CYLINDRICAL BRUSH AND METHOD OF MANUFACTURE
A method for manufacturing a cylindrical brush of a cleaning tool, comprises a cylindrical brush having a core member, a plurality of rail plates, a plurality of polyvinyl alcohol (PVA) nodule foam bars and a pair of end caps. The core member includes an outer wall having a plurality of core holes and a pair of openings. The plurality of rail plates having a plurality of rail holes arranged along the outer wall of the core member. The plurality of polyvinyl alcohol (PVA) nodule foam bars is installed at each of the plurality of rail plates such that each of a plurality of nodules of the PVA nodule foam bar aligns with the plurality of core holes and with the plurality of rail holes. The pair of end caps encloses the pair of openings of the core member.
1 . A cylindrical brush for cleaning electronic components, comprising:
a core member extending along a longitudinal axis;
a plurality of rail plates mounted around the core member, each rail plate including an internal cavity and a plurality of rail holes;
a plurality of polyvinyl alcohol (PVA) nodule bars, each PVA nodule bar being disposed in the internal cavity of a respective rail plate and including a continuous bar portion disposed in the internal cavity and a row of PVA nodules projecting outwardly through the rail holes of the respective rail plate; and a pair of end caps coupled to opposite ends of the core member,
wherein the rail plates and the pair of end caps include mating registration features configured to constrain successive rail plates to alternating circumferential orientations about the core member.
2 . The cylindrical brush of claim 1 , wherein each rail plate comprises a rail top portion and a rail bottom portion wherein each rail plate comprises a rail top portion and a rail bottom portion that together define the internal cavity.
3 . The cylindrical brush of claim 1 , wherein one of the end caps is keyed to secure each rail plate in a predetermined circumferential location along the core member.
4 . The cylindrical brush of claim 1 , wherein at least one rail hole adjacent an axial end of the rail plate includes an internal crossbar configured to retain an end portion of the respective PVA nodule bar.
5 . The cylindrical brush of claim 1 , wherein the continuous bar portion and the row of PVA nodules of each PVA nodule bar are integrally formed as a single piece.
6 . The cylindrical brush of claim 1 , wherein wherein the complementary registration features are configured such
that the cylindrical brush cannot be assembled unless successive rail plates alternate in circumferential orientation in sequence about the core member.
7 . The cylindrical brush of claim 6 , wherein the core member has a dodecagonal cross-section.
8 . The cylindrical brush of claim 1 , wherein the rail plates are rail plates slidably mounted to the core member by dovetail engagement.
9 . The cylindrical brush of claim 1 , wherein the rows of PVA nodules define a zig-zag pattern around the cylindrical brush.
10 . A cylindrical brush for cleaning electronic components, comprising:
a core member extending along a longitudinal axis and defining a plurality of openings distributed about a circumference of the core member;
a plurality of holders mounted in the openings of the core member; and
a plurality of polyvinyl alcohol (PVA) nodules, each PVA nodule being retained in a respective one of the holders and exposed radially outwardly from the core member, wherein each holder is attached to the core member and retains a respective PVA nodule such that each PVA nodule is attached to the core member by a respective holder.
11 . The cylindrical brush of claim 10 , wherein at least one of the holders is attached to the core member by a threaded engagement.
12 . The cylindrical brush of claim 10 , wherein at least one of the holders is attached to the core member by a press fit.
13 . The cylindrical brush of claim 10 , wherein at least one of the holders is attached to the core member by ultrasonic welding, a snap connection, or adhesive.
14 . The cylindrical brush of claim 10 , wherein each holder extends radially inwardly into the core member to occupy a portion of an interior cavity of the core member.
15 . The cylindrical brush of claim 10 , wherein a respective holder has a first stem length and the corresponding PVA nodule has a second stem length greater than the first stem length.
16 . A noduled cylindrical brush for cleaning electronic components,comprising:a cylindrical body extending between opposite ends along a longitudinal axis; anda plurality of polyvinyl alcohol (PVA) nodules distributed along the longitudinal axis,wherein thePVA nodules exhibit a variable density of nodules per unit length along the longitudinal axis.
17 . The noduled cylindrical brush of claim 16 , wherein axial spacing between adjacent PVA nodules varies along the longitudinal axis.
18 . The noduled cylindrical brush of claim 16 , wherein a number of the PVA nodules per unit length increases with distance from a center of the cylindrical body.
19 . The noduled cylindrical brush of claim 16 , wherein at least some of the PVA nodules are spaced about 13.6 mm apart in a first longitudinal region, about 12.8 mm apart in a second longitudinal region, and about 11.8 mm apart in a third longitudinal region.
20 . The noduled cylindrical brush of claim 16 , wherein the PVA nodules vary in size, shape, or both along the longitudinal axis.