Fusion interlocking bristle strip and method of manufacturing the same

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.