Patent ID: 7565729

Claim:
A method of manufacturing a brush seal comprising: a) winding a wire about a subassembly including first and second form plates in back-to-back relation to one another to form first and second spaced runs of wire along opposite sides of the subassembly and about first and second opposite edges of the form plates; b) securing first and second elongated elements to and on opposite sides of the subassembly adjacent the first form plate edges with the first and second elements overlying portions of the first and second wire runs respectively; c) removing portions of the wound wire overlying the first edges of the form plates leaving portions of the wire runs extending respectively between the first and second elements on said opposite sides of the subassembly and wire portions about the second edges of the form plates; d) securing the first run portion, the first element and the first form plate to one another; e) securing the second run portion, the second element and the second form plate to one another; f) removing (i) remaining portions of the wire extending about the second edges of the form plates and (ii) portions of said form plates adjacent the second edges thereof leaving the first and second wire run portions cantilevered from the form plates and elements; and g) separating the first and second form plates from one another to form a pair of brush seal segments.