Method for producing brushes and brush-producing machine

Abstract

The invention relates to a method for producing brushes (10), wherein tufts of bristles (31) are pushed between a plurality of intermediate magazines (22, 24) and then profiled in a second intermediate magazine (24) by means of profiled pins and profiled sliding surfaces (64). A brush-producing machine is also proposed.

Description

[0001] Method for manufacturing brushes and brush manufacturing machine

[0002] The invention relates to a method for manufacturing brushes and a brush manufacturing machine.

[0003] More precisely, the invention relates to a method and a brush manufacturing machine for producing anchorless toothbrushes with preferably very large bristle bundles that are profiled at their free end.

[0004] The bristles of such bristle bundles are usually either rounded or chemically or mechanically pointed, which makes them difficult to process and handle. The production of anchorless brushes, especially toothbrushes, is achieved, for example, by inserting the bristle bundles through openings in a bristle holder, which becomes part of the finished brush, with the rear end of the bristle bundles protruding from the back of the bristle holder.

[0005] The back ends of the bristle bundles are melted by heat (for example, radiation, heated air, or contact heating). A die compresses the molten plastic mass, creating a kind of layer or plate to which all the bristles are then bonded. This bristle carrier, now containing the bristle bundles, can then be overmolded on the back or, if it is formed as a plate, inserted into a handle or embedded in it by injection molding a handle onto it. This handle then naturally also incorporates part of the future brush head.

[0006] Another method for the anchorless production of brushes, known from DE 10 2017 122 879 A1, consists of applying heat to the rear end of the bristles of a bristle bundle, causing them to fuse together and form a common thickening. The bristle bundles formed with this rear thickening are then inserted into blind holes in the bristle carrier. Subsequently, pressure, and optionally additional heat, is applied from the front of the bristle carrier to the edge of the blind hole surrounding the opening, narrowing the cross-section at the edge of the hole to a smaller cross-section than that of the thickening. This mechanically fixes the thickening and the bristle bundle in the blind hole.

[0007] In contrast to this prior art, DE 40 27 108 A1 provides for creating holes in the bristle carrier by means of hot pins that penetrate the plastic of the bristle carrier. The thickened bundle ends are then pressed into the mass of the still-hot plastic to displace the hot mass, which is intended to rise in the hole. However, the hole is sealed at the front, so that the rising mass fills the front cavity and thus seals the entire space at the front.

[0008] The trend, especially in toothbrushes, is towards using increasingly larger bristle bundles, meaning bundles with a large number of bristles. These bristle bundles also feature highly profiled front ends. Some bundles even have a cross-section diameter of 2.5 to 5 mm. The cross-sectional shapes of the bundles are virtually unlimited, ranging from circles, ovals, squares, and rectangles to arcs, stars, and the like. Any shape is currently available on the market and will be feasible in the future. The profiling of the bundles at the front end also varies. Hemispherical, crenellated, or serrated shapes, among others, are produced.

[0009] Such large bristle bundles cannot be attached to the bristle carrier with an anchor, but must be attached without anchors, for example, using the methods mentioned above.

[0010] Profiling is particularly problematic with pointed bristles, and this problem increases with the number of bristles per bristle bundle. Profiling is typically achieved by moving the bristle bundles through openings in a magazine using a slide or compressed air. The bristle bundles then protrude from the magazine at the front and are moved or pressed against a stop. This stop is not flat but has a surface at the front ends of the bundles that is complementary to the desired profile. Thus, the bristles move relative to each other within the bristle bundle until they reach the profiled stop surface. Subsequently, the rear end of the bristle bundle protruding from the magazine is either melted or first cut off, followed by the melting of the deflected end.

[0011] If the end of the bristle is very sharply pointed, this pointed end is very soft and can easily bend when axial force is applied to it, that is, when it is pressed against the contact surface. There is then a risk that the pointed end will buckle, which in turn allows for excessive displacement of this bristle. Ultimately, this means that the bristle ends do not terminate on, for example, the hemispherical surface of the bristle bundle, but rather individual bristles protrude from the desired profiled surface and extend beyond it.

[0012] Another problem arises from the fact that the bristles used in the brush industry are becoming increasingly thinner. Bristle diameters of 0.07 mm are no longer uncommon, which reduces the inherent stiffness of the bristles and thus increases the difficulty of producing profiled bristle bundles with these thin bristles.

[0013] The object of the invention is to provide a method for manufacturing brushes and a brush manufacturing machine by which high-quality brushes with profiled bundle ends can be produced, in which large quantities of bristles and thin bristles can also be used for the bristle bundles.

[0014] The invention provides a method for manufacturing brushes, characterized by the following steps: a) inserting bristle bundles into adjacent through-openings of a first intermediate magazine, b) moving the bristle bundles from the through-openings into receiving openings of a second intermediate magazine positioned next to the first intermediate magazine, wherein the rear ends of the bristle bundles (in the insertion direction) remain in the first intermediate magazine, while the front ends of the bristle bundles (in the insertion direction) move into the

[0015] c) Positioning the receiving openings, c) Moving the first and second intermediate magazines away from each other so that the rear ends emerge from the first intermediate magazine, d) Displacing at least one bristle bundle in one of the receiving openings of the second intermediate magazine by means of a profiled pin, which is inserted into the receiving opening and is movable along its length. The pin engages the front end of the bristle bundle, and a sliding surface, shaped complementary to the front of the pin, engages the rear end of the bristle bundle to profile the rear end of the bristle bundle. e) Cutting off the section of the bristle bundle protruding from the second intermediate magazine, f) Moving the bristle bundle into a hole in a third intermediate magazine, with the rear, trimmed end of the bristle bundle protruding from the hole, and g) fusing the ends of the bristles of the bristle bundle together at the rear, trimmed end.

[0016] In the inventive method, the bristle bundles in the second intermediate magazine are displaced by a profiled pin, which is held in the receiving opening provided therein and is slidable along the receiving opening. This means that the fine ends of the bristle bundles do not protrude from the intermediate magazine, but are still held within the receiving opening and thus laterally stabilized by the wall of the receiving opening when they contact the profiled pin. A sliding surface, which has a geometry complementary to the end face of the pin, then engages at the rear end of the bristle bundle. The bristle bundle is thus positioned at both ends between complementary contact surfaces. Optionally, when the bristle bundle is in the second intermediate magazine, it can also be moved back and forth between the pin and the sliding surface to move the individual bristles relative to each other.However, as mentioned, this is only one option. The inventive method can also be used particularly successfully when oversized bristle bundles are to be profiled. For this purpose, the second intermediate magazine has at least one enlarged receiving opening, to which several through-openings in the first intermediate magazine are assigned and which has a larger cross-section than that of the assigned through-openings. The bristle bundles from the assigned through-openings are pushed into the enlarged receiving opening or openings, if several enlarged receiving openings are provided in the second intermediate magazine, so that during the movement in step b), bristle bundles from the first intermediate magazine are combined into a larger bristle bundle in the at least one enlarged receiving opening. In this case, the intermediate magazines therefore have an additional function, namely to generate enlarged bristle bundles.

[0017] Between the first and second magazines, an intermediate plate with a collecting channel can be provided when the bristle bundles are inserted into the enlarged receiving opening. This collecting channel is open to the first intermediate magazine at several associated through-openings, and towards the second intermediate magazine and the enlarged receiving opening, this collecting channel runs in such a way that the bristle bundles are gathered in the collecting channel and guided into the enlarged receiving opening. In the simplest case, this collecting channel is therefore a conical opening. However, this cone does not have to run symmetrically around a central axis perpendicular to the end faces of the intermediate plate; the cone can also run obliquely to this axis.

[0018] As mentioned previously, the second intermediate magazine can contain several enlarged receiving openings. Each of these enlarged receiving openings is then associated with several through-openings in the first magazine. These receiving openings are filled from the first intermediate magazine with the corresponding bristle bundles. The third intermediate magazine can be vibrated after step f) and before step g), at least in one, preferably at least two, and more preferably three spatial directions. This simplifies and optimizes the movement of the bristles relative to each other, reduces the tension between adjacent bristles of the bristle bundle, and allows the bristles to align themselves. These vibrations can be generated by shaking or tapping, but also by high-frequency excitation.This alignment of the bristles with each other is due to the fact that individual bristles become slightly interlocked within the bristle bundle through friction and can spring back due to vibrations to assume their desired position. Therefore, only minimal pressure needs to be applied to the bristles for final alignment.

[0019] The third intermediate magazine may contain a bristle carrier, which will form part of the brush. This bristle carrier is inserted into the third intermediate magazine before the bristle bundles are inserted. The bristle carrier has an opening adapted to the cross-section of the bristle bundle, through which the bristle bundle is pushed into the corresponding hole in the third intermediate magazine. The bristle carrier thus sits in front of the hole in the third intermediate magazine. The rear, trimmed end protrudes freely from the opening and can be melted there. Typically, the bristle carrier is a small plate that is later attached to the brush head. The hole in the third intermediate magazine, into which the bristle bundle enters, stabilizes the position of the bristle bundle, as the bristle carrier has a minimal thickness.

[0020] An alternative to this manufacturing process involves fusing the ends of the bristles of a bristle bundle to form a thickening, and then inserting the enlarged bristle bundle, thickening first, into a blind hole in a bristle carrier that forms part of the brush. A rim running around the opening of the blind hole on an end face of the bristle carrier is reshaped by applying pressure and, optionally, heat, preferably without melting the bristle carrier. This reduces the cross-section of the blind hole at the rim to a smaller cross-section than that of the thickening. The hole in the third intermediate magazine can, in particular, be a blind hole with a bottom profile complementary to that of the front end of the bristle bundle inserted into the blind hole.This means that the profile created at the front end of the bristle bundle in the second intermediate magazine is stabilized in the third intermediate magazine. The bristles cannot lose their alignment with each other in the third intermediate magazine.

[0021] Such a perforated base can be produced, for example, by inserting a profiled pin into a through-hole. This pin then has the profiled end face. Such production is significantly simpler than profiling the perforated base, for example, by electrical discharge machining (EDM).

[0022] When the bristle bundles from the intermediate magazine are inserted, for example, into a blind hole in the bristle carrier with the thickened end facing forward, the bottom of the blind hole is formed by a pin or plunger that can then be moved relative to the third intermediate magazine in order to, as mentioned, push the bristle bundle out of the third intermediate magazine. Such a plunger should also have a profiled end face.

[0023] The hole for the bristle bundle in the third intermediate magazine does not necessarily have to be perpendicular to the front face of the third intermediate magazine, but can be angled to the insertion direction of the bristle bundle. Several holes can also be accommodated in the third intermediate magazine, angled to each other and to the insertion direction of the bristle bundle. This results in brushes with bristle bundles angled towards each other.

[0024] After the bristle bundles are cut at the rear end, they can be moved into the third intermediate magazine by a slide with a planar end face. No profiling of the slide is necessary here, which simplifies its manufacture.

[0025] In step b), sliders entering through the through-holes push the bristle bundles into the receiving openings in the second intermediate magazine. For this to work, the leading ends of the bristle bundle(s) are not pushed all the way to the end of their assigned receiving opening, but rather end at a distance from the ends. In step c), the sliders remain in contact with their bristle bundles. The first intermediate magazine is moved away from the bristle bundles until it has completely ejected them. Because the sliders remain in contact with the bristle bundles while the first intermediate magazine is moved away, no bristles get caught in the through-holes of the first intermediate magazine, and the bristles are positioned very precisely relative to each other. The position of the bristle bundles in the second intermediate magazine also remains constant. This improves the quality of the produced bristle bundles.

[0026] Since several bristle bundles from the first intermediate magazine are combined into a larger bristle bundle in the second intermediate magazine, the still individualized or separated rear ends of the multiple bristle bundles can then unite once the first intermediate magazine has been removed. In the second intermediate magazine, the bristle bundles had already previously united at the front end to form the larger bristle bundle. This means that after the removal of the first intermediate magazine, the individual bundles and their bristles spring into their final target shape, and tensions within the bristles of the bundles can be relieved. After this step, the profiling process can proceed largely without tension.

[0027] The object, as previously described, is also achieved by a brush manufacturing machine for carrying out the method according to the invention, comprising a first intermediate magazine, a second intermediate magazine arranged adjacent to the first, and a third intermediate magazine arranged adjacent to the second, wherein the first intermediate magazine has several parallel through-openings, the second intermediate magazine has one or more receiving openings, and the third intermediate magazine has a hole aligned with one or each of the several receiving openings in the second magazine, and several slides having a displacement path such that they push bristle bundles from the parallel through-openings into the one or more receiving openings until the leading ends of the bristle bundles, in the insertion direction, enter the associated receiving opening without completely leaving the parallel through-openings.a drive for moving the first intermediate magazine away from the second intermediate magazine after the bristle bundles have been inserted into the at least one receiving opening, one or, in the case of several receiving openings, one reciprocating, end-profiled pin for each receiving opening, which can be inserted into the associated receiving opening towards the front end of the bristle bundle located therein in the insertion direction, a reciprocating support element with a sliding surface shaped complementary to the end face of the pin, wherein the bristle bundle is moved back and forth between the sliding surface located outside the second intermediate magazine and the end face, a cutting device for separating the section of the enlarged bristle bundle protruding from the second intermediate magazine, at least one slide for moving the bristle bundle into the hole in the third intermediate magazine,and a melting device adjacent to the third magazine for melting the ends of the bristles of the enlarged bristle bundle at the rear, trimmed end of the bristles.

[0028] The aforementioned advantages explained for the process also apply to the brush manufacturing machine according to the invention.

[0029] If several bristle bundles in the first intermediate magazine are to be combined to form an enlarged bristle bundle in the second intermediate magazine, the brush manufacturing machine according to the invention preferably has several through-openings in the first intermediate magazine which, viewed in the longitudinal direction of the through-openings, overlap with a receiving opening enlarged to the through-openings.

[0030] The second intermediate magazine can also have multiple enlarged receiving openings; that is, there are then several through-holes in the first intermediate magazine, each corresponding to an enlarged receiving opening in the second intermediate magazine. In the third intermediate magazine, there is then one hole for each (enlarged) receiving opening.

[0031] Conversely, it is not necessary to provide only enlarged receiving openings in the second intermediate magazine. Alternatively or additionally, the second intermediate magazine can have at least one non-enlarged receiving opening that corresponds to a single through-hole in the first intermediate magazine. A hole in the third intermediate magazine is then also not enlarged in cross-section, so that a bristle bundle, in the sense of a single bristle bundle, is moved between the through-hole in the first and then to the corresponding hole in the third intermediate magazine. With the brush manufacturing machine according to the invention, it is possible to process small bristle bundles as well as to combine bristle bundles into large bundles and to anchor all these different sizes of bristle bundles in the same brush.

[0032] According to another variant, an intermediate plate is provided between the first and second intermediate magazines, with a collecting channel that is open at several designated receiving openings towards the first intermediate magazine and extends towards the enlarged receiving opening of the second intermediate magazine, so that the bristle bundles are gathered in the collecting channel and pushed into the enlarged receiving opening. The intermediate plate facilitates the insertion and gathering of the bristle bundles into the designated receiving openings.

[0033] A vibration device on the third intermediate magazine can set it in motion to keep the bristles movable relative to each other and to align them.

[0034] As previously mentioned, the hole in the third intermediate magazine can be a blind hole with a profiled bottom. This bottom can either be an integral part of the rest of the intermediate magazine or a pin with a profiled end face that is inserted into the hole, sealing it, and permanently attached to the rest of the intermediate magazine. Alternatively, this pin can be designed to slide relative to the rest of the intermediate magazine in order to push the bristle bundle out of the intermediate magazine.

[0035] The third intermediate magazine can also contain a receptacle for a bristle carrier forming part of the brush. This intermediate magazine not only serves as a carrier for this receptacle but also, by means of the hole(s) in the third intermediate magazine, provides for the positioning and retention of the bristle bundles. Further features and advantages of the invention will become apparent from the following description and the following drawings, to which reference is made. The drawings show:

[0036] Figure 1 shows a toothbrush produced by the inventive method in the area of ​​the head,

[0037] Figure 2 shows a schematic longitudinal sectional view through a brush manufacturing machine according to the invention for carrying out the process according to the invention in a first process step,

[0038] Figure 3 shows the brush manufacturing machine in a subsequent process step,

[0039] Figure 4 shows the brush manufacturing machine in a further subsequent step,

[0040] Figure 5 shows the brush manufacturing machine in yet another subsequent step,

[0041] Figure 6 shows the brush manufacturing machine before profiling the bristle bundles.

[0042] Figure 7 shows the brush manufacturing machine during profiling.

[0043] Figure 8 shows the brush manufacturing machine cutting off the rear ends of the bristle bundles.

[0044] Figure 9 shows the trimmed and profiled bristle bundles in the second intermediate magazine.

[0045] Figure 10 shows the brush manufacturing machine before the brush bundles are inserted into the third intermediate magazine.

[0046] Figure 11 shows the brush manufacturing machine during the insertion of the bristle bundles into the third intermediate magazine.

[0047] Figure 12 shows the third intermediate magazine with inserted bristle bundles,

[0048] Figure 13 shows the third intermediate magazine with a vibration device; Figure 14 shows the brush manufacturing machine shortly before the rear ends of the bristle bundles are melted.

[0049] Figure 15 shows a bristle carrier of a toothbrush manufactured according to the invention before it is fitted with bristle bundles, and

[0050] Figure 16 shows a sectional view through the brush manufacturing machine according to the invention during the forming of the hole edge.

[0051] Figure 1 shows a brush 10 in the shape of a toothbrush, with a brush head 12 that also forms a brush holder to which bristle bundles 14 and 16 are attached. As can be seen in Figure 1, the bristle bundles 14 are significantly larger than the bristle bundles 16; that is, they contain significantly more bristles than the bristle bundles 16.

[0052] Furthermore, the bristle bundles 14, 16 are profiled at their respective free, front end 18, here as an example hemispherical or dome-shaped.

[0053] The bristles used here are particularly pointed, meaning that the free ends of the respective bristles are mechanically or chemically treated to taper to a point.

[0054] The thickness of the individual bristles can be very small, for example only 0.07 mm, although this is not to be understood as a limitation.

[0055] In the following, a brush manufacturing machine 20 is explained and illustrated schematically from Figure 2 onwards, with which the brush 10 is manufactured.

[0056] The brush manufacturing device comprises a first intermediate magazine 22, a second intermediate magazine 24 arranged to the side of it, and an intermediate plate 26 arranged between the intermediate magazines 22, 24, as well as a third intermediate magazine 28, which adjoins the second intermediate magazine 24 on the side opposite the first intermediate magazine 22 with the intermediate plate 26 interposed.

[0057] The first intermediate magazine 22 comprises numerous parallel, adjacent through-openings 30 into which individual bristle bundles 31 are inserted, for example via slides or via compressed air or vacuum. These through-openings preferably have the same cross-section (this is not to be understood as a limitation), and the bristle bundles 31 can also have the same number of bristles.

[0058] The second intermediate magazine 24 has receiving openings 32, 34 in the area of ​​the through openings 30, wherein the receiving openings 32 have a significantly larger cross-section compared to the through openings 30, whereas the uppermost through opening 30 in Figure 2 has the same cross-section or substantially the same cross-section as a receiving opening 34 opposite it and aligned with it (the uppermost receiving opening shown in Figure 2).

[0059] Each of the enlarged receiving openings 32 is assigned several through-openings 30, so that they can be filled with the bristle bundles 31 from several through-openings to form an enlarged bristle bundle 14.

[0060] To simplify the subsequent process of moving the bristle bundles 31 into the enlarged receiving openings 32, an intermediate plate 26 is optionally provided between the first and second intermediate magazines 22, 24. This intermediate plate includes, for each enlarged receiving opening, an approximately funnel-shaped collecting channel 36, which terminates at the second intermediate magazine 24 with a cross-section and in a position corresponding to the cross-section and position of the associated enlarged receiving opening 32. The opposite end of each collecting channel 36 has a cross-section and position such that it encloses the through-openings 30 from which the bristle bundles 31 are to be led out and pushed into the associated enlarged receiving opening 32.

[0061] Looking longitudinally at the through-openings 30, several through-openings with an associated receiving opening 32 overlap in cross-section. However, if the collecting channel 36 runs at a very steep angle, it is possible that a through-opening 30, viewed longitudinally, lies outside the cross-section of the associated receiving opening 32, so that the collecting channel 36 must cause a significantly larger lateral displacement of the corresponding bristle bundle 31. In the second intermediate magazine 24, however, there is also one or more receiving openings 34 that are not enlarged compared to the through-opening 30 opposite it, for example, for the formation of the bristle bundles 16. The intermediate plate 26 has a corresponding opening 40 that is also aligned with the receiving opening 34 and the corresponding through-opening 30, and has the same cross-section.

[0062] For each through-opening 30, there is a slide 42 whose cross-section is only minimally smaller than that of the associated through-opening 30. As shown in Figure 2, the slides 42 can also be coupled. A drive 44 for the slides 42 ensures that they are pushed axially in an insertion direction V, which is simultaneously the longitudinal direction of the through-openings 30, pushing all bristle bundles 31 through the associated through-opening 30, the collecting channels 36, or the opening 40 into the receiving openings 32, 34, with the front ends leading. During this movement, as can be seen in Figure 3, the intermediate plate 26 is in end-face contact with the first intermediate magazine 22, and the second intermediate magazine 24 is in end-face contact with the intermediate plate 26. This end-face contact is always present when bristle bundles are transported to an adjacent part.These elements can be moved relative to each other by means of drives or a common drive, as will be explained below.

[0063] Figure 3 shows the displaced position in which the slides 42 are inserted so deeply into the through-openings 30 that, although the front ends of the bristle bundles 31 are already deep inside the second intermediate magazine 24, their rear ends are still also located in the through-openings 30 in the first intermediate magazine 22. However, the front ends are still far from the end face of the second intermediate magazine 24 that faces the third intermediate magazine 28.

[0064] Figure 3 shows the end position of the slides 42.

[0065] In a subsequent process step, with the slides 42 and the second intermediate magazine 24 stationary, the first intermediate magazine 22 and the intermediate plate 26 are pushed away from the second intermediate magazine 24 by means of a drive 45. The slides 42 prevent the bristle bundles from being carried along against the insertion direction V during this movement, i.e., they hold the bristle bundles 31 in position.

[0066] Figure 5 shows that the rear ends 58 of the bristle bundles 31 have left the first intermediate magazine 22. As shown in Figure 5, the intermediate plate 26 is held in position after a certain displacement, and the first intermediate magazine 22 is advanced.

[0067] This intermediate position of the intermediate plate 26 in Figure 5, at a distance from the first and second intermediate magazines 22, 24, ensures that the already exposed rear ends 58 of the bristle bundles 31 are held together for a slightly longer period when the rear ends 58 leave the through-openings 30 and spring towards each other. This snapping movement of the bristle ends is thus more controlled when the intermediate plate 26 still holds the bristle bundles 31 in a central section, than if the intermediate plate 26 were always in contact with the second intermediate magazine 24 during the movement of the first intermediate magazine 22 away from the second intermediate magazine 24.

[0068] The intermediate plate 26 is then moved again in the insertion direction V to the second intermediate magazine 24 until it contacts it (see Figure 6).

[0069] After the front ends 46 of the bristle bundles 31 remain positioned in the receiving openings 34 at a distance from the end face of the receiving openings 32, 34, a pin 50 with a profiled end face 52 can be inserted into each receiving opening 32, 34 from the end face of the second intermediate magazine 24 that faces away from the first intermediate magazine 22. The profile shape corresponds to the final, i.e., desired shape of the front end 46 of each bristle bundle 31.

[0070] The pins 50 can be moved back and forth in the insertion direction V by a common drive 54. They are coupled via a connecting bridge 56.

[0071] The rear ends 58 of the bristle bundles 31 are contacted by a contact element 60, which is also moved back and forth in the insertion direction V by means of a drive 62. The contact element has a sliding surface 64 in the region of the rear ends, which is complementary to the profile of the end faces 52.

[0072] Figure 7 shows the position in which profiling takes place, in which the pins 50 contact the front ends 46 at their ends and profile them, while simultaneously the rear ends 58 are contacted by the sliding surfaces 64. This prevents individual bristles from shifting in the insertion direction.

[0073] V can be detached from the aligned, profiled composite.

[0074] The bristle bundles 31 are then optionally inserted several times in the direction of insertion.

[0075] V and is moved back and forth in the opposite direction of insertion V by the pins 50 and the sliding surfaces 64, which can improve the profiling compared to just a singular pressing movement of the pins 50.

[0076] Subsequently, while maintaining contact between the front ends 46 and the rear ends 58 with the profiled end faces 52 and the sliding surfaces 64, the intermediate plate 26 is moved away from the second intermediate magazine 24 in the opposite direction of insertion V, whereby the intermediate plate 26 continues to stabilize the rear ends 58.

[0077] A cutting device 68 then passes the end wall of the second intermediate magazine 24 facing the first intermediate magazine 22 in order to cut off the rear ends 58.

[0078] Figure 9 then shows the bristle bundles 31 still sitting in the respective receiving openings 32, 34, which are still profiled at the front end 46 as desired.

[0079] Subsequently, a slide 70 with pin-like extensions 72, which have flat end faces, is inserted in the insertion direction V into the receiving openings 32, 34 in order to push the bristle bundles 31 through the receiving openings 32, 34 into a third intermediate magazine 28 which is then moved forward.

[0080] This intermediate magazine 28 has holes 74 that can accommodate the enlarged bristle bundles 31 and the individual bristle bundles 31.

[0081] As can be seen in Figure 10, these holes can be oriented differently from the receiving openings 32, 34, i.e., slightly obliquely. In any case, their entrances to the exits of the receiving openings 32, 34 are aligned so that the bristle bundles can be inserted into them.

[0082] The holes 74 are blind holes with a hole bottom 76 that is profiled complementarily to the front ends 46.

[0083] Optionally, the holes 74 can be through holes during manufacturing, which then receive their hole bottom 76 by means of inserted pins with a profiled end face.

[0084] As can be seen in Figure 10, a stepped recess is provided on the end face of the third intermediate magazine 28 facing the second intermediate magazine, before the start of the holes 74. This recess forms a receptacle 78 for a plate-shaped bristle carrier 80. The plate-shaped bristle carrier 80 is then inserted into this receptacle 78. The openings 81 in the bristle carrier 80 are designed to match the dimensions and, if applicable, the orientation of the holes 74 and the receiving openings 32, 34.

[0085] After the third intermediate magazine 28 has been moved end-to-end against the second intermediate magazine 24, all bristle bundles 31 are pushed completely into the third intermediate magazine 28 and the holes 74 therein by the slide 70.

[0086] Figure 12 then shows the resulting state. The bristle bundles 31, with their deflected posterior ends 82, protrude slightly from the bristle carrier 80.

[0087] By means of a vibration device 84 acting on the third intermediate magazine 28, the third intermediate magazine 28 is set into vibration at least in one plane, preferably in two or even in three planes, so that the individual bristles can realign themselves against each other and move axially until the bristle ends perfectly conform to the profile on the bottom of the hole 76.

[0088] Finally, as shown in Figure 14, the temperature of the projecting, deflected rear ends 82 is increased by means of a melting device 86, which is moved relative to the third intermediate magazine 28, so that the material melts and, after pressing down a possibly heated stamp, a continuous plastic film is formed. This connects all the bristles to each other and to the bristle carrier 80. The resulting unit is then removed from the intermediate magazine 28.

[0089] The variant shown in the preceding figures depicted a bristle carrier 80 in the form of a plate, which is then attached to a brush body, or the brush body is produced on the bristle carrier 80 by overmolding.

[0090] Figure 15, however, shows a bristle carrier 80, which is already the brush head including neck and handle, and which is then inserted into the intermediate magazine 28. After insertion and rear fusing of the deflected, rear ends 82, this area is overmolded or covered.

[0091] Another variant for manufacturing the brush is shown in Figure 16. In this variant, the bottom of the hole 76 is formed by a pin 90, also called an adjusting pin, which is slidable in the through-hole in the intermediate magazine 28 and is also profiled on its end face as previously mentioned. In this embodiment, the bristle carrier 80 is not positioned in the intermediate magazine 28, but outside of it. According to Figure 16, the bristle carrier 80 has a blind hole 102.

[0092] In this variant, similar to Figure 14, each rear, deflected end 82 is melted with heat from the melting device 86; however, here not all bristle bundles 31 are joined together by a plunger that dips into the molten metal at the rear ends. Instead, only the rear ends of the bristles of each bristle bundle 31 are fused together to create a thickening 100.

[0093] With this thickening in front, the bristle bundle 31 is then pushed over the pin 90 into the corresponding blind hole 102 in the bristle carrier 80. Subsequently, the intermediate magazine 28 presses against the edge of the hole 104 on the end face around the opening of the blind hole in the bristle carrier 80. A counter plate 106 absorbs the pressure at the opposite end of the bristle carrier 80. This pressure reduces the cross-section of the blind hole at the edge of the hole 104 to a cross-section that is smaller than that of the thickening 100, thus mechanically securing the bristle bundles 31.

[0094] Optionally, the edge of the hole 104 can also be heated, for example by having a heater in the area of ​​the contact surface of the third intermediate magazine 28.

[0095] However, the applied heat should not cause the bristle carrier 80 to melt.

[0096] Finally, the intermediate magazine 28 is moved away, and the bristle carrier is equipped with bristle bundles 31.

Claims

Patent claims 1. Method for manufacturing brushes (10), characterized by the following steps: a) Inserting bristle bundles (31) into adjacent through-openings (30) of a first intermediate magazine (22), b) Moving the bristle bundles (31) from the through-openings (30) into receiving openings (32, 34) of an intermediate magazine (22) next to the first a) the first intermediate magazine (22) is positioned in the second intermediate magazine (24), wherein the rear ends (58) of the bristle bundles (31) remain in the first intermediate magazine (22) in the insertion direction (V), whereas the front ends (46) of the bristle bundles (31) are in the receiving openings (32, 34) in the insertion direction (V), c) the first and second intermediate magazines (22, 24) are moved away from each other so that the rear ends (58) emerge from the first intermediate magazine (22), d) at least one bristle bundle (31) is moved in one of the receiving openings (32, 34) of the second intermediate magazine (24) by means of a pin (50) which is inserted in the receiving opening (32, 34), is displaceable along the same, is profiled at the end face, and engages at the front end (46) of the bristle bundle (31), and at the rear end (58) of the The sliding surface (64) engages the bristle bundle (31) and is shaped in a complementary manner to the end face (52) of the pin (50),to profile the first end (46) of the bristle bundle (31), e) cutting off the section of the bristle bundle (31) protruding from the second intermediate magazine (24), f) moving the bristle bundle (31) into a hole (74) in a third intermediate magazine (28), with the rear, trimmed end (82) of the bristle bundle (31) protruding from the hole (74), and g) fusing the ends of the bristles of the bristle bundle (31) together at the rear, trimmed end (82).

2. Method according to claim 1, characterized in that the second intermediate magazine (24) has at least one enlarged receiving opening (34) to which several through-openings (30) are assigned and which have a has a larger cross-section than that of the associated through-openings (30), wherein the bristle bundles (31) from the associated through-openings (30) are pushed into the at least one enlarged receiving opening (34), so that when moving in step b) bristle bundles (31) of the first intermediate magazine (22) are combined to form a larger bristle bundle (31) in the at least one enlarged receiving opening (34).

3. Method according to claim 2, characterized in that an intermediate plate (26) with a collecting channel (36) is provided between the first intermediate magazine (22) and the second intermediate magazine (24) when the bristle bundles (31) are inserted into the enlarged receiving opening (34), the collecting channel being open to the first intermediate magazine (22) at several associated through-openings (30) and extending to the enlarged receiving opening (34) of the second intermediate magazine (24), so that the bristle bundles (31) are brought together in the collecting channel (36) and guided into the enlarged receiving opening (34).

4. Method according to claim 2 or 3, characterized in that the second intermediate magazine (24) has several enlarged receiving openings (34) which are filled with associated, several bristle bundles (31) from the first intermediate magazine (22).

5. Method according to one of the preceding claims, characterized in that the third intermediate magazine (28) is set into vibration after step f) and before step g), in at least one, preferably in at least two, preferably in three spatial directions, and that bristles of the bristle bundle (31) are moved relative to each other by the vibration.

6. Method according to one of the preceding claims, characterized in that in the third intermediate magazine (28) a bristle carrier (80) forming part of the brush (10) is received before the insertion of the bristle bundle (31), which has an opening (81) adapted to the cross-section of the bristle bundle (31), through which the The bundle of bristles (31) is pushed into the associated hole (74), with the rear, trimmed end (82) protruding freely from the opening (81) and being melted there.

7. Method according to one of claims 1 to 5, characterized in that the ends of the bristles are fused together to form a thickening (100) and the enlarged bristle bundle (31) is pushed with the thickening (100) leading into a blind hole (102) of a bristle carrier (80) forming part of the brush (10) and a hole edge (104) extending around the opening of the blind hole on an end face of the bristle carrier (80) is reshaped by applying pressure and optionally additional heat, preferably without melting the bristle carrier (80) and the cross-section of the blind hole (102) at the hole edge (104) is reduced to a cross-section smaller than that of the thickening (100).

8. Method according to one of the preceding claims, characterized in that the hole (74) in the third intermediate magazine (28) has a blind hole with a hole bottom (76) which has a profile complementary to the profile of the first end (46) of the bristle bundle (31) inserted into it.

9. Method according to one of the preceding claims, characterized in that the hole (74) for the bristle bundle (31) in the third intermediate magazine (28) is inclined to the insertion direction (V) of the bristle bundle (31), in particular that several bristle bundles (31) optionally inclined to each other and inclined to the insertion direction (V) of the bristle bundle (31) are received in holes (74) in the third intermediate magazine (28).

10. Method according to one of the preceding claims, characterized in that the bristle bundle (31) is moved into the third intermediate magazine (28) after being cut off at the rear end (58) by a slide (70) having a flat end face.

11. Method according to one of the preceding claims, characterized in that in step b) by means of slides (42) entering the through-openings (30) the bristle bundles (31) are pushed into the receiving opening (32, 34) in the second intermediate magazine (24), and remain with their front end in the through-opening (30) spaced apart from the opposite end faces of the second intermediate magazine (24), wherein in step c) the slides (42) remain in contact with their bristle bundles (31) and the first intermediate magazine (22) is moved away from the bristle bundles (31) until the first intermediate magazine (22) has left the bristle bundles (31).

12. Brush manufacturing machine for carrying out the method according to one of the preceding claims, comprising • a first intermediate magazine, a second intermediate magazine arranged adjacent to the first and a third intermediate magazine arranged adjacent to the second (28), • wherein the first intermediate magazine (22) has several parallel through-openings (30), the second intermediate magazine (24) has one or more receiving openings (32, 34), and • the third intermediate magazine (28) has a hole (74) aligned with one or each of the several receiving openings (32, 34), • several slides (42) which have such a displacement path that they push bristle bundles (31) from the parallel through-openings into one or more receiving openings (32, 34) until the leading ends of the bristle bundles (31) in the insertion direction (V) enter the associated receiving opening (32, 34) without completely leaving the parallel through-openings (30), • a drive (45) for moving the first intermediate magazine (22) away from the second intermediate magazine (24) after the bristle bundles (31) have been inserted into the at least one receiving opening (32, 34), • one or, in the case of several receiving openings (32, 34), for each receiving opening (32, 34) a reciprocating, end-profiled pin (50) which engages in the associated The receiving opening (32, 34) can be inserted into the front end (46) of the bristle bundle (31) located therein in the insertion direction (V). • a reciprocating attachment part with a sliding surface (64) shaped complementary to the end face (52) of the pin (50), wherein the bristle bundle (31) is moved back and forth between the sliding surface (64) located outside the second intermediate magazine (24) and the end face (52), • a cutting device (68) for separating the section of the bristle bundle (31) protruding from the second intermediate magazine (24), • at least one slide (70) for moving the bristle bundle (31) into the hole in the third intermediate magazine (28), and • a melting device (86) adjacent to the third intermediate magazine (28) for melting the ends of the bristles of the bristle bundle (31) at the rear, trimmed end (82) of the bristles.

13. Brush manufacturing machine according to claim 12, characterized in that, viewed in the longitudinal direction of the through-openings (30) in the first intermediate magazine (22), several through-openings (30) overlap with a receiving opening (34) enlarged to the through-openings (30).

14. Brush manufacturing machine according to claim 13, characterized in that the second intermediate magazine (24) has several receiving openings (34) enlarged compared to the associated through-openings (30), and the third intermediate magazine (28) has a hole (74) for each enlarged receiving opening (32, 34), and / or the second intermediate magazine (24) has at least one non-enlarged receiving opening (32) that is associated with a singular through-opening (30) in the first intermediate magazine (22), as well as a hole (74) in the third intermediate magazine, such that between the through-opening (30) in the first Only one bristle bundle (31) is moved between the intermediate magazine (22) and the associated hole (74) of the third intermediate magazine (28).

15. Brush manufacturing machine according to claim 13 or 14, characterized in that an intermediate plate (26) is provided between the first and second intermediate magazine (22, 24), with a collecting channel (36) which is open to the first intermediate magazine (22) at several associated receiving openings (34) and extends to the enlarged receiving opening (34) towards the second intermediate magazine (24), so that the bristle bundles (31) are gathered together in the collecting channel (36) and guided into the enlarged receiving opening (34).

16. Brush manufacturing machine according to one of claims 12 to 15, characterized by a vibration device (84) on the third intermediate magazine (28), which vibrates the third intermediate magazine (28) in at least one, two, preferably three spatial directions.

17. Brush manufacturing machine according to one of claims 12 to 16, characterized in that the hole (74) in the third intermediate magazine (28) has a blind hole with a hole bottom (76) which has a profile.

18. Brush manufacturing machine according to claim 17, characterized in that the bottom of the hole (76) is formed by a movable, end-face profiled pin (90) which is inserted into the hole (74).

19. Brush manufacturing machine according to one of claims 12 to 17, characterized in that the third intermediate magazine (28) has a receptacle (78) for a bristle carrier (80) forming a part of the brush (10).

Images