Industrial brushes have a wide range of applications, including brushes and brush rollers, with different manufacturing materials selected based on varying operating environments. The category is rich and diverse, and is analyzed as follows.
Surface treatment of metal hardware materials.
Cleaning, polishing, and other processes of various industrial products and materials.
Surface cleaning and grinding of printed circuit boards.
Surface cleaning of steel plates by shot blasting.
In general, industrial brush rollers are widely used in metallurgical industries, such as high temperature strip transport, surface treatment, cleaning, removal of oxides, and polishing of plates.
Horse nail brush planting
This is the most traditional brush-making process, where the brush bristles are punched into the brush rollers or plates one bundle at a time using a horse nail planting machine. Brushes made using this process have the most widespread applications. Firstly, the cost is lower; the cost of the brush, which is a consumable, must be considered.
However, horse nail planting-made industrial brush rollers have several disadvantages:
Firstly, the density is not high, because there must be a certain distance between the punched holes for brushing, so a high-density effect cannot be achieved. With some special industries requiring high-density brush rollers for operations, this type of brush roller cannot be used.
Secondly, the bonding strength of the brush wire is not strong enough. The so-called horse nail planting method uses iron wire pressed into a "U" clip through a groove to hold the brush wire, and then implants it in the punched hole. The "U" clips intersect in the hole and plug into it, thereby bonding the brush wire to the roller shaft. However, the tensile strength is limited. If some special industries require brush rollers to operate at high speeds, this process for making brush rollers is not ideal.
Brush rollers made using spring brush technology solved the problems of high density and strong bonding strength. During manufacturing, the brush bristles are pressed into aluminum or stainless steel strips to make strip brushes using a strip brush device, and then wound onto the roller shaft. The two ends are welded and firm. In some special industrial production, spring brushes with certain clearances are also required because special effects such as dust removal must be considered.
This involves arranging the brush bristles closely together and placing them in a specific mold. Steel sheets pass through a punching machine to form one brush wheel at a time. During the manufacture of the brush roller, multiple brush wheels can be connected in a series and fixed to the roller shaft. The brush density of brushes made using this process can achieve the highest, but the disadvantage is that the cost is high and the efficiency of manufacture is low.
Injection molding brush
This involves placing the brush bristles in a specially designed mold, and then using an injection molding process to fuse the bristles and brush plate together to form an integrated brush. The advantage of this process is that the bristle bond strength is high because they are fused with the brush plate. Currently, sweeper brushes for environmental sanitation vehicles are made using this process.