Brush and bristle assembly therefor

Abstract

A brush with a body portion, an outer surface, and bristle apertures extending from the outer surface into the body portion. Each bristle aperture has a sidewall with a first portion defining an inner portion and a second portion defining an outer portion. Opposing portions of the first portion of the sidewall are parallel. Opposing portions of the second portion of the sidewall extend outwardly from the body portion toward the outer surface. A tuft is anchored in each bristle aperture. During use, the inner portions of the bristle apertures maintain a proximal portion of the tuft in a substantially stationary position, and direct a distal portion of the tuft through the outer portion and beyond the outer surface. The outer portions of the bristle apertures are shaped to maintain a minimum bend radius and allow the distal portion of the tuft to deflect when lateral forces are applied thereto.

1 . A brush comprising:
 a body portion with an outside surface, and   a plurality of bristle apertures formed in the outside surface and extending into the body portion, each of the plurality of bristle apertures comprising:   a sidewall defining a first aperture portion and a second aperture portion, the first aperture portion being within the body portion of the brush and spaced from the outside surface, the second aperture portion being adjacent to the outside surface,   the first aperture portion having a substantially constant cross-sectional area, and the second aperture portion having an increasing cross-sectional area that increases toward the outside surface.   
   
   
       2 . The brush of  claim 1 , wherein the substantially constant cross-sectional area of the first aperture portion is defined by an elongated cross-sectional shape having a first longitudinal axis and a width orthogonal to the first longitudinal axis,
 an outer portion of the increasing cross-sectional area of the second aperture portion adjacent the outside surface is defined by an elongated cross-sectional shape having a second longitudinal axis and a length, the second longitudinal axis being orthogonal to the first longitudinal axis, and   the length of the outer portion of the second aperture portion is at least two to three times greater than the width of the first aperture portion.   
   
   
       3 . The brush of  claim 1 , wherein the second aperture portion is one of trumpet shaped, funnel shaped, conically shaped, flared, or tapered. 
   
   
       4 . The brush of  claim 1 , wherein the first aperture portion is cylindrical and the substantially constant cross-sectional area of the first aperture portion is defined by a first cross-sectional shape comprising one of a circle, an ellipse, a portion of a parabola, or a portion of a hyperbola. 
   
   
       5 . The brush of  claim 1 , wherein the first aperture portion is cylindrical and the substantially constant cross-sectional area of the first aperture portion is defined by a cornerless first cross-sectional shape. 
   
   
       6 . The brush of  claim 1 , wherein each of the plurality of bristle apertures further comprises:
 a bottom surface inside the body portion of the brush spaced from the outside surface of the brush, the first aperture portion being adjacent to the bottom portion.   
   
   
       7 . The brush of  claim 1 , wherein the second aperture portion extends from the first aperture portion to the outside surface. 
   
   
       8 . The brush of  claim 1 , wherein the second aperture portion comprises an outwardly extending shoulder portion at the intersection of the second aperture portion and the outside surface. 
   
   
       9 . The brush of  claim 1 , wherein the cross-sectional area of the second aperture portion is constantly increasing from the first aperture portion to the outside surface. 
   
   
       10 . The brush of  claim 1 , wherein the cross-sectional area of the second aperture portion increases non-uniformly from the first aperture portion to the outside surface. 
   
   
       11 . The brush of  claim 1 , wherein each of the plurality of bristle apertures comprises a total depth,
 the first aperture portion of each of the plurality of bristle apertures comprises a first depth, and   the first depth is approximately 5% to approximately 40% of the total depth.   
   
   
       12 . The brush of  claim 1 , further comprising:
 a bristle tuft corresponding to each of the plurality of bristle apertures, each tuft comprising a plurality of bristles having a bent portion flanked by a first bristle portion and second bristle portion,   each tuft being anchored inside the first aperture portion of a corresponding bristle aperture, the first bristle portion and the second bristle portion extending from the first aperture portion through the second aperture portion, and extending outward beyond the outside surface of the brush,   during use, the first bristle portion and the second bristle portion being held in a substantially stationary position within the first aperture portion and being free to deflect within the second aperture portion.   
   
   
       13 . The brush of  claim 12 , wherein the plurality of bristles of each of the bristle tufts has a minimum bend radius, the sidewall of each of the plurality of bristle apertures comprises a smooth wall portion defining the second aperture portion, the smooth wall portion being configured to maintain ones of the plurality of bristles of the bristle tuft anchored inside the bristle aperture and deflected against the smooth wall portion at a bend radius greater than the minimum bend radius of the plurality of bristles. 
   
   
       14 . The brush head of  claim 12 , wherein the plurality of bristles of each of the bristle tufts comprises a minimum radius of curvature, and
 the sidewall of each of the plurality of bristle apertures comprises an outwardly flaring sidewall defining the second aperture portion, the outwardly flaring sidewall having a minimum radius of curvature that is larger than the minimum radius of curvature of the plurality of bristles of each of the bristle tufts.   
   
   
       15 . The brush of  claim 12 , wherein the plurality of bristles of each of the bristle tufts is constructed from one of shape memory alloy, super elastic memory wire, or nitinol wire. 
   
   
       16 . The brush of  claim 12 , wherein the sidewall comprises a smooth flared wall portion defining the second aperture portion, the smooth flared wall portion being configured to provide a curved surface against which at least one of the first bristle portion and the second bristle portion may be pressed without being damaged during use. 
   
   
       17 . The brush of  claim 12 , further comprising:
 a pair of channels formed in the sidewalls of each of the plurality of bristle apertures, the channels being opposite one another along the sidewalls of each of the plurality of bristle apertures and configured to receive a fastener;   for each pair of channels formed in the sidewalls of each of the plurality of bristle apertures, a fastener received inside the pair of channels, the fastener being non-removably anchored inside the bristle aperture by engagement between the fastener and the pair of channels, the fastener anchoring the bent portion of the plurality of bristles of the tuft inside the bristle aperture.   
   
   
       18 . The brush of  claim 1 , further comprising:
 a pair of channels formed in the sidewalls of each of the plurality of bristle apertures, the channels being opposite one another along the sidewalls of each of the plurality of bristle apertures.   
   
   
       19 . A brush comprising:
 a brush head having a body portion and an outer surface;   a plurality of bristle apertures formed in the brush head extending from the outer surface into the body portion, each of the plurality of bristle apertures having a sidewall with a first portion defining an inner portion of the bristle aperture and a second portion defining an outer portion of the bristle aperture, opposing portions of the first portion of the sidewall being parallel and opposing portions of the second portion of the sidewall extending outwardly toward the outer surface; and   a plurality of tufts each anchored in one of the plurality of bristle apertures, each of the plurality of tufts comprising bristles having an proximal portion and a distal portion, during use:   the inner portion of each of the bristle apertures maintaining the proximal portion of the bristles of the tuft anchored in the bristle aperture in a substantially stationary position relative to the brush head, and directing the distal portion of the bristles through the outer portion of the bristle aperture and beyond the outer surface, and   the outer portion of each of the bristle apertures being configured to allow the distal portion of the bristles of the tuft anchored in the bristle aperture to deflect a predetermine amount in response to lateral forces applied to the tuft.   
   
   
       20 . The brush of  claim 19 , wherein the plurality of tufts are each constructed from one of shape memory alloy, super elastic memory wire, or nitinol wire. 
   
   
       21 . The brush of  claim 19 , wherein the inner portion has an elongated cross-sectional shape having a first longitudinal axis and a width orthogonal to the first longitudinal axis,
 adjacent the outside surface the outer portion has an elongated cross-sectional shape having a second longitudinal axis and a length, the second longitudinal axis being orthogonal to the first longitudinal axis, and   the length of the elongated cross-sectional shape of the outer portion is at least two to three times greater than the width of the elongated cross-sectional shape of the inner portion.   
   
   
       22 . The brush of  claim 19 , wherein each of the plurality of bristle apertures comprises a total depth,
 the inner portion of each of the plurality of bristle apertures comprises a first depth, and   the first depth is approximately 10% to approximately 40% of the total depth.   
   
   
       23 . A brush head for use with a plurality of tufts each constructed from a group of bristles bent back on itself to define a bent portion flanked by first and second end portions, the brush head comprising:
 a body portion;   an outer surface outward of the body portion; and   a plurality of bristle apertures extending from the outer surface into the body portion, each of the plurality of bristle apertures comprising an orientation portion and a deflection portion, the deflection portion being closer to the outer surface than the orientation portion,   the orientation portion being configured to orient the first and second end portions of the group of bristles relative to the outer surface of the brush head,   the deflection portion being configured to receive the first and second end portions of the group of bristles therein and provide a deflection area within which the first and second end portions of the group of bristles may deflect laterally in response to an application of a laterally directed force to the tuft.   
   
   
       24 . The brush of  claim 23 , wherein each of the plurality of bristle apertures comprises a total depth,
 the orientation portion of each of the plurality of bristle apertures comprises a first depth, and   the first depth is approximately 10% to approximately 40% of the total depth.   
   
   
       25 . The brush head of  claim 23 , wherein the orientation portion is further configured to prevent disengagement of the tuft from the bristle aperture. 
   
   
       26 . The brush head of  claim 23 , wherein the group of bristles of each of the plurality of tufts comprises a minimum radius of curvature, and
 each of the plurality of bristle apertures comprises a flared sidewall defining the deflection portion, the flared sidewall having a minimum radius of curvature that is larger than the minimum radius of curvature of the group of bristles of each of the plurality of tufts.   
   
   
       27 . A brush comprising a plurality of tufts anchored one each inside a plurality of bristle apertures, each of the bristle apertures comprising an internal deflection area into which the tuft anchored in the bristle aperture may deflect in response to lateral forces applied to the tuft. 
   
   
       28 . The brush of  claim 27 , wherein each of the plurality of tufts comprises a minimum bend radius,
 each of the plurality of bristle apertures comprises a sidewall defining the deflection area, the tuft anchored inside the bristle aperture is pressed against the sidewall when sufficient lateral forces are applied to the tuft to defect the tuft against the sidewall, and the sidewall is configured to induce a radius of curvature in the tuft that is greater than its minimum radius of curvature.   
   
   
       29 . The brush of  claim 27 , wherein the plurality of tufts are each constructed from one of shape memory alloy, super elastic memory wire, or nitinol wire. 
   
   
       30 . The brush head of  claim 27 , wherein the internal deflection area has a central portion,
 each of the plurality of tufts comprises a plurality of bristles, and   each of the plurality of bristle apertures comprises a means for positioning the plurality of bristles of the tuft anchored in the bristle aperture in the central portion of the internal deflection area.   
   
   
       31 . The brush of  claim 27 , wherein the internal deflection area of each of the plurality of bristle apertures comprises a filler material. 
   
   
       32 . The brush of  claim 31 , wherein the filler material is a low durometer silicone. 
   
   
       33 . The brush of  claim 31 , wherein the filler material within each of the plurality of bristle apertures extends therefrom along a portion of the plurality of tufts. 
   
   
       34 . A brush comprising:
 a body portion;   an outer surface;   a plurality of tufts each comprising a plurality of bristles; and   a plurality of bristle apertures extending from the outer surface into the body portion, each of the plurality of bristle apertures comprising:   means for anchoring the plurality of bristles of one of the plurality of tufts inside the bristle aperture,   means for orienting the plurality of bristles of the one of the plurality of tufts anchored inside the bristle aperture by the anchoring means relative to the outer surface, and   means for allowing the plurality of bristles of the one of the plurality of tufts anchored inside the bristle aperture by the anchoring means to deflect inside the bristle aperture in response to an application of force to the one of the plurality of tufts.   
   
   
       35 . The brush of  claim 34 , wherein the plurality of tufts are each constructed from one of shape memory alloy, super elastic memory wire, or nitinol wire. 
   
   
       36 . The brush of  claim 34 , wherein each of the plurality of bristle apertures is at least partially filled with a filler material. 
   
   
       37 . The brush of  claim 36 , wherein the filler material comprises low durometer silicone. 
   
   
       38 . The brush of  claim 36 , wherein the filler material extends from the plurality of bristle apertures along a portion of the plurality of tufts. 
   
   
       39 . A brush comprising:
 a body portion with an outside surface, and   a plurality of bristle apertures formed in the outside surface and extending into the body portion, each of the plurality of bristle apertures comprising a sidewall defining an aperture portion adjacent to the outside surface, the aperture portion having an increasing cross-sectional area that increases toward the outside surface.   
   
   
       40 . A brush comprising:
 a body portion with an outside surface, and   a plurality of bristle apertures formed in the outside surface and extending into the body portion, each of the plurality of bristle apertures comprising:   a sidewall defining a first aperture portion and a second aperture portion, the first aperture portion being within the body portion of the brush and spaced from the outside surface, the second aperture portion being adjacent to the outside surface,   the first aperture portion having a substantially constant cross-sectional area, and the second aperture portion having a substantially constant cross-sectional area that is larger than the substantially constant cross-sectional area of the first aperture portion.   
   
   
       41 . A brush comprising:
 a brush head having a body portion and an outer surface;   a plurality of bristle apertures formed in the brush head extending from the outer surface into the body portion, each of the plurality of bristle apertures having a sidewall with a first portion defining an inner portion of the bristle aperture and a second portion defining an outer portion of the bristle aperture, opposing portions of the first portion of the sidewall being parallel and opposing portions of the second portion of the sidewall being parallel; and   a plurality of tufts each anchored in one of the plurality of bristle apertures, each of the plurality of tufts comprising bristles having an proximal portion and a distal portion, during use:   the inner portion of each of the bristle apertures maintaining the proximal portion of the bristles of the tuft anchored in the bristle aperture in a substantially stationary position relative to the brush head, and directing the distal portion of the bristles through the outer portion of the bristle aperture and beyond the outer surface, and   the outer portion of each of the bristle apertures being configured to allow the distal portion of the bristles of the tuft anchored in the bristle aperture to deflect in response to lateral forces applied to the tuft.   
   
   
       42 . A brush comprising a plurality of tufts comprising bristles constructed from one of shape memory alloy, super elastic memory wire, or nitinol wire coated with nylon. 
   
   
       43 . A brush comprising a plurality of tufts comprising bristles constructed from one of shape memory alloy, super elastic memory wire, or nitinol wire coated with an elastomeric material.