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Anchor Set Brushes: Tufts are wrapped around a piece of rectangular shaped anchor wire and anchored into the tufting hole. This style is especially useful in small depth tufting holes and where block thickness is at a minimum. Anchor set construction is common with toothbrushes and hairbrushes.
Cylinder Brushes: Filaments are affixed to a core by either staple set construction, cord and epoxy, the winding of a strip brush coil around a core, or by combining multiple wheel style brushes side by side.
Disc Brushes: Filaments arise out of a flat plate or disk that is spun such that the working surface is the face of the brush, as opposed to a wheel brush whose working surface is the edge of the brush.
Epoxy Set Brushes (Pitch Set): Tufts or a spread of filaments is set in place and attached using glue, epoxy or pitch. This style of construction creates a very strong and stable bond and is especially useful in applications where filament retention is essential. Traditional paint brushes are epoxy set.
Fused Brushes: A fused brush is made joining the filament to the block using ether heat or RF to melt, weld or fuse the materials together.
Paint Brushes: Traditional paint brushes are often made using epoxy for bonding and an internal card and external ferrule for stiffness control.
Paint Pad Brushes: A painting pad is attached to a block for painting pad applications.
Paint Roller Brushes: A cylinder roller with a textured or fabric cover is attached to a frame for the fast painting of mostly flat surfaces like walls, ceilings and doors.
Power Driven Brushes: Filament is affixed to mounting hardware which may then be attached to a power device. The filament works under speed providing brush and deburring action in surface preparation and conditioning applications. There are three main types of construction:
Cup: A brush on a shank with a cup shaped end.
End: End mounted filaments in many end shape configurations permanently anchored on shanks for cleaning confined or hard to reach areas.
Wheel: Wheel shaped brush attached to mounting hardware with a press and washer.
Staple Set Brushes: Individual tufts are wrapped with pre-cut and shaped wire that forms a staple around the tuft, and is driven into the tufting hole.
Strip Brushes: Filament is laid down uniformly and continuously along a metal or plastic channel backing. With a metal backing strip brush the backing channel is continuously formed in the shape of a U to compress and hold the filament in place. In the case of a plastic strip brush the backing is continuously formed and fused to the filament as they are joined together.
Twisted In Wire Brushes: Twisted in Wire brushes are manufactured by twisting filaments between stem wires. The wire ends may be cut on both ends or looped (cut on one end). There are three different construction types:
Single Stem, Single Spiral: A layer of filament is twisted between two stem wires.
Double Stem, Single Spiral: A layer of filament is twisted between four stem wires, two on each side.
Double Stem; Double Spiral: A layer of filament is twisted between four stem wires, two on each side. Double twisted for increased strength and fill density.
Wire Drawn Brushes: This manufacturing technique involves hand-drawing the filaments through the tufting hole using a length of wire and often tying the wire off in the back of the block. The tufting hole goes all the way through the block to allow the wire to be drawn through.
Wound Brushes, Brooms and Mops: Wound brushes are manufactured by winding wire around the brush fibers on a pole or a stick and may involve secondary stitching of the fibers to create a determined level spread and stiffness. Many corn brooms, mops and daubers are made using this technique.
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