Patent Application
20150135456
The present invention relates to a domestic brush or a body care brush according to the preamble of claim 1 and to an injection mold according to Claim 17.
Toothbrushes are not included in the term body care brushes.
Domestic brushes in the form of washing-up and scrubbing brushes are known, for example, from documents DE 939 685, DE 940 891 and DE 1 951 132. They comprise a handle in the form of a shaft with a clamping body or a bristle supporting plate by means of which a flat bristle carrier, which is produced from caoutchouc-like or rubber-like material, is clamped. Individual bristles, which are produced integrally with the bristle carrier, project from said bristle carrier. Said individual bristles are soft and very flexible.
The plastics material washing-up brush known from document DE 1 951 132 also comprise a pan scourer in addition to the soft bristles. Said pan scourer consists of relatively hard plastics material bristles which are embedded in the brush supporting plate. To this end, the pan scourer bristles in the root form a prism-shaped holding part, which is inserted into a recess provided specifically for this purpose in the brush supporting plate and on the side remote from the bristles has a widened edge by way of which it abuts against the inside of the wall of the brush supporting plate in the manner of a stop.
In addition, documents WO 94/04057 and AU 81 674/82 make known domestic brushes in the form of brooms which also comprise individual bristles which are realized integrally with a bristle carrier and protrude from said bristle carrier.
Proceeding from said prior art, it is an object of the present invention to create a domestic brush or a body care brush with improved cleaning characteristics as well as an injection mold for the cost-efficient manufacture thereof.
Said object is achieved with a domestic brush or a body care brush with the features of claim 1 and an injection mold according to claim 17.
The domestic brush or body care brush according to the invention comprises a handle and a bristle field which is carried by said handle, said bristle field having injected bristles which are produced using the injection molding method. Said injected bristles project from a bristle carrier which is realized integrally with them. In each case several injected bristles are combined to form a bristle bundle and the bristle bundles are arranged spaced apart from one another at a distance.
Each of the bristle bundles consequently comprises a plurality of injected bristles which are packed closely together. The distance between bundles is many times greater than the possible distance between the injected bristles inside the bristle bundle.
The domestic brush or body care brush according to the invention can comprise a much greater density of injected bristles compared to the known domestic brushes or body care brushes with injected bristles, which leads to improved use with an improved cleaning effect or also application effect.
In a preferred manner, the cross section of the injected bristles is circular. However, it can also be realized elliptical, star-shaped or polygonal manner and, in principle, can assume an arbitrary closed contour. Over and above this, a change in the form over the length of the bristles is possible. The restrictions in this connection are the possibilities for removal from the mold or those for forced removal from the mold.
In a preferred manner, the cross section of the injected bristles is tapered from the exit out of the bristle carrier in the direction toward the free end, in particular in a continuous manner. This latter means that there is conicity.
In a preferred manner, the injected bristles in the bristle bundle, measured upon exit out of the bristle carrier, are at a mutual distance from between 0 mm and a maximum of 1.5 mm. In a particularly preferred manner, the mutual distance is between 0 mm and 0.8 mm.
In a preferred manner, the bristle carrier is common to at least some of the bristle bundles. In a particularly preferred manner, the bristle carrier is common to all the bristle bundles.
In the case of a domestic brush or body care brush according to the invention which can be produced in a very favorable manner, the common bristle carrier is formed by the handle and the handle as well as the injected bristles consist of the same plastics material component. If the bristle carrier is common to all the bristle bundles, it is possible to produce a domestic brush or body care brush of this type completely in one single injection molding step.
The bristle carrier is realized accordingly—in the abovementioned embodiment—not as a layer but more as a voluminous body.
The material which is used for forming the domestic or body care brush from one single plastics material component, is preferably chosen on the basis of the characteristics of the injected bristles. In this case, it can be that said characteristics do not correspond to the necessary characteristics for forming a conventional handle. Consequently, it can be necessary to design the geometry of the handle, especially the neck and handle region of a corresponding domestic brush or body care brush, such that the necessary, for example, stability characteristics can nevertheless be achieved. A central point of said designing is that the removal from the mold is achieved in as simple a manner as possible in spite of all the design aspects.
In the case of the aforementioned development variant, it is possible for ergonomic or design-technical reasons for one or several further plastics material components to be injected onto the handle or also onto the bristle field. In this case, the plastics material components can be both soft components and hard components.
In a further preferred embodiment, in the case of the domestic brush or body care brush according to the invention the common bristle carrier and the handle are injected together. In a preferred manner, the common bristle carrier and the handle realize at least one positive locking connection and in a further preferred manner also a material bond.
The common bristle carrier, which is produced integrally with the injected bristles, is either produced in a first injection molding step and the handle is injected onto the bristle carrier in a second injection molding step or vice versa. This occurs preferably using a two-component or multiple-component injection molding method. In a preferred manner, at least a positive locking connection is created in this case between the bristle carrier and the handle and in a further preferred manner also a material bond.
In this case, the handle or the basic body thereof is preferably produced from a hard component. Another or several further hard components can be injected onto the basic body along with the said hard component. In addition, another or several soft components can be injected onto said hard components. In addition, cleaning elements of soft material can be injected on the bristle carrier. The hard component of the basic body as well as the hard or soft component (s) injected thereon once again form at least a positive locking connection and in the case of a preferred solution also a material bond.
In a preferred embodiment, the handle of the domestic brush or body care brush comprises a head region and a handle region. There can also be a neck region between said regions. The common bristle carrier with the injected bristles which are integral with the same is injected onto the head region.
In a preferred manner, in the case of said embodiment, the handle comprises at least one passage in the head region and the common bristle carrier extends on both sides of the handle between which the passage extends. In addition, in this case, the (integral) bristle carrier comprises a connecting web which extends through the passage. In the case of said embodiment, extremely sturdy fastening between the bristle carrier and the injected bristles on the handle is ensured, even when plastics material components which do not enter into any material bond together in the injection molding process are used for the handle and the bristle carrier and the bristles. A mechanical connection by means of positive locking is generated as a result of said measure.
In the event of the development of a mechanical connection between the handle and the bristle carrier, it is such that the plastics material component injected first has to have a higher melting point than the plastics material component injected second as otherwise when the plastics material component injected second is injected, the plastics material component injected first would be deformed or it would act as a sponge.
If plastics material components which enter into a connection (material bond) with one another in the injection molding process are used, the bristle carrier can also only be situated on that side or those sides of the handle or of the head region on which the injected bristles are also located. In the case of said embodiment, the at least one passage and the corresponding connecting web can be omitted.
In the case of another preferred embodiment of the domestic brush according to the invention, the handle, once again, comprises a head region and a handle region, as well as preferably a neck region in between and the common bristle carrier is mounted onto the head region with the bristles which are produced integrally therewith.
In the case of said embodiment, the handle and the common bristle carrier with the injected bristles are produced separately from one another using the injection molding method. Assembly follows thereafter. In this case, it is conceivable for the common bristle carrier with the integral injected bristles to be arranged so as to be exchangeable on the head region of the handle.
In a preferred manner, the common bristle carrier is realized in a sleeve-shaped or cup-shaped manner and is fitted onto the head region which is preferably realized in a cylindrical manner. In addition, the bristle carrier can also comprise a form as described, however with recesses in certain surfaces such that in part no full-surface connection is created but, for example, a type of banding forms part of the outside sleeve.
A further development variant provides that the bristle carrier is mounted under pre-load and is somewhat deformed and as a result the bristle bundles are spread out. The handle or the head region of the handle, which forms the interface between the handle and the bristle carrier, is developed such that the bristle carrier is deformed or bent on assembly and thus comprises a form other than that formed after the injection molding.
The bristle carrier can be produced, for example, in a flat form and during assembly moved into a form in which the bristle bundles are spread apart. This means that the longitudinal directions of the bristle bundles are not at the same angle with respect to one another when producing the bristle carrier as they were after assembly.
The advantages are obvious, the injection molding method for the bristle carrier is simplified and greater angularity can be generated than was possible.
In addition, the bristle carrier can be designed specifically to the spreading geometry, for example as a result of developing different layer thicknesses in the bristle carrier, that is the forming of places at which the subsequent deforming behavior is modified.
It is also possible for at least some of the bristle bundles (or all of the bristle bundles) to comprise an individual bristle carrier each and for only the injected bristles of the relevant bristle bundle to project from said bristle carrier.
In this case, it is possible first of all for the bristle carriers to be produced with the injected bristles using the injection molding method and then the handle to be injected onto the individual bristle carriers. However, it is also possible for the handle to be produced first of all using the injection molding method and then the bristle carriers together with the injected bristles which are produced integrally with said bristle carrier to be injected onto the handle or to be mounted onto the handle using another method, for example bonding, welding, riveting, etc.
In the case of said embodiment, in a preferred manner the handle and the individual bristle carriers with the injected bristles consist of different plastics material components.
In this case, it is also possible for the individual bristle bundles to differ in the plastics material component from which they are produced. It is also possible to shape cleaning elements which consist of soft material and are used.
The domestic or body care brush which is to be produced can be constructed, in this case, as from a modular system by the bristle carriers and the carrier structures of soft-elastic elements being able to comprise the same form and be used in the same recesses. Extremely wide variability is produced in this manner, relating to the configuration of the bristle field.
In addition, the bristle bundles and correspondingly also the bristle carrier can consist of several different plastics material components. In this case, the bristle materials specified further back, soft materials and hard materials are preferably possible. As a result, it is possible to vary, for example, the hardness or the color of the bristles and, where applicable, of other cleaning elements in the bristle field. Such that, for example, harder bristles are arranged at the head end of the bristle field and softer bristles at the neck end of the bristle field; in this case, the variability of the arrangement is purely restricted by the plasticity in the injection molding process. The bristles are injected with the one plastics material component in the first injection molding step and the bristles are injected with the further plastics material component in the second injection molding step. The most varied solutions for molding are possible as regards manufacturing, for example core back technology or shifting can be used in order to provide the cavity for the second plastics material component.
In a preferred manner, the injected bristles upon exit out of the bristle carrier have a diameter of between 0.4 mm and 1.2 mm. In an especially preferred manner, in the case of domestic brushes diameters are between 0.6 mm and 1 mm and in the case of body care brushes diameters are between 0.4 mm and 0.7 mm.
The free length of the injected bristles in the case of domestic brushes is between 12 mm and 25 mm, in a particularly preferred manner free lengths are between 15 mm and 22 mm. In the case of body care brushes, the free length is between 4 mm and 16 mm, preferably between 8 mm and 12 mm.
In general, the ratio of bristle length to diameter at the bristle end is between 20:1 and 125:1, preferably between 40:1 and 60:1.
In a preferred manner, the injected bristles comprise a bristle stem which extends from the bristle carrier up to the free end of the injected bristles, this means that the end of the bristle stem corresponds to the free end of the injected bristle. However, it is also possible for the bristle stem to bear an end cap on its end remote from the bristle carrier. Said end cap can comprise, for example, a rounded, in particular hemispherical form.
The diameter of the bristle stem at its end remote from the bristle carrier is preferably between 0.2 mm and 0.6 mm for domestic brushes, in an especially preferred manner said diameter is between 0.35 mm and 0.55 mm. For body care brushes the diameter is between 0.05 mm and 0.35 mm, preferably between 0.15 mm and 0.3 mm.
If the bristle stem bears an end cap, the outside contour thereof, in a preferred manner, connects continuously to the outside contour of the bristle stem. It can also be possible in a manufacturing process for a very small shoulder to be formed; this means that the end cap has a smaller diameter compared to the end of the bristle stem. As a result, if the end cap is positioned in an inaccurate manner in relation to the bristle stem, demolding problems in the form of extrusion can be avoided.
The diameter of the end cap at the transition from bristle stem to the end cap is between 0.17 mm and 0.57 mm and preferably between 0.32 mm and 0.52 mm in the case of domestic brushes and in the case of body care brushes is between 0.03 mm and 0.33 mm and preferably between 0.13 mm and 0.27 mm. The extension of the end cap in the longitudinal direction of the bristles or of the bristle bundle is between 0.2 mm and 0.8 mm and preferably between 0.4 mm and 0.6 mm.
The end cap can also have an acute form as well as a round form. For example in the form of a cone. The functionalities of the tapered bristles can be reached as a result of said form.
It is also conceivable for the bristle supporting stem to bear several small bristle-like extensions at the free end instead of an end cap.
The longitudinal axis of the bristles is at an angle of between 60° and 90° a and preferably between 80° and 90° in relation to the exit surface of the bristle carrier out of which the bristles emerge.
The bristle bundles are preferably round or approximately round in cross section.
In addition, however, cross sections in a square, rectangular, generally polygonal, triangular, trapezoidal, rhomboidal or generally n-angular form are possible. This applies to both domestic brushes and to cosmetic applicators and to all embodiments named in this document.
The bristle bundles, in the case of domestic brushes, in a preferred manner comprise between 10 and 35 injected bristles and in particular between 15 and 35 injected bristles. In the case of body care brushes, the number of bristles per bristle bundle can also be less. The number, in this connection, is within the range of between 5 and 30 bristles and preferably is between 5 and 25 bristles per bristle bundle. It is conceivable within said framework for the number of injected bristles per bristle bundle on a domestic or body care brush to be different. In a preferred manner, however, all bristle bundles of a bristle field comprise the same number of injected bristles.
The diameter of the injected bristles in a bristle bundle can vary, it is not absolutely necessary for all the bristles to have the same diameter. The arrangement of the diameters, in this case, can be random, symmetrical or non-symmetrical. If different diameters are realized in one bristle bundle, the bristles with the larger diameters are realized on the edge of the bundle.
The bristle diameters of the bristle bundles can also vary as a whole in one bristle field. In this case, bristle bundles with smaller diameter bristles can be arranged more easily in the center of the bristle field and bristle bundles with larger diameter bristles can be arranged more easily at the edge.
The distance between bristles in the case of domestic brushes is preferably between 1 and 10 mm. When viewed in the longitudinal direction of the handle or of the bristle carrier, the distance between bristles is between 1 mm and 5 mm, in particular in a preferred manner between 2 mm and 3 mm. In the direction transversely with respect to the longitudinal direction, the distance between bristles is between 1 mm and 10 mm, in particular in a preferred manner between 6 mm and 8 mm.
In the case of body care brushes, the distance between bundles is preferably between 0.5 mm and 2 mm.
In a particularly preferred manner, in the case of domestic brushes the bristle bundles are arranged in longitudinal rows which extend in the longitudinal direction of the handle or of the head part or of the bristle carrier. In a preferred manner, such a row comprises between 3 and 9, in particular between 4 and 7, bristle bundles. The bristle bundles are preferably arranged offset in the transverse direction. In the end region of the handle or of the head part, the bristle bundles are arranged in a preferred manner in circular-like rows.
The bristle carrier is realized in a preferred manner in a layered manner and in this case, both in the case of domestic brushes and body care brushes, comprises a layer thickness of between 1 mm and 5 mm and preferably of between 2 mm and 4 mm.
The handle, in the case of domestic brushes, comprises, in the head region which connects to the neck region, a thickness of between 1 cm and 2.5 cm and preferably between 1.3 cm and 2 cm, measured between the rear side of the brush and the front side of the brush without the bristle carrier. The present method according to the invention makes it possible for smaller body densities to be able to be achieved than with the known punching method for the embedding of the bristles because the embedding depths in said method require certain body densities.
In the case of domestic brushes or body care brushes according to the invention, bristle bundles cannot be aligned parallel to one another, i.e. the longitudinal directions of said bristle bundles do not extend parallel to one another, but are skew with respect to one another or together enclose an angle. The injection mold according to the invention also enables the production of domestic brushes or body care brushes according to the invention with such bristle bundles that do not extend parallel to one another.
Domestic brushes or body care brushes according to the invention with bristles injected according to the invention can be provided additionally with conventional, extruded cylindrical or subsequently tapered bristles. Specific functionalities can be achieved as a result of the combination. The brushes are provided with conventional, extruded bristles in a known manner once the injected bristles have been produced.
The providing of conventional, extruded bristles can also be effected prior to the production of the injected bristles.
The injection mold according to the invention comprises several mold parts which, in the closed state of the injection mold, form a cavity for the injection molding of the injected bristles and at least of the bristle carrier. However, it is also conceivable for said cavity to serve also for the injection molding of the handle.
At least one of said mold parts comprises a receiving body which defines the cavity with the remaining mold parts and a support body which is movable in relation to said receiving body. Said mold part serves in particular for producing bristle bundles which are not arranged parallel to one another, for example at the point where the handle or the bristle carrier is formed in a three-dimensionally curved manner. The receiving body is provided with passages in which one mold insert is displaceably mounted per relevant bristle bundle to be injected. The mold inserts are provided with the bristle cavities for producing the relevant injected bristles. The bristle cavities make it possible to shape the injected bristles in one part.
In the closed position of the injection mold, the support body supports both the receiving body and the mold inserts. When the injection mold is opened, in a first opening step the two mold halves (stationary mold part and further mold part) are moved apart from one another and the washing-up brush remains suspended in the cavity in the further mold part, for example because there are certain undercut structures present.
In a following second opening step, the support body is raised from the receiving body which remains in its closed position and the mold inserts are moved outward together with the support body relative to the receiving body in the direction of the interior of the cavity. At the same time, the injected bristles are removed in part from the mold.
In a third opening step which follows the second opening step, the receiving body, together with the support body and the mold inserts, is then moved completely into the open position. In this case, the relevant bristles are completely removed from the mold (where applicable in a forced manner).
The injection mold is opened as one unit.
In a preferred manner, the mold inserts, which are movable relative to the receiving body, are pre-biased in the direction toward the support body by means of springs. This results in a simple mold design.
By means of the springs, it is ensured, on the one hand, that during the named second opening step the mold inserts are moved relative to the receiving body together with the support body in the opening direction and, on the other hand, it is made possible for the support body to need only to support the tool inserts.
In addition, in a preferred manner the injection mold comprises at least two mold parts which are realized as described above. Each of said mold parts comprises a receiving body each with mold inserts mounted therein so as to be movable and a support body. The directions of movement of said mold parts during closing and opening of the injection mold extend in a preferred manner at an angle with respect to one another when the mold inserts guided by them form bristle bundles of very different longitudinal directions.
By means of an injection mold of this type, domestic brushes and body care brushes according to the invention can be produced where bristle bundles comprise different longitudinal directions.
Possible plastics material components as hard components are:
The following soft components are examples from the range of thermoplastic elastomers (TPE's):
In addition, the thermoplast polyethylene (PE) and polyurethane (PU) as named can be used both as hard components and as soft components.
PP is particularly suited as a hard component, most preferred is PP with a modulus of elasticity of between 1000 and 2400 N/mm2, preferably between 1300 and 1800 N/mm2. In a preferred manner a TPE-S is used as a soft component. The Shore A hardness of the soft components are preferably below 90 Shore A. The soft components form a material bond with the hard component by means of over injection using the two-component or multiple-component injection molding method.
Example materials for the production of injected bristles and bristle carriers (bristle material):
The bristle materials have a Shore D hardness of between 0 and 100, preferably of between 30 and 80.
Conventional extruded bristles (tapered or cylindrical) are preferably produced from polyamide (PA) or polyester (PBT). Rubber-elastic cleaning elements are produced from a soft component.
So-called bioplastics materials, i.e. plastics materials which are produced from renewable raw materials, can also be used.
Additives can also be added to the plastics material component that is used for forming the bristles. For example, decorative particles such as glitter or abrasive particles, for example perlite, to increase the abrasiveness of the bristles.
For domestic brushes of the named type, the requirements for the materials are less specific than, for example, for toothbrushes. However, it is not only the named materials that can be used for injected bristles. It is also possible to form the bristles from PP, PE, PA, PBT, TPE or a mixture of the named materials.
In the case of body care brushes, the requirements for the materials are different depending on the application. Only the materials named further above can be used for certain applications, further materials, as named in the case of domestic brushes, can also be used for other applications.
In principle, it is possible to shape the handle as discussed from one or several hard and soft components. The bristle carrier or the cleaning elements in the bristle field can also be produced from different plastic material components. In this case, one or several bristle components and one or several soft components can be used. It is possible to introduce said components in different sequences in the production method, for example not the bristle components first but rather the soft components.
The handle or the head region or the end region can additionally have an edge incorporated which allows surfaces to be scraped. This can be formed from the most varied materials.
As a result of describing and specifying the domestic brush or body care brush and the injection mold according to the invention, the method for producing the domestic brushes or body care brushes is consequently also disclosed in a corresponding manner.
Bristle fields which comprise bristles which comprise more than the said number of bristles can obviously also be formed using the injection mold according to the invention. In this case, flatter bristle bundles or also bristle strips or bristle faces are formed which, in turn, are fastened at angles on a brush head. The combination of the different possible types of bristle bundles is obviously possible, for example flat bundles and bristle bundles as primarily described in the same brush.
At least one injection mold is used to produce the brushes according to the invention. Both the handle and the bristle carrier with the bristles can be produced in said mold. However, it is also possible to inject the handle separately and to provide a second mold for the bristle carrier with the bristles, the handle either being inserted and injected around in the second mold or simply a separate bristle carrier with bristles being produced which is then or subsequently mounted onto the handle.
For the sake of completeness, it must be mentioned that it is also possible in all the development variants to form combined bristle fields. This means that along with the injected bristles conventional cylindrical or tapered filaments can also be used, it being possible to fasten these in the bristle carrier as a result of the most different methods, for example using anchor stamping or loop stamping methods, or also by means of known AFT methods (anchor free tufting), IMT methods (in-mold tufting) or the IAP method (integrated anchorless production) as also other brush production methods. In addition, soft-elastic/rubber-elastic cleaning elements can also be incorporated in the same bristle field along with said elements.
Washing-up brushes, WC/toilet brushes, floor mops/brooms, scrubbing brushes, bottle washers and nail brushes apply in particular as domestic brushes according to the description and applicators which can be used for the application of cosmetics (e.g. nail varnish, mascara), hair care products (e.g. hair colorings) or of medical products apply in particular as body care brushes.
The invention is explained in more detail by way of exemplary embodiments which are shown in the drawing, in which, in a purely schematic manner:
The head region 20 of the handle 14 is realized at least approximately in a straight manner and comprises an almost circular segment-like cross section, as can be seen in particular in
In the free end region 28, the head region 20 is realized convexly curved in a three-dimensional manner, similar to part of a spherical segment.
As can be seen in particular from
In addition, in the transition from the head region 20 to the neck region 18 the handle 14 comprises a groove 32 which runs round in the circumferential direction and is open to the outside in the radial direction.
In the exemplary embodiment shown, the entire head region 20 of the handle 14 is injected around by means of a second plastics material component with which all the injected bristles 34 are also realized in an integral manner. Said second plastics material component covers the head region 20 in a layered manner and forms a bristle carrier 36 for the injected bristles 34.
The second plastics material component also forms a connecting web 38 each which reaches through the relevant passages 30 and connects the region of the bristle carrier 36 facing the front side 26 of the brush to the region facing the rear side 24 of the brush. In addition, the second plastics material component, i.e. the bristle carrier 36, engages in a bead-like manner in the groove 32.
As a result of the engagement in the groove 32 and by means of the connecting webs 38, excellent fastening of the bristle carrier 36 to the handle 14 is ensured, even when the first plastics material component and the second plastics material component are chosen from materials which do not form a connection together during injection molding.
Even if materials which do enter into a connection using the injection molding method are used for the first and the second plastics material component, it is possible to choose the embodiment shown. In the latter case, however, it is also possible to dispense with the passages 30 and the connecting webs 38 and, where applicable, the part of the bristle carrier 36 facing the rear side 24 of the brush.
All the bristles 34 are injected together with the bristle carrier 36 and are arranged in bristle bundles 40. The bristle field 42 is consequently formed exclusively by a plurality of bristle bundles 40 with injected bristles 42.
In the exemplary embodiment shown, all the bristle bundles 40 are realized in an identical manner and the injected bristles 34 extend parallel to one another in the respective bristle bundles 40.
Longitudinal directions of the bristle bundles 40 are indicated by way of dot-dash lines 44.
The bristles 34 projecting from the bristle carrier 36 area closely packed together in the bristle bundles 40, whilst the bristle bundles 40 are spaced apart from one another at a distance A.
The bristle field 42 comprises several rows 48 of bristle bundles 40, in the exemplary embodiment shown seven rows 48. Said rows extend in the longitudinal direction of the head region 20 or of the bristle carrier 36 and of the bristle field 42 and are arranged at least distributed in an approximately uniform manner in the circumferential direction within a bristle field angle α (
When measured in the longitudinal direction, the bristle bundles 40 of in each case one row 48 are situated approximately in the middle with reference to the bristle bundles 40 of the adjacent rows 48; the adjacent rows 48 are consequently offset in the longitudinal direction.
The bristle bundles 40 are no longer arranged in straight rows in the end region 28 but are distributed three-dimensionally with respect to one another in such a manner (ray-like) that they are spaced apart substantially by the same distance A as the bristle bundles 40 in the rows.
The bristle bundles 40 no longer extend parallel to one another in the end region 28 as in the individual rows 48, but they, or the longitudinal directions 44 thereof, are arranged in a skew manner or enclose (solid) angles with one another.
The bristle carrier 36 comprises a layer thickness of between 1 mm and 5 mm, preferably of between 2 mm and 4 mm.
The bristles 34 of the bristle bundle are realized integrally with the bristle carrier 36 which is common to all the bristles bundles 40.
Each of the injected bristles 34 comprises a bristle stem 50, the length of which is designated by way of the reference L in
The diameter of the bristle 34, or of the bristle stem 50, when exiting out of the bristle carrier 36 is characterized by way of the reference D in
The bristles 34 preferably taper in a conical manner from the exit up to the free end.
For the sake of completeness, it must be mentioned that the outside contour of the bristle stem 50 preferably merges continuously into the outside contour of the end cap 52, a slightly offset outside contour is nevertheless possible. It must be mentioned, however, that the bristles 34 can also end at the free end of the bristle stem 50; the free end of the bristles 34 would be realized in a flat manner in this case.
Suitable plastics materials for the plastics material components of the handle 14 and the plastics material component for the bristle carrier 36 and the bristles 34 as well as preferred dimensions of the bristles 34, of the realization of the bristle bundle 40 and of the bristle carrier 36 are specified in the introduction.
In this case, it is also possible to produce the handle 14 from several plastics material components. For example, the handle 14 can also comprise further hard components or one or several soft components along with the hard component. In addition, it is also possible to arrange soft-elastic elements from a soft component also in the bristle field 42.
In addition, possible realization forms of the bristle bundle are described in more detail further below in connection with
In the case of the embodiment of the domestic brush 12 which is shown in
The washing-up brush 10 comprises, once again, a handle 14 with a handle region 16, a neck region 18 which connects thereto and a head region 20 which is carried by said neck region, see also
The head region 20, once again, is realized in a straight manner, as in the example shown further above, its cross section from the end on the side of the neck region 18 as far as up to the free end region 28 also being realized in a lightly tapered manner. Said cross section, once again, is circular-segment-like, the arc part facing the front side 26 of the brush and the chord part facing the rear side 24 of the brush. The free end region 28 is formed similarly to part of a spherical segment, once again bent in a three-dimensional manner.
The surface of the head region 20 facing the front side 26 of the brush is provided with three groove-shaped recesses 54 which extend in the circumferential direction and are spaced apart from one another in the longitudinal direction. Corresponding groove-like further recesses 56 are situated in the flat side of the head region 20 facing the rear side 24 of the brush. These extend at right angles to the longitudinal direction of the head region 20 or in the same plane which extends at least approximately at right angles to the longitudinal direction of the head region 20, as the associated recess 54.
As can be seen in particular from
When viewed from the free end of the head region 20, in each case the surface of the head region 20 ascends to the groove-shaped further recesses 56 in a (slightly) ramp-shaped manner in order to facilitate the mounting of the sleeve-shaped bristle carrier 36; see
On its inside surface the bristle carrier 36 comprises the beading 58 which projects corresponding to the recesses 54 and further recesses 56, which in the mounted state engage in the recesses 54 or further recesses 56; compare
The bristle carrier 36 is realized in a sleeve-shaped manner using the injection molding method, the inside contour corresponding substantially to the outside contour of the head region 20 of the handle 14.
The injected bristles 34, which are arranged in bristle bundles 40 in a precisely identical manner as in the case of the embodiment of the washing-up brush 10 described further above, are produced integrally with the bristle carrier 36.
The bristle field 42 is realized identically as in the case of the embodiment according to
To produce the washing-up brush 12 according to
The handle 14 can also be produced from several plastics material components, as has already been described also in connection with the handle 14 in
Seven injected bristles 34, which are realized integrally with the bristle carrier 36 and extend parallel to the longitudinal direction 44 which in its turn extends at right angles to the bristle carrier 36, project from said bristle carrier. The bristles 34 comprise a bristle stem 50 which tapers conically from the exit point out of the bristle carrier 36 to the free end. The free end of the bristle stem 50 carries a hemispherical-like end cap 52. The outside contours of the bristle stem 50 and the end cap 52 merge steplessly into one another.
The length of the bristle stem is designated by way of the reference L. The diameter of the bristles 34 on exit out of the bristle carrier 36 is designated by way of the reference D and the diameter of the bristles 34 at the end of the bristle stem 50 remote from the bristle carrier 36 by the reference D1. Preferred lengths and thicknesses of the injected bristles 34 are specified in detail in the introduction.
One of the bristles 34 stands centrally of the bristle bundle 40 and the six remaining bristles are uniformly distributed in the circumferential direction around said central bristle 34.
The bristles 34 are packed very closely together on exit out of the bristle carrier 36; they preferably touch one another.
In the exemplary embodiment shown, the bristle carrier 36 is associated exclusively with the one bristle carrier 34. However, it is also conceivable for the bristle carrier 36 shown to be part of a bristle carrier 36 which is common to several or all of the bristle bundles 40.
If after the injection molding of the bristle bundles 40 together with the bristle carrier 36, as is shown in
This behavior during cooling can generally be achieved with bristle bundles 40 which consist of a bristle carrier 36 per bristle bundle 40 according to the description. Consequently, this is not shown separately for the embodiment according to
Five of the bristles are arranged distributed uniformly along an inner circle which is concentric with respect to the longitudinal direction 44 (longitudinal axis). Ten further bristles are arranged distributed uniformly in the circumferential direction along a central circle which is located radially on the outside with reference to the inner circle and is also concentric with respect to the longitudinal direction 44 (longitudinal axis) and the remaining ten bristles 34 are arranged distributed uniformly along an outer circle which is located on the outside in the radial direction with reference to the center circle and is also concentric with respect to the longitudinal direction 44 (longitudinal axis).
In the exemplary embodiment shown, the outermost bristles 34 are realized with a larger diameter than the remaining bristles 34 at the exit point out of the bristle carrier 36.
The dimensions of the injected bristles 34 correspond to those specified in the introduction.
For the sake of completeness it must be remarked that the bristles 34 which are associated with an adjacent circle located radially on the inside, when viewed in the circumferential direction, are arranged in each case between two adjacent bristles 34 which are associated with the adjacent radially outer circle.
Here too, the bristles 34 almost touch one another when exiting out of the bristle carrier 36.
The bristle carrier 36 is once again shown as an individual bristle carrier 36 which is associated with the bristle bundle 40. However, it is also possible for the bristle carrier 36 shown to be part of a bristle carrier 36 which is common to several or to all of the bristle bundles 40 of the domestic brush, for example washing-up brush 10.
If a domestic brush 12, in particular a washing-up brush 10 or an applicator brush 90 with bristle bundles 40, is produced with individual bristle carriers 36, the handle 14 is preferably injected from plastics material first of all. In this case, the handle 14 can be injected from one or several hard components and with one or several soft components. Recesses which are intended for receiving the bristle carrier 36 are present on said handle. In addition, supply channels, which extend from an injection point to the recesses and through which the second plastics material component for the production of the bristle carrier 36 and of the bristles 34 which are to be realized integrally with said bristle carriers, can be provided in the handle 14, in particular in the head region 20 thereof. The handle 14, once it has been produced, is moved into another cavity which serves for producing the bristle carrier 36 and the injected bristles 46.
However, it is also possible to produce the bristle bundle 40 with its individual bristle carrier 36 using the injection molding method first of all, then to move it into a cavity for the production of the handle 14 and then to inject the handle 14 in such a manner that the plastics material of the handle 14 flows around the bristle carrier 36.
In addition, it is possible for the handle 14 and the bristle bundle 40 to be produced separately and then mounted. A relatively expensive method as a whole, but it can certainly be that as a result the injection molds are able to be designed in a considerably simpler manner.
The bristle carrier 36 is realized in the form of a sleeve and comprises a straight, hollow-cylindrical portion 64 and a hemispherical end portion 66 which connects integrally thereto.
Four bristle bundles 40 are arranged in each case in a row 48 in the hollow-cylindrical portion 64, the rows extending in the longitudinal direction of the hollow-cylindrical portion 64 and there being 12 rows distributed uniformly in the circumferential direction. The number of bristle bundles per row can be varied and is between 3 and 12 bristle bundles, preferably between 4 and 8 bristle bundles 40. The number of rows in the circumferential direction is between 4 and 16, preferably between 8 and 14. The distances between the bristle bundles can be adapted in a corresponding manner.
The bristle bundles shown are realized as shown in
The bristle bundles 40 of every other row, or of the longitudinal direction thereof 44 (longitudinal axis), are arranged in bristle planes 68 which extend at right angles to the longitudinal direction of the WC brush 62 (i.e. to the axis 70) and are spaced apart from one another in the longitudinal direction of the WC brush 62 (i.e. to the axis 70). The bristle bundles 40 of the remaining rows 48 are arranged in each case in bristle planes 68′ which are arranged offset to said bristle planes 68 in the longitudinal direction by half the distance between said bristle planes. The bristle bundles 40 of the bristle planes 68′ are arranged offset in relation to the bristle bundles 40 of the bristle planes 68.
The longitudinal direction 44 of a bristle bundle 40 coincides with the axis 70 of the bristle carrier 36 in the end portion 66. Between said bristle bundle 40 and the rows 48 of bristle bundles 40 there are two rings 72 of six bristle bundles 40 each in the exemplary embodiment shown which protrude (in a ray-like manner) from the bristle carrier 36 by way their longitudinal direction 44 in the radial direction with respect to the spherical end portion 66.
The bristle bundles 40 are spaced apart from one another by the distance A in this embodiment also.
The interior 74 which is formed by the hollow-cylindrical form of the bristle carrier 36 is intended for receiving a cylindrical head region 20 of the handle 14, the neck region and handle region of which form a, for example, straight shaft. However, it is also conceivable for the shaft to be curved.
The wall thickness of the bristle carrier 36 is realized in a preferred manner so as to be thinner in the open end region than in the remaining region. In a corresponding manner, the handle 14 preferably comprises a corresponding diameter enlargement in order to achieve sufficient force locking between the handle 14 and the bristle carrier 36 with the integrally realized bristles 34 as a result of the elasticity of the plastics material components.
However, it is also possible to realize in the hollow-cylindrical portion 64 a thread into which a handle 14 can be screwed with a corresponding counter thread. However, it is also possible to incorporate in the said hollow-cylindrical portion 64 other geometries which enable the handle 14 to be fastened, for example as a result of snap-type catches.
Any connections between the handle 14 and the bristle carrier 36 can be formed so as to be either releasable or non-releasable. Thus, along with the already named connection variants, bonding can also be suitable or also a one-time assembly with geometries which connect in a non-releasable manner. A releasable connection implies that the brush heads are able to be exchanged and this means that the handle 14 is able to be used multiple times.
In addition, it is also possible to inject the bristle part directly onto the handle. A WC brush 62 where everything is injection molded and non-releasably connected is created in this way.
The production of the bristle carrier 36 of the WC brush 62 is effected using the injection molding method analogously to the washing-up brush 12, as will be described subsequently. The difference is that in the case of the WC brush the injection mold comprises a higher degree of complexity as bristle bundles 40 with bristles 34 are arranged right around the bristle carrier 36.
As an alternative to this, a WC brush 62 can be achieved as a result of assembling several bristle carriers. Thus, it is possible to form several bristle carriers which are in the form of the head region of an over-dimensioned washing-up brush. As a result of a suitable handle and by forming the bristle carrier in a corresponding manner, said elements can be mounted back to back such that a domestic brush which has bristles right around its circumference is also created. As a result of assembly it can be achieved that identically formed bristle carriers can be mounted twice or more times onto the same handle. The injection mold is correspondingly simpler because bristles, which have to be removed from the mold, are not mounted right around the bristle carrier.
The handle 14 comprises a flat, approximately rectangular bottom 78 from which holding walls 80 protrude along the longitudinal sides.
Four rows 48 of bristle bundles 40 which are associated with the rear side 24 of the brush are situated between the holding walls 80.
On the opposite front side 26 of the brush, six rows 48 of further bristle bundles 40 protrude from the bottom 78.
In the exemplary embodiment shown, the handle 14 and the injected bristles 34 of the bristle bundles 40 consist of the same plastics material component. The handle 14 itself, or the bottom 78 thereof, consequently forms the bristle carrier 36 for all the bristle bundles 40.
In the case of said embodiment too, the bristles 34 and bristle bundles 40 are realized in a manner such as is described further above. In addition, the bristle bundles 40 are also arranged in this case spaced apart from one another at a distance A.
The lengths of the bristles 34 are preferably identical on both sides of the nail brush 76. In addition, identical bristle bundles 40 are preferably formed on both sides.
For functional reasons, it is nevertheless possible to use different bristle bundles 40 so that the corresponding bristle fields 42 are able to achieve different strengths, for example one for preliminary cleaning and one for fine cleaning.
The height of the holding walls 80 between the bottom 78 and the free end of the holding wall is between 15 mm and 30 mm, preferably between 18 mm and 25 mm.
The sweeping head comprises a bar 84 which serves as a head region 20 of the handle 14. Said sweeping head is produced using the injection molding method from at least one plastics material component.
On the side remote from the bristle field 42—the rear side 24 of the brush—the bar 84 carries an articulated shaft holder 86, a shaft being fastenable in the articulated sleeve 88 thereof in a known manner
The bristle carrier 36, which extends around the rounded side edges of the bar 84 as far as approximately up to the center of the height of the side wall of the bar 84, is injected as a flat layer onto the bar 84 on the side facing the bristle field 42—the front side 26 of the brush.
As an alternative to this, the bar 84 and bristle carrier 36 can be formed integrally as one part.
In the exemplary embodiment shown, the bristle field 42 comprises three parallel rows 48 of bristle bundles 40 which extend in the longitudinal direction of the bristle field 24 and of the bristle carrier 36, each with 29 bristle bundles 40 in the exemplary embodiment shown. Said bristle bundles 40 protrude perpendicularly from the bristle carrier 36.
Two further rows of bristle bundles 40 extend on each of the two sides of said rows 48. The longitudinal direction 44 of said bristle bundles 40, however, when viewed in the longitudinal direction of the bar 84 (see
Further bristle bundles 40, in the example shown 4 in each case, the longitudinal direction 44 of which, also when viewed in front view (
In addition, the outermost bristle bundles 40 in the longitudinal direction are situated in the region of the rounded edge of the bar 84.
Here too, the bristles 34 and the bristle bundles 40 are realized in a manner such as described further above. The bristle bundles 40 are arranged spaced apart from one another at a distance A.
In the case of the broom 82, in a preferred manner the bristles 34 comprise a length L which lies at the larger end of the preferred length specifications mentioned in the introduction.
The distances between bundles A are substantially identical to those named for the domestic brush.
The bar 84 has a length of between 23 cm and 33 cm, preferably between 25 cm and 30 cm. The width of the bar 84 is between 4 cm and 8 cm, preferably between 5 cm and 7 cm.
In the case of a realization of the sweeping device head as a scourer, which is also possible, the region of the width remains identical, the length, however, is different. In the case of a scourer, the length is between 15 cm and 25 cm, preferably between 18 cm and 22 cm.
Obviously, it is also possible to arrange all the bristle bundles 40 on the broom 82 in such a manner that their longitudinal directions 44 extend parallel to one another and in a preferred manner at right angles to the bar 84.
In addition, it must be mentioned at this point that it is also possible to attach conventional bristles or bristle bundles in a known manner in the bar 84 along with the injected bristles 34.
Obviously, the number of rows 48 and the number of bristle bundles 40 per row can be different.
In the exemplary embodiment shown, the longitudinal direction 44 of the bristle bundle 40 coincides with the longitudinal axis of the handle 14.
In the exemplary embodiment shown, the bristle bundle 40 is realized identically as shown in
The handle comprises a head region 20 which widens in a conical manner when viewed from the bristle bundle 40, followed by a circular-cylindrical portion as the neck region 18 and connected thereto a handle region 16 which is realized in a conically tapering manner.
The head region 20 is injected around with the plastics material component of the bristle carrier 36, with which the bristles 34 of the bristle carrier 36 are integrally realized and which protrude from the end face thereof.
Here too it is possible for the entire applicator brush 90 to be realized from the plastics material component of the bristle carrier 36 and of the bristles 34. In this case, the applicator brush 90 can be produced in one single injection molding step.
A further embodiment of an applicator brush 90 is shown in
In the embodiment shown, the bristle bundles 40 are realized identically to the bristle bundle of the embodiment according to
The handle region 16 is realized widened conically from the free end in the direction of the bristle bundles 40 and a circular-cylindrical neck region 18 connects thereto. The head region 20, which, when viewed in front view, is realized widened in a trapezoidal manner, but when viewed in side view, tapers toward the bristle-side end, connects to the neck region 18 on the other side.
The head region 20 is injected around with the plastics material component for the bristle carrier 36, forming the same, and the bristles 34 of the three bristle bundles 40 are realized using the injection molding method integrally with the bristle carrier 36.
In the case of said embodiment also, it is possible for the handle 14 and the bristle carrier 36 as well as the bristles 34 to be produced from one and the same plastics material component. Both in the case of the embodiment according to
Here too, the bristle bundles 40 are arranged spaced apart from one another at a distance A and they, or their bristles 34, are realized in a manner such as disclosed further above.
In the exemplary embodiment shown, two bristle bundles 40 each are realized on a common bristle carrier 36. Said bristle carriers 36 are each arranged on an arm of the U-shaped head region 20 of the handle 14.
The bristle bundles 40, in the exemplary embodiment shown, are aligned such that their longitudinal axes 44 intersect or that the free end regions of the bristle bundles 40 get mixed together. This can be achieved, for example, as a result of the cooling process during the injection molding, by mounting the bristle bundles 40 on the arms or by post-machining, for example by reshaping the arms.
In the exemplary embodiment shown, the bristle bundles 40 are realized in an identical manner as shown in
The handle 14 is shaped such that the handle region 16 can serve at the same time as a closure for a receptacle with a medium to be applied. A neck region 18, which in the present case is developed as a cylindrical body, once again such that it is able to be inserted into said receptacle with the medium to be applied, follows connecting to the handle region. The head region 20, which consists of two arms, which at each of their ends comprise bristle carriers 36 which carry the bristle bundles 40 in an integral manner, is realized connecting directly to said neck region.
The head region 20 is injected around with the plastics material component of the bristle carrier 36, with which the bristles 34 of the bristle bundle 49 are integrally realized and which project from the end face of said bristle carrier.
Here too, it is possible for the entire applicator brush 90 to be realized from the plastics material component of the bristle carrier 36 and of the bristles 34. In this case, the applicator bush 90 can be produced in one single injection molding step.
Here too, the bristle bundles 40 are arranged spaced apart from one another by a distance A and they, or their bristles 34, are realized in a manner such as disclosed further above.
The bristle bundles 40, in the exemplary embodiment shown, are realized on a common bristle carrier 36. The head region 20 of the handle 14 consists, once again, of two arms. The bristle carrier 36 is realized on the one arm and the support surface 91 on the other, flat arm.
The bristle bundles 40 are aligned such that their longitudinal axis 44 intersects the longitudinal axis of the support surface 91. The bristle bundles 40 and the support surface 91 abut against one another or almost against one another. This can be achieved, for example, as a result of the cooling process during the injection molding, or by mounting the bristle bundles 40 on the relevant arm or by post-machining, for example by reshaping the head region 20.
In the exemplary embodiment shown, the bristle bundles 40 are realized in an identical manner as shown in
The handle 14 is shaped such that the handle region 16 can serve at the same time as a closure for a receptacle with a medium to be applied. A neck region 18 of the brush, which in the present case is developed as a cylindrical body, once again such that it is able to be inserted into said receptacle with the medium to be applied, follows connecting to the handle region 16. The head region 20, which consists of two arms, which at each of their ends carry the bristle carrier 36 or the support surface 91, is realized connecting directly to said neck region.
The head region 20 is injected around with the plastics material component of the bristle carrier 36, with which the bristles 34 of the bristle bundle 40 are integrally realized and which project from the end face of said bristle carrier.
Here too, it is possible for the entire applicator brush 90 to be realized from the plastics material component of the bristle carrier 36 and of the bristles 34. In this case, the applicator brush 90 can be produced in one single injection molding step.
Here too, the bristle bundles 40 are arranged spaced apart from one another by a distance A and they, or their bristles 34, are realized in a manner such as disclosed further above.
The support surface 91 can fulfill different functions. On the one hand, the support surface 91 supports the bristles 34 in application, this means the bristles 34 are pressed against the support surface 91 under load. As a result, a longer service life can be achieved for the bristles 34. On the other hand, a certain reservoir for the medium to be applied can be created by the support surface 91. Said medium can be collected between the bristles 34 and the support surface 91 and is discharged little by little by the bristles 34.
In the case of the applicator brush 90 shown in
An injection mold 92 for producing the bristle carrier 36 and the bristle bundles 40 for the washing-up brush 10, as is shown in
It must be mentioned at this point that the same type of injection mold 92 is used in a preferred manner whenever bristle bundles 40, the longitudinal directions 44 of which do not extend parallel to one another, are to be produced by means of a mold 94.
These types of injection molds 92 are suitable in particular for the production of domestic brushes according to
The injection mold 92 comprises a plate-like stationary mold part 96. Said mold part, in a preferred manner, is arranged on the nozzle side. It defines the cavity 98 for the production of the bristle carrier 36 and of the bristles 34 which are arranged in bristle bundles 40 on the rear side 24 of the brush. The stationary mold part 96 is realized with a recess 100 for the arrangement of the hot channel and a supply channel 102 for the injection nozzle for supplying the plastics material component for the production of the bristle carrier 36 and of the injected bristles 34 into the cavity 98. Said supply channel 102 or the associated injection nozzle defines the injection point.
For defining the cavity 98 on the front side 26 of the brush, the injection mold 92 comprises six mold parts 94. Each of said mold parts 94 comprises a receiving body 104 which defines the cavity 98. Each of said receiving bodies 104 has associated therewith (on the side remote from the cavity 98) a support body 106, the support bodies 106 supporting the receiving bodies 104 in the closed position of the injection mold. In addition, a towing connecting 108, which, when the injection mold 92 is opened, allows a relative movement between the receiving body 104 and the support body 106 over an opening stroke region (in one opening step) and in the remaining region of the opening stroke (in a subsequent opening step) entrains the receiving body 104 together with the support body 106 in the corresponding opening direction and moves them away from the injected body, is arranged in each case between the receiving body 104 and the associated support body 106.
In the exemplary embodiment shown, the towing connecting 108 is realized in such a manner that it comprises a screw 110, which extends in the direction of the common movement of the receiving body 104 and of the support body 106, the shaft 112 of which screw reaching through a continuous bore 116 in the support body 106 and being screw-connected into the receiving body 104.
The head 114 of the screw 110 is arranged in the bore 116, said bore comprising a support shoulder 118, against which the head 114 of the screw 110—where applicable by means of spring rings—comes to abut after the opening step in order to entrain the receiving body 104 in towing connection in the subsequent opening step; see
In the named opening step, the receiving bodies 104 remain in the closed position. This is achieved as a result of a mechanism which is not shown.
The mold parts 94 comprise per associated bristle bundle 40 a passage 122, the longitudinal axis of which coincides with the longitudinal direction 44 of the relevant bristle bundle 40 to be formed. In a preferred manner, said passages 122 are realized so as to be circular-cylindrical.
A mold insert 124, in which the bristle cavities 126 for the production of the injected bristles 34 of the relevant bristle bundle 40 are realized, is situated in each of the passages 122.
The mold inserts 124 are displaceably mounted in the passages 122 in a clearance fit of such a type that during the injection molding no plastics material is able to penetrate between the receiving bodies 104 and the mold inserts 124.
On the side remote from the cavity 98, the mold inserts 124 are each supported by a mushroom-shaped support element 128 which engages in a corresponding opening of the mold insert 124 by way of its stalk and abuts against the support body 106 at the other end by way of its head.
The mold inserts 124 comprise on the end on this side a flange portion 130 which projects radially outward, on which a helical compression spring 132 is supported by way of one end. The helical compression spring 132 is supported on the receiving body 104 by way of the other end.
The heads of the support elements 128 and the flange portions 130 of the bristle cavities 126 or mold inserts 124 are received with lateral play in relevant blind hole-like recesses of the support body 106. Consequently, they are able to move along their longitudinal axis even if the support body 106 has a different direction of movement.
The mold inserts 124 comprise per bristle 34 of the bristle bundle 40 to be injected a continuous bristle cavity which tapers outward conically in the direction of the cavity 98, i.e. in the direction toward the support element 128. The bristle cavities 126 can be produced using the wire eroding method and their surface is preferably not treated. Their dimensions are produced from the dimensions of the bristles 34 to be injected; corresponding dimensions are specified in the introduction and further above.
The bristle cavities 126 or the mold insert 124 are a central component part of the injection mold. They can be produced using a tool steel which is available as a cost-efficient material.
To improve quality, the bristle cavities 126 or the tool insert 124 can be produced from a powder metallurgical steel.
Powder metallurgy production methods are characterized by the mechanical compaction of metal powders in molds or presses and simultaneous or subsequent sintering of the “green compact” at high temperatures or hot rolling to form a block. For example, the powder metallurgical steel Microclean M390 of Böhler Edelstahl GmbH & Co. KG is suitable (Microclean is a trademark of Böhler Edelstahl GmbH & Co. KG). The very small number of material inclusions, the particle sizes in the steel and the regular structural constitution are optimized in the case of such steels. As a result, a higher quality of the eroding contour is achieved during machining, which ultimately leads to qualitatively better bristles.
If the bristles 34 comprise only a bristle stem 50—said stem is defined by the bristle cavities 126—but no end cap 52, the bristle cavity 126 is closed by the even end face of the stem of the support element 128.
If, however, the bristles 34 do comprise end caps 52, the end cap cavities are realized in a preferred manner at the end face of the stem of the support element 128.
In addition, the support elements 128 serve for ventilating the injection mold during the injection of the plastics material.
For the sake of completeness, it must be mentioned that the support elements 128 and the mold inserts 124 are not fixedly connected together. In the closed position of the injection mold they abut against one another as a result of the pressure between the receiving body 104 and the support body 106. During the opening step they are clamped against one another by means of the helical compression spring 132 and the flange portion 130 of the bristle cavity 126 is pressed against the flange of the support element 128.
In the embodiment of the injection mold 92 shown, one mold part 94a each is provided for each of the outside two rows 48 of bristle bundles 40—see FIG. 12—and one further mold part 94b is provided for the three rows 48 of bristle bundles 40 arranged in between.
In addition, there are three mold parts 94 present for the realization of the bristle bundles 40 in the three-dimensionally curved end region 28. The central one 94c of said three last-mentioned mold parts 94 has associated therewith the tool inserts 24 for the realization of the four bristle bundles 40 on the free end of the washing-up brush 10.
Between the mold part 94c and the two mold parts 94a, by means of which each of the two lateral rows 48 of bristle bundles 40 are produced, is situated a further mold part 94d or 94e for producing each of the five further bristle bundles 40 in the three-dimensionally curved end region 28.
Common to all the mold parts 94 is that in their receiving bodies 104 are arranged mold inserts 124, the longitudinal directions of which extend at least in part at an angle with respect to one another or in a skew manner with respect to one another.
Linear guides 136, which, for example, can be in the form of guide rails or guide grooves, are realized or arranged on a guide body 134 of the injection mold 92 for each mold part 94.
In the exemplary embodiment shown, the guide body 134 is reached through by an entrainment body 138. The entrainment body 138 is fastened at the one end on a linearly movable part of the injection molding machine and at the other end is connected to the support bodies 106 of the mold parts 94 in such a manner that the support bodies 106 also move in the direction of movement of the entrainment body 138.
For the sake of completeness it must be mentioned that the direction of movement B of the entrainment body 138 is directed toward the stationary mold part 96 and away from said stationary mold part; preferably at right angles to the parting plane between the stationary mold part 96 and the mold parts 94 (i.e. 94a, 94b, 94c, 94d, 94e) which abut against the injection mold 92 in the closed position thereof; in the closed position of the injection mold 92 the receiving bodies 104, together with the mold inserts 124 arranged therein, the support elements 128 as well as the stationary mold part 96 define the cavity 98 for producing the bristle carrier 36 and all the bristle bundles 40 with the injected bristles 34.
Finally, the injection mold 92 comprises a core 140 which serves for realizing the interior of the sleeve-shaped bristle carrier 36. In the closed position of the injection mold 92, the core 140 is moved into the cavity 98, as shown in
If a washing-up brush 10 according to
In the closed position of the injection mold 92, which is shown in
After the plastics material component for the production of the bristle carrier 36 and of the bristles 34 has been injected into the cavity 98 and said plastics material component has hardened at least in part, the injection mold is opened. To this end, in a first step the entrainment body 138 is moved away in the direction of the stationary mold part 96.
In a second opening step which includes a part stroke of the opening stroke, for example 5 mm, the support bodies 106, each along its guide 136, are entrained in the opening direction, the mold inserts 126 or the associated bristle cavities 126 are removed from the mold in a ray-like manner, whereas the receiving bodies 104 remain in the closed position as a result of the mechanism which is not shown. The helical compression springs 132, however, ensure that the mold inserts 124 move in the direction out of the cavity 98 in the relevant recesses 102 and that the mold inserts abut against the support elements 128. This leads to the injected bristles 34 being partially removed from the mold. Said mold removal step occurs without any forced removal from the mold.
In the following third opening step, which includes the remaining opening stroke, the receiving bodies 104, together with the support bodies 106, are also entrained each in their guides 136 into the open position of the injection mold 92. As a result, the bristles 34 which do not extend in the direction of the relevant guide 136, or are laterally offset, are forcibly removed from the mold. The elements of the respective mold parts 94 remain in the same position relative to one another inside the same mold part 94.
Finally, the bristle carrier 36 with the integrally formed bristles 34 can be removed from the injection mold 92. To this end, the core 140 is moved away from the cavity 98 and the bristle carrier 36 is then pulled away from the core 140, for example by means of a robot.
If a washing-up brush 10 according to
In the case of a washing-up brush 10 according to
The sequence of the injection molding process for the bristle carrier 36 and the bristles 34 is as follows:
The named mold design with mold inserts 124 which receive the bristle cavities 126 enables the injection mold 92 to be designed in a modular manner. Specifically, a brush with differently realized bristle bundles 40 is able to be formed at relatively low expenditure as just the mold inserts 124 have to be exchanged. The size of said modularity is naturally limited to the dimensions of the mold insert 124, but does allow for different bristle quantities, heights, etc.
Further processing of the injection-molded product, or of the washing-up brush after injection molding can be effected in a directly coupled manner or in an uncoupled manner. Just the packaging process has to be run through downstream.
The most varied possibilities are available for the packaging of the washing-up brush. Thus, for example, the brushes can be packaged completely or in part in a blister and sleeve-wrapping can be placed around the product.
In the event of coupling the processes, the packaging machine is connected directly to the injection molding machine and the products are packaged directly after the injection molding. A maximum of one buffer step which picks up performance fluctuations can be arranged in between. This provides the advantages of the product not having to be separately stored temporarily, of the positioned part being forwarded positioned and not having to be re-aligned again and of expenditure being cut as a result of the reduction in storage. The costs of said variant are a disadvantage and the linking of the processes is relatively complex and expensive.
If the steps are not coupled, the product is stored temporarily
after the injection molding and is supplied to the packaging process when required.
The injected bristles for domestic brushes can be used according to the description of the figures for washing-up brushes, WC/toilet brushes, floor mops/brooms, scourers and nail brushes, the body care brush is used as an applicator brush for the application of cosmetics (e.g. nail varnish, mascara), hair care products (e.g. hair coloring) or of medical products. In addition, bottle washers can also be produced using the method according to the invention.
The development variants shown in this document are obviously given as an example. Within the framework of the invention, the individual peculiarities and elements of said development variants can be combined with other development variants without departing from the framework of said invention.
The descriptions given for specific figures can obviously also be transferred to other figures which show identical or similar peculiarities and in which the peculiarities are not described in the same detail.
| Number | Date | Country | Kind |
|---|---|---|---|
| 12004915.0 | Jul 2012 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2013/001482 | 5/17/2013 | WO | 00 |
