Curling Brush with Improved Pressure Distribution, Snap-Fit Head Assembly, Moulded Brush Pad and Pivot Limiting Means

Abstract

A curling brush head incorporates an array of rib-like and ring-like structures designed to effectively transmit force from the handle through the brush head and onto the surface of the ice. A receptacle of the head attaches to the brush handle, and incorporates the ribs and rings which transmit the force to the pad. The pad is features a mounting plate, a layer of pad material, and a layer of fabric material, all of which are co-moulded into a single unit. The mounting plate allows the pad to be attached to the receptacle by way of a convenient snap-fit. A brush handle incorporates a radial enlargement, for example in a mandrel thereof, so that abutting contact between the enlargement and the topside of the brush head limits the angular range of movement therebetween to prevent the brush head from overturning during slide delivery of a curling rock.

Claims

1. A brush head receptacle for a curling brush, said receptacle comprising: a topside at which the receptacle couples, or is arranged to couple, to the lower end of a curling brush handle; an opposing underside at which the receptacle carries, or is arranged to carry, a brush pad; an outer ring lying circumferentially of the brush head receptacle adjacent an outer perimeter thereof; an inner ring spanning circumferentially around a center of the receptacle at a distance inward from the outer ring; a plurality of ribs spanning outwardly away from the inner ring toward the outer ring at spaced apart positions around the center of the receptacle, wherein a profile height of each rib is lesser at an outer end thereof nearest the outer perimeter than at an inner end of the rib nearest the center of the receptacle.

2. A brush head receptacle for a curling brush, said receptacle comprising: a topside at which the receptacle couples, or is arranged to couple, to the lower end of a curling brush handle; an opposing underside at which the receptacle carries, or is arranged to carry, a brush pad; an outer ring lying circumferentially of the brush head receptacle adjacent an outer perimeter thereof; an inner ring spanning around a center of the receptacle at a distance inward from the outer ring a plurality of ribs spanning outwardly away from the inner ring toward the outer ring at spaced apart positions around the center of the receptacle; and valley-like areas delimited between the inner and outer rings and the ribs; wherein the inner ring, the outer ring and the ribs all have taller profiles at the topside of the receptacle than at valley-like areas delimited between the inner and outer rings and the ribs, and a profile height of each rib is lesser at an outer end thereof nearest the outer perimeter than at an inner end of the rib nearest the center of the receptacle.

3. The brush head receptacle of claim 2 wherein the profile height of each rib reduces at a gradual slope moving outwardly toward the outer end thereof.

4. The brush head receptacle of claim 1 wherein the profile height of each rib reduces at a gradual slope moving outwardly toward the outer end thereof.

5. The brush head receptacle of claim 1 wherein each rib reaches fully outwardly the outer ring.

6. The brush head receptacle of claim 1 wherein each rib fully reaches fully inwardly to the inner ring.

7. The brush head receptacle of claim 1 wherein the outer perimeter of the brush receptacle delimits an oblong shape of the receptacle, and the ribs comprise longitudinal ribs spanning outwardly toward longitudinally separated ends of the oblong shape of the receptacle and shorter lateral ribs spanning outwardly toward laterally separated sides of the oblong shape of the receptacle.

8. The brush head receptacle of claim 7 wherein the longitudinal ribs comprise two respective longitudinal ribs extending toward each of the longitudinally separated ends of the oblong shape, said two respective longitudinal ribs being symmetrically disposed across a central major axis of the oblong shape of the receptacle.

9. The brush head receptacle of claim 7 wherein the lateral ribs comprise two respective lateral ribs extending toward each of the laterally separated sides of the oblong shape, said two respective lateral ribs being symmetrically disposed across a central minor axis of the oblong shape of the receptacle.

10. The brush head receptacle of claim 9 wherein the lateral ribs comprise a respective third lateral rib extending toward each of the laterally separated sides of the oblong shape of the receptacle on the central minor axis thereof.

11. The brush head receptacle of claim 7 wherein the longitudinal ribs are of greater profile height than the lateral ribs.

12. The brush head receptacle of claim 1 wherein each rib wraps over the outer ring in a slightly raised profile thereover.

13. The brush head receptacle of claim 1 wherein the topside of the receptacle comprises a concave bowl-like area centered thereon.

14. The brush head receptacle of claim 13 wherein the bowl-like area comprises sloped walls that transition continuously into upper surfaces of the ribs.

15. The brush head receptacle of claim 13 wherein a pair of opposing sloped walls of the concave bowl-like area have aligned holes therein in which a coupling bar is received to span between said pair of opposing sloped walls for use in coupling the receptacle to the curling brush handle.

16. The brush head receptacle of claim 1 wherein the topside of the receptacle comprises a pair of opposing walls having have aligned support holes therein in which a coupling bar is received to span between said pair of opposing walls for use in coupling the receptacle to the curling brush handle.

17. The brush head receptacle of claim 15 comprising a pair of channels respectively extending into the aligned support holes from the underside of the receptacle, and a respective pair of holders received or receivable in said channels to engage the coupling bar and prevent axial sliding thereof in the aligned support holes.

18. The brush head receptacle of claim 17 wherein the coupling bar has a respective circumferential groove therein inside each of the aligned support holes, the holders being shaped to engage said slots to block said axial sliding of the coupling bar.

19-20. (canceled)

21. The brush head receptacle of claim 1 in combination with the brush pad, wherein the brush pad comprises a mounting plate selectively connectable to the receptacle at the underside thereof, a pad of material molded in place to the mounting plate with at least some said material disposed at an underside of the mounting plate, and a fabric cover fitted at least partially over said pad of material.

22. The brush head receptacle of claim 21 wherein the underside of the mounting plate comprises openings therein extending toward an opposing topside of the mounting plate, the material of the pad including material reaching into each of said openings from the underside of the mounting plate toward the topside thereof.

23-50. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0069] The embodiments of the present invention are described with reference to the attached figures, wherein:

[0070] FIG. 1 shows an exploded view of a curling brush head, including a receptacle with a coupling bar to which the brush handle attaches, a pair of holders used to anchor the coupling bar to the receptacle, and a brush pad unit made up of a mounting plate, a pad and a fabric cover.

[0071] FIG. 2 an exploded elevational view of the curling brush head of FIG. 1.

[0072] FIG. 3 shows a close-up perspective view of the receptacle, which incorporates rib-like and ring-like structures that improve pressure distribution over the area of the brush head.

[0073] FIGS. 4A and 4B show top and bottoms views of the receptacle, the top view showing the rib-like and ring-like structures that are incorporated therein.

[0074] FIG. 5 shows a close-up perspective view of the mounting plate of the brush pad assembly, including snap-fit tabs for insertion into the receptacle, and openings which facilitate moulding of the mounting plate, pad, and fabric cover into a single unit.

[0075] FIG. 6 is a schematic illustration of the moulding process, where foam material injected into a mold cavity in a flowable state is received between the mounting plate and the fabric cover to form a foam pad therebetween.

[0076] FIG. 7 is a perspective view of a variant of the receptacle featuring the addition of a small exterior lip at each side thereof.

[0077] FIG. 8 is a top view of the receptacle of FIG. 7.

[0078] FIG. 9 is a perspective view of another variant of the receptacle assembled with a lobed mandrel that is used to connect the receptacle to a brush handle and limit a pivotal range of movement therebetween.

[0079] FIG. 10 is a top plan view of the receptacle of FIG. 9.

[0080] FIG. 11 is a bottom plan view of the receptacle of FIG. 9.

[0081] FIG. 12 is a perspective view of the lobed mandrel of FIG. 9 from an opposing side thereof.

[0082] FIG. 13 is a bottom plan view of the lobed mandrel of FIGS. 9 and 12.

[0083] FIG. 14 provides a schematic side-by-side comparison of curling brushes with lobed and unlobed mandrels during a curling slide delivery, thereby illustrating how the lobed mandrel of FIG. 9 limits the pivotal range of movement between the receptacle and brush handle to keep the brush head at a suitable angle during the slide delivery.

[0084] FIG. 15 is a perspective view of a variant of the brush pad mounting plate.

[0085] FIG. 16 is a bottom plan view of the brush pad mounting plate of FIG. 15.

DETAILED DESCRIPTION

[0086] The systems described herein are directed to a curling brush head designed to increase sweeping effectiveness by enabling a sweeper to exert force onto a greater area of the ice, to simplify the process of installing and removing the brush pad from the brush head receptacle and to restrict pivotal motion between the brush head and handle during slide delivery of a curling rock in order to maintain the brush head in a suitable orientation atop the ice surface during said delivery.

[0087] As required, particular embodiments of the present invention are disclosed herein. However, the disclosed embodiments are merely exemplary, and it should be understood that the invention may be embodied in various and alternative forms. The figures are not to scale and some features may be exaggerated or minimized to show details of particular elements while related elements may have been eliminated to prevent obscuring novel aspects. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. For purposes of teaching and not limitation, the illustrated embodiments are directed to the device designed to increase sweeping performance and ease the assembly of a curling brush.

[0088] The present application discloses a distinctly different configuration of brush head and presents a significant advantage over heads that are conventionally used. This configuration increases the area of the brush head that exerts pressure on the ice. The result is that the force with which sweepers exert down the handle of the brush is more effectively transmitted through the brush head and onto the surface of the ice, increasing the extent to which they can influence the trajectory of the rock. The present disclosure also includes a unique means of attaching the pad to the receptacle. Whereas conventional brushes currently used require the use of screws to attach the pad to the receptacle, the present disclosure uses tabs which allow all new pads to be “snapped into” the receptacle, allowing for fast and easy replacement of worn pads. Additionally, the disclosure includes use of a unique enlargement at the connection between the handle and the topside of the brush head to prevent the brush head from pivoting too far into a somewhat inverted or over-turned position atop the ice during slide delivery of a curling rock.

[0089] FIGS. 1 and 2 show exploded views of a curling brush head according to one embodiment of the present invention. It is comprised of a receptacle 11 which attaches to the curling brush handle that is gripped by the sweeper. In the illustrated embodiment, the receptacle 11 is approximately oval in shape. The size of the receptacle may vary and it will be understood that the brush receptacle and the other parts of the head do not need to be ovoid in shape, as shown in FIG. 1, but could be other shapes, for example rectangular or round.

[0090] A mounting plate 12 attaches to the receptacle by way of tabs 13 which snap into the receptacle 11. A pad 14 of foam material covered by fabric 15 is mounted on the mounting plate 12 as part of a single-piece brush unit which is attached to the receptacle 11. A portion of the illustrated fabric cover is cut away to reveal to the foam pad 14 concealed between the fabric cover and the mounting plate. While the illustrated embodiment shows the fabric as fully covering the pad on the bottom and all perimeter edges, in other embodiments the fabric cover may be installed over only the bottom of the pad, thus leaving the foam material uncovered and visible at the perimeter edges of the pad. The receptacle 11 and the mounting plate 12 may be constructed of metal, plastic, composite materials, or other materials or combinations of materials. In cross section these components may be solid, hollow, or some combination of both. In addition, the size and shape of the receptacle, mounting plate, and pad may differ in size, shape, and thickness.

[0091] While referred to herein as a foam pad 14 of resiliently compressible nature, the pad may be constructed of other materials or combination of materials. The fabric 15 may be nylon, polyester, or other natural or synthetic materials or combination of materials. The fabric covers the foam layer and is the part of the brush which contacts the ice. The foam makes up an intermediate area between the mounting plate and fabric, thereby providing isolation between the ice-contacting fabric and the harder materials of the receptacle and mounting plate.

[0092] FIGS. 1 and 2 also show snap-fit tabs 13 of the mounting plate 12, and the coupling bar 17 which is inserted into the receptacle through two support holes 20 and secured by two holders 16 which are inserted through the bottom of the receptacle 11. The handle of the curling brush is attached to the curling head in a known manner via the coupling bar 17. The holders 16 secure the coupling bar 17 in place by engaging into circumferential grooves 17a in the coupling bar 17.

[0093] FIG. 3 shows a close up view of the receptacle 11 with the coupling bar 17 inserted. It also shows the rib-like structures 18 and the ring-like structures 19 that are incorporated into the receptacle 11 in order to facilitate transfer of force exerted down the shaft of the curling brush handle through the coupling bar 17 toward the edges of the brush head, thus increasing the area over which pressure is effectively transmitted to the face of the brush head and then to the ice. The number, shape, and size of the rib-like and ring-like structures may vary.

[0094] FIG. 4 shows a top view of the receptacle 11 with the rib-like structures 18 and ring-like structures 19, the support holes 20 for insertion of the coupling bar 17, and the holes 21 for insertion of the tabs 13 of the brush pad.

[0095] FIG. 5 shows a close up view of the mounting plate 12 in isolation prior to the moulding of the pad and fabric cover thereto. The mounting plate includes the tabs 13 that “snap into” the receptacle, and openings 22 that pass through the mounting plate to facilitate the bonding of the foam and fabric layers into the mounting plate during the moulding process.

[0096] Attention is now turned to a more detailed description of the features introduced generally above.

[0097] As most visible in FIG. 2, the receptacle 11 features a flat central bottom surface 1102 spanning a substantial majority of the receptacle's area the underside thereof. A remainder of the underside area of the receptacle is defined by an outer area 1104 circumscribing the central bottom surface 1102 at a slightly raised elevation therefrom, whereby the central bottom surface resembles an inverted plateau that is situated a short distance downward from the surrounding outer area 1104 in a height or thickness direction of the receptacle. The central bottom surface and surrounding area are of similar outer shape to one another, being generally oval-shaped in the illustrated embodiment, whereby the outer area spanning around the central bottom surface resembles a band of generally uniform width measured outwardly from the outer edge of the central bottom surface to the outer perimeter edge of the receptacle. The central bottom surface 1102 and the surrounding outer area 1104 collectively define an underside 1106 of the receptacle at which the brush pad is to be mounted, as described in greater detail further below.

[0098] With continued reference to FIG. 2, a central axis C extends through the receptacle 11 in an orientation normal to the flat bottom surface 1102, thereby defining the thickness direction of the receptacle. The underside 1106 of the receptacle 11 thus faces downwardly along the central axis C. A lateral direction and a longitudinal direction lie perpendicular to one another in a plane parallel to or coincident with the flat bottom surface 1102, and thus also perpendicular to the thickness direction. With reference to FIG. 4, the lateral direction and longitudinal direction are denoted in the drawings by a minor axis M1 and a major axis M2 respectively. In the illustrated embodiment where the receptacle has an oblong shape of greater length than width, the major axis and longitudinal direction lie lengthwise of the receptacle, and the minor axis and lateral direction lie widthwise of the receptacle. Such major and minor axes may similarly be used as reference points even in embodiments that do have an elongated or oblong receptacle, including the instance of a circular receptacle, in which case the dimensions of the receptacle measured along the major and minor axes are equal, and the terms between major and minor are used merely to distinguish the two reference axes from one another.

[0099] A topside 1108 of the receptacle 11 resides oppositely of the underside 1106 thereof to face upwardly along the central axis C, and unlike the substantially flat underside composed of only two distinct areas, each of which is entirely flat, features a number of differently profiled areas of varying height or thickness that cooperate to provide a structure capable of delivering a substantially uniform pressure distribution to the underside of the receptacle from a curling broom handle centrally coupled to the topside of the receptacle.

[0100] The distinct areas of the receptacle topside 1108 include an outer ring 191 spanning circumferentially around the central axis C adjacent an outer perimeter edge 1112 of the of receptacle, an inner ring 192 spanning circumferentially around the central axis C at a distance inward from the outer ring 191, an upwardly concave bowl 1116 centered on the central axis C, a plurality of ribs 18 emanating outwardly from the concave bowl 1116 to connect the inner ring 192 to the outer ring 191, and a plurality of valleys 1118 each delimited between an adjacent pair of the ribs and the inner and outer rings. The term valley is used herein to denote an area of reduced profile, height or elevation to neighbouring features, and not necessarily to denote any particular shape or curvature of the valley floor and the transitions therefrom to the neighbouring features.

[0101] The inner and outer rings and the ribs are therefore all raised or elevated in profile relative to the upward facing floor 1118a of each valley. The valley floors join the inner and outer rings and all the ribs together at the bases thereof. Each valley floor is fully intact over the entire area of the respective valley so as to make these connections to the other features in a continuous and uninterrupted manner, except where otherwise noted herein. At the floor 1118a of each valley 1118, the profile of the topside of the receptacle measured upwardly in the thickness direction (i.e. parallel to the central axis C) from a reference plane lying normal to the central axis C and occupied by the flat outer surface 1104 of the receptacle's underside is less than at the inner and outer rings and the ribs 18 spanning therebetween. The outer ring 191 has a convex profile in cross-sectional planes containing and radiating outwardly from the central axis C. The outer ring profile first curves upwardly from the valley floor 1118a to a peak 191a of the outer ring, from which the ring profile then curves back downward toward the plane of the underside's outer area 1104, which is joined to the profile of the outer ring by the perimeter edge 1112 of the receptacle 11.

[0102] Likewise, each rib 18 has a raised profile relative to the valleys 1118 of the receptacle's topside. The illustrated embodiment features ten ribs, of which four ribs are referred to as longitudinal ribs 18a. The longitudinal ribs 18a are arranged in two pairs of adjacent longitudinal ribs. The adjacent longitudinal ribs 18a of each pair extend outwardly from the inner ring 192 on opposite sides of the major axis M2 to a respective one of the two longitudinally separated ends 1120 of the receptacle. These two longitudinal ribs 18a diverge from one another toward the respective end 1120 of the receptacle in a symmetrical manner about the major axis M2. In the illustrated embodiment where, in plan view, the overall outer shape of the receptacle, the matching shape of the outer ring, and the shape of the inner ring are each symmetric about both the major axis M2 and the minor axis M1, the four longitudinal ribs 18a are all of equal length to one another.

[0103] The six remaining ribs are referred to as lateral ribs, and extend outwardly from the inner ring 1992 to the laterally separated sides 1122 that extend longitudinally of the receptacle on opposite sides of the major axis M2. These six lateral ribs are defined in two groups of three, each of which extends out to one of the two laterally separated sides 1122 of the receptacle. In each group of lateral ribs 18, there is a pair of diverging lateral ribs 18b of equal length disposed on opposite sides of the minor axis M1 and diverging from one another symmetrically across the minor axis as they extend out toward the respective side of the receptacle. The third lateral rib 18c of each group lies directly on the minor axis M1 between the diverging lateral ribs 18b so as to bisect the angle defined between the diverging lateral ribs 18b of the group. This third lateral rib is therefore also referred to herein as a central lateral rib 18c. Due to the symmetry of the receptacle about both the major and minor axes, the four diverging lateral ribs are all of equal length to one another, as are the two central lateral ribs 18c.

[0104] In the illustrated embodiment with an oval-shaped receptacle, the longitudinal ribs 18a are of greater length than the lateral ribs, among which the diverging lateral ribs 18b are of greater length than the central lateral ribs 18c. This would also be true of other oblong receptacle shapes, for example a rectangular receptacle. On the other hand, a circular receptacle with circular inner and outer rings would feature equal length among all the ribs, regardless of their different radiating directions away from the central axis C of the receptacle.

[0105] Each rib 18 has a convexly contoured upper surface sloping gradually downward from an inner end of the rib 18 that resides in an elevated position over the inner ring 192 to an opposite outer end of the rib 18 at the outer ring 191. In the illustrated embodiment, this outer end of each rib wraps over the peak 191a of the outer ring in a slightly raised profile relative thereto. Accordingly, the profile height of the topside of the receptacle is not only greater at each rib 18 than at the valley areas 1118 between the ribs, but is also greater than the profile height at the inner and outer rings 192, 191, which are of equal or similar profile height to one another. The inner rib 192, in a manner similar to the outer rib, has a convex profile in the aforementioned cross-sectional planes that first slopes upwardly to a peak 192a before turning back downwardly.

[0106] The bowl-shaped area 1116 at the center of the receptacle's topside forms a concave recess between the inner ends of all the ribs 18. The concavely sloped walls of the bowl-shaped area are continuously and seamlessly integral with the top surfaces of the ribs 18, thus having smooth gradual curves joining the upwardly-sloping concave bowl wall to the downwardly-sloping convex upper rib surfaces. Longitudinally sloped walls 1116a of the bowl that slope longitudinally toward the opposing ends 1120 of the receptacle 11 span further outward from the central axis, and achieve greater elevation, than the laterally sloped walls 1116b of the bowl that slope laterally toward the opposing sides 1122 of the receptacle. The inner ends of the longitudinal ribs are therefore more elevated than those of the lateral ribs, thereby providing the longitudinal ribs with greater profile than the lateral ribs.

[0107] A pair of support holes 20 aligned over the major axis M2 are provided in the longitudinally sloped walls 1116a at an elevated height above the bottom floor 1116c of the bowl. End portions of the coupling bar 17 are received in these aligned support holes 20 in order to support the coupling bar 17 in a position spanning longitudinally across the bowl in perpendicular intersection with the central axis C. Each support hole is a through-hole that communicates the interior of the bowl 1116 with the valley 1118 located between the respective pair of longitudinal ribs 18a. During manufacture of the receptacle 11, the coupling bar 17 is therefore insertable into the aligned support holes 20 from between an adjacent pair of the longitudinal ribs 18a. As shown in FIGS. 1 and 2, the coupling bar 17, for example in the form of a solid cylindrical pin or rod, features a pair of circumferential grooves 17a therein at axially spaced positions along the bar. Each groove 17a resides adjacent a respective end of the bar 17 so as to reside within a respective one of the support holes 20.

[0108] For each support hole 20, a respective slot-shaped channel 20a opens into the flat bottom surface 1102 of the receptacle and intersects the bottom half of the support hole 20. The channel 20a does not pass fully through the support hole 20, and therefore does not penetrate fully through the receptacle at the topside thereof. Each channel 20a is dimensioned for insertion of a support bar holder 16 therein, which features a U-shaped cutout 16a in the top end thereof to form a cradle, the width of which exceeds the support bar diameter at the grooves 17a therein, but not at the ungrooved majority thereof. During manufacture of the receptacle 11, insertion of the holder 16 upwardly into the respective channel after insertion of the support bar into the support holes 20 thus engages the top end of the holder 16 into the respective groove 17a of the support bar, whereby the holder 16 blocks axial sliding of the support bar 17 out of the respective support hole 20, thus locking the support bar in place. So to assemble the receptacle to a curling brush handle during manufacture of the curling brush, one places the lower end of the brush handle into the central bowl 1116 of the receptacle in a position residing between the support holes 20 of the receptacle, and inserts the support bar 17 through the aligned supports holes to engage with the curling brush handle in manner pivotally coupling the handle and receptacle together. The holders 16 are inserted in order to lock the support bar against axial displacement, and then the holders are permanently affixed in place in the respective channels by filling the open bottom end of the channel with a resin or other hardenable/settable/curable filler. The installed holders 16 are thus effectively embedded within the receptacle in order to permanently affix the brush handle thereto.

[0109] With reference to FIG. 4, in the valley 1118 between each pair of longitudinal ribs 18a, a respective snap-fit hole 21 passes upwardly through the valley floor 1118a from the flat bottom surface 1102 of the receptacle 11 on the major axis M2. Turning back to FIG. 1 or 2, the tabs 13 on the mounting plate stand upwardly from a topside thereof, and each feature a catch tang 132 that juts outwardly from one side of the tab toward a respective one of the mounting plate's longitudinally separated ends 1120. The outside-to-outside distance between the two tabs 13, not including the catch tangs 132 thereon, is approximately equal or slightly less than the outside-to-outside distance between the snap-fit holes 21 in the receptacle, each of which is flat-sided on the outer side 21a thereof. The mounting plate 12 is of equal or similar outer shape to the receptacle 11, whereby alignment of the mounting plate beneath the receptacle places the tabs 13 in alignment with the snap-fit holes. Pushing the mounting plate 12 up against the underside of the receptacle 11 causes the upwardly and outwardly sloping face of each catch tang 132 to ride against the outer side 21a of the respective snap-fit hole 21, thereby causing inward deflection of the two resiliently flexible tabs 13 toward one another so that the catch tangs 132 can clear the outer sides 21a of the snap-fit holes. At this point the tabs achieve fully insertion into the snap-fit holes and the two resiliently flexible tabs 13 flex back into their normal default positions, i.e. snap back into place. Accordingly, the catch tangs now jut outwardly over the respective valley floors 1118a above the snap-fit holes 21 at the topside 1108 of the receptacle so that downward withdrawal of the mounting plate 12 from the underside 1106 of the receptacle 11 is prevented by the default positions of the tabs 13. To remove the mounting plate 12, once simply pushes the two engaged tabs 13 inwardly toward the center of the receptacle, thereby forcing the catch tangs inwardly over the snap-fit holes to unlock the tabs from the receptacle and enable withdrawal of the tabs from the snap-fit holes 21 by pulling or dropping of the mounting plate 12 from the underside 1106 of the receptacle.

[0110] Such snap-fit engagement of a brush pad to the receptacle can be employed regardless of how the pad body and fabric cover are attached to the mounting plate. While the illustrated embodiment places the snap-fit tabs 13 on the topside of the mounting plate 12 and the mating snap-fit holes 21 in the underside of the receptacle, other embodiment may employ a reverse configuration with the tabs on the receptacle and the holes on the mounting plate 12. The mounting plate 12 of the illustrated embodiment features a sunken central area of equal or slightly greater size than the central bottom surface 1102 of the receptacle's underside for mating receipt thereof in the assembled condition of the receptacle and mounting plate, which helps maintain alignment therebetween. As a result, the mounting plate 12 has a raised rim around the outer perimeter thereof that mates up against the raised outer area 1104 of the receptacle's underside.

[0111] In addition to the unique ring-and-rib structure of the receptacle, and the unique snap-fit between the receptacle and the brush pad, the illustrated embodiment also features a unique construction of the brush pad itself. At its central area inside the outer rim, the mounting plate 12 of the brush pad features an array of openings 22 therein passing fully therethrough between the topside and underside thereof, which like the topside and underside of the receptacle, are spaced apart on the central axis C and face opposing directions therealong when the brush pad is assembled to the receptacle. The openings 22 of the illustrated embodiment are frustoconically tapered over at least part of their axial length so as to widen toward the topside of the mounting plate 12 from a narrower end of the opening at the underside of the mounting plate. The foam pad 14 is pre-moulded to the mounting plate 12 during factory manufacture of the brush pad.

[0112] To accomplish this, with reference to FIG. 6, the mounting plate 12 is placed upside down in a mold cavity 23 with the fabric cover 15 placed over the inverted mounting plate 12 (i.e. placed over the untabbed side thereof, which serves as the above described ‘underside’ of the mounting plate in the useful upright position of an assembled brush head, but is actually at the top of the inverted mounting plate during the described moulding process). A foam material is injected into the mold cavity, specifically into the space between the fabric material 15 and the untabbed side of the mounting plate 12, as schematically illustrated by arrows entering the mold cavity through an injection port 24 that aligns with a flow-through hole 26 passing through the seated mounting plate 12 in the thickness direction. Filling of this space between the fabric cover 15 and the mounting head 12 with the flowable foam material expands the flexible fabric cover against the boundary walls of the closed mold cavity, which is shaped according to the desired final shape of the foam pad. During this process, the flowing foam material not only fills the space between the mounting head and the fabric cover, but also fills the openings 22 in the mounting plate.

[0113] The initially flowable foam material hardens/cures/sets in place, during which it bonds itself to the fabric cover and the receptacle. The openings 22 in the mounting plate serve to improve the fixation of the foam pad to the mounting plate 12. During the injection moulding process, the flowable foam enters the narrow ends of the openings 22 from the untabbed side of the mounting plate, and fills the widened areas of the openings at the opposing tabbed side of the mounting head, where the outward expansion of the material into the wider end of the frustoconcial taper at the tabbed side of the mounting plate forms an enlarged head or button once the foam has hardened. The enlarged head or button 25, visible in the finished brush pad of FIG. 1, blocks this foam material from being drawn back through the opening 22 to the untabbed side of the mounting plate, thereby anchoring the foam pad, and the fabric cover bonded thereto, to the mounting plate. If a separate flow-through hole 26, as opposed to one of the openings 22, is used to introduce the foam material during the pad moulding process, the flow-through hole may be subsequently closed off after the moulding process with a resin or other suitable filler. Alternatively, it may not be necessary to close the flow-through hole 26 after the moulding process. The flow-through hole 26 may be molded into the mounting plate 12, for example in the case of a moulded plastic mounting plate, or may be drilled into the mounting plate regardless of its material composition. Alternatively, it may be possible to use one of the openings 22 to introduce the foam during the moulding process.

[0114] FIGS. 7 and 8 show a variant of the receptacle featuring all the same features as the receptacle of FIGS. 1 to 4, but additionally featuring a small outwardly-jutting lip 27 at the outer perimeter edge 1112 on each of the laterally separated sides 1122 thereof. The lip 27 of this receptacle 11′ resides at the central area of the receptacle where the width of the receptacle 11′ is at is maximum, and does not extend the full length of the receptacle. In the assembled brush head, the lip 27 juts outwardly beyond the periphery of the brush pad so that when the curling brush is used for support while throwing a rock, this lip 27, and not the side of the brush pad, rides on the ice surface. The lip may alternatively extend the full length of the receptacle 11′, and therefore not project outwardly from adjacent non-lipped areas 28 of the perimeter edge 1112 in the manner shown by the illustrated partial-length lip FIGS. 7 and 8. In the illustrated version, the lip extends between, but not past, the two diverging lateral ribs 18b on each side of the receptacle.

[0115] The above-disclosed curling brush technology is very different from, and has significant advantages over, the conventional brush head. The incorporation of rib-like and ring-like structures into the receptacle effectively transmits the force exerted down the brush handle across the face of the brush head, allowing the sweeper to warm and clean a greater area of the ice, and therefore have greater effect on the trajectory of the curling rock. Testing with a brush head containing arrays of sensors confirms that this technology results in a much greater area of effective force being applied to the ice. The increased thickness or height profile of the receptacle at the rings and ribs thereof provide increased rigidity or stiffness to better prevent deflection of the outer areas of the receptacle relative to the central handle-attached area thereof, thereby maintaining the planar state of the underside surfaces providing more uniform pressure distribution over the full area of the receptacle. Ways of providing stiffening rings and ribs other than by increased thickness or profile may alternatively be employed, for example by embedding rib and ring shaped inserts of more rigid material into the receptacle, for example by insert moulding such inserts into a surrounding plastic body of the receptacle. The use of tabs to attach the pad to the receptacle allows for much quicker and easier replacement of pads than conventional brushes which require a new pad to be attached to receptacles by two screws.

[0116] Different versions of the present invention may be marketed. Variables include but are not limited to the length, width, and shape of the receptacle, mounting plate, ribs, and rings, and the materials used to construct and those components. Variables also include the shape and density of the pad and the materials used in the pads and fabric. It will be appreciated that embodiments employing the ring and rib structures of the receptacle for improved pressure distribution may optionally use conventionally fastened attachment of a brush head to the receptacle in place of the described snap-fit connection, and may optionally forgo the moulded-together brush head components for an alternate brush head assembly or configuration. Likewise, the unique snap-fit connection and the moulded brush head unit are useful independently of one another, and independently of the rib and ring receptacle design. While the illustrated embodiment employs a pin-like support bar for pivotal connection between the handle and brush head, other connection types may be employed without detriment to the pressure distributing ring and rib structures, the unique snap-fit connection or the moulded brush head unit.

[0117] FIGS. 9 to 11 illustrate another variant of the receptacle. One way in which this receptacle 11″ differs from the other illustrated receptacles is in the inclusion of a more pronounced lip 27′ on one of the two laterally separated sides 1122 of the outer perimeter edge 1112. In this variant, the lip 27′ reaches further outwardly from the neighbouring areas of the perimeter edge at this side of the receptacle, and spans a full height of the outer ring 191 of the receptacle.

[0118] With particular reference to FIG. 11, another way in which the variant of FIGS. 9 to 11 differs from the other illustrated receptacles is that the underside does not have a purely planar configuration over the substantially full area thereof like the central bottom surface 1102 of the other illustrated receptacles. Instead, the underside receptacle 11″ features an array of hollowed out cavities recessing upwardly toward the opposing topside of the receptacle. These cavities include outer cavities 1124 underlying the valleys 1118 of the receptacle's topside at areas disposed between the inner and outer rings 192, 191 thereof, and inner cavities 1126 underlying the central bowl-like area 1116 of the receptacle's topside.

[0119] At the plane occupied by the central bottom surface 1104 of the other receptacle's 11, 11′ described above, this receptacle 11″ features an array of thin edge-like surfaces 1128 defined by the bottom ends of internal reinforcement walls that depend downwardly beneath the topside of the receptacle. These reinforcement walls include radial walls emanating outward from the center of the receptacle to the outer perimeter thereof, where the radial walls decrease in height so that their bottom ends join up with a coplanar flat underside of the topside's outer ring 191 in the plane occupied by the flat outer area 1104 of the other receptacles described above. These radial walls include primarily radial walls 1130 running beneath matching ribs 18 at the topside of the receptacle, and shorter secondary radial walls 1132 interposed between the primary walls.

[0120] The reinforcement walls also include an inner ring wall 1134 underlying the inner ring 92 at the topside of the receptacle, an oblong intermediate ring 1136 wall lying intermediately between the inner and outer rings of the receptacles contoured topside. Additional reinforcement walls include closed walls 1138 spanning around the snap fit holes 21. At each slot shaped channel 20a in the underside of the receptacle 11″, the inner ring wall 1134 bifurcates around the slot-shaped channel 20a so that the bifurcated section of the inner ring wall cooperates with the two primary radial walls 1130 spanning outwardly past the channel 20a on opposite sides thereof to fully close around the channel 20a. The two secondary radial walls lying in the longitudinal direction of the receptacle are segmented walls, each being interrupted at the respective slot-shaped channel 20a and snap fit hole 21.

[0121] The receptacle of FIGS. 10-11 demonstrates a configuration by which pressure-distributing ribs and rings at the topside of the receptacle may be incorporated into a hollowed-out receptacle to provide improved pressure distribution even where the receptacle is not a fully-solid body with a flat singular surface spanning a substantial majority of the receptacle's underside.

[0122] FIG. 9 shows the receptacle 11″ assembled together with a mandrel 30 of a two-piece brush handle assembly comprised of said mandrel 30 and an elongated handle unit 32, which for example may be a linearly extending shaft similar to a conventional curling brush handle or may have a varying shape, such as that disclosed in Applicant's Canadian Patent No. 2,819,036. The mandrel is shown in isolation in FIGS. 12 and 13, and schematically illustrated together with a brush head and handle unit 32 in the left hand side of FIG. 14.

[0123] In a conventional manner, the mandrel has an elongated shape having an upper end 301 and an opposing lower end 302 spaced apart on a longitudinal axis 303 of the mandrel. An insertion body 304 of suitable size for axial receipt in a hollow lower end of the handle unit 32 spans a majority of the mandrel's length from the upper end thereof, and for example may have the illustrated cruciform shape in cross-sectional planes normal to the mandrel's longitudinal axis 303, with cylindrical sections 308 disposed at spaced apart intervals along the otherwise cruciform-shaped body to reinforce the body and resist bending deflections thereof. The outer peripheries of the cylindrical sections are flush with the outer tips of the cruciform sections 306. A cylindrical boss 310 incorporated into a fin of one of the cruciform sections 306 has an internal bore 312 extending radially into the body 304 to receive a threaded screw fastener 314 that is driven through the circumferential wall of the hollow lower end of the handle unit 32 to affix the mandrel and the handle unit together.

[0124] At the bottom end of the upper insertion body 304, a larger-diameter lower section 316 presents an upwardly facing annular shoulder 318 against which the annular rim of the hollow lower end of the handle unit 32 is abutted when fully seated over the upper insertion body 304. At the bottom end 302 of the mandrel, this larger-diameter lower section 316 is rounded off, and features a slot 320 passing diametrically through the mandrel. This slot 320 has a width slightly exceed the diameter of the coupling bar 17 of the brush head. A cross-bore 322 crosses diametrically through the lower section 316 of the mandrel near the bottom of the slot 320 in a direction perpendicular to the slot 320. With reference to FIG. 9, in the assembled state of the mandrel 30 on the brush head, the coupling bar 17 of the brush head receptacle 11″ passes through an upper portion of slot 320, and a cross-pin 324 is engaged through the cross-bore 322 of the mandrel 30 to span beneath the coupling bar 17 in a cross-wise direction thereto. Accordingly, the lower section of the mandrel is pivotally coupled to the brush head receptacle 11″ in a manner enabling pivotal movement of the brush handle relative to the brush head about the axis of the coupling bar 17.

[0125] The mandrel 30 most notably differs from those of the prior art by the inclusion of an offset lobe 326 forming a radial enlargement that reaches further outward from the mandrel's longitudinal axis 303 than any other portion of the mandrel. The offset lobe 326 is situated on the larger-diameter lower section 316 of the mandrel at a location a short distance below the upward facing shoulder 318, and at or above the upper end of the slot 320. The offset lobe 326 thus resides a short distance above the pivot axis defined by the coupling bar 17 of the brush head receptacle. The offset lobe is oblong in shape and offset from the central longitudinal axis 303 of the mandrel so that the lobe 326 projects further outward on one side of the mandrel than on a diametrically opposing side thereof. The distal end 326a of the more protruding side 326 thus forms the radially outermost extent of the mandrel, which reaches further outward from the shared longitudinal axis 303 of the mandrel and handle unit than the hollow lower end of the handle unit and all other portions of the mandrel.

[0126] Referring to FIG. 9, the protruding side of the lobe 326 points toward the side of the receptacle at which the pronounced lip 27′ is disposed. On the same side of the bowl-shaped central area of the receptacle's topside as the pronounced lip 27′, the laterally-sloped side of the bowl-shaped central area of the receptacle's topside is of lesser height and slope than the opposing laterally-sloped side of the bowl-shaped area. Accordingly, with the handle mandrel in the perpendicular position shown in FIG. 9, where it stands normal (i.e. orthogonal) to the reference plane occupied by the edge-like surfaces 1128 at the receptacle's underside, the projecting side of the lobe 326 resides over this shallower half of the bowl 1116. If the handle mandrel is pivoted out of this normal position toward the shallower side of the bowl, eventually the handle mandrel will bottom out due to contacting abutment of the distal end 326a of the lobe 326 with the shallow side wall of the receptacle's bowl-shaped central area. Accordingly, this contact between the topside of the receptacle and the lobed mandrel limits the available angular range of movement between the mandrel and attached handle unit 32 relative to the brush head, thereby preventing tilting of the collective brush handle past the limit defined by this abutting contact.

[0127] The reason for limiting this pivotal range between the handle and the brush head is illustrated by FIG. 14, in which the brush head and mandrel are shown schematically without detail for ease of illustration. During sliding delivery of a curling rock, the curler's brush is typically used to stabilize the curler's sliding position, with the curling rock handle gripped in one hand in a leading position out in front of the curler's body, and the curling broom handle gripped at an intermediate position therealong in the other hand out to one side of the curler's body. The brush handle slopes obliquely downwardly toward the ice in a direction spanning laterally outward from the curler's body, and the brush head carried at the lower end of the handle rides along the ice surface 40. As described above for the first variant of the receptacle, the lip 27′ of the brush head receptacle faces downwardly toward the ice so that the lip 27′ rides along the ice surface in order to keep the side of the brush pad slightly elevated therefrom.

[0128] The left hand side of FIG. 14 illustrates a brush featuring the pronounced lip 27′ and the lobed mandrel 30 of the present invention, where the contact between the lobe 326 of the mandrel and the topside of the receptacle 11″ limits the available angular motion between the brush handle and the brush head to prevent over-tilting of the brush to the point where the topside of the brush head, rather than the lipped lateral side thereof, rides on the ice surface. For comparison, the right hand side of FIG. 14 shows a brush that lacks the lobed mandrel or other means for limiting the angular range between the handle and brush head, and illustrates how without such means, the brush head may be over-tilted into a partially inverted position in which the topside of the brush head rides on the ice surface, potentially causing wear to the outer ring and ribs of the pressure distributing receptacle.

[0129] While the illustrated embodiment uses a lobe on the mandrel of a two-piece handle to define a radial enlargement on the handle that limits the angular motion between the handle and brush head, it may be possible to instead use such a lobe or enlargement on the hollow lower portion of the handle unit 32 for similar purpose. Alternatively, another embodiment may have a one-piece handle which lacks a separate mandrel component, and instead couples directly to the brush head. In another alternative embodiment, rather than a radial enlargement on the handle that projects radially outward a further distance than neighbouring areas of the handle to cause early contact with the topside of the brush head and thereby limit the angular range of movement therebetween, the topside of the brush head itself may instead feature an enlarged area that stands further upright from neighboring areas of the brush head's topside in order to make this early contact with a respective side of the handle.

[0130] FIGS. 15 and 16 illustrate a variant of the brush pad mounting plate. In this version of the mounting plate 12′, a central flow-through hole 26 passes fully through the thickness of the mounting plate from the underside thereof to the opposing topside in order to enable introduction of foam therethrough during the moulding process. In this mounting plate 12′, the openings 22′ in the underside of the mounting plate do not pass fully through the mounting, but rather are blind holes recessed only partially therethrough, hence the need for a separate flow-through hole 26. The blind hole openings 22′ are cylindrical holes of uniform cross-section, and lack the frustoconically tapered areas of the other mounting plate 12 described earlier herein. Two additional fastening holes 34 illustrated at locations near the tabs 13, but which may vary in quantity and position, pass fully through the mounting plate in the thickness direction from the underside thereof to the opposing topside for use in fastening the mounting plate into the mold during the moulding process. The flow-through hole 26 and fastening holes 34 may be sealed closed with epoxy or other suitable filler after the moulding process.

[0131] As used herein, the terms “comprised” and “comprising” are to be construed as being inclusive and open-ended and not exclusive. Specifically, when used in this specification including claims, “comprised” and “comprising” and variations thereof mean the specific features or components included. These terms are not to be interpreted to exclude the presence of other features or components.

[0132] Since various modifications can be made in this invention as herein above described, and many apparently widely different embodiments of same made within the scope of the claims without departure from such scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.