Unitary brush having abrasive coated bristles and method of making the same

Abstract

The present invention relates to a unitary brush (such as a cup brush, for example) which has abrasive particles secured to at least some of its bristles via a first coating. The unitary brush is made by providing a unitary brush, coating at least a portion of the surfaces of the bristles with a first coating, adhering abrasive particles to at least some of the coated bristles and curing the first coating.

What is claimed:  
     
         1 . An article comprising: 
 (a) a unitary brush, the brush having a plurality of bristles, each bristle having a surface;    (b) a first coating over at least a portion of at least some of the bristle surfaces; and    (c) a plurality of abrasive particles secured to at least a portion of at least some of the bristle surfaces via the first coating.    
     
     
         2 . The article of  claim 1  wherein the first coating is an adhesive.  
     
     
         3 . The article of  claim 1  which further comprises a second coating coated over the abrasive particles and the first coating.  
     
     
         4 . The article of  claim 3  wherein the second coating is an adhesive.  
     
     
         5 . The article of  claim 1  wherein the abrasive particles are partially embedded in the first coating.  
     
     
         6 . The article of  claim 1  wherein the abrasive particles are selected from the group consisting of silicon carbide, talc, garnet, glass bubbles, glass beads, cubic boron nitride, diamond, and aluminum oxide.  
     
     
         7 . The article of  claim 1  wherein the first coating comprises a material selected from the group consisting of polyurethanes, epoxy resins, and acrylate resins.  
     
     
         8 . The article of  claim 3  wherein the second coating comprises a material selected from the group consisting of polyurethanes, epoxy resins, and acrylate resins.  
     
     
         9 . The article of  claim 1  wherein the brush is selected from the group consisting of radial brushes and cup brushes.  
     
     
         10 . The article of  claim 1  wherein the bristles comprise a material selected from the group consisting of polyamide, polyester, and polyolefin.  
     
     
         11 . The article of  claim 1  wherein the bristles further comprise abrasive particles which are embedded within the bristles.  
     
     
         12 . The article of  claim 1  wherein said unitary brush is an injection molded brush  
     
     
         13 . An article comprising: 
 (a) an injection molded brush, the brush having a plurality of bristles, each bristle having a surface;    (b) a first coating over at least a portion of at least some of the bristle surfaces; and    (c) a plurality of abrasive particles secured to at least a portion of at least some of the bristle surfaces via the first coating.    
     
     
         14 . A method of making an abrasive brush, said method comprising: 
 (a) providing a unitary brush comprised of a base portion formed of a material and a plurality of bristles comprised of the same material extending therefrom and wherein each bristle has a surface;    (b) coating at least a portion of the surfaces of at least a portion of the bristles with a first coating;    (c) adhering a plurality of abrasive particles to at least some of the bristle surfaces via the first coating; and    (d) curing the first coating to adhere the abrasive particles to the bristle surfaces.    
     
     
         15 . The method of  claim 14  further comprising: 
 (a) coating the abrasive coated bristles with a second coating; and  
 (b) curing the second coating  
 
     
     
         16 . The method of  claim 14  wherein said unitary brush is an injection molded brush.