GB2273237A

GB2273237A - A brush and a method of making a brush

Info

Publication number: GB2273237A
Application number: GB9323649A
Authority: GB
Inventors: Robert L Altemare; Joseph Sigal
Original assignee: Jason Inc
Current assignee: Jason Inc
Priority date: 1992-12-11
Filing date: 1993-11-16
Publication date: 1994-06-15
Anticipated expiration: 2013-11-16
Also published as: DE4342118A1; JPH0739423A; GB2273237B; GB9323649D0

Description

io 2273237 A BRUSH AND A METHOD OF MAKING A BRUSH This invention relates

generally to a brush e.g. an end or cup brush and method of making such a brush. More particularly a simplified process, as disclosed herein, of distributing, orienting and securing the bristle or filament fill material in an end brush design results in a too! with inherently better concentricity and balance. The process reduces manufacturing costs while reducing vibration resulting in better performance in both manual and automatic applications. Better balance in manual operation results in less hand and operator fatigue.

End brushes are often manufactured utilizing rings, sleeves, pins or keys as anchors to secure the bristle fill material bundle in the holder with the fill material bundles being folded like a hairpin in the cup of the holder. This results in non-uniform distribution and density of the fill material and also normally requires a secondary operation such as trimming of the brush face. Such internal anchors can affect the balance or stability of the tool quite apart from causing non-uniform distribution of the fill material.

Samples of end brushes and tools using mechanical anchors or keys may be seen in prior U.S. Patent No. 2,982,983 to Peterson. Other examples are seen in Benyak U.S. Patents 2,449, 158 and 2,755,496, Less U.S. Patent 3, 106,739, Peterson U.S. Patent 2,421,647 and Tilgner U.S. Patent 3,237,234.

The brush making methods of these prior patents are such that it is difficult to distribute properly the fill material and any also insert key such that good dynamic balance is obtained.

it is therefore desirable to have a method and end or cup brush made by that method which will achieve good dynamic balance and which can be made quickly, automatically, and efficiently.

According to the invention in a broad aspect, there is provided a method of making a cup brush comprising the steps of supporting a cup holder having a bottom and a circular wall terminating in a rim, forming and driving a hollow cylindrical bundle of filaments towards the bottom of the cup, distributing the bundle against the cup wall and around a centre core, and deforming the cup wall inwardly against the bundle and core to lock the ffilaments in place about the axis of the cup.

In accordance with preferred aspects of the invention, an end brush and a method making the brush employs the automatic distribution and insertion of the bristle fill material into the cup of a cup-shaped shank holder. Preferably, a centered drive system projects from the bottom of the holder. Conveniently, after a measured amount of the fill material is inserted through fill tubes and a guide funnel, a centering core insert is forced into the centre of the cup to distribute the fill material around and against the interior of the wall of the cup. The material is preferably cut -to proper length and in the same or a separate station the exterior wall of the cup of the holder is conveniently deformed or crimped inwardly girdling the core, securing and centering the core and material in the holder. Preferably, axial ribs are also formed which improves transfer of heat from the holder improving tool life. Preferably the insert is softer than the fill material and may also be softer than the holder. A wide variety of fill materials may be employed as well as various shapes of inserts and holders. The end brush according to the invention is easier to make, has a longer life, and has inherently better balance making the tool easier to use by hand or machine.

There now follows a description of preferred embodiments of the invention, by way of example, with reference being made to the accompanying drawings in which:

Figure 1 is a vertical section of apparatus with the parts in place and prior to closing for making a brush according to the process of the present invention; Figure 2 is a horizontal section through the fill material tubes as seen from the line 2-2 of Figure 1; Figure 3 is a view similar to Figure I but with the parts closed and fill material in place; Figure 4 is a view similar to Figure 3 showing the insert in place and the fill material being cut; Figure 5 is a view similar to Figure 1 with the parts separating; j! 1 Z Figure 6 is a view illustrating the step of deforming the cup wall against the waist of the insert; insert on a pilot; Figure 7 is a vertical section of an end brush in accordance with the present invention using twisted wire or cable as the fill and with a more cylindrical insert; Figure 8 is an elevation of the brush of Figure 7 illustrating one form of girdling deformation; Figure 9 is a view similar to Figure 7 illustrating a brush with a metallic or non-metallic fill material and with a ball insert; Figure 10 is an elevation of the brush of Figure 9; Figure 11 is a side elevation of another form of insert girdling deformation, such brush being shown in section in Figure 5, for example; Figure 12 is an axial section of a form of the invention using a twopiece shank or cup, an insert pilot, an exterior bridle, and an inside sleeve; Figure 13 illustrates in a similar manner a one-piece cup or shank with an Figure 14 illustrates a tool with a headed pilot option; Figure 15 illustrates a one-piece shank or cup and an insert with two different types of pilots; Figure 16 illustrates a standard piloted hollow insert; Figure 17 illustrates a hollow center type brush with both the insert and the cup wall somewhat flared; and Figure 18 illustrates in essence the same brush with both parts more severely flared to form a circular end brush.

Referring initially to Figures 1-5 there is illustrated a press or jig which includes upper and lower portions 20 and 21 respectively. The movable or lower portion 21 includes a support 22 for cup holder 23.

The cup holder 23 includes a cylindrical wall 25, a bottom interior wall 26, and a concentric drive stem 27 projecting from the bottom of the holder. On top of the support 22 there is provided a funnel 29 which at its lower end overlies the rim 30 of the cup wall 25. The funnel is readily removed from the support 22 for is insertion and removal of the cup holder. The tooling 22 and 29 may readily be replaced with similar tooling for different size or types of end brushes. As indicated by the arrow 32 the lower portion 21 is vertically movable toward and away from the upper portion 20.

The upper portion 20 includes two annular cut-off dies seen at 35 and 36 which are juxtaposed and mounted on sleeve 37. Extending vertically upwardly from the plate 35 are fill tubes 38, which, as shown in Figure 2, are eight in number and equally spaced around the vertical axis of the jig. The fill tubes 38 are mounted above slightly inwardly angled holes 40 in plate 35 and as seen, plate 36 includes slightly more angled holes 42 forming a continuation of the holes 40. It is also noted that the diameter of the slightly more angled holes 42 is slightly larger than the diameter of the holes 40 in the plate 35. It is also noted that the maximum circle formed by the holes 42 in the bottom of the plate 36 is slightly smaller than the maximum diameter of the upper edge of the funnel 29.

Situated within each fill tube is an equal measured amount of fill material indicated at 44. As illustrated in Figure 1, the fill material projects through the tubes and through the holes 40 to the line 46 which is the cut-off line between the two annular cut-off dies. It will be appreciated that more or fewer fill tubes may be provided depending upon the size of the brush being formed. The purpose of the equally circumferentially spaced fill tubes and corresponding holes is to assist in achieving proper fill distribution.

In the center of the upper portion of the jig there is provided a core or insert pusher indicated generally at 50. The pusher 50 comprises a vertically movable plunger 51 mounted in sleeve 37 for vertical movement. The insert pusher includes a downwardly projecting guide pin 52 which is urged to its extended position by compression spring 53. The guide pin 52 extends through insert 55 which is seated in the recess shown in the lower end of sleeve 37. The tip of the pin 52 is provided with a conical recess indicated at 56 which mates with a conical projection on pilot stud 57 projecting from the bottom wall 26 of cup holder 23. The cup holder 23 and the insert 55 may be loaded manually or automatically into the equipment illustrated.

Referring now to Figure 3 with the cup holder elevated the fill material 44 is fed through the series of guide tubes 38 to the guide funnel 29 and then into the is holder 23 as indicated by the arrows 60 and 61. In this manner the fill material is positioned symmetrically around the holder to achieve substantially proper distribution. In such position the guide pin 52 and pilot 57 are in engagement with each other.

As seen in Figure 4, the insert pusher 50 is now actuated to feed the insert 55 into the holder as indicated by the arrow 62. This wedging of the insert into place applies a slight pressure on the fill material which will cause the fill material to be evenly distributed in the holder. The downward movement of the pusher compresses spring 53 and slides the insert down the guide pin 52 and telescopes the insert over the pilot stud 57. With the fill material and insert secured, the fill material is cut to the proper length as indicated in Figure 4 by rotation of the plate 35 as seen by arrow 63 severing the fill material at 64.

As seen in Figure 5 the equipment opens as indicated by the arrow 66 and returns to the position seen in Figure 1. The end brush thus formed shown generally at 68 is manually or automatically removed and is loaded into secondary swaging press seen in Figure 6 and shown generally at 70. The swaging apparatus or press comprises an annular ring 72 which includes an internal wedge surface 73. The swaging equipment may also include a brush support indicated generally at 74 which receives the drive stem 27 holding the brush concentrically with respect to the axis of the cone of wedge surface 73. A series of circularly arranged swaging dies indicated at 75 and 76 have external conical wedge surfaces 77 mating with the surface 73. As the ring 72 moves axially, the swaging dies shown at 75 and 76 close as indicated by the arrows 78 and 79 causing the inward projections seen at 80 and 81 to engage and deform inwardly the circular wall of the cup.

It is noted that the insert 55 is beveled both top and bottom, the lower bevel being seen more clearly at 82 in Figure 1. Between such beveled ends the insert is provided with a right circular cylindrical exterior surface. The swaging or crimping dies act opposite that surface to provide a girdling swage which is effective to lock uniformly the fill material into the cup holder and uniformly distribute it around the axis of the tool. In this manner the girdling deformation of the cup wall is spaced axially both from the rim 30 of the cup as well as from the bottom wall 26, and the inward extent of deformation is symmetrical and centered with respect to the axis of the cup.

is The completed assembly is then unloaded manually or automatically from the press and the completed tool is shown in Figure 11. As illustrated in Figure I I there are eight different crimping dies in the swaging press which form recessed panels indicated at 84 which are separated by axially extending ribs 85. Thus in the closed position the dies don't form a complete circle and the metal of the cup holder cold flows between the dies to form such axial ribs.

It has been found that a ribbed surface on the exterior of the holder will generate the movement of air which will improve the transfer of heat from the holder to the surrounding air. The reduction of heat build-up in the holder subsequently reduces the heat in the fill material which improves the life of the fill material and of course the life of the tool. It is also important that the girdling swage of the cup wall be spaced from the cup rim indicated at 30 in Figure 11 so that the filaments or fill material are supported through a gradual flare of the brush face and are not pinched or constricted where they exit the holder.

Referring now to Figures 7 and 8 there is illustrated a brush embodiment shown generally at 88 which utilizes twisted wire or cable as the fill material shown generally at 89. Each twisted wire or cable may be inserted through a single fill tube. The brush 88 also utilizes a somewhat more cylindrical insert 90 which is beveled top and bottom as indicated at 91 and 92. The cup wall of cup holder 93 is provided with two axially spaced girdling deformations seen at 94 and 95, both being provided with axial ribs 96.

In Figures 9 and 10 there is illustrated another type of end brush 98 using the same type of cup holder 93 with the horizontal axially spaced deformation bands 94 and 95 again having vertical ribs 96. The fill material 98 may be metallic or nonmetallic material. However, the insert as illustrated 100 is in the form of a ball.

Other modifications of and options usable with the present invention are illustrated in Figures 12-18. Referring initially to Figure 12, it will be seen that the i cup holder is formed of two parts which may be termed a shank 104 and a cup body 105. The cup body includes a cylindrical cup wall 106 which terminates in rim 107. The shank projects inwardly of the cup body and includes a pair of radially facing grooves 108 and 109. Mounted in the shank is an axially projecting pilot 110. Such pilots are commonly employed when the end brush is used to spot face a surface around a hole. The pilot simply projects into the hole. The brush of Figure 12 also includes an annular elastic bridle Ill surrounding fill material 112 as well as an internal resilient sleeve 113. The exterior of the cup wall is deformed inwardly as seen at 114 and 115 in a manner similar to that seen in Figure 8 and 10.

The tool of Figure 13 is formed with a one-piece cup holder 118 which includes a projecting pilot 119 inserted in recess 120 located in the center of the internal bottom wall of the cup. A grooved insert 122 is mounted on the pilot 119 against flange 123 of the pilot which slightly spaces the insert 122 from the bottom of the cup. The tool is also provided with bridle 111 and the axially spaced girdling deformations 124 and 125 locking the fill material 126 in place. The insert 122 also has axially spaced radially outwardly facing grooves as seen at 127. The number and type of grooves are optional. Pilot 119 and insert 122 may be one piece.

The tool of Figure 14 also includes a one-piece cup holder 128 which includes a male projecting pilot 129 from the center of the bottom wall of the cup on which the insert 130 is positioned. The insert includes a relatively smaller through-hole into which is positioned headed pilot 131. The tool of Figure 14 also includes a bridle 111 and the external deformations 124 and 125 locking the fill material 126 in place. The insert also has external grooves 132.

Figure 15 illustrates a tool formed with the same one-piece cup holder 128 but utilizing an insert 134 having a somewhat larger diameter throughhole 135 into C which fit both the male pilot projection 129 and pilot pin 136. The insert also has external grooves seen at 137. As illustrated, the pilot pin 136 may be replaced by pilot pin 138 which has a head 139 of the same diameter as the pin 136.

Figure 16 illustrates a brush similar to that shown in Figure 15 but without the pilot pin and utilizing simply a hollow center in the insert as indicated at 142. The hollow center 142 of the insert 143 fits over the male projection 129 and the girdling inward deformations 124 and 125 again lock the fill material in place. The insert may or may not include the exterior grooves. Figure 16 thus illustrates a standard hollow center brush.

Figure 17 illustrates essentially the same brush but with a slightly different hollow insert. The insert 145 of Figure 17 is fitted on the male pilot 129 of the cup shank 128 but includes a hollow center 146 with a relatively thin peripheral wall 147. Both the cup wall indicated at 149 and the wall 147 are flared to provide a flared hollow center type brush.

is Figure 18 illustrates essentially the same brush but with a somewhat different insert 151 having a hollow center 152 with somewhat longer flared walls 153. Again the exterior wall of the cup indicated at 149 is also flared. The flaring indicated provides in essence a circular end brush with the flaring directing the fill material 154 essentially radially of the cup holder.

In all embodiments, the location of the insert and the deformation with respect to the holder results in a reduction of stress to the fill material. The filaments are supported through a gradual flare of the brush face. The deformation provides uniform pressure across a wide area of the fill material.

Proper positioning of the insert with or without the use of a pilot will result in the proper distribution of the fill material and the proper distribution results in better balance and reduced vibration. This in turn results in better performance for the tool and longer life due to the reduction of vibration. The reduction of vibration is also better suited for hand held applications.

A somewhat soft material is preferred for the insert such as a malleable metal such as brass, or even a plastic. It is preferred that the insert be softer than steel and softer than the holder and softer than the fill material. This permits the insert to conform to the shape of the filaments and results in better distribution and locking of the filaments in place.

As far as the holder is concerned the outer and inner configurations of the cup holder may vary in size and shape and be of metallic or nonmetallic materials. As illustrated the insert may be an integral part of the holder or the holder may include a pilot or the mating geometry for a pilot to help in positioning the insert. If a plastic holder is employed, the swaging or crimping dies may be heated to provide a permanent set to the plastic body.

The fill material may include a wide variety of filaments such as wires, cables, non-metallic filaments, abrasive filled or coated metallic or nonmetallic filaments, and natural fibers.

Although a swaging or crimping operation has been illustrated, the deformation of the cup wall may be accomplished by a variety of operations such as swaging, crimping, clamping, compression, upsetting, rolling with horizontal, vertical or cylindrical impressed surface areas.

The process provides a low cost tool which may be made with a high degree of automation and shorter cycle times and also the elimination of trim loss. The better balanced tool utilizes the positive positioning of the insert to keep the filaments aligned and evenly distributed and the girdling deformation of the cup wall away from the cup rim results in improved tool life.

Although the invention has been shown and described with respect to preferred embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification. The present invention includes all such equivalent alterations and modifications, and is limited only by the scope of the claims.

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Claims

CLAIMS is I. A method of making a cup brush comprising the steps of

supporting a cup holder having a bottom and a circular wall terminating in a rim, forming and driving a hollow cylindrical bundle of filaments towards the bottom of the cup, distributing the bundle against the cup wall and around a centre core, and deforming the cup wall inwardly against the bundle and core to lock the filaments in place about the axis of the cup.
2. A method as set forth in claim 1 wherein said core comprises an insert inserted into the cup after the insertion of the bundle.
3. A method as set forth in claim 1 or claim 2 wherein said core is part of the cup holder and said bundle is driven around said core.
4. A method as set f orth in any preceding claim wherein said step of deforming the cup wall takes place at a location spaced away f rom said rim.
5. A method as set forth in any preceding claim wherein said deforming step also forms axial ribs on the exterior of the cup circular wall to improve the transfer of heat from the cup holder.
6. A method as set forth in any preceding claim wherein said deforming of the cup wall inwardly girdles the core and wall providing uniform pressure on the bundle within the cup across a substantial area.
7. A method as set forth in any preceding claim wherein said inward deformation against the core occurs in at least two axially spaced locations.
8. A method as set forth in any preceding claim wherein said core is provided with annular grooves radially opposite the deformations.
9. A method as set forth in any preceding claim wherein said core is circular in transaxial section.
10. A method as set forth in any preceding claim wherein said core is softer than the filaments of the bundle.
11. A method as set forth in any of claims 2 to 10 wherein said insert interfits with the cup to maintain the insert centered into the cup.
12. A method as set forth in any preceding claim including the step of aligning the extent of inward deformation to be symmetrical about v -ilthe axis of the cup.
13. A method as set forth in any preceding claim including the step of trimming said filaments before or after deforming said wall.
14. A method of making a cup brush comprising the steps of supporting a cup having a bottom, circular wall terminating in a rim, and a drive axis; providing a plurality of continuous bundles of filaments; and arranging such bundles circularly around and parallel to the axis of the cup; driving said bundles to the bottom of the cup, distributing the filaments between a central circular core and the interior of the wall of the cup; and deforming the circular wall of the cup inwardly opposite the core further to distribute and grip the filaments between the cup wall and core.
15. A method as set forth in claim 14 wherein said core comprises an insert inserted axially into the centre of the cup after insertion of the bundles.
16. A method as set forth in claim 14 or claim 15 including the step of aligning the extent of inward deformation to be symmetrical about the drive axis of the cup.
17. A method as set forth in claim 15 or claim 16 including the step of interfitting the insert with the cup to maintain the insert centred in the cup.
18. A method as set forth in any of claims 14 to 17 wherein said deforming step takes place axially spaced from the rim of the circular wall.
19. A method as set forth in any of claims 14 to 18 including the step of forming axial ribs in said cup wall to facilitate air cooling of the brush.
20. A method as set forth in any of claims 15 to 20 wherein said insert is softer than the filaments of the bundle.
21. A method as set forth in any of claims 15 to 20 wherein said deforming of the cup girdles the insert and wall providing uniform pressure on the bundles across a substantial area.
22. A method as set forth in claim 21 wherein said inward deformation against the core occurs in at least two axially spaced locations.
23. A method as set forth in any of claims 15 to 22 including trimming said fill material after insertion of the insert but before deformation of said wall.
24. An end brush comprising a cup having a bottom and circular wall terminating in a rim, a hollow cylindrical bundle of material mounted in said cup, one end of said bundle engaging the bottom of the cup, the opposite end projecting beyond the rim, and a core within the cup distributing said one end of the bundle around the wall, said wall including an inwardly deformed section girdling the core and gripping the bundle within the cup.

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25. An end brush as set forth in claim 24 wherein said core is an insert of circular transaxial section.
26. An end brush as set forth in claim 25 wherein said insert interfits with said cup.
27. An end brush as set forth in claim 24 or claim 25 wherein said inwardly deformed section is centered with respect to the axis of the cup.
28. An end brush as set forth in any of claims 24 to 27 wherein said core includes external grooves.
29. An end brush as set forth in any of claims 24 to 28 wherein said core is softer than said fill material.
30. An end brush as set forth in any of claims 24 to 28 wherein said deformation is substantially axially spaced from the rim whereby the fill material is flared gradually from the deformation.
31. An end brush as set forth in any of claims 25 to 30 wherein said insert is hollow and both said cup wall and insert are flared axially beyond the defqrmation.
32. An end brush as set forth in any of claims 24 to 31 including the axial ribs in said deformed section for moving air with respect to the cup wall.

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33. A brush comprising a cup having a bottom wall and a circular side wall extending from the bottom wall and terminating in an annular lip to form the opening of the cup element, a drive stem projecting from the bottom wall to enable the brush to be driven for rotation about its axis, fill material in a cylindrical array secured in said cup and projecting axially therefrom, and an insert wedged into said array within the cup distributing and locking the fill material in place and W is substantially axially aligned with said drive stem.
34. A brush as set forth in claim 33 including a girdling swage in the side of the cup opposite the insert and compressing the fill material against the insert.
35. A brush as set forth in claim 33 or claim 34 wherein the material of the insert is softer than steel.
36. A brush as set forth in claim 34 or claim 35 wherein said girdling swage includes a plurality of axially extending ribs.
37. A brush as set forth in claims 33 to 36 including a pilot projecting axially from the bottom wall inside the cup axially aligned with the drive stem and interfitting with the insert to ensure concentricity.
38. A brush as set forth in any of claims 34 to 37 wherein the inward extent of said girdling swage is concentric with the drive stem thus forcing the insert and circular array of fill material into substantial axial alignment with the drive stem.
39. A brush as set forth in any of claims 34 to 38 wherein said girdling swage is spaced away from the annular lip of the cup to avoid constricting said cylindrical array of fill material as it exits the opening of the cup extent.
40. A brush as set forth in any of claims 33 to 39 wherein said insert is cylindrical and includes an axial recess.
41. A brush as set forth in claim 40 wherein said recess forms a projecting skirt adapted to be flared to cause the cylindrical array of fill material to project radially of the axis of the cup.
42. A brush as set forth in any of claims 33 to 41 including a bridle surrounding said cylindrical array of fill material as it exits the cup.
43. A brush as set forth in any of claims 33 to 42 including a pilot projecting from the centre of the cup through the cylindrical array of fill material.
44. A method of making a brush and/or a brush generally as herein described, with reference to or as illustrated in the accompanying drawings.