METHOD FOR MANUFACTURING BRUSHS AND BRUSH MANUFACTURING DEVICE

Description

[0001] The invention relates to a method for manufacturing a brush, in particular a toothbrush, with a bristle carrier and a bristle covering made of bristle filaments, as well as a brush manufacturing device for manufacturing brushes, in particular toothbrushes.

[0002] The publication WO 2018 177 594 A1 discloses a pressure plate unit for a brush manufacturing device for the thermal pressing of at least one bristle into an anchoring opening of a bristle carrier. The pressure plate unit comprises an electrically heated pressure plate and a funnel plate provided on the back, between which an insulating layer is placed.

[0003] German patent application DE 198 53 030 A1 discloses a method for manufacturing bristle products, in which a bristle carrier made of thermoplastic material with receptacles for the bristles is produced, the bristles are inserted into the receptacles with their attachment-side ends and are attached to the bristle carrier by applying mechanical forces, wherein, after the bristles have been inserted into the receptacles, the bristle carrier is subjected to pressure on its surface having the receptacles in such a way that the bristle carrier is compressed, reducing its height, and the mass of the bristle carrier is displaced laterally around the attachment-side ends of the bristles, narrowing the receptacles.

[0004] DE 34 03 341 A1 discloses a method for joining bristles to a bristle carrier, wherein the bristles are each made of thermoplastic material, by melting the bristles at one end and the bristle carrier at its bristle-receiving side, then bringing the bristles and bristle carrier together and, if necessary, holding them in this position until the melt solidifies. During this process, the bristle ends are heated such that the oriented, elongated molecules revert to their non-oriented, coiled molecular form, thereby creating a thickening at the bristle end. Finally, the bristles are pressed into the molten bristle carrier with their thickened end until the melt flows back together behind the thickened end.

[0005] In brush manufacturing, various methods for connecting the brush head to the bristle filaments are known from practical experience. For example, it is known to attach the bristle filaments of the bristle pack, grouped into bristle bundles, using so-called anchors in the mounting holes of the brush head. The bristle bundles are punched into the mounting holes together with the anchors. However, for the bristle bundles to be attached using anchors in the mounting holes, the brush head must have a certain material thickness, which should not be undercut. If the brush head has too little material thickness, the anchor technology for attaching the bristle bundles can no longer be used reliably and effectively, as there is then too little material in which to fix the anchors.

[0006] Alternatively, methods for anchorless attachment of bristle filaments and bristle filament bundles to bristle carriers are also known. In these methods, bristle filaments and bristle carriers can be bonded together, for example, by means of a material bond. Here, the bristle filaments and the bristle carrier are at least partially melted and then joined together. However, this approach also reaches its limits with thin-walled bristle carriers, as it is difficult to guarantee the dimensional accuracy of thin-walled bristle carriers using this method.

[0007] The object of the invention is to provide a method for manufacturing brushes, in particular toothbrushes, and a corresponding brush manufacturing device with improved performance characteristics, in which the processing of thin-walled bristle carriers is also reliably possible.

[0008] To solve the problem, a method for manufacturing a brush, in particular a toothbrush, is first proposed, which includes the means and features of the independent claim directed to such a method. To solve the problem, a method for manufacturing a brush, in particular a toothbrush, with a bristle carrier and a bristle arrangement made of bristle filaments is thus proposed, wherein the bristle carrier and the attachment-side ends of the bristle filaments of the bristle arrangement are heated, and the attachment-side ends of the bristle filaments are melted in contrast to the bristle carrier, after which the bristle carrier and the bristle filaments of the bristle arrangement are joined together, wherein the bristle carrier and the bristle filaments of the bristle arrangement are bonded together in a metallurgical manner.

[0009] The process enables a reliable bond between the bristle filaments of the bristle assembly and the bristle carrier of the brush, without requiring the bristle carrier to be melted. This can improve the dimensional stability of the bristle carrier and thus the quality of the manufactured brush. Therefore, the process according to the invention is particularly suitable for the production of brushes with delicate and thin-walled bristle carriers, which, for example, could not previously be produced using an anchor technology.

[0010] The invention is based on the finding that for a reliable and preferably metallurgical bond between the bristle filaments of the bristle assembly and the bristle carrier of a brush, the bristle carrier does not need to be melted. Rather, it is sufficient to heat only the attachment-side ends of the bristle filaments of the bristle assembly until they melt. It is enough to simply heat the bristle carrier to prepare it for bonding with the bristle filaments of the bristle assembly. It is not necessary to melt even a portion of the bristle carrier.

[0011] Preferably, the bristle carrier and the attachment-side ends of the bristle filaments of the bristle assembly are heated to different temperatures. This can promote an energy-efficient implementation of the process, particularly if the bristle carrier is heated to a lower temperature than the attachment-side ends of the bristle filaments.

[0012] According to the invention, the bristle carrier and the bristle filaments of the bristle assembly are bonded together in a material-bonded manner. In this way, the bristle filaments of the bristle assembly are attached to the bristle carrier of the bristle assembly with particular reliability and strength. Furthermore, with this type of attachment, no structures on the bristle carrier are necessary for, for example, a form-fit connection between the bristle carrier and the bristle assembly. This can simplify the manufacture of the bristle carriers.

[0013] It is advantageous if the bristle carrier and the bristle filaments are made of materials compatible with each other for a material-bonded connection, or of the same material compatible with each other for a material-bonded connection.

[0014] To produce a particularly environmentally friendly brush, it can be advantageous if the bristle carrier and the bristle filaments, preferably all parts of the brush, are made of a biodegradable material, in particular a biodegradable plastic, for example polyamide, preferably PA 10.10 or PA 12. The use of such a material for the production of the bristle carrier and the bristle filaments promotes environmentally friendly disposal or the simplest possible recycling of the brush.

[0015] Particularly when the bristle filaments and the bristle carrier are made of different materials, it may be advantageous to simplify and / or improve the connection between the bristle filaments and the bristle carrier by using bristle filaments and / or bristle carriers that contain at least one additive that acts as an adhesion promoter.

[0016] Especially when the bristle filaments and the bristle carrier are made of different materials, applying a primer as an adhesion promoter to the bristle filaments and / or the bristle carrier before bonding them can simplify and / or improve the connection between the two materials. The primer can act as an adhesion promoter and facilitate the creation of a reliable bond between the bristle filaments and the bristle carrier. A lacquer can be applied as a primer.

[0017] A primer and / or additive can be, for example, an adhesion promoter for plastics, especially polypropylene. A PP-g-MAH type adhesion promoter can be used as a primer and / or additive. Examples of suitable products include Priex 20097, Polybond 3200, Exxelor PO 1020, Scona TPPP 8012, Scona TPPP 9012, Scona TPPP 9112, Licocene PP MA 6252, and / or Licocene PP MA 7452.

[0018] For joining bristle filaments and / or bristle carriers made of different plastics, for example, bristle filaments made of polyamide (PA) or polybutylene terephthalate (PBT) and bristle carriers made of polypropylene (PP), it can be advantageous to use additives and / or primers that increase the graft content of the bond, particularly the plastic bond, between the bristle filaments and the bristle carrier. Preferably, the joining partner, i.e., the bristle carrier or the bristle filaments, which are made of polypropylene, is modified by an additive and / or a primer. This can preferably be the bristle carrier, as it is often made of polypropylene.

[0019] With the primers and / or additives mentioned above, it may be possible to connect a bristle carrier, made of polypropylene, for example, with bristle filaments made of another material, such as polyamide or polybutylene terephthalate, without having to melt the bristle carrier.

[0020] The use of an additive as an adhesion promoter can be particularly advantageous. An additive can be added to, or already be present in, the raw material from which the bristle carrier and / or bristle filaments are made. This makes it possible to produce the bristle carrier and / or bristle filaments directly from the raw material modified with the additive, for example, by extrusion and / or injection molding. A separate process step for subsequently applying a primer as an adhesion promoter to the bristle carrier and / or bristle filaments can thus be avoided. This facilitates the economical implementation of the process.

[0021] In one embodiment of the brush to be manufactured, the bristle carrier and / or the bristle filaments can be made, for example, of polypropylene (PP), polybutylene terephthalate (PBT), and / or polyamide (PA). By using a previously mentioned adhesion promoter, i.e., an additive and / or a primer, during the process, the bristle carrier and the bristle filaments can be bonded together even if their materials are not actually well suited for a bond, particularly a weld or adhesive bond.

[0022] A material-bonded connection within the meaning of the invention can in particular be a welded connection.

[0023] By melting the attachment ends of the bristle filaments, at least one carrier plate can be created, consisting of the melted filament material from these attachment ends. This carrier plate can connect bristle filaments from one or more bristle bundles. A single carrier plate can also connect multiple bristle bundles or all of the bristle bundles. Thus, by melting the attachment ends, the bristle filaments of one, more, or all of the bristle bundles can be interconnected before being attached to the bristle carrier. This can simplify the manufacturing of the brush and, in particular, the attachment of the bristle bundle to the bristle carrier.

[0024] In a preferred embodiment of the method, the bristle carrier is heated to a temperature below its melting point. This ensures that the bristle carrier does not melt, even partially, in any area. This prevents unwanted deformation of the bristle carrier when it is joined to the bristle filaments and ensures the dimensional stability of the bristle carrier during the process.

[0025] Especially when the bristle filaments and the bristle carrier are made of the same material, the bristle carrier can be heated to a lower temperature than the attachment ends of the bristle filaments. This allows the attachment ends of the bristle filaments to melt, while the bristle carrier is only heated, not melted. This approach is particularly energy-efficient.

[0026] To join the bristle filaments to the bristle carrier, it can be advantageous to insert the bristle carrier into a mold. The mold can have a mold wall that surrounds the bristle carrier, in particular a receiving recess in the bristle carrier for the attachment ends of the bristle filaments, at least partially. The mold wall can guide the molten filament material from the attachment ends of the bristle filaments during the joining of the bristle filaments to the bristle carrier in such a way that the molten filament material does not flow over the outer circumference of the bristle carrier. This approach promotes the maintenance of a smooth and even outer contour of the bristle carrier. Furthermore, this variant of the process can be particularly well suited for the production of brushes with especially thin-walled bristle carriers.To connect the bristle filaments to a thin-walled bristle carrier, using a mold during the connection process can be advantageous for supporting the carrier. Furthermore, the mold can improve the dimensional stability of the bristle carrier during the connection process.

[0027] If the bristle carrier has a receiving recess in which the bristle filaments are attached to the bristle carrier with their fastening ends, this receiving recess can be filled with the molten filament material from the fastening ends of the bristle filaments, thus reinforcing and completing the bristle carrier. This variant of the bristle carrier, or of the method for manufacturing a brush, allows for the production of brushes with particularly compact bristle carriers.

[0028] An edge of the bristle carrier, which laterally limits the aforementioned receiving recess, can then be supported by the shape and, in particular, its shape wall.

[0029] The bristle filaments can be pressed against the heated bristle carrier with their molten, attachment-side ends, or vice versa, by pressing the heated bristle carrier against the molten ends of the bristle filaments. A press from a brush-making device can be used for this purpose. The molten, attachment-side ends are also still warm and preferably still molten, or at least still soft and plastic, so that a good bond can be established between the bristle carrier and the bristle filaments.

[0030] To cure the bond formed between the bristle carrier and the bristle filaments as quickly as possible after the bristle carrier has been joined to the bristle filaments, the bristle carrier can be cooled after joining. This can be done using a cooling device of a brush manufacturing apparatus, which will be described in more detail below, and / or via the previously mentioned mold.

[0031] To solve the problem, a brush manufacturing device for producing brushes, in particular toothbrushes, is also proposed, which has the features of the independent claim directed to such a brush manufacturing device. According to the invention, the brush manufacturing device is thus configured to carry out a method according to one of the claims directed to such a method.

[0032] According to the invention, the brush manufacturing device has a heating device which is configured to heat the fastening-side ends of bristle filaments of a bristle arrangement and a bristle carrier with which the bristle filaments of the bristle arrangement are to be connected, and to melt the fastening-side ends of the bristle filaments in contrast to the bristle carrier.

[0033] With the brush manufacturing device, the fastening ends of the bristle filaments can be melted by heating, while the bristle carrier is only heated but not melted and therefore remains dimensionally stable.

[0034] In a preferred embodiment of the brush manufacturing device, the heating device comprises two heating surfaces. Of these two heating surfaces, a first heating surface is provided for heating the attachment-side ends of bristle filaments of a bristle assembly of a brush to be manufactured, and a second heating surface is provided for heating a bristle carrier of the brush to which the bristle filaments of the bristle assembly are to be attached. In this embodiment of the brush manufacturing device, the heating device is configured, by means of its two heating surfaces, to heat the attachment-side ends of the bristle filaments and the bristle carrier, and to melt the attachment-side ends of the bristle filaments, unlike the bristle carrier.

[0035] Preferably, the heating device, particularly by virtue of its two heating surfaces, is configured to heat the fastening ends of the bristle filaments and the bristle carrier to different temperatures. This is advantageous when the bristle filaments and the bristle carrier have the same melting point and only the fastening ends of the bristle filaments are to be melted.

[0036] The heating device can, for example, be configured to heat the heating surfaces to different temperatures. In this way, it is possible to heat the fastening ends of the bristle filaments on the one hand and the bristle carrier of the brush being manufactured on the other hand to different temperatures, thus carrying out the previously described process in detail.

[0037] The heating device can be configured, in particular, to heat the first heating surface to a temperature sufficient to melt the attachment ends of the bristle filaments. The heating device can further be configured to heat the second heating surface to a temperature sufficient to heat the bristle carrier to a temperature below its melting point. In this way, it is ensured that, when using the brush manufacturing device, the attachment ends of the bristle filaments are melted, while the bristle carrier is heated but not melted, thus remaining dimensionally stable and retaining its shape.

[0038] In one embodiment of the brush manufacturing device, the distance between the first heating surface and a position specified by the device, in which the fastening ends of the bristle filaments are held for heating and melting, is greater than the distance between the second heating surface and a position specified by the device, in which the bristle carrier is held for heating. With this variant of the brush manufacturing device, it is therefore possible to heat both heating surfaces to the same temperature.The different distances between the positions specified by the brush manufacturing device, in which the fastening-side ends of the bristle filaments on the one hand and the bristle carrier on the other hand are held, and the respective heating surface ensure the desired, possibly different, heating of the fastening-side ends of the bristle filaments and the bristle carrier.

[0039] In a particularly compact embodiment of the brush manufacturing device, the two heating surfaces are arranged on a common heating element, preferably on opposite sides of the common heating element, and ideally on sides facing away from each other. In this way, the heating element can be positioned between the bristle carriers held on one side and the fastening ends of the bristle filaments held on the other.

[0040] To carry out the previously described method, it may be advantageous if the heating device is configured for the preferably independent control of the temperatures of the two heating surfaces. The heating device may include a control unit and at least one temperature sensor for detecting and controlling the temperature of at least one of the two heating surfaces. Preferably, at least one temperature sensor is assigned to each heating surface. In this way, it is possible to detect and individually monitor the temperatures of the two heating surfaces of the heating device independently of one another and, if necessary, to adjust them using the control unit of the brush manufacturing device should a deviation between the actual temperature of the heating surfaces and a target temperature of the heating surfaces be detected.

[0041] The brush manufacturing device can have a form for receiving and supporting the bristle carrier during the joining of the bristle carrier to the bristle filaments of the bristle assembly. The advantages of such a form have already been explained in the context of the process. The use of such a form is particularly suitable for processing thin-walled bristle carriers.

[0042] The brush manufacturing device can include a dispensing device for applying primer to bristle filaments and / or bristle carriers. Primer can thus be applied to the bristle filaments and / or bristle carriers before they are bonded to them. The primer can promote the formation of a reliable bond between the bristle filaments and bristle carriers.

[0043] The brush manufacturing device can further include a filament holder for holding, in particular by clamping, the bristle filaments of the bristle assembly. With the aid of the filament holder, it is possible to hold the filaments of the bristle assembly with their attachment ends in the previously mentioned position on the first heating surface of the heating device in order to heat and ultimately melt the attachment ends of the bristle filaments. The filament holder can also be used to guide the bristle filaments of the bristle assembly during the bonding of the bristle filaments to the bristle assembly. In this process, the bristle filaments, particularly via a cleaning side of the bristle assembly, can be axially acted upon with respect to their longitudinal axes and pressed against the heated bristle carrier.For this purpose, the brush-making device can include a press configured to press bristle filaments of the bristle assembly with their molten, attachment-side ends against a heated bristle carrier, thus bonding the bristle filaments to the bristle carrier. The press can also be configured to press a heated bristle carrier against molten ends of bristle filaments, thus bonding the bristle carrier and the bristle filaments together.

[0044] Furthermore, it is advantageous if the filament holder has a hole pattern of preferably through holes designed as receiving holes for the bristle filaments and / or bristle bundles of the bristle covering made of bristle filaments.

[0045] If the receiving holes of the filament holder are designed as through holes, the bristle filaments and / or bristle bundles located in the receiving holes can be pushed out of the receiving holes in an axial movement with respect to their longitudinal axes in order to press the melted fastening-side ends of the bristle filaments against the heated bristle carrier and to connect the bristle filaments to the bristle carrier.

[0046] The filament holder can, for example, be designed as a cassette and / or be transportable between individual stations of the brush manufacturing device.

[0047] The filament holder can also feature a clamping mechanism that secures the bristle filaments of the bristle assembly in the holder's receiving holes. During the heating and melting of the bristle filament ends, the clamping mechanism can be closed, ensuring that the bristle filaments are reliably and accurately held in position within the filament holder.

[0048] Once the attachment ends of the bristle filaments have melted and the bristle carrier has heated up, the filament holder clamp can be opened. With the filament holder clamp open, the bristle filaments of the bristle assembly, with their melted attachment ends, can be pressed against the heated bristle carrier, for example, using the previously mentioned pusher of the brush-making device, to bond the bristle filaments to the bristle carrier.

[0049] To reduce the processing time required to bond and, more importantly, cure the bristle filaments and the bristle pack, it is advantageous for the brush manufacturing device to include a cooling system. This cooling system can be designed to cool the bristle carrier after the bristle filaments have been bonded to it. For example, the cooling system can act on the bristle carrier placed within the brush manufacturing device via the previously mentioned design.

[0050] The brush-making device may further comprise a magazine for holding a supply of loose bristle filaments. Downstream of the magazine, the brush-making device may include a bundling device configured to extract bristle filament bundles from the supply of loose bristle filaments contained in the magazine and to provide them for assembling a bristle arrangement.

[0051] The brush manufacturing device may further include a bundle forming unit which is designed to transform the bristle bundles taken from the bristle magazine into a target shape desired for the manufacture of the brushes.

[0052] From the bundle forming unit, the bristle bundles can be transferred to the previously mentioned filament holder. In the filament holder, the bristle bundles can then be held in an arrangement relative to each other that they will later have in the bristle configuration of the brush being manufactured.

[0053] The invention is explained in more detail below with reference to an exemplary embodiment. The invention is not limited to the embodiment shown in the figures. Further embodiments of the invention result from combining the features of individual claims and / or from combining the features of the illustrated embodiment. The figures show: Figures 1 to 4 show different views of a brush designed as a toothbrush, showing that a bristle carrier of the brush has a receiving recess for receiving the attachment-side ends of bristle filaments of a bristle arrangement of the brush, which is filled with melted filament material after the bristle filaments are attached to the bristle carrier. Figure 5 shows a perspective view of the bristle arrangement of the bristles in the Figures 1 to 4 The brush shown after melting the fastening-side ends of its bristle filaments, Figures 6 to 9 different views of another embodiment of a comparable brush, the receiving recess for receiving a bristle arrangement is penetrated by a structure of stiffening ribs, Figure 10 a perspective view of the bristle arrangement of the Figures 6 to 9The brush shown after melting the fastening-side ends of its bristle filaments, Figure 11 a schematic representation of parts of a brush-making apparatus for producing the brushes shown in the previous figures, and Figures 12 to 14 further parts of the brush-making apparatus to illustrate a method for producing the brushes shown in the Figures 1 to 10 Brushes shown at least in part.

[0054] The Figures 1-5 Figures 6-10 show at least parts of a brush, designated as a whole by 1, which is designed as a toothbrush. Unless explicitly stated otherwise, the following descriptions refer to both embodiments of brush 1 shown in the figures.

[0055] The brush 1 has a bristle carrier 2, namely a brush head, to which a bristle arrangement 3 made of bristle filaments 4 is attached.

[0056] For example, the Figure 1 and 6To illustrate that the brush 1 has a receiving recess 5 on its bristle carrier 2. Bristle filaments 4 are attached to the receiving recess 5 with their fastening ends 6. The receiving recess 5 is filled with filament material melted onto the fastening ends 6 of the bristle filaments 4 on the finished brush 1. The bristle carrier 2, namely the brush head, is connected to a handle 8 of the brush 1 via a neck section 7 of the brush 1. For example, the Figure 1 and 4 The figures show that the bristle carrier 2 has its smallest measurable material thickness in the area of ​​the receiving recess 5 before the bristle filaments 4 are attached. In adjacent areas, the bristle carrier 2 is thicker. This is shown, for example, by the Figures 4 and 9, in which the material thickness E in the area of ​​the receiving recess 5 and the material thickness D in adjacent sections of the bristle carrier 2 are illustrated by a dimension.

[0057] The bristle carrier 2 is reinforced by the melted filament material of the bristle filaments 4 after the bristle filaments 4 have been attached to the bristle carrier 2 in the area of ​​its filled receiving recess 5.

[0058] In the Figures 6-10 In the illustrated embodiment of a brush 1, stiffening ribs 9 are formed within the receiving recess 5, which give the bristle carrier 2 good stability despite its comparatively small material thickness E in the area of ​​the receiving recess 5. This can simplify the handling of the bristle carrier 2 during the manufacture of the brush 1.

[0059] The stiffening ribs 9 within the receiving recess 5 segment the receiving recess 5. The arrangement of the stiffening ribs 9 creates a pattern of individual recesses which, in terms of shape and arrangement, correspond to the cross-sectional shape and arrangement of bristle bundles 10 of the bristle covering 3, which consist of the bristle filaments 4.

[0060] The Figures 5 and 10 illustrate that the melted filament material of the respective bristle arrangement 3 forms at least one carrier plate 11 which fills the receiving recess 5 of the respective brush 1 after the bristle filaments 4 have been attached to the bristle carrier 2.

[0061] The carrier plate 11 allows the bristle filaments 4, or the bristle bundles 10 formed from the bristle filaments 4, to be interconnected. This is particularly relevant in the case of the Figure 5 The case is shown in the carrier plate 11.

[0062] At the in Figure 10 In the bristle arrangement 3 shown, the bristle filaments 4 within a bristle bundle 10 are connected by a carrier plate 11. Each of the eight bristle bundles 10 thus has a carrier plate 11.

[0063] The carrier plate 11 fills the receiving recess 5 in such a way that a surface 12 of the carrier plate 11 is flush with a brush surface 13 of the brush 1 adjacent to the receiving recess 5 and the bristle arrangement 3. The multiple carrier plates 11 of the assembly also fill the receiving recess 5 in a similar manner. Figure 10 The bristle arrangement shown 3 includes the parts of the receiving recess 5 segmented by the stiffening ribs 9 in the Figures 6 to 9 The bristle carrier 2 shown is also shown. There, too, surfaces 12 of the carrier plates 11 are flush with a brush surface 13 of the brush 1 surrounding the receiving recess 5.

[0064] The bristle filaments 4 and the bristle carrier 2, as well as the neck section 7 and the handle 8 of the brush 1, are made of the same material, which also allows a material-bonded connection between the bristle filaments 4 and the bristle carrier 2.

[0065] The brushes 1 shown in the figures are therefore so-called single-material brushes. Since a biodegradable plastic, for example polyamide, preferably PA 10.10 or PA 12, is used as the material for the manufacture of the bristle carrier 2, the neck section 7 and the handle 8 as well as the bristle filaments 4 of the bristle arrangement 3 of the brush 1, the brush 1 is particularly environmentally friendly and can be easily recycled.

[0066] The bristle filaments 4 and the bristle carrier 2, which are attached in the receiving recess 5, form a materially homogeneous, monolithic unit after their connection and are materially bonded to each other.

[0067] The bristle carrier 2 has a rim 14 that laterally limits the receiving recess 5. The rim 14 serves to guide the molten filament material during the connection of the bristle filaments 4 to the bristle carrier 2 in such a way that the receiving recess 5 is filled with the molten filament material of the attachment-side ends 6 of the bristle filaments 4.

[0068] In the rim 14, several recesses 15 are formed, which are preferably filled flush with adjacent rim sections by the molten filament material of the fastening-side ends 6 of the bristle filaments 4. This is illustrated, for example, by Figure 3 , which shows a top view of the bristle carrier 2 designed as a brush head of a brush 1.

[0069] This illustration shows that the recesses 15 in the edge 14 are almost completely filled with the melted filament material of the fastening-side ends 6 of the bristle filaments 4.

[0070] Figures 3 and 8 show that the bristle arrangement 3 on the finished toothbrush is located in an area where the bristle arrangement 3 is adjacent to the edge 14 of the bristle carrier. 2, which limits the receiving recess 5, is arranged, for example, at a distance A of 0.5 mm to 3 mm from the circumference of the bristle carrier 2. In this case, the distance A also defines the distance of the bristle bundles 10 from the circumference of the bristle carrier. 2.

[0071] Figures 3 and 8The figures also show that the molten filament material, and thus the carrier plate 11, can have a distance B to the circumference of the bristle carrier 2 of, for example, 0.3 mm to 2 mm where it is surrounded by the edge 14 of the bristle carrier 2. In this case, the distance B also defines the edge thickness of the edge 14 of the bristle carrier. 2, which limits the receiving recess 5 and rests against the support plate 11.

[0072] Figures 3 and 8Furthermore, it is shown that the molten filament material, and thus the carrier plate 11, can have a distance C from the circumference of the bristle carrier 2 of, for example, 0 mm to 2 mm in the area of ​​a recess 15 in a rim 14 surrounding the receiving recess 5 of the bristle carrier 2. The molten filament material forming the carrier plate 11 can therefore extend completely to the outside in the area of ​​a recess 15 in the rim 14, filling the recess 15 and forming a flush finish with adjacent rim sections.

[0073] Figures 4 and 9 The study shows that the bristle carrier 2 can have a material thickness D of 2 mm to 6 mm at its edge and after the bristle filaments 4 have been attached to the bristle carrier 6. The material thickness D defines the head thickness of the bristle carrier.

[0074] Figures 4 and 9Furthermore, it shows that the material thickness E in the area of ​​the receiving recess 5 before the bristle filaments 4 are attached to the bristle carrier 2 can be, for example, 1 mm to 4 mm in toothbrushes. The difference between the dimensions D and E then defines the height of the rim 14 above the receiving recess 5.

[0075] The Figures 11-14 illustrate a process for manufacturing a brush 1, as used in the Figures 1-9 at least partially depicted. Figure 12 This shows that first, the attachment-side ends 6 of the bristle filaments 4 and the bristle carrier 2 are heated to connect the bristle filaments 4 to the bristle carrier 2. In this process, the attachment-side ends 6 of the bristle filaments 4 are melted, unlike the bristle carrier 2. Subsequently, the bristle carrier 2 and the bristle filaments 4 of the bristle assembly 3 are joined together.

[0076] The previously mentioned receiving recess 5 of the bristle carrier 2 is filled by molten filament material from the attachment-side ends 6 of the bristle filaments 4 when the bristle filaments 4 are attached to the bristle carrier 2. Figure 12 further shows that not only the fastening-side ends 6 of the bristle filaments 4, but also the bristle carrier 2 in the area of ​​its receiving recess 5 is heated without contact by means of thermal radiation.

[0077] The attachment ends 6 of the bristle filaments 4 and the bristle carrier 2 are heated to different temperatures and bonded together. Specifically, the attachment ends 6 of the bristle filaments 4 are heated to a higher temperature than the bristle carrier 2. While the attachment ends 6 of the bristle filaments 4 are heated to the point of melting, the temperature to which the bristle carrier 2 is heated in the area of ​​its receiving recess 5 is chosen to be lower, so that the bristle carrier 2 does not melt. The temperature to which the bristle carrier 2 is heated is below its melting point. After being attached to the bristle carrier 2, the bristle filaments 4 and the bristle carrier 2 are bonded together and form the previously mentioned homogeneous, monolithic unit.This is possible because the bristle carrier 2 and the bristle filaments 4 are made of the same material, which is compatible with each other for a material-bonded connection.

[0078] To simplify and / or improve the bond between the bristle filaments 4 and the bristle carrier 2, the bristle filaments 4 and / or the bristle carrier 2 contain at least one additive that acts as an adhesion promoter. Furthermore, a primer can be applied to the bristle filaments 4 and / or the bristle carrier 2 as an adhesion promoter before bonding them to the bristle carrier 3.

[0079] A primer applied to the bristle carrier 2 and / or the bristle filaments 4, and / or an additive, for example, which may be mixed into the material of which the bristle carrier 2 and / or the bristle filaments 4 are made, can simplify the production of a reliable bond between the bristle filaments 4 and the bristle carrier 2.

[0080] The use of additives and / or primers that increase the graft content of the bond, particularly the plastic bond between the bristle filaments 4 and the bristle carrier 2, is advantageous. This allows bristle carriers 2 and bristle filaments 4 made of different materials to be reliably joined using the described method. For example, additives and / or primers can be used to join bristle carriers 2 made of polypropylene to bristle filaments 4 made of polyamide or polybutylene terephthalate.

[0081] In carrying out the process, at least one carrier plate 11 is produced by melting the fastening-side ends 6 of the bristle filaments 4, which connects the bristle filaments 4 of one or more bristle bundles 10 and / or several bristle bundles 10 or all bristle bundles 10 of the bristle arrangement 3 together.

[0082] The recesses 15 in the edge 14 of the bristle carrier 2, which laterally limits the receiving recess 5, are preferably filled flush with adjacent edge sections by the filament material of the fastening-side ends 6 of the bristle filaments 4 when attaching the bristle filaments 4 to the bristle carrier 2.

[0083] The bristle carrier 2 is inserted into a mold 16 to secure the bristle filaments 4 in the receiving recess 5. The mold 16 has a mold wall 17 that laterally surrounds the receiving recess 5 of the bristle carrier 2 in such a way that the edge 14 of the bristle carrier 2, which laterally limits the receiving recess 5, is laterally supported.

[0084] The bristle carrier 2 is according to Figure 13The bristle filaments 4 and the bristle carrier 2 are inserted into the mold 16 after the fastening ends 6 have been heated. The bristle carrier 2 is inserted using a lifting device 36 of a brush manufacturing device 18, which will be described in more detail below.

[0085] After the bristle filaments 4 are attached to the bristle carrier 2 and after the receiving recess 5 is filled with the filament material from the attachment ends 6 of the bristle filaments 4, the bristle carrier 2 is cooled via the mold 16. This causes a bond to harden between the bristle filaments 4 and the bristle carrier 2.

[0086] To carry out the process, a brush manufacturing device designated as 18 is used. The brush manufacturing device 18 has a heating device 19. The heating device 19 comprises two heating surfaces 20 and 21, of which a first heating surface 20 is provided for heating and melting the attachment-side ends 6 of bristle filaments 4 and a second heating surface 21 for heating a bristle carrier 2. The heating surfaces 20 and 21 transfer the heat to the bristle filaments 4 and the bristle carrier 2, respectively, by means of thermal radiation.

[0087] The heating device 19, with its two heating surfaces 20 and 21, is designed to heat the fastening ends 6 of the bristle filaments 4 and the bristle carrier 2, melting the fastening ends 6 in contrast to the bristle carrier 2. The bristle carrier 2 remains dimensionally stable because it is not heated to the point of melting.

[0088] The heating device 19 is designed to heat the two heating surfaces 20 and 21, and via these the attachment-side ends 6 of the bristle filaments and the bristle carrier 2 in the area of ​​its receiving recess 5, to different temperatures. The heating surface 20 can be heated to a temperature sufficient to melt the attachment-side ends 6 of the bristle filaments 3 by means of thermal radiation.

[0089] The two heating surfaces 20 and 21 are arranged on a common heating element 22 and are located on different sides of the heating element 22, namely on opposite sides.

[0090] In this way it is possible to place the heating element 22 in its Figure 12to position the bristle carrier 2 and bristle filaments 4 in the position shown, in order to heat the fastening-side ends 6 of the bristle filaments 4 via the heating surface 20 and the bristle carrier 2 via the heating surface 21.

[0091] The heating device 19 is designed for independent control of the temperatures of the two heating surfaces 20 and 21. For the purpose of detecting and controlling the temperatures of the two heating surfaces 20 and 21, the heating device 19 includes at least one temperature sensor 23 for each of the heating surfaces 20 and 21.

[0092] The temperature sensors 23 enable the temperature of the heating surfaces 20 and 21 to be measured, thus allowing the temperature of both surfaces to be controlled to a target temperature. To control the temperature of the heating surfaces 20 and 21, the heating device 19 is equipped with a corresponding control unit 24. The control unit 24 is connected to the temperature sensors 23 and can adjust the temperature of the heating surfaces 20 and 21 based on the deviation of the actual temperature from the target temperature of the heating surfaces 20 and 21, as detected by the temperature sensors 23.

[0093] The previously mentioned form 16 is part of the brush manufacturing device 18. The form 16 serves to receive and support the bristle carrier 2 during the attachment of the bristle filaments 4 to the bristle carrier 2. To attach the bristle filaments 4 in the receiving recess 5, the bristle carrier 2 is lowered into the form 16 by the lifting device 36 of the brush manufacturing device 18 after heating and melting the attachment-side ends 6 of the bristle filaments 4 and after heating the bristle carrier 2 without melting it.

[0094] The brush manufacturing device 18 also includes a profiling device 25. The profiling device 25 is in Figure 11 as well as in parts in the Figures 12 and 13 shown. The profiling device 25 is used to profile the bristle arrangement 3 of the brush 1 to be manufactured.

[0095] The profiling device 25 has a profiling tool 26 for profiling a cleaning side 27 of the bristle assembly 3 and a counter-profiling tool 28 for supporting and profiling a fastening side 29 of the bristle assembly 3.

[0096] The functionality of the profiling device 25 is described, for example, from Figure 11 As can be seen, the profiling tool 26, with its shaping, convex surface, is moved against the cleaning side 27 of the bristle assembly 3. This causes the bristle filaments 4 to be axially displaced with respect to their longitudinal axis according to the shape of the profiling tool 26. The counter-profiling tool 28, which is positioned against the mounting side 29 of the bristle assembly 3 and whose surface has a contour corresponding to the target contour of the bristle assembly 3 on its cleaning side 27 and is concave in shape, supports and shapes the bristle filaments 4.

[0097] The different protrusion of the bristle filaments 4 on the attachment side 29 of the bristle arrangement 3 is equalized when the attachment-side ends 6 of the bristle filaments 4 are melted to attach the bristle filaments 4 to the bristle carrier 2 of a brush 1 to be manufactured.

[0098] Figure 11Figure 18 shows that the brush manufacturing device 18 also has a filament holder 30 with a clamping device 39 for clamping the bristle filaments 4 of the bristle assembly 3. The filament holder 30 is designed as a cassette and can be moved from station to station of the brush manufacturing device 18 and holds the bristle filaments 4 during the profiling of the bristle assembly 3 as well as during the heating and melting of their attachment ends 6 on the heating device 19. The filament holder 30 has a hole pattern 37 of receiving holes 38 for bristle bundles 10 made of bristle filaments 4, which corresponds to a bundle arrangement of bristle bundles 10 in the bristle assembly 3.

[0099] The filament holder 30 is also used when pressing the attachment-side ends 6 of the bristle filaments 4 into the receiving recess 5 of a bristle carrier 2. However, its clamp 39 is open in this case. This allows the bristle filaments 4 to be pressed into the receiving recess 5 and against the heated bristle carrier 2 with the aid of the profiling tool 26, which axially applies pressure to the bristle filaments 4 at the attachment side 27 of the bristle assembly 3. The bristle filaments 4 are guided by the filament holder 30 and its through-holes 38. The profiling tool 26 then acts as a pusher for the brush manufacturing device 18 and enables the bristle carrier 2 to be connected to the bristle filaments 4.The bristle filaments 4 are pressed against the heated bristle carrier 2 with their melted fastening-side ends 6 by the pusher 26 of the brush manufacturing device 18 and thus attached to the bristle carrier 2.

[0100] To cool the bristle carrier 2 after the bristle filaments 4 have been attached to the bristle carrier 2, the brush manufacturing device 18 also includes a cooling device 31. The cooling device 31 is designed to cool the bristle carrier 2 arranged in the mold 16.

[0101] According to Figure 11 The brush manufacturing device 18 also has a magazine 32 in which a supply of loose bristle filaments 33 is arranged.

[0102] Using a dividing device 34 of the brush manufacturing device 18, bristle bundles 10 can be separated from the supply of loose bristle filaments 33 in the magazine 32. Using a bundle forming unit 35, the bristle bundles 10 can be formed into their desired target shape in the bristle arrangement 3 of the brush 1 to be manufactured.

[0103] From the bundle forming unit 35, the bristle bundles 10 are transferred to the filament holder 30 and fixed in the receiving holes 38, which are designed as through holes, by means of the clamping device 39.

[0104] The brush manufacturing device 18 has a dispensing device 40 for dispensing primer onto bristle filaments 4 and / or bristle carriers 2. Primer can thus be dispensed onto the bristle filaments 4 and / or bristle carriers 2 before they are joined. The primer can facilitate the formation of a reliable bond between the bristle filaments 4 and the bristle carriers 2 according to the previously described method.

[0105] Furthermore, bristle carriers 2 and bristle filaments 4 can be used in the process, which contain at least one additive that improves the bond between the bristle carriers 2 and the bristle filaments 4. Additives and primers that increase the graft content of the polymer bond between the bristle carriers 2 and the bristle filaments 4 are advantageous.

[0106] Fig 14Figure 1 shows how the finished brush 1, after the bristle carrier 2 has cooled, is lifted out of the mold 16 using the lifting device 36. The bristle assembly 3 is now connected to the bristle carrier 2 of the brush 1.

[0107] The invention relates to improvements in the technical field of brush manufacturing and relates, among other things, to a brush 1 which has a bristle carrier 2 with a receiving recess 5 which, when bristle filaments 4 are attached to the bristle carrier 2, is filled by melted filament material from the attachment-side ends 6 of the bristle filaments 4 of the brush 1 to be manufactured. Reference symbol list

[0108] 1 Brush 2 Bristle carrier, brush head 3 Bristle arrangement 4 Bristle filaments 5 Receptacle 6 Mounting-side ends of 4 7 Neck section 8 Handle 9 Stiffening rib 10 Bristle bundle 11 Carrier plate 12 Surface of 11 13 Brush surface 14 Edge 15 Recess in 15 16 Mold 17 Mold wall 18 Brush manufacturing device 19 Heating device 20 Heating surface for 6 21 Heating surface for 2 22 Heating element 23 Temperature sensor 24 Control unit 25 Profiling device 26 Pusher, profiling tool 27 Cleaning side 28 Counter-profiling tool 29 Mounting side 30 Filament holder 31 Cooling device 32 Magazine 33 Supply of loose bristle filaments 34 Dividing device 35 Bundle forming unit 36 ​​Lifting device 37 Hole pattern of 30 38 Receiving hole in 30 39 Clamping of 30 40 Dispensing device for primer

Claims

1. A method for manufacturing a brush (1), in particular a toothbrush, having a bristle carrier (2) and a bristle complement (3) of bristle filaments (4), wherein the bristle carrier (2) and fastening-proximal ends (6) of the bristle filaments (4) of the bristle complement (3) are heated, and the fastening-proximal ends (6) of the bristle filaments (4), as opposed to the bristle carrier (2), are fused, whereupon the bristle carrier (2) and the bristle filaments (4) of the bristle complement (3) are connected to one another, characterized in that the bristle carrier (2) and the bristle filaments (4) of the bristle complement (3) are connected to one another in a materially integral manner.

2. The method as claimed in the preceding claim, wherein the bristle carrier (2) and fastening-proximal ends (6) of the bristle filaments (4) of the bristle complement (3) are heated to different temperatures, and / or wherein the bristle carrier (2) and the bristle filaments (4) are composed of materials which are compatible for a mutual materially integral connection, or are composed of the same material which is compatible for a mutual materially integral connection.

3. The method as claimed in one of the two preceding claims, wherein a bristle carrier (2) and / or bristle filaments (4) are / is used which contain / contains at least one additive that simplifies and / or improves a connection between the bristle carrier (2) and bristle filaments (4), and / or wherein prior to connecting the bristle filaments (4) to the bristle carrier (2) a primer as a bonding agent is applied to the bristle filaments (4) and / or the bristle carrier (2).

4. The method as claimed in one of the preceding claims, wherein by fusing the fastening-proximal ends (6) of the bristle filaments (4) at least one carrier plate (11) which connects the bristle filaments (4) of one or of a plurality of bristle bundles (10) and / or a plurality of bristle bundles (10), or all bristle bundles (10), of the bristle complement (3) to one another is generated, and / or wherein the bristle carrier (2) is heated to a temperature below its melting temperature.

5. The method as claimed in one of the preceding claims, wherein the bristle carrier (2) is heated to a lower temperature than the fastening-proximal ends (6) of the bristle filaments (4).

6. The method as claimed in one of the preceding claims, wherein the bristle carrier (2) for connecting the bristle filaments (4) to the bristle carrier (2) is inserted into a mold (16) which has a mold wall (17) that at least in portions laterally surrounds the bristle carrier (2), in particular a receptacle depression (5) of the bristle carrier (2) for the fastening-proximal ends (6) of the bristle filaments (4).

7. The method as claimed in one of the preceding claims, wherein the bristle filaments (4) for connecting to the bristle carrier (2) by way of their fused fastening-proximal ends (6) are pressed against the heated bristle carrier (2), or wherein the heated bristle carrier (2) is pressed against the fused fastening-proximal ends (6) of the bristle filaments (4), and / or wherein the bristle carrier (2) after connecting to the bristle filaments (4) is cooled, in particular by way of the mold (16).

8. A brush manufacturing device (18) adapted for manufacturing brushes (1) having a bristle carrier (2) and a bristle complement (3) of bristle filaments (4) by a method as claimed in one of claims 1 to 7, wherein the brush manufacturing device (18) has a heating device (19), wherein the heating device (19) is specified to heat fastening-proximal ends (6) of bristle filaments (4) of a bristle complement (3) and a bristle carrier (2) to which the bristle filaments (4) of the bristle complement (3) are to be connected, and to fuse the fastening-proximal ends (6) of the bristle filaments (4), as opposed to the bristle carrier (2), in order to connect the bristle carrier (2) and the bristle filaments (4) of the bristle complement (3) in a materially integral manner.

9. The brush manufacturing device (18) as claimed in the preceding claim, wherein the heating device (19) comprises two heating areas (20, 21) of which a first heating area (20) is provided for heating fastening-proximal ends (6) of bristle filaments (4) of a bristle complement (3) of a brush (1) to be manufactured, and a second heating area (21) is provided for heating a bristle carrier (2) of the brush (1) to be manufactured, to which bristle carrier (2) the bristle filaments (4) of the bristle complement (3) are to be connected, wherein the heating device (19) is specified to heat the fastening-proximal ends (6) of the bristle filaments (4) and the bristle carrier(2), and to fuse the fastening-proximal ends (6) of the bristle filaments (4), as opposed to the bristle carrier (2).

10. The brush manufacturing device (18) as claimed in one of claims 8 or 9, wherein the heating device (19) is specified to heat the fastening-proximal ends (6) of the bristle filaments (4) and the bristle carrier (2) to different temperatures.

11. The brush manufacturing device (18) as claimed in one of claims 9 or 10, wherein the heating device (19) is specified to heat the heating areas (20, 21) to different temperatures.

12. The brush manufacturing device (18) as claimed in one of claims 9 to 11, wherein the heating device (19) is specified to heat the first heating area (20) to a temperature that is sufficient to fuse the fastening-proximal ends (6) of the bristle filaments (4), and / or wherein the heating device (19) is specified to heat the second heating area (21) to a temperature that is sufficient to heat the bristle carrier (2) to a temperature below its melting temperature.

13. The brush manufacturing device (18) as claimed in one of claims 9 to 12, wherein a spacing between the first heating area (20) and a position which is predefined by the brush manufacturing device (18) and in which the fastening-proximal ends (6) of the bristle filaments (4) are offered up for heating, in particular for fusing, is larger than a spacing between the second heating area (21) and a position which is predefined by the brush manufacturing device (18) and in which the bristle carrier (2) is offered up for heating.

14. The brush manufacturing device (18) as claimed in one of claims 9 to 13, wherein the two heating areas (20, 21) are disposed on a common heating element (22), in particular on different sides, preferably on sides of the heating element (22) that face away from one another.

15. The brush manufacturing device (18) as claimed in one of claims 9 to 14, wherein the heating device (19) is specified to preferably independently feedback-control the temperatures of the two heating areas (20, 21), in particular wherein the heating device (19) has a control unit (24) and at least one temperature sensor (23) for detecting and feedback-controlling the temperature of at least one of the two heating areas (20, 21), preferably wherein each heating area (20, 21) is assigned at least one temperature sensor (23).

16. The brush manufacturing device (18) as claimed in one of claims 8 to 15, wherein the brush manufacturing device (18) has a mold (16) for receiving and supporting the bristle carrier (2) when connecting the bristle carrier (2) to the bristle filaments (4) of the bristle complement (3), and / or wherein the brush manufacturing device (18) has a dispensing device (40) for dispensing primer onto bristle filaments (4) and / or bristle carriers (2).

17. The brush manufacturing device (18) as claimed in one of claims 8 to 16, wherein the brush manufacturing device (18) has a filament holder (30) for holding, in particular in a clamping manner, the bristle filaments (4) of the bristle complement (3), and / or has a cooling device (31) for cooling the bristle carrier (2), and / or a pusher (26) which is specified for pressing bristle filaments (4) of the bristle complement (3), by way of their fused fastening-proximal ends (6), against a heated bristle carrier (2), or a heated bristle carrier (2) against fused ends (6) of bristle filaments (4).