of the apparatus shown in Fig. 1 further illustrating another step in the method of the present invention.
Fig. 4 is a perspective view of a portion of one of the elements used in constructing the cleaning device of the present invention.
Fig. 5 is side view of the cleaning device according to the present invention, partially in perspective format and with portions in dashed lines which are merely repetitive. Portions are cut away to show the configuration of the base member.
Fig. 6 is a side view of an alternate cleaning device according to the present invention, partially in perspective format and with portions in dashed lines which are merely repetitive. Portions are cut away to show the configuration of the base member.
Fig. 7 is side view of the cleaning device illustrated in Fig. 5 showing the different configurations the cleaning device takes in the operation of being pulled through a tube with portions cut away for purposes of illustration.
Fig. 8 is a side view of a cleaning device similar to the cleaning device illustrated in Fig. 5 except that a leader member is attached to both ends of the portion with filaments. The cleaning device is illustrated cleaning a tube shown in partial section. The filaments in a portion of the cleaning device have been removed to illustrate the configuration taken by the base member when both ends of the cleaning device are in tension. The drawing illustrates how the cleaning device can be used in a "sawing" motion to clean a tube.
Fig. 9 is a schematic drawing of a trumpet illustrating four removable slides which may be cleaned by the cleaning device of the present invention.
Fig. 10 is a side view of an alternative embodiment of cleaning device according toe the present invention.
Fig. 11 is an enlarged scale cross sectional view of the cleaning device shown in Fig. 10 taken along line 11-11.
Fig. 12 is an enlarged scale end view of the cleaning device shown in Fig. 10 taken in the direction of line 12-12.
The cleaning device 1 of the present invention consists briefly of a base member 2, a plurality of fibers 3 integrally connected to the base member 2 and protruding therefrom, the base member 2 has an elongated helix-like configuration 4.
In the preferred form of the cleaning device, as best shown in Figs. 5 and 6, base member 2 has an elongated helix configuration.
In one form of the invention, the base member 2 has an elongated helix-like configuration 4 having a constant helical angle 5 as shown in Fig 5.
In another form of the cleaning device, the base member 2 has an elongated helix-like configuration having a varying helical angle.
In still another form of the cleaning device 1 as shown in Figs 5 and 7, the cleaning device has a base member 2 with an elongated helix-like configuration 4 having a selected helical angle 5 which forms a cleaning device with coils 6 which are close fitting one to the other.
In another form of the cleaning device, as illustrated in Fig 6, the base member 2' has an elongated helix-like configuration 4' having a selected helical angle 5' which forms a device with coils 6' which are spaced one from the other a selected distance 43' greater than the distance 43 in Fig 5.
In still another form of the cleaning device, the fibers protrude from the base member 2 at varying selected lengths from the base member 2.
In another form of the cleaning device, base member 2 has an elongated helix-like configuration 4 having a constant selected helical angle 5.
In a further form of the cleaning device, base member 2 has an elongated helix-like configuration 4 having varying selected helical angles 5.
In another preferred form of the invention base member 2 is formed from a thermoplastic spring memory return material.
As shown in Figure 4 the basic building element of the cleaning device of the present invention is simply a strip of thermoplastic material 2 such as polypropylene with fibers 3 of the same material fused to the base 2. By fusing the filaments 3 to the base 2, the fibers cannot separate from the base unless they are actually severed. One of the sources of the base 2 and fibers 3 is a product made by a number of manufacturers for several years which is primarily used as a weather stripping element when it is attached to the lower edge of outside doors. The product is also used for making floor sweeps, foot sweeps and even push brooms. The product is thermoplastic and softens at approximately 200° F. so that it can be easily wound on a mandrel 11. When the base 2 is cooled, the base 2 assumes the same configuration as the mandrel 11. The product is preferably a spring memory material so that when wound in a helix and force applied at opposite ends, the helix will elongate. When the force is released, the helix returns to its former length and diameter.
Preferably a polypropylene ball is fused to the end 19 of the leader 18 and to the other end of the base member 2 so that there will be no sharp edges.
Figures 1, 2 and 3 illustrate an apparatus for practicing a method of the present invention. The drawings are schematic and illustrate a simplified form of the apparatus for purposes of understanding the method. Various changes and improvements are contemplated for increasing the mass production of the cleaning device 1.
A platform 31 is provided and affixed thereto is a speed controller 32 which controls the speed of a motor 33 which turns a drive shaft 34 connected to a chuck 35 for releasably gripping mandrels 11 of varying size. A gripping member 12 for gripping the end of base member 2 is attached to and rotates with the mandrel 11. A guide 20 is pivotally mounted on a carriage 24 for guiding the base member 2 therethrough at a selected angle 21 in relation to the axis 22 of mandrel 11. Preferably the base member 2 enters the guide member 20 with the fibers 3 directed downwardly so that hot air from a heat tube 36 will be directed upon the base member 2. The heat tube 36 is preferably mounted on a swivel device 37 so that when no base member 2 is being fed through the guide member 20, the heat may be directed onto a thermal device 38 which measures the temperature and signals when the temperature is hot enough to begin the operation of the device. A speed controller 39 may be provided to control the velocity by which the carriage 24 traverses the platform 31 in tracks 26. A shear device 40 severs the base member 2 at leader end 19. An angle controller 41 pivots guide 20 at selected angles to feed the base member 2 at varying angles 21 to the axis 22 of the mandrel 11. When the cleaning device has received the selected number of coils 6, The rotation of mandrel 11 is stopped and cooling air is directed against the heated base member 2 through a cooling tube 42 or other cooling means. If the mandrel 11 is hollow, the cooling tube 42 may be placed through the mandrel.
The various cleaning devices of the present invention may be made using a method which includes the steps of: selecting an elongated base member 2 formed from a thermoplastic material and having a plurality of fibers 3 integrally connected thereto and protruding therefrom; attaching a first portion 10 of the base member 2 as shown in Fig. 3 to a rotatable mandrel member 11 at a starting point 12 on the mandrel 11; simultaneously rotating the mandrel 11, and progressively feeding the base member 2 onto the mandrel 11 at an ever increasing distance from the starting point 12 on the mandrel 11; applying sufficient heat to the base member 2 to soften the thermoplastic material so that it will conform to the outer surface 14 of the mandrel 11; continuing the rotating and feeding steps until a selected end point 15 away from the starting point 12 on the mandrel 11 is reached; applying a cooling medium to the base member 2 until the base member 2 hardens and remains conformed to the outer surface 14 of the mandrel 11; and removing the base member 2 from the mandrel 11.
In the preferred form of making the cleaning device 1, the method of manufacture includes selecting a base member 2 wherein the fibers 3 protrude from one side only of the elongated base member 2; and feeding the base member 2 onto the mandrel 11 as previously described so that the base member 2 is fed onto the outer surface 14 of the mandrel 11 so that the fibers 3 protrude radially outwardly from the mandrel 11.
In another method for forming a cleaning device , a base member 2 is selected wherein the fibers protrude from one side only of the elongated base member 2. A mandrel having a tubular configuration having an inside wall is selected. The base member 2 is releasably attached to a clamp member or other attachment member on a mandrel. As the mandrel is rotated, the base member 2 is fed into the mandrel tube so that the fibers 3 protrude radially inwardly from the inside wall of the mandrel tube. Using this method of construction, a cleaning device is formed which is useful in cleaning the outer circumference of tubes. Such a situation may exist where the tube is located within a tube and it is difficult to clean the outer surface of the tube with standard cleaning devices. The device may also be used in cleaning the outside surfaces of glass drinking containers or other tubular housewares.
The preferred method for forming the cleaning device 1 of the present invention, is to apply the heat for softening the base member 2 prior to the step of feeding the base member 2 onto the mandrel 11 as shown in Figs. 1 and 3. Other methods as previously indicated could include feeding the base member 2 in its unaltered state onto a mandrel 11 which is preheated, or heated during the feeding step. The method of heating may include impinging hot gases on the mandrel, applying ultrasound waves, or charging the mandrel with an electric current.
Another method of making an alternate form of the cleaning device is to follow the steps of making the cleaning device as previously described. Then, after a selected number of coils 6 of the device have been wound upon the mandrel 11, the rotation of the mandrel 11 is stopped and instead of severing the base member 2 at or near the last coil 6, the base member 2 is severed at a selected distance from the last portion of the base member 2 which was fed upon the mandrel. In this manner a leader member 18 is provided which can be used to feed through a tubular member 45 and once the leader end 19 emerges from the tube 45, as shown in Fig 7, the remainder of the cleaning device 1 can be pulled through the tube which is generally much easier than pushing the cleaning device through the tubular member 45, particularly where, as in the illustration in Fig. 7, the tube 45 makes a 180° turn at portion 46.
The cleaning device 1 of the present invention could be entirely hand fed onto the mandrel 11, but preferably, a guide 20 is provided so that the base member 2 can be fed onto the mandrel 11 at a specific angle of rotation at a specific angle 21 in relation to the longitudinal axis 22 of the mandrel as shown in Fig. 3.
The cleaning device 1 may also be formed by hand by feeding the base member 2 onto the rotating mandrel 11 so that the base member 2 enters upon the mandrel 11 at a progressively greater distance axially from the point 23 the base member 2 initially entered upon the mandrel 11. In order to make the cleaning device 1 in a more uniform manner with the coils 6 of the cleaning device 1 spaced one from the other at either a uniform distance or a progressively greater or a progressively less distance, a carriage means 24 as shown in Figs. 1, 2, and 3 is provided for carrying the guide member 20. The carriage means 24 could be provided with wheels 25 which run along a track 26 or any other sliding mechanism. Generally the carriage means 24 is moved at a selected velocity during the feeding step. Carriage means 24 is moved back and forth in the direction of double arrows 30 as shown in Fig. 1. When the base 2 is being fed onto mandrel 11, the carriage is moved in the direction of arrow 44 illustrated in Fig 3.
To make cleaning devices 1 which have coils 6 which vary in distance one from the other, a speed controller 39 for varying the velocity of the carriage 24 during the feeding step may be provided. Thus a cleaning device 1 may be constructed which has coils 6 widely spaced at the entering portion of the cleaning device 1 so that the entering portion of the cleaning device exerts less pressure upon the inner walls of the tube and thus less resistance to the cleaning device 1 passing through the tube to be cleaned would be encountered. After the leader 18 has passed through the tube to be cleaned, the portion of the cleaning device with more densely packed coils enters the tube. The increased resistance to passage through the tube may be overcome by pulling the cleaning device 1 through the tube by grasping the leader member 18.
Another form of cleaning device 1'; may be constructed in which the plane of each coil 6' may be varied in relation to the longitudinal axis 29' of the cleaning device 1'. As shown in Fig. 6, angle 5' is greater than angle 5 as shown in Fig. 5. This causes the coils 6' to have a greater angle 28' in relation to longitudinal axis 29' of the cleaning device 1' than angle 28 in relation to longitudinal axis 29 in Fig 5. One advantage of this form of the invention is the fact that fibers 3' protruding from base 2' may have the same length as a cleaning device formed with a smaller angle 5 but the overall diameter of the cleaning device will be less.
Still another form of cleaning device 1 may be constructed in which the angle 21 at which the base 2 is fed to the mandrel 11 is varied during the feeding operation. Thus the angle 5 made by the base 2 to the longitudinal axis 29 of the cleaning device 1 will vary. Coils 6 of some portion of the cleaning device 1 will be at a greater angle 5 than coils 6 at a different portion of the cleaning device 1. For example, to make it easier for the cleaning device 1 to enter a tube to be cleaned, the angle 5 of the coil 6 relative to the longitudinal axis 29 may be greater than the angle of the coils relative to the longitudinal axis 29 on the trailing end of the cleaning device 1. This duality of coil angles 5 is used in some specialized wood screws where the screw has a greater thread angle at the pointed end to enable the point to quickly enter the wood member and then after the screw enters the wood the thread angle decreases. This dual thread angle is unknown in the tube cleaning device industry. With such a dual angle cleaning device, and with the greater angled coils occurring at the lead end, it is easier for the cleaning device to enter a tube with a small diameter.
In most instances it is desirable to provide the cleaning device with a leader 18 adjacent lead coil 27 which is devoid of fibers 3. Accordingly, after the selected number of coils 6 of the base member 2 and fibers 3 are formed on the mandrel 11, the rotation is stopped, the base member 2 is cooled, the base member 2 is cut a measured distance from the last coil 6, and then the fibers 3 are cut from the base member 2 between the last coil 6 and the end 19 of the leader 18.
Some special uses of the cleaning device require a leader 18" and a tail piece 47 as shown in Fig 8. By providing a leader 18 " and a tail piece 47, the cleaning device 1" can be inserted through a tubular member 48, pulled further by means of the leader 18" until the body of the cleaning device 1" reaches a predetermined portion of the tube 48 and then the leader 18" and tail piece 47 can be grasped and the cleaning device 1" reciprocated back and forth within the tube 48 as indicated by double arrows 68 and 69. Such procedure is more effective and certainly much quicker in cleaning the tube 48 than repeatedly inserting , pulling the cleaning device 1" completely through the tube 48 and then reinserting the cleaning device 1" in the tube 48.
Very little needs to be done in changing the method of making the cleaning device. One solution is simply to measure a portion of the base member 2 which is to become the tail 47 and simply attaching the base member 2 at the upstream end 49 of the tail 47 to the mandrel 11. After the cleaning device 1 has been formed and cooled, the fibers 3" on coils 6" are simply cut from the base member 2" which forms the tail 47.
Still another form of the cleaning device is constructed from a base member 2 which is formed with different types of fibers 3. Some of the fibers could be soft, for example, and some of the fibers could be relatively more rigid. Still another form of the cleaning device would be to provide the base member 2 with a mixture of different fibers 3 such as cotton fibers and synthetic fibers. Such fibers 3 could be attached to the base member 2 in patterns of uniformly mixed distribution or patterns of segregated blocks of different fibers, or indeed, a mixture of the two types of patterns.
The versatility of using a thermoplastic base member 2 is illustrated by comparing the cleaning devices illustrated in Figures 5 and 6. The base member 2 in Figure 5 is identical in size to the base member 2' in Figure 6. The cleaning device 1' in FIG. 6 is greater in diameter, however, than the cleaning device 1 illustrated in Fig. 5, by merely providing longer fibers 3. Different diameter cleaning devices using the same base member 2 may also be achieved by winding the base member on different diameter mandrels, or by changing the angle 21 in which the base member 2 is fed onto the mandrel 11.
The spacing of coils 6 to each other may be varied in several ways, one of which is shown in FIG. 6. As shown in FIG. 5, the spacing of the coils 6 is very close so that a dense packing of fibers 3 is achieved. This may be accomplished by winding the base member 2 on the mandrel 11 at nearly a right angle so that there is a small space 43 between the helically wound base member 2 upon the mandrel. In contrast, in Fig. 6, there is considerable spacing between each of the coils 6' so that the cleaning device fibers 3' are less densely packed. As shown in Fig. 6, there is a substantial distance 43' between each coil 6'. This is generally accomplished by moving the carriage 24 at a greater velocity. Cleaning device 1' in Fig. 6 may be formed with a leader 18' adjacent lead coil 27'.
Figures 4 and 5 also illustrate that the slope of the coils 6 may be varied even though the exact same base 2 is used and the fibers 3 are attached in the same manner. Note that the coils 6 make almost a right angle with the axis 29 of the cleaning device 1 whereas the coils 6' in FIG. 6 make a greater angle 5' with the axis 29'. This is accomplished by either changing the velocity of the carriage 24 as previously described, or actually feeding the base 2 onto mandrel 11 at a different angel 21 as shown in FIG. 3.
The cleaning device of the present invention was initially invented to provide a cleaning device for musicians playing brass instruments to clean their instruments. A trumpet 50 for example , as shown in Fig 9 has four valve slides: a first slide 51, a second slide 52, a third slide 53 and a tuning slide 54; all of which must be removed from the instrument and regularly cleaned. The cleaning device of the present invention has been found to be ideal since is able to be inserted and pulled through all of the trumpet valve slides which are small in diameter and have very tight right turns. Since the cleaning device is entirely made of plastic, there are no metal wires to scrape the inside walls of the slide valves, or poke a hole in weak or old brass musical instruments. The cleaning device, itself is easily cleaned after each use. The cleaning device is light, rolls up into a tight spiral and returns instantly and automatically to a straight configuration ready for use. The entire cleaning device being made from plastic dries quickly and with no metal parts, it requires no expensive water proof sheathing and will not rust or contaminate the instrument or tubing it is cleaning.
The cleaning device of the present invention is not limited to musical instruments and can be used to clean glass or plastic tubing used in chemistry labs. In fact the cleaning device can be used commercially or in homes for a wide variety of devices and apparatus which have tubes or constricted openings. which must be cleaned from time to time.
Referring to FIG. 7, a cleaning device 1 such as the device illustrated in Fig 5 may be used to clean a tube 45 such as a metal or glass tube. The cleaning device 1 may be used either with a cleaning solvent, with soap and water, or by itself. Using it with water helps flush the tubing during the cleaning process. Tube 45 could be a portion of any tube as for example one of the slides 51 - 54 of a trumpet 50 illustrated in Fig. 9. To clean the tube, leader 18 is first inserted through end 55 until it emerges through end 56. As illustrated in Fig. 7, as the cleaning device 1 is pulled through the tube 45 in the direction indicated by arrow 58 the coils 6 at the tail end of the cleaning device 1 in the straight portion of the tube 45 indicated by the arrow 57 remain in substantially their original spacing one from another. As the cleaning device moves around curved portion 46, the pulling force on the base member 2 must be increased because of the friction of the fibers 3 against the sides of the curved portion. This additional resistance to movement of the cleaning device 1 causes the helical base member 2 to stretch and cause greater spacing to occur between each of the helical coils 6 as indicated by the arrows 59 . As demonstrated in Fig 6, when the spacing between coils open up and becomes greater, the effective diameter of the coils 6 is reduced by the fact that the slope of the coils is increased as illustrated in Fig. 6. Because the effective diameter of the coils is reduced, the friction that the ends of the fibers 3 exert on the inside wall 60 of the tube 45 is reduced. This makes it easier to pull the cleaning device 1 through the tube. After all of the cleaning device 1 has traversed the curved portion 46 of the tube, the friction of the cleaning device 1 against the walls 60 is reduced, and the distance between coils is reduced thus causing the coils to once again exert a greater force on the wall 60. As the coils emerge from end 56 of the tube such as coil 76, as shown in illustration Fig. 7, because of the memory of the fibers 3 and the base 1, the coils 6 grow in diameter.
Referring to Figs 10, 11 and 12, an alternate form of the cleaning device 1''' is illustrated. Cleaning device 1''' is formed from the same base 2 and fibers 3 as illustrated in Fig. 4; both of which are made from a polypropylene thermal plastic. Cleaning device 1''' consists of a holder member 61 having an end portion 62 configured to provide angularly related sides 63 and 64; a base member 2"' formed from a thermoplastic material; a plurality of fibers 3"' integrally connected to the base member 2''' and protruding therefrom; and the base member 2''' is configured to overlap the end portion 62 and to register with the angularly related sides 63 and 64 so that the fibers protrude outwardly from the base member 2"' and the holder member 61. Holder member 61 may be round or polygonal such as a square and the angularly related sides may be curvilinear, flat or multifaceted so long as the faces 63 and 64 are angular one to the other.
Only one strip of base member 2"' has been attached to the holder member 61, but two or more base members with fibers could be used to provide additional fibers. The holder member could be straight or curvilinear depending upon the particular cleaning purpose of the cleaning device.
Preferably the thermoplastic base 2"' should be heated at least in the U-shaped portion 65 and the memory of the material reset so that the entire base member 2"' can be more easily affixed to the holder member 61.
The base member 2''' may be attached to the end portion 62 of the holder 61 by any mechanical means such as taping, or by applying adhesive, but preferably by a method set forth below.
No drawings are believed necessary for an understanding of the method used to make the cleaning device illustrated in Figs.. 10 - 12 in view of the extensive illustrations of the method of forming a helical cleaning device as shown in Figs. 1 to 3.
The method for forming a cleaning device 1''' includes the steps of: selecting an elongated base member 2"' formed from a thermoplastic material such as polypropylene and having a plurality of fibers 3''' integrally connected thereto and protruding therefrom; bending the elongated base member 2''' in a U-shape-like configuration forming a head portion 65 and depending leg portions 66 and 67; heating the thermoplastic material sufficiently to reset the memory of the thermoplastic material to the U-shape-like configuration; and attaching the leg portions 66 and 67 to a holder member 61.
Using the method above described, the legs 66 and 67 may be attached to the holder 61 by tape or other mechanical means, but the preferred method is to attach the entire base member 2"' by the method set forth below.
Another method for forming a cleaning device 1"' which comprises the steps of: selecting a holder member 61 having an end portion 62 formed from a thermoplastic material; selecting an elongated base member 2"' formed from a thermoplastic material and having a plurality of fibers 3''' integrally connected thereto and protruding therefrom; bending the elongated base member 2"' in a U-shape-like configuration forming a head portion 65 and depending leg portions 66 and 67; and heating the thermoplastic portion 62; and elongated base member 2''' sufficiently to reset the memory of the thermoplastic base member 2''' to the U-shape-like configuration and to fuse at least a portion of the elongated base member 2''' to at least a portion of the thermoplastic portion of the holder member 61.
In summary, the cleaning device of the present invention may be configured to almost any geometric or random configuration by heating a strip of thermoplastic material, bending the strip to the desired shape and then cooling the material. The U-shape-like and helical-like configurations are only illustrative of two of the shapes envisioned by applicant.
The configuring of the cleaning device to a large extent determines the use to which the device may be put. Again, cleaning the tubes in brass instruments, the glass ware in chemistry labs and common housewares is only illustrative of the unlimited uses to which cleaning devices, commonly called brushes have been employed.

Claims

A cleaning device comprising:
an elongated flexible base member formed from a thermoplastic material having fibers protruding from at least one side of a portion thereof and said base member having a characteristic permitting memory reset from a first configuration to a second configuration.
A cleaning device comprising:

a base member formed from a thermoplastic material; and

a plurality of fibers integrally connected to said base member and protruding therefrom, wherein:
said base member has an elongated helix-like configuration.
A cleaning device as claimed in claim 2 wherein:
said base member has an elongated helix configuration.
A cleaning device as claimed in claim 2 or claim 3 wherein:
said elongated helix-like configuration has a constant helical angle.
A cleaning device as claimed in claim 2 or claim 3 wherein:
said elongated helix-like configuration has a varying helical angle.
A cleaning device as claimed in claim 2 or claim 3 wherein:
said elongated helix-like configuration has a selected helical angle which forms a device with coils which are close fitting one to the other.
A cleaning device as claimed in claim 2 or claim 3 wherein:
said elongated helix-like configuration has a selected helical angle which forms a device with coils which are spaced one from the other a selected distance.
A cleaning device as claimed in any one of claims 1 to 7 wherein:
said fibers protrude from said base at varying selected lengths from said base.
A cleaning device as claimed in claim 2 or claim 3 wherein:
said base member has an elongated helix-like configuration having varying selected helical angles.
A cleaning device as claimed in any one of claims 2 to 9 wherein:
said thermoplastic base member is a spring memory return material.
A method for forming a cleaning device which comprises the steps of:

selecting an elongated flexible base member formed from a thermoplastic material having a plurality of memory states and having a plurality of fibers integrally connected to and protruding from at least one side of a portion thereof;

bending said base member having a first memory state from a first position to a second position; and

applying heat to said base member to reset said first memory state to a second memory state.
A method for forming a cleaning device which comprises the steps of:

selecting an elongated base member formed from a thermoplastic material and having a plurality of fibers integrally connected thereto and protruding therefrom;

attaching a first portion of said base member to a rotatable mandrel member at a starting point on said mandrel;

simultaneously rotating said mandrel, and progressively feeding said base member onto said mandrel at an ever increasing distance from said starting point on said mandrel;

applying sufficient heat to said base member to soften said thermoplastic material so that it will conform to the outer surface of said mandrel;

continuing said rotating and feeding until a selected end point away from said starting point on said mandrel is reached;

applying a cooling medium to said base member until said base member hardens and remains conformed to the outer surface of said mandrel; and

removing said base member from said mandrel.
A method for forming a cleaning device as claimed in claim 12 further comprising the steps of:

selecting a base member wherein the fibers protrude from one side only of said elongated base member; and

feeding said base member onto said mandrel as described in claim 13 so that said base member is fed onto the outer surface of said mandrel so that said fibers protrude radially outwardly from said mandrel.
A method for forming a cleaning device as claimed in claim 12 further comprising the steps of:

selecting a base member wherein the fibers protrude from one side only of said elongated base member;

selecting a mandrel having a tubular configuration; and

feeding said base member into the tubular interior of said mandrel so that said fibers protrude radially inwardly from said mandrel circumference.
A method for forming a cleaning device as claimed in any one of claims 12 to 14 wherein said step of:
applying said sufficient heat to said base member is prior to said feeding step.
A method for forming a cleaning device as claimed in any one of claims 12 to 15 further comprising the step of:
severing said base member at a point at a selected distance from the last portion to be fed upon said mandrel thus providing a leader member.
A method for forming a cleaning device as claimed in any one of claims 12 to 16 further comprising the step of:
providing a guide for said base member directing said base member toward said mandrel at a selected angle.
A method for forming a cleaning device as claimed in any one of claims 12 to 16 further comprising the step of:
providing a carriage means for carrying a guide for said base member which is movable at a selected velocity parallel to said mandrel during said feeding step.
A method for forming a cleaning device as claimed in claim 18 further comprising the step of:
selecting a speed controller for varying the velocity of said carriage during said feeding step.
A method for forming a cleaning device as claimed in claim 18 or claim 19 further comprising the step of:
selecting an angle controller for varying the angle of said guide member for varying the angle said base member is directed toward said mandrel.
A method for forming a cleaning device as claimed in any one of claims 17 to 20 further comprising the step of varying the angle of said guide member during said feeding step.
A method for forming a cleaning device as claimed in any one of claims 16 to 21 further comprising the step of:
severing the fiber members from said leader member.
A method for forming a cleaning device as claimed in any one of claims 12 to 22 further comprising the steps of:

providing a tail portion before attaching said base member to said rotatable mandrel member; and

severing the fiber members from said tail member.
A method for forming a cleaning device as claimed in any one of claims 12 to 23 wherein:
the base member selected has one or more types of fibers integrally connected thereto in patterns of uniformly mixed distribution or patterns of segregated patterns of different fibers.
A cleaning device comprising:

a holder member having an end portion configured to provide angularly related sides;

a base member formed from a thermoplastic material;

a plurality of fibers integrally connected to said base member and protruding therefrom; and wherein

said base member is configured to overlap said end portion and to register with said angularly related sides so that said fibers protrude outwardly from said base member and said holder member.
A method for forming a cleaning device which comprises the steps of:

selecting an elongated base member formed from a thermoplastic material and having a plurality of fibers integrally connected thereto and protruding therefrom;

bending said elongated base member in a U-shape- like configuration forming a head portion and depending leg portions;

heating said thermoplastic material sufficiently to reset the memory of said thermoplastic material to said U-shape-like configuration; and

attaching said leg portions to a holder member.
A method for forming a cleaning device which comprises the steps of:

selecting a holder member having an end portion formed from a thermoplastic material;

selecting an elongated base member formed from a thermoplastic material and having a plurality of fibers integrally connected thereto and protruding therefrom;

bending said elongated base member in a U-shape- like configuration forming a head portion and depending leg portions; and

heating said thermoplastic portion of said holder portion and elongated base member sufficiently to reset the memory of said thermoplastic base member to said U-shape-like configuration and to fuse at least a portion of said elongated base member to at least a portion of said thermoplastic portion of said holder member.
A method of use of a cleaning device according to any one of claims 1 to 10 or as formed according to a method as claimed in any one of claims 12 to 24, the method including use of the cleaning device to clean an inside surface of a curved pipe in a musical instrument or in glassware.