Brush material

Abstract

To firmly hold a sufficient amount of abrasive grains relative to the brush bristles, prevent scattering due to bristle breakage, and reduce the amount of abrasive grains used. [Solution] This brush bristles 100 refers to the brush material attached to the handle, and abrasive grains 101 are electroplated onto the entire surface. With the brush bristles 100 constructed in this way, the electroplated abrasive grains 101 prevent the brush bristles 100 from breaking, and even if the brush bristles 100 break, the abrasive grains 101 remain firmly attached to the brush bristles 100, preventing the broken pieces from flying off. The amount of abrasive grains 101 can be less than in conventional brushes because the strong adhesion due to electroplating makes them difficult to remove.

Description

Technical Field

[0004] , , ,

[0001] The present invention relates to a brush material to be attached to a processing machine for performing processing operations such as deburring of workpieces related to automobiles, aviation, ships, vehicles, semiconductor manufacturing processes, and general household goods.

Background Art

[0002] In the case of using a metal brush material when attached to a device that rotates electrically, there was a possibility that when the brush hair broke due to pressing force, rotational speed, the way of applying to the workpiece, or long-term use, the broken brush hair could fly far away and cause an accident. For this reason, in some conventional metal brush hairs, abrasive grains are mixed into the resin, and the metal brush hairs are covered with this resin so that the brush hairs do not fly far away. For example, in the brush hair material described in Patent Document 1, a plurality of abrasive grain-containing synthetic resin monofilaments are wound around the core of a synthetic resin monofilament that does not contain abrasive grains, and a film composed of at least one selected from a solvent-evaporating adhesive and a synthetic resin is formed on the surface.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When mixing abrasive grains into the resin or attaching abrasive grains to metal brush hairs, if the amount of abrasive grains increases, the processing efficiency can be improved and the life of the brush can be extended. On the other hand, if there are too many abrasive grains, there will be a lot of waste. Therefore, it is possible to solve the problem by firmly holding the necessary and sufficient amount of abrasive grains for the brush hairs, and it is also necessary to prevent the scattering of the brush hairs. The present invention has been made from such a perspective.

Means for Solving the Problems

[0005] In this invention, abrasive grains are not only electroplated onto the entire surface, tip, and center of the brush material, but also electroplated onto the brush material itself, such as by bundling or weaving multiple brushes, or by electroplating abrasive grains onto the covering resin. This increases the grinding and polishing capacity of the brush material, allowing for a reduction in pressing pressure and rotational speed. The frequency of brush replacement is also reduced. The abrasive grains are diamonds, etc. [Brief explanation of the drawing]

[0006] [Figure 1] This is an explanatory diagram showing the brush bristles according to Embodiment 1 of the present invention. [Figure 2] This is an explanatory diagram showing another example of brush bristles according to Embodiment 1 of the present invention. [Figure 3] This is an explanatory diagram showing another example of brush bristles according to Embodiment 1 of the present invention. [Figure 4] This is an explanatory diagram showing a cup brush according to Embodiment 2 of the present invention. [Figure 5] This is an explanatory diagram showing a cylindrical brush according to Embodiment 3 of the present invention. [Figure 6] This is an explanatory diagram showing a coil brush according to the present invention. [Figure 7] This is an explanatory diagram showing a roll brush according to the present invention. [Figure 8] This is an explanatory diagram showing a tribaling jig according to Embodiment 5 of the present invention. [Figure 9] This is an explanatory diagram showing a manual brush according to Embodiment 6 of the present invention. [Modes for carrying out the invention]

[0007] (Embodiment 1) Figure 1 is an explanatory diagram showing brush bristles according to Embodiment 1 of the present invention. These brush bristles 100 refer to the brush material attached to the handle, and are electroplated with abrasive grains 101 (see Figure (a)). Abrasive grains 101 are fine particles used for grinding and polishing, and are used in tools for cutting materials such as metals, stone, and glass. Abrasive grains 101 have different properties depending on their hardness, shape, and grain size, and are selected according to the application. For example, to cut very hard materials, abrasive grains with high hardness are required, and diamond and cubic boron nitride (CBN) are considered to be very effective abrasive grains due to their high hardness. On the other hand, alumina and silicon carbide are suitable for relatively soft materials and for finishing polishing.

[0008] Figure (b) shows the brush bristles 102 with abrasive grains 103 electroplated onto the tips. Figure (c) shows the brush bristles 104 with abrasive grains 105 electroplated onto the center.

[0009] The materials used for electroplated metal brush bristles include stainless steel, brass, carbon steel, phosphor bronze, and aluminum. These materials are selected based on the purpose of the brush and the environment in which it will be used, with metals possessing appropriate properties.

[0010] The abrasive grains to be electroplated are at least one or more types of diamond abrasive grains, metal abrasive grains, or other abrasive grains (the aforementioned other abrasive grains refer to at least one of the following, for example, silicon carbide, alumina, ceramics, ceramic alumina, ceramic aluminum oxide, zirconia, zirconium, aluminum trihardlite, boron carbide, boron nitride, cerium oxide, garnet, hard glass, quartz, etc.).

[0011] Electrodeposition is a process of electrochemically attaching materials to the surface of brush bristles. For example, when electrodepositing diamond abrasive particles, the process is carried out as follows: Oils and oxides are removed from the surface of the brush bristles by alkaline cleaning, and the surface of the brush bristles is roughened as necessary to ensure adhesion. These brush bristles are then immersed in an electrolyte solution containing metal ions. The electrolyte solution contains diamond abrasive particles, which are stirred and uniformly dispersed.

[0012] The brush bristles are positioned as the cathode, and a pair of anodes made of the same material as the metal ions are placed there. When an electric current is passed through, the metal ions move to the cathode, depositing metal onto the surface of the substrate. At the same time, diamond particles dispersed in the electrolyte also adhere to the surface of the substrate. The thickness of the electrodeposited layer and the degree to which the diamond abrasive particles are embedded are adjusted by the current density, temperature, time, etc. After this, the brush bristles are heat-treated to stabilize them.

[0013] In this configuration, the abrasive grains 101 deposited by electroplating prevent the brush bristles from breaking, and even if the brush bristles break, the strong adhesion of the abrasive grains 101 to the brush bristles prevents the broken pieces from flying off. The amount of abrasive grains 101 can be less than in conventional designs because the strong adhesion by electroplating makes them difficult to remove. The effects of the electroplated brush bristles remain the same.

[0014] Figure 2 is an explanatory diagram showing another example of brush bristles according to Embodiment 1 of the present invention. The brush bristles 120 shown in Figure 2(a) have a structure in which a plurality of metal brush bristles 121 are bundled in one direction, and abrasive grains 122 are electroplated onto them in this bundled state. As a result, the abrasive grains 122 adhere to the spaces between the brush bristles 121, and these abrasive grains 122 cause the brush bristles 121 to adhere more strongly to each other. The bonding by electroplating has an effect similar to resin covering, which prevents the brush bristles 120 from breaking and flying off. Furthermore, because the abrasive grains 122 adhere firmly by electroplating, the abrasive grains 122 are less likely to come off during processing, and as a result, the amount of abrasive grains 122 used is reduced.

[0015] Similarly, as shown in Fig. 2(b), by attaching abrasive grains 124 by electrodeposition in a state where a plurality of metallic brush bristles 123 are braided, the adhesiveness between the brush bristles 123 is improved. Also, since the abrasive grains 124 adhere firmly, the amount of abrasive grains used can be reduced. Further, as shown in Fig. 2(c), in a state where a plurality of metallic brush bristles 125 are bundled, other brush bristles 126 can be wound around and fixed, and abrasive grains 127 can be electrodeposited in this state. Thereby, the brush bristles 125 and 126 are firmly joined. Since the abrasive grains 127 are firmly joined, the amount used can be reduced.

[0016] Fig. 3 is an explanatory view showing another example of the brush bristles according to Embodiment 1 of the present invention. As shown in Figs. 3(a) and (b), this brush bristle 130 is obtained by covering the surface of a brush bristle 131 with electrodeposited abrasive grains 132 such as diamond with a resin 133. The resin for covering is mixed with the same abrasive grains 132 as the electrodeposited abrasive grains 132. The covering 133 may be performed by winding a paper mixed with the abrasive grains 132. As shown in Figs. 3(c) and (d), the covering 133 may be performed with a resin or paper mixed with abrasive grains 134 and 135 different from the abrasive grains 132 electrodeposited on the brush bristle 131.

[0017] (Embodiment 2) Fig. 4 is an explanatory view showing a cup brush according to Embodiment 2 of the present invention. The cup brush 200 shown in Fig. (a) of the same figure is composed of a brush bristle 201 with electrodeposited abrasive grains 202. The abrasive grains 202 are electrodeposited on the brush bristle 201 and the brush bristle 201 is attached annularly to the cup 203 (see Fig. (b) of the same figure). Also, when electrodeposition is performed after forming the brush bristles 201 in a cup shape, the brush bristles 201 are adhered to each other, so the strength of the cup brush 200 changes. Since the abrasive grains 202 adhere firmly, the amount of the abrasive grains 202 can be reduced.

[0018] As shown in FIG. (c), the brush hairs 201 with the abrasive grains 202 electrodeposited thereon may be arranged on the central side of the cup 203, and other brush hairs 204 may be arranged on the outside to adjust the outside to be soft and the inside to be hard. Also, a cup brush may be configured using brush hairs with different gauges of the abrasive grains 202 to be electrodeposited. It is also possible to use brush hairs with larger-gauge abrasive grains electrodeposited on the outer brush hairs and brush hairs with smaller-gauge abrasive grains electrodeposited on the inner brush hairs. As shown in FIG. (d), the inside of the cup brush may be configured with brush hairs 205 having a polygonal cross-section such as triangular or square mixed therein. The outer brush hairs 206 are configured with the abrasive grains 202 electrodeposited on the brush hairs 206 having a round cross-sectional shape. In this case, the outside is adjusted to be soft and the inside to be hard.

[0019] (Embodiment 3) FIG. 5 is an explanatory diagram showing a cylindrical brush according to Embodiment 3 of the present invention. (a) is a side view and (b) is a perspective view. This cylindrical brush 300 has brush hairs 302 provided inside a cylindrical body 301, and the abrasive grains 303 are electrodeposited on the brush hairs 302. By electrodepositing the abrasive grains 303 on the brush hairs 302, the brush hairs 302 adhere to each other and the abrasive grains 303 are firmly fixed to the brush hairs 302. As a result, it becomes difficult for the abrasive grains 303 to fall off during processing, so that the amount of the abrasive grains 303 can be reduced.

[0020] A ring brush 310 may be attachable to the outside of the cylindrical brush 300. The ring brush 310 has a configuration in which brush hairs 312 are provided on a ring-shaped main body 311. Abrasive grains 313 can be electrodeposited on the brush hairs 312 of this ring brush 310. When electrodepositing the abrasive grains 313, those with different gauges of the abrasive grains 313 may be used. By electrodepositing the abrasive grains 313, the brush hairs 312 adhere firmly to each other and it becomes difficult for the abrasive grains 313 to fall off during processing. Therefore, the amount of the abrasive grains 313 can be reduced.

[0021] In this configuration, the outer ring brush 310 can be set to soft, and the inner cylindrical brush 300 to hard. The ring brush 310 can be made detachable and replaceable. Therefore, the overall brush bristle setting can be freely changed. In addition, it is also possible to use brush bristles for the ring brush 310 that do not have abrasive particles electroplated onto them.

[0022] (Embodiment 4) Figure 6 is an explanatory diagram showing a coil brush according to the present invention. The coil brush 400 is made by winding metal wire into a coil shape, and attaching brush bristles 401 to the metal channels that make up the coil. It can be used as a scratch brush or for various other purposes. A shaft 402 is provided for the brush bristles 401, and abrasive grains 403 are electroplated onto the brush bristles 401.

[0023] A ring brush 410 can be attached to the outside of this coil brush 400. The ring brush 410 has a ring-shaped body 411 with brush bristles 412. Abrasive grains 413 are electroplated onto the brush bristles 412 of the ring brush 410. When electroplating the abrasive grains 413, it is also possible to use abrasive grains 413 of different grits.

[0024] In this configuration, the outer ring brush 410 can be set to soft, and the inner coil brush 400 can be set to hard. The ring brush 410 can be made detachable and replaceable. Therefore, the setting of the brush bristles 412 can be freely changed. Note that the brush bristles 412 do not need to have abrasive grains 413 electroplated onto them.

[0025] Figure 7 is an explanatory diagram showing a roll brush according to the present invention. In this roll brush 450, a shaft 453 is provided for the brush bristles 451, and abrasive grains 452 are electroplated onto the brush bristles 451. The grit of the abrasive grains 451 may be the same throughout, or they may be of different grits in some parts. Because the abrasive grains 452 are attached by electroplating in the roll brush 450, the abrasive grains 452 are difficult to remove from the brush bristles 451, and therefore fewer abrasive grains 451 are needed.

[0026] (Embodiment 5) Figure 8 is an explanatory diagram showing a trimming jig according to Embodiment 5 of the present invention. In this trimming jig 500, as shown in Figure 8(a), hard steel wires 501 are arranged in an arc shape circumferentially at the tip of the shaft 510, and abrasive grains 502 are electroplated onto a part of each hard steel wire 501 that is in contact with the burrs of the workpiece, for example, the central part 501a. This prevents the abrasive grains 502 from being wasted and reduces costs. A twisted brush or coil brush can also be arranged inside.

[0027] As shown in Figure 8(b), the trimming jig 520 has brush bristles 522 wound around a round bar 521, and abrasive grains 523 are electroplated onto the entire surface of the brush bristles 522. Other brushes may be attached coaxially to the rear of this trimming jig 520, or they may be made interchangeable so that they can be combined as desired (not shown).

[0028] (Embodiment 6) Figure 9 is an explanatory diagram showing a manual brush according to Embodiment 6 of the present invention. As shown in Figure (a), this manual brush 600 has brush bristles 602 at the tip of the handle portion 601, and abrasive grains 603 are electroplated onto these brush bristles 602. Even with a manual brush 600, electroplating the abrasive grains 603 causes the brush bristles 602 to adhere to each other, and the abrasive grains 603 are less likely to come off, thus extending the lifespan of the brush.

[0029] Furthermore, as shown in Figure (b), the abrasive grains 603 may be electroplated onto the brush bristles 602 of a manual brush of the type in which a grip 605 is provided on the plate portion 604. In this way, even in the manual brush 600, the electroplating of the abrasive grains 603 causes the brush bristles 602 to adhere to each other, making them less likely to fly off even if they break, and the abrasive grains 603 are less likely to come off the brush bristles 602, thus requiring fewer abrasive grains 602. [Explanation of Symbols]

[0030] 100 brush bristles 101 Abrasive grains

Claims

1. A brush material with abrasive particles electroplated onto it.

2. A brush material in which abrasive particles are electroplated onto brush bristles that are bundled or woven together.

3. Furthermore, the brush material according to claim 1 or 2 is covered with resin.

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