Patent Abstract:
Golf turf is disclosed and claimed herein which simulates fairway, rough or putting green surfaces. Golf clubs which strike the golf turf disclosed herein do not experience the shock of typical golf mats made from Astroturf® and the like, lessening fatigue and preventing injury to the elbow and wrist. Crimped filaments made of synthetic resinous fibers are used to make strip brushes having flared end portions which form a homogeneous surface. Receiving slots in a substrate retain a plurality of strip brushes spaced apart and parallel to each other. The strip brushes are configured to simulate homogeneous surfaces which approximate actual golf surfaces. Alternatively, the brushes may be inserted into a liquified plastic substrate and then the substrate is allowed to cool securing the brushes within the substrate. Still alternatively, the brushes may welded and then inserted into the liquified plastic substrate which is then allowed to cool securing the brushes within the substrate.

Full Description:
[0001]    This application is a continuation-in-part of patent application Ser. No. 10/324,835 filed Dec. 20, 2002. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention is in the field of artificial golf surfaces otherwise known as artificial golf turf.  
         BACKGROUND OF THE INVENTION  
         [0003]    It is desired to have an artificial golf surface which simulates actual golf course turf. Golf has become a popular sport which is played in all 12 months of the year in some locations. In northern climates it is necessary to practice golf indoors for obvious reasons. It is desirable, therefore, to play indoors with conditions which simulate actual golf.  
           [0004]    Further, for outdoor golf practice ranges with heavy traffic it is difficult to keep the grass in good shape. Too many players taking too many divots results in practice ranges with little or no turf left. It is, therefore, desirable to practice golf on artificial golf turf surfaces at practice ranges or warm-up areas which are outdoors. It is desirable, therefore, to have artificial golf turf outdoors for practice ranges or warm-up areas which emulates actual golf surfaces, namely, fairway surfaces, rough surfaces, putting surfaces and tees.  
           [0005]    When playing golf on an outdoor course, natural grass and grass roots and dirt beneath the roots succumb to the force of a golf club and a divot is taken. A divot is the grass and root system of the grass which is sliced away or cutaway by a golf “iron.” When using an iron a divot is sometimes intentionally taken so as to impart a certain spin on the golf ball which will affect its flight and/or its response when it comes down to the golf course.  
           [0006]    The difference between a properly hit iron shot and a poorly hit iron shot is sometimes expressed by whether or not the golf ball is hit first and then a divot is taken beneath the ball and/or beneath the grass immediately in front of the golf ball. If the divot is taken too far behind the golf ball then the shot will be a poor one and the shot is said to have been hit “fat.” 
           [0007]    When a player hits behind the golf ball it is known as hitting the ball “fat.” When a golf ball is hit fat it usually doesn&#39;t go too far because the golf club first contacts the grass too far behind the golf ball followed by the roots of the grass and dirt and/or whatever material lies beneath the grass at that particular point on the course or practice range. A fat golf shot can sometimes result in the grass being compressed between the golf club and the golf ball.  
           [0008]    In any event it is quite common to hit down into the ball properly and/or to hit the ball fat. Missing a ball by striking it too high on the ball results in the ball being driven down into the grass and the material beneath the grass. This is known as topping the golf ball. Actual golf surfaces such as the fairway or rough are grass surfaces with material underneath which provide some relief or cushion when a ball is driven into it.  
           [0009]    There is a need for an artificial golf surface which approximates the actual conditions of golf, namely, a grass like surface which has the ability to cushion a golf club which necessarily must engage the surface. There is a need for artificial golf turf which approximates actual golf turf. It is necessary for golfers to hit down into a golf ball and into the turf in proximity to the golf ball.  
           [0010]    In certain circumstances a golfer may desire to “pick” the golf ball from the playing turf so as to generate a particular flight or action on the golf ball. By “pick” it is meant that the club does not hit the grass beneath the ball or that the club does not hit much into the grass. For instance, shots employing woods or long irons may require that the golfer pick them from the turf.  
           [0011]    Therefore, it is desirable that the golf ball be supported by the artificial golf turf so that it may be “picked” from the surface with the appropriate golf club or with the appropriate technique of the golfer. It is desirable that artificial golf turf be capable of allowing the golfer to make the kind of shot that s/he wishes and to approximate the look and feel of real golf turf.  
           [0012]    Related Art patents are now discussed. U.S. Pat. No. 6,155,931 to Perrine issued Dec. 5, 2000 discloses a golf swing practice mat for placement on an underlying base to aid a golfer in improving the golfer&#39;s swing. The golf swing practice mat comprises a low friction, flexible and resilient top sheet that is contacted by the golf club. The top sheet has a rigidity of 40 pounds per square inch or less and has an underlying supporting pad for supporting the top sheet and for providing space for the top sheet to move under force of the club. The support pad is compressible to 50% of its resting height in any area near its center line by an applied pressure of 8 psi or less. A bottom sheet is used underneath the support pad.  
           [0013]    U.S. Pat. No. 6,139,443 to Reynolds issued Oct. 31, 2000 and discloses a turf-simulating surface. The device is made of components which simulate the layers of natural soil according to the patent. One component is a composite mat having an integral pile section having tufted strands that simulate grass and a plastic foam layer. A lateral-strength fabric is used with the pile section which has loops which interact with the lateral-strength fabric. The plastic foam layer is bonded to the lateral-strength fabric and the looped regions of the pile section. A rimmed base is integrally formed around a composite core.  
           [0014]    U.S. Pat. No. 5,885,168 to Bair issued Mar. 23, 1999 and discloses mats which are plastic brush mats with plastic tufts embedded in a plastic base. The mats have regions or panels of different pile depth and density for simulating different types of playing surfaces.  
           [0015]    A better understanding of the invention will be had when reference is made to the Summary of the Invention, Brief Description of the Drawings, Description of the Invention and Claims which follow hereinbelow.  
         SUMMARY OF THE INVENTION  
         [0016]    Golf turf comprising a substrate and a plurality of brush elements retained by said substrate is disclosed and claimed. Each of the brush elements are spaced apart from one another and oriented parallel to each other. Each of the brush elements include filaments, a metal housing and wire for retaining said filaments. The filaments extend outside the metal housings and they flare as they extend outside the metal housing. Preferably the filaments are crimped which increases the degree of the flare.  
           [0017]    The filaments of each brush interengage the filaments of the adjacent brush. Each of the filaments has a diameter in the range of 0.006 to 0.020 inches. Preferably the filaments are 0.006 inches in diameter and are crimped in a general sinusoid having a frequency of 3 cycles per inch. Alternatively, the filaments may be crimped in a general sinusoid having a frequency considerably higher than 3 cycles per inch. Further, it is specifically contemplated by this invention that crimping patterns other sinusoids may be employed.  
           [0018]    A process for making golf turf comprising the steps of: forming brush strips from crimped filaments; inserting the brush strips in a substrate; and, locking the brush strips in the substrate is disclosed and claimed. The step of forming the brush strip includes the steps of laying a flat piece of metal on a surface; placing synthetic resinous filaments on the flat piece of metal; placing a wire on top of the filaments; and, deforming the flat piece of metal into a housing so as to entrap the filaments and wire within the housing.  
           [0019]    Preferably the brush strips are mounted in a relatively heavy substrate which can be made of plastic or some metal which has been treated so as to not corrode. The brush strips are preferably oriented parallel to one another although other arrangements are specifically contemplated by this disclosure. The spacing between the parallel brush strips is important because the strips support each other when deformed under the influence of a golf club. Further proper spacing between the parallel strips is important because the crimped filaments of the brush strips flare as a function of the filament used together with the amount of compression applied by the metal housing of the brush strip. Still further the spacing of the brush strips is important as drainage of water is permitted on the lands of the substrate between the parallel brush strips.  
           [0020]    Golf clubs which strike the golf turf disclosed herein do not experience the shock of typical golf mats made from Astroturf® and the like, lessening fatigue and preventing injury to the elbow and wrist. Southwest Recreational Industries, Inc. 701 Leander Drive Leander, Tex. is the owner of the trademark registration Astroturf®.  
           [0021]    It is an object of the present invention to provide an artificial golf turf which simulates actual golf turf.  
           [0022]    It is an object of the present invention to provide an artificial golf turf which enables the golfer to use an iron which deforms the turf and provides a cushioning effect when the golf club passes through the turf.  
           [0023]    It is an object of the present invention to provide an artificial golf turf which is resilient and does not permanently deform.  
           [0024]    It is an object of the present invention to provide an artificial golf turf which gives the appearance and feel of actual golf turf.  
           [0025]    It is an object of the present invention to provide an artificial golf turf which has a homogeneous surface.  
           [0026]    It is an object of the present invention to provide an artificial golf turf which is durable and long-lasting.  
           [0027]    It is an object of the present invention to provide artificial golf turf which is formed by rows of brush elements placed into a liquified plastic substrate which is allowed to cool securing the brush elements to the substrate. Alternatively, a portion of the brushes may be welded together such that the welded portion of the brushes is then placed into a liquified plastic substrate which is allowed to cool securing the brush elements to the substrate.  
           [0028]    Further objects of the present invention will be understood when reference is made to the Brief Description of the Drawings, Description of the Invention and Claims which follow hereinbelow. 
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0029]    [0029]FIG. 1 is an enlarged schematic top view of one of the brush elements.  
         [0030]    [0030]FIG. 1A is enlarged portion of FIG. 1.  
         [0031]    [0031]FIG. 2 is an enlarged schematic front view of the brush element of FIG. 1 illustrating a portion of the crimped filaments of the brush.  
         [0032]    [0032]FIG. 3 is a schematic end view of the end of the brush element of FIG. 1 illustrating a portion of the crimped filaments of the brush.  
         [0033]    [0033]FIG. 4A is a schematic front view of a stack of straight filaments.  
         [0034]    [0034]FIG. 4B is a schematic end view of a brush element having straight filaments in a substrate.  
         [0035]    [0035]FIG. 4C is a schematic front view of a stack of crimped filaments.  
         [0036]    [0036]FIG. 4D is a schematic end view of a brush element having crimped filaments.  
         [0037]    [0037]FIG. 4E is a schematic end view of two brush elements having straight filaments.  
         [0038]    [0038]FIG. 5 is a top view of the substrate in which a plurality of brush elements reside.  
         [0039]    [0039]FIG. 5A is a front view of the substrate of FIG. 5.  
         [0040]    [0040]FIG. 5B is an end view of the substrate of FIG. 5.  
         [0041]    [0041]FIG. 5C is an end view of an end latch.  
         [0042]    [0042]FIG. 5D is a front view of the substrate of FIG. 5 with the end latch.  
         [0043]    [0043]FIG. 5E is a cross-sectional view of FIG. 5 taken along the lines  5 E- 5 E.  
         [0044]    [0044]FIG. 5F is a top view of the substrate similar to FIG. 5 except having closed slots in which a plurality of brush elements reside.  
         [0045]    [0045]FIG. 5G is a front view of the substrate of FIG. 5 illustrating the end latches, a brush element and tee.  
         [0046]    [0046]FIG. 5H is a front view of the substrate similar to that of FIG. 5G with a taller brush element illustrated.  
         [0047]    [0047]FIG. 6 is a schematic view of a stack of crimped filaments resting on a metal housing and a wire placed on the stack of crimped filaments prior to bending and deforming the metal housing.  
         [0048]    [0048]FIG. 7 is a schematic cross-sectional view of the crimped filaments together with the deformed metal housing and wire of FIG. 6.  
         [0049]    [0049]FIG. 8 is a schematic top view of the substrate together with the brush elements in place.  
         [0050]    [0050]FIG. 9A is a cross-sectional view taken along the lines  9 A- 9 A of FIG. 8 illustrating the brush elements forming a homogeneous surface.  
         [0051]    [0051]FIG. 9B is a cross-sectional view similar to FIG. 9A with a tee extending beneath the substrate.  
         [0052]    [0052]FIG. 9C is a cross-sectional view similar to FIG. 9A illustrating a tee without a bushing in the substrate.  
         [0053]    [0053]FIG. 9D is a cross-sectional view similar to FIG. 9B illustrating a tee without a bushing.  
         [0054]    [0054]FIG. 10 is a cross-sectional view of another embodiment illustrating the brush elements directly secured into a plastic substrate.  
         [0055]    [0055]FIG. 11 is a cross-sectional view of another embodiment illustrating brush elements fused (welded) together.  
         [0056]    [0056]FIG. 11A is a cross-sectional view of another embodiment illustrating the brush elements of FIG. 11 fused in the substrate. 
     
    
       [0057]    The drawings will be best understood when reference is made to the following Description of the Invention and Claims which follow hereinbelow.  
       DESCRIPTION OF THE INVENTION  
       [0058]    [0058]FIG. 1 is an enlarged schematic top view of one of the brush elements  100 . Individual crimped filaments  101  are illustrated schematically in FIG. 1. In reality a top view of a brush element is opaque because the individual filaments are spaced very closely together and form a homogeneous surface which resembles grass when the filaments are colored green. See FIG. 5G, a front view  500 G of the substrate of FIG. 5 illustrating the end latches  516 , a brush element  100  which is illustrated as solid black and a tee  902 . FIG. 1A is enlarged portion  100 A of FIG. 1 illustrating individual filaments  101 .  
         [0059]    [0059]FIG. 2 is an enlarged schematic front view  200  of the brush element  100  of FIG. 1 illustrating a portion of the crimped filaments  101  of the brush. Metal brush housing  201  is a non-corrosive deformable metal which secures as will be explained hereinbelow the individual crimped filaments  101  of the brush elements  100 . At the ends of the brush element or strip  100 , crimped elements  204  show the periodicity of the crimped filaments. Metal housing  201  includes deformed end portions  202 ,  203 . Preferably the brush elements  100  are approximately two (2) feet long but other lengths are specifically contemplated by the disclosure herein. Those skilled in the art will readily recognize that different lengths may be employed such that artificial surfaces 10 feet long or longer may be constructed. Further, since the structure described herein provides a homogeneous artificial turf surface, sections thereof may be employed so that the extent of the artificial surface is virtually unlimited. It is necessary to understand in connection with FIG. 2 that it is a schematic only for describing the invention such that it will be understood. The nature of the crimped filaments is represented by reference numeral  204 . In reality, a side view of a brush element and filaments thereof would be opaque as viewed in FIG. 5G.  
         [0060]    [0060]FIG. 3 is a schematic end view  300  of the end of the brush element  100  of FIG. 1 illustrating a portion of the crimped filaments of the brush. By portion it is meant that the crimped nature of the individual filaments  101  is illustrated otherwise the end view of the brush element would be opaque because the crimped filaments  101  are spaced very closely together. A slight opening or crack  301  is illustrated in FIG. 3 which is a result of the forming process for metal housing  201 .  
         [0061]    The crimped filaments  101  are a synthetic resinous material such as nylon or polyester and are available from Specialty Filaments, Inc. located in Vermont. Preferably, the diameter of the crimped filaments are 0.006 inches and are nominally crimped with a frequency of 3 cycles per inch or 3 waves per inch. The amplitude of the crimped filaments  101  may be nominally 0.012 inches. Different filaments having different amplitudes may be used. Different diameter filaments may be used in the range of 0.006 inches to 0.020 inches. As the diameter of the filament increases the amplitude of the waves also increases for a given crimp frequency. The disclosure set forth herein is given by way of example only and those skilled in the art will readily recognize that different crimped filaments may be used having different features (including different diameters, amplitudes and crimped frequencies) without departing from the spirit and scope of the appended claims.  
         [0062]    [0062]FIG. 4A is a schematic front view  400 A of a stack of straight filaments  401 . Although straight filaments may be used they do not provide as much flare as crimped filaments provide as will be discussed hereinbelow. A stack of straight filaments renders a height as represented by reference numeral  408 . The straight filaments  401  will compact together well because of their uniformity. It is this uniformity, however, which reduces the flare  410  in FIG. 4B which is a schematic end view  400 B of a brush element having straight filaments  401  in a substrate  402 . Again, as with the other drawing figures, FIGS. 4A and 4B illustrate only a portion of the filaments so as to depict their relationship to each other and their nature. Reference numeral  403  illustrates the channel in the substrate  402  and reference numeral  404  represents the engagement of the metal housing of the brush element with the channel  403  in the substrate  402 .  
         [0063]    [0063]FIG. 4C is a schematic front view  400 C of a stack of crimped filaments  405 / 406 . These filaments are arranged like crooked logs such that for the same number of straight filaments a larger height  409  is realized. Using crimped filaments results in a larger flare  411  as illustrated in FIG. 4D which is a schematic end view of a brush element having crimped fibers.  
         [0064]    The amount of crimping pressure on housing  201  will influence the flare  411  of the crimped filaments as illustrated in FIG. 4D. The larger the crimping pressure the larger the flare within the limits as dictated by spatial restraints of the filaments. The filaments cannot be over stressed during crimping to form the metal housing  201  or the filaments will be broken. Again, drawing FIGS. 4C and 4D are schematics so as to depict the interrelationship of the filaments as discussed above in connection with the other drawing figures.  
         [0065]    [0065]FIG. 4E is a schematic end view  400 E of two brush elements having straight filaments arranged side by side in a substrate. Although not preferred because of their limited ability to flare, straight filaments are specifically contemplated by the disclosure and claims herein.  
         [0066]    [0066]FIG. 5 is a top view  500  of the substrate  510  in which a plurality of brush elements reside. FIG. 5 illustrates just the substrate  510  and not the brush elements in the substrate  510 . Slots  501  engage the metal housings  201  as illustrated in FIG. 9A and secures them in place so that they may not be extracted therefrom. Although a plurality of slots  501  are used in the substrate  510  it is specifically contemplated by this invention that other ways of securing the strip brushes or elements  100  to a substrate of sufficient mass be used. For instance, the brush elements might be tack welded or secured with adhesive to the substrate.  
         [0067]    Referring to FIG. 5, reference numeral  508  represents lands or raised flat spaces which reside between slots  501 . Ends  505  and  506  of the substrate  510  have flat portions  502  proximate ends  505  and  506  of substrate  500 . Lands  503  are raised for guiding end latches  516  as can be best viewed in FIG. 5B, an end view of the substrate of FIG. 5. Flat portions  504  proximate lands  508  guide end latch  516  as can be viewed in FIG. 5A. Bushing  507  for holding or assisting in holding a tee is also illustrated in FIG. 5.  
         [0068]    [0068]FIG. 5A is a front view  500 A of the substrate of FIG. 5 and illustrates the ends  505 ,  506  of the substrate together with knobs  512 ,  513  on lands  503 . Also illustrated in FIG. 5A are the guiding surfaces  502  and  504  for the end latches  516 . FIG. 5B is an end view  500 B of one end  505  of the substrate  510  of FIG. 5 illustrating slots  501 , lands  508  intermediate slots  501 , end guide  502  and guide lands  503 .  
         [0069]    [0069]FIG. 5C is an end view  500 C of an end latch  516  illustrating legs  517  and  518  which interengage reciprocal knobs or protrusions  512 ,  513  of the substrate  510 . FIG. 5D is a front view  500 D of the substrate of FIG. 5 with the end latches  516  secured to each end  505 ,  506  of the substrate  510 . End latches when secured in place as illustrated in FIG. 5G prevent the brush elements from being extracted from the substrate  510 .  
         [0070]    [0070]FIG. 5E is a cross-sectional view  500  E of FIG. 5 taken along the lines  5 E- 5 E which illustrates slots  501  having lips  530  which prevent the metal housings of the brush elements from escaping out of the top of the slots. Also shown in FIG. 5E are the lands  508  intermediate the brush elements and the bushing  507  having top circumferential end portion  511 .  
         [0071]    [0071]FIG. 5F is a top view  500 F of the substrate  510  similar to FIG. 5 except having closed slots  501  at one end thereof in which a plurality of brush elements reside. FIG. 5G is a front view  500 G of the substrate of FIG. 5 illustrating the end latches  516 , a brush element  100  and tee  902 . FIG. 5H is a front view  500  H of the substrate similar to that of FIG. 5G will a taller brush element illustrated. The brush elements are comprised of filaments as set forth above. The characteristics of the filaments are selected so as to emulate actual turf. For instance, a stiffer and shorter filament may be used to emulate a putting surface because putting surfaces usually have grass which is mown to a very short height. Longer and thicker filaments may be used to emulate the rough on a golf course.  
         [0072]    Fairway turf is emulated by the brush elements  100  depicted herein which have a height of approximately 0.75 inches above the surface of the substrate  510 . Rows of brush elements are arranged in parallel in slots that are approximately 0.50 inches from center of the slot to the center of the slot  
         [0073]    [0073]FIG. 6 is a schematic view  600  of a stack of crimped filaments  405 ,  406  resting on a metal housing  201  and a wire  601  placed on the stack of crimped filaments prior to bending and deforming the metal housing  201 . It will be understood by those skilled in the art that the wire  601  runs the length of the brush element as illustrated in FIG. 7. FIG. 7 is a schematic cross-sectional view  700  of the crimped filaments  101  together with the deformed metal housing  201  and wire  601  of FIG. 6.  
         [0074]    [0074]FIG. 8 is a schematic top view  800  of the substrate  510  together with a plurality of brush elements  100  secured thereto. Surface  801  is a homogeneous surface as the filaments  1   0   1  of one brush element  100  mesh with the filaments  10   1  of the adjacent brush element  100 . Latch  516  is also depicted at one end of the substrate for securing the brush elements in place. The brush elements may be removed and replaced by simply removing the latch  516 . Other forms of securement may be used, for instance, a rod may be used to secure the metal housings to the substrate by drilling a hole through the substrate and metal housings in the middle of the substrate.  
         [0075]    Ths substrate as depicted in FIG. 8 may be in any practical dimension. Groups of substrates may be linked together to form a putting surface or a large fairway surface.  
         [0076]    [0076]FIG. 9A is a cross-sectional view  900 A taken along the lines  9 A- 9 A of FIG. 8 illustrating the brush elements  100  forming a homogeneous surface  801 . Lands  508  between the slots  501  are clearly shown. Spaces  901 , which are approximately triangular, exist between the brush elements and permit the temporary deformation of one brush element or a group of brush elements when struck by a golf club head. As illustrated in FIG. 9A, the brush elements are approximately 0.50 inches from center line to center line apart and the filaments extend approximately 0.75 inches above lands  508 . The geometry of embodiment of FIG. 9A has been found to emulate fairway golf turf well and to provide a homogeneous surface  801  which does not permanently deform after repeated use. The geometry of the embodiment of FIG. 9A enable use with an iron and specifically enables the head of the golf club to penetrate the surface without shock to the user&#39;s hands, arms and body. Other geometric configurations may be used.  
         [0077]    Still referring to FIG. 9A, spaces  901  permit the flow of water along the lands  508  and out the ends  505 ,  506  of the substrate  510 . FIG. 9B is a cross-sectional view  900 B similar to FIG. 9A with a tee  902  extending beneath the substrate. The tee may assist in orienting the substrate and preventing it from slipping under the force of a swinging golf club head if a small substrate is being used. However, a plastic substrate which is two feet long, one foot wide, and 0.25 inches high together with the weight of 25 brush elements has been found to have enough inertia such that it will not move when struck by a golf club head.  
         [0078]    When using the device, the golf club head may penetrate the homogeneous surface formed by the brush elements without substantially uncovering the lands  508  due to the interaction of the filaments.  
         [0079]    [0079]FIG. 9C is a cross-sectional view  900 C similar to FIG. 9A illustrating a tee  902  without a bushing in the substrate. FIG. 9D is a cross-sectional view  900 D similar to FIG.  9 B illustrating a tee without a bushing.  
         [0080]    [0080]FIG. 10 is a cross-sectional view  1000  of another embodiment illustrating the brush elements  1003  directly secured into a plastic substrate  1002 . Reference numeral  1001  indicates the interface between the brush elements  1003  and the substrate  1002 . Interface  1001  is the point where the individual filaments are bonded (molded) to the substrate  1002 . As viewed in FIG. 10, rows of brush elements are inserted in the substrate while the substrate is in a liquified plastic state and the substrate is allowed to cool trapping the brush elements in the substrate thus producing a brush-filled substrate  1002  having a uniform surface  1004 . The substrate may be any polymeric substrate.  
         [0081]    The embodiments illustrated in FIGS.  10 - 11 A utilize periodically crimped brush elements as disclosed and described previously hereinabove.  
         [0082]    [0082]FIG. 11 is a cross-sectional view  1100  of another embodiment illustrating the bottom portion of the filaments  405 ,  406  of the brush elements fused (welded) together. In this embodiment, the bottom portion of the filaments  405 ,  406  of the brush elements are fused together by heat welding, ultrasonic welding, electromagnetic welding, microwave welding, or induction welding. Once fused (welded), rows of the partially welded (fused) brush elements are inserted in the substrate while it is in a liquified plastic state and the plastic is allowed to cool producing a brush-filled substrate having a uniform surface.  
         [0083]    [0083]FIG. 11A is a cross-sectional view  1100 A illustrating the partially fused filaments which comprise the brush elements of FIG. 11 fused in the substrate  1102 . With rows of fused brush elements running parallel to each other as, for example, illustrated in FIG. 9, a brush-filled substrate  1102  having a uniform surface  1004  is made and formed.  
         [0084]    The invention has been described with particularity by way of example as set forth above. Those skilled in the art will readily recognize that changes may be made to the invention as described herein without departing from the spirit and scope of the claims which follow herein below.

Technology Classification (CPC): 8