Device for Compacting Bristle Bundles, Bristle Product Production Machine, and Method for Compacting Bristle Bundles

This application is a 371 National Phase of PCT/EP2023/057788, filed Mar. 27, 2023, which claims priority from German Patent Application No. 10 2022 111 906.8, filed May 12, 2022, both of which are incorporated herein by reference as if fully set forth.

The invention relates to a device for compacting bristle bundles for the production of bristle products, to a bristle product production machine having such a device, and to a method for compacting bristle bundles.

Known from publication DE 100 05 249 A1 is a brush pro duction machine having a multiple infeed for strand-shaped bristle material, which has an advancing device for the bristle strands, and having a crosscutting apparatus for bristle bundles and an infeed apparatus for feeding the bristle bundles to an apparatus for connecting the bristle bundles to a brush body. The brush production machine is characterized in that the advancing apparatus is designed for a mutually independent, controllable advancement of the individual bristle strands, in that the infeed apparatus has a conveying means which is positionable in steps and has holes for bristle strands, or bristle bundles; in that infeeds for the bristle strands to a step position of one of the holes are in each case provided in the conveying means, and in that one or a plurality of trimming apparatuses, which interact with the conveying means, for crosscutting the bristle strands are disposed in the bristle strand infeeds.

For the production of bristle products, for example of brushes such as toothbrushes, bristle filaments are picked from a supply of loose bristle filaments in the form of bristle bundles by way of a preparation means, for example a bundle separator.

For this purpose, the preparation means used herein can have bundle notches by way of which the preparation means are guided past the supply of loose bristle filaments. In the process, a certain number of bristle filaments make their way into the bundle notches. The bristle filaments which are disposed in a bundle notch conjointly form a bristle bundle.

The bristle bundles are present in the bundle notches still not being shaped and compacted. The filament density of the bristle bundles located in the bundle notches is still comparatively minor, and the bristle bundles also still do not have the shape that they should have later on the finished bristle product. With a view to the use on the finished bristle product it is desirable to increase the filament density of the bristle bundles and optionally also to bring the bristle filaments into a specific shape.

The compacting and optionally also the shaping of bristle bundles is associated with a certain degree of complexity. For compacting, the bristle bundles in practice are pushed through ducts of so-called funnel plates, which narrow in the course of their profile, for example. The precise manufacturing to the funnel plates is comparatively expensive but decisive in order to achieve the desired degree of compaction. Depending on the desired degree of compaction, the compacting is optionally performed in a plurality of stages, in which instance a plurality of funnel plates disposed behind one another are accordingly required.

It is an object of the invention to provide a device for compacting bristle bundles, a bristle product production machine, and a method for compacting bristle bundles, which permit an efficient and economical compaction of bristle bundles for the production of bristle products.

In order to achieve this object, a device for compacting bristle bundles having one or more of the features disclosed herein directed toward a device of this type is first proposed. Thus, in order to achieve the object, a device for compacting bristle bundles, which has a preparation means, in particular a bundle separator, with bundle notches, a number of compaction receptacles for bristle bundles, corresponding at least to the number of bundle notches, and for each of its compaction receptacles in each case one compaction tool, is in particular proposed, wherein the compaction receptacles are specified to retrieve bristle bundles from the bundle notches of the preparation means, and the compaction tools are specified to compact bristle bundles positioned in the compaction receptacles.

Bristle bundles can be separated from a supply of loose bristle filaments by the preparation means and provided in a still non-compacted form. With the aid of the compaction receptacles of the device, the still non-compacted bristle bundles can in one operative step first be retrieved from the bundle notches of the preparation means, and subsequently with the aid of the compaction tool be compacted to a desired degree of compaction which the bristle bundles are to have later in a downstream operative step, and/or on the finished bristle products. A particularly efficient production of bristle products is enabled in this way.

In one embodiment of the device it is provided that the compaction receptacles of the device are formed in one retrieval plate, or in two or a plurality of retrieval plates, of the device.

The compaction tools by way of a relative movement of the compaction receptacles in relation to the compaction tools can be movable transversely to the direction of longitudinal extent of the compaction receptacles to a compacting position at or into the compaction receptacles. The relative movement of the compaction receptacles in relation to the compaction tools here can be carried out transversely, in particular orthogonally, to an orientation of bristle bundles defined by the alignment of the bundle notches of the preparation means and to the longitudinal axes of said bristle bundles in the bundle notches.

The compaction receptacles can in each case have one introduction opening by way of which bristle bundles and/or compaction tools are able to be introduced into the compaction receptacles. The introduction openings can in each case be aligned transversely or orthogonally to a longitudinal axis of the respective compaction receptacle, and/or transversely or orthogonally to a longitudinal axis of bristle bundles disposed in the compaction receptacles. In this way it is possible to first retrieve the bristle bundles from the bundle notches of the preparation means in a relative movement transverse or orthogonal to the longitudinal axis of said bristle bundles, and then to compact the latter in the same direction.

The compacting can be performed, for example, in that the compaction tools make their way into the compaction receptacles through the introduction opening of the compaction receptacles in a compacting movement which is aligned transversely or orthogonally to the orientation of the longitudinal axes of the bristle bundles disposed in the compaction receptacles, in which compaction receptacles said compaction tools impinge the bristle bundles located in the compaction receptacles in a compacting manner.

The introduction openings of the compaction receptacles can be delimited by introduction bevels. The introduction bevels enable a gentle introduction of the compaction tools into the compaction receptacles of the device, and can assist in avoiding damage to the compaction tools, and/or compaction receptacles.

It is to be pointed out here that the compaction receptacles either can be moved per se in order to reach a compacting position within the compaction receptacles, or else the compaction receptacles can be moved relative to the compaction tools in order to carry out the above-described relative movements of the compaction receptacles in relation to the compaction tools. It is also possible that the compaction receptacles as well as the compaction tools are moved in order to carry out the relative movements for compacting.

In order to prevent that bristle filaments make their way out of a compaction receptacle during compacting, it can be advantageous when at least one compaction tool has a sharp-edged transition between its flanks and its end side that faces the compaction receptacle to which the compaction tool is assigned. Owing to the sharp-edged transition between the flanks and the end side of the compaction tool, the compaction tool can be designed to rest on an internal wall of the compaction receptacle in a precise and tight fit. The sharp-edged transition between the flanks and the end side of the compaction tool can prevent that bristle filaments which are disposed in the compaction receptacle make their way out of the compaction receptacle and past the compaction tool when carrying out the previously explained relative movement for compacting the bristle bundles.

At least one compaction tool can be smoothened and/or hardened on at least one flank which is contiguous to the end side of the compaction tool that faces a compaction receptacle. The flank can have, for example, a surface roughness of Ra 0.01 to 1.6, preferably of Ra 0.01 to 0.04, and/or a hardness, in particular a case hardness with a depth of 1.2 to 1.8 Rht, of 55 to 63 HRC, preferably of 60 to 63 HRC.

The compaction tool can in each case have a cross section of which the measurable width is smaller than a width of a cross section, disposed in the same cross-sectional plane, of a cross section of the respective compaction receptacle assigned to said compaction tool. In this way, the compaction tool for compacting bristle bundles can be introduced into the compaction receptacles by way of the introduction openings.

At least one compaction tool of the device in a width direction of the compaction receptacle assigned thereto can be undersized by a measurable dimension of 0 μm to 50 μm, in particular undersized by a dimension of 0 μm to 20 μm, in relation to an available width measurable in the same width direction of an introduction opening of the compaction receptacle assigned thereto.

The tolerance widths of the undersized dimension stated above can be a function of the gauge of the bristle filaments of the bristle bundles to be compacted, for example. In the case of bristle filaments with a gauge of 3 mil, the tolerance range can be, for example, 0 μm to 20 μm. In the case of larger filament gauges, thus for example in the case of bristle filaments that have a gauge of 8 mil, a comparatively larger tolerance range will optionally suffice, for example the tolerance range of 0 μm to 50 μm, for the undersized dimension explained above.

At least one compaction receptacle of the device can have an undercut. The undercut can enlarge a volume of the compaction receptacle laterally and/or radially in terms of a longitudinal axis of the compaction receptacle. The longitudinal axis of the compaction receptacle can define the longitudinal alignment of the bristle filaments in the compaction receptacle.

As a result of the undercut, the compaction receptacle can be imparted a cross section which is enlarged laterally in terms of an introduction opening of the compaction receptacle and/or in terms of a longitudinal axis of the compaction receptacle. This can facilitate the shaping and compacting of bristle bundles having a cross-sectional shape which deviates from a circular cross-sectional shape and/or is asymmetrical, for example.

The undercut of the compaction receptacle can be an undercut in a cross section of the compaction receptacle that is disposed in a cross-sectional plane which is oriented orthogonally to a longitudinal axis of the compaction receptacle.

The compaction receptacles can be movable in a retrieving movement aligned transversely or orthogonally to a longitudinal axis of the bundle notches that defines the longitudinal alignment of the bristle bundles in the bundle notches, and/or be movable in a compacting movement relative to the preparation means. In this way, it is possible to guide the compaction receptacles past the preparation means and its bundle notches, so as to first retrieve the bristle bundles from the bundle notches, and to subsequently compact said bristle bundles with the aid of the compaction tool.

The device can have at least one target plate which is disposed downstream of the compaction receptacles and comprises target receptacles for receiving the compacted bristle bundles.

The target plate can be designed, for example, as a cartridge and/or as a transport holder for compacted bristle bundles. After the target receptacles of the target plate have been populated with compacted bristle bundles, the target plate can then be fed to a downstream process step for the further processing of the bristle bundles.

The target receptacles of the target plate can have introduction bevels. The introduction bevels can simplify the transfer of the compacted bristle bundles from the compaction receptacles into the target receptacles.

In one preferred embodiment of the device, the target receptacles of the target plate can be disposed in a hole arrangement which corresponds to an arrangement of bristle bundles on a bristle carrier of a bristle product to be produced. In this way it is possible to not only keep the bristle bundles ready in the target plate at the desired degree of compaction, but also already in the arrangement that the bristle bundles later assume on a bristle carrier of the bristle product to be produced.

At least one retrieval plate of the device can have compaction receptacles which are arranged in a hole pattern that corresponds to at least one hole sub-pattern of the hole arrangement of the target receptacles of the target plate. In this way, it is possible to transfer the bristle bundles that are offered up in the compaction receptacles of a retrieval plate of the device directly into target receptacles of the target plate, once said bristle bundles have been compacted. If the compaction receptacles of the device are distributed among more than one retrieval plate, it is possible to populate the target receptacles of the target plate successively, in sub-groups, with bristle bundles.

The device can have a transfer device for transferring bristle bundles from the compaction receptacles into target receptacles of the above-mentioned target plate. The bristle bundles which are disposed and compacted in the compaction receptacles can be moved into the target receptacles of the target plate with the aid of the transfer device. In the process, the transfer device can define and/or carry out a transfer movement which is aligned in the direction of the longitudinal axes of the compaction receptacles and/or in the direction of the longitudinal axes of the target receptacles and/or in the longitudinal direction of the bristle bundles located in the compaction receptacles.

The bristle bundles are preferably removed from the bundle notches of the preparation means in a retrieving movement and/or compacting movement which are/is aligned transversely or orthogonally to the direction of longitudinal extent of said bristle bundles, and/or subsequently compacted with the aid of the compaction tool. The subsequent transfer of the compacted bristle bundles from the compaction receptacles into the target receptacles of the target plate can then be performed in the longitudinal direction of the longitudinal axes of the bristle bundles and thus transversely or orthogonally to the retrieving direction and/or the compacting direction.

The transfer device can have at least one sliding pin by way of which bristle bundles can be pushed out of the compaction receptacles into the target receptacles of the target plate in the longitudinal direction of the longitudinal axes of said bristle bundles. Preferably, the transfer device for each compaction receptacle has in each case one sliding pin. The at least one sliding pin preferably has the same cross section as the receptacle opening to which the sliding pin is assigned, and/or as a bristle bundle compacted in said receptacle opening.

The transfer device can have for each retrieval plate one pin plate having a number of sliding pins that corresponds to the number of compaction receptacles of the respective retrieval plate.

In this way it is possible to transfer the bristle bundles located in the compaction receptacles of a retrieval plate in one operative step from the compaction receptacles into corresponding target receptacles of a target plate with the aid of the pin plate and the sliding pins thereof.

The at least one retrieval plate and/or at least one compaction tool can have a receptacle space, for example a slot, in which the preparation means is positioned when retrieving bristle bundles.

As a result of the receptacle space it is possible during the retrieval and/or compaction of bristle bundles to position the retrieval plate and/or the at least one compaction tool relative to the preparation means in such a way that the preparation means is at least partially disposed in the receptacle space of the retrieval plate and/or of the compaction tool. In this way, the bristle bundles can be contacted, supported and/or compacted by the retrieval plate and/or the compaction tool on both sides of the bundle notch of the preparation means when retrieving and/or compacting.

The device can have at least one counterpart which is assigned to the preparation means. Bristle bundles located in the bundle notches can be secured against loss by the counterpart on their way from retrieval from a supply to the compaction receptacles. Preferably, the device in the region of the compaction receptacles has at least one movable counterpart which during and/or by a retrieving movement and/or compacting movement of the compaction receptacles relative to the preparation means is movable from an initial position to a target position. In this way, the movable counterpart can yield and make space for the movement of the compaction receptacles during retrieval and/or compaction of the bristle bundles. The movable counterpart can impinge and/or contact a bristle bundle located in a compaction receptacle transversely or orthogonally to its longitudinal axis for so long until the bristle bundle for compacting is impinged by a compaction tool.

The device can have a separator slide, a separator disc, an arc and/or a separator ring as a preparation means.

Also proposed for achieving the object is a bristle product production machine, for example a brush production machine or a broom production machine or a paint brush production machine, which has a device for compacting bristle bundles having one or more of the features disclosed herein.

Also proposed for achieving the object is a method for compacting bristle bundles while using such a device, which has one or more of the means and features disclosed herein directed toward a method of this type. Accordingly, a method for compacting bristle bundles while using a device for compacting bristle bundles is proposed for achieving the object, in which bristle bundles provided to the device by the preparation means are retrieved from the bundle notches of the preparation means with the aid of the compaction receptacles of the device and compacted with the aid of the compaction tools of the device. The compacting of the bristle bundles here preferably takes place up to a defined degree of compaction.

When carrying out the method, the bristle bundles can be compacted up to a degree of compaction of, for example, 60% to 90%, or up to a degree of compaction of 70% to 80%, or up to a degree of compaction of 75%.

When compacting the bristle bundles, the compaction tools make their way into the compaction receptacles through introduction openings of the compaction receptacles, and in the process come into contact with the bristle bundles located in said compaction receptacles. The bristle bundles for compacting can be impinged transversely and/or orthogonally to their longitudinal axis by the compaction tools.

In one embodiment of the method it is provided that bristle filaments of at least one bristle bundle during the compaction of the bristle bundle are pushed into an undercut of a compaction receptacle of the device. In this way, it is possible to form the bristle bundle during its compaction. During its compaction, the bristle bundle can be formed in such a way that it is imparted a cross-sectional shape which corresponds to the cross-sectional shape of the compaction receptacle having the undercut. The cross-sectional shape of the compacted bristle bundle can be, for example, a cross-sectional shape which deviates from a circular cross-sectional shape and/or is asymmetrical.

The bristle bundles, upon their compaction, can then be transferred into target receptacles of a target plate of the device. With the aid of the target plate it is possible to make available the bristle bundles, which are then compacted as desired, to downstream process steps for producing bristle products. The target plate can be populated with a bristle carrier. The compacted bristle bundles, by way of their fastening-proximal ends, can then be pushed through bundle receptacles of the bristle carrier. Subsequently, the fastening-proximal ends can be fused for connecting the bristle bundles to the bristle carrier.

In the description hereunder of different embodiments of the invention, functionally equivalent elements are provided with identical reference signs even in the case of a deviation in terms of design or shape. Unless explicitly pointed out and wherever possible, the description hereunder relates to all exemplary embodiments of the invention shown in the figures.

All of the figures show at least parts of a device, which in its entirety is identified by the reference sign, for compacting bristle bundles.

The devicehas at least one preparation means, specifically a bundle separator, having bundle notchesand a number of compaction receptaclesfor bristle bundles, said number of compaction receptaclesbeing at least identical to the number of bundle notches, and for each of its compaction receptacleshaving in each case one compaction tool.

The compaction receptaclesare specified to retrieve bristle bundlesfrom the bundle notchesof the preparation means, and the compaction toolare specified to compact bristle bundlespositioned in the compaction receptacles.

In all embodiments of the deviceshown in the figures, said devicehas a plurality of retrieval plateson which the compaction receptaclesare distributed.