STAPLED TUFT BRUSHES
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These
traditional brush style (staple set) modules, can be cut to any size to best fill your
machine bed layout, AND they can be easily replaced as needed |
Stapled tuft brushes
offer the brush designer a wider range of individual brush design
options than any other single brush style. From single tuft to complex
designs stapled brushes can be produced in small quantities on
semiautomatic machines or in high volume on highly automated computer
controlled tufting equipment. Practically any type and size of bristle
material, block or core material, tuft pattern or brush size is within
the range of possibility. When new designs require tooling, brush
patterns are now generated with CAD programs that not only reduce the
time needed to produce tools but also at a much lower cost.
Stapled brushes consist of tufts of filaments inserted into drilled or
molded holes in a solid block or core of wood, plastic, composite,
rubber or leather. The doubled over tuft is secured with a staple at the
base of the hole. As the tufted pattern is filled, the brush fibers are
then trimmed or cut to the required height, either as a part of the
machine stapling process, or as a secondary operation at a separate
trimming station. The staple material is usually made from a lacquer
finish, steel wire. If the application requires special materials as
additional protection against corrosion from moisture or chemicals,
staples can be made from stainless steel or brass wire. Staple diameter
and length is determined by the size and depth of the tuft hole, the
type of bristle material being inserted and, the tuft retention
requirements of the specific application.
Stapled
tuft brushes are manufactured in six BASIC SHAPES or STYLES
STAPLED TUFT BRUSH DESIGNS
Stapled tuft brushes are manufactured in six basic
shapes or styles. Requirements of the application and the characteristics of the
bristle material being used usually determine hole patterns and the densities of
stapled brushes. Today's computer controlled brush making machines are only
limited by block shape and certain size restrictions. Tuft hole diameters can
vary from as small as .086" up to 7/16" and larger. Hole depth is usually at
least 1-1/2 times the hole diameter but this ratio can be reduced in certain
applications where stapled retention can be assured.
Tufts holes are usually
vertical but can be angled (flared or converged) for specific applications.
Brush parts can be trimmed to
many shapes and
styles based on the function of the brush. Specialized
trims can be designed to conform to irregular shapes
and contours.
 Size ranges of stapled
tuft brushes are nearly unlimited. Brushes too small
or too large to be made on automated equipment can always be made in
semiautomatic and hand operated machines. Stapled brushes can be single tuft,
end style brushes as small as 1/8" diameter or huge, flat brushes for metal
stamping machine beds. They can be twelve feet or longer cylinder brushes (same
as large as six feet in diameter) for washing trucks and buses, sheet metal or
carpet; or thousands of in-between sizes and shapes for countless applications.
This chart lists size ranges and design options for staple set brushes that can
be manufactured on Felton's existing equipment. Special tooling can be designed
to handle other requirements that fall outside this range of capabilities.
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