JP3987882B2 - Industrial brush and its manufacturing method - Google Patents

Description

【００３８】
これまでブラシ毛材と同素材で溶融固着すると説明してきたが、更に詳しく述べると主なブラシ毛材である各種ナイロンや共重合素材またはポリプロピレンなどで構成される単一素材の場合は毛材と同じ樹脂素材のみで溶融固着するものであり、毛材に選択した樹脂素材の中に研磨砥粒材が混入されている場合には同じ研磨砥粒入り樹脂素材でブラシの内径部分を溶融固着するものである。
【００３９】
また、研磨砥粒とは現在汎用的に用いられている炭化珪素、酸化アルミナ、ダイヤモンド、ＧＣ、ＣＢＮ等の汎用砥粒の事を指すものである。フランジ部分あるいはコア部分が必要な場合には、ブラシ毛材と同質の素材を低圧射出成形あるいは低圧押出成形により被着成形するものである。
【００４０】
【発明の効果】
以上説明したように、本発明は工業用ブラシを構成する植毛板や外金具及び毛材を固定する結束線等の素材に金属金具類を一切使用する事無くブラシ毛材と同質素材・同等の化学構造を有する素材でブラシを構成した事を特徴としブラシ毛材自体を固着成形する事でディスク板やフランジ・コア等の金属金具と同じ各構成をなし且つ、ブラシ内径部を円形あるいは異形に成形して空回り防止機能を持つ工業用ブラシに関する発明である。
またブラシ形成時に、ブラシ毛材を十分に圧接・圧縮した状態で溶融固着成形したことにより実際の特性面でもブラシ密度が向上でき、筋目の抑制ができた。さらには金属金具を一切使用しない為、軽量化ができ、ワークの金属金具部への誤接触による傷発生率低減による品質向上と多くの効果実績が得られている。加えてブラシ消耗時に分離・分別廃棄する必要の無い地球環境に配慮したリサイクルブラシの製造を可能とした。
【図面の簡単な説明】
【図１】 毛材を帯状に画設する専用治具
【図２】 毛材の仮設外観図
【図３ａ】 外巻き仮設外観図
【図３ｂ】 外巻き仮設外観図
【図４】 溶融固着後のブラシ外観図
【図４ａ】 溶融固着後のブラシ断面形状例
【図４ｂ】 溶融固着後のブラシ断面形状例
【図５】 放射状に環送する治具例
【図５ａ】 放射状に環送した場合の断面図
【図６ａ】 工具ホーンの断面形状例
【図６ｂ】 工具ホーンの断面形状例
【図７】 工具ホーンによる超音波溶融状態図
【図８ａ】 溶融固着後のブラシ断面図例
【図８ｂ】 溶融固着後のブラシ断面図例
【図９】 内径部成形した形状参考例
【図９ａ】 内径部成形した断面図
【図１０】 ブラシを重層する場合の参考図例
【図１１】 フランジを被着した場合の断面図
【図１２】 交換式フランジの参考例
【符号の説明】
▲１▼・・・ブラシ毛材
▲２▼・・・仮設用治具
▲３▼・・・溶融固着部
▲４▼・・・溶融部
▲５▼・・・仮設用治具底板
▲６▼・・・仮設用外径規制リング治具
▲７▼・・・仮設用治具上板
▲８▼・・・キー溝部
▲９▼・・・溶融フランジ部
▲１０▼・・・交換式樹脂フランジ[0001]
[Industrial application fields]
The present invention relates to an industrial brush used for deburring and polishing finishing after machining of mechanical parts such as general steel materials, stainless steel and aluminum, and surface treatment and cleaning of automobile steel plates.
[0002]
[Prior art]
As a general-purpose flocking method for industrial brushes, a method is generally used in which a brush material is inserted into a small hole provided in the circumferential direction of the disk plate, bent in half, and bound with a drawn wire of stainless steel or steel wire. .
[0003]
In addition, U.S. S. Although weight reduction by the structure in which by using a thermosetting resin as described in P No. 5,105,155 are fixed to the base of the bristles partially is FIG centrifugal force due to high speed rotation during use brush and bristle materials There is a problem that the hair material is pulled out or the resin is damaged due to the impact applied to the hair. It is also known to use a metal reinforcing ring as a countermeasure against these problems.
[0004]
As described above, since the brush material uses a different thermosetting resin or metal reinforcing ring in the brush , the brush material has a structure that requires time and effort to separate and classify when the brush is consumed . Also, capillary action occurs according to the viscosity difference of thermosetting resin that partially fixes the base of the hair material, and the resin flows irregularly inside the hair material, so the thermosetting resin is uniformly injected and extruded. There is a technical problem to fix it.
[0005]
On the other hand, an enameled wire is wound around one end of a brush material described in JP-A-2000-83736, heat-sealed and formed into a substantially arc shape, and then a plurality of substantially arc shapes are bonded with an adhesive to form a roll-shaped rotating brush and fixed to a shaft. There are things to do.
[0006]
However, the brush is used at high speed rotation. When used intensive brush rotating at high speed, there is a risk of damage can not withstand the stresses plurality of strong impact and centrifugal forces be molded into a roll approximately arcuate in the adhesive is applied continuously .
Moreover, although the heating means is not specified, the heating means that promotes the crystal destruction of the material itself has a problem that the bristle material is easily broken when the brush is formed.
[0007]
[Problems to be solved by the invention]
When the brush is fixed using a metal fitting, the weight is increased by about 3 to 4 times due to the specific gravity, and the burden on the attachment device is also increased. In addition, there are problems such as causing the work to come into contact with the metal part of the brush during work and causing defective products to occur frequently, and problems that the brush wears down and the hair length becomes shorter, resulting in streaking and transfer to the product. ing.
Furthermore, in recent years, disposal problems and pollution problems due to used consumable tool materials have been caused, which has become a major social problem.
[0008]
Is required brush structure such as departing from the existing industrial brush structure in addition to the quality problem of the cost problem, a crack eyes prevention measures by reducing demand and defective multiple of the device share can cope with environmental problems as described above ing.
[0009]
[Means for solving the problems]
The present invention does not use any metal fittings such as flocking plates, outer fittings and reinforcing rings as the material constituting the brush, and the flocking plate portion and the flange portion with the same material having the same chemical structure as the brush bristle material alone or the brush bristle material It provides industrial brushes with a wide range of excellent features and performance that promotes weight reduction, improves flocking density, eliminates streak, improves durability, and reduces work defect rate. brush is intended to solve the above-mentioned problems with it to provide a technique for recycling brush and cost reduction were considered in the environmental problems there is no need to separate separation can be achieved at the time of disposal exhausted.
[0010]
The brush bristle material used in the present invention is not particularly limited and can be produced as long as it is a generally known brush material.
Of these , nylons (6/66/610/612) and various copolymer materials are particularly suitable as the brush bristle material . It may be incorporated an abrasive material such as glass fiber or abrasive grains in these brush hairs.
[0011]
The brush shape manufactured by the present invention is basically a wheel type, but a cup-shaped flange made of a thermoplastic resin can be put on a wheel-type brush to form a cup-shaped brush or a bottom-type brush shape.
[0012]
If there is a device that generates a heat source for an electric heater, dryer, hot press, etc., as a means for melting and fixing the inner diameter portion of the bristle material arranged radially and in an annular shape, it is apparently melted and fixed. However, when the brush bristle material is used in the form of a brush because the change in rigidity of the bristle material and the crystal breakage of the bristle material itself are promoted, the bristle material tends to break.
[0013]
In the present invention, it is possible to perform melt-fixing molding using a non-heat storage source that has an effect of suppressing crystal breakage of the material without changing the rigidity of the hair material itself .
[0014]
In the present invention, a plate or a core portion corresponding to a flange portion can be formed on both side surfaces of a brush that is melt-fixed by using injection molding or extrusion molding technology together .
When the flange part is formed of the same material and the same chemical structure as the brush bristle material , it has better compatibility with the bristle material than the thermosetting resin and is fixed, and the same quality material. There is a merit that elasticity and impact resistance are improved due to its own flexibility.
[0015]
Due to this merit, a brush fixed with a thermosetting resin, such as an epoxy resin , may be accidentally dropped and the resin part may be damaged, or the flange part may be damaged by impacting the brush during actual polishing work. Loss and improve safety.
[0016]
Due to the combination of elasticity and stickiness, the shock applied to the bristle material when using an actual brush is mitigated at the bristle root (flange edge), so the stress generated in the bristle material is also mitigated and the bristle material itself The breakage of the brush is suppressed, and the life extension effect of the brush life is obtained.
[0017]
Brush of the present invention, a heat source, for example a brush which is secured melted and fused and fused by ultrasonic techniques, has the feature that the central portion is secured in a semi-molten state is alleviated melt degree toward the outer circumferential direction ing. (See Fig. 4- (4) and Fig. 4a (4))
[0018]
Since this feature has a function of adding a further synergistic effect to the impact mitigation effect described above , it has an extremely large influence and effect on the life extension of the brush.
[0019]
In general-purpose industrial brushes, trimming of the outer diameter is originally performed after the brush is formed, but a large amount of brush waste is generated during trimming and is treated as industrial waste. The present invention relates to bristles outer diameter is regulated within a ring-shaped type of temporary conditions, radially leaving a space in the center in the length defined, and arranged and is inscribed in So Tamaki form the The inner diameter part on the center side of the bristle material is made into a ring shape in a non-pressure-welded / compressed state, and the other outer-peripheral-side bristle material is embedded in the mold in a face-welded / compressed state, and the ring-shaped part in the non-pressure-welded / compressed state is placed after melt-fusion and fusion by a heat source, very little merit generation needs is free rather brush debris outside diameter trimming after that the brush formation is cooled anchor fused portion in surface pressure and compression have.
[0020]
【Example】
The brush shape manufactured by the present invention is basically a wheel type, but a cup-shaped flange or a bottom-type brush shape can be formed by covering a wheel-shaped brush with a cup-shaped flange molded with a thermoplastic resin. In the present invention, details of the embodiment will be described with reference to the shape of a wheel type brush.
[0021]
As temporary method features a brush bristle material radially to So Tamaki are considered some are shown in FIG techniques duplicate as a reference example.
[0022]
Example 1 dedicated jig when the E設the obi-like ▲ 2 hairs ▲ 1 ▼ was embedded in ▼, melting one brush bristle material by the heat source ▲ 3 ▼ to be temporary. (Refer to FIGS. 1 and 2) After the temporary setting, the inner and outer windings can be arbitrarily wound within the ring-shaped mold in which the outer diameter regulating ring and the bottom plate are fitted, leaving a space in the center with a specified length. It is refracted into a shape and embedded in a radial and ring shape. (See Figures 3a and 3b)
[0023]
Next, the inner diameter part on the center side of the bristle material is brought into a non-pressure contact / compression state in the form of a ring, and the other outer peripheral side bristle material is fitted with an upper plate that is in a face pressure contact / compression state from the upper side to be in a non-pressure contact / compression state In this method, after the ring-shaped part is melted / fused / fused with a heat source, the fused part is subjected to surface pressure welding / compression and then cooled and fixed . (See Figure 7)
[0024]
In the case of Example 2, a bristle material is provided in a dedicated mold fitted with an outer diameter regulating ring and a bottom plate that is equally divided, and the upper plate is fitted in an annular state to fasten the bristle material in a holding state. (Refer to the cross section of Fig. 5 and Fig. 5a)
[0025]
In the same manner as in Example 1, the inner diameter portion of the brush material in the holding state is melted, fused, and fused by a heat source , and then the fused portion is subjected to surface pressure welding / compression to cool and fix . (See Figure 7)
[0026]
Ultrasound techniques in listed in Example as a heat source in the present invention, ultrasonic vibration energy brush material Internal brush hairs one that is set embedded in the fixture by the effect of concentrating the local propagates 1 The book vibrates and slides locally, generates heat from the inside of the material itself, and melts and fuses.
[0027]
Any even excessive melting degree melt bonding strength is as high as that crystal destruction is effective to suppress the brush material in already Takeno is very Umate a short time to generate heat melted material by heating from the inside brush material Have characteristics that can be adjusted .
[0028]
Tip shape of the ultrasonic tool horn listed as a heat source for melting and fixing the adjustment ring shape to fit the melting and fixing the shape of the object, a circle, half-rings, ellipses, squares, polygons, a wavelength in the bulging shape By doing so, a sufficient melting effect can be obtained .
[0029]
The hair materials that are fused and fixed by ultrasonic technology are securely bonded to each other in close contact with each other. There is a merit not to cut. (See Figures 4, 4a, and 4b)
[0030]
The melt-fixed portion contains elements that greatly affect the life of the brush, and is roughly divided into a complete melted portion and a semi-melted portion.
Complete melting portion may serve to completely melt bonding the same effect as one by one the bristles and bristle plate, thermal deterioration together to promote the crystallization of the nylon resin is brush material by being in semi-molten Is effective in preventing breakage of the hair material.
[0031]
6a or 6b-shaped tool horn is pressed against both sides of a brush (closed in FIG. 5a) in a pressed state, and ultrasonic sliding heat is applied to perform fusion fixation. It can be performed from both sides at the same time, and the same effect can be obtained even if one of the processes is performed separately .
Also, temporary brushes can form a single brush itself stuck in such molten state of FIG. 8a · Figure 8b sectional the shape of the jig or the tool horn to cool sticking.
[0032]
The inner diameter portion of the brush can be formed into a melt-fixed portion having a circular or irregular hole shape by fusing, fusing, and fusing with a heat source, and then cooling and fixing the fused portion by surface pressure welding / compression . (Refer to the cross section of Fig. 9 and Fig. 9a)
[0033]
When a single brush having an inner diameter portion formed at the time of melting and fixing is inserted into the shaft or core portion and a plurality of layers are laminated in an arbitrary L-direction dimension, a high-density and seamless roll-shaped brush can be formed. (See Figure 10)
[0034]
Similarly, a material with the same material as the brush bristle material or a resin material with the same chemical structure on both sides of a single brush that has been molded with an inner diameter portion at the time of melting and sticking is attached by low pressure injection or low pressure extrusion. By simultaneously forming the flange and the core portion, it can be utilized as a single product having a narrow L width direction. (See Figure 11)
[0035]
In the case where the flange portion is not attached, there is also a method in which a separate replaceable flange is sandwiched and an inner diameter collar is inserted into the shaft portion and then tightened with screws. (See Figure 12)
[0036]
Actual polishing work place who implemented from a specific user company A metal bracket to the material constituting the brush with the brush of the present invention is not used at all, accidentally contacting the workpiece metal fitting portion of the brush unwanted scratches There has been a track record of improving the scratch occurrence rate to 0%, in which the scratch occurrence rate of 100% is completely absent.
In addition, the response to the life of brushes by company ratio has almost doubled.
[0037]
The results at this time are shown in Table 1 below.
[Table 1]

[0038]
While there have been described as melted and fixed by the brush hairs of the same material, in the case of single material constituted such by various nylon or copolymer materials or polypropylene is the main brush hairs More particularly the hair materials When the abrasive material is mixed in the resin material selected for the bristle material, the inner diameter part of the brush is fused and fixed with the same resin material containing abrasive particles. Is.
[0039]
The abrasive grains refer to general-purpose abrasive grains such as silicon carbide, alumina oxide, diamond, GC, and CBN that are currently used for general purposes. When a flange portion or a core portion is required, a material having the same quality as that of the brush bristle material is applied and molded by low pressure injection molding or low pressure extrusion molding.
[0040]
【The invention's effect】
As described above, the present invention is flocked plate and an outer bracket and that no brush bristles that use any metal metal fittings to the material of the tie wire or the like for fixing the bristles of the same quality materials and equivalent constituting industrial brushes The brush is composed of a material with a chemical structure, and the brush bristle material itself is fixed and molded to form the same structure as the metal fittings such as the disk plate, flange, and core, and the inner diameter of the brush is circular or deformed. The invention relates to an industrial brush that has a function of preventing idling .
In addition, when the brush was formed , the brush bristle material was melt-bonded and molded in a sufficiently pressed and compressed state, so that the brush density could be improved in terms of actual characteristics, and streaking could be suppressed. Furthermore, since no metal fittings are used, the weight can be reduced, and quality has been improved and many effects have been achieved by reducing the rate of scratches caused by erroneous contact of the workpiece with the metal fittings . In addition, it has become possible to manufacture recycling brushes that are friendly to the global environment and do not need to be separated and disposed of when the brushes are consumed.
[Brief description of the drawings]
[Fig. 1] Dedicated jig for drawing hair material in a strip shape [Fig. 2] Temporary external view of bristle material [Fig. 3a] External appearance of external winding [Fig. 3b] External appearance of external winding [Fig. 4] After fusion fixing [Fig. 4a] Example of cross-sectional shape of brush after fusion fixing [Fig. 4b] Example of cross-sectional shape of brush after fusion fixing [Fig. 5] Example of jig for circular feeding [Fig. 5a] In case of circular feeding Sectional view of tool horn [Fig. 6b] Example of sectional shape of tool horn [Fig. 6b] Example of sectional shape of tool horn [Fig. 7] Ultrasonic melting state diagram by tool horn [Fig. 8a] Example of sectional view of brush after melting and fixing [Fig. ] Example of cross-sectional view of brush after melting and fixing [Fig. 9] Reference example of shape formed by inner diameter part [Fig. 9a] Cross-sectional view of formed inner diameter part [Fig. 10] Reference example of overlapping brushes [Figure 11] Covering flange Cross section when worn [Fig. 12] Reference example of replaceable flange [Explanation of symbols]
▲ 1 ... ・ ・ ・ Brush bristle material ▲ 2 ▼ ・ ・ ・ Temporary jig ▲ 3 ▼ ・ ・ ・ Melting part ▲ 4 ▼ ・ ・ ・ Melting part ▲ 5 ▼ ・ ・ ・ Temporary jig bottom plate ▲ 6 ▼・ ・ ・ Temporary outer diameter regulating ring jig ▲ 7 ▼ ・ ・ ・ Temporary jig upper plate ▲ 8 ▼ ・ ・ ・ Key groove ▲ 9 ▼ ・ ・ ・ Fused flange ▲ 10 ▼ ・ ・ ・ Replaceable resin flange

Claims (3)

Various types of copolymer hair materials that are industrial brush materials or various copolymer hair materials containing abrasive materials are placed in a ring-shaped mold with a regulated outer diameter, leaving a space in the center with a specified length, and The inner diameter part of the bristle material arranged in a ring is placed in a ring shape in a non-pressure-welded / compressed state. Method of manufacturing an industrial brush in which a ring-shaped part in a state is melted / fused / fused with a heat source, and then the fused part is cooled / fixed by surface pressure welding / compression The industrial brush manufactured with the manufacturing method of Claim 1 WHEREIN: The industrial brush which attached and formed the flange which consists of resin of the same chemical structure as a brush raw material and the resin raw material containing abrasive grain material on both sides The industrial brush manufactured with the manufacturing method of Claim 1 WHEREIN: The brush for industrial use which shape | molded the brush inner-diameter part in circular shape or the unusual shape

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