TECHNICAL FIELD
[0001] The present invention relates to a method for manufacturing a brush having a row
of brush bristles arranged, between a plurality of metal core wires twisted continuously
in the longitudinal direction, in spiral along the twist of the core wires, and a
brush manufactured by this method.
BACKGROUND OF THE ART
[0002] Conventionally, a brush having brush bristles held, between twisted metal core wires,
in spiral along the twist of the core wires, is used for the various purposes such
as industrial, medical, and noncommercial uses. Brushes of this type, although the
size thereof vary from 1 mm or less to 100 mm or more depending on the applications,
are both manufactured in the similar way.
[0003] The Patent Document 1 discloses a method for manufacturing a brush for polishing
the inner periphery end surface of a magnetic disk substrate wherein the brush bristles
thereof are arranged in double spiral (see Fig. 2B). This polishing brush is constituted
by sandwiching bristles between core wires at two different positions of the four
core wires followed by twisting these core wires together. This brush has double spiral
row of bristles, and is called a "double spiral brush".
[0004] On the other hand, the Patent Document 2 discloses a torsion brush manufactured by
passing core wires through two cylindrical coils respectively, and adding torsion
to the core wires. Further, the Patent Document 3 discloses a method for manufacturing
a mascara brush comprising, inserting a shaft member to each of two to four spirally
wounded fibers which becoming brush bristles, twisting the shaft members to form a
brush axis, to thereby arranging a large number of fiber loops in spiral form around
the brush axis and forming a spiral groove between the rows of adjacent loops (see
Fig. 14).
PRIOR ART DOCUMENT
PATENT DOCUMENT
SUMMARY OF INVENTION
PROBLEM TO BE SOLVED
[0006] According to the method for manufacturing a brush disclosed in the Paten Document
1, the bristles are required to bend into substantially V-shape in the central portion
in accordance with the twist of the core wires. However, depending on the application,
when the bristles with more rigid are employed, the bristles may not bend by simply
twisting the core wires, and in this case, the twist of the core wires inflating unevenly,
so that it is not possible to arrange the row of bristles orderly in spiral. Therefore,
such work is necessary as to apply a twist to the core wires while bending the bristles
to bring into close contact between the core wires by applying a strong force to the
two core wires located in the center of the bristles. There is a problem that this
operation requires skill and is an inefficient work.
[0007] According to the methods for manufacturing a brush disclosed in the Patent Documents
2 and 3, since the fibers of the spiral brush bristles are in direct contact when
twisting the core wires, the other loop penetrates irregularly each other between
adjacent loops so that array of the spiral becomes irregular. This phenomenon is remarkable
when the thickness of the brush bristles is different and when the spirals are not
in close contact. Uniform arrangement is not obtained when using brush bristles of
different fibers in material.
[0008] Accordingly, an object of the present invention is to provide a method for manufacturing
a brush efficiently and without skill wherein the brush comprising loop-shaped brush
bristles or radially extended curved brush bristles forming a plurality of spiral
rows around core wires.
MEANS FOR SOLVING THE PROBLEMS
[0009] Hereinafter, although the description is made with reference to the signs of the
accompanying drawings, the present invention is not limited to thereto.
[0010] For solving the above problems, a method for manufacturing a brush according to the
present invention comprises the steps of: forming a plurality of bristle and core
wire combination bodies 7 each comprising a bristle 6 of resilient wire formed into
the shape of coil and a core wire 2 of metal passed through the loops of the bristle
6; preparing the same number of other core wires 3 of metal (other metal core wires)
as the combination bodies 7; forming a core wire assembly 8 by approaching the core
wires 2 of the combination bodies 7 and the other core wires 3 and placing in the
direction of rotation of twisting alternately; and twisting the core wire assembly
8 continuously in the longitudinal direction, to thereby form a brush having a number
of loops 9 of the bristles arranged in spiral in the longitudinal direction along
the twist of the core wires 2, 3.
[0011] According to another method for manufacturing a brush of the present invention comprises
additional step of cutting the loop 9 of the bristles 6 after said entire steps to
thereby form a brush having brush bristles extending radially curbed in substantially
perpendicular direction with respect to the core wires.
EFFECT OF THE INENTION
[0012] According to the method of the present invention, it is possible to manufacture a
brush comprising loop-shaped brush bristles arranged orderly to form a plurality of
spiral rows around core wires, without skill and efficiently.
[0013] According to the another method of the present invention, it is possible to manufacture
a brush comprising radially extended curved brush bristles arranged orderly to form
a plurality of spiral rows around core wires, without skill and efficiently
BRIEF DESCRIPTION OF THE DRAWINGS
[0014]
[Fig. 1] (A) is a front view, and (B) is a plan view of a brush according to the present
invention.
[Fig. 2] (A) is a front view, and (B) is a plan view showing the manufacturing process
of the brush of Fig. 1.
[Fig. 3] (A) is a front view, and (B) is a plan view showing the manufacturing process
of the brush of Fig. 1.
[Fig. 4] (A) is a front view, and (B) is a plan view showing the manufacturing process
of the brush of Fig. 1 or finished body of other brush.
[Fig. 5] A plan view showing the manufacturing process of yet another brush or finished
body of the yet another brush.
MODE FOR CARRYING OUT THE INVENTION
[0015] Embodiments of the present invention will be described with reference to the drawings.
[0016] In Fig. 1, a brush 1 comprises a shaft 4 having four metal core wires 2, 2, 3, 3
which are continuously twisted in the longitudinal direction, and rows of brush bristles
5 arranged in spiral and held to the shaft 4. The brush bristles 5 extend to be curved
in a direction substantially perpendicular to the core wires 2, 3 and are arranged
in spiral along the twist of the core wires 2, 3 at each between the core wire 2 and
the core wire 3. The rows of brush bristles 5 are arranged to form a double spiral
around the core wires 2, 3. As shown in Fig. 1(B), each of the brush bristles 5 is
pressed at central portion by the core wire 2, and is sandwiched between the other
two core wires 3 adjacent to both sides of the core wire 2. Therefore, the core wire
3 is interposed between each spiral row of the brush bristles 5.
[0017] The manufacturing process of this brush is shown in Figs. 2 to 4. In Fig. 2, the
core wire 2 of metal is inserted into each of two loops of bristles 6 to form two
bristle and core wire combination bodies 7, wherein the bristles 6 are made by forming
an resilient wire into coil shape and is used as the brush bristles 5. On the other
hand, two other core wires 3 of metal are prepared. The bristle 6 may be either a
single wire or a twisted wire.
[0018] In Fig. 3, the core wire 2 of the combination body 7 and the other core wire 3 are
approached, and as shown in FIG. 3 (B), alternately arranged in the rotation direction
of the twisting, and bundled together to form a core wire assembly 8.
[0019] In Fig. 4, by twisting the core wire assembly 8 continuously in the longitudinal
direction, a large number of loops 9 of the bristles 6 are arranged in a spiral shape
in the longitudinal direction along the twist of the core wires 2, 3 to form a twisted
wire body 10. This twisted wire body 10 constitutes a brush as one embodiment of the
present invention. This brush has a series of brush bristles in loop. Since brush
bristles will not fall out from the core wire, this brush is suitable for cleaning
of machinery and equipment and the like that dislike the contamination in the cleaning
process.
[0020] Subsequently, by cutting the loops 9 of the bristles in the twisted wire body 10
along the line C in FIG. 4, the brush 1 of the embodiment shown in FIG. 1 is formed.
This brush 1 has two rows of spiral brush bristles 5 extending substantially radially
around the axis 4. The brush bristles 5 are curved substantially in an arc shape.
Incidentally, if necessary, bristles may be straight by performing heat treatment
or the like to correct the curvature.
[0021] Since the bristles 6 are a series up to the step of forming a twisted wire body 10,
the handling thereof is easy. Since the bristles 6 are pre-curved in the direction
to be refracted, they are easily refracted by the pressure due to the twist between
the core wires 2 and 3. Therefore, such brush 1 can be easily manufactured as the
twist of the core wires 2, 3 is uniform and a row of the brush bristles are arranged
orderly in spiral.
[0022] A manufacturing process of the brush according to another embodiment is shown in
Fig. 5. In Figure 5, three bristle and core wire combination bodies 7 and three core
wires 3 are prepared. Core wires 2 passed through the coil-shaped bristles 6 and other
core wires 3 are approached and arranged alternately in the rotational direction of
the twisting, and the core wires 2, 3 are twisted together. Thus, a brush with a looped
brush bristle rows arranged in triple spiral along the three core wires 2 is formed.
Further, by cutting the loops along line C, another brush bristles spreading radially
can be formed. By increasing the number of combination body 7 and the core wire 3,
it is possible to make the shaft 4 tougher, and the density of the brush bristles
5 can be increased. In each case, by setting the combination body 7 and the core wire
3 in the same number, and by alternately placing the core wire 2 and the core wire
3 in the direction of rotation of the twisting, it is possible to interpose the core
wire 3 between each spiral row of brush bristles 5.
[0023] Each pair of core wires 2, 3 in Fig. 2 may be made by folding a single metal wire.
The core wire 3 may be of larger diameter than the core wire 2. The shape of the loop
coils of bristles 6 is not limited to a circle and may be changed variously in shape
and size depending on the intended use. For the bristles 6, the different ones of
the thickness, material and coil pitch may be mixed. In addition, the coils having
different diameters may be overlapped double.
DESCRIPTION OF THE SIGN
[0024]
- 1
- brush
- 2
- core wire
- 3
- core wire
- 4
- shaft
- 5
- brush bristle
- 6
- bristle
- 7
- combination body
- 8
- core wire assembly
- 9
- loop
- 10
- twisted wire body
1. A method for manufacturing a brush having a plurality of rows of brush bristles arranged,
between a plurality of metal core wires twisted continuously in the longitudinal direction,
in spiral along the twist of the core wires,
characterized in comprising the steps of:
forming a plurality of bristle and core wire combination bodies each comprising a
bristle of resilient wire formed into the shape of coil and a core wire of metal passed
through the loops of the bristle;
preparing the same number of other core wires of metal as said combination bodies;
forming a core wire assembly by approaching the core wires of said combination bodies
and said other core wires and placing in the direction of rotation of twisting alternately
to thereby isolate the bristles between different combination bodies by the other
core wires; and
twisting said core wire assembly continuously in the longitudinal direction, to thereby
form a brush having a plurality of rows of loop-shaped brush bristles arranged in
spiral.
2. The method for manufacturing a brush according to claim 1, further comprising a step
of:
cutting the formed loops of said bristles after entire processes claimed in claim
1, to thereby form a brush having brush bristles extending radially curbed in substantially
perpendicular direction with respect to the core wire.
3. The method for manufacturing a brush according to claim 1 or 2,
wherein said core wire assembly is formed by alternately arranging two said combination
bodies and two said other core wires in the direction of rotation of the twisting.
4. The method for manufacturing a brush according to claim 1 or 2,
wherein said core wire assembly is formed by alternately arranging three said combination
bodies and three said other core wires in the direction of rotation of the twisting.
5. A brush manufactured by the method according to one of claims 1 to 4.
6. A brush having a row of brush bristles arranged, between a plurality of core wires
of metal twisted continuously in the longitudinal direction, in spiral along the twisting
of the core wires, wherein said brush bristles are curved, and extending radially
in substantially perpendicular direction with respect to said core wires, characterized in that,
said plurality of core wires of metal comprising the core wires of metal of the bristle
and core wire combination body claimed in claim 1, and the same number of other core
wires of metal as said core wire.