Low cost conductive brushes manufactured from conductive loaded resin-based materials

Abstract

Conductive brushes are formed of a conductive loaded resin-based material. The conductive loaded resin-based material comprises micron conductive powder(s), conductive fiber(s), or a combination of conductive powder and conductive fibers in a base resin host. The percentage by weight of the conductive powder(s), conductive fiber(s), or a combination thereof is between about 20% and 50% of the weight of the conductive loaded resin-based material. The micron conductive powders are formed from non-metals, such as carbon, graphite, that may also be metallic plated, or the like, or from metals such as stainless steel, nickel, copper, silver, that may also be metallic plated, or the like, or from a combination of non-metal, plated, or in combination with, metal powders. The micron conductor fibers preferably are of nickel plated carbon fiber, stainless steel fiber, copper fiber, silver fiber, aluminum fiber, or the like.

1 . A conductive brush device comprising: 
 a plurality of conductive bristles comprising conductive loaded, resin-based material comprising conductive materials in a base resin host; and    a conductive frame wherein said plurality of conductive bristles is attached to said conductive frame.    
   
   
       2 . The device according to  claim 1  wherein the percent by weight of said conductive materials is between about 20% and about 50% of the total weight of said conductive loaded resin-based material.  
   
   
       3 . The device according to  claim 1  wherein said conductive materials comprise micron conductive fiber.  
   
   
       4 . The device according to  claim 2  wherein said conductive materials further comprise conductive powder.  
   
   
       5 . The device according to  claim 1  wherein said conductive materials are metal.  
   
   
       6 . The device according to  claim 1  wherein said conductive frame comprises said conductive loaded resin-based material.  
   
   
       7 . The device according to  claim 6  wherein said conductive frame is in the shape of a handle.  
   
   
       8 . The device according to  claim 1  wherein said conductive frame is a cylinder and wherein said conductive bristles radiate from said cylinder.  
   
   
       9 . The device according to  claim 1  wherein said conductive loaded resin-based material further comprises ferromagnetic loading such that said plurality of bristles is magnetic.  
   
   
       10 . The device according to  claim 1  wherein said conductive frame comprises said conductive loaded resin-based material and further comprises ferromagnetic loading such that said conductive frame is magnetic.  
   
   
       11 . A conductive brush device comprising: 
 a plurality of conductive bristles comprising conductive loaded, resin-based material comprising conductive materials in a base resin host; and    a conductive handle comprising said conductive loaded resin-based material wherein said plurality of conductive bristles is attached to said conductive handle and wherein the weight of said conductive materials is between 20% and 50% of the total weight of said conductive loaded resin-based material.    
   
   
       12 . The device according to  claim 11  wherein said conductive materials are nickel plated carbon micron fiber, stainless steel micron fiber, copper micron fiber, silver micron fiber or combinations thereof.  
   
   
       13 . The device according to  claim 11  wherein said conductive materials comprise micron conductive fiber and conductive powder.  
   
   
       14 . The device according to  claim 13  wherein said conductive powder is nickel, copper, or silver.  
   
   
       15 . The device according to  claim 13  wherein said conductive powder is a non-conductive material with a metal plating of nickel, copper, silver, or alloys thereof.  
   
   
       16 . The device according to  claim 11  wherein said conductive handle is a cylinder and wherein said conductive bristles radiate from said cylinder.  
   
   
       17 . The device according to  claim 11  wherein said conductive loaded resin-based material further comprises ferromagnetic loading such that said conductive brush is magnetic.  
   
   
       18 . The device according to  claim 11  wherein said plurality of conductive bristles is attached to said conductive handle by an adhesive.  
   
   
       19 . A conductive brush device comprising: 
 a plurality of conductive bristles comprising conductive loaded, resin-based material comprising micron conductive fiber in a base resin host; and    a conductive handle comprising said conductive loaded resin-based material wherein said plurality of conductive bristles is attached to said conductive handle and wherein the weight of said micron conductive fiber is between 20% and 50% of the total weight of said conductive loaded resin-based material.    
   
   
       20 . The device according to  claim 19  wherein said micron conductive fiber is stainless steel.  
   
   
       21 . The device according to  claim 19  further comprising conductive powder.  
   
   
       22 . The device according to  claim 19  wherein said micron conductive fiber has a diameter of between about 3 μm and about 12 μm and a length of between about 2 mm and about 14 mm.  
   
   
       23 . The device according to  claim 19  wherein said conductive handle is a cylinder and wherein said conductive bristles radiate from said cylinder.  
   
   
       24 . The device according to  claim 19  wherein said conductive loaded resin-based material further comprises ferromagnetic loading such that said conductive brush is magnetic.  
   
   
       25 . The device according to  claim 19  wherein said plurality of conductive bristles is attached to said conductive handle by an ultrasonic weld.