Method for manufacturing bristle products, bristle product manufacturing machine, bristle product, and use of a fastening anchor made of plastics material

Abstract

A method of manufacturing bristle products (2), in which a bristle carrier (3) provided with at least one bundle receptacle bore (4) is provided, and a bristle bundle (5) is incorporated conjointly with a fastening anchor (6) into the bundle receptacle bore (4) and anchored in the latter by the fastening anchor (6). The fastening anchor (6), during incorporation into the bundle receptacle bore (4), is deformed while forming at least one end-proximal anchoring structure (7).

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority from German Patent supplication No. 10 2024 112 486.5, filed May 3, 2024, which is incorporated herein by reference as if fully set forth.TECHNICAL FIELD

[0002] The invention relates to a method for manufacturing bristle products, for example toothbrushes, wherein a bristle carrier provided with at least one bundle receptacle bore is provided, and a bristle bundle is incorporated conjointly with a fastening anchor into the bundle receptacle bore and anchored in the latter by means of a fastening anchor.

[0003] The invention furthermore also relates to a bristle product manufacturing machine which is specified to manufacture bristle products, and to a bristle product and to the use of a fastening anchor.BACKGROUND

[0004] EP 0 888 072 B1 discloses a method for manufacturing a brush, in particular a toothbrush, having a bristle body that supports bristle bundles made of plastics material. In the method, sleeve-type supporting elements made of plastics material, which enclose the individual bristle bundles, are manufactured integrally with the bristle body for at least part of the bristle bundles by an injection-molding procedure.

[0005] DE 197 38 256 C2 discloses a method for manufacturing bristle fields for brushes, wherein bundles of plastic bristles are introduced into perforations of a holding plate, and the ends of said plastic bristles that face away from their later free working ends are fused to one another and are fixedly established on the holding plate as a result. Protrusions having heads, widenings or projections are formed on the holding plate, the holding plate as a result being provided with undercuts. Prior thereto, or thereafter, the bristles are introduced into the perforations so as to have a projection that protrudes into the region of the protrusions or the undercuts, whereby the bristles in the region of the protrusions or the undercuts are heated in such a manner that a melt and / or a plastic mass consisting of the plastics material of the bristles is created that completely or partially fills the undercuts. As a result of the subsequently solidifying mass of the plastics material of the bristles, a form-fit is formed between the bristles or bristle bundles and the undercuts of the holding plate.

[0006] When manufacturing bristle products, in particular toothbrushes, bristle bundles are fixed in the bundle receptacle bores of the bristle carriers of bristle products of this type by way of fastening anchors.

[0007] For this purpose, the bristle bundles are incorporated conjointly with the fastening anchors into the bundle receptacle bores of the bristle carriers. In practice, fastening anchors made of metal, for example stainless steel, are often used in the process in order to reliably anchor the bristle bundles in the bundle receptacle bores. The bristle bundles can indeed be reliably fixed in the bundle receptacle bores with the aid of fastening anchors of this type made of metal. However, the use of fastening anchors made of metal in a bristle product in which the other constituent parts are composed of a different material, in particular of plastics material, may impede the recycling of the bristle product.SUMMARY

[0008] It is therefore an object of the invention to provide a method for manufacturing bristle products, a bristle product manufacturing machine, a bristle product and the use of a fastening anchor, which enable reliable anchoring of bristle bundles in bristle carriers of bristle products, and at the same time simplify the recycling of bristle products of this type.

[0009] Proposed for achieving the object is firstly a method for manufacturing bristle products, having one or more of the features disclosed herein directed toward a method of this type. Proposed in particular for achieving the object is thus a method for manufacturing bristle products, wherein a bristle carrier provided with at least one bundle receptacle bore is provided, and a bristle bundle is incorporated conjointly with a fastening anchor into the bundle receptacle bore and anchored in the latter by means of the fastening anchor, wherein the fastening anchor during incorporation into the bundle receptacle bore is deformed while forming at least one end-proximal anchoring structure. A fastening anchor which is composed of plastics material is preferably used in the process. The fastening anchor can preferably be plastically deformed while forming the at least one anchoring structure during incorporation into the bundle receptacle bore. The method enables the manufacturing of a single-material bristle product, the recycling of the latter being significantly simplified.

[0010] In comparison to the use of fastening anchors which are not deformed during the incorporation of the bristle bundles into the bundle receptacle bores, but are instead pushed into the material of the bristle carriers in order to anchor the bristle bundles in the bundle receptacle bores, the method according to the invention utilizes the deformation of a fastening anchor in the bundle receptacle bore so as to cause reliable fixing of the bristle bundle in the bristle carrier.

[0011] When the fastening anchor is incorporated conjointly with the bristle bundle into the bundle receptacle bore, in particular pushed into the latter, the fastening anchor is deformed while forming at least one end-proximal anchoring structure which enables reliable anchoring of the bristle bundle in the bundle receptacle bore.

[0012] The at least one anchoring structure during incorporation of the fastening anchor into the bundle receptacle bore can be generated due to contact between the fastening anchor and a bore wall of the bundle receptacle bore. In the process, the bristle carrier by way of its bundle receptacle bore functions as a shape-imparting tool, so to speak, which deforms the fastening anchor in such a way that the at least one end-proximal anchoring structure is formed on the fastening anchor.

[0013] An end-proximal thickening, for example a cudgel-shaped thickening, can be generated as at least one end-proximal anchoring structure.

[0014] In particular when the fastening anchor during incorporation into the bundle receptacle bore is symmetrically deformed, one end-proximal thickening on both ends of the fastening anchor can be formed as end-proximal anchoring structures. The fastening anchor can assume a bone shape.

[0015] It is also possible that the fastening anchor during incorporation into the bundle receptacle bore is asymmetrically deformed, thus an anchoring structure being formed only at one of the two ends of the fastening anchor, for example. It is also possible that anchoring structures are asymmetrically formed at two ends of the fastening anchor.

[0016] It can be advantageous also to compress the fastening anchor upon incorporation into the bundle receptacle bore. This can take place, for example, by a thruster tongue of a stuffing tool of a bristle product manufacturing machine. By compressing the fastening anchor upon incorporation into the bundle receptacle bore, the fastening anchor can be deformed in a particularly targeted manner so as to form the at least one end-proximal anchoring structure and to effect the reliable anchoring of the bristle bundle in the bundle receptacle bore in the bristle carrier.

[0017] In one variant of the method, the fastening anchor is compressed upon incorporation into the bundle receptacle bore and, as a result, a filling level of the bristle bundle is increased. In the process, a filling level of at least 65% or else of at least 72% can be achieved. The targeted compression of the fastening anchor can then lead to a deformation of the fastening anchor which leads to a displacement of the bristle filaments of a bristle bundle fixed in the bundle receptacle bore by the fastening anchor, said bristle filaments resting on the fastening anchor. As a result, the filament density in the volume of the bundle receptacle bore occupied by the bristle filaments can be increased, and the filling level of the bristle bundle can be increased in this way. Bristle products having particularly dense bristle bundles can be manufactured in this way by the method.

[0018] In one variant of the method it is provided that the fastening anchor upon incorporation into the bundle receptacle bore is compressed and, as a result, an extraction force which is withstood by the fixing of the bristle bundle in the bristle carrier is increased. The extraction force herein can be the force which has to be applied in order to overcome the retaining force provided by the fastening anchor and to release the bristle bundle from the bundle receptacle bore.

[0019] During incorporation of the fastening anchor into the bundle receptacle bore, material of the bristle carrier can be displaced from a peripheral region of the bundle receptacle bore into the bundle receptacle bore and over the fastening anchor placed in the bundle receptacle bore. The displacement of the material of the bristle carrier can take place, for example, by a thruster tongue of a stuffing tool of a bristle product manufacturing machine. This will be explained in more detail hereunder in the context of the bristle product manufacturing machine according to the invention.

[0020] The material of the bristle carrier which is displaced from the peripheral region of the bundle receptacle bore into the bundle receptacle bore can be displaced by way of the anchoring structure which has been generated on the fastening anchor as a result of the deformation of the fastening anchor. In this way, a form-fitting fixing of the fastening anchor in the bundle receptacle bore of the bristle carrier is established.

[0021] The fastening anchor and the bristle carrier during incorporation of the fastening anchor into the bundle receptacle bore can be connected to one another in a materially integral manner. The bristle carrier and the fastening anchor can be adhesively bonded and / or welded to one another in the process.

[0022] The fastening anchor and the bristle carrier can be adhesively bonded and / or welded to one another, thus the materially integral connection between the fastening anchor and the bristle carrier can be established, by frictional heat generated during the incorporation of the fastening anchor into the bundle receptacle bore.

[0023] In order to facilitate the materially integral connection between the bristle carrier and the fastening anchor, the bristle carrier can be heated prior to and / or upon incorporation of the fastening anchor. This takes place in particular in the region of the at least one bundle receptacle bore.

[0024] For forming the at least one anchoring structure on the fastening anchor during incorporation of the fastening anchor in the bundle receptacle bore it is advantageous when a length of the fastening anchor is larger than a diameter of the bundle receptacle bore into which the fastening anchor for anchoring a bristle bundle is incorporated.

[0025] In this way, the portions of the fastening anchor that project beyond the periphery of the bundle receptacle bore are correspondingly deformed during incorporation of the fastening anchor into the bundle receptacle bore, as a result of which the at least one end-proximal anchoring structure can then be formed on the fastening anchor. In this context, it can be expedient when the fastening anchor is incorporated into the bundle receptacle bore in an alignment in which said fastening anchor meets the bundle receptacle bore by way of an identical projection beyond a periphery of the bundle receptacle bore on both sides. This can facilitate a symmetrical deformation of the fastening anchor during incorporation into the bundle receptacle bore.

[0026] The fastening anchor can be incorporated into the bundle receptacle bore by a thruster tongue of a stuffing tool of a bristle product manufacturing machine, wherein the thruster tongue has on its front end a width larger than a diameter of the bundle receptacle bore.

[0027] The use of a thruster tongue designed in such a manner enables the abovementioned displacement of material of the bristle carrier from the peripheral region of the bundle receptacle bore into the bundle receptacle bore and over the fastening anchor.

[0028] During incorporation of the fastening anchor the thruster tongue can peel material of the bristle carrier from the peripheral region of the bundle receptacle bore and displace said material into the bundle receptacle bore in order to also fix the fastening anchor in the bundle receptacle bore in a form-fitting manner.

[0029] The fastening anchor and / or the bristle carrier are / is preferably composed of plastics material, particularly preferably having a content of recycled plastics material. This facilitates an environmentally friendly manufacturing of bristle products, and a positive utilization of plastics material as a resource. Moreover, such a bristle product can be recycled to an ideally great extent and in a simple manner.

[0030] The fastening anchor can be composed of a plastics material which is softer than a plastics material of which the bristle carrier is composed. This facilitates a clean forming of the fastening anchor while forming at least one anchoring structure, and an intact bundle receptacle bore in the bristle carrier.

[0031] The fastening anchor can also be composed of a plastics material which is harder than a plastics material of which the bristle carrier is composed. This facilitates an additional penetration of the fastening anchor into the bristle carrier and, as a result, a form-fitting connection between the fastening anchor and the bristle carrier.

[0032] The form-fitting connection between the fastening anchor and the bristle carrier can be facilitated when the fastening anchor and the bristle carrier are composed of plastics materials of the same plastics material family, or of the same plastics material.

[0033] A fastening anchor and / or a bristle carrier which are / is composed of a plastics material having a hardness of at least 60 Shore D, 70 Shore D, or particularly preferably of at least 80 Shore D, can be used for carrying out the method. As an upper limit, the plastics material can have a hardness of 100 Shore D, for example.

[0034] A materially integral connection between the fastening anchor and the bristle carrier can likewise be facilitated when the bristle carrier and the fastening anchor are composed of a plastics material having a comparable, preferably an identical, hardness.

[0035] Providing the bristle carrier can be simplified when the at least one bundle receptacle bore of the bristle carrier is designed to be free of an anchor track. In comparison to concepts previously known from practice, in which the bundle receptacle bores have a predefined anchor track for the fastening anchor so as to simplify positioning of the fastening anchor in the material of the bristle carrier, an anchor track of this type can be dispensed with in the proposed method. Instead, a bundle receptacle bore which is free of an anchor track can facilitate a defined deformation of a bristle bundle while forming at least one anchoring structure, and be advantageous in this context.

[0036] The bundle receptacle bore used when carrying out the method can have a bore wall which is at least in portions cylindrical, and / or a conical bore wall tapering toward the bore base, and / or a stepped bore wall and / or a bore wall having a retaining structure, for example latching lines. In one embodiment of the bristle carrier, a cone angle of a conical portion of a bore wall, which tapers toward the bore base, can be, for example, at most 7°, so as not to compromise a reliable fixing of the bristle bundle and of the fastening anchor in the bundle receptacle bore.

[0037] In order to be able to implement the desired extraction forces which the bristle bundles and the fastening anchors are to withstand during use of the bristle product, in particular when the latter is designed as a toothbrush, it can be advantageous when the plastics material of the bristle carrier and / or of the fastening anchor has an E modulus of at least 1000 MPa (megapascal) or 2000 MPa, in particular an E modulus which is between 1000 MPa or 2000 MPa and 10,000 MPa.

[0038] The fastening anchor can be anchored in the bundle receptacle bore in a particularly reliable manner when the plastics material of which the bristle carrier and the fastening anchor is composed, has a tensile strength of at least 30 MPa or of at least 45 MPa. The plastics material preferably has a tensile strength between 30 MPa or 45 MPa and 110 MPa.

[0039] The use of the following plastics material has proven to be particularly suitable: polyamide 12 (PA12), polyamide 6 (PA6), polyamide 6.12 (PA6.12), polystyrene (PS), polybutylene terephthalate (PBT), polycarbonate (PC), polyoxymethylene (POM), styrene acrylonitrile resin (SAN), acrylonitrile, polyethylene terephthalate (PE), or polypropylene (PP), in particular fiber-reinforced polypropylene.

[0040] In a preferred embodiment of the bristle product, the bristle carrier and the at least one fastening anchor are composed of polybutylene terephthalate (PBT). PBT can have a tensile strength of 60 MPa and an E modulus of 2500 MPa. Due to the relatively high tensile strength and the likewise relatively high E modulus of PBT, extraction forces which the anchoring of the bristle bundles in the bristle carrier withstands can be achieved in the range between 10 N and 30 N using fastening anchors of PBT to anchor bristle bundles of PBT in bristle carriers of PBT.

[0041] As has already been indicated above, the fastening anchor and the bristle bundle can be incorporated into the bundle receptacle bore of the offered-up bristle carrier, in particularly stuffed into the latter, by a stuffing tool of a bristle product manufacturing machine. This enables the fully automated manufacturing of bristle products.

[0042] The fastening anchor used when carrying out the method can be profiled, i.e. have a cross section deviating from a rectangular cross section. The profiling of the fastening anchor can facilitate the forming of the anchoring structure according to the invention on at least one end of the fastening anchor.

[0043] The fastening anchor can be cut to length from a, for example profiled, anchor strip by means of an anchor cutting device, and be supplied to the stuffing tool of the bristle product manufacturing machine. The anchor strip can be unwound from an anchor spool and supplied to the anchor cutting device. For example, the supply of the anchor strip from the strip spool can take place in a force-and / or impulse-decoupled manner. The anchor strip can be supplied to the anchor cutting device from a strip buffer in which a portion of the anchor strip is kept ready without tension. The strip buffer herein can be disposed between the strip spool and the anchor cutting device.

[0044] For fixing the bristle bundles and the fastening anchors in bundle receptacle bores of bristle carriers of bristle products to be manufactured, the bristle bundles and the fastening anchors can be stuffed into the bundle receptacle bores at a stuffing rate of at least 400 stuffing procedures per minute, or of at least 600, 800, 1000 or 1200 stuffing procedures per minute. This enables particularly efficient manufacture of bristle products. An upper limit of the stuffing rate can be, for example, 1500 or 2000 stuffing procedures per minute.

[0045] A thruster tongue by which the bristle bundle and the fastening anchor are incorporated into the bundle receptacle bore can strike the bundle receptacle bore at a speed between 1.2 m / s and 4.0 m / s, preferably between 1.8 m / s and 3.5 m / s, particularly preferably between 2.2 m / s and 2.8 m / s. It is ensured in these speed ranges that a sufficient amount of kinetic energy acts on the fastening anchor for the targeted deformation of the fastening anchor and for forming at least one end-proximal anchoring structure, when said fastening anchor is incorporated into the bundle receptacle bore.

[0046] Proposed for achieving the object is also a bristle product manufacturing machine which is specified for carrying out the method for manufacturing a bristle product having one or more of the features disclosed herein.

[0047] For this purpose, the bristle product manufacturing machine can have a stuffing tool which comprises a thruster tongue for incorporating bristle bundles and fastening anchors into bundle receptacle bores of offered-up bristle carriers.

[0048] The thruster tongue can have at least one peeling edge which is formed on a narrow side of a front end of the thruster tongue. The front end of the thruster tongue is the side by way of which the thruster tongue incorporates fastening anchors conjointly with bristle bundles into bundle receptacle bores, and in the process plunges into the bundle receptacle bores. With the aid of the at least one peeling edge it is possible to peel material of a bristle carrier from the peripheral region of the bundle receptacle bores, and during incorporation of the fastening anchor to displace said material into the bundle receptacle bores so as to also fix the fastening anchors in a form-fitting manner in the bundle receptacle bores. Preferably, the thruster tongue has in each case at least one peeling edge on each of two sides of its front end that face away from one another. In this way, material can be displaced from two sides into the bundle receptacle bores. This facilitates a particularly reliable, form-fitting fixing of the deformed fastening anchors in the bundle receptacle bores.

[0049] In this context, it can be advantageous when a spacing between the two narrow sides of the front end of the thruster tongue is larger than a bore diameter of the bundle receptacle bores which are to be stuffed with bristle bundles and fastening anchors with the aid of the thruster tongue.

[0050] In one embodiment of the bristle product manufacturing machine, the thruster tongue has on its front end, preferably adjacent to a narrow side of the front end, at least one clearance having at least one material-guiding face. It is then possible to displace peeled material of the bristle carrier in the direction of the bundle receptacle bore by way of the material-guiding face and, as a result, to fix the fastening anchors in a form-fitting manner within the bundle receptacle bores.

[0051] The material-guiding face can be aligned obliquely to a longitudinal axis of the thruster tongue, and / or face the longitudinal axis of the thruster tongue, and define the displacement direction for the peeled material of the bristle carrier in the direction of the bundle receptacle bore. In a preferred embodiment, the thruster tongue has, adjacent to each of its two narrow sides, on the front end in each case at least one clearance of this type and / or material-guiding face for guiding the material. The at least one clearance can have a concave and / or semi-cylindrical contour. The previously mentioned material-guiding face can be formed on this contour. Furthermore, the at least one clearance can penetrate the thruster tongue transversely to the flat sides of the latter.

[0052] In one embodiment of the bristle product manufacturing machine, the thruster tongue has in its front end a longitudinal groove which extends between two narrow sides of the thruster tongue that face away from one another. The longitudinal groove can have a V-shaped cross section, for example. With the aid of the longitudinal groove it is possible to deform fastening anchors in a targeted manner while forming at least one end-proximal anchoring structure. The longitudinal groove in the front end of the thruster tongue can also effect an increase of the filling level of the bristle bundles in the bundle receptacle bores on account of a targeted deformation of the fastening anchors.

[0053] Proposed for achieving the object is also a bristle product having a bristle carrier which has at least one bundle receptacle bore in which a bristle bundle is fastened using a fastening anchor which is preferably composed of plastics material, wherein the fastening anchor has at least one anchoring structure which has been generated by an in particular plastic deformation of the fastening anchor caused during the incorporation of the fastening anchor into the bundle receptacle bore.

[0054] The at least one anchoring structure can be at least partially covered by material of the bristle carrier that has been displaced into the bundle receptacle bore. The fastening anchor, and conjointly with the latter then also the bristle bundle, can be fixed in a form-fitting manner in the bundle receptacle bore by material of the bristle carrier that has been displaced into the bundle receptacle bore. In this way, the bristle bundle can be particularly reliably anchored in the bristle carrier. For high extraction forces it is particularly advantageous when the bristle carrier and the fastening anchor are connected to one another in a materially integral manner, in particular are adhesively bonded and / or welded to one another.

[0055] A subject matter of the invention is also the use of a fastening anchor, composed in particular of plastics material and deformed during the incorporation of a bristle product into a bundle receptacle bore of a bristle carrier, for anchoring a bristle bundle in the bundle receptacle bore. The fastening anchor can have at least one anchoring structure which has been generated by a preferably plastic deformation of the fastening anchor during the incorporation into the bundle receptacle bore. The at least one anchoring structure can be an end-proximal anchoring structure. The fastening anchor in the bundle receptacle bore can be connected to the bristle carrier by way of the anchoring structure.BRIEF DESCRIPTION OF THE DRAWINGS

[0056] The invention will be described in more detail hereunder by means of exemplary embodiments, but is not limited to these exemplary embodiments. Further exemplary embodiments are derived by combining the features of individual or a plurality of claims with one another, and / or by combining individual or a plurality of features of the exemplary embodiments. In the figures:

[0057] FIG. 1 shows a perspective view of a bristle product manufacturing machine having a stuffing tool which has a thruster tongue which is specified to stuff bristle bundles conjointly with fastening anchors into bundle receptacle bores of offered-up bristle carriers;

[0058] FIG. 2 shows a lateral view of a bristle carrier for visualizing the anchoring of a bristle bundle in a bundle receptacle bore of the bristle carrier according to the prior art, wherein a fastening anchor of metal is anchored conjointly with a bristle bundle in the material of the bristle carrier with the aid of a thruster tongue of a stuffing tool;

[0059] FIG. 3 shows the bristle carrier shown in FIG. 2 in a lateral view rotated by 90°;

[0060] FIG. 4 shows a top view of the bristle carrier shown in FIGS. 2 and 3, wherein a fastening anchor in the use position in the bundle receptacle bore is depicted in the lowermost of the three bundle receptacle bores, while the bristle bundle is not illustrated;

[0061] FIG. 5 shows a perspective illustration of the bristle carrier shown in FIGS. 2 to 4, wherein it can be seen in particular on the righthand one of the three bristle bundle bores how the fastening anchor, composed of metal, has penetrated the material of the bristle carrier in the peripheral region of the bundle receptacle bore;

[0062] FIG. 6 shows a lateral view of a bristle carrier of the highly schematically illustrated bristle product in the process of manufacturing the latter according to the method according to the invention, wherein a fastening anchor, composed of plastics material, is stuffed conjointly with a bristle bundle into a bundle receptacle bore of the bristle carrier while being plastically deformed and forming end-proximal anchoring structures for anchoring the bristle bundle;

[0063] FIG. 7 shows the bristle carrier shown in FIG. 6 in a lateral view which is rotated by 90° in comparison to FIG. 6;

[0064] FIG. 8 shows a top view of the bristle carrier shown in FIGS. 6 and 7, wherein it can be seen by means of the two lower bundle receptacle bores how the fastening anchor has been deformed while forming two end-proximal anchoring structures on account of being incorporated into the bundle receptacle bore;

[0065] FIG. 9 shows a perspective illustration of the bristle carrier shown in FIGS. 6 to 8;

[0066] FIG. 10 shows a lateral view of a further bristle carrier of a bristle product in the process of the latter being manufactured according to the method according to the invention, wherein the fastening anchors are additionally fixed in a form-fitting manner in the respective bundle receptacle bore by material of the bristle carrier that has been displaced into the bundle receptacle bores;

[0067] FIG. 11 shows a lateral view of the bristle carrier which is rotated by 90° in comparison to FIG. 10;

[0068] FIG. 12 shows a top view of the bristle carrier shown in FIGS. 10 and 11, wherein, apart from the end-proximal anchoring structures on the fastening anchors at the lowermost bundle receptacle bore that has been deformed during incorporation into the bundle receptacle bores, the material of the bristle carrier that has been displaced from the peripheral regions of the bundle receptacle bores for the form-fitting anchoring within the bundle receptacle bores can be seen above the anchoring structures;

[0069] FIG. 13 shows a perspective illustration of the bristle carrier shown in FIGS. 10 to 12;

[0070] FIG. 14 shows a sectional lateral view of a bristle carrier for visualizing different geometries of bundle receptacle bores;

[0071] FIG. 15 shows a top view of the bristle carrier shown in FIG. 14;

[0072] FIG. 16 shows a fragmented illustration of a first embodiment of a thruster tongue for carrying out the method, wherein the thruster tongue has on its front end a planar end face as a contact face for a fastening anchor;

[0073] FIG. 17 is a fragmented illustration of a thruster tongue which has on its two front-end narrow sides in each case one peeling edge and therebetween a clearance, wherein material from a peripheral region of a bundle receptacle bore can be displaced into the bundle receptacle bore for the form-fitting fixing of a fastening anchor stuffed into the latter with the aid of the peeling edges;

[0074] FIG. 18 shows a further fragmented illustration of a thruster tongue which has, adjacent to its two front-end narrow sides in each case one semi-cylindrical clearance on which one peeling edge is in each case formed on the outside;

[0075] FIG. 19 shows a fragmented illustration of a thruster tongue which has in its front end two semi-cylindrical clearances having material-guiding faces for displacing peeled material from a peripheral region of a bundle receptacle bore in a targeted manner into the bundle receptacle bore, wherein a contact face for a fastening anchor is formed between the two clearances; and

[0076] FIG. 20 shows a fragmented illustration of a thruster tongue which has on its front end a V-shaped longitudinal groove with the aid of which a fastening anchor can be deformed in a targeted manner during incorporation into a bundle receptacle bore of a bristle carrier so as to, for example, increase a filling level of a bristle bundle in the bundle receptacle bore.DETAILED DESCRIPTION

[0077] FIGS. 1 and 6 to 13 and 16 to 20 show at least parts of a bristle product manufacturing machine which as an entity is denoted with the reference sign 1 and which is specified for carrying out the method for manufacturing bristle products 2, explained hereunder. Individual steps of the method are shown in FIGS. 6 to 13. FIGS. 2 to 5 visualize a method of the prior art, in which bristle bundles 5 are fastened in bristle carriers 3 by means of fastening anchors 6 of metal.

[0078] In the method which makes use of the invention, a bristle carrier 3 of a bristle product 2 to be manufactured is provided, said bristle carrier 3 having at least one bundle receptacle bore 4. Subsequently, a bristle bundle 5 is incorporated, specifically pushed, conjointly with a fastening anchor 6 into the bundle receptacle bore 4 and anchored therein by means of the fastening anchor 6. During incorporation into the bundle receptacle bore 4, the fastening anchor 6 is plastically deformed while forming at least one end-proximal anchoring structure 7.

[0079] The fastening anchors 6 shown in FIGS. 6 to 13 have two end-proximal anchoring structures 7 which have been generated by a plastic deformation of the fastening anchor 6.

[0080] The anchoring structures 7 are created when incorporating the respective fastening anchor 6 into the bundle receptacle bore 4, due to contact between the fastening anchor 6 and a bore wall 8 of the bundle receptacle bore 4. The end-proximal anchoring structures 7 are end-proximal thickenings. In this way, the fastening anchor 6 which has been plastically deformed during incorporation into the bundle receptacle bore 4 obtains the approximately bone-shaped design shown, for example, in the righthand bundle receptacle bores 4 of the bristle carriers 3 of FIGS. 9 and 13.

[0081] In the exemplary embodiments of the method shown in FIGS. 6 to 13, the fastening anchors 6 are symmetrically deformed. Depending on the embodiment of the method, it is also possible for the fastening anchors 6 to be asymmetrically deformed during incorporation into the bundle receptacle bores 4.

[0082] Upon incorporation of the fastening anchors 6, the fastening anchors 6 can also be compressed in their respective bundle receptacle bore 4. This can take place, for example, by means of a thruster tongue 9, likewise shown in the Figures, of a stuffing tool 10 of the bristle product manufacturing machine 1. The fastening anchors 6 are also incorporated into the bundle receptacle bores 4 conjointly with the bristle bundles 5 by the thruster tongue 9. Upon incorporation into the bundle receptacle bores 4, the fastening anchors 6 can be compressed and, as a result, a filling level of the bristle bundle 5 placed in the respective bundle receptacle bore 4 can be increased. A filling level of at least 65% or else of at least 72% can be achieved in the process. Furthermore, the fastening anchors 6 upon incorporation into the respective bundle receptacle bore 4 can also be compressed and, as a result, an extraction force of the bristle bundle 5 fixed by the respective fastening anchor 6 can be increased. The extraction force of the bristle bundle 5 herein is the force that has to be applied in order to extract the bristle bundle 5 from the receptacle bore 4 counter to the retaining force of the fastening anchor 6.

[0083] In the variant of the method shown in FIGS. 10 to 13, it is moreover provided that, during incorporation of the fastening anchor 6 into the bundle receptacle bore 4, material of the bristle carrier 3 from a peripheral region of the bundle receptacle bore 4 is displaced into the bundle receptacle bore 4 and in the process is displaced over the fastening anchor 6 placed in the bundle receptacle bore 4 by the already mentioned thruster tongue 9 of the stuffing tool 10 of the bristle product manufacturing machine 1. In the process, the displaced material 19 makes its way over the anchoring structures 7 of the fastening anchor 6, as can be particularly readily seen by means of FIGS. 12 and 13, for example.

[0084] The fastening anchor 6 and the bristle carrier 3 during incorporation of the fastening anchor 6 into the bundle receptacle bore 4 are connected to one another in a materially integral manner, in particular adhesively bonded and / or welded to one another. To this end, it is advantageous when the fastening anchors 6 and the bristle carriers 3 are composed of correspondingly compatible materials which enable a materially integral connection between the fastening anchors 6 and the bristle carriers 3. In order to facilitate the materially integral connection between the bristle carriers 3 and the fastening anchors 6, the respective bristle carrier 3 can be heated prior to and / or upon incorporation of the fastening anchor 6.

[0085] It is highlighted in particular by the top views of a bristle carrier 3, or else by the perspective illustrations of a bristle carrier 3 according to FIGS. 9 and 13, that a length of the respective fastening anchor 6 is larger than a diameter of the respective bundle receptacle bore 4. This facilitates the plastic deformation of the fastening anchors 6 while forming the anchoring structures 7 during incorporation of the fastening anchors 6 into the bundle receptacle bores 4.

[0086] In the method visualized in FIGS. 10 to 13, the fastening anchors 6 are incorporated into the respective bundle receptacle bore 4 by a thruster tongue 9 which on its front end 12 has a width larger than a diameter of the bundle receptacle bore 4 in the bristle carrier 3. This makes it possible that, during incorporation of the fastening anchors 6 into the bundle receptacle bores 4, material from the peripheral region of the bundle receptacle bores is peeled by the thruster tongue 9 and displaced into the bundle receptacle bores 4 so as to in the latter also fix the fastening anchors 6 in a form-fitting manner. The width of the thruster tongue 9 corresponds to a spacing between two narrow sides of a front end 12 of the thruster tongue 9.

[0087] The fastening anchors 6 and the bristle carriers 3 used when carrying out the method are composed of plastics material and preferably have at least some content of recycled plastics material. The fastening anchors 6 are composed of a plastics material which, depending on the specific application, can be softer or harder than a plastics material of which the used bristle carriers 3 are composed. It is advantageous when the fastening anchors 6 and the bristle carriers 3 are composed of materials from the same plastics material family, or even of the same plastics material. This can facilitate a materially integral connection between the fastening anchors 6 and the bristle carriers 3, as has been described above.

[0088] The plastics material of which the fastening anchors 6 and the bristle carriers 3 are composed, can have the hardnesses of at least 60 Shore D to 80 Shore D or 100 Shore D, or optionally even more, as mentioned earlier.

[0089] The plastics material of the fastening anchors 6 and / or of the bristle carriers 3 can have, for example, an E modulus of at least 1000 MPa or of at least 2000 MPa, in particular an E modulus between 1000 MPa and 2000 MPa and 10,000 MPa. The respective plastics material can have a tensile strength of, for example, at least 30 MPa or of at least 45 MPa, preferably a tensile strength between 30 MPa or 45 MPa and 110 MPa.

[0090] For example, polyamide 12 (PA12), polyamide 6 (PA6), polyamide 6.12(PA6.12), polystyrene (PS), polybutylene terephthalate (PBT), polycarbonate (PC), polyoxymethylene (POM), styrene acrylonitrile resin (SAN), acrylonitrile, polyethylene terephthalate (PET), or polypropylene (PP), in particular fiber-reinforced polypropylene, can be used as a plastics material for the bristle carriers 3 and / or the fastening anchors, for example.

[0091] FIG. 14 shows a sectional lateral view of a bristle carrier 3 which has bundle receptacle bores 4 of various geometries.

[0092] All of the bundle receptacle bores 4 herein are designed to be free of anchor tracks. The first two bundle receptacle bores of FIG. 14, when viewed from the left, have a bore wall 8 which in the first portion is initially cylindrical and then is conical and tapers toward the bore base.

[0093] The third bundle receptacle bore 4 from the left in FIG. 14 has an introduction chamfer which is then adjoined by a cylindrical portion of the bore wall 8. In the end portion, the bore wall 8 tapers conically toward the bore base of the bundle receptacle bore 4.

[0094] The third bundle receptacle bore 4 from the right of the bristle carrier 3 of FIG. 14 has a bore wall 8 which first has a conical design tapering toward the bore base, then transitioning into a portion which tapers even more conically toward the bore base. The double arrow plotted at the entry into the bundle receptacle bore 4 visualizes a cone angle which is presently at most 7°.

[0095] The second bundle receptacle bore 4 when viewed from the right in FIG. 14 has a conical bore wall 8 which tapers toward the bore base of the bundle receptacle bore 4 and is moreover of stepped design. The stepped design serves as a retaining structure 13 and facilitates reliable fixing of a fasting anchor 6 in the bundle receptacle bore 4.

[0096] The bundle receptacle bore 4 on the extreme right of the total of six bundle receptacle bores 4 shown in FIG. 14 has a cylindrical bore wall 8 which transitions into a conically tapering end portion. A retaining structure 13 in the form of retaining grooves, which facilitate a form-fitting fixing of a fastening anchor 6 within the bundle receptacle bore 4, is formed in the cylindrical region of the bore wall 8 of this bundle receptacle bore 4.

[0097] When carrying out the method, the bristle bundles 5 conjointly with the fastening anchors 6 can be stuffed into the bundle receptacle bores 4 at a stuffing rate of at least 400 stuffing procedures per minute.

[0098] Even higher stuffing rates of, for example, 600, 800, 1000 or 1200 up to, for example, 1500 stuffing procedures per minute, can be applied when carrying out the method.

[0099] The thruster tongue 9 by which a bristle bundle 5 is incorporated conjointly with a fastening anchor 6 into a bundle receptacle bore 4 can strike the bundle receptacle bore 4 at a speed between, for example, 1.2 m / s and 4.0 m / s, preferably between 1.8 m / s and 3.5 m / s, particularly preferably between 2.2 m / s and 2.8 m / s. It is ensured in this way that the fastening anchor 6 penetrates the bundle receptacle bore 4 with sufficient kinetic energy in order to achieve the desired targeted deformation of the fastening anchor 6 while forming the previously explained anchoring structures 7.

[0100] For carrying out the method, the bristle manufacturing machine 1 thus has the stuffing tool 10 having the thruster tongue 9 in order to incorporate the bristle bundles 5 conjointly with the fastening anchors 6 into the bundle receptacle bores 4 of offered-up bristle carriers 3. FIGS. 16 to 20 show that the thruster tongues 9 depicted therein have on their respective front end 12 on narrow sides that face away from one another in each case at least one peeling edge 14.

[0101] With the aid of the peeling edges 14, material from the peripheral regions of the bundle receptacle bores 4 of the respective bristle carrier 3 can be peeled, and ultimately be displaced into the bundle receptacle bores 4 for the form-fitting fixing of the fastening anchors 6 in the bundle receptacle bores 4, as highlighted in FIGS. 10 to 13. The thruster tongue 9 which is shown in FIG. 17 has on its front end 12, adjacent to the narrow sides of the front end 12, a clearance 15 having material-guiding faces 16. The material-guiding faces 16 are aligned obliquely to a longitudinal axis of the thruster tongue 9, and face the longitudinal axis and also face one another. The material-guiding faces 16 serve to direct material of bristle carriers 3 that has been peeled from the peeling edges 14 into bundle receptacle bores 4. The thruster tongue 9 shown in FIG. 18 has on its front end 12 two clearances 15. The clearances 15 are in each case formed adjacent to one of the peeling edges 14 of this thruster tongue 9 in the front end 12 of the thruster tongue 9, and likewise provide material-guiding faces which enable peeled material of a bristle carrier 3 to be directed in the direction of a bundle receptacle bore 4.

[0102] A planar contact face 17 for a fastening anchor 6 is formed between the two clearances 15 of the thruster tongue 9 shown in FIG. 18. This contact face 17 facilitates the precise introduction of fastening anchors 6 into bundle receptacle bores 4.

[0103] Similar to the thruster tongue 9 shown in FIG. 18, the thruster tongue 9 shown in FIG. 19 likewise has two clearances 15 having material-guiding faces 16 in the front end 12 of the thruster tongue 9. In comparison to the clearances 15 shown in FIG. 18, which penetrate the thruster tongue 9 across its entire thickness from one flat side to the other flat side, thus connect the two flat sides of the thruster tongue to one another, the clearances 15 of the thruster tongue 9 shown in FIG. 19 are laterally closed.

[0104] The thruster tongue 9 shown in FIG. 20 has on its front end 12 a V-shaped longitudinal groove 18. The longitudinal groove 18 is disposed between narrow sides of the thruster tongue 9 that face away from one another, and connects said narrow sides. The V-shaped longitudinal groove 18 enables a filling level of a bristle bundle 5 fixed in the bundle receptacle bore 4 by a fastening anchor 6 to be increased by a targeted compression and further deformation of the fastening anchor 6.

[0105] In this way, a bristle product 2 which comprises a bristle carrier 3 having at least one bundle receptacle bore 4 can be manufactured by the method. A bristle bundle 5 having a fastening anchor 6 of plastics material, which is plastically deformed during incorporation into the bundle receptacle bore 4, is fastened in the bundle receptacle bore 4. The fastening anchor 6 has anchoring structures 7 which have been generated by the plastics deformation and which can be at least partially covered by material of the bristle carrier 3 that has been displaced into the bundle receptacle bore 4, as is highlighted in FIG. 13, for example.

[0106] A subject matter of the method visualized in particular in FIGS. 6 to 13 is the use of a fastening anchor 6 which has been deformed during incorporation into a bundle receptacle bore 4 of a bristle carrier 3 of a bristle product 2 and which is preferably composed of plastics material, for anchoring a bristle bundle 5 in the bundle receptacle bore 4.LIST OF REFERENCE SIGNS1 Bristle product manufacturing machine

[0108] 2 Bristle product

[0109] 3 Bristle carrier

[0110] 4 Bundle receptacle bore

[0111] 5 Bristle bundle

[0112] 6 Fastening anchor

[0113] 7 Anchoring structure

[0114] 8 Bore wall

[0115] 9 Thruster tongue

[0116] 10 Stuffing tool

[0117] 11 Bristle filament

[0118] 12 Front end of 9

[0119] 13 Retaining structure

[0120] 14 Peeling edge

[0121] 15 Clearance

[0122] 16 Material-guiding face

[0123] 17 Contact face

[0124] 18 Longitudinal groove

[0125] 19 Displaced material

Claims

1. A method for manufacturing bristle products (2), the method comprising:providing a bristle carrier (3) with at least one bundle receptacle bore (4);incorporating a bristle bundle (5) conjointly with a fastening anchor (6) into the bundle receptacle bore (4) and anchoring the bristly bundle (5) in the bundle receptacle bore (4) with the fastening anchor (6); anddeforming the fastening anchor (6) during incorporation into the bundle receptacle bore (4) to form at least one end-proximal anchoring structure (7).

2. The method as claimed in claim 1, further comprising at least one of a) generating the at least one anchoring structure (7) during incorporation of the fastening anchor (6) into the bundle receptacle bore (4) due to contact between the fastening anchor (6) and a bore wall (8) of the bundle receptacle bore (4), or generating an end-proximal thickening as the at least one end-proximal anchoring structure (7).

3. The method as claimed in claim 1, wherein the fastening anchor (6) is at least one of a) deformed symmetrically or asymmetrically, or b) plastically deformed while forming the at least one end-proximal anchoring structure (7).

4. The method as claimed in claim 1, further comprising compressing the fastening anchor (6) upon incorporation into the bundle receptacle bore (4) by a thruster tongue (9) of a stuffing tool (10) of a bristle product manufacturing machine (1).

5. The method as claimed in claim 1, further comprising compressing the fastening anchor (6) upon incorporation into the bundle receptacle bore (4) and, as a result, at least one of a) increasing a filling level of the bristle bundle (5) in the bundle receptacle bore (4), or b) increasing an extraction force of the bristle bundle (5).

6. The method as claimed in claim 1, further comprising, during incorporation of the fastening anchor (6) into the bundle receptacle bore (4), displacing material of the bristle carrier (3) by a thruster tongue (9) of a stuffing tool (10) of a bristle product manufacturing machine (1), from a peripheral region of the bundle receptacle bore (4) into the bundle receptacle bore (4) and over the fastening anchor (6).

7. The method as claimed in claim 1, further comprising connecting the fastening anchor (6) and the bristle carrier (3), during incorporation of the fastening anchor (6) into the bundle receptacle bore (4), to one another in a materially integral manner.

8. The method as claimed in claim 1, further comprising heating the bristle carrier (3) at least one of prior to or upon incorporation of the fastening anchor (6).

9. The method as claimed in claim 1, wherein a length of the fastening anchor (6) is larger than a diameter of the bundle receptacle bore (4), and / or wherein the fastening anchor (6) is incorporated into the bundle receptacle bore (4) by a thruster tongue (9) which on a front end (12) thereof has a width larger than a diameter of the bundle receptacle bore (4).

10. The method as claimed in claim 1, wherein at least one of the fastening anchor (6) or the bristle carrier (3) are formed of plastics material.

11. The method as claimed in claim 1, wherein the fastening anchor (6) is formed of a plastics material which is softer or harder than a plastics material of which the bristle carrier (3) is formed.

12. The method as claimed in claim 1, wherein the fastening anchor (6) and the bristle carrier (3) are formed of materials from a same plastics material family, or of a same plastics material.

13. The method as claimed in claim 1, wherein at least one of a) the fastening anchor (6) and / or the bristle carrier (3) are formed of a plastics material having a hardness of at least 60 Shore D, or b) the fastening anchor (6) and the bristle carrier (3) are formed of a plastics material having a comparable hardness.

14. The method as claimed in claim 1, wherein the at least one bundle receptacle bore (4) is at least one of free of a) an anchor track, b) has a cylindrical bore wall (8) or a conical bore wall (8) tapering toward the bore base, or has a bore wall (8) provided with a retaining structure (13).

15. The method as claimed in claim 13, wherein the plastics material of the fastening anchor (6) and / or of the bristle carrier (3) has an E modulus of at least 1000 MPa and a tensile strength of at least 30 MPa and / or the plastics material is polyamide 12 (PA12), polyamide 6 (PA6), polyamide 6.12 (PA6.12), polystyrene (PS), polybutylene terephthalate (PBT), polycarbonate (PC), polyoxymethylene (POM), styrene acrylonitrile resin (SAN), acrylonitrile, polyethylene terephthalate (PET), or polypropylene (PP).

16. The method as claimed in claim 1, further comprising stuffing the fastening anchor (6) and the bristle bundle (5) into the bundle receptacle bore (4) of the bristle carrier (3) by a stuffing tool (10) of a bristle product manufacturing machine (1).

17. The method as claimed in claim 1, further comprising stuffing the bristle bundles (5) and the fastening anchors (6) into the bundle receptacle bores (4) at a stuffing rate of at least 400 stuffing procedures per minute.

18. The method as claimed in claim 1, wherein a thruster tongue (9) by which the bristle bundle (5) and the fastening anchor (6) are incorporated into the bundle receptacle bore (4) strikes the bundle receptacle bore (4) at a speed between 1.2 m / s and 4.0 m / s.

19. A bristle product manufacturing machine (1), comprising a stuffing tool (10) which has a thruster tongue (9) for incorporating bristle bundles (5) and fastening anchors (6) into bundle receptacle bores (4) of offered-up bristle carriers (3).

20. The bristle product manufacturing machine (1) as claimed in claim 19, wherein the thruster tongue (9) has at least one peeling edge (14) which is formed on a narrow side of a front end (12) of the thruster tongue (9).

21. The bristle product manufacturing machine (1) as claimed in claim 20, wherein the thruster tongue (9) has in each case at least one of the peeling edges (14) on each of two sides of the front end (12) that face away from one another.

22. The bristle product manufacturing machine (1) as claimed in claim 19, wherein the thruster tongue (9) has on a front end (12) thereof, at least one clearance (15) having at least one material-guiding face (16), and the material-guiding face (16) is aligned obliquely to a longitudinal axis of the thruster tongue (9), and / or faces the longitudinal axis of the thruster tongue (9).

23. The bristle product manufacturing machine (1) as claimed in claim 22, wherein the at least one clearance (15) has at least one of a concave or a semi-cylindrical contour, and the at least one clearance (15) penetrates the thruster tongue (9) transversely to the flat sides thereof.

24. The bristle product manufacturing machine (1) as claimed in claim 20, wherein the thruster tongue (9) has in a front end (12) thereof a longitudinal groove (18) which extends between two narrow sides of the thruster tongue (9) that face away from one another.

25. A bristle product (2) having a bristle carrier (3) which has at least one bundle receptacle bore (4) in which a bristle bundle (5) is fastened by a fastening anchor (6), wherein the fastening anchor (6) has at least one anchoring structure (7) formed by a deformation of the fastening anchor (6) during incorporation of the fastening anchor (6) into the bundle receptacle bore (4).

26. The bristle product (2) as claimed in claim 25, wherein the at least one anchoring structure (7) is formed by a plastic deformation of the fastening anchor (6) during the incorporation of the fastening anchor (6) into the bundle receptacle bore (4), and / or the at least one anchoring structure (7) of the fastening anchor (6) is at least partially covered by material of the bristle carrier (3) that has been displaced into the bundle receptacle bore (4).

27. The bristle product (2) as claimed in claim 25, wherein the fastening anchor (6) is formed of plastics material.

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