FIEUD OF INVENTION

The present invention generally relates to brush manufacturing.

BACKGROUND OF THE INVENTION

This section is intended only to provide background information pertaining to the similar field of the present invention, and may be used only to enhance the understanding of the present invention and not as admissions of prior art. Presently, there is a constant need to produce unique types of brushes for specific cleaning purposes. These brushes are required in various shapes and sizes for distinct and particular applications. There was a requirement to produce modular brushes for the delicate cleaning of a filter mesh. The filter mesh could be made from metal, plastic or fabric.

Due to the unique shape of these filters, the brushes need to be modular pieces that are fitted together to form a single brush product. The dimensions of each brush module are generally smaller than 20 mm in length and width. The brush modules are either square or rectangular shaped. To effectively make contact with the filter surfaces, the modules are curved.

To effectively clean the interstices of the filter mesh, the bristle tufts are required to be implanted in a matrix configuration. The various product families required different arrays. For example, there was a specification for a product with 5 rows and 4 columns with the pitch between bristle tufts less than 5 mm.

Based on the above requirements, there was a need to manufacture the brush products in an economically efficient and viable manner. The manufacturing process had to deliver the daily production quota of brush modules with a short turnaround times, minimal in-process waste of raw material and reduced defects. However, a commercially available machine to produce this particular family of brush products was not available. Accordingly, in light of the foregoing discussion there was a need to overcome the above- mentioned limitations with regards to brush manufacturing.

SUMMARY OF INVENTION In light of the limitations of the existing brush manufacturing machines to increase the throughput by reducing the waiting time between processes, reducing raw material waste and minimizing the process defects.

In one aspect, the embodiments of the present disclosure provides a brush manufacturing machine comprising a rotary transportation mechanism; a bristle carrier loading station; one or more bristle dispensing station comprising a bristle feed mechanism, a bristle tuft picker, and a bristle plant feeder, that plants high-density and short length bristle tufts on a bristle carrier with fine pitch openings; an ultrasonic fusion station; a heating station; an unloading station; and a logic controller system for providing programmed commands, controlling the machine sequence and monitoring the feedback of operating conditions at every station through a network of sensors and actuators.

In another aspect, embodiments of the present disclosure provides a system for manufacturing brushes comprising a rotary transportation mechanism; a bristle carrier loading station; one or more bristle dispensing station ; an ultrasonic fusion station; a heating station; an unloading station; a logic controller system for providing programmed commands, controlling the machine sequence and monitoring the feedback of operating conditions at every station through a network of sensors and actuators. BRIEF DESCRIPTION OF DRAWINGS

The drawing/s mentioned herein disclose exemplary embodiments of the claimed invention. Detailed description and preparation of well-known compounds/substances/elements are omitted to not unnecessarily obscure the embodiments herein. Other objects, features, and advantages of the present invention will be apparent from the following description when read with reference to the accompanying drawing.

FIG. 1A illustrates a schematic illustration of the present invention in accordance with an embodiment of the present disclosure; FIG. IB illustrates an example of a bristle carrier in accordance with an exemplary implementation of the present disclosure;

FIG. 2A illustrates an example of a bristle feed mechanism in accordance with an exemplary implementation of the present disclosure;

FIG. 2B illustrates an example of a bristle turf picker in accordance with an exemplary implementation of the present disclosure;

FIG. 2C illustrates an example of a nozzle in accordance with an exemplary implementation of the present disclosure;

FIG. 2D illustrates an example of a cross-sectional view of a blower and suction system in accordance with an exemplary implementation of the present disclosure; FIG. 3 illustrates an example of an ultrasonic device in accordance with an exemplary implementation of the present disclosure. DETAILED DESCRPTION

This section is intended to provide an explanation and description of various possible embodiments of the present invention. The embodiments used herein, and the various features and advantageous details thereof are explained more fully with reference to non-limiting embodiments illustrated in the accompanying drawing/s and detailed in the following description. The examples used herein are intended only to facilitate understanding of ways in which the embodiments may be practiced and to enable the person skilled in the art to practice the embodiments used herein. Also, the examples/embodiments described herein should not be construed as limiting the scope of the embodiments herein. Referring to Fig. 1, the embodiment of the present disclosure provides a brush manufacturing machine (100) comprising a rotary transportation mechanism (160); a bristle carrier loading station (110); one or more bristle dispensing station (120a-d) comprising a bristle feed mechanism (200), a bristle tuft picker (240), and a bristle plant feeder (250), that plants high- density and short length bristle tufts on a bristle carrier (170) with fine pitch openings; an ultrasonic fusion station (130); a heating station (140); an unloading station (150); and a logic controller system for providing programmed commands, controlling the machine sequence and monitoring the feedback of operating conditions at every station through a network of sensors and actuators.

The brush manufacturing machine (100) further comprising a network of sensors and actuators controlled by the logic controller system that enables a pre-programmed sequence of processing steps.

The stations (110, 120a-d, 130-150) of the brush manufacturing machine (100) are linked by a rotary transportation mechanism (160) that stops at each station. The rotary transportation mechanism (160) is preferably a turntable.

The movement of the rotary transportation mechanism (160) is directed by a servo motor. Where, station 1 is the bristle carrier loading station (110), station 2 is the bristle dispensing station (120a-d), station 3 is the ultrasonic welding station (130) to seal the bristle carrier openings (172), station 4 is the heating station (140) to securely fasten the bristle tuft to the bristle carrier (170), and station 5, is the unloading station (150).

Furthermore, a plurality of bristle dispensing stations (120a-d) can be present to dispense bristles to the various rows and columns of the bristle carrier openings (172). The number of bristle dispensing stations ( 120a-d) is based on the configuration of rows and columns of the bristle carrier openings (172). In an exemplary embodiment of this machine, there are four bristle dispensing stations (120a-d).

The bristle carrier loading station (110) comprises a vibrating feeder bowl, an orientation check feature, a gripper arm having a presence sensor that controls the movement of the gripper arm. The vibration of the vibrating feeder bowl is provided by a rotary vibrating exciter. Bristle carriers (170) are loaded into the vibrating feeder bowl. The vibration causes the bristle carriers (170) to move in an upward spiral until the bristle carriers (170) are oriented correctly and transported along a track to the bristle carrier loading station (110) for pick-up. An orientation check feature ensures the bristle carrier is oriented correctly for the pick-and-place unit. Once the presence sensor detects a bristle carrier (170), the gripper arm delivers the bristle carrier (170) to the rotating turntable. A second presence sensor activates the rotation of the rotary transportation mechanism (160).

With reference to Fig. 2A-2D, the bristle dispensing station (120a-d) comprises a bristle feed mechanism (200) together with a bristle tuft picker (240), and a bristle plant feeder (250). Further, the bristle feed mechanism (200) comprises a magazine (210) for the bristle tufts, having a vertical compression plate (230) and a horizontal compression plate (220) controlled by a solenoid valve and reed switch.

The bristle tufts are manually loaded into a magazine (210). The vertical compression plate (230) is designed to move in a vertical direction, to ensure the bristles are levelled to the same height. The horizontal compression plate (220) pushes the bristles in a horizontal direction towards the bristle tuft picker (240). The simultaneous dual compression motion is to continuously feed an equal number of bristle tufts into the bristle tuft picker (240). To minimize in-process waste, the bristles were pre-cut to a specific length and supplied in the required density.

The bristle tuft picker (240) comprises a picker plate (241) with a picker face (242) with one or more through holes (244) with dimensions consistent with the through holes of the bristle carrier openings (172). Preferably, the shape of the through holes (244) are semi-circular, but are not limited to such. Further, a sensor is used to detect the bristle tufts in all the through holes (244) of the picker plate. And a control mechanism slides the picker plate (241) and the horizontal compression plate (220) into a clamping position. The bristle tufts are clamped at the top and bottom to prevent the bristle tuft from entering into the transport line (270).

Further, as illustrated in Fig. 2C, the bristle plant feeder (250) comprises a conically shaped nozzle (252). The conically shaped nozzle (252) embodies a first opening (254), and a second opening (256), where the diameter of the first opening (254) is larger than the diameter of the second opening (256). The first opening (254) of the conically shaped nozzle (252) receives a distal end of a transport line (270). The conically shaped nozzle (252) receives the bristle tufts through the transport line (270) through the first opening (254) to the second opening (256) via a blower and suction system (260). Where the diameter of the second opening (256) is smaller than the diameter of the through holes of the bristle carrier openings (172).

The conically shaped nozzle (252) enables fine pitch dispensing of the bristle tufts allowing for acute angles due to the curved profile of the bristle carrier (170). When the bristle carrier (170) is detected, the stopper at the distal end of the conically shaped nozzle (252) is retracted. The conically shaped nozzle (252) moves in a vertical motion towards the bristle carrier (170). It is set to stop just above each bristle carrier opening (172). In an exemplary embodiment, the distance between the conically shaped nozzle (252) and the bristle carrier opening (172) can be less than 5 mm. Each conically shaped nozzle (252) is uniquely placed and directed at specific angles of the targeted bristle carrier opening (172). The activation of the high-pressure blower and the vacuum suction transports the bristle tufts through the transport line (270) into the bristle plant feeder (250). Within the bristle plant feeder (250), the push of the high-pressure blower, and the pull of the vacuum suction, plants the bristle tufts in each bristle carrier opening (172). Once the bristle tuft discharge is detected, the bristle plant feeder (250) moves in a vertical motion away from the bristle carrier. Before the bristle plant feeder (250) is retracted, the low-pressure blower is activated. The suction from the vacuum chamber, pulls down the bristle tufts, while a second pressure is applied through the bristle plant feeder (250). The second pressure is lower than the first pressure. This pressure maintains the bristle tufts at the bristle carrier openings (172) and prevents the bristle tufts from plugging the cone feeder as it is retracted.

As illustrated in Fig. 2D, the blower and suction system (260) comprises a high-pressure blower, a low-pressure blower, a vacuum suction, transport lines (270) with the conically shaped nozzle (252) at the distal end, and a stopper. In an exemplary embodiment, there are 4 transport lines (270) at the bristle dispensing station (120a-d). The placement of the bristle carrier (170) at the bristle plant feeder (250) triggers a presence sensor. When the bristle carrier (170) is detected, the stopper is removed and the bristle plant feeder (250) moves vertically towards the bristle carrier (170). This creates an unimpeded path from the bristle tufts at the bristle tuft picker (240) to the bristle carrier (170) at the end of the transport line (270). The bristle tuft advances towards the bristle carrier (170) due to the activation of the high-pressure blower and vacuum suction. Once the bristle tuft is discharged into the bristle carrier opening (172), the bristle plant feeder (250) will move vertically upwards to its zero or rest position. To ensure the bristle tuft remains in the bristle carrier openings (172), the high-pressure blower is switched off and the low-pressure blower is activated. When the bristle plant feeder (250) is at the zero position, the high-pressure blower, the low-pressure blower and the vacuum suction are deactivated. The stopper is then extended at the distal end of the transport line (270). The timing and pressure settings for the high-pressure blower, low-pressure blower and the vacuum suction ensures the bristle tufts are transported and retained within the openings of the bristle carrier opening (172).

The blower and suction system (260) is managed by the logic controller system. The logic controller system varies the pressure difference applied on the bristle tuffs. The pressure difference is varied by monitoring and varying the blower and suction pressure. Also, the monitoring and timing of the sequence of activation and deactivation between the blower and suction is managed by the logic controller system to feed the bristle tufts through the conically shaped nozzle (252) and transport line (270), and to provide the required pressure difference to hold the bristle turfs in the bristle carrier openings (172) after planting, when deactivating the blower and suction system (260). With the bristle turfs retained in the bristle carrier openings (172), the bristle carrier (170) is transported to the next station.

With reference to Fig. 3, the ultrasonic fusion station (130) comprises a power supply, a vibrator, a transducer, and an ultrasonic horn (132). The ultrasonic horn (132) is preferably shaped to match the bristle carrier (170) profile and dimensions. When the ultrasonic horn (132) is pressed against the bristle carrier (170), it transfers energy to the energy director (174) features on the bristle carriers (170). The concentrated energy enables the material of the energy director (174) to melt and flow into the bristle carrier openings (172). The material of the energy director (174) will completely fill the bristle carrier openings (172) when the process is optimised. The desired outcome from this process is to seal the bristle carrier openings (172) from the distal end and retain the bristle tufts in the bristle carrier (170).

The heating station (140) comprises a heating controller, and a heating element having a heating plate shaped to match the bristle carrier (170) profile and dimensions. The objective of the heating station is to increase the bristle retention strength. This is achieved by melting the distal end of the bristle tufts, resulting in the bristle tuft material forming a thickened end. This enables the bristle tufts to be securely embedded within the sealed bristle carrier openings (172). The post- heated bristle tuft in the bristle carrier (170) has high retention strength.

The unloading station (150) comprises a presence sensor and a pick-and-place gripper. When the bristle carrier (170) is detected by the presence sensor at the unloading station (150), the bristle carrier (170) filled with bristles are taken out for assembly.

In another embodiment, a system for manufacturing brushes (100) comprising a rotary transportation mechanism (160); a bristle carrier loading station (110); one or more bristle dispensing station (120a-d); an ultrasonic fusion station (130); a heating station (140); an unloading station (150); a logic controller system for providing programmed commands, controlling the machine sequence and monitoring the feedback of operating conditions at every station through a network of sensors and actuators. The system for manufacturing brushes (100) further comprising a network of sensors and actuators controlled by the logic controller system that enables a pre-programmed sequence of processing steps.

As will be readily apparent to a person skilled in the art, the present invention may easily be produced in other specific forms without departing from its essential composition and properties. The present embodiments should be construed as merely illustrative and non-restrictive and the scope of the present invention being indicated by the claims rather than the foregoing description, and all changes which come within therefore intended to be embraced therein.