Flat punched brushes
Generally they are mounted on fixed parts of machines, however sometimes they can also be installed on cylindrical drums to form a roller or on skids with reciprocating motion. The work surface can be continuous, in sectors or shaped according to the customer’s design. In these brushes, flatness is often fundamental, both as regards the brush body and the shaving, which defines the work surface.
Flat brushes are used for:
- Precision brushes
- Brushes with complex geometric shapes
- Transportation plans
- Guides for sliding products
- Complex shape barriers for chips and powders
The bunches are generally straight, but it is possible to give them an inclination as in the Figure, in order to make the brush asymmetrical.
This can be useful to make its action more delicate or to prevent the displacement of the material in the opposite direction to the motion. The angle α cannot generally exceed 30 °
The brush body is generally synthetic, but also in aluminum in case of flatness tolerances. Composite materials can also be used, such as wooden core and aluminum sheath to have both lightness and rigidity.
We can also couple a synthetic base with a shaped metal plate to allow for a solid mounting. Flat brushes are usually mounted on plates. For this purpose we can provide smooth holes or, on rigid materials such as PVC or aluminum, threaded holes. We can also mount metal threaded inserts. The aluminum brushes can be self-supporting and have joints for mechanical parts.
To obtain large brush surfaces, on which to handle or process slabs, it is necessary to compose several brushes side by side. We have therefore developed a modular product that has practically no dimensional limits. It is a 10 mm thick PVC sheet with dimensions of 200×1500 mm, which has joints on the sides.
The brushes are quickly produced on this basis and then assembled and finally cut according to the customer’s design. This system, which has been patented by us, allows us to produce large and special pieces even in small quantities while maintaining a competitive price.
Linear brushes with one or more rows of bunches are available, to be mounted on a metal profile. The latter gives rigidity and flatness to the brush with synthetic body, and allows the customer to replace the worn strips without intervening on the assembly system.
The stainless steel profile is also available on request. Below is the standard measurement of the brush body and its profile. Other sizes are available upon request.
The special feature of the brush is that the work surface is made up of millions of individual elements, which are the ends of the individual filaments.
This gives the brush an adaptability that no other element, however deformable, can have.
It depends on various factors. In a nutshell, it can be said that 2 mm is a good compromise. The important thing is that the filaments of the brush work “at the tip” and not on the side.
Depending on the materials used and the dimensions, there is a tensile limit load that a single bunch can withstand.
Beyond this limit the bunch comes off, therefore the brush must be calculated according to the use. This limit can be greatly increased by building “sewn” or “tied” brushes by hand, where a continuous steel wire is placed instead of a single anchor element.
There is no single answer. Speaking for example of cylindrical brushes, the strip brush is generally cheaper when dimensions are important (e.g. over one meter in length). For small dimensions, punched brushes are certainly more suitable and convenient.
It can only happen if the brush has a manufacturing defect, like any other type of object (e.g. a roller made with silicone flakes, one of which is defective and breaks).
When it is important that no contamination occurs, it is advisable to use synthetic (non-natural) fibers with a diameter greater than or equal to 0.15 mm.
Virtually all degrees of hardness can be had, from very soft to very hard. In fact, the hardness is given by the combination between the diameter of the filament, its free length and the density of the bunches.
Of course, we can provide FDA or FOOD GRADE certifications and filament traceability.
Unfortunately not, as it is the machine + brush assembly that must be ATEX certified, not just the brush.
It is however possible to provide the materials that the certifier requires, eg. conductive bases, conductive filaments etc …
Generally speaking it is possible, but it is necessary to evaluate if it is economically convenient, and it is not always. Furthermore, in the case of a punched brush, it is not advisable to regenerate the brush more than twice in order not to reduce the holding of the bunches.