Patent Publication Number: US-2002004963-A1

Title: Method for forming variable paint applicators

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
     [0001] The present application claims priority under 35 U.S.C. §119 from U.S. Provisional Patent Application Ser. No. 60/196,513, entitled PAINT BRUSH AND METHODS OF MANUFACTURE filed on Apr. 11, 2000, the full disclosure of which is hereby incorporated by reference. The present application is also related to co-pending U.S. Patent Application Ser. No. ______, entitled ADJUSTABLE FERRULE PAINT BRUSH AND METHODS OF MANUFACTURE by Brian E. Woodnorth, Darryl L. Kaminski, and Kenneth R. Morris which was filed on the same date herewith, the full disclosure of which is hereby incorporated by reference. 
    
    
     
       FIELD OF THE INVENTION  
       [0002] The present invention relates generally to the field of paint applicators and methods for manufacturing paint applicators.  
       BACKGROUND OF THE INVENTION  
       [0003] Paint applicators, such as paint brushes, are used to apply paint, varnish, stains and other liquid coatings to surfaces. Conventional paint brushes typically include a handle, a group of bristles and a ferrule securing the group of bristles to the handle. The handle typically includes an elongate narrow diameter gripping portion or shank which widens at a shoulder to form a head. The handle is typically formed from either wood or a rigid plastic. Brush handles formed from rigid plastic are typically injection molded. As conventionally known, injection molding involves filling a cavity that is in the shape of the brush handle with a liquid plastic which is then allowed to solidify before the mold is separated from the finished handle. In some applications, a mold core is positioned inside the mold such that the injected plastic flows within the mold about the core. After the plastic has solidified, the core is removed and the mold is separated to leave a handle having a hollow interior. The resulting cored-out handle has an open axial end. In particular applications, the plastic brush handle is overlaid or co-molded with a soft and compressible plastic as set forth and described in co-pending U.S. Patent application Ser. No. 08/841,271, the full disclosure of which is hereby incorporated by reference.  
       [0004] The group of bristles typically comprises a plurality of individual brush filaments formed from hair or artificial fibers such as nylon. The filaments are generally interleaved with one or more wedges or spacers. The filaments as well as the spacers are secured to one another and are secured to the ferrule by an epoxy.  
       [0005] The ferrule typically comprises a thin band of metal partially overlapping the group of bristles and the head of the brush handle, while securing the bristles to the handle. Typically, the ferrule is secured to the group of bristles by the aforementioned epoxy and is secured to the head of the brush handle by staples, rivets or other fasteners extending through the ferrule and into the head or by adhesives between the ferrule and the head.  
       [0006] Manufacture of such conventional brushes is generally as follows. First, the brush handle is formed as described above. Second, the brush filaments are bunched together and are pulled through the ring formed by the ferrule. Third, the spacers are inserted between the bristle filaments and then the spacers and adjacent bristle filaments are pulled into the ferrule whereby the spacers wedge the axial end of the filaments against the ferrule. Fourth, a relatively thin layer of liquid epoxy is deposited into the ferrule, bonding the bristle filaments and the spacers to the ferrule. Lastly, the ferrule is secured to the head of the brush handle as described above.  
       [0007] Although most paint brushes are formed by the above described process, the process and the resulting brush have several disadvantages. First, the solid brush handles formed by injection molding are time consuming to manufacture, require large amounts of material and are heavy. Coring out the head of the handle to produce a lighter handle increases complexity and time required to manufacture the handle and also results in a structurally weaker handle which, as a result, must be formed from stronger yet more expensive plastics. Moreover, because a uniquely sized and configured mold and possibly core is required for each differently sized paint brush handle and paint brush, manufacturing costs are further exacerbated.  
       SUMMARY OF THE INVENTION  
       [0008] According to one embodiment of the present invention, a method for forming a plurality of distinct paint applicators having a common exterior head configuration and distinct paint applying medium configurations includes forming a plurality of handles and forming a plurality of paint carrying units. Each handle formed includes a head having an exterior configuration and an interior having a mouth and head thickness between the exterior configuration and the mouth. Each paint carrying unit includes at least one paint applying medium coupled to a mounting portion that is disposed within an interior of one of the plurality of handles. The mounting portion has a mounting portion exterior configuration and a mounting portion thickness between the mounting portion exterior configuration and the paint applying medium. To form the plurality of distinct paint applicators, the configuration of the paint applying medium is varied while also varying at least one of the head thickness and the mounting portion thickness. According to another embodiment of the present invention, a method for forming a plurality of distinct paint applicators having a common exterior head configuration and distinct paint applying medium configurations includes forming a plurality of handles and forming a plurality of paint carrying units. Each handle formed includes a head having an exterior configuration and an interior having a mouth and head thickness between the exterior configuration and the mouth. Each paint carrying unit includes at least one paint applying medium coupled to a mounting portion that is disposed within an interior of one of the plurality of handles. The mounting portion has a mounting portion exterior configuration and a mounting portion thickness between the mounting portion exterior configuration and the paint applying medium. To form the plurality of distinct paint applicators, the configuration of the paint applying medium is varied while also varying at least one of the head thickness and the mounting portion thickness.  
       [0009] According to another embodiment, a plurality of paint applicators includes a first applicator and a second applicator. The first applicator has a first handle having an exterior configuration that first paint applying medium coupled to the first handle and having a first medium configuration with a first width and a first thickness. The second applicator includes a second handle having the same exterior configuration in a second paint applying medium coupled to the second handle. The second paint applying medium has a second medium configuration having a second width and a second thickness different than the first width and the first thickness, respectively.  
       [0010] According to another embodiment, the plurality of paint applicators includes a first applicator and a second applicator. The first applicator includes a first handle having a first paint applying medium. The first handle has an exterior configuration and a first interior cavity having a first interior configuration. The first paint applying medium is coupled to the first handle and has a first medium configuration. The second applicator includes a second handle and a second paint applying medium. The second handle has the same exterior configuration and a second interior cavity having a second interior configuration different than the first interior configuration. The second paint applying medium is coupled to the second handle and has a second medium configuration different than the first medium configuration.  
       [0011] According to another embodiment, a plurality of paint applicators includes a first applicator and a second applicator. The first applicator includes a first handle and a first paint applying medium. The first handle has an exterior configuration. The first paint applying medium has a first configuration that is coupled to a first mounting portion having a first size dimension. The second applicator includes a second handle and a second paint applying medium. The second handle has the same exterior configuration. The second paint applying medium has a second configuration and is coupled to a second mounting portion. The section mounting portion has a second size dimension different from the first size dimension.  
       [0012] According to another embodiment, the paint applicator includes a handle, at least one paint applying medium and a mounting portion. The handle has an internal cavity including at least one projection. The mounting portion is coupled to the at least one paint applying medium and is received within the interior cavity. The at least one projection engages the mounting portion. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0013]FIG. 1 is a top elevational view of a paint applicator according to one embodiment of the present invention.  
     [0014]FIG. 2 is a top elevational view of a handle of the paint applicator of FIG. 1 prior to complete assembly.  
     [0015]FIG. 3 is a sectional view of the paint applicator of FIG. 1 taken along line  3 - 3 .  
     [0016]FIG. 3A is a top elevational view of a first alternative embodiment of the paint applicator of FIG. 1.  
     [0017]FIG. 3B is a top elevational view of a handle of the paint applicator of FIG. 3A prior to complete assembly.  
     [0018]FIG. 3C is a sectional view of the handle of the paint applicator of FIG. 3A taken along line  3 C- 3 C.  
     [0019]FIG. 4 is a top perspective view of a second alternative embodiment of the paint applicator of FIG. 1 prior to complete assembly.  
     [0020]FIG. 5 is a sectional view of the paint applicator of FIG. 4 after being assembled.  
     [0021]FIG. 5A is a sectional view of a first alternative embodiment of the paint applicator of FIG. 5.  
     [0022]FIG. 6 is a sectional view of a second alternative embodiment of the paint applicator of FIG. 5.  
     [0023]FIG. 7 is a sectional view of a paint applicator handle forming system illustrating the formation of a paint applicator handle.  
     [0024]FIG. 8 is a sectional view of a first alternative embodiment of the system of FIG. 7.  
     [0025]FIG. 9 is a sectional view of a second alternative embodiment of the paint applicator handle forming system of FIG. 7.  
     [0026]FIG. 10 illustrates the paint applicator handle forming system of FIG. 9 during the formation of a paint applicator handle.  
     [0027]FIG. 11 is an enlarged view of the system of FIG. 11 taken along line  11 - 11 .  
     [0028]FIG. 12 is a sectional view of the paint applicator handle forming system of FIG. 7 further illustrating the formed handle being filled with a material.  
     [0029]FIG. 13 is a fragmentary sectional view of a paint applicator handle forming system configured to form variously configured applicator handles.  
     [0030]FIG. 14 is a sectional view of the system of FIG. 13 taken along line  14 - 14 .  
     [0031]FIG. 15 is a sectional view of a first alternative embodiment of the system of FIG. 13 taken along line  14 - 14 .  
     [0032]FIG. 16 is a sectional view of a paint applicator forming system according to one embodiment of the present invention.  
     [0033]FIG. 17 is a fragmentary sectional view of a first alternative embodiment of the paint applicator forming system of FIG. 16.  
     [0034]FIG. 17A is a schematic view of a paint applicator handle forming system according to one embodiment of the present invention.  
     [0035]FIG. 18 is a sectional view of a paint applicator bristle plug forming system forming a paint applicator bristle plug.  
     [0036]FIGS. 19 and 20 are fragmentary sectional views of a paint applicator forming system according to one embodiment of the present invention forming a paint applicator handle about a bristle plug.  
     [0037]FIG. 21 is an enlarged view of the system of FIG. 20 taken along line  21 - 21 .  
     [0038]FIGS. 22 and 23 are fragmentary sectional views of a first alternative embodiment of the paint applicator forming system of FIGS.  19 - 21  illustrating the formation of a paint applicator.  
     [0039]FIG. 24 is a fragmentary sectional view of a second alternative embodiment of the paint applicator forming system of FIGS.  19 - 21 .  
     [0040]FIGS. 25 and 26 are fragmentary sectional views of a third alternative embodiment of the paint applicator forming system of FIGS.  19 - 21 .  
     [0041]FIGS. 27 and 28 are fragmentary sectional views of a fourth alternative embodiment of the paint applicator forming system of FIGS.  19 - 21 .  
     [0042]FIGS. 29 and 30 are fragmentary sectional views of a fifth alternative embodiment of the paint applicator forming system of FIGS.  19 - 21 .  
     [0043]FIGS. 31 and 32 are fragmentary sectional views illustrating a method for forming a paint applicator bristle subassembly according to one embodiment of the present invention.  
     [0044]FIGS. 33 and 34 are fragmentary sectional views of an alternative embodiment of the method illustrated in FIGS. 31 and 32.  
     [0045]FIG. 35 is a fragmentary top elevational view of a paint applicator forming system according to one embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION  
     I. Paint Brush with Clamshell Handle  
     [0046]FIG. 1 is a top elevational view of a paint applicator (illustrated as paint brush  10 ) generally including handle  12 , bristles  14  and ferrule  16 . Bristles  14  comprise a plurality of brush filaments  24  grouped together and interleaved by a plurality of wedges or spacers (not shown). Filaments  24  comprise conventionally known paint brush filaments formed from natural material such as hair or man-made material such as nylon. Filaments  24  serve as a paint carrying and applying medium. Alternatively, other mediums may be employed to carry and release paint onto a surface such as sponge, foam and a variety of other such materials. The spacers are formed from cardboard, felt or plastic. Axial ends of filaments  24  are bound to one another and are bound to the spacers (not shown) by a conventionally known epoxy (not shown). This epoxy further secures bristles  14  to ferrule  16 .  
     [0047] Ferrule  16  secures bristles  14  to handle  12 . Ferrule  16  comprises a band of metal secured to and overlapping portion of handle  12 .  
     [0048] Handle  12  generally includes gripping portion or shank  18  and head  20 . Shank  18  comprises an elongate narrow portion of handle  12  configured for grasp by a user&#39;s hand. Head  20  widens from shank  18  and forms a wide surface to which ferrule  16  is secured and provides a surface against which brush  10  may be grasped by a user during painting. Handle  12  supports bristles  14  and ferrule  16 . Handle  12  is easily manufactured, is lightweight and is relatively inexpensive as compared to conventional brush handles.  
     [0049]FIGS. 2 and 3 illustrate handle  12  in greater detail. FIG. 2 is a top elevational view of handle  12  prior to the completed assembly of handle  12 . FIG. 3 is a sectional view of handle  12 , once assembled, taken along lines  3 - 3  of FIG. 1. As best shown by FIG. 2, handle  12  is generally formed from a pair of opposing handle clamshell halves  32 ,  34 . Each clamshell half  32 ,  34  generally forms a shank half  36  and a head half  38 . Shank halves  36  and head halves  38  are complementarily shaped so as to mate with one another and form shank  18  and head  20  of brush  12  when assembled together. Each of halves  32 ,  34  is preferably injection molded from a rigid polymeric material such as polyethylene. Alternatively other polymer or plastic materials may be used such as polypropylene, polyvinylchloride and the like.  
     [0050] To facilitate a secure coupling of clamshell halves  32 ,  34  together to form handle  12 , each of halves  32 ,  34  is complementarily shaped with opposing male-female structures. In the exemplary embodiment, clamshell half  32  includes a plurality of female cavities  40  while clamshell half  34  includes a corresponding number of opposite male projections or protuberances  42 . Female cavities  40  receive male protuberances  42  to insure proper alignment of clamshell halves  32  and  34  when handle  12  is assembled. As best shown by FIG. 3, female cavities  40  and male protuberances  42  are preferably configured to resiliently flex when joined together such that clamshell halves  32  and  34  snap together and are retained in their assembled state. In particular, each of female cavities  40  includes a narrowing throat  44  which resiliently flexes to receive the enlarged head  46  of male protuberance  42 . Clamshell halves  32 ,  34  may alternatively include other complementary male-female structures aligning halves  32  and  34  when assembled. For example, the perimeter edges of halves  32  and  34  may alternatively include complementary ribs and channels receiving such ribs. As will be appreciated, the complementary male and female structures on halves  32  and  34  may be intermixed such that a single half contains both male and female structures. Although less desirable, clamshell halves  32 ,  34  may alternatively include structures which align with one another but which do not provide a snap-fit. Halves  32 ,  34  may also alternatively omit any such structures whereby other means are provided for securing halves  32  and  34  together such as adhesives, overmolds, welds or fusion bonds.  
     [0051] As shown by FIGS. 2 and 3, halves  32  and  34  each include a continuous peripheral wall  50  that extends about the entire perimeter of each of halves  32 ,  34  about an interior cavity  52 . As a result, when halves  32 ,  34  are aligned opposite one another in an assembled state, handle  12  is generally hollow through both shank  18  and head  20 . Because handle  12  is hollow, handle  12  requires less material and is lighter in weight. At the same time, handle  12  may be quickly and easily manufactured through simple injection molding equipment not requiring moveable inserts or cores.  
     [0052] As further shown by FIG. 3, walls  50  of halves  32 ,  34  extend opposite to one another and abut one another when halves  32  and  34  are aligned with one another. Walls  50  abut one another about the entire perimeter of handle  12  including an axial end of head  20 . As a result, handle  12  is structurally stronger and more rigid, allowing handle  12  to be formed from less expensive, less strong polymer or plastic materials. At the same time, walls  50  may be provided with a uniform wall thickness for easier manufacture and for reduction in material cost.  
     [0053] As shown by FIGS. 2 and 3, handle  12  additionally includes a living hinge  56  integrally formed as part of the single unitary body with both halves  32  and  34 . Hinge  56  is preferably formed so as to span or bridge opposing side walls  50  of halves  32 ,  34  on head  20 . Hinge  56  is preferably formed in the injection cycle or shot as halves  32  and  34 . Hinge  56  facilitates assembly of halves  32  and  34  by providing and maintaining alignment of halves  32  and  34  at all times. As a result, once formed, halves  32  and  34  may be quickly and easily aligned and joined to one another by simply pivoting one of halves  32 ,  34  about hinge  56 . As shown by FIG. 3, in the exemplary embodiment, hinge  56  is preferably configured so as to extend into cavity  52  when halves  32  and  34  are assembled such that adjacent walls  50  remain substantially flush with one another to provide handle  12  a smooth outer surface for better gripping and for improved aesthetic appearance. Although less desirable, hinge  56  may alternatively be configured such that hinge  56  remains upon an adjacent and exterior of wall  50 , wherein hinge  56  is left intact or is severed once halves  32  and  34  are joined.  
     [0054]FIGS. 3A, 3B and  3 C illustrate paint applicator  10 A, an alternative embodiment of applicator  10  shown in FIGS.  1 - 3 . Applicator  10 A is substantially identical to applicator  10 , except that applicator  10 A includes handle  12 A. Handle  12 A is similar to handle  12 , except that handle  12 A includes an outer elastomeric layer  60  overlying halves  32  and  34 . The elastomeric layer preferably comprises a paint solvent resistant elastomeric material such as SANTOPRENE. Alternatively, other elastomeric materials may be used. As best shown by FIGS. 3B and 3C, layer  60  preferably overlies the mating edge of wall  50  of half  32  along half&#39;s entire perimeter. As a result, when halves  32  and  34  are closed to form handle  12 A, the upper perimeter edge of wall  50  of half  34  is compressed against layer  60  overlying the upper perimeter edge of wall  50  of half  32  to form a seal between halves  32  and  34  at their junction. Thus, in addition to providing handle  12 A with a soft elastomeric grippable outer surface, layer  60  also serves as a gasket between halves  32  and  34  to form a seal therebetween.  
     [0055] Although layer  60  is illustrated as preferably overlying the exterior surfaces of both halves  32  and  34 , layer  60  may alternatively extend along only portions of halves  32  and  34 , and may have varying thicknesses so as to form finger locators and the like. In alternative embodiments, layer  60  may only extend along the upper perimeter mating edge of one of halves  32  and  34 . Moreover, in yet another alternative embodiment, layer  60  may overlie mating edges of walls  50  of both halves  32  and  34 .  
     [0056]FIGS. 4 and 5 illustrate brush  110 , an alternative embodiment of applicator  10  shown in FIGS.  1 - 3 . Brush  110  includes handle  112 , bristles  14  and ferrule  116 . Handle  112  is similar to handle  12  except that handle  12  omits portions of wall  50  along the axial end of head  20  to form mouth  111  which communicates with cavity  52  of head  20 . As best shown by FIG. 5, each of halves  32 ,  34  further includes grooves or detents  113  configured to fit with corresponding ribs  115  of ferrule  116 . Although grooves  113  preferably continuously extend along the inner circumferential surface of head  20  when halves  32  and  34  are joined, grooves  113  may alternatively only partially extend along the inner circumferential surface of cavity  52 . For ease of illustration, the remaining components of brush  110  which correspond to similar components of brush  10  are numbered similarly.  
     [0057] Ferrule  116 , like ferrule  16 , receives axial ends of brush filaments  24  as well as the interleaved spacers and epoxy (not shown). Ferrule  116  also joins bristles  14  to handle  112 . However, unlike ferrule  16 , ferrule  116  is received through mouth  111  into cavities  52  between halves  32  and  34 . In the exemplary embodiment, ferrule  116  includes ribs  115  which snap into grooves  113  of head  20 . In the exemplary embodiment, ferrule  116  is formed from a polymer or plastic such as polyethylene having a sufficient degree of resilient flexibility to allow ribs  115  to flex so as to be inserted through mouth  111  until reaching corresponding grooves  113 . As a result, ribs  115  and grooves  113  form a mechanical interlock securing ferrule  116  to head  20 . Alternatively, ferrule  116  may be retained within cavities  52  of head  20  between halves  32  and  34  by other means such as being press fit, by means of epoxy or other adhesives, by fusion bonds or welds. Although less desirable, ferrule  116  may be secured to head  20  by means of fasteners extending through head  20  into ferrule  116 . Because head  20  of handle  112  receives ferrule  116 , head  20  may be provided with a smooth exterior surface omitting the edges or fasteners usually associated with an exterior ferrule. Although the exterior surface of head  20  of handle  112  is illustrated as being generally flat, head  20  as well as the remaining portions of handle  112  may alternatively be configured to provide various surface contours to provide easier gripping such as those set forth and described in co-pending U.S. Provisional Patent Application Ser. No. 60/193,219, entitled “Paint Accessories” filed on Mar. 30, 2000 by Brian E. Woodnorth, Michael J. Walsh, Brian C. Bone, Heath A. Doty, Kent P. Ritzel, William Dean Ungar, Mark A. Gilbertson, John W. Grosz, Timothy D. Killinger and Aaron W. Smith, the full disclosure of which is hereby incorporated by reference.  
     [0058] Handles  12  and  112  of paint brushes  10  and  110 , respectively, are each illustrated and described as including a pair of opposing halves which join together to form the entirety of the respective handle. Alternatively, each of handles  12  and  112  may be configured to be composed of greater than two sections which join or possibly mate with one another to form a handle of a paint brush or a paint applicator. For example, in one alternative embodiment, such a handle would alternatively include three sections which join or mate together to form a complete handle. In particular, the sections would include a middle section and two substantially identical side sections. The middle section is hinged on opposite sides to the two side sections, such that when the sections are in an open position, the sections would form the shape of an “N” wherein the “|” comprises each of the two side sections and wherein the “\” comprises the middle section. In a closed position, the three sections would be substantially parallel to one another, wherein the opposite faces of the brush handle would be formed by the side sections and wherein the middle section would join the two side sections and provide increased structural stability.  
     [0059] In yet another alternative embodiment, only a portion of the paint applicator handle is provided by two at least partially hollow sections which mate with one another or join to one another to form a portion of the handle. For example, in one particular embodiment, only the shank is formed by two opposing hollow halves which mate together while the head of the handle is connected to the shank and is either formed as a solid member for mounting to bristles or other paint applying medium in a similar fashion to that of brush  10  or is cored out to be joined to bristles or another paint applying medium in a fashion similar to brush  110 .  
     [0060]FIG. 5A illustrates paint applicator  110 A (shown as a brush), an alternative embodiment of brush  110  shown in FIGS. 4 and 5. Applicator  110 A is similar to applicator  110  except that applicator  110 A includes handle  112 A. Handle  112 A is similar to handle  112 , except that handle  112 A includes an elastomeric layer  160  of material overlying the exterior surface of each of halves  32  and  34  in a similar fashion to that of layer  160  in applicator  10 A. However, as shown in FIG. 5A, layer  160  further extends around mouth  11  and into cavity  52  between halves  32  and  34  so as to line the interior cavity of handle  112 A which receives ferrule  116 . Because layer  160  is elastomeric, layer  160  is capable of being slightly compressed when ferrule  116  is positioned within cavities  52 . At the same time, layer  160  grips ribs  115  of ferrule  116  to retain ferrule  116  within cavities  52 . In addition to securing ferrule  116 , layer  160  further forms a seal against ferrule  116  to prevent the undesirable ingress of paint into the interior of handle  112 A. Although layer  160  within cavity  52  is illustrated as being preferably smooth prior to being compressed by ribs  115 , layer  160  may alternatively be provided with ribs, notches or ratcheting teeth configured to engage ferrule  116  or alternatively configured ferrules so as to secure bristles  14  or alternative paint applying mediums to handle  112 A.  
     [0061]FIG. 6 illustrates brush  210 , an alternative embodiment of brush  10 . Brush  210  is similar to brush  110  (shown in FIGS. 4 and 5) except that brush  210  includes an outer layer  217  of material overlying substantially the entire exterior periphery of handle  112  and extending across the junction formed by adjoining edges  219  of walls  50  of halves  32 ,  34 . As a result, halves  32 ,  34  are further retained in alignment with one another and held adjacent to one another even in those particular applications where mechanical interlocks, adhesives or other means for securing halves  32  and  34  together are not provided. Moreover, layer  217  also provides a smooth continuous exterior surface to handle  18  overlapping the edges or crevices. Consequently, handle  112  of brush  210  is more comfortable to grip. To further facilitate a comfortable grip, layer  217  is preferably formed from a soft, compressible, rubber-like material such as an elastomer that is resistant to solvents commonly used with paint brushes. One common elastomer comprises SANTOPRENE sold by Advanced Elastomer Systems. Although less desirable, layer  217  may alternatively comprise a rigid polymeric material.  
     [0062] In addition to providing handle  112  a smooth exterior surface, providing a more comfortable grip, and retaining halves  32  and  34  in an aligned assembled state, layer  217  also seals across edges  219 . As a result, the ingress of paint, solvents or other materials between edges  219  into cavities  52  is substantially minimized or eliminated. As an added benefit, layer  217  also provides handle  112  with a continuous outer appearance which is more aesthetically pleasing.  
     [0063] In the exemplary embodiment, layer  217  preferably has a thickness of approximately 0.060 inches. Layer  217  is preferably molded about halves  32 ,  34 . Although not illustrated, layer  217  is preferably secured to halves  32  and  34  by being heat fused thereto or by mechanical interlocks between layer  217  and halves  32 ,  34 . For example, halves  32 ,  34  may be provided with radially extending projections that extend through layer  217  to form a mechanical interlock. Such mechanical interlocks are illustrated in U.S. Pat. No. 6,138,313 entitled “Paint Brush with Improved Grip Construction and Method of Manufacture Thereof”, the full disclosure of which is hereby incorporated by reference.  
     II. Continuous Hollow Paint Brush Handle and Method of Manufacture  
     [0064]FIGS. 7 and 8 illustrate a method of manufacturing paint brush handle  312 . Handle  312  is shown completed and in section in FIG. 8. As best shown by FIG. 7, handle  312  is preferably formed using mold  314 , extrusion blow molding apparatus  316  and end mold  318 . Mold  314  generally consists of a pair of opposing mold halves or segments  322 ,  324  (halves is not intended to limit a mold to only two segments) which mate to form an internal mold cavity  326  generally in the shape of paint brush handle  312 . In particular, cavity  326 , formed by joined halves  322  and  324 , has an enlarged head portion  328  communicating with a narrower shank portion  330  which extends through an end of mold halves  322 ,  324  to provide an opening into cavity  326 . As further shown by FIGS. 7 and 8, each half  322 ,  324  includes vacuum assist ports  332  connected to a vacuum source (not shown).  
     [0065] Extrusion blow molding apparatus  316  is conventionally known and generally includes extrusion die  334  and nozzle  336 . Extrusion die  334  is fluidly coupled to a source of fluid or semi-fluid handle material (not shown) and is configured to extrude a balloon of the material called a parafin. In the exemplary embodiment, apparatus  316  is configured to extrude a parafin of material into cavity  326 .  
     [0066] Nozzle  336  projects into the interior of the parafin and is coupled to a source of pressurized gas. In operation, as shown by FIG. 7, a parafin of material is extruded by die  334  into cavity  326  as indicated by arrows  338 . Afterward, air is injected into the interior of the parafin through nozzle  336  to blow up or expand the parafin against the interior of cavity  326  as indicated by arrows  340 . To further assist the parafin in contacting the interior of cavity  326 , vacuum pressure is applied through port  332  as indicated by arrows  342 . During these steps, both halves  322  and  324  are pressed together as indicated by arrows  344  and end die  318  is retracted as indicated by arrow  346 .  
     [0067] Once the parafin has been completely blown adjacent to and in contact with the interior walls of cavity  326 , apparatus  316  is withdrawn, as indicated by arrow  348 , and end die  318  is inserted in between halves  322 ,  324  as indicated by arrow  350 . End die  318  closes the end of the parafin while the parafin is in a partially formable state. After the material forming parafin has substantially cooled and solidified, halves  322 ,  324  and end die  318  are withdrawn, leaving brush handle  312 . As shown by FIG. 8, the resulting brush handle  312  is generally hollow having a cavity  354  and continuous solid wall  356  extending about cavity  354 . Because handle  312  is hollow, handle  312  is lightweight, requires less material and can be quickly and efficiently manufactured at a lower cost. Because walls  356  are substantially continuous, handle  312  does not include any edges or joints where halves would otherwise come together such as with brush  10 . Because walls  356  are continuous, brush  312  is structurally stronger, enabling less expensive less strong materials to be employed in the manufacture of brush  312 .  
     [0068] In the exemplary embodiment, brush  312  is preferably formed from an expandable polymer such as polyethylene or polypropylene. Alternatively, brush  312  may be formed from various other polymeric materials. Although brush  312  is illustrated as having the general configuration shown in FIGS. 7 and 8, brush  312  may alternatively have the various configurations set forth in the appended provisional application. Moreover, brush  312  may additionally include an overlying layer of soft, compressible, rubber-like material such as an elastomer. Once completed, brush handle  312  is secured to ferrule  16  and bristles  14  as described above.  
     [0069] In lieu of employing end die  318 , handle molding system  310  may alternatively include an extrusion and blow molding apparatus  316  configured to close the open end of the parafin upon withdrawal from mold  314 .  
     [0070] FIGS.  9 - 11  illustrate brush handle molding system  410 , an alternative embodiment of brush molding system  310  described above. Brush handle molding system  410  is configured to produce a completed brush handle  412  (shown in FIGS. 10 and 11) and generally includes mold  414  including mold halves  422 ,  424  and heating members  432 . Mold halves  422 ,  424  extend opposite one another and form cavity  426  when joined. Cavity  426  is configured in the general shape of a paint brush handle. When joined together, halves  422 ,  424  further define port  428  pneumatically connectable to a source of pressurized gas. Cavity  426  is configured to receive preform  430  as shown in FIG. 9.  
     [0071] Preform  430  generally comprises an elongate tubular shaped member formed from a thermoplastic polymeric material such as polyethylene or polypropylene. Alternatively, preform  430  may be formed from other thermoplastic materials. Preform  430  is preferably preformed by injection molding that includes a detailed head portion  419  including injection molded detents or grooves  413 . Because head portion  419  is injection molded, the size and location of grooves  413  may be controlled to precise tolerances.  
     [0072] Preform  430  further includes shank portion  417  sized smaller than the surrounding cavity  426  of mold  414 . As best shown by FIG. 11, heating members  432  elevate the temperature of shank portion  417  such that shank portion  417  is formable. Once attaining a sufficient temperature, pressurized gas is directed into cavity  426  through port  428  as indicated by arrows  434 . The pressurized gas expands shank portion  417  of preform  430  outward towards the inner surface of cavity  426 . In addition, gas assist may be used as a vacuum to draw shank portion  417  of preform  430  outward towards the inner surface of cavity  426 . After allowing sufficient time for cooling and solidifying, mold halves  422 ,  424  are separated and a completed brush handle  412  is removed.  
     [0073] The completed brush handle  412  is generally hollow through its head  420  and its shank  418 . As a result, handle  412  is lightweight and uses less materials. As shown by FIG. 11, handle  412  generally has a continuous outer wall, omitting any ridges, adjoining edges or junctures such as those found in handle  12 . Consequently, brush handle  412  is stronger, is more comfortable to the grip and is more aesthetically pleasing. In addition, handle  412  has a generally sealed or closed wall about its cavity  452  which is open ended for the reception of a ferrule and bristles such as ferrule  116  and bristles  14  shown in FIG. 4. At the same time, however, head  420  may include intricately formed grooves or other surface configurations for providing a mechanical lock with ferrule  116  or an alternatively configured ferrule. Although less desirable, brush handle  412  may alternatively omit grooves  413  where the ferrule is crimped, adhesively bonded, welded or fused to handle  412 . As will be appreciated, various other complementary male and female structures may be used to secure a ferrule within head  420 . For example, head  420  may alternatively include ribs or other male projections configured to extend into corresponding female cavities or grooves in the ferrule to thereby form a mechanical lock between handle  412  and the received ferrule.  
     [0074] In yet another alternative embodiment, premolded or preformed elastomer inserts may be positioned within either cavity  326  or cavity  426  or held in place in such molds as the parafin or preform is blown (with or without vacuum assist) in the appropriate shape within the mold interior. In such an alternative method, the parafin or preform would be preferably formed from a compatible material as the elastomer insert so as to fuse or bond thereto. Alternatively, the insert or interior mold shape may be configured such that the parafin or preform at least partially molds about the insert to form a mechanical interlock with the insert or to at least partially encapsulate the insert. Such an ability to provide a premolded elastomer insert facilitates providing the completed handle with more details along its exterior surface than would otherwise be economically achieved through conventional blow molding practices.  
     [0075] As described above, each of brush handles  12 ,  112 ,  212 ,  312  and  412  have a generally hollow head as well as a generally hollow shank. Because such handles are hollow, such handles are lighter in weight and use less materials. However, it is also contemplated that the hollow cavities of each of brush handles  12 ,  112 ,  212 ,  312  and  412  may alternatively be filled to improve the structural strength or where a more solid brush is desired. Preferably, the hollow cavities of such brushes are filled with a foam or a material including a foaming agent so as to fill the cavity yet maintain the lightweight quality of the brush handle. As will be appreciated, in those applications in which the head portion of the brush handle internally receives a ferrule, the filler is injected into the cavity about an insert so as to allow continued receipt of the ferrule. It is also contemplated in some applications where the head of the handle internally receives the ferrule, the ferrule would first be inserted into the cavity and then the filler material such as a foam material would be injected into the cavity about the ferrule.  
     [0076]FIG. 12 illustrates but one example of an internal cavity of the above described brush handles being filled with a foam or a foamed material  513 . In particular, FIG. 12 illustrates brush handle  312  being formed by system  310 . However, as shown by FIG. 12, prior to closing of the shank  318  by end mold  323 , foam material  513  is injected into cavity  352  through end mold  323 . Alternatively, a foam material  513  may be injected into cavity  352  through nozzle  336  or through other injection devices. The resulting modified brush  312  has all the advantages associated with handle  312 , yet is structurally stronger due to the omission of the hollow interior. As a result, the material forming the outer walls of brush handle  312  may consist of a lighter less strong material or may have a reduced thickness. In fact, when filler  513  is formed from a foam material having sufficient structural strength itself, the outer wall of revised handle  312  need not be structurally rigid. For example, outer wall  350  of revised brush handle  312  may alternatively comprise a soft, compressible, rubber-like material such as an elastomer like SANTOPRENE sold by Advanced Elastomer Systems. As a result, the resulting brush handle would provide the user with a soft comfortable grip. In other applications, filler  513  may be formed from a strong yet somewhat compressible foam material further increasing the conformability of brush handle  512  to a user&#39;s hand upon being gripped.  
     III. Variable Paint Applicator Forming Systems and Applicator Handle  
     [0077] FIGS.  13 - 15  illustrate applicator handle forming system  610 . System  610  enables the production of multiple paint brushes having a commonly sized and configured handle outer surface and outer configuration formed from a common mold, yet having differently sized or dimensioned paint applying mediums such as bristle groups or clusters for different painting applications. Alternatively, the paint applying medium may comprise other materials capable of carrying and releasing paint, varnishes, stains or other liquid coatings onto a surface such as foam material, sponge material or any of a variety of other presently known or future developed materials capable of performing such functions. In the illustrated embodiment, the paint applying medium is coupled to a mounting portion, such as a ferrule, to form a paint carrying unit. Alternately, other mounting portions such as the plugs described herein may be used in lieu of a ferrule. The exact configuration and type of mounting portion may varying depending upon a type of paint applying medium or mediums coupled to the handle by the mounting portion.  
     [0078] As best shown by FIG. 13, system  610  generally includes mold  614  and mold inserts  615 A,  615 B and  615 C. Mold  614  comprises an injection molding mold and opposing mold halves  617 ,  619 . Halves  617 ,  619 , when joined together, define an internal cavity  626 . Cavity  626  is in the general shape of a paint brush handle having a shank portion  621  and a head portion  623 . At least one of shank portion  621  or head portion  623  of cavity  626  is in communication with a source of fluid handle material such as a polymeric material. Typical polymeric materials include polyethylene, polypropylene, and the like. Head portion  623  is in communication with shank portion  621  and has an open axial end  625  sized to partially receive a selected one of inserts  615 A,  615 B and  615 C. When injected with a material, cavity  626  forms a brush handle having an exterior surface similar to that of brush handle  412  shown in FIG. 11.  
     [0079] Inserts  615 A,  615 B and  615 C comprise internal cores adapted to be received within cavity  426  during the injection molding process. Inserts  615 A,  615 B,  615 C generally include end cap portions  627 A,  627 B,  627 C and handle cavity-forming portions  629 A,  629 B and  629 C. End cap portions  627 A,  627 B and  627 C are substantially identical to one another and extend outwardly from handle cavity-forming portions  629 A,  629 B and  629 C, respectively, to seal against mold  617  when portion  629 A,  629 B and  629 C project into cavity  626 . As will be appreciated, inserts  615 A,  615 B and  615 C may alternatively omit such end cap portions where other structures are provided for sealing opening  625  and for supporting portion  629 A,  629 B or  629 C in cavity  626 .  
     [0080] Handle-forming portions  629 A,  629 B and  629 C are each substantially identical to one another except that each portion  629 A,  629 B and  629 C has at least one different dimension. In the exemplary embodiment, portions  629 A,  629 B and  629 C have different heights H 1 , H 2  and H 3 , respectively, as shown in FIG. 13. As shown in FIG. 14, portions  629 A,  629 B and  629 C have different widths W 1 , W 2  and W 3 , respectively. As a result, the resulting height and width of brush handle cavity  652  also varies. In particular, insert  615  forms a cavity  652 A having a corresponding height H 1  and a width W 1  capable of entirely receiving a smaller ferrule having an outer height of H 1  and an outer width of W 1  and carrying bristles. Insert  615 B forms a cavity  652 B having a height H 2  and a width W 2  capable of securely receiving a slightly larger ferrule having an outer surface height H 2  and an outer surface width W 2  and carrying a slightly larger group of bristles. Lastly, insert  615 C forms a cavity  652 C having a height H 3  and a width W 3  capable of securely receiving a slightly larger ferrule having a height H 3  and a width W 3  carrying a slightly larger group of bristles.  
     [0081] In operation, a selected one of inserts  615 A,  615 B and  615 C is partially inserted into cavity  626 . Material, such as polypropylene, polyethylene or other injection molding handle material is then injected into cavity  626  about the selected one of inserts  615 A,  615 B or  615 C. After the material has sufficiently cooled or solidified, the insert is withdrawn leaving a handle with an inner cavity  652 A,  652 B or  652 C, depending upon the insert employed. A ferrule carrying a group of bristles such as ferrule  116  and bristles  14  shown in FIG. 14 is then inserted into the cavity  652 A,  652 B or  652 C to form the resulting brush. Each ferrule and group of bristles inserted into cavity  652 A,  652 B or  652 C will have a varying height and width dimension and will carry a variably dimensioned group of bristles. Thus, system  610  produces a multitude of differently sized paint brushes having differently sized groups of bristles for various applications such as trim, detailed painting and the like, yet having a commonly sized handle exterior to allow a user to become accustomed to gripping a particular handle exterior or configuration. Each of the differently sized brushes having a common brush handle is formed from a single system  610  having a single mold  614 . As will be appreciated, the outer exterior surface of the brush formed by  610  may have any one of a variety of alternative configurations. For example, the outer exterior surface of the brush formed by system  610  may be configured similar to those brush handles shown in copending U.S. application Ser. No. 60/193,219 filed on Mar. 30, 2000 by Brian E. Woodnorth, Brian C. Bone, Heath A. Doty, Kent P. Ritzel, William Dean Ungar, Christina L. Fortner, Jonathan Hawley, Daniel T. Williams and Brian Chiaruttini and entitled EASY GRIP PAINT APPLICATOR, the full disclosure of which is hereby incorporated by reference.  
     [0082] As further shown by FIG. 14, the use of different inserts  615 A,  615 B and  615 C results in head portion  620  extending from shank portion  618  to have a wall about cavity  652 A,  652 B or  652 C with varying interior height and width dimensions while maintaining the same exterior dimensions. FIG. 15 illustrates head portion  720  of paint brush handle  712  within mold  614  prior to removal of insert  715 A. Insert  715 A is substantially identical to insert  615 A except that insert  715 A includes projections  754  which provide head portion  720  with ribs  756  which extend towards cavity  752 A. In particular, the inwardly extending surfaces of ribs  756  define the outer boundary of cavity  752 A and engage the outer surface of an inserted ferrule. Overall, insert  715 A forms cavity  752 A which is substantially identical in size to cavity  652 A. However, because head portion  720  includes ribs  756  provided by insert  715 A, the walls of head portion  720  about cavity  752 A require less material and provide head  720  with an overall lighter weight.  
     [0083] As shown by FIG. 13, each of inserts  615 A,  615 B and  615 C preferably includes outwardly extending groove forming portions  757  which are configured to form grooves  713  similar to groove  113  which are described with respect to FIG. 5. Groove  713  receive corresponding ribs to mechanically interlock a ferrule within the interior of head portion  620  of brush handle  612 . Alternatively, inserts  615 A,  615 B and  615 C may be provided with various other exterior molding surfaces forming other mechanical interlocking depressions or projections along the inner surface of interior cavity  652 A,  652 B and  652 C of head portion  620 . In such applications, a particular insert chosen must be withdrawn from mold  614  at an appropriate time so as to not damage the molded interior surface of head  620 , such as when head portion  620  is somewhat resiliently flexible during solidification or cooling. In lieu of forming groove  713 , inserts  615 A,  615 B and  615 C may each be alternatively configured to form rubber-like resilient gripping ribs (similar to ribs  756  seen in FIG. 15) which resiliently flex when receiving the ferrule but which retain and hold the ferrule within the cavity of the handle. Although less desirable, inserts  615 A,  615 B and  615 C may alternatively be configured to form a smooth inner cavity lacking grooves, depressions, or projections. In such applications, other adhesives, fasteners or other structures may be used to secure the ferrule within the cavity such as those described with respect to brush  110 .  
     [0084] In the exemplary embodiment, halves  617 ,  619  of mold  614  are formed from steel, while inserts  615 A,  615 B,  615 C and  715 A are formed from steel. The material injected into cavity  626  about the inserts preferably comprises polypropylene, polyethylene, blends thereof, or other polymeric material. Other materials such as ceramic materials may also be employed. Although inserts  615 A,  615 B and  615 C are illustrated as having different heights H 1 , H 2  and H 3  and different widths W 1 , W 2  and W 3 , inserts  615 A,  615 B an  615 C may additionally be provided with differing lengths. Depending upon the desired dimensions of the ferrule and group of bristles carried by the ferrule, inserts  615 A,  615 B and  615 C may have differing heights, widths and lengths singly or in combination.  
     [0085]FIG. 16 illustrates paint brush forming system  810 . Paint brush forming system  810  provides multiple paint brushes having differently dimensioned groups of bristles for different applications such as performing trim, general painting and the like, yet having identically dimensioned and configured handle exteriors formed from a common tool. As with paint brush handles  612  and  712  discussed above, paint brush handle  812  provides multiple differently sized brushes having a common handle which enables the user to become acquainted and skilled in gripping the different paint brushes and reduces the manufacturing and packaging costs. As shown by FIG. 16, system  810  generally employs handle  812  and differently sized bristle cartridges  815 A,  815 B and  815 C. Handle  812  generally includes shank  818  and head  820  which includes an interior cavity  852 . Shank  818  is substantially identical to shank  318  shown in FIG. 12 and has the same general shape as shank  18  shown in FIG. 1. Head  820  is substantially identical to head  20  shown in FIG. 4 and includes grooves  113  adjacent cavity  852 . Cavity  852  receives each of bristle cartridges  815 A,  815 B or  815 C.  
     [0086] Bristle cartridges  815 A,  815 B and  815 C are substantially identical to one another except that each cartridge  815 A,  815 B and  815 C has a differently dimensioned ferrule  816 A,  816 B and  816 C carrying a differently dimensioned group of bristles  814 A,  814 B,  814 C. In particular, each cartridge  815 A,  815 B and  815 C generally includes a differently sized ferrule  816 A,  816 B,  816 C and a differently sized group of bristles,  814 A,  814 B,  814 C. Groups of bristles  814 A,  814 B,  814 C have groups or clusters of bristle filaments  824  which are secured within corresponding ferrules  816 A,  816 B and  816 C, respectively, by epoxy  826  or other adhesive of polymeric material and have differing bristle height dimensions BH 1 , BH 2  and BH 3 , respectively. Although not illustrated, groups of bristles  814 A,  814 B and  814 C may additionally or alternatively be provided with varying or differing width dimensions (extending into the page). To enable such variably dimensioned groups of bristles,  814 A,  814 B and  814 C to fit within a commonly sized cavity  852  of handle  812 , ferrules  816 A,  816 B and  816 C have differing thicknesses T 1 , T 2  and T 3 , respectively. Overall, the dimensional change between bristle groups  814 A,  814 B and  814 C, whether height, width or length, are generally offset by a corresponding opposite change in dimension, whether height, width or length, of ferrules  816 A,  816 B and  816 C. In the exemplary embodiment, ferrules  816 A,  816 B and  816 C are formed from a polymeric material such as nylon, polypropylene, polyethylene or the like. As a result, ferrules  816 A,  816 B and  816 C may be easily molded and provided with the differing dimensional values that enable differently sized groups of bristles  814 A,  814 B and  814 C to be secured to a commonly sized brush handle  812  within cavity  852 .  
     [0087]FIG. 17 illustrates paint brush forming system  910 . System  910  provides a plurality of differently sized paint brushes having differently dimensioned groups of bristles while also having a commonly sized handle to enable quicker and more reliable gripping of the paint brush handle independent of the particular painting application in which differently dimensioned groups of bristles are required. System  910  generally includes handle  912  and bristle cartridges  915 A,  915 B and  915 C. Handle  912  is substantially similar to handle  12  shown in FIG. 1. Alternatively, handle  12  is substantially similar to handle  112  shown in FIG. 4, handle  312  shown in FIG. 8 or handle  312  shown in FIG. 12. Handle  912  may have various outer surface contours and configurations such as illustrated and described in the appended Provisional Application Ser. No. 60/193,219. Handle  912  is configured for use with each of cartridges  915 A,  915 B and  915 C.  
     [0088] Cartridges  915 A,  915 B and  915 C are substantially identical to one another except that each of cartridges  915 A,  915 B and  915 C has a differently dimensioned group of bristles  914 A,  914 B,  915 C and a differently dimensioned ferrule  916 A,  916 B and  916 C. Bristle groups  914 A,  914 B and  914 C have differing heights BH 4 , BH 5  and BH 6 , respectively, and are generally composed of a plurality of grouped individual bristle filaments  924  comprised of natural or artificial materials such as hair, nylon, polyester, polyolefins or blends thereof which are interleaved with spacers (not shown) and which are secured to one another and to ferrules  916 A,  916 B,  916 C by epoxy  925  or other adhesives of polymeric material binders. Bristle groups  914 A,  914 B and  914 C are selectively secured to handle  912  by ferrules  916 A,  916 B and  916 C, respectively.  
     [0089] Each ferrule  916 A,  916 B and  916 C is substantially similar but is differently dimensioned to accommodate the corresponding differently sized bristle group. Each ferrule  916 A,  916 B and  916 C generally includes outer wall  928  defining opening  930  and rib  932 . Wall  928  extends about the end of bristle groups  914 A,  914 B,  914 C. As shown by FIG. 17, outer wall  928  of ferrule  916 A has a uniform thickness FT 1  overlapping handle  912  and overlapping bristle group  914 A. However, outer walls  928  of cartridge  915 B and  915 C have a varying thickness across their longitudinal length. In particular, ferrule  916 B has a ferrule thickness FT 2  while outer wall  928  of ferrule  916 C has a ferrule thickness FT 3 . At the same time, those portions of outer wall  928  about bristle groups  914 B and  914 C have a larger inner diameter to accommodate the increased volume of filaments  924 . The increased thickness of outer wall  928  of each of ferrules  916 B and  916 C enables opening  930  of each of cartridges  915 A,  915 B and  915 C to be uniformly sized for receiving the portion of head  920  of handle  912 . As a result, each of cartridges  915 A,  915 B and  915 C may be mounted upon handle  912  to form a differently sized paint brush. To further facilitate retention of ferrules  915 A,  915 B and  915 C, each ferrule includes rib  932  which resiliently flexes and snaps into corresponding groove  936  formed in an exterior surface of handle  912 . Although less desirable, ferrules  916 A,  916 B and  916 C may alternatively be secured over and about portions of head  920  of handle  912  by other means such as adhesive, fusion, welding, crimping or fasteners that extend through the ferrule into handle  912 .  
     [0090] Moreover, handle  912  (the exposed portion) may then be overcoated with a layer of rigid or soft compressible elastomeric material to provide the paint brush with a continuous, uninterrupted outer exterior surface. In an alternative embodiment, both handle  912  (the exposed portion) and ferrule  916  are overlaid with a layer of rigid or soft compressible elastomeric material or a rigid polymeric material. In one alternative embodiment, the layer is thinner across ferrule  916  yet is thicker over handle  912  where handle  912  is exposed adjacent to ferrule  916  to provide the paint brush with a smooth, continuous uninterrupted outer exterior surface.  
     [0091] Each of the above-described paint applicators  610 ,  710 ,  810  and  910  have a common exterior shank and head configuration while providing a plurality of distinct paint applying medium configurations. For example, paint applicator  610  has a common exterior shank and head configuration (shape and configuration) while having a cluster of paint bristles which have varying overall widths and thicknesses. As noted above, this feature enables a user to become accustomed to gripping the same exterior configuration while utilizing a brush having a bristle configuration best suited for a particular application. In addition to varying the paint applying medium configuration or bristle configuration, while maintaining the same exterior configuration of the head of the brush handle, it may also be desirable to vary the exterior configuration of the shank portion of the handle while maintaining the same exterior head configuration. Accordingly, according to yet another embodiment, the head portion of the handle would be configured to be releasably mounted to one of a variety of shanks having various shank configurations such as long, short, beaver-tail and the like. In lieu of the handle having a shank portion releasably mounted to a common configured head portion, inserts configured to form one of various desirable paint brush handle shank configurations such as long, short, beaver-tail and the like, may be inserted within a generic mold to enable the single generic mold to form a multiple of paint brushes having a common exterior head configuration yet varying shank portion configurations. In lieu of employing inserts, the mold halves forming the head may be comprised of multiple interchangeable sections, wherein the configuration of the shank portion of a handle may be easily varied by interchanging sections in a mold.  
     [0092]FIG. 17A schematically illustrates brush forming system  950  for forming variously configured paint applicator handles. System  950  generally includes frame  952 , mold sections  954 A,  954 B,  954 C,  956 A,  956 B, and  956 C. Frame  952  comprises a structural frame support or other mechanism configured to releasably hold and retain one of mold sections  954 A,  954 B and  954 C adjacent to one of mold sections  956 A,  956 B,  956 C. Frame  952  allows mold section  954 A,  954 B and  954 C to be selectively interchanged with one another, and allows mold sections  956 A,  956 B and  956 C to be selectively interchanged with one another to particularly and easily produce differently configured brush handles. In particular, mold sections  954 A,  954 B and  954 C preferably comprise molds having internal cavities configured to form differently configured paint applicator handle shank portions. For example, mold section  954 A is configured to form a conventionally known long shank configuration, mold section  954 B is configured to form a conventionally known short shank handle portion while mold section  954 C is configured to form a conventionally known beaver-tail shank paint applicator handle configuration. Mold sections  956 A,  956 B and  956 C are configured to form differently configured head portions of a paint applicator handle. In one preferred embodiment, mold sections  954  and  956  are interchanged with one another by means of a rotatable turret to rotate to selectively position one of the sections  954  and one of sections  956  within frame  952 . Once positioned within frame  952  adjacent to one another, paint applicator handle material, such as polyethylene or the like, is injected into the interior of the mold sections within frame  952  or is blown into the interior of mold sections  952  to form the desired handle. Thereafter, the mold sections within frame  952  are separated and the resulting paint brush is removed.  
     [0093] Alternative configurations may be employed to interchange mold sections  954  and  956 . For example, mold sections  954  and  956  may alternatively be interchanged in and out of frame  952  by means of a track or other mechanisms which permit movement of components relative to one another. The interchange of mold sections may be performed manually or may be done by various actuation mechanisms which rely on hydraulic, pneumatic, electrical or mechanical actuation mechanisms. Moreover, the interchange of mold sections into and out of frame  952  may be under manual control or may be under the control of a control circuit configured to generate control signals which one or more actuators respond to by interchanging mold sections  954  and  956 . The control circuit may also be configured to control the type of paint applicator handle material being injected or blown into the interior of the mold to further control the qualities of the selected paint applicator handle being formed.  
     IV. Bristle Plug and Methods of Brush Manufacture using Plug  
     [0094]FIG. 18 illustrates plug forming method  1010 . FIG. 18 illustrates the formation of bristle plug  1016  by mold  1014  including halves  1016 ,  1018 . As shown by FIG. 18, halves  1016 ,  1018 , when joined together, form an annular mold  1014  having an internal cavity  1015 . To form bristle plug  1016 , bristle filaments  1024  are grouped and are pulled through cavity  1015 . Wedges or spacers  1025  are then inserted or interleaved between ends of bristle filaments  1024  which are pulled back through cavity  1015 . Alternatively, spacers  1025  may be positioned between and among filaments  1024  by various other methods. Once ends of filaments  1024  and spacers  1025  are positioned within cavity  1015 , a fluid plug material is injected or supplied into cavity  1015 , preferably under low pressure. The fluid plug material preferably penetrates bristle filaments  1024  so as to contact bristle filaments  1024  and spacers  1025 . Upon solidifying or hardening, the material secures filaments  1024  and spacers  1025  together and in place and at the same time forms body  1028 . Body  1028  preferably includes at least one mechanical locking structure  1030  distant filaments  1024  and at least one locking structure  1032  proximate filaments  1024 . Structures  1030  and  1032  enable body  1028  and plug  1016  to be more securely fixed to a surrounding brush handle. As will be appreciated, locking structures  1030  and  1032  may comprise male or female structures. Although less desirable, locking structures  1030  and  1032  may be omitted where other means are provided for securing plug  1016  to a handle.  
     [0095] In the illustrated embodiment, the plug material securing filaments  1024  together and to spacers  1025  and forming body  1028  comprises an epoxy, a polymer or resin, or mixture thereof. Preferably, the material forming body  1028  is capable of forming strong bonds with the material of filaments  1024 . Preferably, the material has a tie-layer such as an anhydride acid modified polymer compatible with polypropylene which would enable body  1028  and the material comprising it to bond to normally incompatible filaments  1024  formed from nylon, polyester or polyolefins and to bond to the polypropylene handle while being resistant to most solvents used in painting applications. Such an acid modified polypropylene is commonly sold under the trademark BYNEL produced and sold by DuPont. Other binding materials which body  1028  may be formed from include polyethyleneterathalate (PETA), polyethylene, polypropylene or other hardening materials. In applications where plug  1016  is heat fused to a handle, the material forming body  1028  should preferably be formed from a thermoplastic polymer. In less preferred embodiments, a thermoset material such as polyurethane or an epoxy may be employed.  
     [0096] Overall, plug  1016  retains bristle filaments  1024  and spacers  1025  together while providing a body  1028  having a large surface area for being mechanically locked, bonded, welded, fused or otherwise secured to and within an internal cavity of a brush handle. Body  1028  enables a paint brush to be formed without a ferrule since body  1028  simultaneously holds filaments  1024  and spacers  1025  together and provides a structure that is attachable to a brush handle such as in an internal cavity of a brush handle. By eliminating the need for a ferrule, plug  1016  reduces the number of parts required to form a paint brush, reduces assembly time and reduces the overall cost. In addition, because plug  1016  is preferably solid, plug  1016  lacks internal cavities or voids where paint or other fluid may enter. More importantly, plug  1016  may be pre-manufactured independently using forming system  1010  and stored for later assembly wherein plug  1016  is simply inserted into a handle such as any of handles  112 ,  412  or  612 . In addition, body  1028  of plug  1016  may be provided with various thicknesses while supporting differently dimensioned groups of bristles for use with system  810  in lieu of cartridge  815 . Furthermore, body  1028  of plug  1016  may alternatively be provided with an opening  930  into which an end of a handle may be inserted similar to that shown in FIG. 17.  
     [0097] FIGS.  19 - 21  illustrate the formation of a paint brush  1110  using brush forming system  1210  which includes mold  1214  having mold halves  1216 ,  1218  which receive plug  1016 . Halves  1216 ,  1218  each include lower plug engaging blades or edges  1220  which penetrate into plug  1016  as shown in FIGS. 20 and 21 to seal against plug  1016 . Alternatively, edges  1220  may extend into a corresponding groove preformed into an exterior surface of body  1028  of plug  1016  to seal against plug  1016 . In yet another alternative embodiment, the plug may be provided with a raised surface around its perimeter, wherein the mold halves clamp down upon the raised surface to “crush” this zone to provide a secure shut-off for the mold. Halves  1216 ,  1218  define a cavity  1215  which extends above and partially about sides of plug  1016  adjacent to locking structure  1032 .  
     [0098] As shown by FIGS.  19 - 21 , brush  1010  is formed by first bringing mold halves  1216 ,  1218  together about plug  1016  such that edges  1220  penetrate body  1028  to seal against body  1028 . An insert  1015  is positioned above body  1028  within cavity  1215 . Afterwards, a handle material, such as PETA, polyethylene, polypropylene or other polymeric material is injected into cavity  1215  through injection port  1224 . The fluid material flows into cavity  1215  around and about body  1028  to a point just above edges  1220 . The material also flows upward throughout the remainder of mold halves  1216 ,  1218  to form the remainder of the paint brush handle which has a head portion and a shank portion similar to those head portions and shank portions described above and as defined by the internal surfaces of mold halves  1216 ,  1218 . After the material injected through port  1224  has cooled and/or solidified to form handle  1112  which is molded about plug  1016 , both halves  1216 ,  1218  may be separated, leaving brush  1110 .  
     [0099] Insert  1015  may be an insert of lightweight foam material or may be an insert of rigid strong material depending upon the desired characteristics of paint brush  1010 . Moreover, insert  1015  may alternatively be omitted, wherein the material injected into cavity  1015  at about body  1028  of plug  1016  forms the entirety of the remainder of brush  1110  which is substantially solid (not hollow). In a further alternative embodiment, the material injected through port  1224  about body  1028  may comprise a soft compressible elastomeric material that is resistant to most solvents commonly used in painting applications such as SANTOPRENE. In such an alternative embodiment, the elastomer encapsulates both body  1028  of plug  1016  and insert  1015 . The resulting brush is rigid in strength due to the rigidity of plug  1016  and insert  1015  but is comfortable to grip due to the compressibility and rubber-like characteristics of the material injected about insert  1015  and body  1028 .  
     [0100] In the exemplary embodiment, the material injected through port  1224  and partially encapsulating body  1028  of plug  1016  envelops locking structures  1030  and  1032  of body  1028  to mechanically interlock plug  1016  with the remainder of the paint brush handle  1112 . Such a mechanical interlock is extremely important where bonding of plug  1016  to the remainder of handle  1112  may be difficult due to the incompatibility of the materials chosen. In alternative applications where body  1028  of plug  1016  and remainder of handle  1112  are compatible such that the two may be joined together by heat fusion or welding or where both materials may be adhesively bonded to one another, locking structures  1030  and  1032  may be omitted.  
     [0101]FIGS. 22 and 23 illustrate brush forming system  1310  used to form brush  1110  in a continuous fashion. System  1310  generally includes filament and spacer guide and feed  1312 , plug mold  1314  and brush mold  1316 . Filament and spacer guide and feed  1312  feeds and guides a clustered group of filaments  1024  and spacers  1025  into plug mold  1314 . Movement of filaments  1024  and spacers  1025  through guide  1312  into plug mold  1314  may be is assisted by gravity or other conventionally known transfer mechanisms and methods.  
     [0102] Plug mold  1314  generally includes side walls  1318  having injection port  1320  and door  1322 . Once filaments  1024  and spacers  1025  have been partially deposited into cavity  1324  defined by wall  1318  and door  1322 , plug body material is injected into cavity  1324  through port  1320  at least partially about filaments  1024  and spacers  1025  to bond and retain filaments  1024  and spacers  1025  together and to form body  1028  of plug  1016 . Once the material forming body  1028  has sufficiently solidified and hardened, door  1322  is opened (as shown in FIG. 23) and the completed plug is transferred into handle forming mold  1316 . Meanwhile, an additional clustered group of filaments  1024  and  1025  is transferred through guide  1312  into the now open plug cavity  1314  for manufacture of a successive brush.  
     [0103] Brush forming mold  1316  is substantially similar to mold  1214  except that mold  1316  includes edges  1320  which actuate between a plug disengaged position (shown in FIG. 22) and a plug engaged position (shown in FIG. 23). In the plug disengaged position shown in FIG. 22, plug  1016  is permitted to be transferred into mold  1316 . Once plug  1016  has been deposited into mold  1316 , edges  1320  are actuate to a plug engaging position in which edges  1320  partially penetrate into plug  1016  to seal cavity  1315 . Afterwards, the paint brush handle material is injected through port  1324  into cavity  1315  to partially encapsulate plug  1016  and to form the remainder of handle  1112  including head portion  1120  and a shank portion (not shown). In alternative embodiments, the material forming the remainder of handle  1112  may be blown into cavity  1315 , with or without vacuum assist, such that the resulting handle extending about plug  1016  would be hollow or at least partially hollow. Once the brush handle material has been allowed to solidify, mold halves  1328 ,  1330  as well as edges  1320  are retracted and the completed brush  1110  is removed, allowing the next successive completed plug  1016  to be directed into handle forming mold  1316  for formation of a successive paint brush  1110 .  
     [0104]FIG. 24 illustrates paint brush forming system  1410 , an alternative embodiment of forming system  1310  for continuously forming paint brushes  1110 . System  1410  is similar to system  1310  except that system  1410  includes plug forming mold  1414  in lieu of plug forming mold  1314 . Plug forming mold  1414  includes mold halves  1418 ,  1419  which pivot about axes  1420  between a plug forming position (shown in solid lines) and a plug release position (shown in phantom). In the plug forming position, halves  1418 ,  1419  form cavity  1424  which extends about ends of filaments  1024  and about interleaved spacers  1025 . Plug forming material is then injected through port  1420  into cavity  1424  to form body  1028  and to complete plug  1016 . After the material has sufficiently solidified, halves  1418  and  1419  are then pivoted by an actuator (not shown) to the plug releasing position, allowing the completed plug  1016  to be transferred into handle forming mold  1316  for completion of paint brush  1110  as set forth above with respect to FIG. 23.  
     [0105]FIGS. 25 and 26 illustrate paint brush forming system  1410  for forming brush  1110 . System  1410  generally includes mold  1414  having halves  1418 ,  1419  which join together to form plug cavity  1421  and handle cavity  1423 . Upon separation from one another, halves  1418  and  1419  release a completed brush. As shown by FIG. 25, each half  1418 ,  1419  includes a plug forming portion  1426  and a handle forming portion  1428 . Plug forming portion  1426  and handle forming portion  1428  are integrally formed as a single integral mold half. Mold  1414  further includes at least one injection port communicating with both cavities  421 ,  423 . In the exemplary embodiment, plug forming portion  1426  includes injection port  1430  and handle forming portion  1428  includes injection port  1432  through which material is injected into mold  1414 . Alternatively, mold  1414  may be provided with a single injection port for injecting material into both of cavities  1421  and  1423 .  
     [0106] To form brush  1110 , bristle filaments  1024  are clustered with interleaved spacers  1025 . Halves  1418  and  1419  are then converged together so as to position plug forming portion  26  of each of halves  1418 ,  1419  adjacent to and partially about bristle filaments  1024  and spacers  1025 . Plug forming material is then injected through port  1430 . The plug forming material bonds bristle filaments  1024  and spacers  1025  together and forms body  1028  of plug  1016 . Once the plug forming material has sufficiently solidified, mold halves  1418 ,  1419  are repositioned as shown in FIG. 26 to position handle forming portions  1428  opposite to the formed plug  1016 . Such repositioning can be achieved by either linearly moving mold halves  1418 ,  1419  downward in the direction indicated by arrows  1436  or by first withdrawing mold halves  1418 ,  1419  away from plug  1016 , lowering halves  1418 ,  1419  in the direction indicated by arrows  1436  and then once again bringing halves  1418 ,  1419  together about plug  1016 . Once positioned as shown in FIG. 26, handle forming material is injected through port  1432  to form handle  1112 . As will be appreciated, in lieu of handle  1112  being solid as shown in FIG. 26, handle  1112  may alternatively include an insert such as  1015  which has different characteristics than the handle forming material. As discussed above, the plug forming material preferably comprises a material compatible with material forming bristle filaments  1024  to form an adequate bond with filaments  1024 . The plug forming material is also preferably compatible with the handle forming material. In the exemplary embodiment, the plug forming material comprises polypropylene with a tie-layer such as BYNEL manufactured and sold by DuPont. In such a case, the handle forming material comprises polypropylene. In alternative embodiments, the plug forming material may comprise polyethyleneterathalate (PETA), polypropylene or other polymeric materials which are resistant to paint solvents. The handle forming material may comprise similar materials.  
     [0107] In lieu of plug forming portion  1426  being integrally formed with handle forming portion  1428 , plug forming portion  1426  may alternatively comprise a distinct member moveable relative to handle forming portion  1428  such that only plug forming portion  1426  of halves  1418 ,  1419  is moved in the direction indicated by arrows  1436  after plug  1016  has been formed. In such an alternative embodiment, plug forming portions  1426  are positioned within the lower ends of handle forming portions  1428  during the formation of plug  1016  as described above. Once plug  1016  has been completed, plug forming portions  1426  are lowered to a point just below the lower ends of handle forming portions  1428 . Thereafter, the handle forming material is injected into cavity  1423  to form handle  1112 . A schematic illustration of this alternative brush forming system  1510  is illustrated in FIGS. 27 and 28.  
     [0108]FIGS. 29 and 30 illustrate brush forming system  1610  for forming brush  1110 . Brush forming system  1610  is similar to brush forming system  1510  except that brush forming system  1610  includes plug forming portions  1626  in lieu of plug forming portions  1426 . Plug forming portions  1626  are substantially identical to plug forming portions  1426  except that plug forming portions  1626  pivot about axes  1640  between a plug forming position shown in FIG. 29 and a handle forming position shown in FIG. 30. In the plug forming position, plug forming portions  1626  extend in close contact with filaments  1024  and spacers  1025 . As shown in FIG. 28, in the plug forming position, plug forming portions  1626  define cavity  1621  such that cavity  1621  is radially inset relative to cavity  1623  formed by handle forming portions  1628  of mold halves  1418 ,  1419 . When plug forming portions  1426  are in the plug forming position shown in FIG. 28, plug material is injected into cavity  1621  through port  1630  to form plug  1016 .  
     [0109] Once the plug forming material has sufficiently solidified to complete the formation of plug  1016 , plug forming portions  1626  are pivoted away from one another about axes  1640  as shown in FIG. 30 to the handle forming position. Thereafter, handle forming material is injected through port  1632  into cavity  1623  and into the space between plug forming portions  1626  and plug  1016  to form handle  1112 . As will be appreciated, in lieu of plug forming material and the handle forming material being injected through separate ports, such materials may alternatively be injected into the mold through a single port in each of systems  1410 ,  1510  and  1610 . Overall, each of systems  1410 ,  1510  and  1610  enable brush  1110  to be easily manufactured in a continuous fashion.  
     V. Ferrule-bristle Subassembly, Handle-bristle Assembly and Methods of Manufacture  
     [0110]FIGS. 31 and 32 illustrate a method for manufacturing ferrule-bristle subassembly  1717 . Subassembly  1717  generally includes ferrule  1716 , bristle filaments  1024  and spacers  1725 . Ferrule  1716  is substantially identical to ferrule  116  shown in FIGS. 4 and 5 such that ferrule  1716  may be positioned within an interior cavity of a brush handle. Alternatively, ferrule  1716  may be configured similar to ferrule  16 , wherein ferrule  1716  is configured to be positioned over an axial end of a brush handle. Ferrule  1716  is preferably formed from a plastic. Alternatively, ferrule  1716  may be formed from a metal.  
     [0111] Spacers  1725 , like spacers  1025 , are interleaved or positioned between bristle filaments  1024  proximate an axial end of ferrule  1716 . Spacers  1725  are at least partially formed from a thermoplastic material. Preferably, the thermoplastic material forming spacers  1725  is sufficiently compatible with material forming filaments  1024  to form a reliable bond therebetween. The material of spacers  1725  may comprise a thermoplastic foam material, such as polypropylene foam, which upon melting solidifies and bonds to filaments  1024 .  
     [0112] As shown in FIG. 31, subassembly  1717  is formed by first positioning filaments  1024  and spacers  1725  within an axial end of ferrule  1716 . This can be achieved by first pulling filaments  1024  through ferrule  1716 , inserting spacers  1725  and pulling filaments  1024  and the interleaved spacers  1725  back through ferrule  1716  such that spacers  1725  wedge filaments  1024  against ferrule  1716 . As shown in FIG. 31, spacers  1725  each include a wedge portion  1727  which extends between filaments  1024  and a melting portion  1729  which extends above and beyond filaments  1024 . In the exemplary embodiment, portions  1727  and  1729  are integrally formed as a single unitary body of the same material. Alternatively, portions  1727  and  1729  may be formed from different materials wherein portion  1729  is made of a thermoplastic material and wherein portion  1727  provides the optimal wedging of filaments  1024  against ferrule  1716 . As shown by FIG. 32, melting portions  1729  are then heated such that portions  1729  melt to at least a partially liquid state so as to penetrate and bond to filaments  1024  and to also bond to interior surfaces of ferrule  1716 . In the exemplary embodiment, interior surface of ferrule  1716  includes detents or grooves  1731  and  1733  into which the fluid material flows and forms a mechanical interlock with ferrule  1716  upon solidifying. The resulting subassembly eliminates the need for an additional epoxy or other adhesive to bond the filaments and the spacers together and to the ferrule. Moreover, the resulting subassembly  1717  produces a stronger bond between the spacers and the ferrule since the spacers themselves serve as the adhesive. As a result, subassembly  1717  is easier to manufacture at a lower cost.  
     [0113] In an alternative embodiment, filaments  1024  and spacers  1725  are directly inserted into an internal cavity formed within an axial end of a brush handle to form a handle-bristle assembly, whereby melting portion  1729  of the spacers is heated to bond the filaments together and to also bond to the interior surfaces of the paint brush handle. Heating of melting portions  1729  may be achieved using flame heating, laser heating, infrared heating, hot air heating or hot iron heating.  
     [0114]FIGS. 33 and 34 illustrate a method for manufacturing subassembly  1817 . Subassembly  1817  generally includes ferrule  1716 , filaments  1824  and spacers  1025 . Ferrule  1716  and spacers  1025  are described above. Bristle filaments  1824  are generally formed from a thermoplastic material and include paint carrying portion  1827  and melting portion  1829  extending above and beyond spacers  1025 . In the exemplary embodiment, portions  1827  and  1829  are formed from the same material such as nylon, polyester, polyolefin or a blend thereof. Alternatively, paint carrying portion  1827  and melting portion  1829  may be formed from different blends of materials wherein only melting portion  1829  is required to be formed from a thermoplastic material.  
     [0115] As best shown by FIG. 33, subassembly  1817  is constructed by positioning filaments  1824  and spacers  1025  within ferrule  1716  such that melting portions  1829  extend above and beyond spacers  1025 . According to an exemplary method, filaments  1824  are pulled through ferrule  1716 , spacers  1025  are inserted or interleaved between and among filaments  1824 , and filaments  1824  are pulled back through ferrule  1716  until spacers  1025  wedge filaments  1824  against ferrule  1716  with melting portions  1829  of filaments  1824  extending above spacers  1025 . As shown in FIG. 34, melting portions  1829  of filaments  1824  are then heated to a temperature above the melting point of melting portions  1829  such that melting portions  1829  of filaments  1824  melt at least partially about spacers  1025  to join filaments  1824  to spacers  1825  and to further join both filaments  1824  and spacers  1025  to ferrule  1716 . According to a preferred method, the melted material of melting portions  1829  of filaments  1824  flows into and against locking surfaces  1731  and  1733  of ferrule  1716  to mechanically interlock with ferrule  1716 .  
     [0116] Moreover, in lieu of bristles  1824  and spacers  1025  being bonded to ferrule  1716  which is then secured to a brush handle, filaments  1824  and spacers  1025  may alternatively be directly inserted into an interior cavity of a brush handle having an interior surface similar to ferrule  1716 , wherein the axial ends of the filaments  1824  are melted to bond to spacers  1025  and to further secure filaments  1824  and spacers  1025  to the brush handle to form a handle-bristle assembly. According to yet another alternative embodiment, both the bristle filaments and spacers include a thermoplastic melting portion, such that upon being heated, melt and fuse together to join the filaments and the spacers and to secure the spacers and the filaments to a ferrule such as ferrule  1716 . In such an alternative embodiment where both the brush filaments and the spacers have at least a thermoplastic portion which is melted, the filaments and spacers may be directly inserted into an interior cavity of a brush handle and then melted while positioned within the interior cavity to form a bond between the filaments and the spacers and to also form a bond to the interior surface of the brush handle cavity.  
     VI. Paint Brush Forming System with Break-away Ferrule  
     [0117]FIG. 35 illustrates paint brush forming system  1910  for forming paint brushes  1950 ,  1952 . Paint brushes  1950  and  1952  include handles  1953 ,  1954  and ferrule-bristle subassemblies  1955 ,  1956 , respectively. Handles  1953 ,  1954 , portions of which are shown in section for purposes of illustration, are substantially identical to one another and include shank portions  1958 ,  1960  and head portions  1962 ,  1964 , respectively. Shank portions  1958 ,  1960  are substantially identical to one another. Head portion  1962  has a general length L 1  longer than the length L 2  of head portion  1964 . Ferrule-bristle subassemblies  1955 ,  1956  are identical to one another prior to assembly of paint brushes  1950  and  1952 . In particular, each of subassemblies  1955 ,  1956  includes bristle filaments  1024  and spacers  1025  (not shown) which are positioned within and secured to ferrule  1916 . Filaments  1024  and spacers  1025  may be secured to ferrule  1916  by epoxy or by either of the methods disclosed with respect to FIGS.  31 - 34 . Ferrule  1916  receives bristles  1024  and spacers  1025  and is configured to be inserted into interior cavity  1970  of head portion  1962  of brush  1950 . Ferrule  1916  preferably includes outwardly extending ribs  1920  which correspond to grooves  1922  formed on an inner surface of head portion  1962  of brush  1950 . During assembly of brush  1950 , ferrule  1916  is inserted into cavity  1970  such that ribs  1920  project into grooves  1922  to mechanically lock ferrule  1916  to head portion  1962  of brush handle  1953 .  
     [0118] Ferrule  1916  also includes an internal groove  1930  preferably extending between ribs  1920 . Groove  1930  sufficiently penetrates the walls of ferrule  1916  so as to serve as a break line allowing ferrule  1916  to be broken along groove  1930 . As a result, portion  1932  of ferrule  1916  may be discarded leaving portion  1934  sized for being completely received within cavity  1972  of head portion  1964  of brush handle  1954 . Although ferrule  1916  is illustrated as including a single break line or groove  1930 , ferrule  1916  may be provided with a plurality of such grooves enabling ferrule  1916  and the bristles  1024  it carries to be easily adapted and modified for use with a multitude of different brush handles having differently sized head portions to form a multitude of differently sized paint brushes. Break line or groove  1930  may alternatively be external or partially internal and partially external. Break line or groove  1930  enables differently sized brushes to be quickly and easily manufactured and assembled without requiring a specially sized ferrule for each differently sized brush handle.  
     [0119] FIGS.  1 - 35  illustrate multiple paint brushes and multiple methods for manufacturing such paint brushes. Although such methods and such paint brushes are illustrated and discussed with respect to the particular exemplary embodiments chosen, it is also contemplated that the disclosed paint brushes may be formed by other methods described above with respect to other paint brush embodiments. For example, although plug  1016  is illustrated in FIGS.  19 - 21  as being provided with handle  1112 , plug  1016  may alternatively be utilized with handle  12  illustrated in FIG. 1. Furthermore, the above disclosed manufacturing methods may be combined or particular manufacturing steps may be rearranged or replaced by other manufacturing procedures described above to vary the resulting paint brush being formed.