Applications
Deriving electrical loads
Technical definition
The diversion of electrical charges using industrial brushes is a technical solution used to eliminate or dissipate static electricity on certain surfaces, which is generated during production processes, handling, or transport of materials, or simply by the friction of that surface, through the brush filaments of industrial brushes towards other grounded parts and to carry out the electrical discharge.
This electrostatic phenomenon frequently appears in manufacturing lines where there is friction between surfaces, movement of conveyor belts, winding of materials, or handling of plastic films, among many other cases.
Conductive brushes allow establishing a controlled discharge point between the charged surface and a grounded metal structure separated from the former, preventing dangerous accumulations of static electricity. This function is critical in industrial sectors where static electricity can cause safety problems, production defects, or interference in electronic equipment, but mainly potential safety problems for people or facilities.
The correct dissipation of electrostatic charges contributes to improving the safety of facilities, preventing ignition risks in potentially explosive atmospheres, and ensuring the stability of sensitive industrial processes.
Types of brushes for diverting electrical charges
The diversion of static electricity is achieved through different configurations of industrial brushes designed to maintain controlled contact with the charged material. The selection of the brush type depends mainly on the type of process, the geometry of the machine, and the surface that generates the electrostatic charge.
We can differentiate two main types of antistatic brushes:
- Brushes with conductive filaments, whose mission is to have electrical conductivity through themselves to divert electrical charges.
- Brushes with antistatic filaments, which have filaments that do not generate static electricity.
Whose definition is mainly determined by the choice of the appropriate filament.
| Brush filament type | Main application | Recommended brush format |
|---|---|---|
| Carbon fiber | Maximum electrical conductivity, but low resistance | Strips, laths, and cylinders |
| Conductive PA6 | Moderate electrical conductivity with high resistance | Strips, laths, and cylinders |
| Antistatic PA6 | Avoid static generation in motorized work | Discs and cylinders |
| Natural (tampico, horse) | Avoid static generation in motorized work | Strips, laths, and cylinders |
| Brass wire | It is both antistatic and conductive. It does not generate sparks and has hardness and work capacity | Laths, discs, and cylinders |
| Carbon steel wire | It is conductive, and has high hardness and work capacity | Laths, discs, and cylinders |
| Stainless steel wire | It is conductive, and has high hardness and work capacity | Laths, discs, and cylinders |
Conductive brushes with carbon fiber
Brushes with conductive carbon fiber filament are one of the most widely used solutions to dissipate electrostatic charges in industrial lines. Their design consists of a metal or aluminum profile that holds conductive carbon fiber filaments capable of coming into contact with the charged surface.
They are frequently installed on conveyor belts, material handling equipment, or packaging lines where continuous movement generates an accumulation of static electricity. The smooth contact of the filament with the surface allows downloading the electrostatic energy without damaging the product.
This type of brush is characterized by its ease of installation, adaptability to different machinery geometries, and low maintenance.
The filament is extremely soft which does not affect the parts or the process at all, but it has the negative aspect of zero capacity to do other work and low resistance.
Brushes with conductive PA 6 filaments
Conductive brushes with synthetic conductive PA6 filaments are mainly used in rotating machinery where the material moves continuously around rollers or drums. They are common in material conversion processes such as plastic film, paper, technical textiles, or laminates.
The conductive filament with a synthetic base of polyamide 6 allows discharging the electrostatic charges generated by friction between the material and the mechanical elements of the machine.
These brushes have less electrical conductive capacity than metals or carbon fiber, but have a great complementary work capacity such as cleaning, moving parts, or resistance, as well as an adequate friction life comparable to the rest of technical polyamide filaments.
Brushes with antistatic PA 6 filaments
Brushes with synthetic antistatic PA6 filaments are mainly used in the same work applications as the previous conductive PA6, but instead of wanting to discharge electrostatic charges, we want the brush not to generate them, which is the opposite approach.
The antistatic filament with a synthetic base of polyamide 6 prevents electrostatic charges generated by the friction between the material and the brush filaments from being generated on the working surface.
These brushes have a great complementary work capacity such as cleaning, moving parts, or resistance, as well as an adequate friction life comparable to the rest of the technical polyamide filaments, and at the same level as the conductive PA.
Brushes with natural filaments
Brushes with natural filaments have antistatic properties and are mainly used in the same work applications as the previous antistatic PA6.
A natural filament like tampico or horsehair prevents electrostatic charges generated by the friction between the material and the brush filaments from being generated on the working surface.
These brushes have a great complementary work capacity such as cleaning, moving parts, or resistance, as well as an adequate friction life, although less than technical filaments based on polyamide.
As an advantage, they have a lower cost than synthetic antistatic ones, but availability is not guaranteed as they are a natural product and prices have volatility effects.
Brushes with brass wires
Brushes mounted with brass wires have both antistatic properties since they do not generate sparks or static electricity, are conductive at the same time, and have work capacity.
The brass wire filament is widely used in facilities that are subjected to explosive environments categorized as ATEX.
These brushes have a moderate work capacity compared to other metallic ones to perform cleaning services.
Brushes with carbon steel wires
Brushes mounted with carbon steel wires have conductive properties and at the same time, are the most aggressive with great work capacity.
The carbon steel wire filament is widely used, but not so much for its conductive capacity but for its work capacity and resistance.
But on certain occasions, such as in cases of high temperature or chemical agents, they are also used looking for their conductive capacity.
Brushes with stainless steel wires
Brushes mounted with stainless steel wires have similar conductive properties to carbon steel and at the same time, are almost as aggressive as them.
The stainless carbon wire filament is widely used, but not so much for its conductive capacity but for its work capacity and resistance in applications where it is necessary to work with surfaces that are also stainless steel to avoid chemical contamination.
Applications by sector
The accumulation of static electricity is a recurrent problem in numerous industrial processes. Conductive brushes allow controlling this phenomenon and preventing its negative effects in different productive sectors.
Food industry
In food production lines, static electricity can cause the adhesion of particles, dust, or product residue to machinery surfaces and conveyor belts. This can affect both equipment cleaning and the quality of the final product, and especially the contamination of the manufactured foods.
Antistatic brushes are used to dissipate these charges on conveyor belts, packaging systems, and handling equipment for dry or powdery products.
Packaging industry
In container manufacturing processes, handling of plastic film, or automated packaging, the friction between materials generates significant accumulations of static electricity.
This can cause problems such as:
- Unwanted adhesion between sheets
- Dust attraction
- Difficulties in positioning the material
- Security
Conductive brushes strategically installed in machinery allow eliminating these electrostatic charges and improving the stability of the production process.
Plastics industry
The transformation of plastic materials is one of the environments where static electricity most frequently appears. Processes such as extrusion, thermoforming, or film winding generate electrostatic charges due to the continuous contact and separation of surfaces and the properties of the plastics themselves.
The use of conductive brushes allows discharging these charges before they cause material handling problems or interference in the process.
Electronics industry
In the manufacture of electronic components, even small accumulations of static electricity can damage or affect sensitive devices or affect the reliability of circuits.
Antistatic brushes are used to guarantee a controlled discharge from the surfaces manipulated during the production process, minimizing the risks of electrostatic discharge (ESD).
Chemical industry and ATEX zones
In industrial environments where flammable gases, vapors, or combustible dust are present, the accumulation of static electricity represents a potential risk of ignition.
The installation of grounded conductive brushes allows eliminating the electrostatic charges generated by the movement of materials and reducing the risk of sparks or dangerous discharges.
Technical selection of the suitable brush
The selection of a conductive brush to divert electrical charges must be made taking into account several technical factors related to the industrial process and the characteristics of the machinery.
It is very important to consider whether the brush will have a complementary service to that of diverting electrostatic charges or not, for the correct selection of the filament material, according to the previous table.
One of the most important aspects is the type of surface on which static electricity is generated. Plastic surfaces, films, technical fabrics, or laminated materials present different electrostatic behaviors and may require different types of conductive filament.
It is also necessary to consider the rotation or advance speed of the material. On high-speed lines, it is essential that the brush maintains stable contact without generating excessive wear or affecting the production process.
The working temperature is another relevant factor, especially in processes where the material or machinery reaches high temperatures. In these cases, conductive filaments capable of withstanding demanding thermal conditions are selected.
Specific regulatory requirements must also be taken into account in certain industrial sectors. For example, food contact applications require materials compatible with food regulations, while facilities in explosion risk areas must comply with ATEX requirements.
Finally, the aggressiveness of the filament must be carefully adjusted to ensure effective discharge without damaging the treated material or surface, and we must ensure that the filament material has sufficient electrical conductivity to divert the electrical charge available in the facility.
Related products
FAQ
What type of brush do I need to eliminate static electricity on a conveyor belt?
For conveyor belts, strip brushes with conductive filament are commonly used, manufactured with conductive polyamide 6 as well as metallic wires. These brushes allow maintaining soft contact with the belt’s surface and discharging electrostatic charges towards the grounded metal structure.
What is the difference between an antistatic and a conductive brush?
The antistatic filament is one that does not generate static electricity upon friction with a surface, while the conductive one is a material that allows the passage of electricity through it to divert the electrical charge through itself to the ground connection.
Which filament is better for antistatic applications?
The most used filaments for the diversion of electrostatic charges are carbon fiber and carbon or stainless steel. Carbon fiber is especially effective for dissipating static electricity with soft contact, while steel offers greater mechanical resistance in demanding industrial applications.
Must conductive brushes be grounded?
Yes. For the diversion of electrical charges to be effective, the conductive brush must be connected to a metal structure or grounding system that allows the accumulated static electricity to be evacuated.
In addition, it must be taken into account that the body is also conductive or at least there is permanent contact of the ground connection with the filaments.
Can custom antistatic brushes be manufactured for specific machinery?
Yes. Technical brushes for diverting electrical charges are usually custom-made to adapt to the geometry of each machine, including dimensions, filament density, type of support, and fixing system.
