FEATURES

of SHOWA INDUSTRIES

Roll brushes for steelmaking

Reliable technology and adaptability that continue to make us the preferred choice of domestic and foreign steelmakers

It is said that the steel industry was the first to use roll brushes in earnest in Japan after World War II. An engineer who was impressed by the polishing technology for U.S. Steel’s steel sheets brought back the idea of roll brushes and started using them in the field. We have been selling roll brushes to companies in the steel industry since the high-growth period, when demand for steel rapidly expanded. We have been creating new manufacturing methods for providing roll brushes with increased strength and bristle density and developing cassette-type products suitable for overseas transportation and promoting their overseas deployment.

Tail seal brushes for shield machines

Rare technology developed jointly with a construction equipment manufacturer, receiving offers even from overseas

The shield tunneling method has now become the mainstream method for underground excavation work. We jointly developed a high-performance tail seal brush that prevents water from entering the machine with a construction equipment manufacturer from the conceptual stage and commercialized it. The development of the brush to protect the safety of construction was a large-scale project, involving the use of a huge high water pressure testing machine. To use a brush, which flexibly follows the shape of objects, to shield water instead of conventionally used rubber, we ensured its performance to withstand high water pressure. We continue to evolve the product in response to needs, including the use of high-strength fibers to improve water sealing performance and increase strength according to geological conditions and excavation depth. The high-quality brushes that have been proven in Japan are highly trusted in the overseas market as well, and we have received offers from many countries.

CMP conditioners for semiconductor manufacturing process

Participating in joint research from the prototype stage
A patented technology that has been presented at international conferences and is advancing to practical use

This brush-based flexible fiber conditioner (FFC) was developed to recover the surface roughness of polishing pads used in the Chemical Mechanical Polishing (CMP) process of semiconductor manufacturing. This is a new concept product that was developed through technical cooperation provided by us from the prototyping stage and joint research with inventors and universities. We confirmed that the brush-based FFC can condition polishing pad surfaces more uniformly and finely than conventionally used conditioners with electrodeposited diamond abrasives, and we presented papers at professional conferences.

Coriolis-type flowmeter cleaning brushes

Realized by ultra-small brush manufacturing technology
Roll brushes made with #1 channel brushes with a width of 1 mm

Our experience and know-how in the field of brushes are reflected in the series of flexible brushes that are used to clean the inside of the Ω-shaped bent measuring tube of flowmeters.
The roll brush with an outer diameter of φ 8 mm × length of 80 mm is made by coiling a #1 channel brush with a width of 1.1 mm × height of 1.4 mm. The manufacturing technology and machinery used were based on our experience in developing delicate toothbrushes, which are put into the mouth.
The brush for cleaning inside tubes with an inner diameter of Φ1.2 mm is based on the know-how of twisting brushes for endoscopes with an outer diameter of approximately 2 mm. It is the nail of a machine tool, which is less than 1 mm in diameter, that makes it possible to process the tip of each brush, which can only be seen with a microscope. The meticulous machine tool to finish the product by a craftsperson by hand supports outstanding accuracy.

Basic manufacturing methods

Channel brushes

Basic brushes adaptable to various shapes

A channel brush is a brush made by sandwiching bristles between a U-shaped steel channel and a metallic core wire and clamping the channel. The manufacturing method used to make channel bristles is applied to a wide range of applications by changing the type of channel and bristle material, processing into circular, spiral and cup shapes, and processing into roll brushes that are rotated. Because channel brushes are basic, they must be stable and of high quality.
We can manufacture a wide variety of brushes, from sturdy brushes used in steelmaking and civil engineering to #1 channel brushes that are only 1.1 mm wide and 1.4 mm high. Even for fine brushes, our delicate bristle-implanting technology and ingenuity in equipment and machinery ensure consistent high quality.

Hyper-tight channel brushes

Brushes whose bristles stay attached continuously and are highly effective in dissipating heat

A hyper-tight channel brush is a brush with a unique structure made by sandwiching bristles between an H-shaped steel channel and a V-shaped core wire and clamping the channel. Its channel is H-shaped and hollow at the bottom to dissipate heat, and it has a unique liquid discharge structure, providing a remarkable water-cooling effect.

Disc brushes

Manufacturing method that enables high-density brush bristles

A disc brush is a brush in which bristles are implanted in a disc plate with holes drilled. Disc brushes are stacked to form a disc roll brush. SHOWA INDUSTRIES’ SK Type Disc Roll Brush has extremely low bristle breakage, is high in density and enables high-performance brushing for a long period of time. We can manufacture disc roll brushes with an integrated stacked structure and with a variety of disc shapes. Furthermore, we can freely adjust the density of bristles by changing the assembly compression pressure.

Twisting brushes

Craftspersonship with careful attention to detail, right down to the tip

A twisting brush is a brush made by twisting bristles sandwiched between core wires and holding them in place. It is one of the standard manufacturing methods of brushes often used for cleaning and polishing of hard-to-reach small spots and deep areas, including the inner surfaces of pipes and threaded holes. SHOWA INDUSTRIES uses the manufacturing methods of double (two core wires), double single (four core wires) and double spiral (four core wires) depending on the desired number of bristles and application. We manufacture high-quality twisting brushes, including brushes with the bristles implanted on the brush tip and the tip chamfered.

Implant brushes

Flexible manufacturing method allowing bristles to be implanted in any base

An implant brush is a brush made using a manufacturing method of implanting bristles in a wooden, aluminum or resin base with holes drilled. It features a high degree of freedom in shape and easy control of bristle density according to hole diameter, pitch and number of rows for bristle implantation. SHOWA INDUSTRIES can manufacture products using both machine- and hand-implanting methods.

Shapes and bristle materials

Products in a variety of shapes available

Suitable machining used for installed machines and objects

SHOWA INDUSTRIES can manufacture products in a wide range of sizes, from extra-long brushes to brushes as fine as 1 mm in width. Furthermore, we can manufacture products with various shapes according to the installed machine and objects, such as bent/rolled brushes, brushes with a stacked structure and complex shapes. We can meet detailed requests, for example, in terms of the end treatment, shaft length and mounting method, angle of the bristles, and the method of sweeping up dust and metal fragments after cleaning.

Synthetic fiber, metal wire, animal fiber, plant fiber and secondary fabrication

Adding functions according to application

Depending on the bristle material, various functionalities are added to the brush. The functionality also depends on the material, diameter, height and density of the bristles. In addition, durability, heat resistance, chemical resistance and other functions must be selected according to the conditions of use and the objects. SHOWA INDUSTRIES selects the most suitable bristle material based on its deep understanding of bristle materials. We also provide secondary fabrication of bristle materials.

Hearing – Proposal

The experience of sales representatives who know the field shows in their ability to make proposals.

We have the capability to make proposals that meet the expectations of our customers, not only when specifications are available but also at the conceptual stage or even from vague consultations. When there is an existing product, we ask about current issues and requests and investigate the usage environment and the actual product as much as possible. Based on our extensive experience, our sales representatives work closely with the engineering and manufacturing departments to develop an appropriate plan.

Prototyping and testing

We can also prototype mass-produced products.

Please contact us for special order and custom-made products, mass-produced products, prototypes and performance tests of brushes to be incorporated into machines and equipment, and operational tests for replacing existing products.
We have a large durability and wear tester and a high-speed, high-performance optical digital dimensional measuring instrument capable of measuring small brushes with an accuracy of ±2 ㎛, enabling us to perform functional verification and accuracy/precision measurement upon request.