Method and device for manufacturing brush bodies

Abstract: Method for manufacturing brush bodies, more particularly brush bodies (1) made of synthetic material, which are provided with at least one insert (2), characterized in that the insert (2) is firstly covered by injection at one side in a die (5) and subsequently at the other side.

Description: This invention aims at a method and device for manufacturing brush bodies. It is hereby an object of the invention to provide for a method and a device which allows the manufacture in an optimal way of brush bodies of synthetic material, which are provided with at least one insert, whereby this insert can be of a different nature and can consist for example of a logo, letters, numbers, or an object, such as a gadget or similar. It is a first object of the invention to apply inserts made of synthetic material in brush bodies. Likewise the invention aims in particular at applying inserts, preferably coloured inserts, in a transparent brush body, whereby this insert is completely enveloped with the transparent synthetic material. However, the invention does not exclude the use of non-transparent synthetic material for the brush bodies. Likewise the invention does not exclude the possibility that the inserts are not fully enveloped. Indeed, according to the method of the invention the inserts could also be mounted in such a way that they are seated against the outer surface of the brush body. Likewise the invention is particularly intended for tooth-brushes, but can evidently be used for other brushes. A method for manufacturing articles provided with an insert, in which the articles are formed by die moulding, is disclosed in EP 0.607.968. According to this method, a previously produced insert is put freely into a first mold, whereafter it is covered by injection at a first side, and subsequently it is covered at the second side by injection in a second die. Another method, which relates to the manufacturing of brush bodies provided with an insert, is disclosed in US 2.923.035. Hereby the insert is disposed freely in a cavity which is provided in a first already moulded piece, whereafter it is covered by synthetic material by means of injection moulding. The present invention aims in the first place a method which is new and inventive in view of the methods disclosed in the above-mentioned documents, and which offers several advantages. To this end the invention relates to a method for manufacturing brush bodies, more particularly brush bodies made of synthetic material, which are provided with at least one insert, whereby, on the one hand, the insert is firstly covered by injection at one side in a first die and subsequently at the other side, successively by the steps of clamping the insert in a die wall of a first die; filling the die cavity of the first die which is adjacent to the insert with synthetic material; presenting the product obtained from the first die, in which the insert is at least partly enveloped, to a second die, with the insert adjacent to the die cavity of this second die; and the filling of the second die with synthetic material, this method being characterized in that the die cavities of the aforementioned two dies define the shape of a brush body and in that, on the other hand, said insert is previously formed by injection in a third die, whereby a part of this third die is used to successively act as a die wall of the first die and whereby the insert remains present in this part during the filling of the first die. In such way the insert remains most favourably positioned during the filling of the first die and automatically a perfect fit of the die wall around the insert during the injection moulding process in the first die is offered. Likewise the invention aims at a device for manufacturing brush bodies, more particularly brush bodies made of synthetic material, which are provided with at least one insert, comprising a first die for forming a semi-finished product which forms a portion of the brush body; a second die intended to finish the brush body; and filling means to fill the dies with synthetic material, characterised in that said device further at least comprises: a third die comprising cavities for forming the insert, which precedes the aforementioned first die, which is likewise provided with filling means for filling this third die with synthetic material, whereby this third die is composed of several parts and thereby can be opened in such way that the insert formed therein can be partly and slidably removed thereout; transfer means to transfer the insert from the third die to the first die, while the insert remains clamped in the cavities of a part of the third die; means to partly remove the insert from the cavities of said part of the third die, such that the insert protrudes from said part and the protruding portion ends up in the die cavity of the first die, whereby said part acts as means to hold the insert in the wall of the first die; and transfer means to transfer the semi-finished product formed in the first die, together with the insert partly enveloped therein, from the first die to the second die. More particularly this device is characterized in that the third die is composed of three parts and consists of a plate provided with cavities in the shape of the insert to be formed and two closing elements to close off these cavities during the injection, whereby this plate is mutually movable between the third and the first die, whereby it can operate as a wall of the first die; and in that the means to partly remove the insert from the opened die, in this case from said plate, consist of plungers or similar which can be inserted into the cavities of the plate. With the aim to better show the characteristics of the invention some preferred embodiments are described hereafter, without limitative character, reference being made to the accompanying drawings, in which : figure 1 represents a tooth-brush with a brush body which has been provided with an insert according to the method of the invention; figure 2 to 7 schematically represent different steps of the method of the invention as well as the obtained products; figures 8 and 9 schematically represent two steps according to the method of the invention, which according to the most preferred embodiment precede the step represented in figure 2; figure 10 represents a cross sectional view of a device according to the invention in closed position of the dies; figure 11 represents the device as shown in figure 10 in open position of the dies; figures 12 and 13 represent the device of figure 10 in still two other positions; figure 14 represents a sectional view according to the line XIV-XIV in figure 13; figures 15 and 16 show two variants of the device according to the invention. As represented at figure 1 the invention relates the manufacture of brush bodies 1, which are provided with at least one insert 2, which in the represented embodiment is composed of a series of interconnected block-shaped elements, but in practice, however, as said in the introduction, can take other shapes as well. As represented in figure 1 the invention is in the first place intended for the manufacture of brush bodies 1, handles included, of tooth-brushes 3, with the intention to obtain that the insert 2 is fully enveloped in the brush body 1. As schematically represented in figures 2 to 9, according to the invention a method is provided whereby the insert 2 is firstly covered by injection at one side in a die and subsequently at the other side. In a first step, as represented in figure 2, the insert 2 is hereby presented to the die cavity 4 of a first die 5, whereby it is clamped in the die wall 6 of this die 5. Preferably the insert 2 protrudes partly from the die wall 6 while the non-protruding part is hold by cavities 7 in the die wall 6, which exactly match the shape of the insert 2. By filling the die 5 with synthetic material, a first semi-finished product 8 as represented in figures 3 and 4 is obtained, which respectively show an elevational view and a bottom view of the obtained semi-finished product 8. Subsequently, as represented in figure 5, the semi-finished product 8, in which the insert 2 is at least partly enveloped, is presented to a second die 9, with the insert 2 adjacent the die cavity 10 of this second die 9, respectively introduced herein. By the subsequent filling with synthetic material of the second die 9 a brush body 1 is obtained in which, as represented in the elevational view of figure 6 and the top view of figure 7, the insert 2 is fully enveloped. It is to be noted that simultaneously openings 11 for the fibre bundles 12 can be formed in the brush body 1, provided that appropriate pins 13 or such like are positioned in the die 9. In another embodiment these pins 13 can be replaced by fibre bundles which are previously inserted whereby the latter by injection are directly embedded in the brush body 1, the ends of the fibre bundles having been melted together previously or not. According to the invention use is made of an insert 2 made of synthetic material, which precedingly, as represented in figure 8, is injected in a die, hereinafter defined as third die 14. Preferably this third die 14 is of such a shape that a part 15 of this die 14 can be used to subsequently act as the wall 6 of the first die 5. As represented in figure 8 the third die 14 can to this end be composed of three parts, on the one hand the aforementioned part 15 which is provided of continuous cavities 7 for the injection moulding of the insert 2 and two closing elements 16 and 17 to close the cavities 7. After the cavities 7 have been filled with synthetic material and the closing elements 16-17 have been removed after setting of the synthetic material, according to the method of the invention the part 15 is presented to the first die 5, whereby the insert 2 is partly pushed out of the cavities 7, for example such as schematically represented in figure 9 by the arrows 18. It is clear that in doing so, the insert 2 remains most favourably positioned and that no separate positioning means are necessary. In order to realize the foregoing method preferably a device 19 as represented in figures 10 to 14 is used. According to the preferred embodiment this device 19 consists in the combination of a first die 5, for forming a portion of the brush body 1, more particularly the aforementioned semi-finished product 8; clamping means 20 to hold such insert 2 in and/or against the wall 6 of the first die 5; a second die 9 intended to complete the brush body 1; transfer means 21 to transfer the semi-finished product 8 formed in the first die 5, together with the insert 2 partly enveloped therein, to the second die 9; a third die 14 preceding the first die 5; transfer means 22 to transfer the insert 2 formed in the third die 14 to the first die 5; and filling means described hereafter to fill the dies 5-9-14 with synthetic material. As represented in the figures the different dies 5-9-14 are integrated in a common die block. The aforementioned third die 14, which in sequence is positioned first consists, similar to the schematic representation of figure 8, of a part 15 which is provided with cavities 7, and closing elements 16 and 17, cooperating therewith, whereby these three parts can be taken apart when opening the die block, as represented in figure 11. As represented in figure 14, the part 15 can be provided with a great number of cavities 7 for simultaneously forming several inserts 2. The third die 14 is provided with an inlet 23 which can cooperate with an injection nozzle with which the synthetic material of the insert 2 can be injected in the cavities 7. The aforementioned transfer means 22 mainly consist of a symmetrically built-up turning plate 25, composed of two of the aforementioned parts 15, whereby by turning, alternately the first or the second part 15 can cooperate with the third die 14 and the first die 5, and vice versa. This turning plate is fixed on a shaft 26 which by appropriate driving can be turned over 180 degrees. The turning plate 25 also operates as a means 20 to hold the insert 2 in a suitable way in the die cavity 4, as represented in figure 2. It is evident that as a variant use could be made of a slidable plate. The aforementioned first die 5, which in sequence of positioning is situated after the third, shows, similar to the schematic representation of figure 2, at least one die cavity 4, and in this case several of such die cavities 4, whereby each die cavity 4 is defined by a permanent die wall 27 and a die wall 6 which alternately would be formed by the one or the other part 15 of the turning plate 25. The first die 5 is provided with means 28 to sideways push each insert 2, which is situated in the part 15 presented to the die 5, out of the die wall 6 resulting in that such insert 2 is partly protruding thereout and still is clamped. These means 28, in the example as represented in figures 10 to 13, consist in a sliding mechanism with plungers 29, which can be moved by means of a driving element, such as a pressure cylinder 30, and which can excerce a force at the back side of each insert 2 and also can provide in a determined displacement of each insert 2. The first die can be filled with synthetic material by means of an inlet 31 which can cooperate with an injection nozzle 32. The transfer means 21 between the first die 5 and the second die 9 consist, as can best be seen in figure 14, mainly of a driven rotary arm 33, which at the desired moments can also be turned over 180 degrees, and a partly envelopable transfer part 34 connected to the rotary arm 33, with which the semi-finished products 8 can be moved from the first die 5 to the second die 9. The exact built-up and operation of this transfer means 21 are clearly depicted in European patent application No. 0.504.571 of the Applicant. The transfer part 34 can of course be moved in other ways; it can for example be moved in a linear direction by means of appropriate guidance. The second die 9 shows, similar to the schematic representation of figure 5, at least one die cavity 10, and, as in the present case preferably several of such die cavities 10, whereby each die cavity 10 is defined by die walls 35 and 36. Filling occurs by means of an inlet 37 which also cooperates with the injection nozzle 32. It is evident that the dies 5-9-14 are provided with the required driving means 38 so as to enable opening and closure thereof. Likewise it is evident that the transfer means 21 as well as 22 are provided with the required driving means 39-40. The operation of the device 19 is mainly as follows. In a first position, as represented in figure 10, the dies 5-9-14 are closed. By injecting synthetic material by means of the injection nozzle 24 the cavities 7 are filled and in the third die 14 a series of inserts 2 is formed. At the same time already formed inserts 2 are partly pushed out of the cavities 7 provided in the part 15 of the first die 5, by means of the plungers 29, whereby they remain clamped with their half in the disc-shaped part 15. Simultaneously, synthetic material is injected in the first die 5 via inlet 31. Also at the same time a semi-finished product 8 is already present in the second die 9 and this is further finished by injecting synthetic material via inlet 37. In a following step, as represented in figure 11, the dies 5-9-14 are opened, whereby care is taken that the turning plate 25 can freely move, possibly by means of a shift of the shaft 26 by means of the driving element 40. Care is also taken so as to free the semi-finished products 8 formed in the first die 5, with the exception, however, that they still are suspended to the transfer means 21, more particularly to the transfer part 34. Likewise the shaped brush bodies 1 are removed from the device. In a next step, as represented in figure 12, the turning plate 25 and rotary arm 33 are turned over 180 degrees. In a further step, represented in figure 13, the turning plate 25 is moved and the semi-finished products 8 are placed in the second die 9 by means of the transfer means 21, whereupon consecutively the transfer part 34 is turned back in its original position. Hereby the semi-finished products can be fixed or clamped with means which are not reproduced. After closure of the dies 5-9-14 the cycle can be repeated. It is evident that different variants are possible. For example a device 19 is represented in figure 5 whereby a semi-finished product 8 is formed in the first die 5, already containing the head of the tooth-brush, while the brush body in the second die 9 is finished by further injecting the handle. In figure 14 another variant is represented whereby the transfer means 21 consists of a rotary system which turns in each cycle over 180 degrees and which does not return each time to its original position, such as this was the case with transfer part 34. The semi-finished products 8 are hereby carried away by pins 13 positioned on a turn block 41 for shaping the aforementioned openings 11. Evidently other constructions can be imagined in which the pins 13 act as transfer elements. As set out in the introduction the main object is to shape brush bodies 1 made of a transparent synthetic material in such a way that the insert 2, which preferably consists of a non-transparent synthetic material or of a synthetic material of another colour, is clearly visible. It is to be noted that the shading of the inserts 2 shown at the figures, indicates the use of an untransparent insert in a transparent brush body and that this shading in most of the figures does not indicate a sectional view. It is to be noted also that the joints connecting the block-shaped elements of each insert 2 are omitted at the figures 10 to 16 for the sake of clearness. In practice they are, however, needed to obtain that all cavities 7 can be filled via a common inlet 23. According to a variant, different inlets 23 can, however, be provided so as to form in this way an insert 2 composed of different fully separated parts. For the enveloping synthetic material use can be made of CAP (Cellulose-aceto-propionate), SAN (styrene-acrylonitril), ABS, etc. These materials are particularly appropriate due to their high degree of transparency. For the insert 2, a synthetic material is chosen, the melting temperature of which is above the melting temperature of the enveloping synthetic, material, in such way that the latter, when passing over the insert, does not melt or deform it. Especially good results are obtained with an insert 2 made of polyamide, enveloped with CAP. The present invention is by no means restricted to the embodiments described as an example and represented in the accompanying drawings, but such method and device for the manufacture of brush bodies can be realized according to several variants while still remaining within the scope of the invention.

Claims: Method for manufacturing brush bodies, more particularly brush bodies (1) made of synthetic material which are provided with at least one insert (2), whereby, on the one hand, the insert (2) is firstly covered by injection at one side in a die (5) and subsequently at the other side, successively by the steps of clamping the insert (2) in a die wall (6) of a first die (5); filling the die cavity (4) of the first die (5) which is adjacent to the insert (2) with synthetic material; presenting the product obtained from the first die (5), in which the insert (2) is at least partly enveloped, to a second die (9), with the insert adjacent to the die cavity (10) of this second die (9); and the filling of the second die (9) with synthetic material, characterised in that the die cavities (4-10) of the aforementioned two dies (5-9) define the shape of a brush body (4) and in that , on the other hand, said insert (2) is previously formed by injection in a third die (14), whereby a part (15) of this third die (14) is used to successively act as a die wall (6) of the first die (5) and whereby the insert (2) remains present in this part (15) during the filling of the first die (5). Method according to claim 1, characterized in that the insert (2) is clamped in such a way in said part (15) that it is partly protruding therefrom. Method according to claim 1 or 2, characterized in that the insert (2), while being presented to the first die (5), is partly pushed out of the aforementioned part (15) of the die (14) in which it is originally formed. Method according to any one of the preceding claims, characterized in that around the insert (2) transparent synthetic material is applied which enables that the insert (2) can be seen from outside and that the insert (2) is fully enveloped by means of this synthetic material. Device for manufacturing brush bodies, more particularly brush bodies (1) made of synthetic material, which are provided with at least one insert (2), comprising a first die (5) for forming a semi-finished product (8) which forms a portion of the brush body (1); a second die (9) intended to finish the brush body (1); and filling means (32) to fill the dies (5-9) with synthetic material, characterised in that said device further at least comprises: a third die (14) comprising cavities (7) for forming the insert (2), which precedes the aforementioned first die (5), which is likewise provided with filling means (24) for filling this third die (14) with synthetic material, whereby this third die (14) is composed of several parts and thereby can be opened in such way that the insert (2) formed therein can be partly and slidably removed thereout; transfer means (22) to transfer the insert (2) from the third die (14) to the first die (5), while the insert (2) remains clamped in the cavities (7) of a part of the third die (14); means (28) to partly remove the insert (2) from the cavities (7) of said part of the third die, such that the insert (2) protrudes from said part and the protruding portion ends up in the die cavity of the first die (5), whereby said part acts as means (20) to hold the insert (2) in the wall (6) of the first die (5); and transfer means (21) to transfer the semi-finished product (8) formed in the first die (20), together with the insert (2) partly enveloped therein, from the first die (5) to the second die (9). Device according to claim 5, characterised in that the said cavities (7) match the shape of the insert (2) and thus provide in a sealing of the die cavity (4) of the first die (5) around the insert (2). Device according to claim 5 or 6, characterized in that the third die (14) consists of three parts and is composed of a plate (25) with cavities (7) in the shape of the insert (2) to be formed and two closing elements (16-17) to close these cavities (7) during injection, whereby this plate 25 is mutually movable between the third die (14) and the first die (5), whereby it can operate as a wall of the first die (5); and that the means (28) for pushing the insert (2) partly from the aforementioned plate (25), consist of plungers (29) or similar which can be positioned in the cavities (7) of the plate along the outside of the die cavity of the first die (5). Device according to claim 7, characterized in that the plate (25) can revolve between the opened third die (14) and the opened first die (5). Device according to any one of the claims 5 to 8, characterized in that the transfer means (21) which operate between the first die (5) and the second die (9) make use of a movable and partly envelopable transfer part (34). Device according to any one of the claims 5 to 9, characterized in that the transfer means (21) which operate between the first die (5) and the second die (9) are provided with transfer elements in the shape of pins (13) which are used to form the openings (11) needed for inserting the fibre bundles (12). Device according to any one of the claims 5 to 10, characterized in that the dies (5-9-14) form part of a common die block.

Inventors: BOUCHERIE BART GERARD, BOUCHERIE, BART GERARD
Applicants: BOUCHERIE NV G B, G.B. BOUCHERIE, N.V.
Application year: 1996
Main classification: B29C45
IPC codes: A46D3, B29C45