Patent ID: 8632074

Claim:
A method of forming a brush seal including: (a) forming a back plate of a single material having in general longitudinal alignment a first bristle anchor recess; a second reservoir recess and a land for clamping the bristles; (b) laying the back plate horizontally and laying a brush of bristles such that one end of the bristles overlies the anchor reservoir and the other extends beyond the land; (c) locating a mould of the anchor reservoir and filling the mould and the anchor reservoir with an epoxy resin capable of wicking between the bristles; (d) curing the epoxy resins and (e) attaching a front plate to the back plate to clamp the bristles against the land at a pinch line, wherein free movement of the bristles is prevented on a first side of the pinch line and free movement of the bristles is allowed on a second side of the pinch line, and wherein the dimensions of the second reservoir recess are such that the epoxy resin does not wick beyond the pinch line.