Products > Rotary Brushes > Construction & Design Info > Staple Set Tufted Cylinder & Circular Brushes

Staple Set Tufted Cylinder and Circular Brushes

• Detailed Information about Stapled Set Brushes
• Standard Nomenclature
• Stapled Set Brush Shapes and Styles

Detailed Information about Stapled Set Brushes

Stapled set tufted brush construction provides consistent product quality and reliability. The versatility of brush patterns, fill material choices, solid block or core materials available offers numerous design capabilities and options compared to any other brush construction. Tanis Incorporated offers a full range of bristle materials including synthetics, natural bristle, wire and abrasive nylon. Solid block and core materials most commonly selected are wood and plastics including polyvinyl chloride (PVC), polypropylene, high-density polyethylene, ultra-high molecular weight (UHMW), ABS and delrin.

Stapled brushes consist of a series of individual tufts of fill material inserted into a drilled hole in a solid block of plastic or wood. The tufts of material are secured to the block by a wire staple. Stapled set brushes are made with a variety of hole or tuft patterns to obtain the desired brush density and brushing effect. Hole patterns can be made with virtually any brush pattern. The function of the brush application and fill material size determines the density and size of the tuft holes. The brush fill material is trimmed in the final processing stage to give the desired shape required.

Tanis Incorporated technical sales and engineering staff will guide you making your selections of fill sizes and materials along with the block or core materials required for the environment of the application. Please call, fax or e-mail our staff about your stapled set brush requirements. Standard nomenclature and applications are highlighted below for your convenience. Please use our experience to design and manufacture an innovative custom stapled set brush to solve your application problems.

Standard Nomenclature

Hole or Tuft Diameter
The individual hole or tuft diameter can range from, but not limited to, .078” up to 7/16”. The hole depth depends on the diameter of the hole or tuft diameter. The hole depth will help determine the block or core wall thickness required for the brush design. Generally the tuft holes are drilled and filled vertically. Depending on the application, the hole can be drilled and material inserted at an angle. The material can be angled in two ways either flared or converged. A straight filled and angled filled brush is shown in the adjacent picture.

Hole Pattern & Design
With the latest machine technology, the hole pattern and design is virtually endless. Our automated stapling machines can read CAD programs without requiring endless hours of programming on the machine. Small quantity and single tufted patterns can be manufactured on a semiautomatic or hand machine.

Rotary Brush Hole Pattern & Design
Stapled set rotary brushes offer both the straight and staggered patterns plus two additional brush design patterns. Spiral (helical) and chevron (herringbone) patterns are also possibilities for stapled set rotary brushes. A spiral or herringbone pattern is used to orient product in a specific direction or used to give a specific brushing effect. Rotary brush patterns are illustrated.

straight pattern

staggered pattern

chevron pattern

spiral pattern

Stapled Set Tufted Brush Shapes and Styles

Cylinder or Wheel Brushes
A cylinder or wheel brush has tufts inserted into a round block or core construction. As with coil wound Rotary Brushes, stapled set brushes can be made with similar core constructions. The plastic or wood core can be press fit onto a shaft, internal tube made with collars to accept the customer’s shaft, or a tube construction made with journal ends. The internal core construction can be made of steel, stainless steel or aluminum material. Bearings can be press fit into wheel brushes. Core materials are hardwood or plastic.

Common Applications
As there are endless shapes, styles and configurations for stapled set brushes there are an equal number of applications for this brush construction. Specific applications for stapled set brushes include:

• Cleaning plates in printing/processing developing machines
• Guiding paper in sheet offset printing
• Transporting and separating paper and corrugated product
• Clean conveyor belts
• Positioning and transporting product on conveyor lines
• Washing and cleaning glass
• Wax and polishing fruits and vegetables
• Packaging pills in the pharmaceutical industry
• Texturing and waxing downhill and cross-country skis
• Carpet vacuuming and cleaning
• Labeling and cleaning plastic and glass bottles
• Product support for sheet metal processing
• Wood surface treatment