APPARATUS AND METHOD FOR FORMING BRISTLE BUNDLES, BRUSH MANUFACTURING MACHINE, USE OF AN APPARATUS FOR FORMING BRISTLE BUNDLES, BRUSH, COMPUTER PROGRAM AND COMPUTER-READABLE MEDIUM

Abstract

An apparatus (1) for forming bristle bundles (2) is inter alia proposed as an improvement in the technical field of manufacturing and designing brushes. The apparatus (1) includes at least one bundle pocket (3) which is specified for receiving bristle bundles (2) to be formed. The bundle pocket (3) has a common bundle receptacle portion (50) for unifying at least two bristle bundles (2). The bundle pocket (3) and the bristle bundles (2) situated therein are heated by the heating apparatus (4) of the apparatus (1) so as to set the shaping of the bristle bundles (2) that is predefined by the bundle pocket (3) and the displacement means (7).

Claims

1. An apparatus (1) for forming bristle bundles (2) of a bristle complement (39) of a brush (32), the apparatus comprising: at least two bristle bundles (2), at least one bundle pocket (3) having at least two bundle receptacles (40) configured therein; a heating apparatus (4) configured for heating the at least one bundle pocket (3) and the bristle bundles (2) that have been incorporated into the bundle receptacles (40); the bundle receptacles (40) are configured to be bundle-forming and, under an effect of heat dissipated by the heating apparatus (4) on the bundle pocket (3) and thus on the bristle bundles (2) situated therein, form the bristle bundles (2) that have been incorporated into the bundle receptacles (40) in comparison to a shape of said bristle bundles (2) prior to being introduced into the bundle receptacles (40) and set the shape of the bristle bundles (2) that have been incorporated into the bundle receptacles (40) to a shaping predefined by the bundle receptacles (40); and the bundle pocket (3) at least one of a) has the at least two bundle receptacles (40) which open into a common bundle receptacle portion (50), or b) has at least one bundle receptacle (40) which is configured for receiving at least two of the bristle bundles (2) and comprises a common bundle receptacle portion (50) for the at least two of the bristle bundles (2).

2. The apparatus (1) as claimed in claim 1, wherein the bundle receptacles (40) are combined in at least one group (41), and at least one of a) the group (41) comprises a number of the bundle receptacles (40) that corresponds to a number of the bristle bundles (2) of a bristle complement (39) of said bristle bundles (2) that is to be formed by the apparatus (1), or b) the bundle receptacles (40) within the group (41) are disposed like the bristle bundles (2) in the bristle complement (39).

3. The apparatus (1) as claimed in claim 1 wherein at least one of the bundle receptacles (40) of the bundle pocket (3) has at least two cross sections (42, 43) which are axially spaced apart from one another relative to a longitudinal axis of the bundle receptacle (40) and which differ from one another in terms of at least one of shape or size.

4. The apparatus (1) as claimed in claim 1, wherein at least one of a) at least one of the bundle receptacles (40) of the bundle pocket (3) has an introduction duct which opens into at least two ducts of the bundle receptacle that are downstream of the introduction duct, or b) the bundle pocket (3) has a bristle carrier receptacle (44) which is delimited by an encircling periphery (45).

5. The apparatus (1) as claimed in claim 1, wherein at least one of the bundle receptacles (40) of the bundle pocket (3) has a bundle receptacle portion (46) which is defined by envelope faces of two cones or truncated cones, and at least one of a) longitudinal central axes of the two cones or truncated cones are congruent, or b) said two cones or truncated cones have different radii.

6. The apparatus (1) as claimed in claim 1, wherein at least one of the bundle receptacles (40) of the bundle pocket (3) fans out or spreads open to form a chalice-shape or a conical shape.

7. The apparatus (1) as claimed in claim 1, wherein the at least one bundle pocket (3) at least one of a) has at least one heat exchanger element (9) that facilitates a heat exchange, or b) is provided with a surface structure that facilitates a heat exchange.

8. The apparatus (1) as claimed in claim 1, further comprising at least one of a bundle gripper (10) that is movable between an initial position and a machining position, or a bundle pocket gripper (11) that is movable between an initial position and a machining position.

9. The apparatus (1) as claimed in claim 8, wherein at least one of the at least one bundle pocket (3) the bundle pocket gripper (11), or the bundle gripper (10), is assigned a vibrator (12).

10. The apparatus (1) as claimed in claim 1, wherein at least one of a) the at least one bundle pocket (3) has a wall (13) having a constant wall thickness, or b) an inner contour of the bundle pocket (3) is adapted to an outer contour of the bundle pocket (3).

11. The apparatus (1) as claimed in claim 1, wherein at least one of a) the bundle receptacles (40) of the bundle pocket (3) has an introduction opening (5) that is provided with an introduction funnel (14), or b) the bundle pocket (3) is or forms a monolithic unit which is materially homogenous and 3D-printed.

12. The apparatus (1) as claimed in claim 11, wherein the at least one bundle pocket (3) has an exit opening (15) which is disposed in or on a side of the bundle pocket (3) that is opposite the introduction opening (5) of the bundle pocket (3).

13. The apparatus (1) as claimed in claim 1, further comprising at least one of a cutter or a grinder configured for machining the bristle bundle (2).

14. The apparatus (1) as claimed in claim 1, further comprising at least one of a) a cooling apparatus (17) for cooling the at least one bundle pocket (3), or a data interface (55) by way of which the apparatus (1) is configured for establishing a data connection to a computer-readable medium (51).

15. The apparatus (1) as claimed in claim 14, wherein at least one of a) the heating apparatus (4) extends across a region which covers an annular segment with an angular range between 180° and 270°, or b) the cooling apparatus (17) extends across a region which covers an annular segment with an angular range between 180° and 90°.

16. The apparatus (1) as claimed in claim 1, wherein the bundle pocket (3) has at least one introduction opening (5) and at least one lateral cutout (6) through which a displacement pin (7) for profiling a bristle bundle (2) that has been introduced into the bundle pocket (3) is able to be inserted into the bundle pocket (3).

17. The apparatus (1) as claimed in claim 1, wherein the apparatus (1) is configured for forming a bristle bundle (2) by introduction into the bundle pocket (3) from a non-deformed initial shape to a desired target shape under an effect of heat from the heating apparatus (4) that is dissipated to the bundle pocket (3).

18. The apparatus (1) as claimed in claim 17, wherein the bundle pocket (3) has two mutually opposite ones of the lateral cutouts (6), and at least one closure pin (8) configured for temporarily closing the at least one lateral cutout (6) of the at least one bundle pocket (3).

19. The apparatus (1) as claimed in claim 1, further comprising a bundle spreading apparatus configured for spreading the bristle bundles (2) prior to being introduced into the bundle pocket (3).

20. The apparatus (1) as claimed in claim 1, further comprising a humidification apparatus for at least one of humidifying or steam-treating the bristle bundles (2).

21. The apparatus (1) as claimed in claim 1, further comprising a controller (54) configured for actuating the heating apparatus (4) such that the bristle bundles (2) in the bundle pocket (3) are heated according to defined thermal profile curves.

22. The apparatus (1) as claimed in claim 1, wherein at least one of the heating apparatus (4) or the bundle pocket (3) are configured for heating the bristle bundles (2) by thermal conduction via at least one of mechanical contacting, induction, convection or thermal radiation.

23. The apparatus (1) as claimed in claim 1, further comprising a cooling apparatus (17) configured for cooling the bristle bundles (2) by a temperature-controlled fluid, and the cooling apparatus (17) comprises at least one of a cold air gun, a vortex tube, or a cyclone tube.

24. The apparatus (1) as claimed in claim 1, wherein the bundle pocket (3) is produced by at least one of eroding, 3D printing, cutting, or at least one of thin layers or sheets that are connected to one another.

25. The apparatus (1) as claimed in claim 1, wherein at least one of a) the bundle receptacles (40) have a surface roughness of at most 6.3 μm, b) the bundle receptacles (40) in the push-fitting direction of the bristle bundles (2) are at least one of ground or polished, or the bundle receptacles (40) have a surface coating so as to reduce a surface roughness of said bundle receptacles (40).

26. The apparatus (1) as claimed in claim 1, further comprising a suction apparatus by which a negative pressure is adapted to be applied to the bundle pocket (3) to facilitate an introduction of the bristle bundles (2).

27. The apparatus (1) as claimed in claim 1, wherein the bundle pocket (3) is at least one of a) laterally perforated, b) has at least one flow duct, or c) has at least part of the heating apparatus (4) therein.

28. The apparatus (1) as claimed in claim 1, further comprising a discharge apparatus by which fluid that is heated with the heating apparatus (4) is dischargeable, the heating apparatus (4) has a closed system in which fluid heated by the heating apparatus (4) circulates.

29. The apparatus (1) as claimed in claim 1, further comprising a controller (54) configured for monitoring a thermal input into the bundle pocket (3).

30. The apparatus (1) as claimed in claim 1, further comprising at least one temperature sensor, by which a temperature of the bundle pocket (3) is determined.

31. The apparatus (1) as claimed in claim 1, further comprising at least one temperature sensor on at least one of a) the heating apparatus (4), b) in or on an inflow duct, or c) in or on an outflow duct.

32. The apparatus (1) as claimed in claim 1, wherein a cross-sectional area of a bundle receptacle (40) is at least 20% larger than an overall cross-sectional area of individual bristle filaments which are to be introduced into the bundle receptacle (40).

33. A method for forming bristle bundles (2) of a bristle complement (39) of a brush (32) that comprises at least two bristle bundles (2), wherein at least two bristle bundles (2) are unified in a common bundle portion (49), the method comprising: generating a clearance (29) between a first closed bundle portion (35) and a second closed bundle portion (36) of one of the bristle bundles (2) of the brush (32).

34. The method as claimed in claim 33, further comprising forming at least one of the bristle bundles (2), proceeding from a non-deformed initial shape, to a desired target shape, and displacing bristle filaments of the bristle bundle (2) for generating a clearance (29) in the bristle bundle (2) using a displacement pin (7), and then heating the bristle bundle (2) to set the target shape of the bristle bundle (2) and the clearance (29) generated in the bristle bundle (2).

35. The method as claimed in claim 33, wherein the clearance (29) is disposed between the first closed bundle portion (35) that is adjacent to a free end (37) of the bristle bundle (2), and the second closed bundle portion (36) of the bristle bundle (2) that is adjacent to an end (38) of the bristle bundle (2) that is proximal to the bristle carrier and has a closed cross section that is defined by bristle filaments of the bristle bundle (2).

36. The method as claimed in claim 33, wherein at least one of a) at least one of the bristle bundles (2) is formed having two bundle cross sections (47, 48) which are axially spaced apart from one another relative to a longitudinal axis of the bristle bundle, and said two bundle cross sections differ from one another in terms of at least one of a shape or size, b) the at least two bristle bundles (2) at the free ends thereof are unified in a common bundle portion (49), c) at least one of the bristle bundles (2) is imparted a helical, conical, frustoconical or chalice-shaped shape, or d) at least one of the bristle bundles (2) is spread open.

37. The method as claimed in claim 33, further comprising introducing the bristle bundles (2) into bundle receptacles (40) of a bundle pocket (3), and at least one of spreading open, steam treating, or humidifying the bristle bundles (2) prior to being introduced into the bundle receptacles (40).

38. The method as claimed in claim 33, further comprising forming the claims, wherein bristle bundles (2) of the bristle complement (39) in at least one of stages or groups, with inner ones of the bristle bundles (2) being first formed and outer ones of the bristle bundles (2) of the bristle complement (39) being subsequently formed.

39. The method as claimed in claim 33, further comprising forming the bristle bundles (2) such that said bristle bundles (2) conjointly represent at least one of a logo or an image.

40. The method as claimed in claim 33, further comprising heating the bristle bundles (2) according to a defined thermal profile curve.

41. The method as claimed in claim 40, wherein the bristle bundles (2) are heated by at least one of a heating apparatus that is integrated in the bundle pocket (3), thermal conduction, induction, convection, or thermal radiation.

42. The method as claimed in claim 33, further comprising cooling the bristle bundles (2) using at least one of temperature-controlled fluid, compressed air, nitrogen ambient air, a cold air gun, a cyclone tube, or a vortex tube.

43. The method as claimed in claim 37, further comprising at least one of impinging the bundle receptacles (40) of the bundle pocket (3) with negative pressure, or suctioning the bristle bundles (2) into bundle receptacles (40) of the bundle pocket (3) by negative pressure.

44. The method as claimed in claim 34, wherein a thermal input for the heating of the bristle bundles (2) takes place by way of thermally conducting convexities on an external side of a bundle pocket (3) into which the bristle bundles are introduced.

45. The method as claimed in claim 34, wherein for heating the bristle bundles (2) situated within a bundle pocket (3) into which the bristle bundles are introduced, a heated fluid is directed through flow ducts of the bundle pocket (3), and for cooling the bristle bundles (2) situated within the bundle pocket (3), a cooled fluid is directed through the flow ducts of the bundle pocket (3).

46. The method as claimed in claim 45, wherein the fluid for incorporating the heat, upon heating the bristle bundles (2) is at least one of released into the environment, or guided in a recirculating air system or a closed-circuit system.

47. The method as claimed in claim 34, further comprising monitoring a thermal input for heating the bristle bundles (2) using a controller (54).

48. The method as claimed in claim 34, further comprising, prior to the bristle bundles (2) being introduced into a bundle pocket (3), heating the bundle pocket (3) to a temperature above a ambient temperature.

49. The method as claimed in claim 34, further comprising extracting the bristle bundles (2) from a bundle pocket (3) before said bristle bundles (2) have reached a final cooling temperature.

50. The method as claimed in claim 33, wherein the bristle bundles (2) include bristle filaments made from at least one of PE, PBT, PA6.10, PA6.12, PA10.10, PA4.10, or mixtures thereof.

51. A brush manufacturing machine (18) having at least one apparatus (1) for forming bristle bundles (2) as claimed in claim 1.

52. The brush manufacturing machine (18) as claimed in claim 51, further comprising a rotary indexing table (19) for receiving and transporting the bundle pockets (3) that are populated with the bristle bundles (2), the rotary indexing table (19) comprises four arms which are disposed offset by 90° from one another, at least one of an input station (22) or a bundle profiling station (23), on which the apparatus (1) for forming bristle bundles (2) is disposed, and at least one of a bundle fusing station (24), a retrieving station (25), or a further processing station (26) distributed about the rotary indexing table (19).

53. The brush manufacturing machine (18) as claimed in claim 51, further comprising a data interface (55) by which the brush manufacturing machine (18) is configured for establishing a data connection to a computer-readable medium (51).

54. (canceled)

55. A brush (32) comprising: a handle, a bristle complement (39) which comprises at least two bristle bundles (2), wherein at least two of the bristle bundles (2) are unified in a common bundle portion (49), at least one of the bristle bundles (2) has at least one clearance (29) which is disposed between a first closed bundle portion (35) and a second closed bundle portion (36) of the bristle bundle (2), the first closed bundle portion (35) is adjacent to a free end (37) of the bristle bundle (2), and the second closed bundle portion (36) is adjacent to an end (38) of the bristle bundle (2) that is proximal to the handle.

56. (canceled)

57. The brush (32) as claimed in claim 55, wherein the clearance (29) has a closed cross section that is defined by bristle filaments of the bristle bundle (2).

58. The brush (32) as claimed in claim 57, wherein a length of at least one the first closed bundle portion (35) or a the second closed bundle portion (36) is at least 5% of an overall length of the bristle bundle (2) when measured in a direction of a longitudinal extent of the bristle bundle (2).

59. The brush (32) as claimed in claim 55, wherein the brush is a toothbrush, a mascara brush, or a broom.

60. The brush (32) as claimed in claim 55, wherein at least one of a) at least one of the bristle bundles (2) has two bundle cross sections (47, 48) which are axially spaced apart from one another in terms of a longitudinal axis of the bristle bundle and which differ from one another in terms of at least one of a shape or a size, b) at least two of the bristle bundles (2) at the free ends thereof are unified in a common bundle portion (49), or c) the bristle complement (39) has at least one of a helical, conical, frustoconical or chalice-shaped bristle bundle (2).

61. The brush (32) as claimed in claim 55, wherein the bristle bundles (2) have bristle filaments which are comprised of at least one of: PE, PBT, PA6.10, PA6.12, PA10.10, PA4.10, or a mixture thereof.

62. A computer program fixed in a tangible data carrier, comprising commands to be executed by the apparatus (1) as claimed in claim 29 by the controller (54) in order to generate a clearance (29) between a first closed bundle portion (35) and a second closed bundle portion (36) of one of the bristle bundles (2) of a brush (32).

63. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0100] The invention will now be described in more detail by an exemplary embodiment but is not limited to this exemplary embodiment. Further exemplary embodiments are derived by combining the features of individual or a plurality of claims with one another and/or in combination with individual or a plurality of features of the exemplary embodiment. In the figures, to some extent in a highly schematic illustration:

[0101] FIGS. 1 to 12: show highly schematic illustrations of an apparatus according to the invention for forming bristle bundles, for visualizing the forming procedure that is able to be carried out with the aid of the apparatus;

[0102] FIG. 13: shows a perspective illustration of a brush having a bristle bundle which has been formed with the aid of the apparatus illustrated in FIGS. 1 to 12;

[0103] FIG. 14: shows a highly schematic plan view of a brush manufacturing machine according to the invention which at one of the stations thereof has an apparatus for forming bristle bundles;

[0104] FIG. 15: shows a perspective view of another embodiment of a bundle pocket of an apparatus for forming bristle bundles, wherein the bundle pocket has a number of dissimilarly shaped bundle receptacles that corresponds to the number of bristle bundles in a bristle complement of a brush;

[0105] FIG. 16: shows an end view of the bundle pocket illustrated in FIG. 15;

[0106] FIG. 17: shows a lateral view of the bundle pocket depicted in FIGS. 15 and 16, sectioned along the section line A-A from FIG. 16;

[0107] FIG. 18: shows a perspective view of a toothbrush of which the bristle bundles have been formed using the bundle pocket illustrated in FIGS. 15 to 17;

[0108] FIG. 19: shows a perspective view from below of a further embodiment of a bundle pocket;

[0109] FIG. 20: shows a perspective view of a brush of which the bristle bundle has been formed by the bundle pocket illustrated in FIG. 19; and

[0110] FIG. 21: shows a time/temperature diagram for visualizing a thermal profile curve according to which bristle bundles can be heated.

DETAILED DESCRIPTION

[0111] In the description of the figures hereunder, functionally identical or equivalent elements are provided with the same reference signs even in the case of variations in terms of the design or the shaping.

[0112] FIGS. 1 to 17 and 19 show at least parts of different embodiments of an apparatus for forming bristle bundles 2, said apparatus in its entirety being referred to by the reference 1. The apparatus 1 comprises at least one bundle pocket 3. The bundle pocket 3 serves for receiving at least one bristle bundle 2. For receiving a bristle bundle 2, the bundle pocket 3 has at least one bundle receptacle 40. The apparatus 1 furthermore comprises a heating apparatus 4 which by the area marked by zigzag hatching is illustrated in a highly schematic manner in FIG. 14. The heating apparatus 4 serves for heating the at least one bundle pocket 3 and a bristle bundle 2 that is positioned in the bundle pocket 3.

[0113] A bristle bundle 2 can be introduced into the bundle pocket 3 through an introduction opening 5 of the bundle pocket 3. The bundle pocket 3 of the apparatus 1 illustrated in FIGS. 1 to 12 has two lateral piercings 6. A displacement means 7 of the apparatus 1, for profiling a bristle bundle 2 that has been introduced into the bundle pocket 3, can be introduced into the bundle pocket 3 through the lateral piercings 6. FIGS. 6 to 9 highlight the use of the displacement means 7.

[0114] The apparatus 1, under the effect of heat which by the heating apparatus 4 is dissipated to the bundle pocket 2 and the bristle bundle 2 disposed therein, by way of the bundle pocket 3 is specified for forming a bristle bundle 2 that has been introduced into the bundle pocket 3, proceeding from a non-deformed initial shape to a deformed, desired target shape, which can be seen in FIGS. 1 to 3. The result of the forming procedure is a bristle bundle 2 as is shown in FIG. 13, for example.

[0115] The two piercings 6 of the bundle pocket 3 lie opposite one another such that the displacement means 7 for generating a clearance 29 within the bristle bundle 2 can be pushed through the bundle pocket 3 (see FIGS. 6 to 9). The bristle bundle 2 herein is correspondingly profiled or deformed, and the clearance 29 which can be particularly readily seen in FIG. 13 is generated.

[0116] In order to prevent bristle filaments from exiting the bristle bundle 2 from the initially still open piercings 6 when the bristle bundle 2 is introduced into the bundle pocket 3, the apparatus 1 has two closure means 8. The two lateral piercings 6 of the bundle pocket 3 can be temporarily closed with the aid of the two closure means 8.

[0117] FIGS. 1 and 2 show the two closure means 8 in the initial position thereof. A comparison of FIGS. 1, 2 and 3 highlights how the two closure means 8, proceeding from the initial position thereof, are moved to the closing position thereof on the bundle pocket 3, so as to temporarily close the two lateral piercings 6. The two closure means 8 are configured as profiled pins which have in each case an end face 8a. The end faces 8a are adapted to the cross section of the piercings 6 of the bundle pocket 3 such that said end faces 8a in the closure position of the closure means 8 on the bundle pocket 3, conjointly with the internal faces of the bundle pocket 3, forms a surface that is almost free of any offset. This facilitates the introduction of the bristle bundle 2 into the bundle pocket 3.

[0118] As soon as the two closure means 8 have assumed the closing position thereof, the bristle bundle 2 that has been kept ready can be introduced through the introduction opening 5 into the bundle pocket 3. This is illustrated in FIG. 4.

[0119] The bundle pocket 3 illustrated in the figures is with a plurality of heat exchanger elements 9. The heat exchanger elements 9 facilitate a take-up of heat during the heating phase and a dissipation of heat during a cooling phase. The heat exchanger elements 9 are configured as cooling/heating ribs. The heat exchanger elements function as thermally conducting convex moldings on the external sides of the illustrated bundle pocket 3.

[0120] The apparatus 1 moreover has a bundle gripper 10 and a bundle pocket gripper 11. The bundle gripper 10 as well as the bundle pocket gripper 11 are movable between an initial position and a machining position. The bundle gripper 10 serves for moving a bristle bundle 2, proceeding from the initial position (cf. FIGS. 1 to 3), to a machining position and for introducing the bristle bundle 2 into the bundle pocket 3 herein.

[0121] The bundle pocket gripper 11 can be used for holding the bundle pocket 3 and for transferring the latter when required. The bundle gripper 10 as well as the bundle pocket gripper 11 is in each case assigned a vibrator 12. The vibrators 12 are used for setting in vibration the bundle pocket 3, on the one hand, and a bristle bundle 2, on the other hand, when the bristle bundle 2 is being introduced into the bundle pocket 3. This facilitates the bristle bundle 2 sliding into the bundle pocket 3.

[0122] FIG. 2 shows a sectional illustration of the bundle pocket 3. The sectional illustration highlights that the bundle pocket 3 has a wall 13 with an approximately constant wall thickness. An inner contour of the bundle pocket 3 is adapted to an outer contour of the bundle pocket 3.

[0123] The sectional illustration of the bundle pocket 3 according to FIG. 2 furthermore shows that the introduction opening 5 of the bundle pocket 3 is provided with an introduction funnel 14. The introduction funnel 14 facilitates an introduction of bristle bundles 2 into the interior of the bundle pocket 3.

[0124] The bundle pocket 3 of the apparatus 1 shown in the figures is present as a materially homogenous, monolithic unit which is 3D-printed. Bundle pockets 3 having comparatively complex pocket geometries can be generated with the aid of a 3D-printing method.

[0125] The embodiment of a bundle pocket 3 shown in FIGS. 11 and 12, on the side thereof that lies opposite the introduction opening 5 into the bundle pocket 3, has an exit opening 15. The free ends 31 of bristle filaments of a bristle bundle 2 that has been introduced into the bundle pocket 3 can protrude from this exit opening 15 (see FIG. 12). While the bristle bundle 2 in this instance is disposed within the bundle pocket 3, the free ends of the bristle filaments are in this way accessible for further machining.

[0126] For the machining of the bristle filaments of a bristle bundle 2 situated in the bundle pocket 3, the apparatus 1 is equipped with at least one machining means 16. The machining means 16 which is illustrated in a highly schematic manner in FIG. 11 is a cutter 16 by way of which the bristle filaments can be trimmed at the free ends 31 thereof.

[0127] The pictogram shown in FIG. 9 indicates that the apparatus 1, apart from the heating apparatus 4 thereof, also has a cooling apparatus 17. The bundle pocket 3 and the bristle bundle 2 situated therein can be actively cooled with the aid of the cooling apparatus 17. The latter, upon successful forming, has the objective of cooling the bristle bundle 2 in an ideally rapid manner to a temperature required for the further machining of said bristle bundle 2.

[0128] The apparatus 1 furthermore has a plurality of guides 30 which predefine adjustment paths for the displacement means 7, the closure means 8, the bundle body 10, and the machining means 16. In the exemplary embodiment of the apparatus 1 shown in the Figures, the guides 30 are illustrated in a highly simplified manner as guide slots 30.

[0129] FIG. 5 now shows the apparatus 1 once the bristle bundle 2 has been introduced into the bundle pocket 3. The displacement means 7, here a profiled displacement pin, can be seen in FIG. 6. The displacement means 7 is initially introduced into the bundle pocket 3 through the first piercing 6. Bristle filaments of the bristle bundle 2 situated in the bundle pocket 3 are laterally displaced herein. The displacement means 7 is further pushed into the bundle pocket 3 until said displacement means 7 exits from the bundle pocket 3 through the second piercing 6 (see FIG. 7).

[0130] The pictogram shown in FIG. 8 highlights that the heating apparatus 4 is subsequently activated so as to heat the bundle pocket 3 and the bristle bundle 2 that in the desired target shape is held within the bundle pocket 3, so as to set the target shape of the bristle bundle 2 as predefined by the bundle pocket 3 and the displacement means 7.

[0131] As soon as the bristle bundle 2 has been heated for a sufficient time, the heating apparatus 4 can be deactivated and the cooling apparatus 17 of the apparatus 1 can be switched on so as to actively cool the bundle pocket 3 and the bristle bundle 2 situated therein (see FIG. 9).

[0132] The displacement means 7 is subsequently retracted from the bundle pocket 3, and the deformed bristle bundle 2 is removed from the bundle pocket 3. To this end, the bundle body 10 is moved back along the guide 30 thereof to the initial position thereof (see FIG. 10). The supporting action of the displacement means 7 in the clearance 29 generated in the bristle bundle 2 can be clearly seen herein.

[0133] The apparatus 1 is thus specified for forming the bristle bundle 2, proceeding from a non-deformed initial shape which can be seen in FIGS. 1 to 3, for example, to a desired target shape. Bristle filaments of the bristle bundle 2 for generating the clearance 29 herein are in particular laterally displaced with the aid of the displacement means 7. The bristle bundle 2 is subsequently heated so as to set the target shape of the bristle bundle 2 and thus the clearance 29 generated in the bristle bundle 2.

[0134] FIG. 13 finally shows a brush 32 of which the single bristle bundle 2 has been shaped using the apparatus 1 illustrated in FIGS. 1 to 12. The clearance 29 which has been generated within the bristle bundle 2 when forming the bristle bundle 2 can be clearly seen. The bristle bundle 2 is connected to a bristle carrier 33 of the brush 32, said bristle carrier 33 simultaneously functioning as the handle 34 of the brush 32. The brush 32 can also be referred to as a paintbrush since the latter has only one bristle bundle 2.

[0135] FIG. 13 furthermore shows that the bristle bundle 2 has a first closed bundle portion 35 and a second closed bundle portion 36, the clearance 29 configured in the bristle bundle 2 being disposed therebetween. The first closed bundle portion 35 of the bristle bundle 2 lies between the clearance 29 and a free end 37 of the bristle bundle 2 on which the free ends 31 of the bristle filaments of the bristle bundle 2 are disposed. The second closed bundle portion 36 of the bristle bundle 2 lies between the clearance 29 and an end 38 of the bristle bundle 2 that is proximal to the bristle carrier or proximal to the handle.

[0136] The first closed bundle portion 35 and the second closed bundle portion 36 of the bristle bundle 2 have in each case a length which corresponds to at least 5% of an overall length of the bristle bundle 2. The overall length of the bristle bundle 2 can be the length of the bristle bundle 2 that can be measured between the bristle carrier 33 and the free end 37 of the bristle bundle 2. The clearance 29 thus forms a cutout or a window within the bristle bundle 2 that is laterally surrounded and thus delimited by a ring or a frame from bristle filaments of the bristle bundle 2.

[0137] FIGS. 15 to 17 and 19 show bundle pockets 3 of an apparatus 1 which are suitable for forming bristle bundles 2 of an entire bristle complement 39 of a brush 32. A brush 32, specifically a toothbrush, the bristle bundle 2 thereof having been formed using the bundle pocket 3 shown in FIGS. 15 to 17, is illustrated in FIG. 18. A brush 32, specifically a toothbrush, the bristle bundle 2 thereof having been formed using the bundle pocket 3 shown in FIG. 19, is illustrated in FIG. 20.

[0138] These bundle pockets 3 have a plurality of bundle receptacles 40 into which the bristle bundles 2 of the bristle complement 39 of the brush 32 are introduced so as to form the bristle bundles 2 in order for the brush 32 to be individualized.

[0139] The apparatus 1 with which the bundle pockets 3 shown in FIGS. 15 to 17 and 19 can be used likewise has a heating apparatus 4. It is to be mentioned at this point that the bundle pocket 3 shown in FIGS. 15 to 17 and 19 can be used on an apparatus 1 as is depicted in FIGS. 1 to 12.

[0140] The bundle receptacles 40 of these bundle pockets 3 are configured so as to be bundle-forming and, under the effect of heat dissipated by the heating apparatus 4, specified for forming the bristle bundles 2 of the bristle complement 39 that have been incorporated into the bundle receptacles 40 in comparison to the shape of said bristle bundles prior to being introduced into the bundle receptacles 40. The latter with the objective of setting the shaping of the bristle bundles 2 that have been incorporated into the bundle receptacles 40 as predefined by the bundle receptacles 40.

[0141] The bundle pocket 3 which is in each case shown in FIGS. 15 to 17 and 19 has a group 41 of bundle receptacles 40. The bundle receptacles 40 of the bundle pocket 3 in the one group 41 are disposed like the bristle bundles 2 in the bristle complement 39 of the brush 32 shown in FIG. 19. There are as many bundle receptacles 40 provided in the group 41 as there are bristle bundles 2 in the bristle complement 39 of the brush 32.

[0142] At least two of the bundle receptacles 40 of the bundle pockets 3 in terms of a longitudinal axis of the respective bundle receptacles 40 have in each case two cross sections 42 and 43 which are axially spaced apart from one another and differ from one another in terms of shape and/or size.

[0143] The bundle pocket 3 shown in FIGS. 15 to 17 on the rear side has a bristle carrier receptacle 44. A bristle carrier 33 of a brush 32, on which the bristle complement 39 of the brush 32 is configured, can be positioned in this bristle carrier receptacle 44, in order for the bristle bundle 2 of the bristle complement 39 to be formed.

[0144] According to FIG. 17, a bundle receptacle 40c of the bundle pocket 3 has a bundle receptacle portion 46 which is defined by envelope faces of two cones or truncated cones. The longitudinal central axes of the cones or truncated cones, respectively, are congruent but the cones or truncated cones respectively, have different radii. A chalice-shaped bundle receptacle 40c is thus created on the bundle pocket 3, said bundle receptacle 40c, proceeding from the introduction portion 44 thereof, fanning out in a chalice-shaped manner.

[0145] The bundle pocket 3 shown in FIGS. 15 to 17 moreover has five bundle receptacles 40b, the longitudinal central axes thereof being helical. The result of the forming of bristle bundles 2 with the aid of these helical bristle receptacles 40 are correspondingly helical bristle bundles 2b as can be seen on the bristle carrier 33 of the brush 32 shown in FIG. 18. The last of the total of seven bundle receptacles 40 of the bundle pocket 3 that is illustrated in FIGS. 15 to 17 is a frustoconical bundle receptacle 40a by way of which frustoconical bristle bundles 2a can be formed.

[0146] The brush 32 shown in FIG. 18 is a toothbrush and has a total of seven individual bristle bundles 2 of which five bristle bundles 2b have a longitudinal axis which winds along a helical line, said five bristle bundles 2b thus being able to be referred to as helical bristle bundles 2b. One of the seven bristle bundles 2 is a conical bristle bundle 2a. A further bristle bundle 2 of the bristle complement 39 is a chalice-shaped bristle bundle 2c. When forming the chalice-shaped bristle bundle 2c, the latter, proceeding from the non-deformed initial shape thereof, is spread open so as to form the chalice shape shown in the figures.

[0147] In the bundle pocket 3 depicted in FIG. 19 a plurality of bundle receptacles 40 which conjointly receive two or more bristle bundles 2 and unify said bristle bundles 2 in a common bundle receptacle portion 50. These bundle receptacles 40 gather at least two separate bristle bundles 2 and unify the latter in the region of the free ends thereof. The bristle bundles 2, at the ends 38 thereof proximal to the bristle carrier, are also identifiable as separate bristle bundles which are still separated from one another in the completely formed bristle complement 39.

[0148] In the use of the bundle pocket 3 shown in FIGS. 15 to 17 and 19, at least one of the bristle bundles 2 of the bristle complement 39 of a brush 32 is formed in such a manner that said bristle bundle 2 in terms of the longitudinal axis thereof has two bundle cross sections 47 and 48 which are axially spaced apart from one another. These two bundle cross sections 47 and 48 differ from one another in terms of shape and/or size.

[0149] In the use of the bundle pocket 3 shown in FIG. 19, at least two bristle bundles 2 from the bristle complement 39 of a brush 32 in the region of the free ends thereof are unified in a common bundle portion 49. In the brush 32 shown in FIG. 20, a plurality of groups of, for example, four or else five individual bristle bundles 2 are gathered so as to form a common bundle portion 49 and are unified therein.

[0150] The bundle receptacles 40 of the bundle pocket 3 illustrated in FIGS. 15 to 18 at the introduction openings 5 thereof for the bristle bundles 2 are equipped with introduction funnels 14. These introduction funnels 14 facilitate a gentle introduction of the bristle bundles 2 into the bundle receptacles 40 of the bundle pocket 3.

[0151] The sectional illustration of the bundle pocket 3 according to FIG. 17 highlights in particular that the frustoconical bundle receptacle 40a is provided with exit openings 15 from which free ends of bristle filaments can exit and, on account thereof, are accessible for further machining.

[0152] The apparatuses 1 for forming bristle bundles 2, the former shown at least in component parts in FIGS. 1 to 12 and 15 to 17 and 19, can be used on a brush manufacturing machine 18 as is illustrated in a highly schematic manner in FIG. 14. The brush manufacturing machine 18 shown in FIG. 14 comprises a rotary indexing table 19 having a total of four arms 20 which are in each case disposed so as to be mutually offset by 90°.

[0153] Each of the arms 20 is specified for receiving a plurality of cassettes 21 which in turn can receive a plurality of bundle pockets 3. The arms 20 are moved in a cycled manner from one station to another station of the brush manufacturing machine 18. The cassettes 21 and/or individual bundle pockets 3 can be transported between the arms 21 and the individual stations of the brush manufacturing machine 18 with the aid of handling apparatuses which are not illustrated in more detail.

[0154] As has already been mentioned above, the brush manufacturing machine 18 has different stations at which bristle bundles 2 can be machined or handled. One of the stations of the brush manufacturing machine 18 is an input station 22. Bundle pockets 3 that are populated with bristle bundles 2 are supplied to the arms 20 of the rotary indexing table 19 with the aid of the input station 22. It is to be expressly stated that the bundle pockets 3 which are illustrated in FIGS. 1 to 12, as well as the bundle pockets 3 which are illustrated in FIGS. 15 to 17 as well as 19, can be used on the brush manufacturing machine 18.

[0155] The brush manufacturing machine 18, in a manner offset by 90° in relation to the input station 22, has a bundle profiling station 23. The apparatus 1 for forming bristle bundles 2, shown in FIGS. 1 to 12, is disposed on the bundle profiling station 23 of the brush manufacturing machine 18.

[0156] The brush manufacturing machine 18, in a manner offset by 90° in relation to the bundle profiling station 23, has a bundle fusing station 24. The formed bristle bundles 2 are fused on one side in the bundle fusing station 24 so as to generate fastening nodes. The bristle bundles 2 can later be fastened to a bristle carrier of a brush with the aid of the fastening nodes.

[0157] A retrieving station 25 of the brush manufacturing machine 18, in a manner offset by 90° is disposed in relation to the bundle fusing station 24. With the aid of the retrieving station 25, machined bristle bundles 2 can be supplied to a further processing station 26 of the brush manufacturing machine that is disposed downstream of the retrieving station 25.

[0158] FIG. 14 shows a heating plate 27 of the heating apparatus 4, said heating plate 27 having the shape of an annular segment and being highlighted with a zigzag hatching. The annular segment-shaped heating plate 27 covers an angular range of 270°. This leads to the bundle pockets 3 being disposed on the arms 20, and bristle bundles 2 situated in said bundle pockets 3 with the aid of the heating apparatus 4, being able to be heated, or held at a temperature, respectively, during the transfer of said bristle bundles 2 from the input station 22 up to the bundle fusing station 24. The annular segment-shaped heating plate 27 of the heating apparatus 4 is adjoined by an annular segment-shaped cooling plate 28 of the already previously mentioned cooling apparatus 17 of the apparatus 1, said cooling plate 28 being smaller in comparison to the heating plate 27. The annular segment-shaped cooling plate 28 can cover an angular range of approximately 90°.

[0159] All of the apparatuses 1 shown can be provided with a bundle spreading apparatus which is specified for spreading the bristle bundles 2 prior to being introduced into the bundle receptacles 40 of the respective bundle pocket 3.

[0160] All of the apparatuses 1 shown can have a humidification apparatus for humidifying and/or steam-treating the bristle bundles 2.

[0161] All of the apparatuses 1 shown can have a controller, for example the controller 54, which is specified for actuating the heating apparatus 4 such that the bristle bundles 2 in the bundle pocket 3 are heated according to defined thermal profile curves. FIG. 21 shows a time/temperature diagram having such a thermal profile curve. A temperature which on a contact face for bristle bundles 2 within a bundle pocket 3 is plotted over time in the diagram. Accordingly, the bristle bundles 2 are heated to a temperature of approx. 174° C. within approx. 13.5 seconds. The temperature of the contact face barely drops for a period of approximately 12 seconds, due to which the bristle bundles 2 are heated. The shaping imparted to the bristle bundles 2 by the bundle pocket 3 is set on account thereof. The contact face subsequently cools down to a temperature of 40° C. within approx. 18 seconds, and the thermal forming of the bristle bundles 2 is completed.

[0162] The bundle pockets 3 shown, due to the bundle receptacles 40 thereof, are specified for heating the bristle bundles 2 by thermal conduction by mechanical contacting, by induction and/or convection, preferably by a temperature-controlled fluid, and/or by thermal radiation.

[0163] The cooling apparatus 17 of the apparatus 1 in one embodiment is specified for cooling the bristle bundles 2 by a temperature-controlled fluid, in particular by compressed air and/or by nitrogen. To this end, the cooling apparatus 17 in this instance is equipped with a cold air gun, with a vortex tube, and/or with a cyclone tube, for example.

[0164] The bundle pockets 3 can be manufactured by eroding and/or by 3D-printing and/or by cutting, and/or from thin layers and/or sheets which are subsequently connected to one another.

[0165] The bundle receptacles 40 have a surface roughness of at most 6.3 μm. Furthermore, the bundle receptacles 40 in the push-fitting direction of the bristle bundles 2 are ground, specifically flow ground and polished. If required, said bristle bundles 2 can be provided with a surface coating so as to further reduce the surface roughness of said bristle bundles 2.

[0166] The apparatuses 1 illustrated can be equipped with a suction apparatus by way of which a negative pressure can be applied to the bundle pockets 3, in particular to the bundle receptacles 40, so as to facilitate an introduction of the bristle bundles 2. The bundle receptacles 40 of the bundle pockets 3 herein are impinged with negative pressure, due to which the bristle bundles 2 are suctioned into bundle receptacles 40 by negative pressure.

[0167] The bundle pockets 3 can be laterally perforated and/or have at least one flow duct 56 so as to accelerate an exchange of heat by way of the bundle pockets 3. A heated or else a cooled fluid can be directed through the flow duct 56 so as to temperature-control the respective bundle pocket 3 and bristle bundles 2 situated therein. Furthermore, at least part of the heating apparatus 4 can be integrated in the bundle pockets 3 shown.

[0168] When heated fluid is used for temperature-controlling bristle bundles situated in the bundle pockets 3, a discharge apparatus can be provided, by way of which fluid heated by the heating apparatus 4, in particular warm air, can be discharged.

[0169] However, it is typically more economical in terms of energy for the apparatus 1 to have a closed system, in particular a recirculating air system, in which fluid that is heated by the heating apparatus 4, in particular heated air, circulates.

[0170] The controller 54 and/or a regulator unit of the apparatus 1 can be used for monitoring a thermal input into the bundle pockets 3.

[0171] The apparatuses 1 shown in the figures can have one or a plurality of temperature sensors by way of which a temperature of the bundle pockets 3 can be determined. The temperature sensors can be disposed at different positions on the bundle pockets 3 so as to determine the temperatures of the bundle pockets 3 at different locations.

[0172] The apparatuses 1 can furthermore have at least one temperature sensor on the respective heating apparatus 4 of said apparatuses 1 and/or in or at an inflow duct and/or in or at an outflow duct through which the temperature-controlled fluid is directed for exchanging heat.

[0173] The bundle receptacles 40 are at least 20% larger than an overall cross-sectional area of individual bristle filaments which are to be introduced into these bundle receptacles 40.

[0174] The bristle bundles 2 of the bristle complement 39 can be deformed in stages and/or in groups. The inner bristle bundle 2 herein can be first deformed, and the outer bristle bundle 2 of the bristle complement 39 can be subsequently deformed.

[0175] The bristle bundles 2, prior to being introduced into the bundle receptacles 40, can be spread open and/or steam-treated and/or humidified. The bristle bundles 2 can be deformed in such a manner that said bristle bundles 2 conjointly represent a logo and/or an image.

[0176] The controller 54 and/or the heating apparatus 4 of the apparatus 1 can be set such that the bristle bundles 2 with the aid of the heating apparatus 4 can be heated according to defined thermal profile curves.

[0177] The bristle bundles 2 can also be cooled with the aid of a temperature-controlled fluid. The bristle bundles 2 can in particular be cooled by compressed air and/or by nitrogen and/or by ambient air, and/or by a cold air gun and/or a cyclone tube and/or a vortex tube.

[0178] In order for the bristle bundles 2 situated within the bundle pockets 3 to be heated, a heated fluid, in particular air, can be directed through flow ducts 56 of the bundle pockets 3. These flow ducts 56 can also be utilized for cooling the bristle bundles 2 situated within the bundle pockets 3. In this instance, a cooled fluid, in particular air, is directed through the flow ducts 56 of the bundle pocket 3 herein.

[0179] The fluid, in particular the air, for incorporating the heat, upon heating the bristle bundles 2, can be released into the environment and/or be guided in a closed system, in particular in a recirculating air system or a closed-circuit system of the respective apparatus 1.

[0180] A thermal input into the bundle pockets 3 for heating the bristle bundles 2 can be monitored by the controller 54 and corresponding temperature sensors 3.

[0181] The bundle pockets 3 are heated to a basic heat above the ambient temperature before the bristle bundles 2 are introduced into the bundle receptacles 40. This helps in reducing the cycle times.

[0182] The bristle bundles 2 can be extracted from the bundle pockets 3 even before said bristle bundles 2 have reached the final cooling temperature thereof. The method can be accelerated on account thereof.

[0183] The bristle bundles 2 have bristle filaments which can be composed of PE, PBT, PA6.10, PA6.12, PA10.10, PA4.10 and/or of a mixture and/or of a composite of said materials.

[0184] The brush manufacturing machine 18 as well as the apparatus 1 for forming bristle bundles 2 are used for manufacturing brushes 32.

[0185] FIG. 14 shows that the brush manufacturing machine 18 can establish a data connection to a computer-readable medium 51. A computer program which comprises commands which have the effect that the apparatus 1 and/or the brush manufacturing 18 carry/carries out the method described in detail above can be stored on the computer-readable medium 51.

[0186] The computer-readable medium 51 in the shown exemplary embodiment according to FIG. 14 is a data storage 52 in a cloud 53. The brush manufacturing machine 18 has a controller 54 which is equipped with a preferably wireless data interface 55. The brush manufacturing machine 18 by way of the data interface 55 can establish a data connection to the cloud 53 by way of a network, for example the internet, so as to communicate with the data storage 52 kept available there and to read the computer program from said data storage 52.

[0187] The invention relates to improvements in the technical field of the manufacture and design of brushes. An apparatus 1 for forming bristle bundles 2 is inter alia proposed as an improvement. The apparatus 1 comprises at least one bundle pocket 3 which is specified for receiving a bristle bundle 2 to be formed. The bundle pocket 3 has at least one lateral piercing 6. A displacement means 7 of the apparatus 1 can be introduced through this piercing 6 into the bundle pocket 3 so as to generate a clearance 29 within a bristle bundle 2 to be formed. The bundle pocket 3 and the bristle bundle 2 situated therein are heated by the heating apparatus 4 so as to set the shaping of the bristle bundle 2 that is predefined by the bundle pocket 3 and the displacement means 7.

LIST OF REFERENCE SIGNS

[0188] 1 Apparatus for forming bristle bundles [0189] 2 Bristle bundle [0190] 2a Frustoconical bristle bundle [0191] 2b Helical bristle bundle [0192] 2c Chalice-shaped bristle bundle [0193] 3 Bundle pocket [0194] 4 Heating apparatus [0195] 5 Introduction opening [0196] 6 Lateral piercing in 3 [0197] 7 Displacement means [0198] 8 Closure means [0199] 8a End faces of 8 [0200] 9 Heat exchanger element [0201] 10 Bundle gripper [0202] 11 Bundle pocket gripper [0203] 12 Vibrator [0204] 13 Wall of 3 [0205] 14 Introduction funnel [0206] 15 Exit opening [0207] 16 Machining means/cutter [0208] 17 Cooling apparatus [0209] 18 Brush manufacturing machine [0210] 19 Rotary indexing table [0211] 20 Arm of 19 [0212] 21 Cassette [0213] 22 Input station [0214] 23 Bundle profiling station [0215] 24 Bundle fusing station [0216] 25 Retrieving station [0217] 26 Further processing station [0218] 27 Heating plate [0219] 28 Cooling plate [0220] 29 Clearance in 2 [0221] 30 Guide for 7, 8, 10, 16 [0222] 31 Free ends of bristle filaments [0223] 32 Brush [0224] 33 Bristle carrier [0225] 34 Handle [0226] 35 First closed bundle portion [0227] 36 Second closed bundle portion [0228] 37 Free end of 2 [0229] 38 End of 2 proximal to the bristle carrier [0230] 39 Bristle complement [0231] 40 Bundle receptacle [0232] 40a Frustoconical bundle receptacle [0233] 40b Helical bundle receptacle [0234] 40c Chalice-shaped bundle receptacle [0235] 41 Group of 40 [0236] 42 First cross section of 40 [0237] 43 Second cross section of 40 [0238] 44 Bristle carrier receptacle [0239] 45 Periphery of 44 [0240] 46 Bundle receptacle portion [0241] 47 Bundle cross section [0242] 48 Bundle cross section [0243] 49 Common bundle portion [0244] 50 Common bundle receptacle portion [0245] 51 Computer-readable medium [0246] 52 Data storage [0247] 53 Cloud [0248] 54 Controller [0249] 55 Data interface [0250] 56 Flow duct in 3