INTEGRAL BRUSH WITH NO GAPS BETWEEN CLEANING ASSEMBLY AND HANDLE AND MANUFACTURING PROCESS THEREOF
An integral brush is formed by performing steps of tufts arrangement, tufts insertion into mold, mold turning and closing, and injection molding, thereby forming no gaps between cleaning assembly and handle. The cleaning assembly includes at least one cleaning unit each having a plurality of tufts integrally formed with one of a plurality of bases in the handle. The tufts are spaced apart and an upper portion of each tuft is shaped to form an uneven tip. The brush can increase a contact area between the cleaning assembly and an object so as to effectively clean the object.
1. Field of the Invention
The invention relates to cleaning instrument and more particularly to an integrally formed brush with no gaps between a cleaning assembly and a handle. The invention also relates to a process of manufacturing the integrally formed brush.
2. Description of Related Art
There are a wide variety of brushes such as toothbrush, brush for cleaning face, and brush for cleaning purpose. Typically, a brush includes a handle and a cleaning assembly formed on a head of the handle.
Conventionally, brushes are secured to a handle by insertion. In detail, a plurality of tufts that include at least one bristle are bent. A hard member such as metal is attached to the bending portion. Next, the tufts and the hard member together are inserted into cavities in the handle. Finally, the tufts are secured to the handle.
However, a plurality of gaps may be formed between the tufts and the cavities. Thus, dirt may be left in the gaps. Further, liquid tends to store in the gaps and thus microorganisms may grow in the gaps. It is not hygienic. Further, the bent tufts may return to an inclined position after a period of time of use due to elasticity thereof. Thus, it is not durable.
Conventionally, a cleaning unit of a brush comprises a plurality of spaced tufts each adapted to provide a point contact with an object such as teeth, skin, or surface when it is rubbed against the object. Unfortunately, this cannot effectively clean dirt in the gaps of the object. The gaps may refer to, for example, the teeth, the gums, the gaps between the teeth, and the areas adjacent to the teeth and the gums. Further, tips of the tufts are flat, and section of the tufts of the cleaning unit is annular. All of these drawbacks hinder an effective cleaning of the dirt left in the gaps when using a brush to rub an object. Thus, the need for improvement still exists.
SUMMARY OF THE INVENTIONIt is therefore one object of the invention to provide a brush having a cleaning assembly and a handle formed integrally by injection molding with no gaps between the cleaning assembly and the handle. This can prevent dirt and liquid from being left on the brush. Otherwise, microorganisms may grow on the brush. The brush of the invention is more hygienic than the conventional brush.
It is another object of the invention to provide an integral brush with no gaps between a cleaning assembly and a handle wherein the cleaning assembly comprises at least one cleaning unit each having a plurality of tufts integrally formed with a base. Each cleaning unit provides a multiple contact with an object similar to an area contact when it is rubbed against the object such as teeth, skin, or surface. Thus, it can totally clean gaps in the object. For example, the teeth, the gums, the gaps between the teeth, and the areas adjacent to the teeth and the gums.
It is still another object of the invention to provide an integral brush with no gaps between a cleaning assembly and a handle wherein the tufts are spaced apart and an upper portion of each tuft is shaped to form an uneven tip, thereby increasing a contact area between the cleaning assembly and an object so as to effectively clean the object.
For achieving above and other objects of the invention, there is provided an integral brush comprising a handle; and a cleaning assembly integrally formed with the handle with no gaps therebetween, the cleaning assembly including at least one cleaning unit each having a plurality of tufts integrally formed with one of a plurality of bases in the handle; wherein the tufts are spaced apart; and wherein an upper portion of each of the tufts is shaped to form an uneven tip.
In a preferred embodiment of the invention, the cleaning unit has a plurality of tufts having a conic portion adjacent to the tip.
In a preferred embodiment of the invention, the cleaning unit has a plurality of tufts having a polygonal section.
In a preferred embodiment of the invention, the polygonal section is a rhombic section.
In a preferred embodiment of the invention, the cleaning assembly includes a plurality of cleaning units.
In a preferred embodiment of the invention, the cleaning units are shaped to form an uneven top.
In a preferred embodiment of the invention, the cleaning assembly has a convex top.
The invention further provides a process of manufacturing an integral brush comprising the steps of tufts arrangement involving arranging a plurality of tufts as one of a plurality of cleaning units and fusing bases of the cleaning units to form a unitary member; tufts insertion into mold involving inserting heads of the cleaning units through a plurality of holes of a die, and activating a pushing device to push the cleaning units further into a plurality of holes of an upper mold with lower portions of the cleaning units disposed out of the upper mold; mold turning and closing involving turning the upper mold upside down to align with a lower mold so as to together form a cavity with a portion adjacent to the base of each of the cleaning units is disposed in the cavity; and injection molding involving forming a handle in the cavity and joining the portion adjacent to the base of each of the cleaning units and the handle by injection molding with no gaps formed between the handle and the portion adjacent to the base of each of the cleaning units.
The invention, as well as its many advantages, may be further understood by the following detailed description and drawings in which:
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It is envisaged by the invention that the integral brush with no gaps between cleaning assembly and handle has the following advantages in comparison with conventional brush: The cleaning assembly and the handle are formed integrally by injection molding and thus there is no gaps between the cleaning assembly and the handle. This can prevent dirt and liquid from being left on the brush. Otherwise, microorganisms may grow on the brush. The brush of the invention is more hygienic than the conventional brush. The cleaning assembly comprises at least one cleaning unit each having a plurality of tufts integrally formed with a base. Each cleaning unit provides a multiple contact with an object (i.e., similar to an area contact) when it is rubbed against the object (e.g., teeth, skin, or surface). Thus, it can totally clean gaps in the object. For example, these gaps exist in the teeth, the gums, the gaps between the teeth, and the areas adjacent to the teeth and the gums. Upper portions of the tufts are spaced apart with an uneven shape formed on its tops. The brush can increase a contact area between the cleaning assembly and an object so as to effectively clean the object.
Many changes and modifications in the above described embodiment of the invention can, of course, be carried out without departing from the scope thereof. Accordingly, to promote the progress in science and the useful arts, the invention is disclosed and is intended to be limited only by the scope of the appended claims.
Claims
1. An integral brush comprising:
- a handle; and
- a cleaning assembly integrally formed with the handle with no gaps therebetween, the cleaning assembly including at least one cleaning unit each having a plurality of tufts integrally formed with one of a plurality of bases in the handle;
- wherein the tufts are spaced apart; and
- wherein an upper portion of each of the tufts is shaped to form an uneven tip.
2. The integral brush of claim 1, wherein the cleaning unit has a plurality of tufts having a conic portion adjacent to the tip.
3. The integral brush of claim 1, wherein the cleaning unit has a plurality of tufts having a polygonal section.
4. The integral brush of claim 3, wherein the polygonal section is a rhombic section.
5. The integral brush of claim 1, wherein the cleaning assembly includes a plurality of cleaning units.
6. The integral brush of claim 5, wherein the cleaning units are shaped to form an uneven top.
7. The integral brush of claim 1, wherein the cleaning assembly has a convex top.
8. A process of manufacturing an integral brush of claim 1, comprising the steps of:
- tufts arrangement involving arranging a plurality of tufts as one of a plurality of cleaning units and fusing bases of the cleaning units to form a unitary member;
- tufts insertion into mold involving inserting heads of the cleaning units through a plurality of holes of a die, and activating a pushing device to push the cleaning units further into a plurality of holes of an upper mold with lower portions of the cleaning units disposed out of the upper mold;
- mold turning and closing involving turning the upper mold upside down to align with a lower mold so as to together form a cavity with a portion adjacent to the base of each of the cleaning units is disposed in the cavity; and
- injection molding involving forming a handle in the cavity and joining the portion adjacent to the base of each of the cleaning units and the handle by injection molding with no gaps formed between the handle and the portion adjacent to the base of each of the cleaning units.
Type: Application
Filed: Nov 13, 2014
Publication Date: Jun 4, 2015
Inventors: CHENG FANG (Taipei City), JUI-HUNG SU (Taipei City)
Application Number: 14/541,110