BRUSH BRISTLE MATERIAL AND BRUSH

Abstract

A brush bristle material comprising a linear metallic material containing powders of one or more kinds of lava abrasive grains and/or basalt abrasive grains in a mixed state at a ratio in the range of 1% to 70%, preferably in the range of 1% to 30%. The powders of the lava abrasive grains and/or the basalt abrasive grains to be included in the linear metallic brush bristle material are incapable of being burnt and melted during the course of the inclusion and capable of enhancing the ability of grinding or abrading. Therefore, it is made possible to optimize the surface treatment of the interior of a hole in a given workpiece and the removal of a burr by grinding and a brush manufactured from the linear metallic brush bristle material.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a brush bristle material that is obtained by causing a linear metallic material to contain in a mixed state abrasive grains, such as lava abrasive grains or basalt abrasive grains or powders thereof, and consequently enabled to optimize the surface treatment of the interior of a hole in a workpiece, the removal of a burr by grinding and the like and to a brush made thereof. This invention particularly relates to a brush bristle material that is obtained by causing a linear metallic material, while being manufactured by melting a metallic material and forming the molten material into a wire, to contain in a mixed state lava abrasive grains or basalt abrasive grains or powders thereof and consequently enabled to give a workpiece such grinding as is suited to hardness, shape and object of polishing of the workpiece and relates to a brush made thereof

2. Description of the Prior Art

The brush disclosed in JP-A 2003-164332 is produced by having a metal wire nipped among three metallic wires and twisted in situ. A hollow pipe made of metal is inserted in the twisted part of the brush and fixed in the inserted state by causing the outer periphery thereof to be drawn.

The brush disclosed in JP-A 2002-254277 is produced by causing an aggregate yarn formed of a plurality of alumina filaments to be impregnated in a binder resin and eventually cured and bundled. The plurality of alumina filaments allow the free ends thereof which have not been cured owing to the adhesion of the binder resin to serve the purpose of removing a burr, for example, by grinding.

The conventional brush bristle material is such that, when it is made to increase strength and caused to sustain breakage consequently, the fragments resulting from the breakage will possibly scatter and induce an accident. Further, since the workpieces requiring abrasion are infinitely varied in hardness, flexibility and shape, the desirability of offering brushes that possess characteristic properties capable of absorbing this infinite variation has been finding recognition. The metallic brush bristle materials have encouraged an attempt to enhance their abrading or honing capacities by causing metallic materials to contain in a mixed state diamond abrasive grains or abrading grains or other kinds of abrasive grains. The abrading grains etc., however, are burnt and melted away at elevated temperatures before they are included in the metallic materials. At times, the conventional brush bristle materials encounter difficulty in producing brushes endowed with abrading hardness suited to the purpose of grinding.

The present inventors having determined to solve the problem mentioned above, have discovered that lave abrasive grains or basalt abrasive grains are capable of being included in a linear metallic material. This invention is aimed at providing a brush bristle material obtained by causing a linear metallic material to contain in a mixed state lava abrasive grains or basalt abrasive grains or powders thereof in a prescribed amount and consequently enabled to retain the included abrasive grains undissolved at an elevated temperature occurring during the course of manufacture and also providing a brush made thereof The invention is also aimed at providing a brush bristle material obtained by bundling a plurality of brush bristle materials and subjecting the perimeter of the resultant bundle to a covering or coating treatment, thereby being endowed with proper strength and grinding property suited to the purpose of grinding without sustaining breakage and also providing a brush made thereof

SUMMARY OF THE INVENTION

The brush bristle material of the first aspect of the invention has a linear metallic brush bristle material contain in a mixed state one or more kinds of lava abrasive grains and/or basalt abrasive grains at a ratio in the range of 1% to 70%.

The brush bristle material of the second aspect of the invention has a linear metallic brush bristle material coated on a partial or entire perimeter thereof with one or more kinds of abrasive grains selected from among inorganic abrasive grains, metal or alloy abrasive grains, volcanic ash abrasive grains, obsidian abrasive grains, lava abrasive grains and basalt abrasive grains.

The brush bristle material of the third aspect of the invention has blended and covered

• • a brush bristle material obtained by causing a linear metallic brush bristle material to contain in a mixed state one or more kinds of lava abrasive grains and/or basalt abrasive grains at a ratio in the range of 1% to 70%,
  • a brush bristle material obtained by causing a linear metallic brush bristle material coated on a partial or entire perimeter thereof with one or more kinds of abrasive grains selected from among inorganic abrasive grains, metal or alloy abrasive grains, volcanic ash abrasive grains, obsidian abrasive grains, lava abrasive grains and basalt abrasive grains, and
  • a synthetic resin material containing animal fibers and/or vegetable fibers in a mixed state.

The brush bristle material of the fourth aspect of the invention has a plurality of brush bristle materials of the first to third aspects of the invention bundled and has the resultant bundle of brush bristle material covered on the perimeter thereof.

The brush bristle material of the fifth aspect of the invention has a plurality of different kinds of brush bristle materials of the first to fourth aspects of the invention bundled and has the resultant bundle of brush bristle materials covered on the perimeter thereof.

The brush bristle material of the sixth aspect of the invention has a plurality of brush bristle materials of the fourth or fifth aspect of the invention bundled and has the resultant bundle of brush bristle materials covered on the perimeter thereof.

The brush of the seventh aspect of the invention comprises the brush bristle materials of the first to sixth aspects of the inventions manufactured into a channel brush, an implanted brush, a welded brush and the like which are fated to serve as a roll brush, a wheel brush, a coiled brush, a tubular brush and a twisted brush.

This invention obtains a metallic brush bristle material by causing a linear metallic material to contain in a mixed state lava abrasive grains, basalt abrasive grains or powders thereof in a prescribed amount and therefore enables the produced metallic bristle material to acquire proper hardness and grinding property suited to a workpiece, the shape of the workpiece and the purpose of use of the workpiece.

This invention enables the brush bristle material containing in a mixed state lava abrasive grains or basalt abrasive grains or powders thereof in a prescribed amount, by subjecting the perimeter of this material to a covering or coating treatment to acquire proper strength and as well ensure prevention of an accident possibly induced when the material is broken and scattered.

This invention enables combinations severally consisting of varying kinds of the brush bristle materials to be bundled. This invention also enables bundles of brush bristle materials to be further bundled. This invention is thus capable of obtaining such brush bristle materials and brush bristles as permit proper grinding suited to the property of a given workpiece.

The above and other objects, characteristic features and advantages of the present invention will become apparent to those skilled in the art from the description to be given herein below with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1(a) and FIG. 1(b) depict Example 1 of this invention in perspective views each for illustrating one brush bristle material having a linear metallic material contain lava abrasive grains in a mixed state.

FIG. 2(a) and FIG. 2(b) depict Example 2 of this invention, FIG. 2(a) representing the case of having the abrasive grains attached to the perimeter of the linear metallic material and FIG. 2(b) the case of having the abrasive grains attached to the perimeter of the linear metallic material by a coating treatment.

FIG. 3(a) and FIG. 3(b) depict Example 3 of this invention in a perspective view and a cross section each illustrating the manufacture of a plurality of brush bristle materials by bundling into one brush bristle material.

FIG. 4(a) and FIG. 4(b) depict Example 4 of this invention in cross sections each illustrating the manufacture of a plurality of brush bristle materials by bundling into one brush bristle material and FIG. 4(c) and FIG. 4(d) are prospecting views thereof.

FIG. 5(a) and FIG. 5(b) depict Example 5 of this invention in a cross section and a perspective view each illustrating the manufacture of a plurality of brush bristle materials by covering into one brush bristle material.

FIG. 6(a) through FIG. 6(h) are schematic views for illustrating the manufacture of brushes from the brush bristle materials of this invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The brush bristle material of the first aspect of the invention is obtained by causing one or more kinds of lava abrasive grains and/or basalt abrasive grains or powders thereof to be included in a ratio in the range of 1% to 70%, preferably in the range of 1% to 30%, in a linear metallic brush bristle material while the linear brush bristle material is being formed by melting iron, copper, aluminum, titanium, nickel, chromium or an alloy thereof. Since the lava abrasive grains and/or basalt abrasive grains to be included in the linear metallic brush bristle material are formed inherently at a high temperature, they are incapable of being burnt and melted during the course of the inclusion but are capable of enabling the produced metallic brush bristle material to acquire an enhanced abrading or grinding ability.

The brush bristle material of the second aspect of the invention is obtained by causing the partial or entire perimeter of a linear metallic brush bristle material made of iron, copper, aluminum, titanium, nickel, chromium or an alloy thereof for example, to be coated with one or more kinds of abrasive grains, such as diamond abrasive grains, inorganic abrasive grains, metal or alloy abrasive grains, volcanic ash abrasive grains, lave abrasive grains or basalt abrasive grains. The coating is sorted, for example, into electrodeposition, vapor deposition, thermal welding and plating. This coating is capable of depositing the relevant abrasive grains in a ratio in the range of 1% to 100%. Since the amount (thickness) of this coating can be optionally fixed, it is made possible to adjust easily the nerve of the produced coat to suit the purpose and the shape of the coat, enable the synthetic resin material to acquire elastic force, and prevent the metallic material from breakage. Incidentally, the coating at a ratio in the approximate range of 1% to 10% on balance is equivalent to a state in which the coat adheres to the perimeter of the metallic material.

The brush bristle material of the third aspect of the invention is obtained as a sole brush bristle material by blending the brush bristle material of the first aspect of the invention, the brush bristle material of the second aspect of the invention and a synthetic resin material containing animal fibers and/or vegetable fibers in a mixed state. The synthetic resin material is formed of polyamide-based resin, polypropylene, polyethylene, polyvinyl chloride, polyimide, polymer, polyester, polyplastics, PolyEtherEtherKetone (PEEK™) resin or aromatic polyamide-based heat-resistant fibers, for example. Particularly, the synthetic resin material containing in a mixed state animal fibers (horse bristles, pig bristles, etc.) and/or vegetable fibers (pakin (tampico), palm, banana, etc.) is covered so that the brush bristle materials of the first and second aspects of the invention may be bundled into one piece.

The covering is intended to have a plurality of brush bristle materials covered with a pipe made of synthetic resin or metal. Otherwise, the covering is performed by causing a plurality of brush bristle materials to be either covered with a cord made of metallic wire or synthetic resin and coiled thereon or wrapped in a pouch woven with the cord.

The brush bristle material of the fourth aspect of the invention is obtained at least solely by bundling a plurality of brush bristle materials of the first to third aspects of the invention and covering the collective perimeter of the bundled brush bristle materials. The brush bristle material of the fourth aspect of the invention may be obtained as a brush bristle material suited to the surface of a given workpiece by properly selecting the raw material of the brush bristle material, the number of the materials, and the number of the materials to be bundled. The covering is implemented by coiling a cord, wrapping with a net or enveloping with a tube made of metal or synthetic resin, or the like.

The brush bristle material of the fifth aspect of the invention is obtained by bundling a plurality of different kinds of brush bristle materials selected from among the brush bristle materials of the first to fourth aspects of the invention. A plurality of the same or different brush bristle materials bundled into one piece as described above are bundled and the perimeter of the resultant bundle is covered. The brush bristle material of the fifth aspect of the invention is enabled by optionally selecting different component brush bristle materials to suit a wider range of applications than the brush bristle material of the fourth aspect of the invention.

The brush bristle material of the sixth aspect of the invention is obtained as one or more pieces by bundling a plurality of brush bristle materials of the fourth and fifth aspects of the invention and subsequently covering the perimeter of the resultant bundle of brush bristle materials. The brush bristle materials of the fourth and fifth aspects of the invention, for the purpose of acquiring strength necessary for grinding a given workpiece, are allowed to select raw materials for the brush bristle materials, select materials used for inclusion or application by coating, and decide the number of component brush bristle materials to be bundled.

The brush of the seventh aspect of the invention is obtained as a channel brush, an implanted brush, a welded brush or the like by causing the brush bristle materials of the first to sixth aspects of the invention to be inserted in a channel member or embedded in a deck member and straightening the resultant product in shape. The brushes are properly shaped and finished as a roll brush, a wheel brush, a coiled brush, a tubular brush and a twisted brush and consequently enabled to acquire such shape, strength and elastic force as are optimized for grinding a given workpiece.

EXAMPLE 1

FIG. 1(a) and FIG. 1(b) depicts Example 1 of this invention in perspective views each for illustrating one brush bristle material obtained by causing a linear metallic material to contain lava in a mixed state. A brush bristle material 111 shown in FIG. 1(a) has a linear metallic material 11 contain lava abrasive grains 12 or powders of the lava abrasive grains 12 in a mixed state. A brush bristle material 112 shown in FIG. 1(b) has the linear metallic material 11 contain lava abrasive grains 12 and basalt abrasive grains 13 or the powders thereof in a mixed state. The brush bristle material may have the linear metallic material 11 contain the powders solely of the basalt abrasive grains 13 in a mixed state. The lava abrasive grains 12 etc. or the powders thereof are included in the linear metallic material 11 while this material is kept heated at a high temperature so as to be adjusted to a prescribed diameter. The lava abrasive grains 12 etc. or the powders thereof are not burnt like diamond abrasive grains because they are inherently formed by a high temperature.

The linear metallic material 11 is made of iron, copper, aluminum, nickel, chromium, titanium or an alloy thereof, for example. The present inventors have discovered that the lava abrasive grains 12 and/or basalt abrasive grains 13 or the powders thereof can be included at a volume ratio in the range of 1% to 70%, preferably in the range of 1% to 30%, in the linear metallic material 11.

EXAMPLE 2

FIG. 2 depicts Example 2 of this invention, FIG. 2(a) illustrating the example of having the abrasive grains attached to the perimeter of the linear metallic material and FIG. 2(b) illustrating the example of having the abrasive grains attached to the perimeter of the linear metallic material by a coating treatment. A brush bristle material 211 shown in FIG. 2(a) forms an example of including lava abrasive grains, etc. in the linear metallic material 11 and subsequently attaching to the perimeter of the metallic material 11 metallic abrasive grains, diamond abrasive grains, grinding abrasive grains, inorganic abrasive grains, CBN abrasive grains, GC abrasive grains, lava abrasive grains, obsidian abrasive grains, or abrasive grains obtained by mixing them by electrodeposition, vapor deposition, thermal welding or plating treatment. A brush bristle material 212 shown in FIG. 2(b) is obtained by including lava abrasive grains 12 and basal abrasive material 13 or the powders thereof in the linear metallic material and subsequently giving to the perimeter of the metallic material 12 a coating 22 with metallic abrasive grains, diamond abrasive grains, grinding abrasive grains, inorganic abrasive grains, CBN abrasive grains, GC-treated abrasive grains, lava abrasive grains, obsidian abrasive grains or abrasive grains obtained by mixing them. The coating treatment is implemented by electrodeposition, vapor deposition, thermal welding or plating treatment, similarly to the product of FIG. 2(a).

EXAMPLE 3

FIG. 3(a) and FIG. 3(b) are a perspective view and a cross section illustrating the example of forming one brush bristle material by bundling a plurality of brush bristle materials. The brush bristle materials shown in FIG. 3(a) and FIG. 3(b) are severally obtained by bundling a plurality of brush bristle materials shown in FIG. 1 and/or FIG. 2 into one piece with a cord or a knit cord or the like. A brush bristle material 111 shown in FIG. 3(a) is obtained by including lava abrasive grains 12 in the linear metallic material 11 and bundling four such linear metallic materials into one piece with a cord 31. A brush bristle material 211 shown in FIG. 3(b) is obtained by including lava abrasive grains 12 in the linear metallic material 11 and depositing abrasive grains on the perimeter of the metallic material 11 by a plating treatment or an electrodepositing treatment. The brush bristle materials 211 and 212 are severally obtained by including lava abrasive grains in the linear metallic material 11 and depositing the abrasive grains on the perimeter of the metallic material by coating. The brush bristle material 211 and brush bristle material 212 are severally covered into one piece with a cord 31 or a knit cord 32.

EXAMPLE 4

FIG. 4(a) and FIG. 4(b) are cross sections severally depicting one brush bristle material obtained by bundling a plurality of brush bristle materials and FIG. 4(c) and FIG. 4(d) are perspective views of the same brush bristle materials. The brush bristle material shown in FIG. 4(a) is obtained by causing the brush bristle material 111 including the lava abrasive grains, etc. or powders thereof as shown in FIG. 1 and FIG. 2 and a synthetic resin material 41 covered, interwoven, or coated with one or more kinds of animal or vegetable fibers to be bundled with a cord 411 or a net 412 as shown in FIG. 4(c) or FIG. 4(d). The cord 411 or the net 412 mentioned above may be made of any of synthetic resin, natural fibers, and a metal.

Then, the brush bristle material shown in FIG. 4(b) is obtained by causing the brush bristle material 111 containing the lava abrasive grains etc. in a mixed state, the brush bristle material 211 having abrasive grains, etc. attached to the perimeter of the brush bristle material 111 by electrodeposition, plating, etc., the brush bristle material 212 having abrasive grains applied by coating to the perimeter of the brush bristle material 111, and the synthetic resin material 41 covered, interwoven or coated with one or more kinds of animal and plant fibers to be bundled with a cord 411 or a net 412 as shown in FIG. 4(c) or FIG. 4(d).

EXAMPLE 5

FIG. 5(a) and FIG. 5(b) severally depict in a cross section and a perspective view the manufacture of a plurality of brush bristle materials by covering into one brush bristle material. The brush bristle material shown in FIG. 5(a) is obtained as a sole product by inserting a plurality of brush bristle materials 211 and 212 (shown in FIG. 2 and FIG. 3) and 511 in a pipe material 51 made of synthetic resin or the like. The brush bristle material shown in FIG. 5(b) is obtained as a sole product by inserting a plurality of brush bristle materials 211, 212 and 511 in a pipe material 52 made of the synthetic resin mentioned above. The pipe material 52 contains abrading grains, diamond abrasive grains and the like in a mixed state. Further, the brush bristle material allows variation of the kind of raw material, the number of component brush bristle materials, the combination of different kinds of brush bristle materials, and the like.

FIG. 6(a) to FIG. 6(h) are schematic views for illustrating brushes that are made of the brush bristle materials of this invention. FIG. 6(a) represents a cup brush, FIG. 6(b) a disc brush having a channel brush attached to the periphery of a disc, FIG. 6(c) a disc brush having a channel brush bent in a circular shape, FIG. 6(d) a brush manufactured by directing inward a brush bristle material attached to a channel, FIG. 6(e) and FIG. 6(f) each a roll brush, FIG. 6(g) a tubular brush and FIG. 6(h) a twisted brush. These brushes are manufactured fundamentally dependent on the brush bristle materials that conform to the examples of this invention.

This invention has been specifically described by reference to examples. The invention nevertheless does not need to be limited to these examples. This invention is capable of allowing various alterations of design unless the matters described in the scope of claims for patent are deviated. The raw material of brush bristle, the number of brush bristle materials, the quality of material of the substance to be included, the sizes, the shapes and the densities of the relevant materials can be optionally selected depending on the kind, the shape and the purpose of use of a given workpiece. Particularly as regards the metallic member, the synthetic resin member, the member to be included and the member to be attached, it goes without saying that those publicly known or universally known can be used besides those specifically cited in the present specification.

Claims

1. A brush bristle material having a linear metallic brush bristle material contain in a mixed state one or more kinds of lava abrasive grains and/or basalt abrasive grains at a ratio in a range of 1% to 70%.

2. A brush bristle material having a linear metallic brush bristle material coated on a partial or entire perimeter thereof with one or more kinds of abrasive grains selected from among inorganic abrasive grains, metal or alloy abrasive grains, volcanic ash abrasive grains, obsidian abrasive grains, lava abrasive grains and basalt abrasive grains.

3. A brush bristle material having blended and covered:

a brush bristle material obtained by causing a linear metallic brush bristle material to contain in a mixed state one or more kinds of lava abrasive grains and/or basalt abrasive grains at a ratio in a range of 1% to 70%;

a brush bristle material obtained by causing a linear metallic brush bristle material coated on a partial or entire perimeter thereof with one or more kinds of abrasive grains selected from among inorganic abrasive grains, metal or alloy abrasive grains, volcanic ash abrasive grains, obsidian abrasive grains, lava abrasive grains and basalt abrasive grains; and

a synthetic resin material containing animal fibers and/or vegetable fibers in a mixed state.

4. A brush bristle material according to any one of claim 1 to claim 3, wherein said brush bristle material comprises a plurality of brush bristle materials bundled into a bundle and the bundle has a perimeter thereof covered.

5. A brush bristle material according to any one of claim 1 to claim 4, wherein said brush bristle material comprises a plurality of different kinds of brush bristle materials bundled into a bundle and the bundle has a perimeter thereof covered.

6. A brush bristle material according to claim 4 or claim 5, wherein the plurality of brush bristle materials bundled are further bundled into a bundle and the bundle has a perimeter thereof covered.

7. A brush comprising the brush bristle material according to any one of claim 1 to claim 6, wherein the brush bristle material is manufactured into a channel brush, an implanted brush, a welded brush which are fated to serve as a roll brush, a wheel brush, a coiled brush, a tubular brush and a twisted brush.