US20090139044A1 - Corrugated Bristle Brush - Google Patents

Abstract

A brush including layers of bristles used with a handle. Plates, with bristles connected to a base at one end, are retained by the handle. Certain stackable plates may also be interconnected by a set of hinges. Plates can be of a unitary plastic construction and can be stacked or folded upon one another to form layers of plates with bristles. A corrugated layer is adjacent to a first plate or between two plates. The corrugated layer has a base and corrugated bristles extending from an end of the base, with the corrugated bristles preferably shaped in alternating ridges and grooves. The corrugated layer is stiffer than an adjacent plate of bristles and assists with liquid retention of the brush. Recesses or holes in the ridges of the corrugated bristles can aid with liquid retention in the brush before applying the liquid on a surface. A method of making a brush with layers of bristles can include forming a first plate having a series of bases connected to a plurality of bristles, stacking bases of the first plate in layers, attaching the stacked bases of the first plate to a handle, and forming and attaching a corrugated layer to be adjacent to the first plate.

Description

BACKGROUND
• This disclosure relates to a brush with flexible bristles, and specifically to a brush with one or more corrugated layers associated with the bristles.
• Brushes used for applying liquids or sauces are typically manufactured as a complete one-piece assembled unit with a handle permanently connected to the bristles. Basting brushes have been made of silicone or similar materials due to heat resistance, odor resistance durability, and cleanability. A particular brush made by Merry Chance Industries, Ltd., which is also presenting this disclosure, is particularly beneficial for these characteristics.
• U.S. Pat. No. 7,059,006, which is incorporated by reference, discloses a brush including removable plates with tines that can be inserted into a complementary handle. The plates, made up of tines connected to a manifold at one end, are retained by the handle. Removable flat plates can be of a unitary construction and can be rolled, stacked or folded upon one another to form layers of tines. The plates are designed to be easily separated from a brush handle after use to allow for cleaning or replacement. The plates may also be interconnected by a set of hinges. The tines may include a plurality of flutes or ribs that increase the surface area of the tines and aid in increasing liquid retention when the brush is being used. After use, the individual plates can be removed from the handle and easily cleaned.
• Williams-Sonoma sells a basting brush covered by U.S. Pat. No. 7,059,006, (i.e. Tovolo U.S. Pat. No. 7,137,961) having the plates as shown in FIGS. 3-6 of the '006 patent with two unitary retaining members pivotally attached that secure the plates. A sleeve encases the handle and is adapted to push the retaining members together to secure the bases to the handle. The sleeve may be slid rearwardly along the handle away from the bristles to allow the retaining members to open, allowing the release of the bases. The sleeve when slid toward the bristles may engage the first and second retaining members to secure them together and to hold the inserted bases having apertures.
• Also, the OXO Good Grips® large silicone basting brush has multiple layers of silicone bristles. Tapered outer bristles are part of an angled brush head. Circles within wide flat center bristles hold liquid for transport.
• In addition to liquid retention, a more robust set of bristles may be desirable in certain circumstances. The strength, firmness, hardness, stiffness, rigidity and sturdiness of the bristles are characteristics to consider for the bristles of various brushes.
• Prior art brushes do not provide for a brush having removable or folding integral plates of bristles with corrugated bristles for enhancing the layers of bristles.
SUMMARY
• The present disclosure provides a brush that comprises bristles having desired characteristics, such as heat and odor resistance, with a corrugated layer associated with the bristles to contribute to the function, strength, firmness, hardness, stiffness, or rigidity of the layers of bristles.
• In this regard, it is desired to have a brush with layers of bristles attached to a handle with at least one plate having a series of bases connected to a plurality of bristles. The first plate is adapted to be stacked in layers. A corrugated layer is adjacent to the first plate, and it has a base and corrugated bristles extending from an end of the base wherein the corrugated bristles are shaped in alternating ridges and grooves. The corrugated layer may be stiffer than the first plate. A method of making such a brush is also disclosed.
• These and other aspects of this disclosure are illustrated in the accompanying drawings and are more fully described in the following specification.
BRIEF DESCRIPTION OF DRAWINGS
• The above mentioned and other features of this disclosure and the manner of obtaining them will become more apparent, and the disclosure itself will be best understood by reference to the following description of embodiments taken in conjunction with the accompanying drawings, which are given as non-limiting examples only, in which:
• FIG. 1 is a top view of a brush having a sleeve securing layers of bristles to a handle;
• FIG. 2 shows an expanded view of a brush with components disassembled;
• FIG. 3 is a view of an end of a brush with a corrugated layer between two other layers;
• FIG. 4 shows a corrugated layer with alternating parallel ridges and grooves; and
• FIG. 5 shows a expanded view of a brush with components disassembled of another brush including a corrugated layer.
• The exemplification set out herein illustrates embodiments of the disclosure that is not to be construed as limiting the scope of the disclosure in any manner. Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.
DETAILED DESCRIPTION
• While the present disclosure may be susceptible to embodiment in different forms, the drawings show, and herein described in detail, embodiments with the understanding that the present description are to be considered an exemplification of the principles of the disclosure and are not intended to be exhaustive or to limit the disclosure to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings.
• In the figures, like reference numerals indicate the same elements throughout. As shown inFIG. 1, abrush10 includes ahandle12 and a plurality ofbristles16 that extend from thebrush10. Thebristles16 are preferably elongated flexible members adapted to allow for a liquid to be transferred from a container to an object, such as grilled food. Thebrush10 has one ormore plate18 with a series ofbases20 connected to a plurality ofbristles16 that are adjacent to acorrugated layer22. The term “plate” is broadly used in a varying meaning than U.S. Pat. No. 7,059,006. Thebrush10 may be used as a basting brush, but it is not so limited by this disclosure.
• Thebrush10 includes layers ofbristles16 attached to ahandle12. Afirst plate18 has a series ofbases20 connected to a plurality ofbristles16. Thefirst plate18 is adapted to be stacked in layers, wherein the series ofbases20 can be formed from a unitary piece of polymeric material. Thefirst plate18 preferably has a series ofbases20 that are pivotally interconnected by aliving hinge92 that is part of the unitary piece of polymeric material, such as silicone. Asecond plate118 may also have abase120 or a second series ofbases120 connected to a second plurality ofbristles16, wherein thesecond plate118 can be adapted to be stacked in layers. Thesecond plate118 may have onebase120 or a series ofbases120 preferably formed from a unitary piece of polymeric material, as interchangeable with the description of thefirst plate18 andbases20. (The 100 series of numerals is a convenience for disclosure and not meant to limit these elements). Acorrugated layer22 can be adjacent to afirst plate18 or secured between the first andsecond plates18 and118.
• Thebristles16 of thebrush10 are part of one ormore plates18,118 that can be stacked or folded together to form layers ofbristles16. Thebristles16 can be molded with thebase20 to form theplates18. Theplates18 are preferably fabricated from a silicone polymer material that has desirable heat resistance and anti-adhesion properties. In addition to silicone polymers, other polymers may be used to fabricate theplates18 or118, such as thermoplastic rubbers. Theplates18 include one ormore base20 with thebristles16 extending therefrom, and thesecond plate118, for example, may have just onebase120 withbristles16. Thebristles16 and thebases20 ofplate18 are preferably of a unitary construction allowing theplate18 to be fabricated from a single type of material by compression molding, injection molding or other molding methods known to those skilled in the art. The preferred compression molding allows the single molded unit to havebristles16 extending from an end of aplate18 in an integral piece. Thebases20 may be interconnected by pivotingdevices92, such as living hinges, which allow thebases20 to be folded on each other to form layers ofbristles16. Living hinges92 may be on a side adjacent to the end withbristles16 or the livinghinge92 may be at a distal end of thebase20, or both.
• Acorrugated layer22 can be placed adjacent to afirst plate18 with a set ofbristles16 or preferably between the first andsecond plates18 and118. This preferred three-part design can be adapted to the desired function, strength, firmness, hardness, stiffness, and rigidity for the total layers ofbristles16 for abrush10.
• Thecorrugated layer22 has abase220 andcorrugated bristles216 extending from an end of thebase220. The corrugated bristles216 are shaped in alternatingridges30 andgrooves32, which are preferably parallel. Theridges30 preferably extend onto the base220 to provide added strength. In a cross-section, theridges30 andgrooves32 may form a zigzag pattern. Ideally, recesses34 orholes36 are molded or made into eachridge30 orgroove32 to further aid with liquid retention. Therecesses34 may only depress into a portion of thelayer22, and holes36 may pass through thelayer22. The design of therecesses34 orholes36 may affect the stiffness. As such, recesses34 orholes36 in the orientation that thecorrugated bristles216 may bend may make corrugated bristles easier to bend; whereas, recesses34 orholes36 transverse to bending orientation may not affect stiffness to the same extent.
• Thecorrugated layer22 can be a continuous piece to form one corrugated bristle216 extending from an end of thebase220, butcorrugated layer22 can also be preferably cut a fraction or the entire length of thecorrugated layer22 to form the corrugated bristles216 extending from an end of thebase220. A continuous piece forming one corrugated bristle216 would be the stiffest, andcorrugated bristles216 cut from a portion of thecorrugated layer22 would be stiffer thancorrugated bristles216 cut the entire length of thecorrugated layer22 from an end of the base220 to distal ends of the corrugated bristles216.
• Thecorrugated layer22 is preferably a stiffer plastic than the polymeric material of thefirst plate18. A stiffercorrugated layer22 can make the complete set of layers ofbristles16 stronger. A stiffer set ofbristles16 may be desirable in certain circumstances. The strength, firmness, hardness, stiffness, rigidity and sturdiness of the set ofbristles16 can be adjusted by varying the characteristics of thecorrugated layer22. Thecorrugated layer22 can be formed from silicone polymers or other polymers including thermoplastic rubbers.
• A set of multi-layer bristles16 preferably has one set ofbristles16athat correspond and align with thegrooves32 of thecorrugated layer22. Thebristles16acomplementing thegrooves32 are on a base20 immediately adjacent to thecorrugated layer22. Theadjacent base20 may haveindentations60 to complementridges30 of thecorrugated layer22 that preferably extend onto thebase20. The set ofbristles16acorresponding to thegrooves32 may be wider apart than the series ofbristles16 that preferably form the outer layer ofbristles16 on anouter base20 when thebrush10 is assembled.
• Outer layers ofbristles16 may be tapered when thebrush10 is assembled, particularly for a basting brush to glide over food being basted.
• As shown in U.S. Pat. No. 7,059,006, each base or alternating bases may have complementary raisedportions102 andapertures104. Eachbase20,120 or220 may include a first section with raisedportions102 andcomplementary apertures104 on an adjacent section to maintain the alignment of a first base with asecond base20. Additionally, anopening106 passing through each base20,120 and220 may be used with to assist with aligning these components and to help secure thebases20,120 and220 to thehandle12.
• Preferably, thebrush10 has analignment mechanism100 that passes through the base (20,120, and220) of each of thefirst plate18, the second plate118 (if any), and thecorrugated layer22 to assist with aligning these components when stacked and possibly to help secure them to thehandle12 of thebrush10. Thealignment mechanism100 may include anopening106, such as in an oval shape, used with a complementary dowel, post or peg108 associated with thehandle12. A preferred oval opening106 passes through the base (20,120, and220) of each of thefirst plate18, thesecond plate118, and thecorrugated layer22 to assist with aligning these components with an oval post, peg orsimilar feature108 directly or indirectly attached to thehandle12. The complementaryoval opening106 passing through the base (20,120, and220) of each of thefirst plate18, thesecond plate118, and the corrugated layer prevents rotation of the bases as a round aperture might allow. The post, peg orsimilar feature108 associated with thehandle12 would pass through theopening106 to secure the bases (20,120, and220) to thehandle12 when assembled.
• Theplates18 ofbristles16 can be detachable and removable as shown in U.S. Pat. No. 7,059,006. Thefirst plate18, thesecond plate118, and thecorrugated layer22 can be removable to be easily separated from thehandle12 of thebrush10 after use to allow for cleaning or replacement. Similarly, asleeve156 can encase thehandle12 and be adapted to push the retainingmembers138 and140 (opposite from138 as shown) together to secure thebases20,220 (optionally120) to thehandle12. Thesleeve156 may be slid rearwardly along thehandle12 away from thebristles16 to allow hinged retainingmembers138 and140 to open allowing the release of thebases20 and220. Thesleeve156 when slid toward thebristles16 may engage the first and second retainingmembers138 and140 to secure them together and to hold the insertedbases20 and220 havingopenings106.
• Optionally, the layers ofbristles16 can be non-detachable. Thebases20 can be permanently bonded together by adhesive or ultra-sonic welding of plastic components. Similarly, thefirst plate18, thesecond plate118, and thecorrugated layer22 can be permanently bonded together.
• A method of making abrush10 with layers ofbristles16 may comprise the steps of forming afirst plate18 from a unitary piece of polymeric material having a series ofbases20 connected to a plurality ofbristles16, stackingbases20 of thefirst plate18 in layers, attaching the stackedbases20 of thefirst plate18 to ahandle12, forming acorrugated layer22 having a base220 andcorrugated bristles216 extending from an end of the base220 wherein the corrugated bristles216 are shaped in alternatingridges30 andgrooves32, and attaching thecorrugated layer22 adjacent to thefirst plate18 to secure thecorrugated layer22 to thehandle12. The method may include possible additional steps of forming asecond plate118 from a unitary piece of polymeric material having at least onebase120 connected to a plurality ofbristles16 and attaching the base orbases120 of thesecond plate118 to thecorrugated layer22 so thecorrugated layer22 is between the first andsecond plates18 and118. The method may include cutting at least a fraction of thecorrugated layer22 to formcorrugated bristles216 either from the base220 or part way up the length of thecorrugated layer22.
• These methods may include the step of permanently bonding thefirst plate18, the second plate118 (if any), and thecorrugated layer22 together or leaving thebristles16 and216 to be detachable.
• While this disclosure has been described as having an exemplary embodiment, this application is intended to cover any variations, uses, or adaptations using its general principles. It is envisioned that those skilled in the art may devise various modifications and equivalents without departing from the spirit and scope of the disclosure as recited in the following claims. Further, this application is intended to cover such variations from the present disclosure as come within the known or customary practice within the art to which it pertains.

Claims (25)

1. A brush including layers of bristles attached to a handle, comprising:

a first plate having a series of bases connected to a plurality of bristles, the first plate adapted to be stacked in layers, wherein the series of bases is formed from a unitary piece of polymeric material, and

a corrugated layer adjacent to the first plate, the corrugated layer having a base and corrugated bristles extending from an end of the base wherein the corrugated bristles are shaped in alternating ridges and grooves, wherein the corrugated layer is stiffer than the first plate.

2. The brush ofclaim 1 wherein the series of bases are pivotally interconnected by at least one living hinge that is part of the unitary piece of polymeric material.

3. The brush ofclaim 1 wherein the first plate is formed from silicone.

4. The brush ofclaim 1 wherein the series of bases of the first plate and the base of the corrugated layer each have a complementary oval opening passing through to assist with aligning said bases and to help secure said bases to the handle.

5. The brush ofclaim 1 further including recesses in the ridges of the corrugated bristles.

6. The brush ofclaim 1 further including holes in the ridges of the corrugated bristles.

7. The brush ofclaim 1 wherein the first plate has a first base with bristles that correspond and align with grooves of the corrugated bristles.

8. The brush ofclaim 7 wherein the bristles corresponding to the grooves are wider apart than the bristles of an adjacent base of the first plate.

9. The brush ofclaim 1 wherein the alternating ridges and grooves are parallel.

10. The brush ofclaim 1 further comprising a second plate having a second series of bases connected to a second plurality of bristles, the second plate adapted to be stacked in layers, wherein the second series of bases is formed from a unitary piece of polymeric material, wherein the corrugated layer is between the first and second plates.

11. The brush ofclaim 10 wherein the first plate, the second plate, and the corrugated layer are removable to be easily separated from the handle to allow for cleaning or replacement.

12. The brush ofclaim 10 wherein the first plate, the second plate, and the corrugated layer are permanently bonded together.

13. The brush ofclaim 10 wherein the bases include an alignment mechanism to maintain correct alignment when stacked in layers.

14. The brush ofclaim 13 having a complementary oval opening passing through each base of the first plate, the second plate, and the corrugated layer to assist with aligning these components and to help secure them to the handle.

15. The brush ofclaim 1 wherein the corrugated layer is made of plastic that is more rigid than the polymeric material of the first plate.

16. The brush ofclaim 1 wherein the ridges and grooves form a zigzag pattern in cross section.

17. The brush ofclaim 1 wherein the corrugated bristles are cut from a fraction of a length of the corrugated layer.

18. The brush ofclaim 1 wherein the corrugated bristles are separated extending from the base to distal ends of the corrugated bristles.

19. A brush including layers of bristles attached to a handle, comprising:

a first plate having a series of bases connected to a plurality of bristles, the first plate adapted to be stacked in layers,

a second plate having at least one base connected to a second plurality of bristles, and

a corrugated layer between the first and second plates, the corrugated layer having a base and corrugated bristles extending from an end of the base wherein the corrugated bristles are shaped in alternating ridges and grooves, wherein the ridges and grooves form a zigzag pattern in cross section, wherein the first plate has a first base with bristles that correspond and align with grooves of the corrugated bristles.

20. The brush ofclaim 19 wherein the corrugated layer is a stiffer plastic than the polymeric material of the first plate.

21. The brush ofclaim 19 wherein the corrugated bristles are cut from at least a fraction of a length of the corrugated layer.

22. A method of making a brush having layers of bristles, comprising:

forming a first plate from a unitary piece of polymeric material having a series of bases connected to a plurality of bristles,

stacking bases of the first plate in layers,

attaching the stacked bases of the first plate to a handle,

forming a corrugated layer having a base and corrugated bristles extending from an end of the base wherein the corrugated bristles are shaped in alternating ridges and grooves, and

attaching the corrugated layer adjacent to the first plate securing the corrugated layer to the handle.

23. The method ofclaim 22 including additional steps of forming a second plate from a unitary piece of polymeric material having a series of bases connected to a plurality of bristles,

stacking bases of the second plate in layers, and

attaching the stacked bases of the second plate to the corrugated layer so the corrugated layer is between the first and second plates.

24. The method ofclaim 23 including the step of permanently bonding the first plate, the second plate, and the corrugated layer together.

25. The method ofclaim 22 including the additional step of cutting at least a portion of the corrugated layer to form corrugated bristles.

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