US3596999A

US3596999A - Novel brush machinery and brush constructions

Info

Publication number: US3596999A
Application number: US841160*A
Authority: US
Inventors: John C Lewis Jr
Original assignee: TUCEL INDUSTRIES
Current assignee: TUCEL INDUSTRIES; TUCEL INDUSTRIES Inc
Priority date: 1968-10-25
Filing date: 1968-10-25
Publication date: 1971-08-03
Anticipated expiration: 1988-08-03

Abstract

This invention consisting of a new and useful method for making brush and brush-related articles, allows tufted brush components to be manufactured having pretrimmed synthetic filament tufts. The method consists in picking precut filament from its trim end and simultaneously trimming and forming the tuft. This method also allows for complete brush constructions to be manufactured in the same instant of time required for inserting single tufts into similar constructions.

Description

United States Patent [72) Inventor John C. Lewis, Jr.

, Middlebury. Vt.

[2l] Appl. No. 841.160

{22} Filed Oct. 25, 1968 Division of Ser. No. 578,840. Sept, 12, 1966, Pat. No. 3,471,202.

[45] Patented Aug. 3, 1971 [73] Assignee TucellndustriesJnc.

Middlebury, vi.

\ [54] NOVEL BRUSH MACHINERY AND BRUSH CONSTRUCTIONS S Claims, 6 Drawing Figs.

[52] U.S. Cl. 300/21 [Sl] Int. CI A46d1/08 [50] Field of Search 3D0/2l [S6] References Cited UNITED STATES PATENTS 2,34l ,823 2/1944 Smith 300/21 X Hervey 2,562,716 7/1951 @O0/2l 2,653,056 9/1953 Montero et al. 300/21 2,664,316 12/1953 Winslow,Jr. et al 300/21 3,053,575 9/1962 Zeilstra 300/21 3,233,944 2/1966 Shaw 300/21 Primary Examiner- Granville Y. Custer, Jr. Attorney- LeBlanc & Shur ABSTRACT: This invention consisting of a new and useful method for making brush and brush-related articles, allows tufted brush components to be manufactured having pretrimmed synthetic filament tufts. The method consists in picking precut filament from its trim end and simultaneously trimming and forming the tuft. This: method also allows for complete brush constructions to be manufactured in the same instant of time required for inserting single tufts into similar constructions.

PMENTED Aus 315m SHEET l UF 3 INVENTOR I JOHN r; LEwls, JR.

ATTORNEYS PAENTl-U AUG 3 Ism mvENToR JOHN c. LEWIS, JR.

ATTORNEYS NOVEL BRUSH MACHINERY AND BRUSH CONSTRUCTIONS This application is a division of my copending application Ser. No. 578,840, filed Sept. 12, 1966 now U.S. Pat. No. 3,471,202, issued Oct. 7, 1969.

This invention relates to improvements in methods of malting brushes, and more specifically relates to brushes made with cut-tolength synthetic filament.

The brush industry and the brushmaking art during the last 50 years has remained, for the most part, unchanged. The only major changes taking place have been in the substitution of synthetic monofilaments (thermoplastic fibers, i.e. nylon monofilament) for the vegetable and hair fibers previously employed. The emphasis has been on finding ways to substitute directly the synthetic for the natural, utilizing the same brushmaking equipment, i.e. stapling machinery, and little or no effort placed upon improving the methods and machinery used. Great strides have been made wherein two or three brushes can be stapled simultaneously, however, it still requires one picking and stapling cycle for each fiber tuft staple-set in the brush back. In this area, there has been no advancement toward finding a way of placing all the desired tufts in a brush back simultaneously; and performing this feat in the same amount of time required to pick and staple-set one fiber tuft employing conventional brush machinery.

The need to improve the machinery for fabricating brush components can be illustrated by comparing and describing conventional brushmaking machinery with the machinery of this invention. The brushmaking machinery of this invention differs from ordinary brush machinery in that it employs a new method of picking fiber tufts. The conventional stapling machine employs a picker which removes a fiber tuft from a stock or feed box by first entering the stock box approximately at its midsection (lateral to the parallel fiber) and picking a given amount of fiber at the fibers midsection. The picker then proceeds to transport the predetermined volume of parallel fiber to a means for doubling the fiber at its midsection (prior to stapling), thus resulting in a tuft having a U- shape wherein both ends of each individual fiber are located at the working tip of the resultant tuft. A staple or anchor (wire member) is then inserted through the U-shaped loop and the tuft then forced into a predrilled hole in a brush back. Each tuft is formed in this manner one after another until the necessary number of holes have been filled.

The picking device ofthe machinery of this invention works on an entirely different principle. The picker or picking unit enters the fiber stock box from the end (longitudinal to the fiber) and engages the fiber from the end, thus instantly forming a fiber tuft. The fiber employed in forming tufts in this manner is one-half the original length of the fiber required using the conventional picking method. The instantly formed fiber tuft is then automatically inserted into a brush back. The resultant fiber tuft can be anchored in many ways; i.e. heat sealed, set in epoxy, and the like. However, the preferred method is to heat seal the fiber tuft. This can be done either prior to inserting the tuft into the brush back or after inserting the tuft through a portion of the brush back. Fiber tufts formed in this manner are anchored securely within the brush back and cannot be removed. i

Since, ,when forming tufts using this new and novel method of picking, there is no requirement for doubling the fiber prior to insertion into the brush back, tufts so formed in accordance with this invention require no trimming. This results in an appreciable savings to the brushmaker. A second economic savings is also realized, that being the elimination of the staple or anchor.

It is of particular importance in this invention that the picking device employed operates in such a manner that at least two fiber tufts are simultaneously formed. However, the preferred cycle for picking is one in which a complete brush component is formed simultaneously by employing a series of picking devices (hereinafter referred to as a picking unit) set in a prearranged pattern and heat sealing all the fiber tufts instantly, thus forming a brush in the same cycling time it takes to pick and staple-set one fiber tuft using the conventional machinery.

The method of making a tufted brush construction is demonstrated by assembling all the cut-to-length filament tufts simultaneously as are shown by U.S. Pat. No. 798,380 to Alexander, dated Aug. 29, 1905; No. 2,363,685 to Neuschaefer, dated Nov. 28, 1944; and No. 2,664,315 to Winslow, .lr. et al., dated Dec. 29, 1953. The disclosures of these patents relating to methods for forming brush constructions are hereby incorporated herein by reference.

Objects and advantages of the invention will be set forth in part hereinafter and in part will be obvious herefrom, or may be learned by practice with the invention, the same being realized and attained by means of the methods, combinations, compositions and improvements pointed out in the appended claims.

The invention consists in the novel steps, methods, combinations, compositions and improvements herein shown and described.

The objects of this invention will :now be described. While the invention is primarily concerned with new and novel brush machinery, it should be realized that the principles of this invention are attained only through the novel method of picking and forming fiber tufts, and these principles are applicable to situations wherein: l single fiber tufts are formed (2) multiple fiber tufts are formed (3) complete brush components are simultaneously formed and (4) continuous modular brush components are formed.

It is therefore an object of this invention to provide a new method for simultaneously picking cut-to-length synthetic filament tufts and assembling the preformed and pretrimmed tufts in a brush construction. Another object of this invention is to provide a method for simultaneously assembling synthetic filament tufts whereby cuttolength synthetic filament sup plied from a suitable stock box is received by tuft-forming pickers and the assembled tufts are heat sealed and inserted into a brush construction. Still another object ofthis invention is to provide a method of the type set forth in the foregoing object for simultaneously forming tufted brush constructions whereby different diameter tufts are so formed.

Yet still another object of this invention is to provide a method for simultaneously forming tufted brush constructions whereby the tuft-forming pickers enter a filament supply container and upon removal contain pretrimmed cut-to-length filament tufts. Another object of this invention is to provide a method of the type set forth in the foregoing object whereby the picking unit comprises an assembly of individual tuft pickers arranged in a predetermined tuft pattern allowing the complete filament portion of the brush construction to be formed simultaneously.

Further objects of this invention are to provide novel methods for the production of tufted brush constructions, and brush constructions employing some of the feature of the types set forth in the foregoing objects.

In the drawing:

FIG. 1 is a longitudinal sectional view of a tuft-forming picker of this invention. FIG. 1A is a cross-sectional view taken along line 11A-11A of FIG. l.

FIG. 2 is a longitudinal sectional view of another tuft-forming picker of this invention having an internal venturi section. FIGS. 2A and 2B are cross-sectional views taken along lines 2A-2A and 22B-2B respectively of FIG. 2.

FIG. 3 is a longitudinal sectional view of a tuft-forming picker of this invention having a square cross-sectional construction. FIG. 3A is a cross-sectional view taken along line 3A-3A of FIG. 3.

FIG. 4l is a longitudinal sectional view of a tuft-forming picker of this invention having a starlike cross-sectional construction. FIG. 4A is a cross-sectional view taken along line dA-dlA of FIG. 4.

FIG. 5 is a vlongitudinal sectional view of a tuft-forming picker of this invention having a triangular cross-sectional construction. FIG. 5A is a cross-sectional view taken along line 5A-5A ofFIG. 5.

FIG. 6 is a longitudinal sectional view of a tuft-forming picker having an internal tapered section in accordance with this invention. FIGS. 6A, 6B and 6C are cross-sectional views taken along lines 6A6A, 6B6B and 6C-6C respectively of FIG. 6.

FIG. 7 is a longitudinal sectional view of the tuft-forming picker of FIG. 6 containing parallel synthetic fiber in accordance with this invention. FIG. 7A is a cross-sectional view taken along line 7A-7A of FIG. 7.

FIG. 8 is a longitudinal sectional view of a tuft-forming picker in accordance with this invention which is employed to form a shaped end on a fiber tuft.

FIG. 9 is a perspective view illustrating how the tuft-forming picker of FIG. 8 may be employed to form a predetermined quantity of individual parallel synthetic fibers into a tuft.

FIG. 10 is a perspective view of a tuft as formed in accordance with this invention with one end heat sealed which forms the tuft base and the other end possessing a rounded trim.

FIGS. 1I, l2, and 13 are longitudinal sectional views of tuftforming pickers illustrating other shapes which may be imparted to tufts in accordance with this invention.

FIG. 14 is a longitudinal sectional view of a group of tuftforrning pickers in accordance with this invention illustrating fiber ends prior to tuft end formation.

FIG. l5 is a longitudinal sectional view of one of the tuftforming pickers of FIG. 14 containing a heat sealed fiber tuft as formed in accordance with this invention.

FIG. 16 is a sectional view in cross section of a brush back with tufts as formed in accordance with this invention.

FIG. 17 is a detailed fragmentary view in perspective and partly in section showing one arrangement of the tuft-forming pickers, a synthetic fiber storage hopper, a heat sealing die and a brush-back/fiber-tuft assembly station in accordance with this invention wherein the tuft-forming pickers are op posite the fiber storage hopper. FIG. 18 and 19 are further extensions of FIG. 17 wherein the tuft-forming pickers are opposite the heat sealing die and the brush-back/fiber-tuft assembly station respectively.

FIG.l 20 is a side cross-sectional view taken along line AA-AA in FIG. I7 of one arrangement of the tuft-forming pickers employed to form a brush in accordance with this invention.

FIG. 21 is a side crosssectional view taken along line BBBB of FIG. I7 of the synthetic fiber storage hopper.

FIG. 22 is a side cross-sectional view taken along line CC-CC in FIG. I7 ofthe heat sealing die.

FIG. 23 is a side cross-sectional view taken along line DD-DD in FIG. 17 of a brush back and brush back mounting support.

FIG. 23A is a side cross-sectional view taken along line EE-EE in FIG. 19 illustrating a brush with tufts made according to this invention.

FIG. 24 is a perspective view illustrating how the tuft-forming pickers of FIG. l may be employed to form a continuous tufted strip brush construction.

FIG. 25 is a perspective view of a strip brush made according to the manner illustrated in FIG. 24.

In order to describe the invention more fully, reference is now made to specific embodiments illustrated in the drawings. The. invention is directed to brushmaking wherein tufted brushes are formed employing tuft-forming pickers in such a manner that each tuft contained in the brush back is simultaneously picked, simultaneously prepared for insertion as a heat sealed tuft into a brush back thus forming a complete brush in the same instant of time it requires an ordinary brush machine to pick and staple-set one fiber tuft. This new and novel way to pick fiber tufts is achieved by employing a longitudinal tube having a definite shape, i.e. circular cross section, and limiting its inside length to that of somewhat less than the length of the fiber used for forming a fiber tuft. Such tuft-forming pickers are shown in FIGS. l through 5.

The tuft-forming picker 1 of FIG. 2 has a venturi section 4 approximately midway along the internal wall as indicated by line 2B-2B. As seen in FIG. 2B, the venturi section is constructed such that it is constricted thus forming a smaller opening 2 at line 2A-2A. When fiber enters the opening at 2, it is allowed to flow along the tubelike picker and as the fiber approaches the venturi at 4, the fiber is further compressed in order to tighten the unsealed fiber tuft which results in holding the fiber together more firmly in order that they may not fall away. The tapered pin section at 3 provides the means for holding the tuft-forming picker in any suitable mounting device.

By employing tuft-forming pickers of the type shown in FIGS. l, 3, 4 and 5 it is possible to form tufts having different shapes. lt should be appreciated that other shaped cross sections can be employed without deviating from the scope of this invention.

A more suitable type of tuft-forming picker of this invention is shown in FIG. 6 wherein the exterior surface of the picker has a section at 7 having a slightly larger diameter which serves to minimize friction between the fiber and the external wall during removal of the tuft-forming picker from the stock feed box. A tapered section is placed at 9 allowing fibers to first enter the picker at 8, travel through the internal section up to 9 and stop at the trim forming end 5. The shape or contour of 5 will determine the trim of the finished fiber tuft. The smaller diameter at 9 acts in much the same way the venturi does in FIG. 2. The tapered pin section 6 provides means for support ofthe picking device.

FIG. 7 shows the tuft-forming picker of FIG. 6 containing synthetic fiber 10 in parallel arrangement. The end of the fiber l0' is slightly compressed together due to the internal taper at 9. Fiber end l0" projects somewhat beyond the end of the tuft-forming picker; this end l0" will eventually forni the heat sealed portion of the fiber tuft. By controlling the length of both the fiber and the tuftforming picker, it is possible to form tufts having different trim lengths and heat sealed portions.

FIGS. 8, 9 and 10 illustrate how a heat sealed tuft l1' can be formed possessing a rounded trim without having to physically trim the tuft. Fiber 11 in parallel arrangement is inserted into the tuft-forming picker and the ends l2 conform to the interior end l2' of the picker. This results in the opposite end l2" conforming to the shape of a concave contour. The sealed fiber tuft will have a fiber length the same as the length for that of the interior of the picker. The excess fiber ends 12" as shown in FIG. 9 extend outwardly from the tuft-forming picker for such a length which makes them desirable for heat sealing. FIG. l0 shows the finished fiber tuft after having been heat sealed at 12" in FIG. 9 possessing a rounded trim l2 and a heat sealed tuft end I3.

FIGS. l1, 12 and 13 illustrate different interior configurations which can be employed for forming different trims in fiber tufts. The fiber 14 in FIG. 1l comforms to the interior shape at 14', likewise,

fiber

15 and 16 of FIGS. 12 and 13 respectively conform to the interior shapes at l5' and 16'.

In order to form a heat sealed tuft like the one shown in FIG. 10 it is necessary to heat the end portion of a group of parallel fibers to a temperature of approximately to that of the melting point of the particular type of synthetic fiber employed. Most thermoplastic fibers have softening points which make them pliable and capable of fusing togetherunder a slight pressure. In the case of oriented synthetic fibers, they usually begin to deorient at their softening temperature, thus causing a decrease in length and an increase in diameter. Consequently, as the heated oriented ends of the fiber soften, they must be shaped and made to fuse in order to create a self-supporting heat sealed tuft. It is usually convenient to cause the fiber ends to become softened while contained within a heated shaping mold. In FIG. 14 the tuft-forming picker 17 containing fiber 18 is moved in the direction D causing the fiber ends I8 to enter the heated shaping mold at I9, the section I9 being more or less a guide means, and filling the cavity of section 20. The tuft-forming picker is allowed to remain in this position long enough for the fiber ends 18' to become fused and shaped like the tuft end 18 of FIG. l5. The cavity section 20 of FIG. 14can be fashioned from stainless steel, however, Teflon (the trade name for a polyfluoride polymer made by Dupont) makes a much more suitable material. The heating means 2l can be set at such a temperature that the time lag of the fibers entry of the end I8' into the cavity 20 will cause the fibers to fuse but not melt. It is desirable, after fusing the v fibers together and imparting the desired shape to the fused portion, to immediately insert the still softened end I8 into a predetermined tuft hole 22 in a brush back 23 of FIG. I6 causing the end 18" to take the form of the tuft hole. After insertion into the tuft hole, the softened fused portion takes a new shape 18"' and becomes solid upon cooling. When the tuftforming picker 17 is drawn away the heat sealed fiber tuft 24 is left exposed and is securely anchored in the brush back without the aid of the conventional wire anchor or staple.

While the invention is susceptible of embodiment in many different forms, there is shown now` in FIGS. 17, 18 and 19 specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principle ofthe invention and is not intended in any way to limit the invention to the embodiments illustrated.

Particular attention is now given to the automatic brush machine shown in FIGS. 17, 18 and I9. This automatic unit consists of three basic forming stations; a synthetic fiber stock box 25, a heating unit for forming the heat sealed fiber tuft ends 26 and a mounting fixture for the brush back 27. The tuft-forming picking device 3l in FIG. 17 is comprised of individual tuft-forming pickers 29 and 29' having configurations like the tuft-forming picker of FIG. l. Outer tuft-forming pickers 29 are larger in diameter than the inner tuft-forming pickers 29' as shown in FIG. 20. By having larger diameter tuft-forming pickers, a brush may result having larger tufts positioned around its outer parameter. The tuft-forming pickers 29 and 29' in the forming device 31 are arranged in such a manner so as to conform to the tuft arrangement desired in the finished brush. Picking is carried out by allowing the picking unit 31 to enter longitudinally to the fibers length into the stock box as shown in FIGS. I7 and 21, through

fiber retaining holes

28 and 28. The pickers first come into contact with the ends of the fiber and by employing a quick entry in the direction ofE the fibers are forced into the interi' or cavity of each tuft-forming picker. Upon reversing the motion of the picking unit 3l the individual tuft-forming pickers retract, each filled with a predetermined amount of synthetic fiber. As the picking unit leaves the fiber stock box more fiber 30 falls so as to occupy the empty spaces created by the removal of fibers 30. Suitable means may be employed for vibrating the fiber stock box in order to facilitate fiber alignment and mobility. After completing the picking operation, the machine support 32 is indexed forward in the direction F in order to allow the heating unit 26 to align itselfopposite the tuft-forming picking unit, as shown in FIGS. 18 and 22. The picking unit is moved forward in the direction G until the fiber contained in each tuft-forming picker comes into Contact with the

cavities

34 and 34 of the shaping mold 33. This shaping mold is preferably constructed from Teflon thermoplastic polymer. The mold is attached to a steel mounting plate 36 containing suitable electric heating elements 35. The fiber ends become heated and shaped in the same fashion as previously described and shown in FIG. I4. Preferably, the fiber 30 is inserted into the cavities and allowed to become heated for 5-l0 seconds while the actual temperature of the cavities is kept higher than the melting point of the fibers; i.e. isotactic polypropylene fibers melt in the range from l to 145 centigrade, (100,000 to 200,000 molecular weight polymer). The cavities in this case might be kept at temperatures in the order of from 150 to 160 centigrade. After the ends of the fiber tufts have been heat sealed, the picking unit 3l is reversed al lowing the tuft heat sealed portion to come away from the cavities. This removal can be facilitated by first applying a mold release to the inner surfaces of the mold cavities. However, if Teflon is employed for the cavity structure, a mold releasing agent is not necessary. The machine support 32'is indexed forward in the direction H in order to align the brush support 36 opposite the heat sealed (stilll moldable) fiber tufts. In FIGS. 19 and 23 the picking unit is then advanced forward in the direction of l whereupon the still-moldable fiber tuft ends are inserted into the cavities 39 and 39' of the brush back 38. As the tuft ends come into contact with the cavities, the moldable end conforms to the cavity contour and cools. The brush back is held against the brush support by means of fixtures 37. Upon reversing the picking unit 31 in the direction J the tuft-forming pickers release the fiber and the overall result is a finished brush as shown in FIG. 23A. The brush back 38 has heat sealed fiber tufts 30". The preferred time taken for the complete fabrication of the brush is approximately 10 seconds. However, there is no definite time cycle. Each cycle depends upon the type of synthetic fiber employed and the size of the fiber tuft desired. There is no trimming required after forming the brush of this invention since there is no dis`- alignment of fibers when forming the fiber tufts. This is true because there is no doubling oftibers prior to insertion.

By employing tuft-picking units as shown in FIG. 24 it is possible to form continuous modular strips of thermoplastic tufted brush constructions. In order to achieve this, it requires an assembly of tuft-forming pickers 39 arranged side by side in aline. After the fiber 44 is inserted in the tuft-picking unit, the unit is then moved toward the forming mold 40 in the direction K thus allowing the fiber ends 414 to become softened and fused within the cavity 4l. The moid 40 is attached to a steel housing 43 which contains suitable heating elements 42. Upon cooling ofthe fused fiber ends 44 the molded construction 45 is indexed forward in the direction of L allowing the picking unit to repeat its cycle. When this operation is carried out properly, the modular brush construction 45 as shown in FIG. 25 results.

The tuft-forming pickers of this invention can be constructed from any of the conventional metal elements or alloys known to man. Also, it is possible to construct the picking devices from thermoplastic materials; i.e. polypropylene, polyacetal, polyamide, and the like. The tuft-forming pickers are not limited to any given size since they can have any length and internal diameter so long as they conform to a given fiber tuft.

It has been found that the tuft-forming pickers of this invention will pick tufts from assembled parallel cut-to-length synthetic fibers having any cross-sectional shape; i.e. circular, X-shaped, star-shaped hollow, and the like. The diameter of the fibers picked range from 0.008 inch to 0.250 inch. The lengths of the cutto-length fiber can range from 0.5 to 30 inches. The composition of the synthetic fiber picked and assembled into fiber tufts is not limited, and thermoplastic fibers either oriented or unoriented can be used to form tufts in accordance with the invention. Polymers like polyamide, polypropylene, polyethylene, copolymers of polypropylene and ethylene, polyfluoride, and the like can be employed.

If more than one fiber stock box is employed, it is possible to pick one color and diameter fiber during one picking step, and another color and diameter during a second picking step and then instantaneously heat seal and assemble the combination of fiber tufts into a brush back.

The foregoing considerations conclusively demonstrate the advantages to be gained by providing picking devices of the type hereinbefore described. When such picking devices are incorporated into automatic brushmaking equipment there is attained new and novel brush constructions heretofore not known.

The invention in its broader aspects is not limited to the specific steps, methods, compositions, combinations and im provements described but departures may be made therefrom alignment with the central axis of said aperture; inserting a hollow picking element into said stock box through said aperture;

retaining a plurality of tuft-forming filaments in said picking element, said element receiving an end and central portion of said tuft-forming filaments only and exposing an end portion of said filaments;

removing said picking element from said stock box through said aperture so that the tuft-forming filaments retained therein are picked from the plurality of cut-to-length filaments supported in said stock box;

inserting the exposed end portion of said filaments retained in said picking element into a heating element to fuse the end portion of said filaments and form a tuft of filaments extending from said fused end portion;

supporting said fused end portion on a brush back.

2. The method of claim l further comprising:

providing a brush back having at least one tuft-receiving aperture therein;

inserting the fused end portion of said tuft into the aperture in said brush back before said end portion cools so that said fused end portion conforms to the internal confines of said tuft-receiving aperture;

allowing said fused end portion to cool in the aperture whereby said tuft is retained in said brush back.

3. The method of claim 2 wherein said box has a plurality of apertures in a face thereof; said method further comprising:

providing a plurality of hollow picking elements, each of said elements aligned with an aperture in said stock box;

simultaneously inserting said elements into said box through said apertures;

retaining the end and central portion of a plurality of tuftforming filaments in each of said elements;

simultaneously withdrawing said elements and tuft-forming fibers from said box through said apertures;

providing at least one heating element;

simultaneously inserting the exposed end portions of said filaments into said heating element to fuse the end portions forming a plurality of tufts having fused end portions;

providing a brush back having a plurality of tuft-receiving apertures therein;

simultaneously inserting said fused end portions of said tufts into said apertures before said fused end portions cool;

allowing said fused end portions to cool in said apertures, said end portions conforming to the internal confines of said apertures to form a tufted modular brush construction.

4. The method of forming a unitary modular brush construction having an integral tuft and support comprising:

providing a stock box for supporting a plurality of cut-tolength synthetic filaments, said box having at least one aperture in a face thereof;

supporting a plurality of cut-to-length synthetic filaments in parallel alignment in said stock box, said filaments being disposed in longitudinal alignment with the central axis of said aperture;

inserting a hollow picking element into said stock box through said aperture;

retaining a plurality of tuft-forming filaments in said picking element, said element receiving an end and central portion of said tuft-forming filaments only and exposing an end portion of said filaments; removing said picking element from said stock box through said aperture so that the plurality of tuft-forming filaments retained therein is picked from the plurality of cutto-length filaments supported in said stock box;

providing a heated support mold having a recess therein, the internal confines thereof describing the configuration of a tuft support;

inserting the exposed end portion of the filaments retained in said picking element into the recess in said heated support mold to fuse the end portion of said filaments and to mold the said end portion in conformance with the internal confines of said recess;

cooling said fused end portions to form a tufted modular brush construction having an integral tuft and support thereof.

5. The method of claim 4 wherein said stock box has a plurality of apertures in the face thereof; said method further comprising:

simultaneously inserting said elements into said box through said apertures;

retaining the end and central portions of the plurality of tuft-forming filaments in each of said elements;

simultaneously withdrawing said elements and tuft-forming filaments from said box through said apertures;

providing a heated support mold having a recess, the internal confines thereof describing the configuration of a brush back;

simultaneously inserting the exposed end portions of said filaments into said recess to fuse the said end portions and to mold the end portions in conformance with the internal confines ofthe said recess;

cooling the molded end portions to form a modular brush construction having a plurality of tufts with an integral supporting back. v

Claims

1. A method for forming a tufted modular brush construction comprising: providing a stock box for supporting a plurality of cut-tolength synthetic filaments, said box having at least one aperture in a face thereof; supporting a plurality of cut-tolength synthetic filaments in parallel alignment in said stock box, said filaments being disposed in longitudinal alignment with the central axis of said aperture; inserting a hollow picking element into said stock box through said aperture; retaining a plurality of tuft-forming filaments in said picking element, said element receiving an end and central portion of said tuft-forming filaments only and exposing an end portion of said filaments; removing said picking element from said stock box through said aperture so that the tuft-forming filaments retained therein are picked from the plurality of cut-to-length filaments supported in said stock box; inserting the exposed end portion of said filaments retained in said picking element into a heating element to fuse the end portion of said filaments and form a tuft of filaments extending from said fused end pOrtion; supporting said fused end portion on a brush back.

2. The method of claim 1 further comprising: providing a brush back having at least one tuft-receiving aperture therein; inserting the fused end portion of said tuft into the aperture in said brush back before said end portion cools so that said fused end portion conforms to the internal confines of said tuft-receiving aperture; allowing said fused end portion to cool in the aperture whereby said tuft is retained in said brush back.

3. The method of claim 2 wherein said box has a plurality of apertures in a face thereof; said method further comprising: providing a plurality of hollow picking elements, each of said elements aligned with an aperture in said stock box; simultaneously inserting said elements into said box through said apertures; retaining the end and central portion of a plurality of tuft-forming filaments in each of said elements; simultaneously withdrawing said elements and tuft-forming fibers from said box through said apertures; providing at least one heating element; simultaneously inserting the exposed end portions of said filaments into said heating element to fuse the end portions forming a plurality of tufts having fused end portions; providing a brush back having a plurality of tuft-receiving apertures therein; simultaneously inserting said fused end portions of said tufts into said apertures before said fused end portions cool; allowing said fused end portions to cool in said apertures, said end portions conforming to the internal confines of said apertures to form a tufted modular brush construction.

4. The method of forming a unitary modular brush construction having an integral tuft and support comprising: providing a stock box for supporting a plurality of cut-to-length synthetic filaments, said box having at least one aperture in a face thereof; supporting a plurality of cut-to-length synthetic filaments in parallel alignment in said stock box, said filaments being disposed in longitudinal alignment with the central axis of said aperture; inserting a hollow picking element into said stock box through said aperture; retaining a plurality of tuft-forming filaments in said picking element, said element receiving an end and central portion of said tuft-forming filaments only and exposing an end portion of said filaments; removing said picking element from said stock box through said aperture so that the plurality of tuft-forming filaments retained therein is picked from the plurality of cut-to-length filaments supported in said stock box; providing a heated support mold having a recess therein, the internal confines thereof describing the configuration of a tuft support; inserting the exposed end portion of the filaments retained in said picking element into the recess in said heated support mold to fuse the end portion of said filaments and to mold the said end portion in conformance with the internal confines of said recess; cooling said fused end portions to form a tufted modular brush construction having an integral tuft and support thereof.

5. The method of claim 4 wherein said stock box has a plurality of apertures in the face thereof; said method further comprising: providing a plurality of hollow picking elements, each of said elements aligned with an aperture in said stock box; simultaneously inserting said elements into said box through said apertures; retaining the end and central portions of the plurality of tuft-forming filaments in each of said elements; simultaneously withdrawing said elements and tuft-forming filaments from said box through said apertures; providing a heated support mold having a recess, the internal confines thereof describing the configuration of a brush back; simultaneously inserting the exposed end portions of said filaments into said recess to fuse the said end portions and to mold the end portions in conformanCe with the internal confines of the said recess; cooling the molded end portions to form a modular brush construction having a plurality of tufts with an integral supporting back.