Integral brush with no gaps between cleaning assembly and handle and manufacturing process thereof

Abstract

An integral brush is formed by performing steps of tufts arrangement, tufts insertion into mold, mold turning and closing, and injection molding, thereby forming no gaps between cleaning assembly and handle. The cleaning assembly includes at least one cleaning unit each having a plurality of tufts integrally formed with one of a plurality of bases in the handle. The tufts are spaced apart and an upper portion of each tuft is shaped to form an uneven tip. The brush can increase a contact area between the cleaning assembly and an object so as to effectively clean the object.

What is claimed is: 
     
         1 . An integral brush comprising:
 a handle; and   a cleaning assembly integrally formed with the handle with no gaps therebetween, the cleaning assembly including at least one cleaning unit each having a plurality of tufts integrally formed with one of a plurality of bases in the handle;   wherein the tufts are spaced apart; and   wherein an upper portion of each of the tufts is shaped to form an uneven tip.   
     
     
         2 . The integral brush of  claim 1 , wherein the cleaning unit has a plurality of tufts having a conic portion adjacent to the tip. 
     
     
         3 . The integral brush of  claim 1 , wherein the cleaning unit has a plurality of tufts having a polygonal section. 
     
     
         4 . The integral brush of  claim 3 , wherein the polygonal section is a rhombic section. 
     
     
         5 . The integral brush of  claim 1 , wherein the cleaning assembly includes a plurality of cleaning units. 
     
     
         6 . The integral brush of  claim 5 , wherein the cleaning units are shaped to form an uneven top. 
     
     
         7 . The integral brush of  claim 1 , wherein the cleaning assembly has a convex top. 
     
     
         8 . A process of manufacturing an integral brush of  claim 1 , comprising the steps of:
 tufts arrangement involving arranging a plurality of tufts as one of a plurality of cleaning units and fusing bases of the cleaning units to form a unitary member;   tufts insertion into mold involving inserting heads of the cleaning units through a plurality of holes of a die, and activating a pushing device to push the cleaning units further into a plurality of holes of an upper mold with lower portions of the cleaning units disposed out of the upper mold;   mold turning and closing involving turning the upper mold upside down to align with a lower mold so as to together form a cavity with a portion adjacent to the base of each of the cleaning units is disposed in the cavity; and   injection molding involving forming a handle in the cavity and joining the portion adjacent to the base of each of the cleaning units and the handle by injection molding with no gaps formed between the handle and the portion adjacent to the base of each of the cleaning units.