Note: Descriptions are shown in the official language in which they were submitted.
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FlDt~813 PC'Z'
TITLE
NE~~IG1D ,~ APPAFATTJ3 FQR ~KI1~TG
H~LI~°Thl3 SU9ASSf'~BT~TTS
g . ~ CO-P~1D~NG AND RET~AT~ APPLTC'..~TIO1~S
Thia is a cantinuatiQn-in-part of U.S. Serial No.
09/455,308, filed December 6~ 1999 ersti,tled "Bristle
Subassemblies Having Parallel Pairs~of Bristles; And
Metb,ods Of Mal~i~.g Same" by Mark S . Edwards, which, is a
cvntinuatiQn-in-part of U.s. serial Na. o9/o9a,o92,
filed Tune ~r 1998 em.titled "Method cad Apparatus Fax
Ma3~iag Art3.cles Having Bristles" by' Mark S. Edwards.
Th~,s application is related to co-pending appl.~.aation
Serial I~o. 09/492, 094. fi7,ed Jutle 5, 1998 ent2tl,ed
"MQnofilament Bristle Assemblies And Methods of Making
Brushes Uairjg Same" by' Mark S. Edwards; axa,d Serial I3'ra.
o9/s5o,65~, filed April 17l 20ao entitled "Method A~xd
Apparatus For Making Bristle Sub~.ssembliesf' bg Mark
S.Edwarda (based on provisional Application NQ.
ao 5o/ma, ss3 fi~.ed .~pri1 ~3, 7.999) .
FIELD aF T~iE TNVENTION .
The gresent invention relates tv a method and
apparatus far making ~aolymeric bz~istle subassemblyes
having a b~,ae string with pa~.y~meric mvr~.ofilament ,
bristles attached thereto az~d also to pv~,ymeric bristle
subassemblies wherein two rows o~ pal~meric
. manofiJ.ament brist7.es axe attached toga single base
String. The two rows are attached b~ passa.ng a 3~ase
string through a bristle bonding~process at least twice
in a "mufti-pass" fashion.
1
Sub~sti~ute Speaifs.vation
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BACiCGR~UND 4F THF' INtTENTIC1N
The followa.ng disclosures may be relevant tv
'v'ar~.ov.s aspects___o_f the presez3.t, invention. and may be
briefly summarized as follaws.~ y
mescri tion. i7f Thg Related A=t
w0 a0/254~6 t~v Chambers et al. discloses a paint
rvllex. that inclur~3~s a core tube hacring f first anc'i
second ogpvsite axial ends. At least one tuftstring is
sp~irally~wrapped around.the cure tube and adhes~.vely ar
otherwise bound tQ tk~e core tube.
WO X0/55138 to Edwards et al, disclQSea a
cantinuaus mcthad and apparatus fvz. making bristles
subassemb7.i:ee . ~ The method far making the bristle
subassembly includes continuously fQZ~n:i.ng a wrap of
f~.laments by wrapping at 7:east one filament around at
Zeast a three sided mandrel hav~.ng a moving cable
2o suppflrt on each. corner ruxinizsg the length of the .
mandrel on the exterior corner of the mandrel capable
.of supporting and moving the~polymeric filament of the
wrap along at least a porta.Qn of the length of the
mandrel. ~1 base string is fed Outside the wraps bonded
to the polXmeric filame~.ts anal then the polymeriv
filaments are cut to form a bristle subassembly.
AlternatZVely the brist~.e subassembly caz~ be made by
bvnd~.ng the wrapped f~.laments to each cipher and
Qm~.tting the base string.
ao
The GoTpending applications noted.'above describe
a method and apparatus for making 'brist7.e subassemt'l~.es .
in which ~. monofilament is wrapped arQUZa,d a mandrel.
There are two,general variations of the apparatus. Trl .
the first variativnr a base stz.~.ng is drawn along the
outer~surface of the mandrel so that the mono~ilament
is wrapped in a transverse diz~ection over tk~e
~,ongit~.dinally disposed and translat~.n~ base strzng~.
Substitv.te 5peaifa.aat~.4rz
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As the base string~movest it carries the "wraps" of . .
monof~.7.ament under an ultrasonic hvz~n which applies .
ultrasonic energy Qf s~u.ffieient o~uantity to cause the
. _ ' _ ~,~tting surfaces of th.e~ b~aae string and monvfilamen,t . . ..
to heat and thus fuse together. After fusion together,
the wraps are cut t.o thus farm what are ca~.Ied "bristle,
sut,assembl~.es," which caz~ be used to make a wide
variet~~ of articles, including bristles for brushes.
. . , . , zrs, this first variatiori of the appara~cus, the. ' ' , ,
Ia 'wraps are transported to the ultrasonic hozws by
movement of the base string.or s'trings~. Typically,
more than one base string is used on the mandrel. In
the second var~.ation, a Gable is used to transport the
wraps, and, the base strings are brought into contact. .
I5 'with the wraps outsa,de the mandrel.. ~ example of the
second variation is illustrated in Figure 1.
Figure 1-shows a schematic view of a preferred'. .
emlavdiment oW the second variation. =n particular,
filament Z is fed_ from a spool (riot shown) throv_gh a
zo tensioning drive (z~.ot shown3 azsd is continuously ,
wrapped around a four-Bided mandrel 5 by a wrapping
mechanism 2 to form a plurality.of continuous wraQs 6
along the length Qf the mar~dre~. 5. The wrapping
mechaz~.ism 2 is a~high speed variant of the wrapping
25 mechanism described in T1.S. ~'atent No. 5~5$~.'i32, which
is incorporated herein by refere~:ce.
. . A cable 4 made of metal w~.re or a suitable
galyGneric material runs down a~.Qng groove ~a on the
face of the rnandre3. and its direction. is reversed by
. ~3o pulley 3a. The cable a then runs up the corner 7b~of.
the mandrel 5 and moves the wraps ~ along the length of
the mandrel. Cable 4 is redirected and runs down the
back of the mandrel 5 in groove '7c and ~.s xedirected
again by pulley 3b and runs up in the corner 7d c~f the
35 maz~.drel to thereby support the wraps and mo'v'e . them
along the length of.the mandrel 5. ~n additional
endless support cable (not shown) i.s ayr~.ahroni~ed with
ca~ale a and is positioned simi~.arly on the two
3
substitute 8peci~zaation
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remaining opposite corners of the mandrel and ~un.s in
groa~res on the opposite side of the mandrel 5. Pulleys
'(net shown) are reauired for the second endless cable
to redirect ,and reverse the directxon~af the ~additio~ta,l
endless cable.
Hase strings 8 a, 8b, ~ c, and 8 d ~.re fed through
c~az~respondirtg guide tubes 13a, l,~b, 13c, and 13d to
each s~.de of the mandrel 5, preferabl~r to each corner,
of the mandrel 5 ~~as shown ice. Figure 1,, azid bought into
to contact with the wraps ~s. tTltrasonic assemblies 9a.,
9b, 9v, and 9d held the base str~.ngs ~a~d in contact .
w~,th the~wrap s and provide sufficient energy to at
least part~.~.lly melt 'the base strings, ~ the filaments . of
the wraps, yr both, , together. Typically, 0 .1~-1. 0 jvu~.e
energy ,is used ~to bond a thermoplasti~e po7.yam.ide
monofilament base string to the filaments of the wrap. .
.As the filaments of the wraps are banded with the
base stx-ings and proceed a~.o~,g the length of the
mandrel 5, the filaments vf~the wrap are eat b~ nutters
20~ ~.va and lob into a plurality of br~.stle subassemblies
11a, 3.~.lar lle and ~.ld. Not shvwxl a.re cutters an the
Qp~aasite sides~of the mandrel 5 posi,t~oned opposite
.cutters loo and 10b. The bristle subas~aemblies 11a-d
.. are then wound orr spools and are available for use in
2~ making articles such as brushes, particular~.y
tQ~athbrush~es .
The brist~.e suba,ssexnb~.~.es described abo~re, after
sl3tti.ng;.comprise a base string with two rows of y
monofilamen.t bra.stles, With the briatle$ of each roar
30 sameurhat ar~g~.ed to form a V-shape Pram 'an end v~~.ew.
'The br~,stlaa Qf each r~W are integrally formed with
corresponding bristles of the othex' row, due to the
fact that. the base, stxing was bonded to the ~~wrape'" at
abov,t a midpoint bets~een twcr cuts impaz~ted by th,e
3~ cutters.
Base strings used for the fabr~,cation of tuft or
brZSt3.e strings have historica~.ly been made with a
single pass through the ultrasonic bonder, in tk~e
4 .
Subt~t$~utc 9pea2fication
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.p,D681'~ PCT
~ltar,~n.er substantial 1y described above (with the . aba~e-
y,ated embodiment being directed to mvnvfilaments rather. ..
tha.~-~ tia.fted filameaate~a . This type of system li.niitg the
number of bristles or tufts per inch of a given:
bristle/tuft string and farms a single~mix Qf . '
br~.stles/tufts Qnl~.
arar~y 4F TFIS 'ZN~ENTTah9'
. ~. . The ,present invention includes inethvdola~' .and an
1U apparatus that v.ses a second ~aa~.d~r and wrapping head
in aeries witb. the first to create bristle/tuft strings
which van have greater flex~.bility for use and
manufacture. For example, a briatle/tu~t string is
first formed from ~lr5t wraps bonded to a base string
~~15 and slit or cut before passing over to a second wrapper
and bQr~der system where another layer of ti~ftsjbristles
are attaohed. TYxe second layer can either be attached
to the same side or the vppvszte side as the first.
bristles/tufts. Thus, the population of bri.stles/tufts
ZO can be extended. to twice the capacity of a sing7.e .
bonder;~moreaver, different sized and tygea of
monvfilaments can be easily cvmbi.ned, or mvz~.of~laments
o~ different colors, shapes and ether surface features
. can be cr~mlained to form bristles having a dessred ,
Z5 combination. The bristles can be partitioned in the
bristle/tuft string, either layered on one side or an
opposite Bides of the base string, ,
=f desired, and according ~to the present
invention, add~.ticnal bandef/u~apPer assemblies aan be
3o placed in series to ~~laui,~.d. ug~ layers of bristles/tutts~
for specific aQplicativnWor customer needs. 8y using
two or .more ultrasonic handers and wrapper assemblies
in'seriesr bristle/tu~t structures Can be ach~.ev'ed that
were z~ot possible using the single pass wrapper/bonder
35 mechani.ams descr~,be~i in. the related ~.pplicatiø~.8. .
Single .bvnder/wrapper mechanisms can generate only'
one cvncen,tration of bristles per length of product.
i.e., two red s~,~c mil filaments combined with one eight
5
.. _ . , S~.tbvtituta ~pecificatior~
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mil white. If desired, this product can have multiple
layers each with its own unique formula of bristles,
i.e., la't'er one comprised v~ twar red; sip m~.l., round _.
filaments mixed with one, six mil, round white; and
layer two comprises. of twQ eight mil, blue, diamona-
shaped fi7.aments. Thus, the invention contemplates
that a wide range. of different shapes,. colors,
calipers, etc.; cap. 3~e formed. either as layers on one
~s3,de or .oppQS~-to . sides .4f the baa~ string.
to
when making~monof~.lament bristles, one
particularly well suited polymeric matez~ial which forms
the . mQnofilament is nylon. These moz~.ofilaments' have
been 'used .to make a side variety of products, including
brush bristles, f~i,ahing line, and tenn:i.s racket
strings. '
The present ~.nvention has several advantages. ~'Qr
example, high densities of ~.arge caliper bristles have
24 a -~e:ry rsaz~row process ~indvw and are thus dsfficult to
produce in a single pasB. This is due to the
combination o~ high st~.ffness of the multitude of wraps
and high points where filaments have twisted and
entangled. ~ The mu7.tigl,e pass process reduces 'the count
per.wrapper~bvnder to a range more suitable for high
speed manuf acture .
The features s.nd advantages Qf the ~.nv'ez~tion will
w become rnQre apparent from the foll,vwing deta~.led
description when,takaz~ in conjunction with the .
3p illustrative, embodiments in the~accompanying drawings.
. E_RI~g 'D83CRTPTTD~1' OF THE DR~,WzNG6
F~.gure 1 is'a schematic view showing a method and
apparatus for forming bristle svbassembl~.es using a
single pass base string,' in which the apparatus
includes wrapping, bvndi.ng and. cutting components; .
Fsgure ~.is a schematic view ~showing:a method and ,
apparatus for forming bristle subassemblies us~.ng a
s ' ' .
Substitute Specificatior~:
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,p,D6~I3 PCT
multiTpass gracess, wherein at least two apparatuses
. ~r~r fQrm~.ng bristle s~.bass.emblies operate, in aeries; .
Figure ~ is a, transverse, cross-sectian.al view of
a. mandrel aceordirag to the present in.~ren.tionr and '
s showing in schematic form the 2ocation of the corner
ultrasonic agaembl~.es used tc~ bond base atring;3 to
wraps at the corkers of the mandrel.;
gzgure 4 is an enlarged view of the mandrel .
according to the present invention, and shc~tring the ~ . .
1o faatures of the anvil and tip of 'the ultrasonic hornF -
Figure 5 is a~further enlarged v~.~w of oke of the
earners of the mandrel, and showing in~detail tk~e angle
of the anvil under a wrap of manofilamentp~
Figure 5 is a cross-sectional vie~r s~.atilar to
~5 Fig~,re~3, showing the ultrasonic assemblies far the
mid-point.base strings; '
Figu~'e 7 i8 an- enlaz~ged view ~vf a portion of the
mandrel and ultrasonic assemblies of Figure ~;
Figure a is a further enlargement of a portion. of
z0 the mandzel and ultrasonic assemblies of Figure 7;
Figure 9 is a transverse sectional v~,ew of the
mandrel. at the second bristle subassembly station, and
showing the location of the u3.trason,ic assemblies for
the corner base strings;
2s Figure 1D is an enlarged view of a portion of the
mandrel and ultrasonic assemblies for the ~mandre~. 4f
Figure 9~ . ,
Figure 11 is a further enlargemer~.t of a partiaz~ of
the mandrel and ultrasozxxc~aesemblies of Figure 9;
sa ~ Figure 12 is a transverse sectional.~riew of the
mandrel at the second bristle subassembly station, az~d
shvwi~.g.the location of the ultrasonic assemblies for .
the mid-point base strings;
Figure ~.3 is an enlarged v~.ew of a portion of the,
35 mandrel and ultrasonic assemb~.ies for the mandrel o~
Figure 12;
7
~ub~atitute S.g.ecif ~.aatzar~
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Figure 24 is a further enlargement showing the
contacting por'tivn,s of the wraps and base strings vf~ ..
the mid-point. i~ase string; ~ ... ... '
Figure is is a trans~rexse seati.vnal view of the
mandrel of the first brist7.e subassembly station, and '
showsng the slitter assemb7,ies;
Fzgure 16 zs an en3.az'ged view of a portion of the
mandrel~of Figure ~.5r w~,th all slitters removed except
one for. the sale of illustration.; ~ , . . '
1o Figure 17 is an enlarged view 4f t~.~ mandrel. of
the second bristle subassembly station, showing a ~riew
similar to Figure 16 of a slitter at the ma.d-poa.rtt base
strit2gf with othez~ slitters removed for the sake of
illustration;
Figure 17a is arc enlarged view showing~a corner y -
slitter and ~cvoperating bed knife or cutter bed; .
Figure ~8 is a schematic view of a conditioning
apparatus for corxditioning the cut ends.vf the brzetles
w~ the bristle subassemblies; -
2o Figure I9 is an end vista of the bristles of a
bristle subassemblyf showing the relatively fagged
proximal ands at the base string, as seen in the broken
line oral "T~~r of Figure 18;
Figure ~0 is an end view of the bristles of a ' v
25 bristle~subasaembly showing the proximal ends rounded
or smoothed fo7.lowing a ~oriditi.~arting step. as. seen from
the broken Line oval-"$~ of Figure 18; .
Figure 21 is an end view of the apparatus of .
Figure 18, showing the conditioning wheel extending
90 ' into a coola.ng tank; ~ . . ~ . . ~ '
~~'i,g~.re ~Z is a partial, enlarged view of the
cax~,ditioning wheel of Figure Z1, as seen from the
broken line oval "C"' of Figure Z~.;
FigureW3 a.s a schematic view of a conditioni~.g
3,5 apparatus~acaox~ding to another embodiment of the
present invent~.vr~.;
. . 8
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ADG813 PCf
Figure 24 is a partial end view of the . .
conditioning apparatus of Figure 23, as seer. alaTig l~.rie
D-p Gf Figure 23; _ _
Figure 25 is are enlarged sectional view of the ~~~~
conditior~,~.ng' wheel. of Figure 23, as seen from the .
broken l~.z~.e rectaz~.gle °E" of Figure 24; .
Figure 26 is a transver8e, cross-sectional ~riew of.
a preferred bsse string, showing mid-point protrusions ' . ..
or ribs that improve canitrQl of the'. flow .zone ~au~~.ng ' .
p the bonding prQCess;
. Fj~gure 27 is an end view showing two
subassetnlalies subjected to forces bring them in
ju~tagosition; .
Figure ~8 is an end view showing the two
~15 sulaassem~alies of Figure 2'7 irr a j'~taPased Pvsztion and
fc,~.lowing app7~.icatiQn of ultrasoz~.ic energy, other
heating source;
Figure 29 is a perspective view of a,n apparatus
for fQrm~.ng madi.fied subassemblies in which the .
2Q staz~ting mater~.als are two a'~assemblies, each
a.ncluding a base str3ng~and a row of elongated members;
Figure 3o is an enlarged, partial~end view showing
the guiding grooves provided 2n the~first and second
guides Qf~~the appazatus of Figure Z9;
25 Figure 3~, is a partial cross sectional view .
showing a mandrel used for combining a first
subassembly with add~.tional wraps, and show~.ng another .
embodiment of a knife bed accQrdi.ng to the preieot ,
invention;
30 Figure ~3Z is a 'v'iew s3,milar to 'Figure. 32, show3.rig .
tla.e 'kr~.ife lied of Figure 37. uBed on a station used to .
ma'!~e subassemblies. . .. . .
Figure 33 is a side elevation view of a brush
according ~o the present invent~.vn,, in which the head
35 ~gortion is provided with, an array of bristles farmed by' .
segments of the mo~.ified subassemblies of the preser~t
invention' and ' . '
~cW~,titutc~ S~ec~.fieation
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Figure 3.4 is a front elevation view o~ the brush
of Figure 33. .
DETAILED DESGRIPThC?N OF . ~ PRB~'FR3i~~.D EM94D~:MENT3
S' Ke~errirtg' to Fa.gure 2, a mufti-pass apparatus ~0
for forming~bzistle subassemblies includes turn bristle
subassembly statiax~s 2~ and ~4 which. operate in ,series.
', , , Tn, the first bristle. subassemblx station 22, a wrapgzng
rnechax~i~m (nc~t shown) wraps ~a monofilamerit around a .
s0 mandra7. 26 to form a plurality of wraps 28. The
mandrel is prazrided with conveying cables (neat shown)
of the type described. with reference to Fi..gure ~~.,
wherein the wxaps are tr~.nsported upwar3ly ifrbm the
. view of Fagots 2 f since the v~rrapgir~,g mechanism would be
1S faceted at the lower end of the mandrel?' by rotation, of
the cables.
In the embodiment of Figure 2; es.ght base stra.ngs
', are fed to the wrapsr four at the respective corners of
the mandrel arf,d four at the a.g~aroximate mid-p4ix~,ts
Zo bet~seer~. the corners. Preferably, all of the ~cvrner
base strings are fed~to the mandrel 2fi at about.~he
same vertical position along the mandrel, Of the four
carnet baba Strings, only two, 29 and 30, are shown ice.
f~.gure Z. Each, of the coxwex base str2nga 29 and 3~
25 are fed. Pram respecta~~ra spools 32 and 34 and through .
respective guides 36 and 38. Again, from the view ref .
Figure 2, Manly two of four guides, arid two of fJUr ~a~e
stz~inga and agoo~.a, are visible .
,~'he guides ~gosi~ion ar~.c3 ha~.~l, the base strings as
3o they pass under bonding mesas 4U and 42 which cav.se the
base strings to bond~and thus bevarne conneatad to the
wraps 28. Each guide has a respective bonding rneans~4Q
and 4~, each of which is p~eferab7.y azz. ~.ltrasonzc~
.assembly_ Each ultrasonic .assembly arxcl;.3.des a horn for
35 delivering ultra,son~.a energy to the abutting tnrraps and
base strings at one side thereof. On the opposi~Ce
side, the mandrel grovidea an anva.7~ sQ that tb.e point
. where the, wraps contact the base stra.ng is bet~aeeza the
xa
subs~tituta Spacificatiort
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anvil and the horn.. When.energiz~d, the horn delivez~~
v.ltrasQnic energy of sufficient .magnitude to cause the , w
base strings and abutting wraps t vibrate, thus
generatiz~g heat at the interfaci.a 'surface of one or '
bath the, base string and wraps. ~~s the bonded wraps
and base strings are transported wa~'from~the
ultr~.sonic assemblies, room temperature cov~,ing occurs '
arid the bond a.s, complete.
' r . Fat a. W ertical pasitio~n, epacel upwardly from the
IO entry point of the corner base strings, the: mid-point
base strings 44 and 4s are fed to the wraps on the
mandxel from r~esp~:ctive apQV~,s 4a and 5v . The two
other mid-paint base strings and ~pvvls are not visible
from the . view of Figure 2 . The b se strix~.ga 44 and ~46 w
is are fed to the wraps Q~ the maz~dr Z through guides 5~
and ~4, respeeti.vely, which are j tagosed respective
bvz~ding means or u.a.trascanio assem~alies ~6 and 58.
These asseeNolies fvnation the eam as the other
nltrason~.c assemTalies Qo and 42, nd when operated, .
. '2o they cause the abutting surfaces f the wraps' ~~~ to
bond 'to the base strings 4~ and 4 .
Downstream Qf the ultrasonic aasernblies 56 and 58,
each face of the mandrel ~.s provi ed wsth, a pa~.r of
rotating cutter blades or~slitter~ 60 and 62, making a
z5 total of eight slitters, whieh ar~ gasitivned to cut
'the wraps ~8 Zn, close proximity t the bond point
between the base strings and the raps. As a result,
eight bristle subassem'~lies 64,66, s9, 70, 72, 74f.75,
., , and 80 are formed. Referring to he enlarged section
30 0~ bristle subassembly 76, each b . istle subasaect~bly
includes a base string e2 a~.d a plurality of bristles
SQ connected to the base string thea,r groacimal ends.
The distal ends of the bristles terminate substantially
in a common plane. the bristles themselves are formed
35 after slitting the monofilament ' raps ~$ both at the
proximal ends and d~.st~l ends. ~ .
A pa~.r of drive rollers 8~ d se take up the
br~.stle subasaernblies antd feed t em to the next brist.Ie
~l . ~ .
Substitute Speaif$catic~n
AMENDED SHEET
.. m.~..-.n .~.~ in ' , r t . ALIT 1"f !'1 '1 r1
.0~-09-2003 ~~ ~9j~~ ~~3 91:1_ ID:DUPOhlT LEGRL DEPT ~flPr~ T FA~:3~2 992 325
PA U~02304~33
~.
AD6813 PCf
subassembly ~stativn~ 24 ~ ~A7.th4ugh~igure 2 only
F
I lers, addition pairs
il7.ustr~.tes two pairs v drive
ro7.
may be employed to deliver the stle avbassemblies,ta
br a take-up spool. . .
the next processing station, or
ti
,5 also, drivevmotors and contraJ. hanisma arewat . ~ - .
m~~ onventional dr~,'~e
illustrated for clarity, but any
c
~
means and control means can be 7.oyad. ~ . .
etn on Z4 inc7.'~.d.es
The bristle subassembly stet ,
the i, stata.on_ 22., such. . . .
structures very ~ similar to st
.
14 as a mandrel 9a around which is agped by a wrapping
mechaz~~.l~m (not shown} a monofila~nnt which forms a
plurality of wraps 92. .As in. first station, the .
the
second station 2~ includes cornerguides 94 (only one
of which is illustrated) and cornsponding ultrasonic
assemblies 95, and mid-point.guids 98 (of wh~.ch only
oza.e is illustrated} and cvrresponi.ng ultrasoniv
assemblies 140, As seen in the taz~. of the guide 94,
d
the guide includes an upper'part 02 and a lower part
104 which together define a slot hieh guidev the base
24 string 31a of the bristle subassely '7.2 with the
bristles 3~. extending radially wardly. In a sima~lar
ou
fashion, the vther,brist~.e subassmbla~es are guided
into juxtaposition with the wraps92 so that the base
strings 29, 3ra, 44,_ ~6 and B2 the ether three babe
(an
25 str~.ng6 not specifically i.llustzaed in Figure 2} and .
attached bristles are fed t4 the ecvxid stativm. 24.
Aftez~ ul.trasvnica7,~.y bondirtgl the wraps 92 to. the
respective base strings at the avrid station 24., the ~ .
se ansport the bonded
cables (not'shown in Figure 2)
t
'
30 to .pairs of rQtati cutter blades or
9ubassemblies
slitters, including slitter.pair l06 and 108. The
s~.itters perform the same functs.as the .slitters in
the first stata.on 22. In part~.c~lar. the sla.t'ters are
grouped in our pairs. two on ea face Qf the mandrel,
35 to cut the wraps 9~ in close pro unity to the
respective base strings. . The itters.cut the wraps .
s
as they are transported by the fitters to form .
s which a second raw of~ ,
modified bristle subassemblies
i
' 12
5ubstztute 9pecif~,catiolr~.
CA 02458469 2004-02-20
AMENDE~ Si~EE a
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32~'~ . ~ . PR US0230433
' . '. ,
AD4813 PGT
. bristles 11o ex~.st now on the of
rid the~base
string
oppos3.te the first row of bristle84_
.
.
'
~A pair ~ of dri~re r.417.ers x.12nd
. 21~
~ P
and
other
are a
neaessaryr a u9ed
drays rollers as to
remove
th,e
.....
_
5~ modified bristle suhassembla.es deliver
an them
to
take-up spools or to subsequent ations,
s where
additional rows of bristles can added
b to
the
exista.ng row or rows of bristles.'fhe
Dpeed
o~
the
' , ~' ~dri~re x~Qlfers at. each of wing
-the pray stations
can
be
1~ varied and cpntrolled~to. ensure at
t bristle
subassertxbl,~.es axe fed to the stati4n
r~.cxt at
a
speed
that allows further prvcess~.xag hoot
wi excessive
~.ag
or
tension.
figure 3 a.a ~ a crass-seatiQna '~'l~w
s$PW~.IIg
all
15 faur,oorner ultrasonic assemblies ~~o,
42,
43,
and
45
of
the mandrel 26 azid corresponding scmovable
insez~t
116,
_
~
1.3.8 , fy.cludes
l2 a , and 222 . Each insert a. ate,
anvil
,
wh~.ch is in contact with the wrap~~
of
monvfilamezzt.
The anvils and. corresponding d~.st1.
ends
of
the
2U ultrasonic horns of each u'ltrason'
c
assemblies
exagage
the base strings and wraps . to eby
the deli-srer
'
ultrasonic energy in an amount ~ective'to induced
ef
locala.xed heating of the base 'n9
str and~ar
the
wraps.
,~ d,etailed view of two of the err
cc~r and
asaoaiated
25 structure is shvwr~ in Figure ~
.
.As seen in F~.gure 4, the az~ erts
are
mounted
within cut-out regzvns of the markred.
~6,
and
aan
be
held in p~,aoe by use of any suit 1e
means,
including
"threaded fasteners, c,~icl~ couple,
interfereia.ce
- ~ 30 fitta.ng, etc. The inserts 1I6, 18, x.20, and y~2 are
1
thus detachably coupled for ease f
replacemez~.t.
~
Each
insert carra.es a corner s.nvil, ick~
w is
best
su~.ted.
for
tk~e partzcular~material of which the
base
string
andjor
wraps are made. Thus,~dependia~g ~n
the
combination
of
35 base string~and wrap, the anvils~~ay
be
farmed
in
a
.
variety of shapes and sizes to it
s. the
gartiaular
base
string. In the iLl,us~rated embo invent,
the
3aase
'
. _ strings, such as base strings ~9 and~3o,
are
square
~.n
' 1~ t '
Sub3t~.tutc S~,aecit~.cat7,on
AMENDED SHEE i
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CA 02458469 2004-02-20
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325r . PA ~~0230433
,,4D6813 PCl'
section a.nd made of a pvlymer3.c m~nofi7.ament matera.al,
Bush as .~La~~ or s,ny other of th~ various materials
that are described in the aforeme tivned re3.ated andJor
_.... oo_gending applications. . .~ . .
In order tø provide proper g idan.ce and delivery
of u3tx~a6onic energy, the horns 4 a and 42a cif the
ultrasonic assembl:~.es 4Q anal 4~f ' nd those of the other
u~,trasonic assa~Zies, Dave a grv ved end portion far . . .
. receiving the cvrrespvndirag base ~ tz~inga .. . Før. square .
.section base strings, the groove $s preferably
.reatangula~' in shape, and for cir ular section base
stra.ngs; the groove has a curved hope of complementary
radius, Base strings of different cruse-'sectiv~nal
shape would preferably reqtiixe.si ilarly shaped grooves
7~5 in the ultrasonic hcz~a. The dept ' of the groove is . '
generally ~.o more than. 70~ of the base string .
thickness, and preferably less th n 30~_
Anvil 116a has an upper surface over which the
wraps 28 slide. Also, the upper urfaae provides the
2o ai~.vil outface impinging upon the apB 2S which abut , .
both the ugper surface of the anv'1, and the base dtring
29 within the gzwQVed end of the orn 40a. 'The anvil . .
116a further 7.7ncludes a groove a the side for slidably
receiving a transport cable 12.4, high transports the
25 wraps 28 upv~rardly along the mandr ~ . .
Similarly, anvil lZZa has upper surf ace aver
which the wraps ~6 slide. .Also, he upper surface
pxovides the anv~.l, surface imp~,ng'ng upon t~k~e wraps 28
whicW abut b4th .the upper surface of the, anvil. , ar~.d the
3o base string 30 within ~th,e groove end of the horn 42a.
The anvil' 122a further izrcludes a groove on ~.he side
for slidably receiving a transpo cable 12~~ WMichr
together with transport cable 124 and similar traz~aport
cables at the Qther.twv corners, txansports the wraps
35 28 upwardly slang the mandrel 26. Since each transport
cable repragents an end7.esa loop, the return path of
each cable is a:ccommvdated ia~. co raapondir~g grooves 12$
arid
14
8~ubratitute Sgeaif~.eatian
AMENDED SHEEN w
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s2~~ . P~ US0230433
~s~a~~ ~cr
,~s seen in Figure 4, the rnid gQint base strings
a4, 4s and 132 have dor~espand~:ng anvi~.a 134, 136, and . .
338 w'lxich can be mounted oz~ the i serfs cammax~. to both
the m~.d-paint anvils a~td the earn~x~ anvils, ar on .
separate inserts. Iz~. the illustr~.tad. embodiments, the
corner anvils and the mid-po2nt a~.vils are mounted, on
common iz~s~rts, t~rv to an insez~t . Tn either event, the
anvils are preferably x'emavable s~.nee different anvils
may tae requzred for base strings, az~d/or.- wraps o~
1D different size, .tape, and use. , M reover, the azwil ss
. a wear surface, both with respect to the wraps and to
the-tra~~fer cable, and thus, det chability is
important t.o facilitate rep~.acerne~.t of urarri anvils.
~s seen in the- further enlar~ec~ v-ie~r of . Figure 5 ,
the anvil 215a tapers gradually d~wnwardly from the
earner towards the midTpoint a~ t a corresponding
mandr~:l dace. Preferably, the an. 1e of tapez~ ig about
0 to 5 degrees, This angle caz~ b seen as the .
diverging gap betvaeexi the sneer s rface of the wrap 28
2o and the upper surface of the nevi l.lGa. Tn any
event, 'the surface characteristic , including the s~.ape
~of the guiding portion of t~ze upp r surface, can be
vaz~ied depending on the produ~ctio speeds axk.d type of
materials used xor the base stri s arid/c~r wraps.
Also, the position of the ultraao ie assemblies does
not necessarily have to be as ~.~1~, strated, wb.ere the
oarner assemb3,~.es are at one paei ion and the mid-paint
aesernblies are at another.
Figure 6 as a axons-section 1 v~,ew si,t~ilar to
3o Figure 3, shawa.ng the ultrasan~.c ~,ssembl,ies 56, 58, 1~0
arad 142 for the mid-poa.nt base strings. In particular,
the ultras4z~,~.c assemblies are po iti.oned adjacent
anvils x.34. 136, x.38, and _144. ~ a anvils are
. detachab7.~r mt~~xn.ted ran the insert 1.1G, 118, 120, anal.
1~2. Alternative~.y' the anvz~.s a uld be mounted on,
separate inserts; a.s a further a ternativ~, all of the
auvils eov.ld be detachably mount d iri correspozzding.
recesses formed in the mazr.drel. Finally, the anvils
~ubotitute specif~.aation.
AMEIVD~D S~i~ET
- ~nn n nzw
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~~'~'~ PADS0230433
,16813 PCT
could k~e .integralllr, and germanent~.yr formed on the
mandrel. However the fact that the an~r~.ls .are
removable is an advantage since different anv~.l . .
geometry may~.be required dependixag an the type and size
of the base strings and/or wraps that are being banded.
,Ala4. the anvils are wen=-surfiaces and can.be~replaced, .
as. they wear out .
Figv.rs 7 .is an enlarged view of Figure 6, showing
the base Strings aW 45 and 132 er~.gagir~.g the wrap. 28 . . .
' to between.the grooved ends of ultraaonic~assemblies 56,
Za2 and 58, reapect~:vely, and the anvils 134, 135, and .
138. ~ It ca,~. be seen th~.'t the a~.vi7.a make tk~e wraps ~8
kink slightly at about the mid-point between the - .
cprners. of the mar~.drel, the angle of the kink
S corresponding t4 the taper angle o~ the anvil. As
noted previously, the taper angle is preferably between
and 5 degrees. '
The taper angle for each. anvil caz~. 1~e seen ira,
greater detail in Figure 8 w~.th respect to base etring
. no 44. The base str~.ng S.s a polymeric monofilament of '
square section. Frorn .the view of k'~-gore s the lower ~, .
left corner of the base string 4~ contacts the
monofi7.ament wrap 28 an,d the lower right hand corner of
the monofilament is s2ightl~r spaced from the wrap 28.
~5 As a result, melting by applicat~,on of u~.trasonic
energy is~a,nitiated at the lower left hand corner and,
' progresses across the face of the base string. The .
lack of ~.nit~.al contact and indeed the spacing between.
the lower right hazed corner of 'the base string and the
30 upper suz~face of fihe. wrap ie~ dependent Qn the degree of
tiger in tha anvil. The .deal degree of taper can be
selected an a case-by-case analysis of what_works 'best
with which.mater3.als, shapes, si~esr etc.r of the base
'stri~,g and wrap combS.nations .
3S Referring to Figure ~', the ~ecvnd bristle
. subassembly' stat~.c~n 24 is showz3. ~ S.n cross-section at the
.paint where the corner ultrasonic assemblies engage the
base strings of the fa.rst subassembly station 22. In
1G
Substitute Spec~,f~.oat~.on
AME~1DED SNEE i
._ _ , .. ' r r ,. mm n men
~g f~g~~4. '03 11:2 ID :DUPflf~l T LEGAL DEPT B~7P~1 r FA~~:3~2 992 3257 PA
US0230433
04-09-2003 ' CA 02458469 2004-02-20
~36~13 PCf
particular, the corner ultrasvz~.iG assemblies 95,. 1~6,
148, and 15L~ are juxtaposed tJ:~.e corners of mandrel. 90_.
'Ihe mandrel 50 includes four iz?.serts~ .152, 154, 3.55, and
'158, which are ~.etaohably m4unted on the mandrel 90. __
. 5 ~a~h insert carries a detachab~.y coupled anvil ~.6Q,
16Z~ 3,6a, and 266 having a shape~and size similar iv
the asivils of the preceding station 22. A wrapping
mechan~.sm (not ahown.)~wraps a mono~ilament around the .
_ mandrel 9 D to form a~ plurality' of. wraps 92 , in a. manner , ..
. la similar to the wrapping that farms the wraps Zs o~ the
first station Z2.
In the first station ZZ, the base strings are fed
via guides to the ultrasonic assemblies.. In the second .
station 24, the subassemblies 64., 6~, 6Sr 7Q, ?2. 74,
15~ 761 ai~.d 84 are fed to the second~station, and the base
Strings of thQSw subassemblies become the base strings
of the second stat~.vn.. In other words, the wraps 92
are banded to the base strings of the subassemblies Gar
_ s6~ 6~, ,~a 72~ 74, 76 and 80'. A more detailed view is.
ZD .shown in Figure Zo.
As seen, i.z~, Figure lo', the wrap 92 extends .
completely around the mandrel 9Q arid engages the corner
anvils -160 and 3.s2. The upper .aurfaaes of the anvils
are not necessari7.y tapered oz' a~.gled as rioted with .
25 respect to the anvi3.s of the first station 22, AISQ
as in the case oW the first station 22, the anvils 160
and 162 are detachably mounted Qn iz~sert5 152 and 154,
respeetive3.y_ blather than feeding base string8 thfough .
guides to engage the wraps at the ultrasonic
3D assemb~.ies, ~ the stat~.vn 24 feeds bristle subassemt~lies
iv the wraQs.
Bristle subassembly ?2, hava.ng a bs.se string 3Q .
and bristles 31 fed throtagh guide ~4 (Fa.gure 2) ,
engages the wrap 92 in a manner that the base string 3D
3.5 of the ~brist~,e subassembly 72 engages the wrap 9Z with,
the brsatles 31 substantially parallel to the wrap 92.
,.' When ~ the ultrasozai,a assennbly 96 is energized.: w~.th the
base string 30 held between the wrap 92 a~.d the
m
S~bstitutc Spccifiaaticn.
AMEN~ED SNEE i
onnn n n1n
CA 02458469 2004-02-20
0~-09-2003 ~$ ~g~~~ . ~~~ ~~''~~ ~D:DUpOhIT LEGAL DEPT EhlPr1'~ FA~:302 992
325' PA US0230433
AD6S13 Pte'
bristles 31., which thernsehcres are held between. the end
of the ultrasvnie horn of assembly 96 and the base
wtring, heat is ge:~erated whbch causes the wrap 9~ to
bond to the base~stzing 30. ~dditiianai heating and
-5 bonding ma'y occur between the bristles 31 and the base
atrir~.g 30, which tends to reirs.force the previously trade
' bond tb,erebetween.
This~prvcess occurs at each c4rner. At the.next
oorner shown, in Figure 1Q, the bustle subassembly '76
to is fed to the mandrel to engage the wrap 92. The
bristle subassembly includes a base strsng B2 and
bristles 8~. Bristle suba8sembly 76, having a bs.ee
. string 8~ and bristles 8a fed through a guide, engages
the wisp 9~ in a manner such that the ba,ae string s~ ~f
I5 the bristle subassembly ?6 exigagea the wrap S2 with the
bristles a4 substantially parallel to~the wrap 92.
When, the ultrasonic assembly 15D is.energixed, with the
base string 82 held between the wrap 92 and the .
' , bristles 84, which themselves are held~between the end _-
20~ of the ultrasonic horn of assembly 15D and tkae base
string B2, heat is generated which causes the wrap 92
to bond to the base'string 82. ~Additianal heating and
bonding may occur between the bristles ~4 and the brae
string 82, wk~,ich tends to reinforce the gxevioualy made
Z5 bond thexebetweera..
As seen in Figure ~.0, trai~.sport cables 168 and 17Q
move successively bound wraps upwardly alc~xig the
mandrel 9D towards the mid-point bonding stations , ,
where the wraps are bound to the bristle subassemblies
. ~ 30 fed. to the',rni.d-poirsts a7.ong the mandrel. 90 - The' base ~,
string 3o is slightly angled from the first bonding
process so that, in the view of Figure 11, the lower
night eorner~of the base strsng ~0 will engage the wrap
9~ before the lower left corner. Thus, bonding will.
~5 begin at the lower right corner and progress along'the.
interface between the wrap az~d the lower surface of the
base string 3o. k'ar this to occur, it is.prefe~'able
that the upper surface of the anvil is flatj as is th,e_
is
Suhati~u~~ SpeC~fiaati.~ar~.
AMEiVDED SHEE i
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04-09-2003 ~ ~~rD~ 9~3 1I :2D ID:DUPIJhI cA o2A 58 s9T ooPro2-2op~~3~2 9q2
~~5~ F~ DS0230433
ADfi~I~ PGT
lo~rer surfaoe of the ultrasonic horn of the ultrasor~.ic
assemblies.-
Figuze 12 ~.7.lustrates how the mad-point- u? tr~.se~iG . '
assemblies 10~, 172, 1T4 and 1?6.bond the bristle
sub~.saemblies at the midpoints of the station 24. The
bristle subassemblies from the pz'ev'ious station 2~ az~e
fed, to the.secvnd station, as herein described, at, the
mid-points between the corners~,to engage the wraps 9~ .
W between the:ends of the ultrasonic assemblies loo, 1?2,
p. 174r and.2?~ and the upper surfaces of the anvils 17s,
180, 182, arid 1g4~ Aa ultrasonic energy is applied to
the bristle subassemblies and the wraps 92, a bond is
formed~between the wraps and the base string of the
bristle subassemblies. ' . .
Referring to Figure 13. the horn of u7.~.rasonic,
as6embly 1v0 has a flat lower surface, which engages
the bristles 185 of the bristle subassembly 68. The.
_w=ags 9~ engage the upper surfaces of the m~.d-paint
anvils, in.alud~.~.g an'~'i1s 178, ~.8~. l82 arid 184, so that
. gp the base strings of the mxd-poa.nt bristle subassemblies
can be bonded to the wraps 92. . As a result Qf .the
bonding process, the wraps 92 are bonded to the Surface
of the base strings opposite the bristles bonded to the
other side. For examp7.e, the base stz~ing 44 c~f~ )~r~.stle
~5 subassembly 68 has bristles 1.8~ bonded thexetv at ane
-side, . and them the wxaps 92 are bor~,ded via energy
supplied by ultraevnie assemlaly ~.Q~ to the opposite
. side . Tb.e bonded wra~as 92 are essentially parallel to
the br~.stles. For example, bristles 7~$~ of br~.stle
30 .subassembly 68, and- bristles 31 v.f bristle, subassembly
are substantially parallel to the wraps 92.
,~s seen ~.n Figure 14, each. base string, such as
base stra.z~g 4g, bonded at the mid-point to wraps 92 is
slightly ang7,ed with respect to the wraps 92. The .
35 ,lower end of the~hvrns of the ultrasonic assemblies,
such'aa ultrasonic,assembly 100, are flat, as are the '
upper surfaces of the anvils, such, as anvil 178. '~hu.s.
when ultrasQniG energy is ag~alied to the wrap 9~. base
' . 1, 9
_ Subst3.tute Sp~ca.f~.cat~-on
AMENDED SHEET
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04-09-2003 ~g ~~~0~ 9 ~~ 1 ~ : ~~ I~D :DUP~hIT LEGAL DEPT B~1P~'17 FAQ :302
9~2 ~2~ r PA US0230433
AD6~13 ACT
s~.ring ~~ and br~.s't1a 186, frietiona~ heat generated
thereby causes the lower right corner pf the baa~
stsii~g' '44 tQ melt ~ fiirst, and then the . melt progresses
along the lowef surtace of the,bass string and upper w
surfaee.ot the wrap 92 until reaching the lower right
corner of the base string 44. The result for all mid-
point base string's is that the wraps 92 will be
connected to the mid-point base strzz~gs with the wraps
being substantially .paralle7~~ to the br3.stlas, such .as . ' ~. ~ .
x~ bristles 31 and 265. ,
A more dstailed explanation of the sl~.t~~r pairs
is seen in Figure 15, which illustrate the.alitter ' .
pa~.~'e of the f~,rst sta.tiQn 22. It will be reada.ly .
apparezst from the description b.erein. axed the drawings
i5 that the slitter pa.its of both stations 22.and 24
operate in sfbstant~.ally the same way. Tn order to
form the bristle suhas~semblies at 'the first station,
. the wraps ~ must be cut ~.~n, an eff~.cient and precise
manner. 'While and one of a variety of means may be
2fl emp~.vyed, the preferred embodiment is to use rotating
slitters that are mounted ~.z~ pairs around the mandrel.
26. The first ~Sair of sl~,ttvrs se and 52 is preferably
rotating disks Qr .cutter blades that are mounted on a
distal. er}.d portion of a common shaft 188. The shaft
25 x.88 ie rotated , by a drive motor (xzot shown) which eari
be of any cvzwentional type of electric motor
controlled by any conventional cvx~trQl means (riot
shown), preferably,,the control means controls at
least the speed of rotation azid power onwff ..
30 .Applicators ~,9~ and .19~ appl.y a lubricant or ~ .
cva~.ant to the rotating nutter bladed so and ~~,
respectively, tta .keep ~frietion between the wraps and .
the blade from causing unwanted heating and deformation .
of the wraps . A single ~l.uid co~.xld provide bath
3s ' cooling and lubricating functions . On,e particularly '
advantageous fluid is water, and one particular ty,~~ of
applicator 'is a drip applicator. ~ Other flu~.ds, and .
other cooling/~,ub~'icata.ng means could be employed. The
Substitute 5pecifiaati,on
CA 02458469 2004-02-20
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325? PA ~5~230433
X6813 PCl'
ease of appl~,cators is preferred, but, not necessary
although when using a polymeric monofilament for the
wrapping material, cooling of the blades is desirable.
' T~ second pair of sl~.'tters is prøvided at the next
5. adjacent face of the mandrel. 26, as seen in Figure 1~. .
In particular,~slitters 194 and 1,96 are mounted on a
shat 198 which is rotated'by a drive motor (npt.shown) .
and controlled by control means ~nvt ahovm). , .
Applicatvra 200 and'202 apply a cvvlant/lubxicant,' .. .
which helps prevent deformation of the wraps duriilg
cutting.
A third pair of slitters is provided at the next
adjacent face of the mandrel 26. =n particular,
slitters 2~4 and 2Q6 are mounted on a shaft~208 which
is rotated by a drive motor (not sha'utn,) and coritra~,led
by control means (not s~.Qwn.? . :~gplica'~Qrs Vila and 2m
. app7.y a .coolant jlubricant, which helps' prevent
deformation of the wraps during cutting.
A fourth pair of slitters is provided at the next
z0 ~ adjacent face c~f the mandrel z6. In particular,
alitters X24 and 216 are mounted on a shaft 218 which
is rotated by a drive motor (net shown) and contxolled
by control meazss (ncrt shown) . . Applicators 220 and 222
apply a coo7.ax~.t/~.ubricant, which helps pre~rent y
z5 deformation of the wraps during cutting.
With eavh pair of slitters, one~blade is
juxtaposed one of the corners Qf the mandrel ~6 to cut
the wraps on the outer side of tha~base string. The
other blade is juxtagoaed the mid-pa~.m.t of the face (or
30 aide) of the ~ mandrel ~ G to ct~'~ 'the Wraps on the same
side at the m~.d.-point base string as the corresponding
.corner base string of the same slitter pair. At each
mid-goiz3,t, a cutter bed 224, 226, f~8 axa,d 230 .is
pro~rided in a aorrasponding recess formed in the
mandrel 26. Each bed Znclude~ a groove into which the
correagandirlg mid-point slitter passes. A detailed
-v~iaw of a blade so fitting irztv its correspvmding bed
22g Zs sl~.own is Figure ~.6. The wrap 28 is pressed ante
z1
.Substitute 8pecificatiQn
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the wiper surfa,ae of the bed ~z~ by the blade so, .
causing a slight b4w in. the wrap 228.
the corner slitters would also cooperate with
~. cutter beds ~.h.at are pasztivned in c~.aae Proatim~.t'y to
each correspond~.n.g corner and are thus prefer'~~-Y
mounted on ar near the ?.nserts, near there the cable
grvoYe~ a=e farttted. ~uch.~an arrangement can be seer in
Figure 1'Ta, in which corner sl~.ttex~ blade 108 fits in a~
. .cutter bed or ether cooperative. fortnatioz~. associated
1o with the corner of the mandrel,' The knife~blade is
beveled on Qne s~.de only and positioned with the bevel
towards the base8 string. The bevel acts as a plough
to push the base string away and thus prevent unwa~.ted
cutting of the base string.
i5 The scale of the drawings in Figure ~.5 is somewhat
e~~,ggerated in order to better illustrate tk~e cutter
blades acid their correspva.ding drive shafts. Also, the
drive shafts are described as each ts.aving a drive motor
.and control means. .An alternative embodiment would be
2o to have all drive shafts linked together and ruz~ by a
common drive motor and common control means. The
. blades can k~e of any cvnventianal type and are chosen
dependir~.g oz~, the type of matez~ials to be cut. Other
cutting devices Cars. be employed, such as reciprocating
z5 blades, se~.ssQrs-type b7.ades, lasers, etc.
w At tJ;is mandrel 9Q of tk~.e second stat~.vn 24, a
similar arrangement of slitters or cutting blades is.
provided. Figure 17 shows a detail of how oz~e of the
slitters 206 cuts the wrap 9~ after the wraps have been
3o banded t~-the base strings. ~In particulaz~, the
rotating duttizag blade extends into a groove prQVide~i
in a bed 23~ to facilitate cutting of the wrap 92 at
the mid-paint between the corners. once the wzaps 92
are simultaneously cv.t bY' the eight slitters associated
35 with station 24, a total oaf eight bristle subassemblies
are formed with .brist7.es attached to both ~ides of the
base strings,. in two parallel rows.
22
wbetitutc~ Sgca~.f~,ca,tion
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After the bristle subassemblz,es.are slit and thus
formed with two rows of br~.stles, an additional
treatqnent step may be employed to enhance the .
connection ~af the bristles to the base string, az~d- also
to enhance the look and feel of the bristle
~ubaa,~emblies. Referring to Figure 18, a bristle .,
s~.basaembly ?6 having two rows of bristles is~fed to an
W apparatus 234 for conditioning the bonded ends Qf the
. ~ bristles. .The apparatus includes means .for. gu~.ding the
~0 bristle subassembly to~az~ end conditioner.
Zn particular, the guiding means includes a first
gu7.de roller X36 which receives a bristle subassembly
moving left try right from the view of Figure 18, a
linear bristle guide 238 disposed tangentially to the,
first gui~.e roller ~36,wnd a second ~~aide roller ~~o,
which moves the conditioned bristle subassembly 76 left
. to right in the view of F~.gure 18. Drive rollers,
take-up spools and other means far delivering bristle
au'bassemblies to the apparatus 234 are not shown; but
can be provided ~.n eny conventivna~. form.
A conditioning whteel ~4~, dieQosed between. the two
guide rollers 236 and 240 has a circumferential groove
which receives the bristles of the bristle subassembly
76, a~,d exposes the base str~.ng to. a source 2a~ of
heated air. The ~GUr'ce 244 could, lee, for example, a.
. hot azr blower. Alternat.a.vely, any other type of.
he~.ting device, such as heating ~ coils., cau7.d be
employed. A cooling tank 246 which contains a cooling
flusd such as watez~ ~.s in fluid communication with the
.conditioning wheel 242. This ensures that the wheel.
dves~ not become heated to the paint of ~meltizzg or .
otherwi.se~ deforming the bristles. In effect, the heat
from the~source 244 is focused on the cut ends of the
l~riatlea where they are attached to the lease string.
g$ gzg,a.r~: 19 shows the cut ends of the brist~.es s4
and 1.7.a where attached to the base string pa ~-f .the
bristle subassembly. As evident from the figure, the
cut ends are somewhat jagged, and tk~e predominant
z~
Subst~,tute sgecificatiQal
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,ADb813 PCT
interface between briatZe material and base atrir~.g
maternal is alpng one side surface of the base stz'ing-
Pfter cor~.ditioning, as seen in F~.gure.~~, the interface
forms along two adjacent surfaces, the original side
surface and then some along the top surface, thus
enhancing the intercannectivn between.the base string .
and the bristles. Moreover, the formerly jagged ends
a~.e r,,ow smooth so that the bristles have a better feel.
for agpl:icatio~,s such as toothbrushes: . .. . . . ~. . -
ip .~ As Seem i~. Figures ~y and ,~~, 'the condition~.ng ..
wheel 242, rotatable about axis "a-arn has a
circumfez~entia3 groove 248 which receives the bristle
subassembly with the base string rid~.z~g on the l.vwer
surface of a first step of the groove. The bristles
extend into a narrower and deeper portion of the
. g~cpvve, which holds ~Ghe bristles ~.n a parallel.,
juxtaposed positioxa.. Moreover, the heating svurae is
directed to the first 8teg portion of the groave,_and
the cQVling.ta~ ~~6 ensuzes that the wheel is not
2o heated b~' ~h~e source of loot air, or other heating
means, to the pv~.rr.t that the bristles are deformed.
other arz~ar~.gements for guiding the. bristles into
the cond~.tiøning wheel can be envisioned. For ~!xample,
and referring to Figure Z3, a cv~.ditioning wheel, 25a
receives a bri~tl,4 subassembly 252, which is fed
thereto by a gua.de roller 254. Arrows at the'top of
the conditioning wheel indicate the source ofi hot air
impinging~upan 'the base string region of the bristle .
subassembly 25~ as ire the previous embad3,ment .
3o As~ seer3 iz~ Figures ~4 and 25, the guide ro7.ler 25~
includes two'side plates 256.and ~S8 separated by a~hub
260, A pair of guide sleeves ~5~ and 2~~4 are connected
to the inner surfaces of respective s~.de plates 256 and
~~5. Tha guide sleeves define a converging pathway for
guiding the bristles into the circumferential groove
266 of the conditioning wheel 25D. The outex end
portions of the guide slee'v'es extend into the groove
~4
Substitute 6pea7.fica.tion
AMEiVDED S~IEE ~
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266 to ensure that the bristles 268 and 2'7o fit within
the groove X56. -
severaa alternatives: within the scope o~ the
inuentiQn, can be e~.visianed. For example, the guide
sleeves do not have t4 be attached to the sa.de plates,
but~instead could be zx~dependently supported between
the conditioning wheel and the guide roller. In
general, any means capable o~ ensuring a guided. entry
.of ~ the 3aristles .i~.t~ the ~ circu~ifersntial : groove, of the '
14 canditioniiig wheel can be employed. Moreover, guiding
means may be avoided~altvgether, depez~.ding on st~,ffn,eas
of the bristles and ether factors, or the guiding means
may be provided as a wider'taper in the oonditianiz~g
wheel, or~by using~ather formations in t~.e conditioning
19 wheel itself.
The base strings can be monofilaments or
pelyfilaments. Three parti,culaxly well-suited
polymeric materials, which ~orm the mono~ilament, are .
nylon, polyester, and acetal reair~~. Nylon ,
20 monofilaments have been used to male a snide variety of
.products, including brush bristles, fishing string, and
tennis racket str~.ngs. One particularly well-suited.
nylon maternal far making mono~~,laments is a nylon
f~.lament'commercially available under the name TYNEX~',
29 manufactured by ~.3- ~uPont de Nemours and Company of
wilmingtoxi, Delaware 'tTSA. ane particularly useful ,
T'f~TEX~ product is a 5,12 nylon ~ilamez~t made of
pvlyhexamethylene dvdecanamide. It has.a melting point
. of between Z08 aid. 215°C and has a specific gravity of
30. 1.05-1.0~, aza.d is availa3ale commercially in.rnany crvss-
sectional shapes anal diameters. Other suitabJ.e
'- materials include HYTREh, a pol~rester, and DEZRTN~, an .
acetal resin. Both HYTRELW and ~ELRIN are
manufactured by E.T. DuPont de ~Temawrs and Company of
35 W~.lmi~tgtoia., Delaware USA axa.d are cornmercialJ.y
available. Chemically, an aaetal is the product of a
., two-step reaction between are alovhol and an aldehyde. v
,psaetal homogvlymer, which became Commercially availalale
as
Eubetitute Spec~fi.aatic~rs
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in 1960 is formed by pa~.ymeriring anhydrous _ '
fvrmaldehyde~ to make a chain. of oxymeth~lene units .
CelcQn acetal copolymer from Hoechst Tech~ieal
Polymers ~H'~P) .was introduced in 19~~., aiid ~a prepared
b~' cop~alymerizing tr.ioxane ,with a cyclic ether into
tFtore chemically resistant chains comprised of
ox~,rmethylex~:e az~.d oxyethylene units. The copolymer ig
also v~fered by other manufacturers.
~'~,e illustrated embodiments include base strings .
1.o Shown of generally square section; however, virtually.
any cress-sectional shape can be used for th.e base
string, zneluding o'~'a1, rvuna, iC4Lw.,~~i.r.lR.~, ~.~.La...
irregular shapes. The same is true for the bristles
and mvnofilaments, wha.ch were .illust.rated to be of
round section. ether shapes carp. be employed including
square, rectangular, oval, aqv.are with mid section .
ribs, and irregular shapes. A,l.gvr the materials maybe '
mixed, for example by having the base string made Qf a
moz~of~,la.ment material and the bristles made of_ either a
2o monofa:lament.material Qr a polyfilament material.
Pvlyfilament materials may be suitable far making, for
example, ear~pet tuft stz~zngs, as opposed to
mono~i7,am~nts which are suitable for making brush.
bristles az~d other products requiring rigidity.
However, according to the present inventyotz, bx~,stle .
str~,r~ga may be avmbined with tuft strings, b~,r feeding
bristle subassemblies to a wrapping station where yarn
wraps are applied to a bonding station.
While a wide vaz~~,ety of products are enu~isioned
~ for maz3.ufae~Gure using the disclosed agparatuses and
methods, one principal article far manufacture ~.s a
b=igtle subassembly, iz~ which the bristle snbassamblies
can, be cut ~ta length and used far various brush
a,pp7.~.cations . Brush applicati4n,s are particularly
' adapted for use with mor~.ofilamex~t wacapa and
monofilament base strings, bath of which. are
thermoplastze, meaning that as they vibrate under the
influence Qf the ultrasonic energy, the x'~.eat causes
26 ~ .
substitute Speca.fication
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AD689,3 ~~T
surface melting, When. the energy is removed, .
frictional heat is immediately and rapidly last~to~the
.adjacent sub-surface znas~, causing the melted material
from the base string or the wzap~~ or both to
mechana.cally lack the ba.s~ string and wraps together. .
Similarly, a polymeric material used as either~the
. base string yr the wraps, Qr both, could be uaed.to
make carpet tuft str~.ngs, in which the wrapping
' ~ materials is a pol~filamex~t.. material of the type . . , .
~.10. typically' used i,n carpet rnanufact.uring. . Such arta.cles
could be ntade.with z~elatively minor modifications to
the disclosed ernbodimer~ts of machinery.
The embodiments described. herein which. describe
bristle suba,saembly stations have described cables that
' are ~uaed to trartspoz~t wraps along the marxdrel . An
example cart be found in Figure 4, ~.n., which cables 1~4
and 125, which move in an endless loop so that a first
run of the laQp moves in one direction i,r~ a. guide
provi~.ed in.earresgondiz~g anvils, while a second run o~
the loop moves in an opposite direction. in a groove
formed in the mandrel (enumerated 12s and.130 in Figure
4) _ A particularly preferred cable ie ~lesar~.bed in
U'.S. Patent Application number 09/6'79,235, filed
October 4, 200a,.entitled "Braided Cvrd Splice" by mark
~5 S~: Edwards, which is incorporated herein by reference.
This application describes an endless loop or belt (or
cable) tttade by j Qining the ends of cord or. braided .
individual plies, in which inc~.udes upbraiding
individual plies of a portion of each end to be joined,
leaving main braided bodies of cgra, locating and
connecting together corresponding plies from each of
the ends., and pulling tk~e ~vnneeted plies baal~ tk~rQU~h
the main braided bodies of oQrd, with each, of the
connected plies being pulled through at a, d~.ffsrent
3S distance. from the ends until the main .braided bodies. of
cord to be jointed are zz~ clps~ proximity and excess
connected plies are protruding from the card. Fina~.ly',
the excess e~annected plies era remo~red from the cord.
27
Subatitutc ~gecificatior~.
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AD~fil~ PCT
The result is a smooth splice with no irregularity iT~
the cord cross-section th:raughout the length of.the
splice. The cords are preferably made of high
..... . Performance materials suGhlas pare-aramids, mete- ..
' ' S aramids, high mvlecuJ.ar Weight linear polyalefins,
polyethylene terephthalate, nylon, and s~.milar .
materials:
Wha~,e the embodiments described and i.~.Iustrated.
. ~~ ~ above .include a.square base string,.a particularly
io preferred embodiment ir~.eludes a base string that has
surface protrusions that ass~.st . ~.n making a point. of
contact between the base stra.ngs and the wraps in a
manner that.achievers a greater efficiency ire ultrasonic .
heating. Referring to Figure 26, a base string 300 is
shown in a traza,sverse, sectional v~,ew as being
substantially square in cross-section with ribs 302,
304, 306, and ~a8 formed at about the mid-point between
two adjacent corners. The ribs are preferably . .
integrally f4rmed with 'the maim. .body of the base stz~ing
20 30D in an extruding process, or othezwise in a cost
effective, expedient mazzner. For such processes, the
~greferred materiaJ.s for use in forming the base string
are the golyrneric cnanofilament materials described
herein with respect to the non-ribbed base st~'iz~tgs.
25 The ribs provide the added advantage that a point
of contact will exist between the base string and the .
inonofilament wraps, in a manner that allows the .
ultrasonic energ~r to concentrate and initiate the
melting of two obj ects, of simi.~.ax cross sectional mass,
30 the wrap and the rib 3v2. ~Of course, the ribs err~rib
.like structures could be formed on base strings of .
other shagea,~ such as circular, rectangular, or
suk~starttialZy irregular shape. In any shape for the
.base string, the ribs set as ~~ezaergy directors" so that
35 the heat~.ng necessary for bonding occurs .efficiently. '
Further, the embodiments described herein have '
. shown tk~~.t the bristles of oath br~.stle subassembly
extend outwardly txom the base string in a
28
$ul~a.'~.itute Speaifiaatiart
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,P.i76813 k'CT
~~svbstantially perpendicular directi.an. Howe~'er, other
angles can be used such that the bristles extend at are
angle greater or lesser than 94 degrees; the az~.gle can
be selected . dependant on the use envisiosZed .for' the ,
articles maxxufaet~a,red acco~dir.g to the present
invent~.on. Far example, if brushes are to be
titanufactured using the sub~.saemblies descrik~ed herein; '
the elQngatec~ members, which. w4u~.d be brush bristles, '
can be banded to the'base string at.a.raked.angle ar at . .
14 a ~a degree angle (as illustrated hez~ein) . .
.2t is also within the scope of the present' .
inventiozi to vary the properties between the wraps caf
the first statia~. compared to those of the second, or
any successive station, so that a single nrisz~e
~ Subassembly can inc~.ude bristles having different
properties. In particular, the first wraps (af the
f~.rst station} can be d~.ffez~ent from the second wraps
(of Ghe secoiZd station) in at least one property. such
as sine, shape, aQmposition, physical grvQe=ties, ar~.d
20 'color. ' .
The cooling source described kierein, used in
association wzth the conditioning wheel, when using a
cooling fluid, ca~,be expected to accumulate heat that
should be removed b~y means other than ambient '
~5 ' temperature . ~l.lthough virtually an~r heat exchange .
~devioe can be emp7,oyad, one simple means would be to
use a ' "once tbraugh" fluid, meaning tkiat the cooling
fluid flows from a source through the tank and is ' .
constantly repl.eza.~.sk~ed with a cool source of f-laid, .
3o such as water..Alternatively, a cooling coil.can be~
plaa~d in the tank~.tQ coal the fluid. However,
- virtual7.y arty heat removal device .can be emp~.ayed.
Als~a, if' the tank is large enough and ambient
temperature is coal enough. it is possible for heat
35 removal to occur at a sufficient le~rel wa,thout .
addit~.ona~, flow through or heat removal structures.
In the embodiments described above, a brast7.a
subassembly i.s combined with a monofi7.amen.t at a
29
Substitute Specification
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wragg.ing station to produce a modified. subassembly that
includes a base string and two rows of elongated
members. in some us~~, the elongated members are
bristles used to assemble brushes . In a further -'~
S variation of the present inv~entian, tww unmodified
svba~semblies cars be combined to form a modified
subassembly that ~.naludes two rows of e~.ongated members
and two base strings.
' .. Referring to Figures 27 and 28, first bristle
1o subassembly 3~Ci and seco~,d. bristle subassembly 322 are
. bzwugh~~ '~Qgethsr by motive forces shown ~by direct~~,oz~al
arrows. Tk~e arrow associated w~.tb. subassembly 3ZO can
.be, for example, the reactive force of an anvil Iz~at
shown), while the arrow associated with subassembly 322
15 can be the reavtive force of an ultraaanie horn.(nvt
shown}, Each subassembly l~a$ a base string connected
to a row of elongated members, and is made accgrdi~,g to
the methods deseribed.hereyn,_ Subassambl~r.320 has a
base string 324 and a row 326 of elongated members.
2o Both the base string.and the elongated members can be
made of polymeric mc~nafilament materZal,. Similarly,
subas$embly 323 includes a base string 32s and a row
330 of elongated members. ~-
When the subassemblies 320 and 322 are brought
35 together, as shown a.n Figure 2~, the anvil, base string
324, rc~w$ 326 and 33a of elongated memlaers, base string
32B and the u7.trasonic horn are in substantial
abutment. -Ultraaoni~c energy is applied by energising
the ultrasonic barn to thereby deliver ultrasonic
30 energy to the interface botween~the rows 326 and 330 a.t
a level and for a time suffic~.ent to form a band area
between. the rpwe. The bond area represez~,ts a~urfa.ce
melting of the elongated members at the interface,
which when. cooled, mechanically connects the two-rows,
35 and thus the two subassemblies, together.
The modified subaa5embly thus formed has two base
strings between wh,~.cb, ors sandwiched two yaws of '
elongated members. This structure results in a better
S~ubstitut~ speci~iaatioz~
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AD6&13 PCT
cagtu,re~of bristles, making it more difficult for them,
to separate from their respective base strings, and..
thus mal~i ng an assembly in.carporating the modif i.ed
subassembly less likely to loose elongated members. . ...
,~7,so, in some applicat~,ans, the~base strings connected
.at apposite sides form a rail,-like structure that can
be useful iz~ guiding the modified subassembly into ~ '
aasemb~.ie~ having grooves or other structures. .
Furthermore, a.r~.vsome assemblies where the. subassembl~.ea
~ .are molded in situ, such as brush heads, the base
strings prQV~~.de an enhanced mechan~.cal connection to
txt,e corresponding base structure and surface, for
sea7.i,ng capability of the mold cavity. .
~s in the~other embodiments, the base strings and
.15 elongated members eon. be made of the aforementioned
mater~,~a~.s~ In a particularly preferred embodiment for
brush bristles, the elvnga~.ed members are made v~ a
mor~ofilament NYhON material, and the base strings are
made of a similar material.
w ~o ,A structure 331 for maJ~ing modifa.ed, bristle
subassemblies sl~owz~, in Figure ~8 is illustrated in
Figures 29 and 3D. A first guide 332 and a second
guide 334 are held is spaced relat~.on.to each other by
mout~.tyng ox~, arty suitable structure, ~ suck~t~ as base plate
25 336. Either or both guides can be provided with means
for adjusting the ~paae between them. In the
illustrated embodiment, the.guide.334 is provided with
elongated slots and correspondiz~g adjusting screws 33S
and 3~~ which permit a side-to-side adjustment.
3~ capability demonstrated by tb,e double-headed ~ ~ . .
directia~aa~, ~.rroW ~ This adjustment cagabi7.~,ty~ ala4
permits the ina.tial feeding o~ subassembl~.es 320 and
322, for example., into the s~.ructure 331.
once fed between the guides 33~ and 334, the
3~ elongated members 326 and 330, ~6 well.as the base
strings 3~4 and 328, are brought into contact for the
application of ultrasonic energy. The second guide 334
functions as an an'~il and. cooperates with air ultrasonic
~,1
~ub3tztutc Egcvi~zaativ~,
AMENDED SHEET
r ,-,r ~nnnn ~-~" Ar~ t'__t ~._ . nnn n n~~
04-09-2003 ~~ ~~~~~ ~~~ 1~' ~2~ TWDUPOhiT ~LEGRL DEPT ~f1P~1'~ FR~:~02 992
325'7 ' PR ~jS0230433
AD6813 PGT
horn 342 to de2~.ver ultrasonic energy to the interface
between. the abutting elongated members, as described
above. The ultrasonic-horn is connectable to any
suitable source of ultrasvniv energy'; and is energised.
for a timer and at an energy level sufficient to cause
surface melting of the e~.oz~gatad members.
While tb,e illustrated entbvdit~ertts show tk~.e
elongated members disposed substantially normal t4 the .
. ~ base. string,. it may be desirab3e.~ in certaiw .
applications t4 have~the elvn~ated~msmbers disposed at
slight angles., or in chevron patterns. These
structures can be formed by changing the relative feed
rates of the base string relative to the rate that the ,
cables deliver the wraps. Depending'on which moves
faster, the elongated can be caused to rake forward or . -
backwards. Combinations of forward and backward
elprigated members can be provided Qn the a~ame base
string to produce a crossed pattern. In any event, the
degree of rake can be at virtually any azzgle but
2o preferably "slight," which is in the range of a-to
degrees in either the forward or rearward directian_ ' .
' , While the embodiments, described above have ,
illustrated cutter blades with corresponding knife beds
that are substantial7.y coplanar w~,th the outer surface
Qf the mandrel, and with grooves that reae~.v~ the .
rotating blade, an alternat~.~re embodiment of knife bed
is showrs in. Figures 33 and'32. In Figure 31r a kz~~~.fe
bed 3~4 project upwardly from the surface of the
mandrel . The upward proj ectior~ ' i~s in degree ~suf f icient _
' 30 to cause a, slight bow from ovrner to .comer fQr~ the
. _ wraps which. encirc3.e the mandrel. The outer surface of
the. knife bed 3~4 is Qrovided with a shoulder 3a5 which
engages the wraps at the.eutting point_ The ,
corresponding knife 34s has its cuttzng edge extending
in close groxim~.ty' to the shoulder 345 and thus aids in
the cutting vperatioza,. As in the previously descra.bed
_embodiments, the cutting operation (which ma'y' occur at
different loeatir~ns along the length of the mandrel. to
32
Substitute 8pecif acat3.on
CA 02458469 2004-02-20 .
AMENDED SHEET
_ .-,_ .r. ~- ._ r . ann n nn n
04-00-2003$ ~~r~~ ~~3 1~:2~ ID:DL~P(7IVT LEGAL DEPT Bf1Pr17 FA~.3C~2 992 3257
PA~S0230433
AD68a3 PGT
include a1.1 mid--point and co~.er Y~ase strings) produces
a plural~.ty of modified subassembl3.es. Similarly, as
seen in Figure 3~. the knife bed 3~4 and corresponding
knife 348 can be used an. the first station"~to fv=m the
initial subasa~~mblies that are~then ~ed to subsequent
~ta.tions to male mvd~.fied subassemblies;
The various embodiments described herein can be
used to form myriad products, such; as br~.shes where
the bristles are made.of.monofilament'Iengths whivh .
1o were cut tQ form the rows of elongated members, For
exampler ~'ig'~.rE's 33 and 34 illustz~ate a brush 350
according ~to the present invention_ The brush 350
includes a body 352 having a handle portion and a head .
~~ portion. The body may by made of a polymeric material
of the kind tk~a~t wan be inj eetivn molded. A bristle ,
array 354 is e~annected to the body 352 at the head
portion by any ,suitable means. The bristle array;35g
includes a plurality of segments of the subas~sembl~.es
or modified subassemblies described herein.
As seen, in Figure 3a, the br~.st~.e arra~r 354
inc~.udes segments 356, 358, 360, 36~ and 36Warranged
in five (5) paral~.el rows. Each segment campz~ises a
length of the modified subassembly that includes t~wv
. rows cf brietl~B sandwiched between two base strings..
' i3aweve~'r the modified swhassemblies that include twQ
rows of br~.stl~s for one base, string could also be .
employed. Irr.~the illustrated embodiment, the base
strings are embedded .in the head pr~rtion of, the body,
as.far example, by placing the segments in a cavity and
3o filling the cavity wyth a, thermo~l.astic material.
virtually any athez~ means can be employed for attaching
the segments a.z~" or cannectixig them to, the body.
The foregoing embodiments illv.atrate and describe
.subassemblies in which a first row of elongated members
are attached to one side of a base string, and a a~oQnd
row is attached to the~apposite side. zn an
alternative embodiment, two roars of elongated members
can be'attached to the same side of the base string,
sv.hatitutc Spcci~ica,tian.
CA 02458469 2004-02-20
AMENDED SHEE I
.04-0'J-2003 ~~ ~Gs~~ ~ ~~ 11: 25 I D : ZaUPDf~IT LEGAL DEPT Bf 1P~1'~ FAQ :
3t~2 992 X25 r PF U S0230433
CA 02458469 2004-02-20
r
,A~~$1'~ PCT . ' -
_ which al3.ows the opportusiity tQ prQVide mixing, in the
same row,. eloi~.gated members of different physical
characteristics; such as sire, stiffness, ~olorr .._.
maherial, etc. S~,basaembliaa of'this,type can be
formed by simply runniag.a first subassembly ~Ghrough
the apparatus described above, but 'with the f~,~'st rv5"'~
of elongated members irl. contact with the wraps of the
second station. , . ,
. ' .' Although~the.invention.has been described with ..
1o reference.ta particular embodiments, it.will be
understood to thQSe spilled in the art that, the
inventive. is aapa3ale o~ a variety of alternati~re
embodiments. within. the spirit of the appended claims.
34
substitute Specificatyon
AMENDED S~1EET
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