Method for producing a brush mat and brush mat

Abstract

The invention relates to a method for producing a brush mat (1) comprising a carrier mat (10) with a fiber trim (12), comprising the steps of: providing a fiber-covered brush body (2), wherein the brush body (2) has a base body (20) with bundled bristles (22) comprising a number of fiber bundles (220), each with a plurality of fibers (120) projecting from the base body (2), and wherein free ends of the fiber bundles (220) form a brush surface (24), potting the brush surface (24) in a potting compound (4), curing the potting compound (4) to form the carrier mat (10), and severing the fibers (120) to separate the base body (20) from the carrier mat (10). The invention further relates to a correspondingly produced brush mat, an intermediate product, and the use of an intermediate product for producing a brush mat with a fiber trim.

Description

FIELD OF APPLICATION AND STATE OF THE ART

[0001] The invention relates to a method for producing a brush mat comprising a carrier mat with a fiber trim. The invention further relates to a correspondingly produced brush mat, an intermediate product, and the use of an intermediate product for producing a brush mat with a fiber trim.

[0002] In the context of this application, a brush mat or brush covering refers to a carrier mat with a fiber coating, wherein the fiber coating comprises, in particular, fibers individually incorporated into the carrier mat, also referred to as individual fibers. The term "mat" is used in the context of this application for a component made of a rigid or flexible material that is arranged in a plane in an undeformed state. Depending on the application, the brush mat's outline can be strip-shaped, rectangular, polygonal, round, oval, or any other free-form shape. In some embodiments, the brush mat comprises a carrier mat made of a flexible material that allows the brush mat to be attached to a curved surface. In some embodiments, the brush mat can be cut into a free-form shape adapted to a specific application.

[0003] Brush mats are known for various applications. Brush mats, whose fibers are arranged at an angle, are used particularly in conveying systems such as vibratory spiral conveyors or linear conveyors. By inducing vibrations on a conveying surface equipped with the brush mat, the materials being conveyed are moved in a conveying direction. The brush mat is arranged such that the free ends of the fibers point in the conveying direction. An example of a vibratory conveyor with a brush mat is described in DE2064584. TASK AND SOLUTION

[0004] It is an object of the invention to provide a method for producing a brush mat comprising a carrier mat with a fiber trim and a correspondingly produced brush mat.

[0005] According to a first aspect, a method for producing a brush mat comprising a carrier mat with a fiber trim is provided. The method comprises the steps of a) providing a fiber-covered brush body, wherein the brush body has a base body with bundled bristles comprising a number of fiber bundles, each with a plurality of fibers protruding from the base body, and wherein free ends of the fiber bundles form a brush surface, b) encapsulating the brush surface in a casting compound, c) curing the casting compound to form the carrier mat, and d) severing the fibers to separate the base body from the carrier mat.

[0006] The process allows for the cost-effective production of a brush mat with a carrier mat and a fiber trim made of individual fibers. A fiber trim made of individual fibers refers to a design in which the fibers of the fiber trim are individually attached to the carrier mat. In contrast, in the fiber-coated brush body, the fibers are each attached to the base body in fiber bundles.

[0007] To produce the fiber-covered brush body, the fiber bundles are punched into the brush body in some embodiments. In some embodiments, suitable clamps or anchors are used for punching, which are inserted into the fiber bundles. The base body of the brush body has holes in some embodiments into which the fiber bundles are punched. Depending on the embodiment, the base body is made of a suitable material. In some embodiments, the remnants of the fiber bundles remaining on the base body after the base body has been separated from the carrier mat can be detached from the base body, so that the base body can be reused for the subsequent production of additional brush mats. In other embodiments, the base body is disposed of with the remnants of the fiber bundles and / or fed into a recycling process.Depending on the application, the fiber-coated brush body can be manufactured immediately before the brush mat is manufactured or separately in time and / or space.

[0008] A fiber material and / or a fiber diameter as well as a design of a fiber corrugation provided in embodiments can be suitably selected by a person skilled in the art depending on the application and field of use of a brush mat to be produced. In embodiments, the fibers are made of a plastic, for example but not exclusively of polyamide, polypropylene, polyester, in particular polybutylene terephthalate, and / or polyvinyl chloride. In embodiments, an additive is mixed into the fibers in order to change the properties of the fibers. For example, in embodiments the fibers are made of an electrically conductive plastic. In other embodiments the fibers are made of an organic material and / or metal. In embodiments all fibers are made of a uniform material. In other embodiments, fibers made of different materials are provided in individual or all fiber bundles.

[0009] After curing, the potting compound forms the carrier mat for the brush mat. The material of the potting compound, and thus the carrier mat, can be selected depending on the application, ensuring that the carrier mat has the appropriate hardness, elasticity, and / or other properties. The potting compound can be, for example but not limited to, a two-component polyurethane resin. The layer thickness of the potting compound can be selected depending on the application. In some embodiments, the material is cast in a potting compound with a layer thickness of approximately 2 mm to approximately 4 mm.

[0010] In some embodiments, a further layer can be applied to a side of the carrier mat facing away from the fiber lining, for example a layer stiffening the carrier mat and / or an adhesive layer covered with a protective film.

[0011] In one embodiment, the fibers are severed according to a desired fiber height of the produced brush mat. In other embodiments, the severed fibers are trimmed to a desired fiber height in a subsequent step. In some embodiments, all severed fibers have the same desired fiber height. In other embodiments, the desired fiber heights of the individual fibers vary, creating a brush mat with a curved surface. The free ends of the severed fibers can be additionally processed in some embodiments.

[0012] In one embodiment, the carrier mat is cut, sawn, punched and / or trimmed in another way to a desired footprint after being separated from the base body.

[0013] In embodiments of the method, a brush mat is produced whose fibers are arranged at an angle. For this purpose, in embodiments, a fiber-covered brush body is provided, wherein the fiber bundles of the fiber-covered brush body are arranged at an inclination angle α to a surface normal of the base body, where 0° ≤ α ≤ 25°, in particular 12° ≤ α ≤ 20°. By using a fiber-covered brush body with fiber bundles arranged at an inclination angle, it is possible to create a brush mat with obliquely positioned fibers without elastic and / or plastic deformation of the fibers during production.

[0014] As described above, the fiber bundles are inserted into bores in the base body of the brush body in certain embodiments. The bores are inserted into the base body at an angle between 0° and 25° relative to a surface normal. The fibers, which are bonded to the carrier mat by casting, are inclined. The angle of inclination relative to a surface normal of the carrier mat corresponds, as an average value, at least approximately to the angle of inclination α. ​​In certain embodiments, the fiber bundles fan out conically from an anchoring point, so that the inclination of individual fibers deviates from the average value.

[0015] The brush mats are designed in embodiments for application on a conveyor system. The brush mats are attached such that the free ends of the diagonally arranged fibers point in the conveying direction. The conveying speed of the conveyor system depends on the degree of inclination, whereby the conveying speed generally increases with the inclination. The degree of inclination can be selected to suit the specific application. In embodiments, inclinations with an angle to a surface normal of between approximately 12° and approximately 20° have proven advantageous, in particular with an inclination with an angle of approximately 15°. However, the method can also be used to produce brush mats with different inclinations.

[0016] By means of the process, brush mats with different fiber densities can be produced, whereby a fiber density of the produced brush mat depends on an arrangement and / or height of the fiber bundles of the fiberized base body.

[0017] In embodiments, a fiber-covered brush body is provided for the production of a brush mat with a uniform fiber trim, wherein the fiber bundles of the fiber-covered brush body are arranged with gaps on the base body of the brush body. An arrangement in which fiber bundles from two parallel rows are not aligned but are arranged offset from one another is referred to as "staggered with gaps." By arranging the fiber bundles with gaps, and with a suitable height of the fiber bundles, a brush surface can be created on which the free ends of the fibers of the fiber bundles are arranged in an at least substantially uniformly distributed manner. A corresponding brush surface is also referred to as a homogeneous brush surface.

[0018] In some embodiments, the brush surface is straightened prior to casting, with free ends of the fibers being trimmed for straightening. This makes it possible to create a carrier mat in which the fibers are cast in an at least substantially uniformly distributed manner.

[0019] According to a second aspect, a brush mat comprising a carrier mat with a fiber trim of fibers individually secured in the carrier mat is provided, wherein the brush mat is manufactured using a method described above. In some embodiments, the brush mat is used in a conveyor device. For this purpose, the fibers are arranged in an inclined position at an angle β to a surface normal of the base body, where 0° ≤ β ≤ 25°, in particular 12° ≤ β ≤ 20°.

[0020] According to a third aspect, the use of an intermediate product for producing a brush mat comprising a carrier mat with a fiber trim is provided, wherein the intermediate product is designed as a fiber-covered brush body, wherein the brush body has a base body with a bundle of bristles comprising a number of fiber bundles, each with a plurality of fibers projecting from the base body, and wherein free ends of the fiber bundles form a brush surface, and wherein the brush surface is cast in a casting compound.

[0021] The use of the fiber-coated base body allows for simple and cost-effective production of the brush mat.

[0022] The fiber trim of the brush mat to be produced can be varied depending on the application by selecting a suitable arrangement and / or design of the fiber bundles of the base body.

[0023] In embodiments, a fiberized brush body is used to produce a brush mat with obliquely arranged fibers, wherein the fiber bundles of the fiberized brush body are arranged at an inclination angle α to the base body, wherein 0° ≤ α ≤ 25°, in particular 12° ≤ α ≤ 20°.

[0024] Alternatively or additionally, in embodiments for producing a brush mat with a dense fiber filling, a fiberized brush body is used, wherein the fiber bundles of the fiberized brush body are arranged offset on the base body.

[0025] In some embodiments, a fiber-covered brush body is used, with the fiber bundles fanning out conically. In some embodiments, a fiber-covered brush body is used to produce a brush mat with a uniform fiber filling, in which the length of the fiber bundles is selected such that the free ends of the fibers of the fiber bundles are arranged at least substantially evenly distributed on the brush surface.

[0026] According to a fourth aspect, an intermediate product for producing a brush mat comprising a carrier mat with a fiber trim is provided, wherein the intermediate product is designed as a fiber-covered brush body, wherein the brush body has a base body with a bundled bristle comprising a number of fiber bundles, each with a plurality of fibers projecting from the base body, and wherein free ends of the fiber bundles form a brush surface, and wherein the brush surface is cast in a casting compound.

[0027] This intermediate product allows for simple and cost-effective production of the brush mat, particularly by cutting the fibers to separate the base body from the cured potting compound. The cured potting compound forms the carrier mat of the brush mat.

[0028] The thickness of the potting compound can be selected depending on the application. In some designs, the potting compound has a thickness of approximately 2 mm to approximately 4 mm.

[0029] In some embodiments, a further layer can be applied to a side of the carrier mat facing away from the fiber lining, for example a layer stiffening the carrier mat and / or an adhesive layer covered with a protective film.

[0030] The fiber trim of the brush mat to be produced can be varied depending on the application by selecting a suitable arrangement and / or design of the fiber bundles of the base body.

[0031] In embodiments, the fiber bundles of the fiberized brush body are arranged at an inclination angle α to the base body, where 0° ≤ α ≤ 25°, in particular 12° ≤ α ≤ 20°.

[0032] Alternatively or additionally, in embodiments the fiber bundles of the fiberized brush body are arranged offset on the base body.

[0033] In some embodiments, the fiber-covered brush body is designed such that the fiber bundles fan out conically. In some embodiments, a fiber-covered brush body is used to produce a brush mat with a uniform fiber fill, in which the length of the fiber bundles is selected such that the free ends of the fibers of the fiber bundles are arranged at least substantially evenly distributed on the brush surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Further advantages and aspects of the invention emerge from the claims and from the description of exemplary embodiments of the invention, which are explained below with reference to the schematic figures. In the figures: Fig. 1 a brush mat in a sectional view; Fig. 2 a fiberized brush body for producing the brush mat according to Fig. 1 in a plan view; Fig. 3 the fiberized brush body according to Fig. 2 in a side view; Fig. 4 a detail of the fiberized brush body according to Fig. 2 ; Fig. 5 a step of a method for producing the brush mat according to Fig. 1 using the fibered brush body according to Fig. 2 and Fig. 6 shows a further step of the method for producing the brush mat according to Fig. 1 using the fibered brush body according to Fig. 2 . DETAILED DESCRIPTION OF THE EMBODIMENTS

[0035] Fig. 1 shows a schematic, sectional side view of a brush mat 1 with a carrier mat 10 and a fiber trim 12 made of individual fibers. Fibers 120 of the fiber trim 12 are each individually secured in the carrier mat 10. The fibers 120 are inclined at an angle β relative to a surface normal 100 of the carrier mat 10. In some embodiments, the angle β is between approximately 12° and approximately 20°.

[0036] For the production of the brush mat 1 according to Fig. 1 an intermediate product in the form of a fibered brush body 2 is used.

[0037] Fig. 2 und 3 show schematically a fiberized brush body 2 for producing the brush mat 1 according to Fig. 1 in a top view or a side view. Fig. 4 shows schematically an enlarged detail of the fiber-covered brush body 2. The fiber-covered brush body 2 comprises a base body 20 with a bundle of bristles 22. The bundle of bristles has a number of fiber bundles 220, each with a plurality of fibers 120 projecting from the base body 20 (see Fig. 4 ). The free ends of the fiber bundles 220 form a brush surface 24.

[0038] The fiber bundles 120 of the fiberized base body 2 are arranged at an inclination angle α to a surface normal 200 of the base body 20, where 0° ≤ α ≤ 25°.

[0039] In Fig. 2 For clarity, only a number of fiber bundles 220 are shown. In some embodiments, the fiber bundles 220 are evenly distributed over the free surface of the base body 2.

[0040] As in Fig. 2 As can be seen, in the illustrated embodiment, the fiber bundles 220 are arranged offset on the base body 20. This enables a uniform, dense arrangement of the fiber bundles 220 on the base body 20.

[0041] As in Fig. 4 As shown schematically, the individual fiber bundles 220 fan out conically from an anchoring point toward the free ends. The length of the fiber bundles 220 is selected such that the free ends of the fibers 120 of the fiber bundles 220 are arranged at least substantially evenly distributed on the brush surface 24.

[0042] To produce the brush mat 1 (see Fig. 1 ) the brush surface 24 of the brush body 2 is machined according to the Fig. 2 bis 4 introduced into a potting compound 4 and cast in this.

[0043] Fig. 5 shows schematically a casting of the brush surface 24 in the casting compound 4. For a better overview, the individual fibers 120 are in Fig. 5 not shown.

[0044] For potting, the brush body 2 in the illustrated embodiment is inserted into the potting compound 4 upside down, i.e., with the free ends of the fiber bundles 220 pointing downward. This prevents the potting compound 4 from getting between the fibers in a section of the fiber bundles 220 that protrudes from the potting compound. At the same time, the arrangement ensures a sufficient penetration depth of the fiber bundles 220 into the potting compound 4. A layer thickness of the potting compound is between approximately 2 mm and approximately 4 mm in certain embodiments.

[0045] After casting, the casting compound is cured, whereby the cured casting compound 4 forms the carrier mat 10.

[0046] The base body 20 is aligned parallel to the casting compound 4 and thus to the subsequent carrier mat 10. The fibers 120 cast in the carrier mat 10 are inclined, wherein an angle β of the inclination relative to the surface normal 100 of the carrier mat is at least substantially equal to an angle of inclination α of the fiber bundles 220 relative to a surface normal 200 of the base body 20. An inclined position of the fibers 120 on the carrier mat 10 is thus possible without elastic and / or plastic deformation of the fibers 120.

[0047] After curing, the fibers are arranged as shown schematically in Fig. 6 shown to separate the base body 20 from the carrier mat 10.

[0048] Subsequently, in embodiments, the severed fibers 120 on the carrier mat 10 are trimmed to a desired fiber height.

[0049] The brush mat 1 created in this way can be cut to a suitable free form for use.

[0050] The method and / or the use of the fiberized brush body 2 as an intermediate product allow a cost-effective production of a brush mat 1, in particular a brush mat 1 with diagonally arranged fibers 120 as in Fig. 1 shown.

[0051] The brush mat 1 with obliquely arranged fibers 120 can be used, for example, in a conveying device not shown, with free ends of the fibers 120 pointing in the conveying direction.

Claims

1. A method for producing a brush mat (1) comprising a carrier mat (10) with a fiber trim (12), comprising the steps of: - providing a fiber-covered brush body (2), wherein the brush body (2) has a base body (20) with a bundle of bristles (22) comprising a number of fiber bundles (220), each with a plurality of fibers (120) projecting from the base body (2), and wherein free ends of the fiber bundles (220) form a brush surface (24), - potting the brush surface (24) in a potting compound (4), - curing the potting compound (4) to form the carrier mat (10) and - severing the fibers (120) to separate the base body (20) from the carrier mat (10).

2. Method according to claim 1, characterized in that the severed fibers (120) on the carrier mat are trimmed to a desired fiber height.

3. Method according to claim 1 or 2, characterized in that the support mat (10) is trimmed to a desired floor plan.

4. Method according to claim 1, 2 or 3, characterized in that the fiber bundles (220) of the fiber-covered brush body (2) are arranged at an inclination angle α to a surface normal (200) of the base body (20), wherein 0° ≤ α ≤ 25°, in particular 12° ≤ α ≤ 20°.

5. Method according to one of claims 1 to 4, characterized in that the fiber bundles (120) of the fiberized brush body (2) are arranged offset on the base body (20).

6. Method according to one of claims 1 to 5, characterized in that before casting, the brush surface (24) is straightened, wherein in particular free ends of the fibers (120) are trimmed for straightening.

7. Brush mat comprising a carrier mat (10) with a fiber trim (12) made of fibers (120) individually fastened in the carrier mat (10), wherein the brush mat (1) is produced in a method according to one of claims 1 to 6, wherein in particular the fibers (120) are arranged in an inclined position at an angle β to a surface normal (100) of the base body (10), wherein 0° ≤ β ≤ 25°, in particular 12° ≤ β ≤ 20°.

8. Use of an intermediate product for producing a brush mat (1) comprising a carrier mat (10) with a fiber trim (12), wherein the intermediate product is designed as a fiber-covered brush body (2), wherein the brush body (2) has a base body (20) with a bundle of bristles (22) comprising a number of fiber bundles (220), each with a plurality of fibers (120) projecting from the base body, wherein free ends of the fiber bundles (220) form a brush surface (24), and wherein the brush surface (24) is cast in a casting compound (4).

9. Use according to claim 8, characterized in that the fiber bundles (220) of the fiber-covered brush body (2) are arranged at an inclination angle α to a surface normal (200) of the base body (2), wherein 0° ≤ α ≤ 25°, in particular 12° ≤ α ≤ 20°.

10. Use according to claim 8 or 9, characterized in thatthe fiber bundles (220) of the fiberized brush body (2) are arranged offset on the base body (20).

11. Use according to claim 8, 9 or 10, characterized in that a length of the fiber bundles (220) of the fiber-coated brush body (2) is selected such that free ends of the fibers (120) of the fiber bundles (220) are arranged at least substantially uniformly distributed on the brush surface (24).

12. Intermediate product for producing a brush mat (1) comprising a carrier mat (10) with a fiber trim (12), wherein the intermediate product is designed as a fiber-covered brush body (2), wherein the brush body (2) has a base body (20) with a bundle of bristles (22) comprising a number of fiber bundles (220), each with a plurality of fibers (120) projecting from the base body, wherein free ends of the fiber bundles (220) form a brush surface (24), and wherein the brush surface (24) is cast in a casting compound (4).

13. Intermediate product according to claim 12, characterized in that the fiber bundles (220) of the fiber-covered brush body (2) are arranged at an inclination angle α to a surface normal (200) of the base body (2), wherein 0° ≤ α ≤ 25°, in particular 12° ≤ α ≤ 20°.

14. Intermediate product according to claim 12 or 13, characterized in that the fiber bundles (220) of the fiberized brush body (2) are arranged offset on the base body (20).

15. Intermediate product according to claim 12, 13 or 14, characterized in that a length of the fiber bundles (220) of the fiber-coated brush body (2) is selected such that free ends of the fibers (120) of the fiber bundles (220) are arranged at least substantially uniformly distributed on the brush surface (24).

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