Abstract:
An orbital blush for an orbital floor brush machine is provided according to an embodiment of the invention. The orbital brush includes a brush frame adapted to fit to the orbital floor brush machine, a first ring of first bristle tufts of a first length and oriented at a first angle, and a second ring of second bristle tufts of a second length and oriented at a second angle.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to an orbital brush, and more particularly, to an orbital brush for an orbital floor brush machine. 
       BACKGROUND OF THE INVENTION 
       [0002]    An orbital floor brush machine is a device that includes a motor and an orbital brush. Tile brush is powered by the motor and rotated on a floor or other underlying surface. The orbital floor brush machine can consequently be used to clean the underlying surface. In addition, the orbital floor brush machine can be used for polishing. Further, the orbital floor brush machine can be used with a variety of cleaning and/or polishing compounds. 
         [0003]    The orbital brush typically is circular or ring shaped. A ring-shaped orbital blush typically includes bristles only in a ring or rings around an outer edge of the orbital brush. Inner bristles may not be included on such a device because the speed of rotation of the inner bristles, especially those near the center of the brush, is very low compared to the rotational speed of the bristles near the outer edge of the orbital brush. As a result, the outer bristles do most of the work performed by the orbital floor brush machine. In addition, inner bristles are not used because they would increase the required rotational energy. As a result, inner bristles would make an orbital brush rotate more slowly. In addition, a reduced area force would be provided at each of the bristles. 
         [0004]    The cleaning power and efficiency of the orbital floor brush machine is related to the number of bristles and/or bristle tufts. Bristle tufts comprise bundles of bristle fibers. The bundles of bristle fibers offer greater stiffness than the bristle fibers alone possess. 
         [0005]    In an orbital floor brush machine, the size and/or stiffness of the individual bristles can be increased in order to improve the effectiveness of the orbital brush. In addition, the number of bristles in a bristle tuft or the compactness of a bristle tuft can be increased. However, this can in turn cause other problems. Increased bristle/tuft stiffness can increase rotational resistance of the orbital brush. This in turn can lead to a hopping of the orbital brush, greatly reducing overall effectiveness of the orbital floor brush machine. In addition, such hopping generates additional strain on the machine and can lead to mechanical failures and customer dissatisfaction. 
       SUMMARY OF THE INVENTION 
       [0006]    An orbital brush for an orbital floor brush machine is provided according to an embodiment of the invention. The orbital brush comprises a brush frame adapted to fit to the orbital floor brush machine, a first ring of first bristle tufts of a first length and oriented at a first angle, and a second ring of second bristle tufts of a second length and oriented at a second angle. 
         [0007]    A method of forming an orbital brush for an orbital floor brush machine is provided according to the invention. The method comprises fastening together a bundle of bristle fibers with a fastener member that is located between a first end of the bundle and a second end, folding the bundle of bristle fibers over substantially at the fastener member to form a first bristle tuft and a second bristle tuft, and affixing the bundle of bristle fibers to a brush frame. The first bristle tuft and the second bristle tuft extend from the blush frame. 
         [0008]    A method of forming an orbital brush for an orbital floor brush machine is provided according to the invention. The method comprises fastening together a bundle of bristle fibers with a fastener member that is substantially offset from a center of the bundle, folding the bundle of bristle fibers over substantially at the fastener member to form a first bristle tuft and a second bristle tuft, and affixing the bundle of bristle fibers to a brush frame. The first bristle tuft and the second bristle tuft extend from the brush flame. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The same reference number represents the same element on all drawings. It should be noted that the drawings are not necessarily to scale. 
           [0010]      FIG. 1  shows an orbital brush of an orbital floor blush machine according to an embodiment of the invention. 
           [0011]      FIG. 2  is a cross-sectional view AA of the orbital brush according to an embodiment of the invention. 
           [0012]      FIG. 3  is a flowchart of a method of forming an orbital brush for an orbital floor brush machine according to an embodiment of the invention. 
           [0013]      FIG. 4  shows a bundle of bristle fibers according to an embodiment of the invention. 
           [0014]      FIG. 5  shows the bundle of bristle fibers according to an embodiment of the invention. 
           [0015]      FIG. 6  shows a portion of the orbital brush according to an embodiment of the invention. 
           [0016]      FIG. 7  shows a portion of the orbital brush according to an embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0017]      FIGS. 1-7  and the following descriptions depict specific embodiments to teach those skilled in the art how to make and use the best mode of the invention. For the purpose of teaching inventive principles, some conventional aspects have been simplified or omitted. Those skilled in the art will appreciate variations from these embodiments that fall within the scope of the invention. Those skilled in the art will also appreciate that the features described below can be combined in various ways to form multiple variations of the invention. As a result, the invention is not limited to the specific embodiments described below, but only by the claims and their equivalents. 
         [0018]      FIG. 1  shows an orbital brush  100  of an orbital floor brush machine according to an embodiment of the invention. The orbital brush  100  includes a brush frame  101  and one or more rings  102  of bristle tufts. The orbital brush  100  can include multiple rings  102  of bristle tufts. Furthermore, each ring  102  of bristle tufts can include two different lengths of fibers (see  FIG. 2 ). 
         [0019]    The brush frame  101  can be formed of any suitable material. The brush frame  101  is configured to be received and rotated by the orbital floor brush machine. The orbital floor brush machine can comprise any manner of floor cleaning or polishing device. As a result, the orbital brush  100  can be employed to clean or polish a floor surface. Any manner of cleaning or polishing compounds can be used in conjunction with the orbital brush  100 . 
         [0020]      FIG. 2  is a cross-sectional view AA of the orbital brush  100  according to an embodiment of the invention. The cross-sectional view in this embodiment includes multiple sets  102  of bristle tufts. The sets  102  can be substantially concentric or can include offsetting or irregular bristle tuft placement. Each set  102  is comprised of a first ring of bristle tufts  104  and a second ring of bristle tufts  105 . The first and second rings of bristle tufts  104  and  105  extend from the brush frame  101 . 
         [0021]    The first ring of bristle tufts  104  and the second ring of bristle tufts  105  in the embodiment shown are formed in substantially concentric rings having first and second diameters D 1  and D 2 . In some embodiments, the second diameter D 2  is larger than the first diameter D 1 , although alternatively the second diameter D 2  can be smaller than or equal to the first diameter D 1 . Alternatively, in other embodiments tie first and second rings of bristle tufts  104  and  105  can be alternated in a single ring that can include bristle tufts of different lengths. 
         [0022]    The first and second rings of bristle tufts  104  and  105  in some embodiments extend unequal lengths from the brush frame  101 , i.e., the first ring of bristle tufts  104  have a first length L 1  and the second ring of bristle tufts  105  have a second length L 2 . In some embodiments, the second length is greater than the first length (i.e., L 2 &gt;L 1 ). Consequently, the shorter first bristle tufts  104  may not contact tie underlying surface during light operation. Instead, the first bristle tufts  104  may contact the underlying surface only during heavier operation, when the second bristle tufts  105  are compressed or flexed by at least a predetermined amount. However, in other embodiments the second length L 2  can be less than or equal to the first length L 1 . 
         [0023]    In some embodiments, tie first ring of bristle tufts  104  and the second ring of bristle tufts  105  extend at different angles from the brush frame  101 . The first bristle tufts  104  can extend from the brush frame  101  at a first angle θ 1  and the second bristle tufts  105  can extend at a second angle θ 2 . In some embodiments, the second angle θ 2  is closer to the horizontal H than the first angle θ 1 , where the horizontal H in the figure comprises an underlying floor surface. In use, the brush frame  101  is substantially parallel to the underlying surface. 
         [0024]      FIG. 3  is a flowchart  300  of a method of forming an orbital brush for an orbital floor brush machine according to an embodiment of the invention. In step  301 , a bundle of bristle fibers is fastened together. The fastening can be achieved by a fastener member  116  that holds the bristle fibers together in the bundle (see  FIGS. 4-5 ). In one embodiment, the fastener member  116  comprises a staple that is wrapped around the bundle of bristle fibers. However, other fastener members are contemplated and are within the scope of the description and claims. In addition, in some embodiments the fastener member is nor required, and the bundle of fibers, including a bundle of already folded fibers, can be affixed together by any manner of bonding agent, melting or welding, compression or crimping, etc. 
         [0025]    In step  302 , the bundle of bristle fibers is folded over at a fold region. The folding brings the two portions substantially together as two substantially parallel bristle tufts, i.e., the folding creates the first and second bristle tufts  104  and  105 . In some embodiments, the fold region is substantially at the fastener member  116 . As previously discussed, the first bristle tuft has a first length L 1  and the second bristle tuft can have a second length L That can be different from the first length L 1 . 
         [0026]    In step  303 , the folded over bundle of bristle fibers is affixed to the brush frame  101 . In one embodiment, the folded over bundle of bristle fibers is inserted into a bore (or blind bore) in the brush frame  101 . In some embodiments, friction and/or compression call retain the folded over bundle in the bore. In other embodiments, the folded over bundle is further stapled or bonded into the bore or is affixed in the bore in some additional manner. 
         [0027]    It should be understood that the above steps can be performed multiple times. The above steps can form a first ring of first bristle tufts and simultaneously form a second ring of second bristle tufts. In addition, the above steps can form multiple sets of first and second rings of bristle tufts. 
         [0028]    In step  304 , the one or more thus affixed bristle tufts can optionally be trimmed. The trimming can comprise changing an angle or shape of a bristle tuft end. Alternatively, one or both of the first bristle tuft  104  and/or the second bristle tuft  105  can be trimmed for length. 
         [0029]    In one embodiment, the longer second bristle tufts  105  are trimmed. The trimming can give the second bristle tuft an end that is substantially parallel with the bottom of the brush frame  101  and therefore substantially parallel to an underlying surface (see  FIG. 7 ). 
         [0030]    In one embodiment, the shorter first bristle tufts  104  are not trimmed, and the end of the first bristle tuft  104  is therefore substantially perpendicular to the component fibers. As a result, the ends of the first bristle tufts  104  are not parallel to tie underlying surface. Consequently, as more load is placed on the orbital brush  100 , more and more fibers of the first bristle tufts  104  will be forced to contact and engage the underlying surface. 
         [0031]      FIG. 4  shows a bundle of bristle fibers  110  according to an embodiment of the invention. The bundle of bristle fibers  110  has been fastened together by a fastener member  116 . On tie right of the fastener member  116  are the first bristle fibers  104  and on the left of the fastener member  116  are the second bristle fibers  105 . The bundle of bristle fibers  110  includes a first end  111  of the first bristle tuft  104  and a second end  112  of the second bristle tuft  105 . The fastener member  116  is located between the first end  111  and the second end  112 . The fastener member  116  in the embodiment shown is substantially offset from the center of the bundle of bristle fibers  110 . As can be seen from the figure, when the fastener member  116  is offset from the center, it creates the first bristle fibers  104  of a first length and the second bristle fibers  105  of a second length. However, in an alternative embodiment the fastener member  116  can be substantially centered (see  FIG. 5 ). 
         [0032]      FIG. 5  shows the bundle of bristle fibers  110  according to an embodiment of the invention. The fastener member  116  in this embodiment is located substantially at the center of the bundle of bristle fibers  110 . One or both ends  111  and/or  112  of the bundle of bristle fibers  110  can be subsequently cut or trimmed. The trimming can shorten a bristle tuft, as shown in the figure by the dashed vertical line on the first bristle tuft  104 . Alternatively or in addition, tie trimming can change the angle of the end of a bristle tuft, as shown by the dashed angled line on the second bristle tuft  105 . 
         [0033]      FIG. 6  shows a portion of the orbital brush  100  according to an embodiment of the invention. The figure shows a single tuft  104  or  105  for purposes of clarity. In this figure, the end of the tuft  104  or  105  is substantially perpendicular to the fibers of the tuft. Consequently, the farthest edge of the tuft  104  or  105  will first contact the underlying surface. As a result, more and more fibers of the tuft  104  or  105  will contact the underlying surface as tie load on the orbital floor brush machine increases (i.e., as contacting fibers flex and/or compress). 
         [0034]      FIG. 7  shows a portion of the orbital brush  100  according to an embodiment of the invention. As before, the figure slows a single tuft  104  or  105  for purposes of clarity. In this figure, the end of the tuft  104  or  105  is angled, such as by trimming, for example. In some embodiments, the end of the tuft  104  or  105  substantially matches the underlying surface, wherein all of the fibers of the tuft  104  or  105  will substantially simultaneously contact the underlying surface. 
         [0035]    The orbital brush according the invention can be implemented according to any of the embodiments in order to obtain several advantages, if desired. The orbital brush can be formed to include bristle tufts of different lengths. The orbital brush can be formed to include bristle tufts having ends of different shapes and/or angles. The orbital brush can be formed to include bristle tufts extending from the brush frame at different lengths. The orbital brush can be formed to include bristle tufts extending from the brush frame at different angles. The orbital brush can be formed in order to control the number of bristle fibers in contact with the underlying surface.