Brush handle assembly and method for making

Abstract

Examples of the present disclosure include apparatus and methods for making a brush handle assembly. Specifically, the present disclosure is for a brush handle assembly comprising a flexible handle, an intermediate connector, and a ferrule. In particular, the present disclosure is for an improved interface between each of the flexible handle, the intermediate connector, and the ferrule for an improved construction providing increased durability and longevity.

Claims

1. A handle for a brush assembly, the handle comprising: an intermediate connector formed of a rigid material and having a top side and a bottom side, the bottom side configured to be inserted into a ferrule for mounting an applicator end, and the top side having a cavity, the cavity including at least one sidewall aperture from the cavity through at least one lateral sidewall between the bottom side and the top side; and a flexible handle having a handle grip and an insert, the insert of the flexible handle formed by molding into the cavity open at the top side of the intermediate connector, wherein at least one cleat is formed on the insert by at least partially filling the at least one sidewall aperture in the intermediate connector during molding exposing the at least one cleat through the at least one lateral side wall, wherein the insert and the at least one cleat create a locking engagement between the flexible handle and the intermediate connector.

2. The handle of claim 1, wherein one or more of a width and thickness of the at least one cleat increases as the cleat projects from the insert.

3. The handle of claim 1, wherein the at least one cleat comprises engaging surfaces for connection to an intermediate connector of the brush assembly.

4. The handle of claim 1, wherein the intermediate connector of the brush assembly is permanently secured to the flexible handle.

5. The handle of claim 1, wherein the flexible handle is asymmetrical about a central axis.

6. The handle of claim 1, wherein the insert of the flexible handle is concealed by the cavity of the intermediate connector.

7. The handle of claim 1, wherein the at least one cleat fully fills the at least one sidewall aperture in the intermediate connector creating a topmost surface of the cleat substantially coincident with an outermost surface of the lateral sidewall.

8. The handle of claim 1, wherein the insert of the flexible handle is shaped by the cavity of the intermediate connector during molding.

9. The handle of claim 1, wherein the intermediate connector includes one or more exterior voids for securing the ferrule to the intermediate connector.

10. The brush handle assembly of claim 1, wherein the at least one sidewall runs laterally through opposing sides of the intermediate connector.

11. The brush handle assembly of claim 10, wherein the at least one cleat includes a plurality of cleats exposed through opposite sides of the at least one sidewall.

12. The brush handle assembly of claim 1, wherein the top side of the intermediate connector further having at least one exterior void configured to secure a ferrule to the intermediate connector.

13. The brush handle assembly of claim 1, wherein the at least one cleat is concealed within the brush assembly when the brush assembly is assembled.

14. A brush handle assembly comprising: a ferrule configured for mounting an applicator end; an intermediate connector formed of a rigid material and having a top side and a bottom side, the bottom side configured to be inserted into the ferrule and the top side having a cavity, the cavity including at least one sidewall aperture from the cavity through a lateral sidewall between the bottom side and the top side; and a flexible handle having a handle grip and an insert, the insert of the flexible handle formed by molding into the cavity open at the top side of the intermediate connector, wherein at least one cleat is formed on the insert by at least partially filling the at least one sidewall aperture in the intermediate connector during molding exposing the at least one cleat through the lateral side wall, wherein the insert and the at least one cleat create a locking engagement between the flexible handle and the intermediate connector, and wherein the intermediate connector is mechanically connected inside the ferrule to connect the applicator end to the flexible handle.

15. The brush handle assembly of claim 14, wherein the intermediate connector is positioned within a top side of the ferrule and is substantially concealed by the ferrule.

16. The brush handle assembly of claim 14, wherein the ferrule is crimped into engagement with the at least one sidewall aperture in the intermediate connector.

17. The brush handle assembly of claim 14, wherein the ferrule is crimped into engagement with the at least one cleat on the insert.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Reference is made to the accompanying drawings in which particular examples and further benefits of the invention are illustrated as described in more detail in the description below, in which:

(2) FIG. 1 is a front view of a brush handle assembly, in accordance with an example.

(3) FIG. 2 is a perspective view of a flexible handle with the intermediate connector removed for clarity, in accordance with an example.

(4) FIG. 3 is a front view of a flexible handle with the intermediate connector removed for clarity, in accordance with an example.

(5) FIG. 4 is top view of a flexible handle, in accordance with an example.

(6) FIG. 5 is a bottom view of a flexible handle with the intermediate connector removed for clarity, in accordance with an example.

(7) FIG. 6 is a side view of a flexible handle at a raised profile with the intermediate connector removed for clarity, in accordance with an example.

(8) FIG. 7 is a side view of a flexible handle with the intermediate connector removed for clarity, in accordance with an example.

(9) FIG. 8 is a bottom side perspective view of an intermediate connector with the flexible handle removed for clarity, in accordance with an example.

(10) FIG. 9 is a top side perspective view of an intermediate connector with the flexible handle removed for clarity, in accordance with an example.

(11) FIG. 10 is a front view of an intermediate connector with the flexible handle removed for clarity, in accordance with an example.

(12) FIG. 11 is a bottom view of a cavity of an intermediate connector with the flexible handle removed for clarity, in accordance with an example.

(13) FIG. 12 is a side view of an intermediate connector with the flexible handle removed for clarity, in accordance with an example.

(14) FIG. 13 is a perspective view of a flexible handle inserted or molded into an intermediate connector, in accordance with an example.

(15) FIG. 14 is a front view of a flexible handle inserted or molded into an intermediate connector, in accordance with an example.

DETAILED DESCRIPTION

(16) The present disclosure includes apparatus and methods for making a brush handle assembly. Specifically, the present disclosure is for a brush handle assembly comprising a flexible handle, an intermediate connector, and a ferrule. The present brush handle assembly provides for a flexible brush with increased durability and longevity. In particular, the interface between the flexible handle, the intermediate connector, and the ferrule reduces or eliminates failure of the brush handle assembly at high stress locations.

(17) Referring to FIG. 1, an example of a brush handle assembly 10 comprising a flexible handle 100, an intermediate connector 200, and a ferrule 300 is illustrated. An applicator end 400, such as bristles, may further extend from the ferrule 300 of the brush handle assembly. The flexible handle is made of rubber or plastic while maintaining flexible characteristics. The intermediate connector may be a hard plastic base constructed of polypropylene, for example. The ferrule may be constructed of a metal. In specific examples, the handle material may be constructed from TPR (thermoplastic rubber), TPE, thermoplastic elastomer, or TPV (thermoplastic vulcanizate, such as Santoprene). The various handle constructions may span all possible shore hardness values. In specific examples, the intermediate connector may be constructed from any thermoplastic, including all blends/varieties of Polypropylene, all blends/varieties of Polyamide (nylon), and all blends/varieties of POM (Polyoxymethylene, such as Acetal and/or Delrin). In specific examples, ferrule material may include ETP (electrolytic tin plate, commonly referred to as coke tin), brass antique brass, nickel, nizon, copper (or other typical decorative plating on top of the ETP), stainless steel, and/or thermoplastics.

(18) Turning to FIGS. 2-7, an example of the flexible handle 100 is illustrated. FIG. 2 illustrates a perspective view of the flexible handle 100. The flexible handle 100 comprises a grip 110 and an insert 150. The grip 110 extends from the intermediate connector when the brush handle assembly is assembled. The insert 150 is inserted into the intermediate connector for securing the flexible handle to the intermediate connector when the brush handle assembly is assembled.

(19) In the example as illustrated by FIG. 2, the grip 110 of the flexible handle 100 comprises a raised profile 120 which is offset, or off-center, to a first side 102 of the flexible handle 100. The raised profile is of an ergonomic design for reducing user fatigue during continuous and/or aggressive use of the brush handle assembly. In particular, the raised profile 120 comprises one or more contours for mating with the purlicue of a user's hand. With particular reference to FIGS. 2-3, a first contour 122 may be provided on the first side 102 of the flexible handle for mating with the purlicue. A second contour 124 may be provided at the front 106 of the flexible handle for indexing a user's finger or thumb. A third contour, opposite the second contour 126, may be provided at the back of the flexible handle for indexing a user's palm. In other words, multiple contours, such as three contours, may be provided on the raised profile 120 for indexing a user's hand. As further illustrated by FIGS. 4-7 the first 122, second 124, and third 126 contours of the raised profile 120 are each convex. The raised profile 120 has a thickness 120.sub.T greater than the thickness 100.sub.T of the flexible handle 100 at a second side 104. The raised profile thickness 120.sub.T and the handle thickness 100.sub.T are illustrated by FIGS. 4-5.

(20) As illustrated by FIGS. 2-3, the flexible handle may also comprise a handle top side 130. In this example, the handle top side 130 comprise a thickness 130T greater than the thickness 100.sub.T of the flexible handle 100 at the second side 104. The topside thickness 130T and the handle thickness 100.sub.T are illustrated by FIG. 4.

(21) The handle top side 130 may also comprise a top side aperture 132. Here, the top side aperture 132 is circular and forms a cylinder extending through the thickness of the flexible handle 100. The top side aperture 132 may receive a lanyard for hanging the brush handle assembly and/or for receiving a strap for suspending a tag at the point of sale, for example. A thickened wall section 134 forms a perimeter of the top side aperture 132. Below the handle top side 130, a width 110.sub.W of the grip increases in a direction toward the insert 150 of the flexible handle as illustrated by FIG. 3.

(22) The insert 150 extends from below the grip 110 and is inserted into and concealed within the intermediate connector 200 when the brush handle assembly is assembled. The insert 150 may comprise one or more cleats 160 for securing the flexible handle 100 to the intermediate connector. In FIG. 2, the insert 150 comprises four cleats 160. Any number of cleats are contemplated herein. In one example, one cleat may be provided. In yet another example, multiple cleats may be provided. As illustrated by FIGS. 5-7, the cleats 160 extend laterally outward from a front 152 and a back 154 of the insert, respectively. Here, each cleat forms a trapezoid extending from the insert. The cleat is shaped to mate with a respective sidewall aperture of the intermediate connector. As illustrated by FIG. 5, The width of each cleat 160.sub.W increases as the cleat extends from the insert 150. As illustrated by FIGS. 6-7, the thickness of each cleat 160T additionally increases as the cleat extends from the insert 150. This provides a locking engagement at the sidewall aperture of the intermediate connector when positioned in the intermediate connector.

(23) Turning to FIG. 8, a perspective view of the bottom side 210 of the intermediate connector 200 is illustrated. The bottom side 210 is inserted into a top side of the ferrule when the brush handle assembly is assembled. Illustrated by FIG. 8 are bottom side voids 212. The bottom side voids 212 are provided to increase the rigidity and strength of the intermediate connector within the ferrule. The bottom side 210 of the intermediate connector 200 forms a taper 214, or reduces in thickness 200T, as the intermediate connector transitions toward the bottom side 210 as illustrated by FIG. 10.

(24) FIG. 9 illustrates a perspective view of the top side 220 of the intermediate connector 200. A cavity 250 is formed within the intermediate connector 200 for receiving the insert 150 of the flexible handle when the brush handle assembly is assembled. The insert of the flexible handle may be molded into the cavity 250. As illustrated by FIGS. 9 and 11, the intermediate connector 200 comprises thickened wall sections 216 for strength and rigidity. Upon inserting the flexible handle into the cavity 250 the strength and rigidity exhibited by the taper 214, the bottom side voids 212, and the thickened wall sections 216 are transferred to the flexible handle by way of the flexible handle insert.

(25) As illustrated by FIGS. 8-10, the intermediate connector 200 may further comprise sidewall apertures 230. The sidewall apertures 230 receive and mate with the cleats 160 of the insert when the brush handle assembly is assembled. In the example as illustrated by FIGS. 8-10 the sidewall apertures 230 are trapezoids. The sidewall apertures may be of any shape including but not limited to, rectangular, circular, or the like.

(26) In one example and with particular reference to FIGS. 9-10, the intermediate connector 200 may further comprise support ribs 240 within the cavity 250. The support ribs 240 extend across the cavity 250 between opposing internal sidewalls 252, 254. The support ribs 240 provide for increased support of the intermediate connector during formation and to further secure and support the flexible handle when the brush handle assembly is assembled. The support ribs 240 may extend the entire depth of the cavity or a partial depth of the cavity. When extending a partial depth of the cavity 250 a flexible handle that is molded within cavity 250 fills the cavity about the support ribs 240. Specifically, the flexible handled molded within cavity 250 may form a locking engagement wherein the flexible handle encases one or more support ribs 240 within the intermediate connector 200. This provides additional support and permanently secures the flexible handle within the intermediate connector when the brush handle assembly is assembled. One or more support ribs may be provided. Likewise, multiple support ribs may be provided. In the example illustrated by FIGS. 9-10, three support ribs 240 are provided.

(27) In FIGS. 8-10 and 12, the intermediate connector 200 may further comprise one or more exterior voids 260 for securing the ferrule to the intermediate connector 200 when the brush handle assembly is assembled. The one or more exterior voids 260 are provided in the exterior surface of the intermediate connector 200. In another example, the exterior void 260 may be an aperture extending through the sidewall of the intermediate connector 200. In the examples of FIGS. 8-10 and 12, the one or more exterior voids 260 are each positioned relative to one of the four corners of the intermediate connector 200. When the brush handle assembly is assembled the ferrule is crimped into the one or more exterior voids 260 forming a mechanical connection between the ferrule and the intermediate connector 200.

(28) As illustrated by FIGS. 8-12, the intermediate connector may further comprise a top lip 270. In these examples, the top lip 270 is positioned to the top side 220 of the intermediate connector 200 and extends the entire perimeter of the top side 220 of the intermediate connector 200. The top lip 220 is seated to a top of the ferrule. Further, the top lip separates the top of the ferrule from the flexible handle. In other examples, one or more top lips may partially extend the perimeter of the top side of the intermediate connector. When the brush handle assembly is assembled the intermediate connector may be fully concealed or substantially concealed by the ferrule. As used herein, substantially concealed means fully concealed with the exception of one or more top lips.

(29) Turning now to FIGS. 13-14, a flexible handle 100 inserted into the intermediate connector 200 is illustrated. The one or more cleats 160 of the insert 150 of the flexible handle 100 penetrate a respective sidewall aperture 230 of the intermediate connector. The one or more cleats 160 may partially or fully fill the respective sidewall aperture 230. Upon being inserted into, molded into, and/or formed within, the flexible handle 100 is secured to the intermediate connector 200. The flexible handle 100 may be removably secured or permanently secured to the intermediate connector 200.

(30) By extending the one or more cleats 160 of the insert 150 through a respective sidewall aperture 230 the one or more cleats are exposed through the intermediate connector 200. By exposing the one or more cleats the one or more cleats may contact, engage, or be open to the ferrule. Thereby, the one or more cleats may be additionally secured mechanically and/or by adhesive to the ferrule. Thereby, the cleats may provide a connection between each of the flexible handle, the intermediate connector, and the ferrule, in combination.

(31) Additional examples of the present disclosure include methods for assembling a brush handle assembly. Examples of a method for assembling a brush handle assembly comprise providing an intermediate connector. The intermediate connector may comprise a cavity formed by sidewalls for receiving a flexible handle. The intermediate connector may further comprise one or more sidewall apertures for mechanically connecting a flexible handle to the intermediate connector.

(32) In one example, a flexible handle is inserted into the intermediate connector. The flexible handle may be secured to the intermediate connector. In one example, the flexible handle may be molded. In particular, the flexible handle may be molded independent of and prior to insertion into the intermediate connector. Alternatively, the flexible handle may be molded directly into the intermediate connector. Cleats of the flexible handle may be molded into or forced into the sidewall apertures for providing a mechanical connection between the intermediate connector and the flexible handle. In other words, one or more cleats of the flexible handle may be extended through one or more sidewall apertures of the intermediate connector.

(33) The intermediate connector may comprise one or more support ribs about which the flexible handle may be molded. By example, the flexible handle may be molded to surround each one or more support ribs on at least three surfaces, thereby, creating a locking engagement between the flexible handle and the intermediate connector. In these examples, the flexible handle may be formed or molded to partially fill the cavity of the intermediate connector or may fully fill the cavity of the intermediate connector. Adhesive may additionally be added to further secure or adhere the flexible handle to the inside surface of the intermediate connector.

(34) The method for assembling a brush handle assembly may further comprise inserting a bottom side of an intermediate connector into a top side of a ferrule. The exterior of intermediate connector may be form fitted to mate with the inside of the ferrule. The exterior of the intermediate connector may further comprise bottom side tapers for guiding the bottom side of the intermediate connector into the top side of the ferrule. Bottom side voids may also be provided at the bottom side of the intermediate connector. The bottom side tapers and/or the bottom side voids may additionally be provided to further secure an applicator end between the intermediate connector and the ferrule at the bottom side taper and the ferrule and/or within the bottom side voids. Adhesive may additionally be provided to further secure the intermediate connector to the ferrule, secure the intermediate connector to the applicator end, secure the applicator end to the ferrule, or any combination thereof. In particular examples, the applicator end is secured to an interior and/or a bottom side of ferrule.

(35) In one particular example, the intermediate connector is fully inserted into the ferrule. In another example, the intermediate connector is substantially inserted into the ferrule.

(36) The method for assembling a brush handle assembly may further comprise crimping the ferrule into one or more exterior voids of the intermediate connector. By crimping, or forcing the material of the ferrule into the one or more exterior voids of the intermediate connector, the ferrule and the intermediate connector are mechanically secured to one another. Adhesive may be used in combination with a mechanical connection to further secure the intermediate connector to the ferrule.

(37) The terms comprising, including, and having, as used in the claims and specification herein, shall be considered as indicating an open group that may include other elements not specified. The terms a, an, and the singular form of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. The terms at least one and one or more are used interchangeably. The term single shall be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as two, are used when a specific number of things are intended. The terms preferably, preferred, prefer, optionally, may, and similar terms are used to indicate that an item, condition or step being referred to is an optional (i.e., not required) feature of the invention.

(38) While this description has been described with reference to particular examples thereof, it shall be understood that such description is by way of illustration only and should not be construed as limiting the scope of the claimed invention. Accordingly, the scope and content of the invention are to be defined only by the terms of the following claims. Furthermore, it is understood that the features of any specific example discussed herein may be combined with one or more features of any one or more embodiments otherwise discussed or contemplated herein unless otherwise stated