US2755496A - Cup brush - Google Patents

Description

July 24, 1956 J. B. BENYAK CUP BRUSH Filed June 16, 1952 IN V EN TOR. JOHN 5 551v YA/C Y mggtw Ri l/01M TTdlf Yg y5 Jjg. 6

United, dtates CUP BRUSH Application June 16, 1952, Serial No. 293,800

8 Claims. (Cl. 15-180) This invention relates as indicated to a novel cup brush, and more particularly to a power driven rotary brush of this type of unusually strong construction and of a design adapted for manufacture in relatively small sizes.

Cup brushes have long been known in the art and are employed for a Wide variety of purposes, commonly being mounted in drill presses or in power driven handheld tools. They are frequently used to remove rust from metal articles prior to the performance of subsequent finishing operations and are also used to remove welding flux and spatter after an arc welding operation, for example.

Many different forms of construction of such brushes have been employed in the past with varying degrees of success. Generally, brushes of this type have been either expensive and strongly made or inexpensive and shortlived due to the manner of assembling the same. In such brushes Where the brush fill is in the form of twisted tufts, the assembly of the brush components has been relatively difiicult and expensive, particularly in the smaller sizes of brushes (Where the brush material may protrude for a distance of only one inch, for example).

It is accordingly a principal object of my invention to provide a novel form of cup brush construction which will be very strong and long-lived and yet which is adapted for assembly from its several component parts in a very simple and expeditious manner.

Another objects of this invention is to provide such novel cup brush constluction in which the bristle retaining element is secured within the outer holder or cup member in a fashion to render it substantially impossible of withdrawal.

A further object is to provide such brush assembly in which the brush material, and more particularly such material in twisted tuft form, will be gripped and sup ported by the constructed neck of an annular channel portion.

Other objects of the invention will become apparent as the description proceeds.

To the accomplishment of the foregoing and related ends, said invention then comprises the features hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawing setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but a few of the various Ways in which the principle of the invention may be employed.

In said annexed drawing:

Fig. 1 is a top plan view illustrating a preliminary stage in the assembly of my new brush;

Fig. 2 is a perspective view illustrating a subsequent stage in the formation of such brush;

Fig. 3 is a vertical sectional view through the cooperatatent ice ing die members employed thus to form the Fig. 2 element from the Fig. 1 element;

Fig. 4 is a vertical sectional view through the cooperating die members employed in the final assembly and forming operation;

Fig. 5 is a vertical sectional View through the finished cup brush as formed by the apparatus of Fig. 4;. and

Fig. 6 is an end view of such finished brush.

Referring now more particularly to such drawing and especially Figs. 1 and 2 thereof, a flat sheet metal disc 1 is provided having a plurality of evenly spaced holes such as 2 punched therein adjacent its outer periphery and a central opening 3 will also desirably be punched to assist in registering such disc during subsequent steps in the brush assembly. A bundle of brush bristles is then inserted through each of the holes 2 and doubled about the outer edge of the disc 50 that both end portions of such bundle extend in the same generally outwardly radial direction. It is contemplated that in my new brush such bundles of brush bristles will ordinarily be of wire and the two end portions will thereupon be twisted together to form twisted tufts 4.

Such disc may now be placed upon a lower die member 5 with a spring-backed indexing finger 6 protruding upwardly through hole 3 and entering axial opening 7 in upper inner die member 8 which is mounted for reciprocation within outer upper die member 9 and resiliently hacked by spring 10. Consequently, finger 6 serves both to center disc 1 and to align the upper and lower die members as the latter are brought together, as shown. The upper die member 9 acts to cup disc 1 so that the edge portions of such disc including holes 2 are bent into planes generally normal to the flat central portion of the disc. The bristle tufts 4 will accordingly now extend in generally parallel relationship to one another as shown in Figs. 26 inclusive. It will, of course, be appreciated that in Figs. 1 and 2 of the. drawing certain of the tufts have been omitted for the. purpose of greater clarity of illustration.

The cup-shaped element of Fig. 2 is now placed upon another lower die member 11 generally similar to die 5 and provided with a corresponding indexing finger 12 adapted to pass through center hole 3' of the cupped disc 1. A small shoulder 13 is, however, provided in die 11 to support a short tubular metal element or sleeve 14 longitudinally proportioned so that the upper edge of such tube will project a short distance beyond the upper end of die 11.

The cooperating upper die member 15 is formed with a central circular recess adapted to receive a closely fitting cup member 16 which may be provided with an axial stem 17 or other means for securing to a drill press or like machine tool. A spring-backed ball 18 may be mounted in die member 15 to assist temporarily in retaining cup 16 in place within the die cavity.

When the dies are now brought together, finger 12 will, of course, be depressed against the action of its supporting spring 19 and cup 16 will be forced tightly down upon inner disc member 1. Moreover, since the upper edge portion 20 of tube 14 projects slightly above the upper end of die 11, it will be flanged somewhat radially outwardly to fit tightly against the rounded base of the twisted tufts 4, and the other end of tube 14 will be likewise bulged radially outwardly as at 21 (Fig. 5) as permitted by the rounded base of such tufts, the bottom loops of such tufts being of somewhat greater transverse dimensions than the remaining turns or twists for the reason that they must include the edge portion of disc 1. The assembled cup brush may then be removed from the dies and the outer lip 22 of cup or holder 16 rolled or crimped slightly inwardly as shown in Fig. 5

to further assist in securing the tufts of bristle material in proper position.

It will thus be seen that the cupped disc 1 to which the bristles are attached is firmly secured within theouter cup or holder 16 and cannot escape therefrom. The central tubular insert 14 fits very tightly within the ring of bristle tufts and is, moreover, flanged slightly outwardly at 20 as above described to prevent its escape from the assembly. Such inner tubular element, however, is not subjected to any substantial axial force tending to dislodge the same and serves principally the purpose of maintaining the twisted tufts in proper axially projecting relationship. Such inner tubular element 14 cooperates with the wall of outer cup or holder 16 to form an annular channel Within which the doubled portions of the twisted tufts are retained and the deformation of the edge portions 21 and 22 aflords a constricted channel neck firmly securing and supporting such tufts. Such assembly has been found to be much stronger, more rigid and uniform than prior art cup brushes wherein the twisted tufts have been strung upon a retaining wire, for example. The resilience of the twisted wire tufts where gripped in their base portions between the wall of holder 16 and tubular element 14 further enhances the press fit obtained.

Not only is my new brush extremely satisfactory in operation but also it is relatively simple and inexpensive of manufacture, and a single operator may assemble a large number of such brushes in an hours time. When the disc 1 is cupped as shown in Fig. 2, it is found that the edge of such disc intermediate holes 2 tends to buckle slightly to form an undulating edge with such edge alternately projecting inwardly and outwardly intermediate such holes and the tufts inserted therethrough.

It will, of course, be appreciated that the disc 1 could be formed to cup shape prior to insertion of the brush material through apertures 2, but assembly is considerably facilitated if performed as previously described. Also, while I prefer, and my new brush construction is particularly adapted for, the employment of brush material comprising bundles of generally parallel metal wires which may be twisted upon themselves as shown and described, nevertheless in some instances it may be desired to pass but a single wire through each of the holes 2 with such wire then ordinarily being twisted upon itself. Moreover, other common brush bristle material may be employed such as horsehair, tampico fiber and the like which will not be twisted upon itself, but only under exceptional circumstances.

If desired, disc 1 may actually be deformed to Fig. 2 shape about inner sleeve element 14 but ordinarily a two-step operation is preferred as more readily controllable. The cupped disc will usually be slightly flared and is of a size to fit snugly in the socket of the holder, as shown. When used as an end brush, this cup brush has the virtue of having no center to restrict the action of the row of tufts around the outer periphery. Holder 16 may be formed with a threaded socket instead of the stem 17, or other mounting means may be provided, such being well-known in the art.

As best shown in Fig. 5, while lip 22 is generally opposed to inner lip 21 it may desirably protrude slightly therebeyond to assist in securing the inner cylindrical member 14 in place. The inner bottom of cup-shaped holder 16 need not be perfectly flat but may be somewhat concave if desired. In eflect, my new cup brush somewhat resembles brushes ordinarily termed end brushes, although of course, having no tufts in the central region. But both the holder and inner member 14 will preferably be cyclindrical, as shown, and not conical or substantially outwardly flaring.

Other modes of applying the principle of the invention may be employed, change being made as regards the details described, provided the features stated in any of the following claims or the equivalent of such be employed.

I therefore particularly point out and distinctly claim as my invention:

1. A cup brush comprising a cup-shaped metal holder, 9. metal disc having a plurality of holes therethrough symmetrically arranged adjacent its outer periphery, tufts of wire bristle material inserted through such holes and doubled and twisted upon themselves, the outer peripheral edge portion of said disc including such holes being cupped to extend generally normal to the body of said disc, with said twisted tufts extending therefrom generally parallel to one another, said disc and tuft assembly being press-fitted within said cup-shaped holder with said tufts protruding frorn'the latter, and an inner tubular metal sleeve press-fitted within said cupped disc and engaging the tufts extending therefrom, the inner end of said sleeve being flared outwardly to engage beneath the inner doubled end portions of said tufts and the outer end portion of said sleeve being flared outwardly toward said tufts, the outer lip portion of said cup-shaped holder being turned inwardly to cooperate with said outwardly flared outer end portion of said sleeve to form a constricted neck through which said tufts emerge.

2. A cup brush comprising a cup-shaped metal holder, a metal disc having a plurality of holes therethrough symmetrically arranged adjacent its outer periphery, tufts of wire bristle material inserted through such holes and doubled and twisted upon themselves, the outer peripheral edge portion of said disc including such holes being cupped to extend generally normal to the body of said disc and crimped alternately inwardly and outwardly intermediate such holes, with said twisted tufts extending therefrom generally parallel to one another, said disc and tuft assembly being press-fitted within said cup-shaped holder with said tufts protruding from the latter, and an inner tubular metal sleeve press-fitted within said cupped disc and engaging the tufts extending therefrom, the inner end of said sleeve being flared outwardly to engage beneath the inner doubled end portions of said tufts and the outer end portion of said sleeve being flared outwardly toward said tufts, the outer lip portion of said cup-shaped holder being turned inwardly to cooperate with said outwardly flared outer end portion of said sleeve to form a constricted neck through which said tufts emerge.

3. A cup brush comprising a cup-shaped metal holder, a metal disc having a plurality of holes therethrough symmetrically arranged adjacent its outer periphery, tufts of Wire bristle material inserted through such holes and doubled and twisted upon themselves, the outer peripheral edge portion of said disc including such holes being cupped to extend generally normal to the body of said disc, with said twisted tufts extending therefrom generally parallel to one another, said disc and tuft assembly being press-fitted within said cup-shaped holder with said tufts protruding from the latter, and an inner cylindrical sheet metal sleeve press-fitted within said cupped disc and engaging the tufts extending therefrom, both the opposed outer lip portions of said holder and sleeve being deformed toward each other to form a constricted neck through which said tufts emerge and the inner end of said inner sleeve abutting against said cupped disc.

4. A cup brush comprising a cylindrical cup-shaped metal holder, a flat metal disc having a plurality of holes therethrough symmetrically arranged adjacent its outer periphery, tufts of wire bristle material inserted through such holes and doubled and twisted upon themselves, the outer peripheral edge portion of said disc including such holes being cupped to extend generally normal to the body of said disc, with said twisted tufts extending therefrom generally parallel to one another, said disc and tuft assembly being press-fitted within said cup-shaped holder with said tufts protruding from the latter, and an inner cylindrical metal sleeve open at both ends press-titted within said cupped disc and engaging the tufts extending therefrom, the outer lip portion of at least one of said holder and sleeve being deformed toward the other to form a constricted neck through which said tufts emerge and the inner end of said inner sleeve abutting against said cupped disc.

5. A cup brush comprising a cylindrical cup-shaped holder, a fiat disc having a plurality of holes therethrough symmetrically arranged adjacent its outer periphery, tufts of bristle material inserted through such holes and doubled upon themselves, the outer peripheral edge portion of said disc including such holes being turned generally normal to the flat body of said disc, with said tufts extending therefrom generally parallel to one another and to the axis of said disc, said disc and tuft assembly being tightly fitted within said cup-shaped holder with said tufts protruding from the latter and an inner cylindrical tubular member open at both ends press-fitted within said cupped disc and engaging the tufts extending therefrom, the inner end of said inner tubular member abutting against said disc.

6. A cup brush comprising a cup-shaped holder having a solid generally flat inner bottom, a fiat disc having a plurality of holes therethrough symmetrically arranged adjacent its outer periphery, tufts of bristle material inserted through such holes and doubled upon themselves, the outer peripheral edge portion of said disc including such holes being turned generally normal to the flat body of said disc, with said tufts extending therefrom generally parallel to one another and to the axis of said disc, said disc and tuft assembly being tightly fitted within said cupshaped holder with said tufts protruding from the latter and said disc flush against said bottom, and an inner tubular member press-fitted within said cupped disc and engaging the tufts extending therefrom, the lip of said cup-shaped holder being turned somewhat radially inwardly to assist in retaining said disc and tubular member therewithin.

7. A cup brush comprising a cup-shaped holder, a flat disc having a plurality of holes therethrough symmetrically arranged adjacent its outer periphery, tufts of bristle material inserted through such holes and doubled upon themselves, the outer peripheral edge portion of said disc including such holes being turned generally normal to the flat body of said disc, with said tufts extending therefrom generally parallel to one another and to the axis of said disc, said disc and tuft assembly being tightly fitted within said cup-shaped holder with said tufts protruding from the latter and an inner tubular member press-fitted within said cupped disc and engaging the tufts extending therefrom, the inner end of said tubular member being flared outwardiy to engage beneath the inner doubled end portions of said tufts.

8. The method of forming a cup brush which comprises forming a plurality of symmetrically spaced holes in a metal disc adjacent the outer periphery thereof, inserting tufts of wire brush material through such holes, doubling the end portions of such tufts upon themselves, twisting such end portions of respective tufts together to form radially extending twisted tufts, deforming such disc to cup shape with such tufts extending generally parallel to one another and the axis of such disc, press-fitting such cupped disc within a cup-shaped holder with such tufts protruding therefrom, inserting a tubular member tightly within such cupped disc and engaging such tufts extending therefrom, expanding the inner end of such tubular member to engage beneath the doubled inner end portions of such tufts, expanding the outer end portion of such tubular member more closely to engage such tufts, and turning in the lip portion of such holder opposed to such outer end of such tubular member to form a constricted neck through which such tufts emerge.

References Cited in the file of this patent UNITED STATES PATENTS 1,347,153 Frost July 20, 1920 1,874,475 Ellingham Aug. 30, 1932 2,062,047 Bickel et al Nov. 24, 1936 2,449,158 Benyak Sept. 14, 1948 2,480,877 Peterson Sept. 6, 1949

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