JP2024519914A - Abrasive Brush System - Google Patents

Abstract

A brush assembly for a floor machine, the brush including a base having an annular moat and a plurality of cleaning elements positioned within the annular moat and secured to the base, the moat including a plurality of pockets for receiving and securing the feet of associated cleaning elements.

Description

RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63/193,728, filed May 27, 2021, entitled "Polishing Brush System," the entire disclosure of which is incorporated herein by reference.

Concrete or cement is a very popular material for use in floors and building materials due to its strength, durability and low cost. Concrete may be left unfinished, partially finished, or fully finished with a high gloss finish. Such concrete floors are often cleaned by rotary driven brush machines, but these floor cleaning machines tend to deteriorate the concrete floor surface. These floor surfaces must then be subjected to an abrasive treatment to restore the floor to a desirable appearance. Such abrasive capabilities may also be beneficial for other types of floor surfaces, such as terrazzo, marble, and granite. Thus, there is a need for an improved abrasive brush system that can be used with conventional rotary flooring machines.

The following summarizes various details of the present disclosure to provide a basic understanding. This summary is not an extensive overview of the present disclosure and is not intended to identify particular elements of the present disclosure or to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the present disclosure in a simplified form before the more detailed description that is presented below.

According to one aspect of the present disclosure, a brush assembly for a floor machine is provided. The brush assembly includes a base having an upper side mountable to the floor machine and a bottom side opposite the upper side. An annular moat is offset within the bottom side and configured to hold a plurality of cleaning elements secured within the annular moat via a hardenable material.

In some embodiments, a brush assembly for a floor machine includes a base having an upper side and a bottom side opposite the upper side that is mountable to a floor machine, an annular moat recessed in the bottom side, and a plurality of cleaning elements secured within the annular moat and extending from a side of the base. In a further embodiment, the plurality of cleaning elements are secured within the annular moat via a hardenable material. In another further embodiment, the cleaning elements each include a base portion configured to mount the base and an abrasive portion. In another further embodiment, the abrasive portion is overmolded to a distal end of the base portion. In another further embodiment, the cleaning elements are oriented along an axis angled relative to a radius of the base. In another further embodiment, the brush assembly further includes a plurality of pockets disposed within the annular moat, each pocket configured to receive one of the plurality of cleaning elements. In another further embodiment, the brush assembly further includes a plurality of pocket sets disposed within the annular moat, each pocket of the pocket set configured to receive a portion of the cleaning element base. In another further embodiment, the base of the cleaning element includes at least two spaced apart legs, and each pocket of the pocket set configured to receive one of the two spaced apart legs. In another further embodiment, each pocket set includes a pocket set axis that is offset at an angle from the radius of the base. In another further embodiment, each cleaning element extends from the bottom surface of the base at an angle of about 25 degrees to about 75 degrees.

According to another aspect of the disclosure, a method for manufacturing a brush assembly is described. An exemplary method includes providing a base having a concave annular moat, providing a plurality of cleaning elements each including a base and an abrasive portion, positioning a base portion of each cleaning element of the plurality of cleaning elements within the annular moat, pouring a hardenable material into the annular moat, and fixing the plurality of cleaning elements to the base by hardening the hardenable material. In a further embodiment, providing the plurality of cleaning elements includes overmolding the abrasive portion on a distal end of the base portion. In another further embodiment, the concave annular moat includes a plurality of spaced apart pockets, and positioning the base portion of each cleaning element includes placing a base of the cleaning element within an associated pocket. In another further embodiment, the cleaning elements are positioned to extend from a bottom surface of the base at an angle of about 30 degrees to about 65 degrees. In another further embodiment, each of the cleaning elements is clocked along an axis angled relative to a radius of the base.

The following figures are included to illustrate certain aspects of the present disclosure and should not be considered exclusive embodiments. The disclosed subject matter is capable of considerable modification, permutations, combinations, and equivalents in form and function without departing from the scope of the present disclosure.

FIG. 2 is a top perspective view of an exemplary brush assembly according to the present disclosure. 2 is a bottom perspective view of an exemplary housing/base utilized in the brush assembly of FIG. 1; FIG. 2 is a bottom view of an exemplary housing/base utilized in the brush device of FIG. 1 . FIG. FIG. 1 is a perspective view of a cleaning element according to the present disclosure; FIG. 3B is a front view of the cleaning element of FIG. 3A. FIG. 2 is a cross-sectional view of a cleaning element and a brush assembly base according to the present disclosure. FIG. 2 is a block diagram of an exemplary method for manufacturing an exemplary brush assembly according to the present disclosure.

The present disclosure relates to floor maintenance machines, and in particular to new and novel constructions of brush devices/assemblies and systems adapted for removable connection to floor maintenance machines of the type particularly suited for use in commercial, institutional and industrial floor maintenance applications such as cleaning, buffing, burnishing and polishing. Such machines can include a series of cleaning pads and have a variety of polishing characteristics that rotate during operation of the machine to perform maintenance operations including buffing, burnishing, spray buffing, polishing, and the like.

FIG. 1 is a perspective view of an exemplary brush assembly 100 that may incorporate the principles of the present disclosure. The illustrated brush assembly 100 is merely an exemplary tool assembly that may suitably incorporate the principles of the present disclosure. Indeed, many alternative designs and configurations of the brush assembly 100 may be employed without departing from the scope of the present disclosure.

As shown, the brush assembly 100 (hereinafter "brush 100") includes a base (or housing) 102 and a plurality of cleaning elements 104 (or blades 104). The base 102 is generally circular in shape and is configured for attachment to a floor maintenance machine, such as a rotary cleaning machine, such that the assembly 100 is rotated in a clockwise or counterclockwise direction. In the illustrated example, the brush 100 is configured for counterclockwise rotational motion, although it will be understood that the brush 100 may instead be configured for clockwise rotational motion without departing from this disclosure.

The base 102 includes a bottom side 106 and an upper side 108 separated by a sidewall (202) of a desired thickness. The cleaning elements 104 are attached to the base 102 to extend substantially downwardly from the bottom side 106, such that the bottom side 106 is configured to clean, prepare, polish, etc., a floor surface. The upper side 108 of the base is configured to attach to a floor machine. In some embodiments, the upper side 108 can include an attachment mechanism 110 that facilitates attachment of the brush 100 to a machine, clutch plate, or riser. Although the attachment mechanism 110 is shown as a substantially circular raised plate having three spaced radially extending lobes 111, it should be understood that other configurations and shapes for connecting to a floor machine may be substituted herein without departing from the scope of the present disclosure. Thus, for example, a clutch plate may be provided on the upper portion 108 of the base 102, which couples the base 102 to the machine. Also, one or more additional components may be provided to aid or facilitate attachment of the assembly 100 to a particular type of floor machine. For example, a riser may be provided on and extend upwardly from the upper surface 108 of the base 102. If necessary, a clutch plate may be provided on the upper surface of the riser (i.e., at the end of the riser opposite the base 102) to provide clearance between the base 102 and the floor machine. However, it is noted that the clutch plate, drive lugs, and drive gimbals are not shown in the figures. Also, it is noted that the upper surface 108 of the base 102 that does not have such attachment features, such as features 110 or lobes 111, may instead be provided as a flat surface and secured differently to the machine.

2A-2B show an exemplary configuration of the base 102 utilized in the brush 100 of FIG. 1. In the illustrated example, the base 102 is substantially circular (or disk-shaped) in shape and has an outer periphery or rim or sidewall 202. As shown, the base 102 includes an annular ("ring-shaped") moat 204 having a depth D that creates a moat surface 205 offset into the bottom surface 106 of the base at the depth D. The annular moat 204 is substantially concentric with a central axis 201 perpendicular to the bottom surface 106. Forming the moat 204 in the base 102 defines a peripheral apex 207 of the sidewall 202. That is, the peripheral apex 207 is the portion of the sidewall 202 that extends vertically from the base of the moat 204. As shown in the exemplary embodiment, the annular moat 204 extends inwardly a distance X from the inner surface of the peripheral apex 207 of the sidewall 202.

In some embodiments, the annular moat 204 is milled/routed into the bottom surface 106 of the base 102 using a CNC milling machine or the like. In other embodiments, the base 102 including the annular moat 204 is created in a casting/molding process. In yet other processes, the base 102 including the annular moat 204 is produced by additive manufacturing methods including 3D printing.

The annular moat 204 is configured to receive a quantity of a hardenable material, such as an adhesive or epoxy. The cleaning elements 104 may be positioned within the annular moat 204 and secured to the base 102 by filling the annular moat 204 with (and curing) a hardenable material. For example, the cleaning elements may be held in place or otherwise positioned within the moat and then secured to the base by filling the moat 204 with a hardenable material and allowing the hardenable material to solidify.

2A-2B, in some embodiments, the base 102 includes a plurality of pockets 210 (or recesses) that extend into the moat surface 205 of the annular moat 204. Each pocket 210 is generally shaped to receive a corresponding cleaning element 104 for securing therein, e.g., via a hardened material. As shown in FIGS. 2A-2B, the base 102 can include a plurality of pocket sets 212, each such pocket set 212 including at least two pockets 210 that extend into (or are formed in) the surface 205 of the annular moat 204.

When the cleaning element 104 is engaged with a corresponding pocket 210, the cleaning element 104 may be positioned such that the abrasive surface of the cleaning element is angled away from the direction of rotation of the base 102 (see FIG. 4). In some embodiments, a portion of the cleaning element 104, such as a portion of the cleaning element base, abuts a surface/edge of the corresponding pocket 210 that provides support, strength and structural rigidity to the multiple cleaning elements 104.

The pockets 210 (or sets 212) are arranged such that each pocket 210 (and thus each cleaning surface of the cleaning element 104) is offset (clocked) at an angle β from the radius R of the base. In the exemplary embodiment of FIGS. 2A and 2B, each pocket 210 of a pocket set 212 is arranged within the annular moat 204 along a shared pocket set axis 214, and each pocket set 212 is configured to receive and attach to the base 102 a single cleaning element 104. In an embodiment having a single elongated pocket 210, the long axis of the pocket is equal to the shared pocket axis 214.

As discussed in more detail below, each cleaning element 104 associated with a pocket set 212 can have a cleaning element face that is substantially aligned with a pocket set axis 214. That is, each pocket set axis 214 (and therefore each cleaning face of the cleaning element 104) is offset (clocked) at an angle β from the radius R of the base. In other words, a cleaning element 104 inserted into a pocket 210 and aligned with the pocket set axis 214 is not radially aligned along the radius R from the center point 201 of the base 102.

The cleaning elements 104 are mounted in the pockets 210 of the base 102 so that they are aligned or oriented along a secant or chord of the base 102, rather than along a radius R of the base 102. Thus, the pockets 210 and/or pocket sets 212 provided in the base 102 are positioned to orient and align the cleaning elements 104 along a secant or chord, rather than along a radius R of the base 102. In this manner, the cleaning elements 104 are clocked outward (i.e., facing outward from the peripheral sidewall 202) to push (or kick) debris outside the footprint of the brush assembly 100 during the rotational movement of the brush 100.

In some embodiments, each pocket 210 is symmetrical about a plane perpendicular to surface 106 and passing through pocket set axis 214, e.g., each pocket 210 may exhibit mirror symmetry about pocket set axis 214. However, it should be understood that pocket symmetry is not limiting.

2A-2B, each pocket 210 has a horizontal cross-section that is substantially dog-bone shaped (or letter H shaped), as best seen in FIG. 2B. However, it should be understood that the horizontal cross-sectional shape is not limiting and other cross-sectional pocket shapes may be used in accordance with the present disclosure. Each of the pockets 210 may be shaped such that the cleaning element 104 disposed therein may be set with a forward-facing cleaning surface oriented in a direction for counterclockwise rotation of the housing 102, or alternatively, may be set therein with a forward-facing cleaning surface oriented in a direction for clockwise rotation of the housing 102.

3A and 3B illustrate an exemplary cleaning element 104 according to one or more embodiments of the present disclosure. Each cleaning element 104 includes a base portion 302 having a thickness Y and an abrasive portion 310. The base portion 302 may be constructed of a variety of materials, such as a polymeric material. The base portion 302 is configured to be set within a pocket 210 recessed within the annular trench 204. The pocket 210 is then filled with a hardenable material that secures the cleaning element to the base 102.

In the illustrated embodiments, each cleaning element 104 is configured to be set within a pocket set 212. In these embodiments, the base portion 302 may include at least one leg 304a, 304b shaped for insertion into each of the pockets 210 of the set 212 and having a bottom edge 306. In embodiments in which the base portion 302 includes two legs 304a, b, each leg may be spaced apart via a saddle portion 303. In some embodiments, the saddle portion 303 is configured to abut and rest on the moat surface 205 when the legs 304a, b are inserted into the corresponding pockets 210. In other embodiments, no such saddle portion 303 is provided, and instead the bottom edge 306 of the base 302 is not broken and contacts the base of the moat pocket 210.

In some embodiments, at least one leg 304a, 304b of the base portion 302 includes at least one adhesive aperture 305. The adhesive aperture 305 is positioned such that when the base portion 302 (and/or its leg) is inserted into the pocket, the adhesive aperture 305, or a portion thereof, is also within the pocket 210. The cured material can flow through the adhesive aperture 205 and, upon curing, interlock the polymer base portion 302 within the moat 204.

Each cleaning element 104 also includes an abrasive portion 310 (adjacent the base portion 302) having at least one abrasive surface 311 facing the direction of brush movement in the offset manner described above. In some embodiments, the abrasive portion 310 is overmolded onto the bottom/distal end 307 (shown as a dashed portion in FIG. 3B) of the base portion 302. The overmolded abrasive portion 310 may be a mixture of epoxy and abrasive particles (e.g., diamond grit), which may have various grit sizes or combinations of grits. At least one surface 311 of the cleaning element 104 is configured to contact a floor surface, thereby providing the abrasive or cleaning function of the brush 100 during use. The abrasive material may include various types of particulates or grits (e.g., diamond grit) of various grit sizes or combinations of grit sizes.

The distal end 307 of the base portion 302 may be configured to lock onto the overmolded abrasive portion 310. In some embodiments, the distal end 307 of the polymer base portion 302 may include at least one opening 309 through which the overmolded material may flow, thus interlocking the abrasive portion 310 onto the polymer base 302. In the illustrated example, the distal end 307 also includes a distally extending tab 313 that is housed within the overmolded material of the abrasive portion 310 and may help provide or reinforce the rigidity of the abrasive portion 310. In the illustrated example, the base 302 includes only one tab 313 aligned with the central opening 309, although multiple such tabs 313 may be provided, e.g., two or more such tabs 313.

4 shows a vertical cross-section of the base 102 around the pockets 210 with the base portion 302 of the cleaning element 104 inserted into at least one pocket 210. Each pocket 210 includes a bottom pocket surface 216 at a pocket depth P within the trench 204. Each pocket 210 also includes a first substantially vertical sidewall 217 and an opposing second substantially vertical sidewall 218 connected via the substantially horizontal bottom surface 216. Each pocket 210 has a bottom width W that provides a spacing distance from the first sidewall 217 to the second sidewall 218.

Each cleaning element 104 is configured to be inserted into a pocket 210 and/or pocket set 212. In general, the thickness Y of the base 302 of the cleaning element 104 is less than the width W of the pocket 210. This allows each cleaning element 104 to be positioned so that the cleaning element is "tilted" in a desired direction. That is, the bottom edge 304 of the base portion contacts the bottom surface 216 of the pocket adjacent the first wall 217. The rear surface 318 of the polymer base portion 302 is supported at an angle on the upper edge 219 of the second wall 218. Once placed, the hardening material is poured into the moat 204 and pocket 210 and hardened, thereby fixing each cleaning element 104 to the base in a preferred orientation. The "tilt" may be defined by an interior angle 405 between the rear surface 340 of the base portion 302 of the cleaning element 104 and the surface 205 and/or bottom surface 106 of the moat 204. That is, the cleaning elements 104 extend from the bottom surface 106 and at an angle 405 in a generally rearward direction (away from the direction of rotation). The angle 405 may range from about 30 degrees to about 65 degrees. In some preferred embodiments, the angle 405 is about 55 degrees to about 65 degrees. In some other preferred embodiments, the angle 405 is about 59 degrees.

It should be understood that the cleaning element 104 may be placed in the opposite orientation. That is, rather than having the bottom edge 306 contact the first wall 217 and bottom surface 216 of the pocket (with an inclined portion on the second wall), the cleaning element 104 may be placed so that the bottom edge 306 contacts the second wall 218 and bottom surface 216 (with an inclined portion on the first wall 217). In this way, only one base configuration is necessary to manufacture a brush assembly 100 that can be configured for clockwise (CW) or counterclockwise (CCW) rotation. In other embodiments, the cleaning element 104 may be placed in the corresponding pocket 210 so that the cleaning element 104 is substantially perpendicular to the base 102, i.e., not angled.

In some embodiments, the saddle portion 303 between the legs 304a, 304b is configured to rest against the surface 205 of the moat 204 between two adjacent pockets 210 (see FIG. 2B). In other embodiments, the saddle portion 303 is shaped to provide a gap between the surfaces 205 of the moat 304, thereby allowing the hardened material to flow therethrough and enhance attachment of the cleaning element 104 to the base 102.

5 illustrates an exemplary method 500 for manufacturing a brush assembly, similar in many respects to the brush assembly 100 of FIG. 1, according to the present disclosure. At block 502, a base 102 is provided. In some embodiments, this involves providing a disk of a machinable material, such as, but not limited to, a metal or plastic. The base or disk 102 is then machined to cut/cut an annular moat 204 in the base 102 at a depth D to form a concave surface 205 configured to hold a volume of hardenable material. In other embodiments, the base 102 is cast into a shape that includes the annular moat 204. In yet other embodiments, the base 102, along with the annular moat 204, is created by additive manufacturing, such as 3D printing.

In some embodiments, at block 502, the exemplary method 500 includes providing a plurality of pockets 210 in spaced apart aparrat relationship within the annular moat 204. In some embodiments, this may include milled/cut pockets 210 and/or pocket sets 212. In other embodiments, the pockets 210 may be formed while casting or 3D printing the base.

Separately, with reference to block 504, the method includes providing a cleaning element 104 configured for insertion into the pocket 210. As briefly described above, this includes providing a polymer base portion 302 and an adjacent abrasive portion 310. In some embodiments, the abrasive portion 310 is overmolded onto the distal end 307 of the base portion 302.

At block 506, a determination is made regarding the desired rotation of the brush assembly 100. That is, the brush assembly may be configured for clockwise (CW) or counterclockwise (CCW) rotation. The determined rotation direction further determines the tilt and positioning of the cleaning element 104 within the trench 204.

At block 508, the cleaning elements 104 are positioned within the grooves 204 of the base 102 based on the determined rotation of the brush assembly 100. In embodiments without the pockets 210, the cleaning elements are held in place with a "slant" away from the direction of rotation. In some embodiments, the cleaning elements 104 are clocked outward (i.e., facing generally outward from the peripheral sidewall 202) to push (or kick) debris outside the footprint of the brush assembly 100 during the rotational movement of the brush 100. In some embodiments, each cleaning element 104 is clocked at an angle β from the radius R of the base such that the face 311 is not radially aligned with the center point 201 of the base 102.

In embodiments that include a pocket 210 or a set of pockets 212, the base portion 302 or legs 304a,b of the cleaning element 104 are placed in the pocket 210 such that the corresponding cleaning element 104 is "tilted" away from the direction of rotation and is supported by an edge of the pocket 210, e.g., edge 219.

At block 510, a quantity of curable material is added to the moat 204 to fill the space between the cleaning element 104 and the base 102. The curable material may be an adhesive material and/or an epoxy that solidifies under certain conditions. For example, the curable material may be a UV curable material, where ultraviolet light is used to initiate a photochemical reaction that creates a cross-linked network of polymers. In other embodiments, the curable material is a thermosetting material where application of heat results in hardening of the material, for example by cross-linking polymer chains. In some embodiments, the curable material is an epoxy resin, which can be cured with a catalyst/reactant to initiate cross-linking. While this disclosure lists several examples of curable materials, it should be understood that this list is not limiting and that other materials that flow to conform to shapes (e.g., within the moat) and harden to attach the cleaning element 104 may be used without departing from the scope of this disclosure.

At block 512, the curable material is cured according to the properties of the material. For example, a UV curable material will bend with the application of UV light to the curable material, and a thermosetting material will be cured with the application of heat. The cured brush assembly (with the cleaning element 104 attached) can then be connected to a floor machine and rotated to treat the floor surface.

Thus, the disclosed system and method are well adapted to achieve the objects and advantages mentioned, as well as those inherent therein. The particular embodiments disclosed above are merely illustrative, as the teachings of the present disclosure may be modified and implemented in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Moreover, no limitations are intended to the details of construction or design shown herein, other than as set forth in the following claims. Thus, it is apparent that the particular exemplary embodiments disclosed above may be altered, combined or modified, and all such variations are contemplated within the scope of the present disclosure. The systems and methods illustratively disclosed herein may be suitably practiced in the absence of any element not specifically disclosed herein and/or any element disclosed herein. Although compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, compositions and methods can also "consist essentially of" or "consist of" various components and steps. All numbers and ranges disclosed above may vary to some extent. Whenever a numerical range with a lower and upper limit is disclosed, any number falling within that range and any included range is specifically disclosed. In particular, all value ranges disclosed herein (in the form of "about a to about b," or equivalently, "about a to b," or equivalently, "about a to b") should be understood to describe all numbers and ranges encompassed within the broader value range. Additionally, terms in the claims have their plain and ordinary meaning unless expressly and unambiguously defined by the patent owner. Moreover, the indefinite article "a" or "an," as used in the claims, is defined herein to mean one or more of the element it introduces. In the event of a discrepancy in the use of a word or term in this specification and one or more patents or other documents that may be incorporated herein by reference, the definition consistent with this specification shall be controlled.

The terms "proximal" and "distal" are defined herein with respect to a user of a floor machine having an interface configured to mechanically couple a tool to a rotating portion of the machine. The term "proximal" refers to a location of an element closer to the user or the rotating portion of the machine, and the term "distal" refers to a location of an element further away from the user or the rotating portion of the machine. Additionally, the use of directional terms such as up, down, upper, lower, upward, downward, left, right, etc. are used with respect to the exemplary embodiment as shown in the figures, with the upward or upper direction being toward the top of the corresponding figure and the downward or lower direction being toward the bottom of the corresponding figure.

As used herein, the phrase "at least one" before a series of items using the term "and" or "or" to separate any of the items modifies the entire list, not each member (i.e., each item) of the list. The phrase "at least one" allows for a meaning including at least one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases "at least one of A, B, and C" or "at least one of A, B, or C" refer, respectively, to only A, only B, or only C, any combination of A, B, and C, and/or at least one of each of A, B, and C.

In order to assist the Patent Office and readers of this application, and any resulting patents, in interpreting the claims appended hereto, applicants do not intend that any of the appended claims or claim elements be invoked under 35 U.S.C. 112(f) unless the words "means for" or "step for" are expressly used in a particular claim.

Claims (15)

1. A brush assembly for a floor machine, comprising:
a base having an upper surface mountable to a floor machine and a bottom surface opposite the upper surface;
an annular groove recessed into the bottom surface;
a plurality of cleaning elements secured within the annular moat and extending from the bottom side of the base. The brush assembly of claim 1, wherein the plurality of cleaning elements are secured within the annular groove via a hardenable material. The brush assembly of claim 1 or 2, wherein each of the cleaning elements includes a base portion configured to mount the base and the abrasive portion. The brush assembly of claim 3, wherein the abrasive portion is overmolded onto the distal end of the base portion. A brush assembly according to any one of claims 1 to 4, wherein the cleaning elements are oriented along an axis angled relative to a radius of the base. The brush assembly of any one of claims 1 to 5, further comprising a plurality of pockets disposed within the annular moat, each pocket configured to receive one of the plurality of cleaning elements. The brush assembly of any one of claims 1 to 5, further comprising a plurality of pocket sets disposed within the annular moat, each pocket of the pocket set configured to receive a portion of the cleaning element base. The brush assembly of claim 7, wherein the base of the cleaning element includes at least two spaced apart legs, and each pocket of a pocket set is configured to receive one of the two spaced apart legs. The brush assembly of claim 7, wherein each pocket set includes a pocket set axis that is offset at an angle from the radius of the base. The brush assembly of any one of claims 1 to 9, wherein each cleaning element extends at an angle of about 25 degrees to about 75 degrees from the bottom side of the base. 1. A method for manufacturing a brush assembly, comprising:
providing a base having a concave annular moat;
providing a plurality of cleaning elements, each including a base portion and an abrasive portion;
positioning the base portion of each cleaning element of the plurality of cleaning elements within the annular moat;
pouring a hardenable material into the annular trench;
and fixing the plurality of cleaning elements to the base by curing the curable material. The method of claim 11, wherein providing the plurality of cleaning elements includes overmolding the abrasive portion onto a distal end of the base portion. The method of claim 11 or 12, wherein the concave annular moat includes a plurality of spaced apart pockets, and positioning the base portion of each cleaning element includes placing the base of the cleaning element within an associated pocket. The method of any one of claims 11 to 13, wherein each cleaning element is positioned to extend at an angle of about 30 degrees to about 65 degrees from a bottom surface of the base. The method of any one of claims 11 to 14, wherein each of the cleaning elements is clocked along an axis angled relative to a radius of the base.

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