Corrugated Bristle Brush

Abstract

A brush including layers of bristles used with a handle. Plates, with bristles connected to a base at one end, are retained by the handle. Certain stackable plates may also be interconnected by a set of hinges. Plates can be of a unitary plastic construction and can be stacked or folded upon one another to form layers of plates with bristles. A corrugated layer is adjacent to a first plate or between two plates. The corrugated layer has a base and corrugated bristles extending from an end of the base, with the corrugated bristles preferably shaped in alternating ridges and grooves. The corrugated layer is stiffer than an adjacent plate of bristles and assists with liquid retention of the brush. Recesses or holes in the ridges of the corrugated bristles can aid with liquid retention in the brush before applying the liquid on a surface. A method of making a brush with layers of bristles can include forming a first plate having a series of bases connected to a plurality of bristles, stacking bases of the first plate in layers, attaching the stacked bases of the first plate to a handle, and forming and attaching a corrugated layer to be adjacent to the first plate.

1 . A brush including layers of bristles attached to a handle, comprising:
 a first plate having a series of bases connected to a plurality of bristles, the first plate adapted to be stacked in layers, wherein the series of bases is formed from a unitary piece of polymeric material, and   a corrugated layer adjacent to the first plate, the corrugated layer having a base and corrugated bristles extending from an end of the base wherein the corrugated bristles are shaped in alternating ridges and grooves, wherein the corrugated layer is stiffer than the first plate.   
   
   
       2 . The brush of  claim 1  wherein the series of bases are pivotally interconnected by at least one living hinge that is part of the unitary piece of polymeric material. 
   
   
       3 . The brush of  claim 1  wherein the first plate is formed from silicone. 
   
   
       4 . The brush of  claim 1  wherein the series of bases of the first plate and the base of the corrugated layer each have a complementary oval opening passing through to assist with aligning said bases and to help secure said bases to the handle. 
   
   
       5 . The brush of  claim 1  further including recesses in the ridges of the corrugated bristles. 
   
   
       6 . The brush of  claim 1  further including holes in the ridges of the corrugated bristles. 
   
   
       7 . The brush of  claim 1  wherein the first plate has a first base with bristles that correspond and align with grooves of the corrugated bristles. 
   
   
       8 . The brush of  claim 7  wherein the bristles corresponding to the grooves are wider apart than the bristles of an adjacent base of the first plate. 
   
   
       9 . The brush of  claim 1  wherein the alternating ridges and grooves are parallel. 
   
   
       10 . The brush of  claim 1  further comprising a second plate having a second series of bases connected to a second plurality of bristles, the second plate adapted to be stacked in layers, wherein the second series of bases is formed from a unitary piece of polymeric material, wherein the corrugated layer is between the first and second plates. 
   
   
       11 . The brush of  claim 10  wherein the first plate, the second plate, and the corrugated layer are removable to be easily separated from the handle to allow for cleaning or replacement. 
   
   
       12 . The brush of  claim 10  wherein the first plate, the second plate, and the corrugated layer are permanently bonded together. 
   
   
       13 . The brush of  claim 10  wherein the bases include an alignment mechanism to maintain correct alignment when stacked in layers. 
   
   
       14 . The brush of  claim 13  having a complementary oval opening passing through each base of the first plate, the second plate, and the corrugated layer to assist with aligning these components and to help secure them to the handle. 
   
   
       15 . The brush of  claim 1  wherein the corrugated layer is made of plastic that is more rigid than the polymeric material of the first plate. 
   
   
       16 . The brush of  claim 1  wherein the ridges and grooves form a zigzag pattern in cross section. 
   
   
       17 . The brush of  claim 1  wherein the corrugated bristles are cut from a fraction of a length of the corrugated layer. 
   
   
       18 . The brush of  claim 1  wherein the corrugated bristles are separated extending from the base to distal ends of the corrugated bristles. 
   
   
       19 . A brush including layers of bristles attached to a handle, comprising:
 a first plate having a series of bases connected to a plurality of bristles, the first plate adapted to be stacked in layers,   a second plate having at least one base connected to a second plurality of bristles, and   a corrugated layer between the first and second plates, the corrugated layer having a base and corrugated bristles extending from an end of the base wherein the corrugated bristles are shaped in alternating ridges and grooves, wherein the ridges and grooves form a zigzag pattern in cross section, wherein the first plate has a first base with bristles that correspond and align with grooves of the corrugated bristles.   
   
   
       20 . The brush of  claim 19  wherein the corrugated layer is a stiffer plastic than the polymeric material of the first plate. 
   
   
       21 . The brush of  claim 19  wherein the corrugated bristles are cut from at least a fraction of a length of the corrugated layer. 
   
   
       22 . A method of making a brush having layers of bristles, comprising:
 forming a first plate from a unitary piece of polymeric material having a series of bases connected to a plurality of bristles,   stacking bases of the first plate in layers,   attaching the stacked bases of the first plate to a handle,   forming a corrugated layer having a base and corrugated bristles extending from an end of the base wherein the corrugated bristles are shaped in alternating ridges and grooves, and   attaching the corrugated layer adjacent to the first plate securing the corrugated layer to the handle.   
   
   
       23 . The method of  claim 22  including additional steps of forming a second plate from a unitary piece of polymeric material having a series of bases connected to a plurality of bristles,
 stacking bases of the second plate in layers, and   attaching the stacked bases of the second plate to the corrugated layer so the corrugated layer is between the first and second plates.   
   
   
       24 . The method of  claim 23  including the step of permanently bonding the first plate, the second plate, and the corrugated layer together. 
   
   
       25 . The method of  claim 22  including the additional step of cutting at least a portion of the corrugated layer to form corrugated bristles.