Products > Staple Brushes > Construction & Design Info

Staple Set Tufted Brush Construction & Design Info

• 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 fill 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. Flexible materials like soft, flexible polyvinyl chloride and urethane are also available. Flexible body materials allow you to bend the brush around a corner or radius. Block shapes, materials and designs can be combined to develop a tailor-made product for your application.

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

straight filled

angle filled

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.

straight pattern

staggered pattern

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. The two most common hole patterns for flat style brushes are a straight or staggered pattern illustrated.

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

Flat Style Brushes
Flat style brushes are the most common and widely used brush shape and style. A flat style brush consists of a rectangular or square shaped block. Stapled strip brushes are included in this category. A stapled strip brush is a thin rectangular or square block with one, two, or three tufts of rows stapled the length of the block. Long flat style stapled brushes are commonly referred to as lag brushes. Flat style blocks can be designed and machined with the mounting holes for easy, ready to assemble and attach directly to your machine. A flat style brush is the easiest and most cost effective stapled set brush to design and manufacture. The diagram illustrates a flat style brush.

RFQ/Design Form

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.

RFQ/Design Form

Disc - no arbor hole

Disc - with arbor hole

Disc Style Brushes
A disc style brush will be a round block and fill material will be stapled on one side parallel to the axis at right angles to the largest diameter. The block will typically have an arbor hole centered in the block or collar to affix to the shaft for mounting purposes. A drive hole or mounting holes can be machined for easy attachment if required. This brush style is designed to be power driven. A disc brush is also known as a face brush.

RFQ/Design Form

Trim Styles
The brush fill material is trimmed in the final processing stage to give the desired shape you need. There are several trim styles to select from to finalize the brush design. Choices include a flat, bevel, concave, convex, step or double bevel trim style. Each style is illustrated.

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
• Brush seals for doors, overhead garage doors and dock levelers
• Transporting and separating paper and corrugated product
• Clean conveyor belts
• Positioning and transporting product on conveyor lines
• Seals for product containment
• 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
• Seals for shot blasting industry
• Wood surface treatment