Title:
Bundle of hairs and manufacturing method for the same
Kind Code:
A1


Abstract:
A bundle of hairs, having a hair portion which is composed of plural hairs of synthetic fiber and a base for connecting base ends of the plural hairs of the synthetic fiber, used for painting, writing, drawing, etc., with liquid impregnated into the bundle of hairs. A rate of synthetic fiber non-existent area to an area defined by dimensions of a base portion of the hair portion is set to correspond to purposes of the bundle.



Inventors:
Nishida, Yoshitsugu (Nara-shi, JP)
Hukuda, Hidemi (Nara-shi, JP)
Watatani, Ryoji (Nara-shi, JP)
Application Number:
10/379541
Publication Date:
10/02/2003
Filing Date:
03/06/2003
Assignee:
Kuretake Co., Ltd. (Nara-shi, JP)
Primary Class:
Other Classes:
15/192, 15/DIG.6, 300/21, 15/159.1
International Classes:
B43K1/12; A45D34/04; A46B3/18; A46B9/06; A46D1/04; A46D3/05; B05C17/10; (IPC1-7): A46B3/02; A46B3/06; A46D3/00
View Patent Images:
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Primary Examiner:
GUIDOTTI, LAURA COLE
Attorney, Agent or Firm:
KRATZ, QUINTOS & HANSON, LLP (WASHINGTON, DC, US)
Claims:

What is claimed is:



1. A bundle of hairs having a hair portion composed of plural synthetic fibers and a base mutually connecting base ends of the plural synthetic fibers, and used for painting, writing, drawing, etc., impregnated with liquid, comprising a ratio of synthetic fiber non-existent area to an area defined by dimensions of a base portion of the hair portion set as to correspond to purposes of the bundle.

2. The bundle of hairs as set forth in claim 1, wherein the ratio of synthetic fiber non-existent area to the area defined by the dimensions of the base portion of the hair portion is 30% to 85%.

3. The bundle of hairs as set forth in claim 1 or claim 2; wherein the hair portion is composed of two or more kinds of synthetic fibers.

4. The bundle of hairs as set forth in claim 1 or claim 2, wherein diameter of the synthetic fiber disposed on a central area of a flat portion of the base is differentiated from diameter of the synthetic fiber disposed on peripheral area surrounding the central area.

5. The bundle of hairs as set forth in claim 1 or claim 2, wherein diameter of the synthetic fiber disposed on a central row area of a flat portion of the base is differentiated from diameter of the synthetic fiber disposed on side row area on the both sides of the central row area.

6. The bundle of hairs as set forth in claim 1 or claim 2, wherein a fluid flowing gap is formed on the base.

7. A manufacturing method for bundle of hairs comprising the steps of: preparing a fiber positioning member having plural through holes and inserting synthetic fibers to desired through holes among the plural through holes on the fiber positioning member; connecting and bundling end portions of the synthetic fibers protruding from the fiber positioning member by melting or adhesion; and drawing the synthetic fibers from the fiber positioning member and cutting the synthetic fibers into a predetermined length.

8. The manufacturing method for bundle of hairs as set forth in claim 7, wherein protruding length of the synthetic fibers in the bundling step is short.

9. The manufacturing method for bundle of hairs as set forth in claim 7, wherein protruding length of the synthetic fibers in the bundling step is sufficiently long.

10. A manufacturing method for bundle of hairs comprising the steps of: preparing a fiber positioning member having plural through holes and inserting synthetic fibers respectively to desired through holes among the plural through holes on the fiber positioning member; connecting and bundling end portions of the synthetic fibers protruding from the fiber positioning member by melting or adhesion; drawing the synthetic fibers from the fiber positioning member and cutting the synthetic fibers into a predetermined length; and tapering forth ends of the synthetic fibers after the cutting.

11. The manufacturing method for bundle of hairs as set forth in claim 7, 8, 9, or 10, wherein the fiber positioning member is constructed as that a wavy concavo-convex flexible thin plate is wound as to form plural through holes.

12. The manufacturing method for bundle of hairs as set forth in claim 7, 8, 9, or 10, wherein two or more kinds of synthetic fibers are used.

13. The manufacturing method for bundle of hairs as set forth in claim 7, 8, 9, or 10, wherein diameter of the synthetic fiber inserted to the desired through hole of the fiber positioning member is differentiated from diameter of the synthetic fiber inserted to the other through holes surrounding the desired through hole.

14. The manufacturing method for bundle of hairs as set forth in claim 7, 8, 9, or 10, wherein diameter of the synthetic fiber inserted to the through holes in a desired row of the fiber positioning member is differentiated from diameter of the synthetic fiber inserted to the other through holes in both side rows on the both sides of the desired row.

15. The manufacturing method for bundle of hairs as set forth in claim 7, 8, 9, or 10, wherein two or more kinds of synthetic fibers having different diameters are inserted to one through hole of the fiber positioning member.

16. The manufacturing method for bundle of hairs as set forth in claim 7, 8, 9, or 10, wherein mutual interval between the through holes of the fiber positioning member is set to be 0.10 mm to 3.00 mm.

Description:

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates to a bundle of hairs used for a brush for calligraphy, a brush for painting pictures, a brush for painting workpieces, a brush for painting walls, and a brush for cosmetic such as manicure, and manufacturing method for the bundle.

[0003] 2. Description of the Related Art

[0004] Most of bundles of hairs, used for brushes used for calligraphy, painting pictures, painting workpieces, painting walls, and cosmetic such as manicure, are formed with animal hair. As the animal hair, hairs of pigs, racoon dogs, weazels, goats, foxes, etc. are used. This bundle made of animal hair is made by that animal hairs are inserted to a cylinder of a certain diameter, ends of the animal hairs are tightened with thread, and the ends are heated to have same length.

[0005] However, as shown in FIG. 27, in a bundle 50 made as described above has problems that intervals hardly exist between animal hairs 50 a and percentage of void is low because animal hairs 50a are most densely disposed. A bundle has low percentage of void hardly generate capillary phenomenon when dipped in liquid, and liquid amount to be held by the bundle becomes small. For this reason, frequent supply of the liquid is laboriously required in writing and painting with this bundle. And, use of a bundle having low percentage of void is limited to certain kinds because only narrow variety of impregnable liquids can be used. Further, animal hair varies in thickness according to species and individual differences, pressure for insertion of the animal hair into the cylinder tends to be unstable, and even bristles of the same size often vary in amount of hair thereby. And, animal hair has become difficult to obtain for recent regulations on hunting sites and species. And, a brush made of animal hair has low durability for vermin, and life of the brush itself is short.

[0006] On the other hand, brushes, having bundles made exclusively of synthetic fiber (polyester fiber) of which forth end is tapered, or made of compound of animal hair and synthetic fiber, are being sold. This bundle is made by that synthetic fiber of which forth end is tapered, or compound of the synthetic fiber and animal hair is inserted to a cylinder of a certain diameter, ends of the fiber are tightened with thread, and the ends are heated to have same length. Therefore, also in this bundle, same as the bundle made of animal hair, there is a problem that the synthetic fiber or the synthetic fiber and the animal hair are most densely disposed, and liquid amount to be held is small and only narrow variety of liquids can be used for low percentage of void. And, it is difficult to keep quality of the bundle stable because the bundle is made by manual work which requires high skill.

[0007] It is therefore an object of the present invention to provide a bundle of hairs having stable quality and improved liquid holding ability, and manufacturing methods for the bundle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present invention will be described with reference to the accompanying drawings, in which:

[0009] FIG. 1 is a front view showing a preferred embodiment of a bundle of hairs relating to the present invention;

[0010] FIG. 2 is an enlarged longitudinal cross-section showing a synthetic fiber included in the bundle of FIG. 1;

[0011] FIG. 3 is a plane view showing disposition of synthetic fibers on a base of the bundle of FIG. 1;

[0012] FIG. 4 is a plane view showing another disposition of synthetic fibers on a base of the bundle of FIG. 1;

[0013] FIG. 5 is a perspective view showing another embodiment of the bundle of hairs relating to the present invention;

[0014] FIG. 6 is a plane view showing an example of disposition of synthetic fibers on a base of the bundle of FIG. 5;

[0015] FIG. 7 is a perspective view showing an example of fiber positioning member used in a manufacturing method for the bundle of hairs relating to the present invention;

[0016] FIG. 8 is a cross-sectional view showing a first process of the manufacturing method for the bundle of hairs relating to the present invention;

[0017] FIG. 9 is a cross-sectional view showing a second process of the manufacturing method for the bundle of hairs relating to the present invention;

[0018] FIG. 10 is a cross-sectional view showing a third process of the manufacturing method for the bundle of hairs relating to the present invention;

[0019] FIG. 11 is a cross-sectional view showing a modification of through holes of a fiber positioning plate in the fiber positioning member of FIG. 7;

[0020] FIG. 12 is a perspective view showing another fiber positioning member used in the manufacturing method for the bundle of hairs relating to the present invention;

[0021] FIG. 13 is a cross-sectional view showing a modification of through holes of a fiber positioning plate in the fiber positioning member of FIG. 12;

[0022] FIG. 14 is a perspective view showing still another fiber positioning member used in manufacturing method for the bundle of hairs relating to the present invention;

[0023] FIG. 15 is a plane view showing a bundle for interior use made by the manufacturing method for the bundle of hairs relating to the present invention;

[0024] FIG. 16 is a perspective view showing the bundle of FIG. 1;

[0025] FIG. 17A is an explanatory view showing a modification of the base of the bundle;

[0026] FIG. 17B is an explanatory view showing a modification of the base of the bundle;

[0027] FIG. 18 is an explanatory view showing a first disposition of synthetic fibers of different diameters inserted to each cylindrical body of the fiber positioning member of FIG. 14;

[0028] FIG. 19 is an explanatory view showing a second disposition of synthetic fibers of different diameters inserted to each cylindrical body of the fiber positioning member of FIG. 14;

[0029] FIG. 20 is an explanatory view showing a third disposition of synthetic fibers of different diameters inserted to each cylindrical body of the fiber positioning member of FIG. 14;

[0030] FIG. 21 is an explanatory view showing a fourth disposition of synthetic fibers of different diameters inserted to each cylindrical body of the fiber positioning member of FIG. 14;

[0031] FIG. 22 is an explanatory view showing a fifth disposition of synthetic fibers of different diameters inserted to each cylindrical body of the fiber positioning member of FIG. 14;

[0032] FIG. 23 is an explanatory view showing that bundles of synthetic fibers spooled out of plural bobbins are inserted to the fiber positioning member through guides;

[0033] FIG. 24 is a front view showing a flexible thin plate of another fiber positioning member;

[0034] FIG. 25 is an explanatory view showing that through holes are formed by winding and inserting the flexible thin plate to a cylindrical member;

[0035] FIG. 26 is a plane view showing a fiber positioning member used for making the bundle of FIG. 2; and

[0036] FIG. 27 is a cross-sectional view showing disposition of animal hairs in a conventional bundle.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0037] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings.

[0038] FIG. 1 shows an embodiment of a bundle of hairs relating to the present invention. This bundle is, for example, applied to bristles of brushes used for calligraphy, painting, stencil, cosmetic, etc. This bundle is composed of a hair portion 2 formed with plural pieces of synthetic fiber 1 and a base 3 which mutually connects base ends of the plural pieces of synthetic fiber 1.

[0039] As shown in FIG. 1 through FIG. 3, the base 3 is discoid, and many synthetic fibers 1 extend from a flat portion 4 of the base 3. And, forth end la of the synthetic fiber 1 is tapered to be thin. In this case, the synthetic fiber 1 may have many micro concave portions on a peripheral face of the tapered forth end. And, the base 3, formed by melting base ends 1b of the many synthetic fibers (thermoplastic synthetic fibers), will be described later in detail.

[0040] The bundle of the present invention has three ways to dispose the synthetic fibers 1 of which the hair portion 2 is composed. Three kinds of bundles A, B, and C are described below. In case of the bundle A, as shown in FIG. 3, the many synthetic fibers 1 are disposed on the flat portion 4 of the base 3 as not to contact one another. And, in case of the bundle B, as shown in FIG. 4, plural (seven, for example) bundles 5 of synthetic fibers are disposed on the flat portion 4 of the base 3 as not to contact one another. The bundle 5 of synthetic fibers is composed of the synthetic fibers 1 of a predetermined number shown in imaginary circles. And, although not shown in Figures, in case of the bundle C, at least one piece of the synthetic fibers 1 and at least one of the bundle 5 of synthetic fibers are disposed on flat portion 4 of the base 3, and at least one of the following conditions {circle over (1)} the fibers 1 do not contact one another, {circle over (2)} the bundles 5 do not contact one another, and {circle over (3)} the fiber 1 and the bundle 5 do not contact each other, is fulfilled. The bundles 5 of synthetic fibers included in the bundle B and bundle C is composed of at least two pieces of the synthetic fiber 1. And, all fibers 1 composing the bundle 5 may contact tightly, or some fibers may not mutually contact.

[0041] And, in each of the bundles A through C, ratio of synthetic fiber non-existent area to an area defined by dimension of a base portion (diameter of the base portion) of each of the hair portions 2 is set according to purposes. The ratio is set to be 30% to 85%. In this case, the purposes include kind of brush to which the bundle is applied, kind of work such as writing, painting, stencil, etc. in which the brush is used, kind of liquid to be applied to the brush, etc. In case of the bundle A shown in FIG. 3 and the bundle B shown in FIG. 4, the area defined by the dimension of the base portion of each hair portion 2 corresponds to the flat portion 4 of the base 3. And, the flat portion 4 of the base 3 may be larger than the area defined by the dimension of the base portion of the hair portion 2 (refer to FIG. 16).

[0042] Therefore, in the bundle of hairs of the present invention, one kind of the synthetic fiber 1, two kinds of the the synthetic fiber 1, or more than two kinds of the synthetic fiber 1 may be used. For example, thermoplastic synthetic fiber can be applied, and one or more than two kinds of thermoplastic synthetic resins selected from the thermoplastic synthetic fibers mentioned below can be used to form the fibers. As the thermoplastic synthetic resins, for example, polyester synthetic resins (polyethylene terephthalate, polybutylene terephthalate, etc.), polyamide synthetic resins (6, 6 nylon, 6-nylon, 6, 10-nylon, 6, 12-nylon, etc.), polyolefine synthetic resins (polyethylene, polypropylene, etc.), polyurethane synthetic resins, polyacrylonitrile synthetic resins (polyacrylonitrile, acrylonitrile-stylene copolymer, acrylonitrile-butadiene-stylene copolymer, etc.) are applicable. Among them, polyester synthetic resins, polyamide synthetic resins, and polyacrylonitrile synthetic resins are preferable for forming the synthetic fiber. Especially, a bundle mainly formed with polyester synthetic resins has higher flexibility than that of a bundle formed with polyamide synthetic resins.

[0043] And, the synthetic fiber 1 used for the bundle of the present invention may have cross-sectional configuration of circle, ellipse, clover-shaped, or star-shaped. And, although the longitudinal cross-section of the synthetic fiber 1 is like a straight line in FIG. 2, the longitudinal cross-section may have concaves and convexes to be crimp configuration (wavy configuration). Liquid holding amount of the bundle is improved by adopting fibers having different configurations such as clover shape or star-shape, or forming the concaves and convexes on the surface of the synthetic fiber 1. And, the bundle may be formed with two or more than two kinds of synthetic fibers 1, while only one kind of the synthetic fiber 1 may be included the bundle.

[0044] And, thickness (diameter) of the synthetic fiber 1 is preferably set to be 0.03 mm to 0.70 mm. The thickness of the synthetic fiber means a thickness of non-tapered part of the synthetic fiber. The bundle may be formed with the synthetic fibers 1 of the same thickness, or synthetic fibers having different thickness. Especially, it is preferable to make the synthetic fibers 1 near the center of the bundle thicker than that on the periphery of the bundle because the bundle (bristle of a brush) becomes firm thereby. This will be described later in detail.

[0045] And, in the bundle of the present invention, while it is described that ratio of the synthetic fiber non-existent area is set to be 30% to 85% of the area defined by dimension of the base portion of the hair portion 2, the above ratio of the area varies according to requirements of kinds of brushes and firmness of the hair portion 2, purpose of the brush, etc. However, when the ratio of the synthetic fiber non-existent area is less than 30%, it is difficult to improve liquid holding ability of the bundle. And, when the ratio of the area is more than 85%, intervals between synthetic fibers, bundles of fibers, or fibers and bundles becomes large, capillary phenomenon is hardly generated, and excellent liquid holding ability is hardly obtained. Therefore, the ratio of the synthetic fiber non-existent area is preferably set to be 30% to 85%. More preferable range is 50% to 80%, and further preferable range is 55% to 75%. In this case, for example, in case that the bundle shown in FIG. 1 is used for calligraphy, the ratio of synthetic fiber non-existent area is set to be 30% to 80%, preferably 35% to 70%, and more preferably 38% to 50%.

[0046] Further, the interval between the synthetic fibers 1 on the base 3, the interval between the bundles 5 of synthetic fibers, and the interval between the synthetic fiber 1 and the bundle 5 are preferably set to generate capillary phenomenon rapidly when the bundle of hairs is dipped in liquid. And, the intervals may have the same size or different sizes in two or more grades.

[0047] Although a case in which the bundle is applied to a bristle of a writing brush is shown in FIG. 1 through FIG. 4, the bundle of the present invention may be applied to other brushes as stationery (for painting pictures, stencil, etc.), a flat brush for cosmetic, and brushes for painting.

[0048] As shown in FIG. 5 and FIG. 6, a bundle of hair for a flat brush or painting brush is composed of a base 3 of rectanguler plate and predetermined plural synthetic fibers 1 extend from a flat portion 4 of the base 3. The base 3 is formed by melting base ends of the plural synthetic fibers 1.

[0049] And, there are three ways (as in the three kinds of bundles A, B, and C described with reference to FIG. 3 and FIG. 4) to dispose the synthetic fibers 1 on the flat portion 4 of the base 3. That is to say, in case of a bundle D (not shown in Figures), the many synthetic fibers 1 are disposed on the flat portion 4 of the base 3 as not to contact one another. And, in case of a bundle E shown in FIG. 6, plural (ten, for example) bundles 5 of synthetic fibers are disposed on the flat portion 4 of the base 3 as not to contact one another. And, in case of a bundle F (not shown in Figures), at least one piece of the synthetic fibers 1 and at least one of the bundle 5 of synthetic fibers are disposed on flat portion 4 of the base 3, and at least one of the following conditions {circle over (1)} the fibers 1 do not contact one another, {circle over (2)} the bundles 5 do not contact one another, and {circle over (3)} the fiber 1 and the bundle 5 do not contact each other, is fulfilled. The bundle 5 of synthetic fibers included in the bundle E and bundle F is composed of at least two pieces of the synthetic fiber 1. And, all fibers 1 composing the bundle 5 may contact tightly, or some fibers may not mutually contact.

[0050] And, in each of the bundles D through F, ratio of synthetic fiber non-existent area to an area defined by dimension of a base portion (length of a side of the base portion) of each of the hair portions 2 is set according to purposes. The ratio is set to be 30% to 85%. In case of the bundle E shown in FIG. 5 and FIG. 6, the area defined by the dimension of the base portion of each hair portion 2 corresponds to the flat portion 4 of the base 3. And, the flat portion 4 of the base 3 may be larger than the area defined by the dimension of the base portion of the hair portion 2.

[0051] In the bundles D through F (for a flat brush or a painting brush) described with reference to FIG. 5 and FIG. 6, kinds of the synthetic fibers 1 are same kinds as described in the above bundles A through C.

[0052] And, configuration of the synthetic fiber 1 included in the bundles D through F can be same as described in the above bundles A through C. However, the forth end of the synthetic fiber 1 may not be tapered according to purposes of the bundles.

[0053] And, thickness of the synthetic fiber 1 included in the bundles D through F is preferably set to be 0.03 mm to 0.70 mm. Especially, it is preferable to make the synthetic fibers 1 near the center of the bundle thicker than that on the periphery of the bundle because the bundle becomes firm thereby. This will be described later in detail.

[0054] And, in the bundles D through F, ratio of the synthetic fiber non-existent area is preferably set to be 30% to 85% of the area defined by dimension of the base portion of the hair portion 2 for the same reason described in the above bundles A through C. More preferable range is 50% to 80%, and further preferable range is 55% to 75%. In this case, for example, in case that the bundle shown in FIG. 5 is used for painting pictures, the ratio of synthetic fiber non-existent area is set to be 30% to 80%, preferably 38% to 70%, and more preferably 40% to 50%.

[0055] The bundle relating to the present invention, normally fixed to a handle or a grip, is used for painting and writing.

[0056] The bundles of the present invention described above are, for example, made by methods described below. First, a manufacturing method of the bundles A through C is described with an example with the bundle A.

[0057] (First Process)

[0058] In the first process, a fiber positioning member 6 having a construction shown in FIG. 7 is used. That is to say, the fiber positioning member 6 is composed of a circular fiber positioning plate 8 on which many circular through holes 7 are formed and a cylinder portion 9 along a periphery of the fiber positioning plate 8 and increasing in diameter outward from an end face side of the fiber positioning plate 8.

[0059] First, necessary number of bobbins of thermoplastic synthetic fiber (refer to FIG. 23) are prepared, the end portions of the synthetic fibers 1 are spooled out of the bobbins and inserted to plural cylindrical guides 10 respectively. Then, each of the end portions of the synthetic fibers 1 are inserted to the through holes 7 of the fiber positioning plate 8 from the cylinder portion 9 side of the fiber positioning member 6, and the end portions of the synthetic fibers 1 are protruded from the fiber positioning plate 8 for a predetermined length. The above is the first process. And, 11 is a hot plate of shallow dish disposed on the fiber positioning plate 8 as to cover each end of the synthetic fibers 1 protruding from the fiber positioning plate 8 for the predetermined length. The hot plate 11 is used in the next second process.

[0060] It is preferable to use two or more kinds of thickness (diameter) of the synthetic fibers 1. Especially, in case that tapering process described later is conducted by immersion into solvent or polishing with immersion into solvent, it is preferable to make thickness of the synthetic fibers 1 inserted to the through holes 7 near the center of the fiber positioning plate 8 larger than that of the synthetic fibers 1 inserted to the through holes 7 on the peripheral side surrounding the through holes 7 near the center. After the insertion as described above, the bundle 5 of synthetic fibers, in which the thick synthetic fibers 1 are disposed on the center, is obtained through the later-described second process and the third process. And, only the synthetic fibers 1 on aimed positions (peripheral side) can be thin and/or short by tapering the bundle 5 with immersion into solvent or polishing with immersion into solvent because the thick synthetic fibers 1 are tapered slowly. And, a bundle of hair easy to use in painting or writing with appropriately firm touch can be obtained.

[0061] And, in the first process, repetition of fiber supply is easily conducted and amount of hair (number of the synthetic fibers 1 ) of the serially manufactured bundles is kept constant by supplying each of the synthetic fibers 1 from each of the bobbins. That is to say, drawing force (tension) of a single fiber of the bundle and number of fibers from the bobbins are constant. And, the plural cylindrical guides 10 prevent the synthetic fibers 1 from being entangled. The guide 10 is, for example, formed with synthetic resin such as vinyl chloride resin or metal, and its configuration, not restricted to cylindrical, may be formed into a square pipe. And, outer faces of the cylindrical guides 10 may be connected and united by adhesive for easy handling.

[0062] And, the fiber positioning member 6 is, for example, preferably formed with metal such as brass, stainless steel, etc. Especially, in case that the later-described tapering is conducted with solvent, stainless steel is preferable considering anti-corrosiveness to the solvent and durability. Although the configuration of the through hole 7 on the fiber positioning plate 8 is circular in the above-described FIG. 7 and FIG. 8, the configuration, not restricted to circular, may be changed to rectangle, triangle, ellipse, etc. For forming the through hole 7 on the fiber positioning plate 8, micro hole punch, electric discharge machine, laser beam machine, photo etching, etc. can be adopted.

[0063] And, mutual interval L between the through holes 7 on the fiber positioning plate 8 is, considering surface tension of liquid, preferably set to be 0.10 mm to 3.00 mm. More preferable range is 0.20 mm to 2.50 mm. When the interval L is more than 3.00 mm, liquid holding ability may be spoiled even with the ratio of the synthetic fiber non-existent area more than 30% of the area defined by the dimension of the base portion of the hair portion 2. On the contrary, when the interval L is less than 0.10 mm, liquid holding amount of the bundle becomes excessively and improperly small.

[0064] And, the ratio of the synthetic fiber non-existent area in the area defined by the dimension of the base portion of the hair portion 2 can be adjusted by changing the configuration of the through hole 7 on the fiber positioning plate 8, size of the through hole 7, the mutual interval L between the through holes 7, etc., or, without changing the construction of the fiber positioning plate 8 itself, by changing the number and position of the through holes 7 to which the synthetic fibers 1 are inserted.

[0065] (Second Process)

[0066] Next, in the second process, as shown in FIG. 8 and FIG. 9, the hot plate 11 of shallow dish is disposed on a flat portion 8a (opposite side to the cylinder portion 9 ) of the fiber positioning plate 8 as to cover each end of the synthetic fibers 1 protruding from the fiber positioning plate 8 for the predetermined length, and heated. Or, heated hot plate 11 is disposed on a flat portion 8aof the fiber positioning plate 8. And, the end portions of the synthetic fibers 1 protruding from the fiber positioning plate 8 is melted by heat of the hot plate 11 to fill the gap between the hot plate 11 and the fiber positioning plate 8 with the melted substance. Then, the hot plate 11 is cooled and the melted substance is formed into a disc to obtain the base 3 which connects and unites the end portions of the synthetic fibers 1.

[0067] And, adhesive may be painted on the flat portion 8a of the discoid base 3 formed beforehand, and the end portions of the synthetic fibers may be adhered to the base 3 to be connected and united by pressing the adhesive-painted side of the flat portion 8 a to the end portions of the synthetic fibers.

[0068] And, the end portions of the synthetic fibers 1, of which protruding length from the fiber positioning plate 8 is sufficiently long, may be covered by a cylindrical hot plate (not shown in Figures) having a bottom to connect and unite the end portions with most dense disposition by melting or adhering and make the base 3.

[0069] (Third Process)

[0070] In the next third process, as shown in FIG. 10, the hot plate 11 is removed, the synthetic fibers 1 are spooled (drawn) out of the fiber positioning plate 8 of the fiber positioning member 6, and a bundle of the synthetic fibers 1 is obtained by cutting the synthetic fibers 1 to be a predetermined length.

[0071] (Fourth Process)

[0072] The above-mentioned bundle A is made by tapering (sharpening) is conducted on the forth ends of the synthetic fibers 1 obtained by cutting.

[0073] As the tapering method, for example, polishing, immersion in solvent, pulling the fiber with heating, polishing with immersion in solvent, or a method in which physical cutting is conducted before immersion in solvent are applicable. Especially, immersion in solvent is preferable. And, it is also preferable to form a taper having many micro concave portions in the tapering process.

[0074] As the above-mentioned solvent, in case of polyester synthetic fiber, for example, one or more solvents selected from sodium hydroxide, potassium hydroxide, sodium bicarbonate, etc., can be used. In case of polyamide synthetic fiber, for example, one or more solvents selected from formic acid, acetic acid, hydrochloric acid, sulfuric acid, methanol solution of m-cresol and calcium chloride, methanol solution of calcium chloride, phenol, P-toluene sulphonate, phosphoric acid, methanol solution of phosphoric acid, etc., can be used. On the other hand, in case of polyacrylonitrile synthetic fiber, for example, one or more solvents selected from dimethyl formamide, dimethyl sulphonoxide, etc., can be used.

[0075] And, to make the above-mentioned bundle B, two or more synthetic fibers 1 are inserted to each of the through holes 7 on the fiber positioning plate 8. And, to make the bundle C, one piece of the synthetic fibers 1 is respectively inserted to some of the through holes 7 on the fiber positioning plate 8, and two or more synthetic fibers 1 are inserted to each of rest of the through holes 7.

[0076] And, although a case that the through hole 7 is formed in a direction at right angles with the flat portion 8a of the fiber positioning plate 8 of the fiber positioning member 6 is shown in FIG. 7 through FIG. 10, as shown in FIG. 11, for example, one of the through holes 7 (7a) positioned on the center of the fiber positioning plate 8 may be formed in the direction at right angles with the flat portion 8a, and rest of the through holes 7 (7b) may be inclined as to concentrate on an entrance side (the cylinder portion 9 side) with the through hole 7a as the center. A bundle, in which forth end portions of hairs are easy to be arranged, is obtained with the fiber positioning member 6 as described above.

[0077] Next, manufacturing method of the above-mentioned bundles D through F with an example with the bundle E.

[0078] (First Process)

[0079] In the first process, a fiber positioning member 6 having a construction shown in FIG. 12 is used. That is to say, plural (ten, for example) circular through holes 7 are formed in rectangle on the fiber positioning plate 8 used in the first process. Concretely, two rows of the through holes 7, each of which includes five through holes 7, are disposed. Mutual intervals between the through holes on one row and on the other row are arranged to be equal respectively.

[0080] First, necessary number of bobbins of the synthetic fiber 1 (refer to FIG. 23) are prepared, each of the synthetic fibers 1 of each bobbin is inserted to the through holes 7 of the fiber positioning plate 8 from the cylinder portion 9 side of the fiber positioning member 6 after going through the cylindrical guide, and the end portions of the synthetic fibers 1 are protruded from the fiber positioning plate 8 for a predetermined length.

[0081] It is preferable to use two or more kinds of thickness (diameter) of the synthetic fibers 1. Especially, in case that tapering process described later is conducted by immersion into solvent or polishing with immersion into solvent, it is preferable to make thickness of the synthetic fibers 1 inserted to the through holes 7 near the center of the fiber positioning plate 8 larger than that of the synthetic fibers 1 inserted to the through holes 7 on the outer side surrounding the through holes 7 near the center. After the insertion as described above, the bundle 5 of synthetic fibers, in which the thick synthetic fibers 1 are disposed on the center, is obtained through the later-described second process and the third process. And, only the synthetic fibers 1 on aimed positions (outer side) can be thin and/or short by tapering the bundle 5 with immersion into solvent or polishing with immersion into solvent because the thick synthetic fibers 1 are tapered slowly. And, a bundle of hair easy to use in painting or writing with appropriately firm touch can be obtained.

[0082] And, in the first process, repetition of fiber supply is easily conducted and amount of hair (number of the synthetic fibers 1) of the serially manufactured bundles is kept constant by supplying each of the synthetic fibers 1 from each of the bobbins. That is to say, drawing force (tension) of a single fiber of the bundle and number of fibers from the bobbins are constant. And, the plural cylindrical guides 10 prevent the synthetic fibers 1 from being entangled. The guide 10 is preferably formed with materials as mentioned in the above-described manufacturing method of the bundles A through C.

[0083] And, the fiber positioning member 6 is preferably formed with materials as mentioned in the above-described manufacturing method of the bundles A through C. And, although the configuration of the through hole 7 on the fiber positioning plate 8 is circular in FIG. 12, the configuration, not restricted to circular, may be changed to rectangle, triangle, ellipse, etc. For forming the through hole 7 on the fiber positioning plate 8, machine and method as mentioned in the above-described manufacturing method of the bundles A through C are applicable.

[0084] And, mutual interval L between the through holes 7 on the fiber positioning plate 8 is, preferably set to be 0.10 mm to 3.00 mm for the same reason as mentioned in the above-described manufacturing method of the bundles A through C. More preferable range is 0.20 mm to 2.50 mm.

[0085] And, the ratio of the synthetic fiber non-existent area to the area defined by the dimension of the base portion of the hair portion 2 can be adjusted by changing the configuration of the through hole 7 on the fiber positioning plate 8, size of the through hole 7, the mutual interval L between the through holes 7, etc., or, without changing the construction of the fiber positioning plate 8 itself, by changing the number and position of the through holes 7 to which the synthetic fibers 1 are inserted.

[0086] (Second Process)

[0087] In the second process, the hot plate 11 (refer to FIG. 9) of rectangular shallow dish having a bottom or rectangular pipe having a bottom is disposed on a flat portion 8a to cover each end of the synthetic fibers 1 protruding from the fiber positioning plate 8 for the predetermined length, and heated. Or, sufficiently heated hot plate 11 is disposed on a flat portion 8a of the fiber positioning plate 8 to cover the ends of the protruding synthetic fibers 1. By this process, the end portions of the synthetic fibers 1 is melted by heat of the hot plate 11 to fill the gap between the hot plate 11 and the fiber positioning plate 8 with the melted substance. Then, the hot plate 11 is cooled and the melted substance is formed into a rectangle plate to obtain the base 3 which connects and unites the end portions of the synthetic fibers 1.

[0088] And, adhesive may be painted on the flat portion 8a of the discoid base 3 formed beforehand, and the end portions of the synthetic fibers may be adhered to the base 3 to be connected and united by pressing the adhesive-painted side of the flat portion 8a to the end portions of the synthetic fibers.

[0089] And, the end portions of the synthetic fibers 1, of which protruding length from the fiber positioning plate 8 is sufficiently long, may be covered by a cylindrical hot plate (not shown in Figures) having a bottom to connect and unite the end portions with most dense disposition by melting or adhering and make the base 3.

[0090] (Third Process)

[0091] In the next third process, the hot plate 11 is removed (refer to FIG. 10), the synthetic fibers 1 are spooled (drawn) out of the fiber positioning plate 8 of the fiber positioning member 6, and a bundle of the synthetic fibers 1, namely, the bundle E is obtained by cutting the synthetic fibers 1 to be a predetermined length. And, forth ends of the obtained bundle of hairs may be tapered or rounded (cut to be round). Methods as mentioned in the above-described manufacturing method of the bundles A through C can be used for the tapering.

[0092] And, to make the bundle D, one piece of the synthetic fibers 1 is inserted to each of the through holes 7 on the fiber positioning plate 8. And, to make the bundle F, one piece of the synthetic fibers 1 is respectively inserted to some of the through holes 7 on the fiber positioning plate 8, and two or more synthetic fibers 1 are inserted to each of rest of the through holes 7.

[0093] And, although a case that the through hole 7 is formed in a direction at right angles with the flat portion 8a of the fiber positioning plate 8 of the fiber positioning member 6 is shown in FIG. 12, as shown in FIG. 13, for example, one of the through holes 7 (7a) positioned on the center of the fiber positioning plate 8 may be formed in the direction at right angles with the flat portion 8 a, and rest of the through holes 7 (7b) may be inclined as to concentrate on an exit side (melted side opposite to the cylinder portion 9) with the through hole 7 a as the center. A bundle opening toward the forth end is obtained with the fiber positioning member 6 as described above.

[0094] Although the fiber positioning member 6 is composed of the fiber positioning plate 8 and the cylinder portion 9 in FIGS. 7 through 13, the cylinder portion 9 can be omitted. And, instead of the member having the construction described above, a member of plural connected cylindrical bodies may be used as the fiber positioning member 6.

[0095] That is to say, in case of making the above-described bundles-A through C, as shown in FIG. 14, for example, a fiber positioning member 6, having a construction in which six cylindrical bodies 12 are connected in approximately circular disposition around one cylindrical body 12 as a center, can be used. In this case, hole of each of the cylindrical bodies 12 is the through hole 7. On the other hand, in case of making the above-described bundles D through F, a fiber positioning member having a construction in which plural cylindrical bodies are connected in rectangular disposition (refer to FIG. 22) can be used. And, cross-sectional configuration of the cylindrical body, not restricted to circular, may be triangle, rectangle, polygonal (honeycomb configuration), etc. The fiber positioning member 6 having the construction of the connected plural cylindrical bodies 12 is easier to make than the fiber positioning member having the fiber positioning plate 8.

[0096] In case of making the bundle with the fiber positioning member 6 composed of the plural cylindrical bodies 12, the ratio of the synthetic fiber non-existent area to the area defined by the dimension of the base portion of the hair portion can be adjusted by changing wall thickness or thickness (diameter) of the cylindrical body 12, or, without changing the construction of the fiber positioning member 6 itself, by changing the number and position for the insertion of the synthetic fibers 1.

[0097] According to the present invention described above, in the bundle of synthetic fiber for painting or writing impregnated with liquid, liquid holding ability of the bundle is improved because percentage of void of the bundle is enlarged by the ratio of the synthetic fiber non-existent area which is 30% to 85% of the area defined by the dimension of the base portion of the hair portion 2. Consequently, amount of liquid held by the bundle is increased, and number of liquid supply in painting and writing is decreased thereby. And, many kinds of liquids can be held by the bundle, and the bundle can be used for various purposes.

[0098] And, according to the present invention, in manufacturing the bundle of synthetic fiber for painting or writing impregnated with liquid, the fiber positioning member 6 provided with plural through holes 7 is prepared, the synthetic fiber 1 is inserted to two or more through holes 7 respectively as the end portion of the synthetic fiber 1 protrudes from the fiber positioning member 6, and the synthetic fibers 1 and the bundles 5 of synthetic fibers can be disposed on predetermined positions as not to contact one another thereby. Further, the fibers are bundled in a condition which fulfills at least one of the following conditions {circle over (1)} the fibers 1 do not contact one another, {circle over (2)} the bundles 5 do not contact one another, and {circle over (3)} the fiber 1 and the bundle 5 do not contact each other by unifying the end portions of the synthetic fibers 1 protruding from the fiber positioning member 6 with melting or adhesion, and the ratio of the synthetic fiber non-existent area can be set more than 30% of the area defined by the dimension of the base portion of the hair portion 2.

[0099] And, according to the manufacturing method relating to the present invention, size of the interval between the bundles of hairs is made appropriate by setting the mutual interval L between the through holes 7 to which the synthetic fibers 1 are inserted to be 0.10 mm to 3.00 mm, capillary phenomenon is smoothly generated in the bundle, and the liquid holding ability of the bundle is improved further.

[0100] And, in the manufacturing method relating to the present invention, qualities of the bundles such as configuration, liquid holding ability, etc. are regularized and the bundles can be efficiently manufactured because amount of hair of the bundle can be made constant by supplying each of the synthetic fibers 1 from each of the bobbins when the synthetic fiber 1 is inserted to two or more of the through holes 7 on the fiber positioning member 6 respectively.

[0101] And, in the manufacturing method relating to the present invention, painting ability and touch of the bundle are made better because proper elasticity is added to the bundle by tapering the forth end of the synthetic fiber 1 obtained in the second process. The tapering is easily conducted by immersion into solvent or polishing with immersion into solvent.

[0102] And, in the manufacturing method relating to the present invention, desired characteristics can be added to the bundle because progress of the tapering the fibers is varied by two or more kinds of thickness of the fibers adopted when the end portions of the synthetic fibers 1 obtained in the second process are tapered by immersion into solvent or polishing with immersion into solvent.

[0103] Further, according to the present invention, ornamental designs can be easily added to the bundle by disposition of colorless or colored fibers of different and/or same diameter. For example, an example of manufacturing method of a rectangle bundle of hairs, composed of thick synthetic fibers 1 (13) disposed in an H turned for 90° as shown in FIG. 15, and thin synthetic fibers 1 (14) having different color from that of the thick synthetic fibers 13 disposed around the thick synthetic fibers 13, is described. A fiber positioning member in which circular through holes of large diameter are disposed in an H turned for 90° and circular through holes of small diameter are disposed around the large through holes is prepared, the thick synthetic fibers 13 are inserted to the large through holes and thin synthetic fibers 14 are inserted to the small through holes respectively. And, end portions of the synthetic fibers 13 and 14 sufficiently distant from the fiber positioning member and most densely disposed are melted or adhered to be united. The fibers 13 and 14, of which end portions are united, are spooled out of the fiber positioning member, cut in a desired length, sharpened with or without rounding the forth ends to obtain the bundle on which a letter H is indicated. Letters and figures are discernible with opposite disposition of the thick and thin synthetic fibers 13 and 14, or combination of colorless and colored fibers of same thickness. And, according to the method above, appearance of the bundle for flat brushes and brushes for painting becomes fine.

[0104] And, according to the present invention, in manufacturing method of the bundle of synthetic fibers for painting or writing impregnated with liquid, a fiber positioning member provided with plural through holes is prepared, synthetic fibers are inserted to a through hole on a desired position, inserted end portions protrude from the positioning member, synthetic fibers thinner than the synthetic fibers above are inserted to through holes surrounding the through holes on the desired position, inserted end portions protrude from the positioning member, the end portions protruding from the positioning member are melted to be united, and a bundle of fibers in which thick synthetic fibers are disposed on the center is obtained. Then, only the synthetic fibers on aimed positions (outer side) can be thin and/or short by tapering the forth end portion of the bundle with immersion into solvent or polishing with immersion into solvent because the thick synthetic fibers are tapered slowly. And, a bundle of hair easy to use in painting or writing with appropriately firm touch can be obtained.

[0105] FIG. 16 shows the above-mentioned bundle B having a discoid base 3 and a hair portion 2 composed of a bundle 5 of synthetic fibers and six bundles 5 of synthetic fibers disposed around the bundle 5 (refer to FIG. 4). In the bundle B, a fluid flowing gap may be formed in the base 3. Concretely, the fluid flowing gap, as shown in FIG. 17A, is obtained by forming at least one through hole 15. For example, plural through holes 15 are formed on positions except the positions of the bundles 5 of synthetic fibers. And, the fluid flowing gap, as shown in FIG. 17B, may be obtained by notching at least one slit 16 between the bundles 5 of synthetic fibers. For example, plural slits 16 are formed radially between the bundles 5 of synthetic fibers. Both of the through holes 15 and the slits 16 may be formed on the base 3. Although not shown in Figures, the through holes 15 and/or the slits 16 can be formed also on the rectangle base 3 of the bundle E described with reference to FIG. 5.

[0106] As described above, with the fluid flowing gap composed of the through holes 15 and/or the slits 16 formed on the base 3, when the bundle B is applied to a brush of which handle portion contains liquid, the liquid in the handle portion is smoothly and sufficiently supplied to the hair portion 2 through the through holes 15 and/or the slits 16 formed on the base 3. In this case, ratio of the fluid flowing gap (fluid flowing gap ratio) to the flat portion 4 of the base 3 is preferably set to correspond to composition and thickness of the liquid (ink, for example). And, although a case that the flat portion 4 of the base 3 is larger than the area defined by the dimension of the base portion of the hair portion 2 in the bundle of hairs shown in FIG. 16, the flat portion 4 may have the same size of the area defined by the dimension of the base portion of the hair portion 2. And, omitting the bundle 5 of synthetic fibers on the center of the bundle B and forming there a through hole 15, when the bundle B is applied to a brush of which handle portion contains liquid, a transfer core supplying the liquid in the handle portion is inserted to the through hole 15.

[0107] And, in the bundle A described with reference to FIG. 3, the fluid flowing gap composed of the through holes 15 and/or the slits 16 may be formed on the base 3 (refer to FIG. 17). In this case, the synthetic fiber 1 is arranged beforehand not to be disposed on the positions on the base 3 on which the through holes 15 and/or the slits 16 are formed. And, the transfer core may be inserted (as described above) to the through hole 15 formed on the center of the base 3. With this arrangement, when the bundle A is applied to a brush of which handle portion contains liquid, the liquid in the handle portion is smoothly and sufficiently supplied to the hair portion 2 through the through holes 15 and/or the slits 16 formed on the base 3.

[0108] Next, as described above, the hair portion 2 may be composed of two or more kinds of synthetic fibers. This is described below in further details.

[0109] As shown in FIG. 16 and FIG. 18, for example, in case of the bundle B that the hair portion 2 is composed of a bundle 5 of synthetic fibers and six bundles 5 of synthetic fibers disposed around the bundle 5, the bundle B may be composed by that the diameter of the synthetic fiber 1 disposed on the center of the base 3 is differentiated from the diameter of the synthetic fiber 1 disposed on the peripheral area surrounding the center. That is to say, the diameter of the synthetic fiber 1 inserted to the through hole 7 on the desired position (the center) on the fiber positioning member 6 is differentiated from the diameter of the synthetic fiber 1 inserted to the other through holes 7 on the peripheral side surrounding the through hole 7 on the desired position.

[0110] Concretely, the synthetic fibers 1 of large diameter (the thick fibers 13) of a predetermined number are inserted to the through hole 7 of the cylindrical body 12 (12a) on the center of the fiber positioning member 6 composed of seven cylindrical bodies 12, and the synthetic fibers 1 of small diameter (the thin fibers 14 ) of a predetermined number are respectively inserted to each of the through holes 7 of the cylindrical bodies 12 (12b) on the peripheral side of the cylindrical body 12a. In this case, as shown in FIG. 23, a bundle G of predetermined plural synthetic fibers is rolled up onto each of the bobbins 1 i beforehand, the bundle G of synthetic fibers spooled out of the bobbin 17 is inserted to the cylindrical guide 10, and then, to the through hole 7 of the fiber positioning member 6. In FIG. 23, the bundle G of synthetic fibers is shown by one line for simplification.

[0111] Then, as described above, the end portions of the synthetic fibers 1 protruding from the fiber positioning member 6 are united and bundled by melting or adhesion to make the base 3 (refer to FIG. 9), drawn out of the fiber positioning member 6 to cut into a predetermined length (refer to FIG. 10), and the forth end 1a of each of the cut synthetic fibers 1 is tapered to obtain the bundle B. In the obtained bundle B, the ratio of the synthetic fiber non-existent area is set to be 30% to 85% of the area defined by dimension of the base portion of the hair portion 2 for the above-described reason.

[0112] The bundle 5 of synthetic fibers composed of the thick fibers 13 is disposed on the center of the hair portions 2 by making the bundle B as described above. The bundle 5 of synthetic fibers on the center serves as “the principal hair” which is a long hair in the midst of hairs of a brush and the most important for good writing. By this bundle 5, usefulness, good touch, and firmness of the hair portion 2 are obtained, and irregularity of the forth ends of the hairs is decreased. And, different from manual work of craftsmen, brushes can be mass-produced with stable quality of the bundle of hairs.

[0113] And, as shown in FIG. 16 and FIG. 19, in the bundle B of which hair portion 2 is composed of plural bundles 5 of synthetic fibers, the diameter of the synthetic fiber 1 disposed on a center row of the base 3 may be differentiated from the diameter of the synthetic fiber 1 disposed on rows on both sides of the center row. That is to say, the diameter of the synthetic fiber 1 inserted to the through hole 7 on a desired row on the fiber positioning member 6 is differentiated from the diameter of the synthetic fiber 1 inserted to the through hole 7 on the both sides of the center row.

[0114] Concretely, the synthetic fibers 1 of large diameter (the thick fibers 13) of a predetermined number are respectively inserted to the through holes 7 of the cylindrical bodies 12 (12c) on the center row of the fiber positioning member 6 composed of seven cylindrical bodies 12, and the synthetic fibers 1 of small diameter (the thin fibers 14) of a predetermined number are respectively inserted to each of the through holes 7 of the cylindrical bodies 12 (12d) on the both sides of the cylindrical bodies 12c of the center row. Then, as described above, the end portions of the synthetic fibers 1 protruding from the fiber positioning member 6 are united and bundled by melting or adhesion to make the base 3, drawn out of the fiber positioning member 6 to cut into a predetermined length, and each of the cut synthetic fibers 1 is tapered to obtain the bundle B. In the obtained bundle B, the ratio of the synthetic fiber non-existent area is set to be 30% to 85% of the area defined by dimension of the base portion of the hair portion 2.

[0115] In the bundle B made as described above, plural bundles 5 of synthetic fibers composed of the thick fibers 13 are disposed in a row on the center row of the hair portion 2. That is to say, the bundle B, in which the above-described “principal hairs” are disposed in a row on the center, is obtained.

[0116] Although it is described that the bundle 5 of synthetic fibers on the center is composed of the thick fibers 13 to form “the principal hair” in the bundle B shown in FIG. 18, the bundle 5 of synthetic fibers may be composed of a combination of the thick fibers 13 and the thin fibers 14. That is to say, as shown in FIG. 20, two or more kinds of the synthetic fibers 1 are inserted to the same through hole 7 on the fiber positioning member 6.

[0117] Concretely, the thick fibers 13 and the thin fibers 14 of a predetermined number are inserted to the through hole 7 of the cylindrical body 12 (12a) on the center of the fiber positioning member 6 composed of seven cylindrical bodies 12, and the thin fibers of a predetermined number are respectively inserted to each of the through holes 7 of the cylindrical bodies 12 (12b) on the peripheral side of the cylindrical body 12a. Then, the bundle B is obtained by similar process as described above. In the obtained bundle B, the ratio of the synthetic fiber non-existent area is set to be more than 30% of the area defined by dimension of the base portion of the hair portion 2.

[0118] With this bundle B made as described above, firmness of “the principal hair” can be adjusted because the ratio of the thick fibers 13 to the thin fibers 14 of the bundle 5 of synthetic fibers disposed on the center of the hair portion 2 is changeable.

[0119] And, as shown in FIG. 21, the bundle B may be made by that the thick fibers 13 and the thin fibers 14 of predetermined number are mixed and inserted to each of the through holes 7 of predetermined plural or all cylindrical bodies 12 of the fiber positioning member 6. With this bundle B made as described above, the synthetic fibers 1 of different diameters can be disposed on the entire hair portion 2 at random or uniformly. In the obtained bundle B, the ratio of the synthetic fiber non-existent area is set to be 30% to 85% of the area defined by dimension of the base portion of the hair portion 2.

[0120] And, as shown in FIG. 22, when a fiber positioning member 6 composed of plural cylindrical bodies 12 in rectangle, concretely, three rows of five cylindrical bodies 12 for example, is used, the bundle E for flat brushes and brushes for painting (as described with reference to FIG. 5 and FIG. 6) may be made by that the thick fibers 13 of a predetermined number are inserted to each of the cylindrical bodies 12 (12c) of the central row, and the thin fibers 14 of a predetermined number are inserted to the cylindrical bodies 12 (12d) on the both sides of the central row. With this bundle E made as described above, the bundles 5 of synthetic fibers composed of the thick fibers 13 are disposed in a row, and the bundle E for flat brushes and brushes for painting, in which “the principal hairs” are disposed in a row on a central portion, can be obtained. In the obtained bundle E, the ratio of the synthetic fiber non-existent area is set to be 30% to 85% of the area defined by dimension of the base portion of the hair portion 2.

[0121] And, in FIG. 22, the bundle E may be made by that the thick fibers and the thin fibers are mixed and inserted to each of the through holes 7 of the cylindrical bodies 12 of the central row. And, the bundle E may be made by that the thick fibers and the thin fibers are mixed and respectively inserted to the through holes of all the cylindrical bodies 12.

[0122] And, in the manufacturing method for bundle of hairs of the present invention, as shown in FIG. 24 and FIG. 25, the bundle B having a hair portion composed of plural bundles of synthetic fibers and a base can be made with a fiber positioning member 6 composed of a wavy concavo-convex flexible thin plate 19 having plural arc concave portions 18a and arc convex portions 18b on an obverse face and a reverse face (refer to FIG. 16). That is to say, the fiber positioning member 6, in which plural through holes 7 are formed with the arc concave portions 18a elastically deformed approximately circular, is obtained by winding the flexible thin plate 19 from one side as shown by an arrow P. In this case, a method in which the flexible thin plate 19 is wound from an end side with bundles of synthetic fibers respectively placed on each of the concave portions 18a is used. In this method, the flexible thin plate 19 is wound with a bundle of synthetic fibers of large diameter placed on the concave portion 18a on the end side and bundles of synthetic fibers of small diameter placed on the other concave portions 18a. The bundle of synthetic fibers of large diameter serving as “the principal hair” is certainly disposed in the through hole 7 on the center of the fiber positioning member 6 formed by the winding. And, the fiber positioning member 6 formed by the winding may be held by an outserted cylindrical member 20. And, the flexible thin plate 19 may be wound to form the fiber positioning member 6, held by the outserted cylindrical member 20, and then, each of the bundles of synthetic fibers may be inserted to each of the through holes 7.

[0123] After the insertion of the bundles G of synthetic fibers to the fiber positioning member 6 constructed as described above, the end portions of the synthetic fibers 1 protruding from the fiber positioning member 6 are united and bundled by melting or adhesion to make the base 3, drawn out of the fiber positioning member 6 to cut into a predetermined length, and each of the cut synthetic fibers 1 is tapered to obtain the bundle B. In the obtained bundle B, the ratio of the synthetic fiber non-existent area is set to be 30% to 85% of the area defined by dimension of the base portion of the hair portion 2. And, one piece of the synthetic fiber 1 may be inserted to each of the through holes 7, or one piece of the synthetic fiber 1 may be inserted to the through holes 7 on desired positions and plural synthetic fibers 1 may be inserted to the rest of the through holes 7. And, the flexible thin plate 19 may be wavy concavo-convex composed of concave portions and convex portions having triangle configuration.

[0124] According to the manufacturing method for bundle of hairs with the winding method as described above, even with many through holes 7 formed in the fiber positioning member 6, the bundle of the thick synthetic fibers serving as “the principal hair” is easily and certainly disposed in the through hole 7 on the center of the fiber positioning member 6. That is to say, a bundle in which “the principal hair” is placed on the center can be easily and certainly obtained, and the bundle can be easily made to correspond to the size of the brush. And, in comparison with boring of many through holes with small intervals on a board, the fiber positioning member 6 can be easily made, and the mutual interval L between the through holes 7 can be easily set to be small. And, the diameter of the through hole 7 can be easily altered by regulating winding pressure of the flexible thin plate 19, and through holes 7 having different diameters can be mixed. And, the ratio of the synthetic fiber non-existent area to the area defined by dimension of the base portion of the hair portion 2 can be adjusted by changing the thickness of the flexible thin plate 19 or number of concavo-convex waves, changing the number and positions of the bundles G of synthetic fibers without changing the construction of the flexible thin plate 19 itself, or loosening the winding of the flexible thin plate 19 to enlarge the interval between the bundles G of synthetic fibers. By this adjustment, for example, the bundle can be appropriate for paint of high viscosity.

[0125] In the present invention, not restricted to the embodiments above, for example, while the case that the bundle of hair is made with two or more kinds of synthetic fibers 1 having different diameters is mainly described, the bundle may be made by that two or more kinds of synthetic fibers having different longitudinal cross-sectional configurations are mixed, two or more kinds of synthetic fibers having different cross-sectional configurations are mixed, or synthetic fibers having different diameters, cross-sectional configurations, and longitudinal cross-sectional configurations are combined and mixed. And, the diameter of the synthetic fibers 1 may be gradually enlarged from the center of the hair portion 2 to the peripheral side to correspond to requirement and demand in the market.

[0126] Examples of the present invention will be described below in detail with reference to Figures.

EXAMPLE 1

[0127] A fiber positioning member 6 made of brass having the construction shown in FIG. 7 in which the diameter of the through hole 7 of the fiber positioning plate 8 is slightly larger than 0.15 mm, the number of the through holes 7 is 560, and the mutual interval between the through holes 7 is 0.3 mm is prepared.

[0128] 560 bobbins of a polyamide synthetic fiber, namely, nylon 610 fiber (of which diameter is 0.15 mm) are prepared, the synthetic fiber of each of the bobbins is inserted to a tube of vinyl chloride as a guide and to the through hole 7 of the fiber positioning plate 8 from the cylinder portion 9 side of the fiber positioning member 6, and the end portions of the inserted fibers are protruded from the fiber positioning plate 8. Then, a hot plate of shallow dish is disposed on the fiber positioning plate 8 as to cover the protruding end portions of the synthetic fibers, and the hot plate is heated to melt the end portions of the fibers and cooled to make a discoid base.

[0129] Next, after removal of the hot plate, the fibers are spooled out of the fiber positioning plate 8 and cut into a predetermined length to obtain a bundle of synthetic fibers of which length is 40 mm and diameter of the base portion is 5.0 mm. The forth end of the obtained bundle is dipped into methanol solution of calcium chloride to be tapered, and the bundle is made for writing.

[0130] The obtained bundle has the area defined by the diameter of the base portion of 19.63 mm2, and the ratio of the synthetic fiber non-existent area is 50% of the area.

EXAMPLE 2

[0131] A fiber positioning member 6 similar to that of the above-described example 1 except the construction of the fiber positioning plate 8 as shown in FIG. 26 is prepared. That is to say, 19 through holes 7 are densely disposed on the fiber positioning plate 8 as to be within a circle approximately. The mutual intervals among the through holes 7 are equal. In this case, the diameter of the through hole 7 is set to be 1.6 mm, and the mutual interval between the through holes 7 is set to be 0.40 mm.

[0132] Seven bobbins of a strand of 80 pieces of polyamide synthetic fiber, namely, nylon 610 fiber (of which diameter is 0.15 mm) are prepared, the strand of 80 synthetic fibers of each of the bobbins is inserted to a guide similar to the guide described in the example 1 and to the seven through holes 7 disposed near the center of the fiber positioning plate 8 from the cylinder portion side of the fiber positioning member, and the end portions of the inserted fibers are protruded from the fiber positioning plate 8. Then, a hot plate of shallow dish is disposed on the fiber positioning plate 8 as to cover the protruding end portions of the synthetic fibers, and the hot plate is heated to melt the end portions of the fibers and cooled to make a discoid base.

[0133] Next, after removal of the hot plate, the fibers are spooled out of the fiber positioning plate 8 and cut into a predetermined length to obtain a bundle of synthetic fibers of which length is 40 mm and diameter of the base portion is 5.6 mm. The forth end of the obtained bundle is dipped into methanol solution of calcium chloride to be tapered, and the bundle is made for writing.

[0134] The obtained bundle has the area defined by the diameter of the base portion of 24.62 mm2, and the ratio of the synthetic fiber non-existent area is 40% of the area.

EXAMPLE 3

[0135] A bundle is made by a method similar to that of the example 2 except the mutual interval between the through holes set to be 1.00 mm.

[0136] The obtained bundle has length of 40 mm, diameter of the base portion of 6.8 mm, the area defined by the diameter of the base portion of 36.30 mm2, and the ratio of the synthetic fiber non-existent area is 60% of the area.

EXAMPLE 4

[0137] A bundle is made by a method similar to that of the example 2 except the mutual interval between the through holes set to be 2.30 mm.

[0138] The obtained bundle has length of 40 mm, diameter of the base portion of 9.4 mm, the area defined by the diameter of the base portion of 69.36 mm2, and the ratio of the synthetic fiber non-existent area is 80% of the area.

EXAMPLE 5

[0139] A bundle is made by a method similar to that of the example 2 except the mutual interval between the through holes set to be 3.00 mm.

[0140] The obtained bundle has length of 40 mm, diameter of the base portion of 10.8 mm, the area defined by the diameter of the base portion of 91.56 mm2, and the ratio of the synthetic fiber non-existent area is 85% of the area.

EXAMPLE 6

[0141] A bundle is made by a method similar to that of the example 2 except the mutual interval between the through holes set to be 1.20 mm.

[0142] The obtained bundle has length of 40 mm, diameter of the base portion of 7.2 mm, the area defined by the diameter of the base portion of 40.69 mm2, and the ratio of the synthetic fiber non-existent area is 65% of the area.

EXAMPLE 7

[0143] A fiber positioning member similar to that of the example 2 except the mutual interval between the through holes set to be 1.40 mm is prepared.

[0144] A bobbin of a strand of 80 pieces of polyamide synthetic fiber, namely, nylon 610 fiber (of which diameter is 0.15 mm) is prepared, the strand of 80 synthetic fibers of the bobbin is inserted to a guide similar to the guide described in the example 1 and to the through hole at the center of the fiber positioning plate from the cylinder portion side of the fiber positioning member, and the end portions of the inserted fibers are protruded from the fiber positioning plate 8. And, six bobbins of a strand of 80 pieces of polyamide synthetic fiber, namely, nylon 610 fiber (of which diameter is 0.13 mm) are prepared, the strand of 80 synthetic fibers of each of the bobbin is inserted to a guide similar to the guide described in the example 1 and to each of the six through holes around (surrounding) the through hole at the center of the fiber positioning plate from the cylinder portion side of the fiber positioning member, and the end portions of the inserted fibers are protruded from the fiber positioning plate 8. Then, a hot plate of shallow dish is disposed on the fiber positioning plate 8 as to cover the protruding end portions of the synthetic fibers, and the hot plate is heated to melt the end portions of the fibers and cooled to make a discoid base.

[0145] Next, after removal of the hot plate, the fibers are spooled out of the fiber positioning plate 8 and cut into a predetermined length to obtain a bundle of synthetic fibers of which length is 40 mm and diameter of the base portion is 7.6 mm. The forth end of the obtained bundle is dipped into methanol solution of calcium chloride to be tapered, and the bundle is made for writing.

[0146] The obtained bundle has the area defined by the diameter of the base portion of 45.34 mm2, and the ratio of the synthetic fiber non-existent area is 70% of the area.

EXAMPLE 8

[0147] A bundle of synthetic fibers of which length is 40 mm and diameter of the base portion is 5.6 mm is obtained by a method similar to that of the example 2 except preparing seven bobbins of a strand of 80 pieces of polyester fiber of which diameter is 0.15 mm. The forth end of the obtained bundle is dipped into methanol solution of calcium chloride to be tapered, and the bundle is made for writing.

[0148] The obtained bundle has the area defined by the diameter of the base portion of 24.62 mm2, and the ratio of the synthetic fiber non-existent area is 40% of the area.

EXAMPLE 9

[0149] A fiber positioning member 6 having the construction shown in FIG. 14, inner diameter of the cylindrical body 12 is 1.6 mm, and outer diameter of the cylindrical body 12 is 2.0 mm is prepared.

[0150] Seven bobbins of a strand of 80 pieces of polyamide synthetic fiber, namely, nylon 610 fiber (of which diameter is 0.15 mm) are prepared, the strand of 80 synthetic fibers of each of the bobbins is inserted to a guide similar to the guide described in the example 1 and to each of the cylindrical bodies 12, and the end portions of the inserted fibers are protruded from the cylindrical bodies 12. Then, the end portions of the synthetic fibers protruding from the cylindrical bodies 12 are covered with a hot plate of shallow dish, and the hot plate is heated to melt the end portions of the fibers and cooled to make a discoid base.

[0151] Next, after removal of the hot plate, the fibers are spooled out of the fiber positioning plate 8 and cut into a predetermined length to obtain a bundle of synthetic fibers of which length is 40 mm and diameter of the base portion is 6.0 mm. The forth end of the obtained bundle is dipped into methanol solution of calcium chloride to be tapered, and the bundle is made for writing.

[0152] The obtained bundle has the area defined by the diameter of the base portion of 28.26 mm2, and the ratio of the synthetic fiber non-existent area is 50% of the area.

COMPARISON EXAMPLE 1

[0153] 560 pieces of nylon 610 fiber (of which diameter is 0.15 mm) of which end portions are tapered are bundled and fastened with a thread at base end portions as to contact one another, namely, as to be most densely disposed as shown in above-described FIG. 27. Then, the pieces of fiber are united by heating and melting the base end face, and a bundle for a writing brush, of which length is 40 mm and diameter of the base portion is 4.1 mm, is made as not to disunite the fibers.

[0154] The obtained bundle has the area defined by the diameter of the base portion of 13.20 mm2, and the ratio of the synthetic fiber non-existent area is 20% of the area.

COMPARISON EXAMPLE 2

[0155] 560 pieces of nylon 610 fiber (of which diameter is 0.15 mm) of which end portions are tapered are bundled and fastened with a thread at base end portions as to contact one another, namely, as to be most densly disposed as shown in above-described FIG. 27. Then, the pieces of fiber are united by heating and melting the base end face, and a bundle for a writing brush, of which length is 40 mm and diameter of the base portion is 4.3 mm, is made as not to disunite the fibers.

[0156] The obtained bundle has the area defined by the diameter of the base portion of 14.51 mm2, and the ratio of the synthetic fiber non-existent area is 25% of the area.

[0157] 20 obtained bundles of each of the examples 1 through 9 and the comparison examples 1 and 2 are prepared, impregnated with water-color paint, the holding amount of the water-color paint is measured, and average holding amount of the 20 bundles is shown in Table 1 below for the examples 1 through 9 and the comparison examples 1 and 2. 1

TABLE 1
RATIO OF THE SYNTHETIC
FIBER NON-EXISTENTHOLDING AMOUNT
AREA (%)OF PAINT (g)
Example 1500.42
Example 2400.35
Example 3600.45
Example 4800.35
Example 5850.29
Example 6650.40
Example 7700.39
Example 8400.36
Example 9500.43
Comparison200.24
Example 1
Comparison250.26
Example 2

[0158] As clearly shown in Table 1, the bundles of the examples 1 through 9 of which ratio of synthetic fiber non-existent area is more than 30% of the area defined by the diameter of the base portion, in comparison with the comparison examples 1 and 2, have large holding amount of the water-color paint. And, in use of bundles made by a method similar to that of the examples 1 and 2 except the bundles are not tapered as a brush for stencil, sufficient amount of paint is held with one time of supply, and touch on a metal net is good. On the other hand, with the bundle of the example 7 obtained by the method in which the the synthetic fibers inserted to the through hole on the center of the positioning plate of the positioning member is made thicker than the synthetic fibers inserted to the through holes on the Peripheral side, appropriate firm touch is obtained in writing because the central portion of the bundle is harder than the periphery of the bundle.

EXAMPLE 10

[0159] A fiber positioning member 6 made of brass having the construction shown in FIG. 12 in which the diameter of the through hole 7 of the fiber positioning plate 8 is 1.1 mm, the number of the through holes 7 is 10, and the mutual interval L between the through holes 7 is 0.5 mm is prepared.

[0160] Ten bobbins of a strand of 39 pieces of a polyamide synthetic fiber, namely, nylon 610 fiber (of which diameter is 0.15 mm) are prepared, the strand of 39 synthetic fibers of each of the bobbins is inserted to a guide similar to the guide described in the example 1 and to the through holes 7 of the fiber positioning plate 8 from the cylinder portion 9 side of the fiber positioning member 6, and the end portions of the inserted fibers are protruded from the fiber positioning plate 8. Then, a hot plate of shallow dish is disposed on the fiber positioning plate 8 as to cover the protruding end portions of the synthetic fibers, and the hot plate is heated to melt the end portions of the fibers and cooled to make a rectangle base.

[0161] Next, after removal of the hot plate, the fibers are spooled out of the fiber positioning plate 8 and cut into a predetermined length to obtain a bundle for brushes for paint.

[0162] The obtained bundle has the length of 40 mm, the longitudinal dimension of the base portion of 7.5 mm, the lateral dimension of the base portion of 2.7 mm, the area defined by the diameter of the base portion of 20.25 mm2, and the ratio of the synthetic fiber non-existent area is 50% of the area.

COMPARISON EXAMPLE 3

[0163] 390 pieces of nylon 610 fiber (of which diameter is 0.15 mm) are inserted to a rectangle pipe as the fibers contact one another, namely, as the fibers are most densely disposed as shown in above-described FIG. 27 and fastened with a thread at the base end portions. Then, the pieces of fiber are united by heating and melting the base end face, and a bundle for a brush for paint, of which length is 40 mm, longitudinal dimension of the base portion is 4.5 mm, lateral dimension of the base portion is 2.2 mm, is made as not to disunite the fibers.

[0164] The obtained bundle has the area defined by the diameter of the base portion of 9.25 mm2, and the ratio of the synthetic fiber non-existent area is 25% of the area.

[0165] 20 obtained bundles of each of the example 10 and the comparison example 3 are prepared, impregnated with water-color Paint, the holding amount of the water-color paint is measured, and average holding amount of the 20 bundles is shown in Table 2 below for each of the example 10and the comparison example 3. 2

TABLE 2
RATIO OF THE SYNTHETIC
FIBER NON-EXISTENTHOLDING AMOUNT
AREA (%)OF PAINT (g)
Example 10500.38
Comparison250.23
Example 3

[0166] As clearly shown in Table 2, the bundles of the example 10 of which ratio of synthetic fiber non-existent area is more than 30% of the area defined by the diameter of the base portion, in comparison with the comparison example 3 having the ratio of synthetic fiber non-existent area less than 30%, have large holding amount of the water-color paint.

[0167] According to the bundle of hairs of the present invention, the bundle is optimum for various use because the hair portion 2 is, for example, set to have the ratio-of synthetic fiber non-existent area proper to various uses such as writing, painting, etc. That is to say, capillary phenomenon is easily generated and liquid holding ability is improved (number of liquid supply is decreased), and very usable brushes for writing and painting can be obtained.

[0168] And, the liquid holding ability of the bundle is certainly improved.

[0169] And, intervals for improvement of the liquid holding ability can be easily formed among the synthetic fibers 1 by the hair portion 2 composed of the synthetic fibers 1 having different diameters, the synthetic fibers 1 having different longitudinal cross-sectional configurations, the synthetic fibers 1 having different cross-sectional configurations, or the synthetic fibers 1 having different cross-sectional configurations and different longitudinal cross-sectional configurations.

[0170] And, the bundle is very usable with firm hair portion 2, hairs are hardly disheveled, further, with firm touch in writing and painting because “the principal hair” composed of the thick fibers 1 (13) is disposed on the center of the hair portion 2. Especially, this bundle is good for writing.

[0171] And, the bundle is very usable with firm hair portion 2, hairs are hardly disheveled, further, with firm touch in writing and painting because “the principal hairs” composed of the thick fibers 1 (13) are disposed on the central row of the hair portion 2. Especially, this bundle is good for a flat brush and a brush for paint.

[0172] Further, according to the bundle of hairs of the present invention, the bundle can be used for a brush which contains liquid in its handle portion, and the liquid is smoothly and sufficiently supplied to the hair portion 2. In this case, ratio of the fluid flowing gap can be freely changed corresponding to composition, thickness, and viscosity of the liquid.

[0173] According to the manufacturing method for bundle of hairs of the present invention, bundles are efficiently mass-produced with stable quality and without high skill. And, in the production of the bundles, the ratio of synthetic fiber non-existent area to the area defined by the dimension of the hair portion 2 can be set to correspond to purposes, and a bundle having improved liquid holding ability can be obtained thereby.

[0174] And, it is easy to set the ratio of synthetic fiber non-existent area to the area defined by the dimension of the hair portion 2 to be high.

[0175] And, it is easy to set the ratio of synthetic fiber non-existent area to the area defined by the dimension of the hair portion 2 to be low.

[0176] And, a bundle of which “principal hair” is positioned at the center of the bundle can be obtained easily and certainly and the bundle is easily adjusted to the thickness of the brush because the fiber positioning member 6 can be formed with the flexible thin plate 19 wound to form the through holes 7. And, the fiber positioning member 6 having many through holes with small mutual intervals L can be easily formed. And, the diameter of the through hole 7 can be easily changed by adjusting the winding pressure of the flexible thin plate 19.

[0177] And, the hair portion 2 is composed of the synthetic fibers 1 having different diameters, the synthetic fibers 1 having different longitudinal cross-sectional configurations, the synthetic fibers 1 having different cross-sectional configurations, or the synthetic fibers 1 having different cross-sectional configurations and different longitudinal cross-sectional configurations, and intervals for improvement of the liquid holding ability can be easily formed among the synthetic fibers 1 thereby.

[0178] And, “the principal hair” composed of the thick fibers 1 (13) is disposed on the center of the hair portion 2, and a highly usable bundle, having the firm hair portion 2, hairs hardly disheveled, further, firm touch in writing and painting, can be obtained thereby. Especially, a bundle good for writing can be obtained.

[0179] And, “the principal hairs” composed of the thick fibers 1 (13) are disposed on the central row of the hair portion 2, and a highly usable bundle, having the firm hair portion 2, hairs hardly disheveled, further, firm touch in writing and painting, can be obtained thereby. Especially, a bundle good for a flat brush and a brush for paint can be obtained.

[0180] Further, according to the manufacturing method for bundle of hairs of the present invention, a bundle in which synthetic fibers 1 having different diameters are disposed on the entire hair portion 2 at random and uniformly can be obtained.

[0181] And, a bundle having excellent liquid holding ability can be obtained.

[0182] While preferred embodiments of the present invention have been described in this specification, it is to be understood that the invention is illustrative and not restrictive, because various changes are possible within the spirit and indispensable features.