Method for manufacturing a flexible strip brush

Abstract

A method for manufacturing a flexible strip brush element is disclosed. A multiplicity of thermoplastic monofilaments respectively having first ends and second ends are arranged in substantially parallel fashion and at a prescribed density. Heat is applied to the first ends of the monofilaments so as to melt the first ends of the monofilaments. The monofilaments are transported toward an extrusion die comprising an outlet. Molten thermoplastic resin is extruded from an extrusion die outlet, wherein the outlet is shaped to produce a base having a top and a bottom. The first ends of the monofilaments are brought into physical contact with the top of the base as the base emerges from the extrusion die outlet. The monofilaments and the base are cooled so that the first ends of the monofilaments are fused to the top of the base and the second ends of the monofilaments are free.

What is claimed is: 
     
         1 . A method for manufacturing a flexible strip brush element, the method comprising the steps of:
 arranging, in substantially parallel fashion and at a prescribed density, a multiplicity of thermoplastic monofilaments respectively having first ends and second ends;   applying heat to the first ends of the monofilaments so as to melt the first ends of the monofilaments;   transporting the monofilaments toward an extrusion die comprising an outlet;   extruding molten thermoplastic resin from an extrusion die outlet, wherein the outlet is shaped to produce a base having a top and a bottom;   bringing the first ends of the monofilaments into physical contact with the top of the base as the base emerges from the extrusion die outlet; and   cooling the monofilaments and the base so that the first ends of the monofilaments are fused to the top of the base and the second ends of the monofilaments are free.   
     
     
         2 . The method of  claim 1 , wherein:
 transporting the monofilaments toward an extrusion die comprising an outlet is in a first direction; and   extruding molten thermoplastic resin from an extrusion die outlet is in a second direction.   
     
     
         3 . The method of  claim 2 , wherein the thermoplastic resin used for the extruded base has a flexural modulus less than 80 ksi as determined by ASTM D790 when solid, the second direction is approximately perpendicular to the first direction, and between the emergence of the base from the extrusion die outlet and the cooling of the monofilaments and the base, movement of the base is made to undergo a change of direction from the first direction to the second direction. 
     
     
         4 . A method for manufacturing a flexible strip brush element, the method comprising the steps of:
 arranging, in substantially parallel fashion and at a prescribed density, a multiplicity of thermoplastic monofilaments respectively having first ends and second ends;   transporting the monofilaments in a first direction toward an extrusion die comprising an outlet;   extruding uncured thermosetting resin in a second direction from the extrusion die, wherein the outlet is shaped to produce a base having a top and a bottom;   bringing the first ends of the monofilaments into physical contact with the top of the base as the base emerges from the extrusion die outlet; and   curing the base so that the first ends of the monofilaments are fused to the top of the base and the second ends of the monofilaments are free.   
     
     
         5 . The method of  claim 4 , wherein:
 transporting the monofilaments toward an extrusion die comprising an outlet is in a first direction; and   extruding molten thermoplastic resin from an extrusion die outlet is in a second direction.   
     
     
         6 . The method of  claim 5 , wherein the thermosetting resin used for the extruded base has a flexural modulus less than 80 ksi as determined by ASTM D790 when cured, the second direction is approximately perpendicular to the first direction, and between the emergence of the base from the extrusion die outlet and the curing of the base, movement of the base is made to undergo a change of direction from the first direction to the second direction. 
     
     
         7 . A method for manufacturing a flexible strip brush from a plurality of flexible strip brush elements, the method comprising the steps of:
 arranging in side-by-side fashion a plurality of adjacent flexible strip brush elements, the strip brush elements each comprising:
 a base having a top and a bottom; 
 a multiplicity of monofilaments, each of the monofilaments having a proximal end and a distal end; and 
 a bristle attachment region, 
 wherein the monofilaments are arranged in substantially parallel fashion, the proximal ends of the monofilaments are attached to the top of the base by way of the bristle attachment region, the distal ends of the monofilaments are free and collectively form a bristle end zone, within the bristle attachment region, there is intermingling of a first material from the base and a second material from the monofilaments, and within the bristle attachment region, the first material from the base fills interstices between the monofilaments; and 
   mutually bonding the adjacent strip brush elements so that the free distal ends of the monofilaments cooperate to form a common bristle end zone.   
     
     
         8 . The method of  claim 7 , wherein the base having a top and a bottom comprises a flexural modulus less than 80 ksi as determined by ASTM D790. 
     
     
         9 . The method for manufacturing a flexible strip brush according to  claim 7 , further comprising forming at least one side bonding region. 
     
     
         10 . The method for manufacturing a flexible strip brush according to  claim 7 , further comprising forming a bottom bonding region comprising substantially a width of the base. 
     
     
         11 . The method for manufacturing a flexible strip brush according to  claim 9 , wherein the side bonding region is formed by one or more species selected from among the group consisting of coextrusion, lamination, glue, heat, and solvent. 
     
     
         12 . The method for manufacturing a flexible strip brush according to  claim 7 , further comprising forming at least one bottom bonding region. 
     
     
         13 . The method for manufacturing a flexible strip brush according to  claim 12 , wherein the bottom bonding region is formed by one or more species selected from among the group consisting of coextrusion, lamination, glue, heat, and solvent. 
     
     
         14 . The method according to  claim 12 , further comprising pressing a heated nonstick tool against the bottoms of the bases while dragging the tool therealong so as to cause melting of the bases to a depth sufficient to cause the flexible strip brush elements to become mutually joined when the melted bases are allowed to cool and resolidify.