Fusion interlocking bristle strip and method of manufacturing the same

1. A method of manufacturing a brush with fusion interlocking bristle strip, the method comprising:

arranging a plurality of bristle fibers ( 310 ) to form a knitted strip ( 300 ) configured to be assembled with multiple profiles;

producing by injection molding, at least one carrier strip ( 810 ) having a slot ( 820 ) to accommodate the knitted strip ( 300 );

interlocking to bond the knitted strip ( 300 ) with at least one carrier strip ( 810 ) by fusion bonding using ultrasonic welding; and

applying an adhesive to a bottom of the at least one carrier strip to strengthen adhesion of the bristles ( 310 ) to the at least one carrier strip ( 810 ) as the adhesive fills in gaps between the bristles ( 310 ) and the at least one carrier strip ( 810 );

wherein the at least one carrier strip ( 810 ) includes a bulbous configuration as an undercut feature ( 1010 ) configured to create a shorter distance between walls of the at least one carrier strip ( 810 ) thereby creating a stronger bonding point, and wherein each of the at least one carrier strip is a multi-piece polymer strip, wherein the bulbous configuration acts as a catch or stopper to prevent the knitted strip ( 300 ) from sliding out wherein a warp yarn prevents the bristles ( 310 ) from sliding out from the at least one carrier strip ( 810 );

wherein the ultrasonic welding further comprises the steps of:

holding one side of the at least one carrier strip ( 810 ) with a metal support base ( 860 );

sandwiching the bristles ( 310 ) inside the slot ( 820 ) of the at least one carrier strip ( 810 );

pressing the at least one carrier strip ( 810 ) from opposite sides with an ultrasonic horn;

generating a high frequency vibration by an ultrasonic machine and transferring the energy produced from the vibration through the horn into the at least one carrier strip ( 810 ); and melting a wall of the carrier strip in contact with the bristles for flowing a molten fluid through an interstice to form an interlocking bond;

bonding the at least one carrier strip due to generation of high heat;

wherein the plurality of bristle fibers ( 310 ) of the knitted strip ( 300 ) is arranged in parallel with two looped ends to form a body portion;

wherein the fibers include a combination of electrically conductive and electrically non-conductive fibers;

wherein the ultrasonic welding creates a molten interface on the at least one carrier strip ( 810 ) surface.

2. The method as claimed in claim 1 wherein the knitted strip ( 300 ) includes interstices ( 720 a ) that form critical pathways allowing a molten carrier strip to flow through and form interlock bonds.

3. The method as claimed in 2 wherein the carrier strip ( 810 ) is bonded by the ultrasonic welding at the interstices created by the knitted strip ( 300 ) wherein an interlock feature ( 710 a ) is created as a primary mechanism for locking the bristle fibers in place.

4. The method as claimed in 3 wherein the ultrasonic welding preserves strength of the bristles ( 310 ) by maintaining its structure wherein the molten carrier encloses the bristles.

5. The method according to claim 1 , wherein said ultrasonic operating frequency for manufacturing the brush is 15 kHz-30 KHz.