U.S. patent application number 12/214401 was filed with the patent office on 2008-12-25 for abrasive article and method of making.
Invention is credited to John Edward Brown.
Application Number | 20080318506 12/214401 |
Document ID | / |
Family ID | 40136974 |
Filed Date | 2008-12-25 |
United States Patent
Application |
20080318506 |
Kind Code |
A1 |
Brown; John Edward |
December 25, 2008 |
Abrasive article and method of making
Abstract
An abrasive sheet material comprising a first sheet having a
first major suface and a second major surface and second sheets
having first major surfaces and second major surfaces wherein the
second major surfaces of the second sheets are affixed to the first
major surface of the first sheet and spaces exist between the
second sheets wherein said spaces form pathways that interweave
between the second sheets wherein the pathways communicate with
each other and form a network of pathways. At least one aperture
extends from at least the first major surface of the first sheet to
the second major surface of the first sheet and communicates with
at least one of the pathways. Abrasive particles are coated onto at
least the first major surface of the second sheets forming an
abrasive first major surface. When air moves through the pathways
by a vacuum source said pathways channel air across and parallel to
the work surface while the air is in contact with the work surface
thereby providing a sweeping movement of air across the work
surface carrying dust with the air for the purpose of vacuuming
dust from the work surface.
Inventors: |
Brown; John Edward; (Coon
Rapids, MN) |
Correspondence
Address: |
John E. Brown
PO Box 683
Anoka
MN
55303
US
|
Family ID: |
40136974 |
Appl. No.: |
12/214401 |
Filed: |
June 18, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60936264 |
Jun 19, 2007 |
|
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61070819 |
Mar 26, 2008 |
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61126254 |
May 2, 2008 |
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Current U.S.
Class: |
451/539 ;
51/295 |
Current CPC
Class: |
B24D 11/00 20130101 |
Class at
Publication: |
451/539 ;
51/295 |
International
Class: |
B24D 11/00 20060101
B24D011/00 |
Claims
1. An abrasive sheet material comprising: (a) A first sheet having
a first major surface and a second major surface and second sheets
having first major surfaces and second major surfaces wherein the
second major surfaces of the second sheets are affixed to the first
major surface of the first sheet and: (b) spaces exist between the
second sheets wherein said spaces form pathways that interweave
between the second sheets wherein the pathways communicate with
each other and form a network of pathways and: (c) at least one
aperture extends from at least the first major surface of the first
sheet to at least the second major surface of the first sheet and
communicates with at least one of the pathways. (d) Abrasive
particles are coated onto at least the first major surface of the
second sheets forming an abrasive first major surface; When the
abrasive sheet is operatively connected to a suction device during
sanding operations, air moves through the pathways, the air in
contact with the work surface sweeps across the work surface
carrying dust with the air and extracted from the work surface by
the suction device.
2. The abrasive sheet material of claim 1 wherein the abrasive
sheet material is in the form of a disc.
3. The abrasive sheet material of claim 1 wherein the second sheets
are circular.
4. The abrasive sheet material of claim 1 wherein the second sheets
are square.
5. The abrasive sheet material of claim 1 wherein the first sheet
is made from a non resilient material.
6. The abrasive sheet material of claim 1 wherein the second sheets
are made from a non resilient material.
7. The abrasive sheet material of claim 1 wherein the second sheets
are adhesively affixed to the first sheet.
8. A method of making an abrasive sheet material the method
comprising: (a) providing a first sheet having a first major
surface and a second major surface and second sheets having first
major surfaces and second major surfaces, affixing the second major
surfaces of the second sheets are to the first major surface of the
first sheet and: (b) providing spaces between the second sheets
wherein said spaces form pathways that interweave between the
second sheets wherein the pathways communicate with each other and
form a network of pathways and: (c) providing at least one aperture
that extends from at least the first major surface of the first
sheet to at least the second major surface of the first sheet and
communicates with at least one of the pathways. (d) providing
abrasive particles and coating the abrasive particles onto at least
the first major surface of the second sheets, forming an abrasive
first major surface; When the abrasive sheet is operatively
connected to a suction device during sanding operations, air moves
through the pathways, the air in contact with the work surface
sweeps across the work surface carrying dust with the air and
extracted from the work surface by the suction device.
9. An abrasive sheet material comprising: (e) A first sheet having
a first major surface and apposite second major surface and second
sheets having first major surfaces and opposite second major
surfaces wherein the second major surfaces of the second sheets are
affixed to the first major surface of the first sheet and: (f)
spaces exist between the second sheets wherein said spaces form
pathways that interweave between the second sheets wherein the
pathways communicate with each other and form a network of pathways
and: (g) at least one aperture extends from at least the first
major surface of the first sheet to at least the second major
surface of the first sheet and communicates with at least one of
the pathways. (h) Abrasive particles are coated onto at least the
second major surface of the first sheet forming an abrasive major
surface; When the abrasive sheet is attached to a back up pad of a
tool and operatively connected to a suction device, air moves
through the pathways, wherein the pathways are opposite the
abrasive surface, the pathways form a conduit between the back up
pad and the abrasive sheet and are in fluid communication with the
at least one aperture thereby providing suction to the work surface
via the at least one aperture.
10. The abrasive sheet of claim 8 wherein the abrasive sheet
material is in the form of a disc
11. The abrasive sheet material of claim 8 wherein the first sheet
is made from a non resilient material
12. The abrasive sheet material of claim 8 wherein the second sheet
is made from a non resilient material.
Description
[0001] This application claim benefit to provisional patent
application 60/936,264 filed on Jun. 19, 2007 and also to
provisional patent application 61/070,819 filed Mar. 26, 2008 and
also to provisional patent application 61/126,254 filed May 2, 2008
all of which are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to surface finishing
tools. Particularly, the present invention relates to abrasive
sheet materials. More particularly, the present invention relates
to abrasive sheet materials that may be connected to tools that
have a dust collection means wherein a vacuum may be directed to
the abrasive sheet material for the purpose of collecting dust.
[0004] 2. Description of the Related Art
[0005] Dustless sanding tools and abrasive sheet material adapted
to be used with dustless sanding tools are well known and widely
used in the industry where sanding operations are common. Some
commonly used sanding tools that use abrasive sheet material
include orbital sanders, palm sanders, back up pads for power tools
having dust collection holes and hand tools configured to be
dustless sanders. Dust has long been a problem in sanding
operations and the need to devise abrasive tools that address
collection of dust while sanding is an ever present need. Sanding
tools that currently address the problem of dust do so by means of
through holes in the abrasive material, typically an abrasive sheet
material wherein the through holes communicate with dust collection
apertures in a back up pad of a tool for example an orbital sander
has a back up pad that typically has a five hole or an eight hole
pattern of dust collection holes in the back up pad. An abrasive
sheet typically a circular abrasive sheet has matching through
holes so that the abrasive sheet may overlay the back up pad with
matching hole patterns so that dust will travel through the
abrasive sheet via a vacuum and into the holes in the back up pad
and be collected by a dust collection receptacle. Such devices are
inefficient at collecting dust as one skilled in the art would
recognize that by placing a flat abrasive disc with through holes
in it on a flat surface it is very difficult do direct vacuum to
the through holes and efficiently apply the vacuum to the surface
on which the abrasive disc overlays or is abrading. It is analogous
to trying to suck air out of a bottle wherein no air is allowed to
come into the bottle while attempting to suck air out of it. Herein
lies the problem with the current technology of dust collection and
abrasive tools. The present invention addresses this problem by
providing an abrasive sheet material that has pathways in
combination with through holes in an abrasive sheet so that the
pathways are recessed below the abrasive surface and communicate
with the through holes or apertures for the purpose of collecting
dust. In this manner when the abrasive sheet material overlays a
flat surface pathways exist in the abrasive sheet and the pathways
become conduits that communicate with the dust collection holes in
the abrasive sheet and in the tool to which it is attached. When a
vacuum source is connected to the abrasive sheet the vacuum is
directed into the pathways via through holes in the abrasive sheet
and air is allowed to enter the pathways from the perimeter or
outside the abrasive sheet thus air is swept across the work
surface that is underneath the pathways bringing any dust that has
accumulated in the pathway with it. The efficiency of dust
collection is greatly increased as well as the cutting efficiency
of the abrasive sheet since pathways also provide a plurality of
cutting edges on the abrasive sheet material. By having dust
collection pathways that are in direct contact with a work surface
air is swept along the work surface by a vacuum applied to the
pathway. In combination with air being swept across the work
surface and air being taken in from outside the abrasive disc the
ability to collect dust is greatly improved in comparison to the
common abrasive disc having only through holes and no dust
collection pathways.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to increase the
efficiency of dust collection while using abrasive sheet materials.
The present invention increases the efficiency of dust collection
by providing an abrasive sheet material that has dust collection
pathways in combination with and in communication with dust
collection apertures or through holes. The abrasive sheet comprises
at least one pathway and at least one aperture wherein said at
least one aperture communicates with the at least one pathway;
wherein a vacuum is directed into the at least on pathway and at
least one aperture The vacuum while in contact with the work
surface beneath the pathways sweeps across the work surface by the
movement of air though the pathways, dust with the air is moved
from the work surface into at least one aperture wherein a vacuum
is applied to the at least one aperture and to the pathways in
communication with the at least one aperture.
[0007] More specifically the abrasive sheet comprises a first sheet
and a plurality of second sheets positioned on the first sheet
wherein gaps or spaces exist between the second sheets providing
pathways between the second sheets. The abrasive sheet has a first
major surface a second major surface and an abrasive first major
surface wherein the pathways are recessed below the abrasive first
major surface. At least one pathway extends from at least the first
major surface or the bottom of a pathway to at least the second
major surface. The pathways communicate with each other and with at
least one aperture wherein the pathways and at least one aperture
are used for directing vacuum to a work surface and for the
collection of dust. And wherein the vacuum moves parallel with and
in contact with the work surface by moving through the pathways
between the work surface and the bottom surface of the pathway or
the first major surface of the abrasive sheet. A more efficient
means of collecting dust is achieved by using pathways in
combination with dust collection apertures in an abrasive sheet
material. One area where efficiency is greatly improved is by the
sweeping movement of air along the work surface through the
pathways as air travels through the pathways by means of a vacuum
that is directed into the pathways via apertures in the abrasive
sheet material. Dust with the air is then taken up into the
apertures of the abrasive sheet material and removed by the dust
collection apparatus to which the abrasive sheet material is
attached. It is the objective of the present invention to provide
an abrasive sheet material that has pathways and apertures that
communicate with each other and with a work surface so that when a
vacuum is directed into the pathways and apertures dust is removed
from the work surface more effectively and efficiently by vacuum.
It is also the objective of the present invention to provide an
abrasive sheet that comprises a first sheet of material with a
plurality of second sheets of material laminated to at least the
first major surface of the first sheet and wherein the second
sheets have open spaces or gaps between the second sheets and
wherein the open spaces form pathways for the collection of dust.
It is also the objective of the present invention to provide at
least one aperture in the first sheet that communicates with at
least one pathway wherein vacuum may be directed into the at least
one aperture and into the pathways thereby forming a network of
dust collection pathways in the abrasive sheet material for the
purpose of collecting and removing dust from the work surface. It
is also the objective of the present invention to provide a method
of making an abrasive sheet material having pathways by kiss
cutting second sheets from a sheet of material laminated to a
releasable liner material wherein the second sheets are spaced
apart from each other and delaminating the second sheets from the
releasable liner material and relaminating the second sheets to a
first sheet material that is not a releasable liner. It is also the
objective to relaminate the second sheets to the first sheet with
gaps or spaces that exist between the second sheets wherein the
gaps form pathways between the second sheets for the purpose of
creating a substrate suitable for coating with abrasive particles
and forming an abrasive sheet material having pathways. Apertures
may be punched into the abrasive sheet material in a secondary
operation or may be formed in the abrasive sheet prior to coating
the substrate with abrasive particles. It is also the object of the
present invention to form an abrasive sheet material having
pathways wherein the abrasive sheet material may not be a resilient
abrasive sheet material. It is however within the scope of the
present invention to use resilient materials or a combination of
resilient materials and non resilient materials in making the
abrasive sheet material of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a preferred embodiment of
the present invention
[0009] FIG. 2 is a side view of the embodiment of FIG. 1.
[0010] FIG. 3 is a top plan view of one embodiment of a disc formed
from the abrasive sheet material of FIG. 1.
[0011] FIG. 4 is a top plan view of another embodiment of a disc
formed from the abrasive sheet of FIG. 1.
[0012] FIG. 5 is top plan view of another embodiment of a disc
formed from the abrasive sheet of FIG. 1.
[0013] FIG. 6 is a cross sectional view of FIG. 5
[0014] FIG. 7 is a top plan view of an alternate embodiment of the
embodiment of FIG. 5.
[0015] FIG. 8 is a side view of the embodiment of FIG. 7
[0016] FIG. 9 is a top plan view of another embodiment of an
abrasive disc of the present invention.
[0017] FIG. 10 is a top plan view of yet another embodiment of an
abrasive disc of the present invention.
[0018] FIG. 11 is a top plan view of another embodiment of an
abrasive disc of the present invention.
[0019] FIG. 12 is a top plan view of an alternate embodiment
abrasive disc having concentric circular second sheets in
segments.
[0020] FIG. 13 is a top plan view of an alternate embodiment of an
abrasive disc having pathway segments that are concentric.
[0021] FIG. 14. Is a top plan view of an alternate embodiment of an
abrasidve disc having pathways of a chain like configuration.
[0022] FIG. 15 is a top plan view of an alternate embodiment of the
present invention showing a rectangular shaped abrasive sheet.
[0023] FIG. 16 is a top plan view of of an alternate embodiment of
the present invention showing an abrasive disc having a hook and
loop attachment system for attaching abrasive sheet to the
disc.
[0024] FIG. 17 is a cross sectional view of the embodiment of FIG.
16.
[0025] FIG. 18 is a top planer view of the embodiment of FIG.
17.
[0026] FIG. 19 is a perspective view of another preferred
embodiment of the present invention showing pathways opposite the
abrasive side of the abrasive sheet.
[0027] FIG. 20 is a top plan view of an alternate embodiment of an
abrasive disc of the present invention showing the back non
abrasive side, the disc having concentric pathways in the abrasive
surface, the pathways in communication with radial slots in the
support sheet.
[0028] FIG. 21 is a cross sectional view of the embodiment of FIG.
20.
[0029] FIG. 22 is a top planar view of an a preferred embodiment of
an abrasive disc having indented pathways.
[0030] FIG. 23 is a cross sectional view of the embodiment of FIG.
22.
[0031] FIG. 24 is a top planar view of an alternate embodiment of
the embodiment of FIG. 22.
[0032] FIG. 25 is a side view of the embodiment of FIG. 24 showing
a work surface.
[0033] FIG. 26 is a side view of an alternate embodiment of an
abrasive disc having indented pathways opposite the abrasive
surface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The present invention is an abrasive sheet material 10 and a
method of forming and making the abrasive sheet material.
[0035] The abrasive sheet material comprises a first sheet having a
first major surface and a second major surface and second sheets
having first major surfaces and second major surfaces wherein the
second major surfaces of the second sheets are affixed to the first
major surface of the first sheet and spaces exist between the
second sheets wherein said spaces form pathways that interweave
between the second sheets wherein the pathways communicate with
each other and form a network of pathways and, at least one
aperture extends from at least the first major surface of the first
sheet to the second major surface of the first sheet and
communicates with at least one of the pathways. Abrasive particles
are coated onto at least the first major surface of the second
sheets forming an abrasive first major surface.
[0036] During sanding operations wherein the abrasive sheet
material is connected to a suction device that provides vacuum to
the apertures and pathways of the abrasive sheet material air is
sucked into the pathways from outside the abrasive sheet material.
The vacuum or suctioned air is channeled through the pathways and
provides moving air that is in contact with and flows or sweeps
across the work surface, providing a flowing or sweeping movement
of air that is in contact with the work surface while the air flows
across and parallel to the work surface. The flowing or sweeping
movement of air is caused by the vacuum or suction device. As the
air flows across the work surface dust is collected and brought
with the air through the pathways and into the apertures and is
extracted into a dust collection receptacle.
[0037] Now in greater detail. FIGS. 1 and 2 depict an abrasive
sheet material 10 comprising a first sheet of material 12 having a
first major surface 14, and a second major surface 16 opposite the
first major surface 14. A plurality of second sheets of material 18
are fixedly attached to the first major surfaces 14 of the first
sheet 12 and spaced apart from each other forming gaps or pathways
30 between the second sheets 18. In the preferred embodiment the
second sheets 18 are substantially smaller than the first sheet 12.
First and second sheets together 12 and 18 respectively form a
substrate 34 suitable for coating with abrasive particles. The
second sheets 18 have a first major surface 22 and an opposite
second major surface 24 and side surfaces 28. Abrasive particles
are coated onto at least the first major surfaces 22 of the second
sheets 18 or substrate 34 forming an abrasive first major surface
26 of the abrasive sheet material 10
[0038] The first sheet of material 12 may be considered equally as
a support member, support layer, support sheet or reinforcing layer
or the like and provides a backing or support for the second sheets
18. Although the first sheet may be considered a support layer or
support sheet or reinforcing layer, for ease and clarity of
description it shall be referred throughout this description as a
first sheet.
[0039] The first sheet 12 is preferably made of a non resilient
material such as paper. Other materials may be used for making the
fist sheet material 12, such materials include but should not be
limited to resilient materials, non resilient materials, cloth,
fabric, foam, rubber, woven and non woven materials, mesh, mesh
screen, screens, perforated sheet materials, plastic, resin,
urethane foam, open and closed cell foam, cork, composite materials
and loop or hook material of the hook and loop fastening system or
a film. The second sheets may in an alternate embodiment be
comprised of glue and not a sheet material wherein the glue has
abrasive particles imbedded in the glue or wherein the glue
attaches abrasive particles to the first sheet 12 so that pathways
exist between the glue portions and wherein the glue portions are
abrasive portions. The second sheets of material 18 may be
comprised of any of the materials of the first sheet 12 as
described above. The first and second sheets of material 12 and 18
respectively are preferably substantially flat and generally
parallel to each other. The first sheet of material 12 preferably
has a thickness in a range of about 0.002'' to about 0.005''. The
first sheet is preferably rectangular and may be a continuous sheet
or roll of sheet material. The second sheets 18 are generally
smaller than the first sheet 12 and may be any conceivable shape
including but not limited to round, square, rectangular,
pentagonal, hexagonal, octagonal, triangular, circular, oval,
oblong, half circle, waved, curved, diamond, disc shaped having a
hole in the center or a circumferential ring or rings, or
concentric circles. The second sheets of material 18 may be planar
or non planar and not parallel to the first major surface 14. For
example the second sheets may have a flat second major surface and
a first major surface that is dome shaped, pyramidal, pointed,
curved or any shape other than flat thereby forming an abrasive
surface that is non planar. In the Preferred embodiment of the
present invention the first sheet of material is substantially
rectangular and generally flat or planar and the second sheets of
material are substantially circular in shape and generally flat and
planar. The second sheets of material 18 may be arranged in any
pattern on the first sheet of material. Such patterns may include
but should not be limited to concentric circles, gridded patterns,
rows, off set rows, diamond shaped, circular, irregular, linear
patterns, circular patterns. A combination of different shaped
second sheets 18 may be arranged on a common first sheet 12 in a
pattern that has either a functional or aesthetic purpose. For
example a second sheet may be in the shape of a disc having an
outside diameter and an inside diameter, wherein a plurality of
second sheets are positioned with the inside diameter and wherein
the second sheets may be square or circular or any other of the
shapes mentioned. In this manner the second sheets 18 may form
repeated patterns on a first sheet material 12 so that abrasive
sheet products may be cut or punched from the abrasive sheet
material 10 wherein the abrasive sheet product has a the particular
pattern that is repeated on the abrasive sheet 10. For example
second sheets may be arranged in a pattern of concentric circles
and that pattern repeated on the first sheet thereby making an
abrasive sheet material 10 having repeated patterns of concentric
circles. In this manner a disc having concentric circles may be cut
from the abrasive sheet material as described above and used on
tools such as orbital sanders. Second sheets may for example be
foam and the first sheet paper, or first sheet foam and second
sheets paper. Alternately the first sheet may be a mesh screen and
the second sheets made of paper or foam. Second sheet may also be
attached to both the first major surface of the first sheet and the
second major surface 16 of the first sheet and wherein abrasive
particles are coated onto at least the first major surfaces 22 of
second sheets wherein second sheets 18 are affixed to both the
first and second major surfaces 14 and 16 respectively of the first
sheet 12.
[0040] The second major surfaces 24 of the second sheets 18 are
fixedly attached by adhesive to the first major surface 14 of the
first sheet 12. It should be noted that the second sheets may be
fixedly attached by flame laminating. The second sheets 18 are
affixed to and positioned on the first major surface 14 of the
first sheet 12 and spaced apart from each other forming gaps or
pathways 30 between the second sheets 18. The pathways 30 serve as
channels or form conduits when pressed against a work surface
wherein the work surface acts as a wall of the conduit. The
pathways or conduits direct or channel a suction force wherein the
suction force moves air parallel to and in contact with the work
surface while abrading the work surface. A plurality of vacuum
holes or apertures 38 in the abrasive sheet material 10 extend from
at least the first major surface 14 of the first sheet 12 to at
least the second major surface 16 of the first sheet 12 wherein the
apertures 38 communicate with the pathways 30 when a suction force
is directed into the apertures so that the suction is dispersed
throughout the network of pathways 30 thereby suctioning the dust
away from the work surface while sanding. Apertures 38 and 44 may
be considered pathway apertures. It should be noted that apertures
and vacuum holes may be used interchangeably in the description of
the present invention each of which equally describes a port for
vacuum. In alternate embodiments as will be shown, apertures 42 may
be configured and arranged wherin the apertures extend from the
abrasive first major surface 26 to the second major surface 16 of
the abrasive sheet material 10 wherein the apertures 42 may be
considered substrate apertures. Apertures are preferably round but
could be any shape including but not limited to round, oval,
square, slots, curved, semi round or any suitable shape. The
pathways 30 have sidewalls 32 that are in common with the side
surfaces of the second sheets 18 and a bottom surface 36 that is in
common with the first major surface 14 of the first sheet 12. The
pathways 30 form a network that interweaves throughout and between
the second sheets 18 and may have an arrangement and shape that is
decided by the arrangement and shape of the second sheets and the
second sheet side surfaces 28. For example the pathways may have a
grid pattern that is generally rectangular wherein the second
sheets are rectangular. The sidewalls of the pathways 32 may be
substantially at a right angle to the first major surface 14 of the
first sheet 12. The sidewalls may alternately be curved wherein the
second major surface 24 of the second sheets 18 are dome shaped.
The pathways 30 are recessed below the abrasive first major surface
26 of abrasive sheet material 10. In alternate embodiments wherein
the second sheets 18 are not coated with abrasive particles the
pathways are recessed below at least the first major surface 22 of
the second sheets 18. It should be noted that only one second sheet
may alternately be affixed to the first sheet 12 wherein the only
one second sheet has openings that form pathways when the second
sheet is affixed the first sheet 12. For example FIG. 13 has
openings that are curved slots 88 wherein the curved slots may be
considered pathways, wherein the pathway or curved slot
communicates with apertures but not with other pathways. Referring
now back to the pathways of the preferred embodiment of the present
invention, the pathways 30 have a depth that is defined by the
distance between the abrasive first major surface 26 and the first
major surface 14. The width of the pathways is defined by the
distances between the sidewalls 32 of the second sheets 18. The
width of the pathways may be variable depending on the shape of the
second sheets. One skilled in the art would recognize the need to
keep the width of the pathways as small as possible while
maintaining efficiency of directing suction through the pathways.
It is desired that the largest amount of abrasive surface is
maintained while in the abrasive sheet material 10 without
sacrificing the effectiveness of the pathways to distribute suction
to the work surface. For example, wherein the second sheets are
square, the pathways may have a width in a range from about 1 mm to
about 10 mm, more preferably from about 2 mm to about 5 mm. Wherein
the pathways are circular the pathways will have a variable width,
it is preferable in such instance that the narrowest distance
between the second sheets 18 is in a range from about 1 mm to about
10 mm and more preferably from about 2 mm to about 5 mm. The cross
sectional shape of the pathway may be v shaped, U shaped, square,
rectangular or convex or concave or any shape formed by the
sidewalls 32 of the second sheets 18 and the first major surface 14
of the first sheet 12.
[0041] An attachment means such as one part of a two part hook and
loop attachment mechanism may be attached to the second major
surface 16 of the first sheet 12. Loop material 40 is preferably
used. Adhesive may alternately be used as an attachment means and
applied to the second major surface 16. A pressure sensitive
adhesive is preferable.
[0042] The apertures of the present invention are preferably
pathway apertures 38 and are positioned within the pathways 30 so
that the pathway apertures 38 extend from at least the first major
surface 14 of the first sheet 12 to at least the opposite second
major surface 16 of the first sheet 12. The pathway apertures 38
have a depth defined by the thickness of the first major surface or
the distance between the first major surface 14 and the second
major surface 16. Wherein an attachment material or mechanism is
attached to the second major surface 16 of the first sheet 12 the
apertures may extend through the attachment material. In such a
case the depth of the apertures 38 would include the thickness of
the attachment material or mechanism.
[0043] Apertures may alternately be positioned strategically
throughout the abrasive sheet material 10 in patterns that coincide
with patterns on back up pads such as back up pads for orbital
sanders or the like. Such aperture patterns may include for example
common five hole and eight hole patterns on orbital sander back up
pads. Such hole patterns may be repeated in the abrasive sheet
material 10 so that individual discs may be cut from the abrasive
sheet material 10 that can be attached to the orbital sanders. It
should be noted that the abrasive sheet material 10 may not have
apertures and that apertures may be cut or punched into the
abrasive sheet material 10 in a secondary operation or at the same
time as cutting an abrasive sheet product from the abrasive sheet
material 10. Wherein apertures are in hole pattern such as five or
eight hole patterns the apertures would preferably not be pathway
apertures 38 rather they would be substrate apertures 42 that
extend through the substrate 34 from the abrasive first major
surface 26 to at least the second major surface 16 and wherein an
attachment means is attached to the second major surface the
substrate apertures 42 would also exend through the attachment
means attached to the second major surface 16. It should be noted
that only one substrate aperture 42 or only one pathway aperture 38
may alternately extend through the substrate or pathways. In such
instances where only one pathway aperture is used a large area of
pathway may be formed by that area being devoid of second sheets
18. For example a large area of the first major surface 14 would
not have second sheets attached to it thereby a large aperture may
be place in the pathway and not extend through the second sheet
material and only extend through the first sheet. Alternately a
pathway aperture 44 that is larger than a second sheet 18 may be
formed by displacing a second sheet wherein the larger pathway
aperture 44 takes the place of a second sheet or otherwise
displaces it. It should be noted that the apertures shown in FIGS.
1 and 2 are shown as examples of the different types and sizes of
apertures and the number, size, quantity and type of apertures
shown should not be considered in any way limiting the scope of the
invention or otherwise indicate a pattern of apertures and the
apertures shown are only for clarity in describing such apertures.
It should be noted that alternately no apertures may exist in the
abrasive sheet material 10 and apertures may be cut or punched into
the abrasive sheet material as a secondary operation in making the
abrasive sheet material as described below.
[0044] Abrasive particles are coated on at least the first major
surface 22 of the second sheets 18 forming an abrasive first major
surface 26. Abrasive may also be coated on the pathway sidewalls 32
and the first major surface 14 or any combination of surfaces
including the first major surface 14 second major surface 16 of the
first sheet 12 and first major surface 22 of the second sheets 18
and sidewalls 32 of pathways 30 and the present invention should
not be limited by excluding any combinations of sides with or
without abrasive coating. It is also within the scope of the
present invention to not have abrasive coated onto any of the
surfaces rather any of the surfaces may have a means of attaching
an abrasive sheet. For example the second sheet material 18 may be
a hook material of the hook and loop attachment system wherein an
abrasive sheet having loop backing could be attached to the hooks
and wherein the abrasive sheet may have apertures or openings that
allow air to pass through the abrasive sheet including sanding
screen. It should also be noted that first or second sheet
materials 14 and 18 respectively may be a lamination or composite
of materials for example second sheet material 18 may be paper
laminated to hook material, or paper having an adhesive or adhesive
film attached to the first major surface 22 of the second sheet 18
wherein the adhesive serves to attach an abrasive sheet
material.
[0045] As previously mentioned abrasive products may be cut from
the abrasive sheet material 10 wherein the abrasive products are
for example circular or disc shaped. Such abrasive products may be
used with tools including power tools such as orbital sanders and
the like. Such examples of abrasive discs are illustrated in FIGS.
3-14.
[0046] FIG. 3 illustrates one such abrasive disc 46 cut from the
abrasive sheet material 10 wherein the abrasive disc has circular
or disc shaped second sheets and wherein the apertures are
substrate apertures 42 that extend from the abrasive first major
surface 26 to at least the second major surface 16. The substrate
apertures in the present example have a five hole pattern that
coincides with a common five hole pattern of back up pads on
orbital sanders. Any hole pattern may be used other than a five
hole pattern as dictated by the hole pattern of the tool to which
the abrasive disc is to be attached. The holes in the back up pads
of such tools are used for collecting dust, while using the tool to
sand a surface. Vacuum is directed into the holes which in turn
direct vacuum into the apertures 42 in the abrasive disc 46. The
vacuum source may be an external vacuum source or an internal
vacuum source provided by the tool. The pathways 30 of the abrasive
disc extend to the edge or perimeter of the abrasive disc in
multiple areas thereby allowing air to be sucked into the pathways
from outside the abrasive disc when the disc is against a work
surface and sanding.
[0047] The abrasive disc 46 may be cut from the abrasive sheet
material 10 wherein no apertures are in the abrasive sheet material
10 and wherein apertures are cut into the abrasive disc in the same
operation as cutting the abrasive disc from the abrasive sheet 10.
Die cutting is the preferred method of cutting the disc as well as
the apertures.
[0048] FIG. 4 illustrates another embodiment of an abrasive disc 48
the same as the disc described In FIG. 3 with the exception that
the second sheets are square second sheets 50 and not circular and
pathways 20 are in a grid formation.
[0049] FIGS. 5 and 6 show a top planer view and a cross sectional
view of an abrasive disc 52 similar to the abrasive disc described
in FIG. 4 with the exception that the apertures are pathway
apertures 38 and not substrate apertures 42. Pathway apertures 38
are located within the pathways 20 and extend from the first major
surface 14 to the second major surface 16 and wherein an attachment
means is attached to the second major surface 16 the apertures 38
would extend through the attachment means. Loop 40 of the hook and
loop attachment system is attached to the second major surface 16.
It should be noted that in all embodiments of abrasive discs
wherein the abrasive disc is to be attached to a back up pad it is
preferable that loop material is attached to the second major
surface 16 providing a means for releasably attaching the abrasive
discs to a tool such as an orbital sander. It should also be noted
that alternate means of attaching abrasive discs to tools are
available and the present invention should not be limited to only
those attachment systems mentioned here. For example abrasive discs
may be attached by screw or clamping mechanisms used on palm
sanders.
[0050] FIGS. 7 and 8 illustrate an alternate embodiment of a
circular abrasive disc 56 similar to the one shown and described in
FIGS. 5 and 6. In FIGS. 7 and 8 a second sheet is a circumferential
circle or ring 54 that is located peripherally on the disc and
provides a boarder. Square second sheets 50 are located within the
ring 54. Pathways 58 do not extend to the outer edge of the disc
56, the pathways 58 are confined within the ring. The pathways
within the ring comprise an enclosed chamber 62 when the disc is
applied to a flat work surface. The enclosed chamber allows a
negative pressure to accumulate wherein no pathways allow outside
air to enter the chamber and by nature of an imperfect seal when
the abrasive disc contacts a work surface 60 air is allowed to seep
into the chamber between the work surface and the abrasive disc.
The movement of air between the abrasive disc and the work surface
is directed toward the pathway apertures and provides more
efficiency in collecting dust, as dust is swept into the chamber
and into the cust collection apertures before dust can migrate from
the confines of the chamber. Alternately a limited number of
pathways may be allowed to exit the chamber wherein the pathways
intersect with the ring 54 and extend to the outer edge of the
disc. One skilled in the art would recognize that the number of
pathways allowed to exit the ring and still maintain a negative
pressure within the chamber would depend on the amount of vacuum
and size of the pathways, thus the amount of pathways exiting the
ring should not exceed the point wherein no negative pressure is
allowed to accumulate in the chamber. It is preferable the in a 5''
or 6'' disc that no more than 4 pathways are allowed to exit the
chamber and still provide a negative pressure within the chamber.
Such pathways are shown in phantom by numerals 64.
[0051] FIGS. 9-14 illustrate circular sheet abrasives that may be
cut from the abrasive sheet material 10 wherein each figure shows
different shaped second sheets 18 that are arranged in different
patterns. FIG. 9 shows second sheets in a waved shape 66 that are
positioned in rows. Pathway apertures are located in the pathways
or between rows. FIG. 10 shows more than one second sheet 68 that
is a concentric ring with circular pathways 70 between concentric
rings. Pathway apertures 38 are positioned in the pathways. Pathway
apertures may be any shape as previously described for example
numeral 73 indicates an alternate slotted pathway aperture that is
curved or of a semi circular ring shape. The slotted aperture 73
may be a concentric slotted aperture. It should be noted that the
first sheet material 12 allows concentric circular rings to be held
in position and supported via a common first sheet 12 thereby
making it possible to position concentric rings on a back up pad
without individually placing such rings on the back up pad one at a
time. The pathway apertures 38 or 73 provide vacuum to the entire
area or pathway between the concentric rings.
[0052] FIG. 11 shows hexagon shaped second sheets 72 with pathway
apertures 38 that are in a pattern that coincide with the pathways
between the hexagonal second sheets 72 so that the pathway
apertures are positioned within the hexagonal pathways 76.
Apertures may not be in a pattern that coincides with the hexagonal
pathways and may be in any pattern such as random or in rows
wherein the apertures would appear in the pathways at random. For
example the apertures may be cut into the first sheet before second
sheets are attached to the fist sheet. In such case the second
sheets will cover some of the apertures and some of the apertures
will fall in the pathways. Some apertures may only partially be
covered for example numeral 78 shows a pathway aperture partially
covered by a hexagonal second sheet.
[0053] FIG. 12 shows second sheets wherein segments of second
sheets 80 together form a concentric circumferential ring that
surrounds a single circular second sheet 84.The pathways 82
partition the second sheet segments 80. All pathways communicate
with at least one substrate aperture 42. The substrate apertures 42
have a hole pattern that coincides with the hole pattern of a back
up pad of a sander such as an orbital sander.
[0054] FIG. 13 shows an abrasive disc having a single second sheet
86 that has curved or semi circular slots 88 that are
concentrically positioned and wherein the slots 88 extend through
the second sheet but not the first sheet 12. The slots 88 form
curved or semi circular pathways 90 that do not communicate with
each other and each pathway 90 has pathway apertures 38 that extend
through the first sheet 12 and into the pathway thereby providing
vacuum to the pathway.
[0055] FIG. 14 shows a circular abrasive disc having a
configuration of chain like second sheets 92 wherein the second
sheets are in strips or rows having rectangular segments that are
connected to each other to form a chain like structure. Pathway
apertures 38 are located in the pathways 94 that separate the chain
like second sheets. FIG. 15 shows a rectangular abrasive sheet
product cut from the abrasive sheet material 10 having circular
shaped second sheets 18. As previously described abrasive sheet
products may be made by cutting or punching them from the abrasive
sheet material 10 in a variety of shapes and sizes. For example
FIG. 4-14 show only circular shaped abrasive products and FIG. 15
shows a rectangular abrasive product. It would be obvious to one
skilled in the art that the shapes and sizes of abrasive sheet
products that may be formed and cut from the abrasive sheet
material 10 as well as the particular shape and sizes of second
sheets of an abrasive sheet product is unlimited and the present
invention only shows some preferred shapes and sizes. The present
invention should not be limited in scope by variables such as
shapes and sizes of second sheets, or pathways or abrasive products
cut from the abrasive sheet material, or the size and shape and
number of apertures or of the shape and size of the abrasive sheet
material 10. Any combination of variables mentioned above and
variables not mentioned but obvious to one skilled in the should be
included within the scope of the present invention. The abrasive
sheet material 10 is preferably in a continuous roll form but may
also be in sheets that are not in rolled form.
[0056] FIGS. 16, and 17 illustrate a top planar view and a cross
sectional view of a disc 96 having second sheets that are a hook
material. FIG. 18 is a top planar view showing an abrasive sheet
having apertures wherein the abrasive sheet is attached to and
overlays the second sheets of hook material 19. In the present
embodiment the second sheets are square second sheets 19 that are a
hook material of the hook and loop fastening system. Abrasive sheet
21 having a loop material backing may attach to the hook material
and overlay the pathways 30. The abrasive sheet 21 is shown in the
cross sectional view FIG. 17 as attached to and overlaying the disc
and pathways however for simplicity it is excluded from the top
planar view of FIG. 16 so that the second sheets 19 and pathways 30
are easily recognized. The abrasive sheet 19 has through holes 23
for the purpose of collecting dust. When the abrasive sheet is
positioned on the disc and overlays the pathways 30, some of the
through holes 23 will overlay pathways 30 thereby suction that is
directed into the pathways will access the through holes 23 as they
overlay the pathways. Dust will travel through the through holes 23
into the pathways 30 and into the substrate apertures 42 and into
the vacuum source receptacle. The abrasive sheet need not have
through holes that are positioned to align with any particular
pathway pattern. The abrasive sheet 21 may be configured with
through holes in any pattern and positioned over disc 96 so that at
least some of the through holes 23 will lie in part or in whole
over at least some of the pathways 30 without deliberate
positioning of through holes over pathways. For example the
abrasive disc 21 may be placed in random positions on the disc
without considering alignment of the holes relative the pathways
and some through holes 23 will still at least partially overlay at
least some pathways 30.
[0057] FIG. 19 is a perspective view of an alternate embodiment of
the present invention with a partial cut away showing an abrasive
sheet material 98 having an abrasive coating 102 on the second
major surface 16 opposite the pathways 30 located on the first
major surface 14 of the first sheet 12. The second sheets 18 are
not coated with abrasive and have a ventilative attachment member
40 affixed thereto wherein the ventelative attachment member
overlays the second sheets 18 and pathways 30. A preferable
ventelative attachment member is loop material 40 of the hook and
loop fastening system. Vacuum holes 100 in the loop material allow
vacuum to access the pathways when the abrasive sheet is attached
to a tool that has a vacuum source for dust collection and wherein
at least one vacuum hole in the loop material communicates with at
least one vacuum hole in the tool to which it is attached. Loop
material 40 may alternately be affixed to the first major surface
22 of each of the individual second sheets 18 as shown by numeral
107 and not overlay the pathways 30. The pathways 30 are on the
opposite side of the abrasive surface 102 and distribute vacuum to
all apertures in the abrasive sheet. Apertures as described in
previous embodiments may be pathway apertures 38 or substrate
apertures 42. The apertures extend through the first sheet of
material 12. A plurality of apertures may be positioned throughout
the abrasive sheet material and at least one aperture 100 in the
loop material 40 aligns with at least one vacuum hole in the tool
to which the abrasive sheet is attached. In this manner vacuum is
distributed to all the pathways thereby distributing vacuum to all
apertures in the abrasive sheet. For example the abrasive sheet may
be in the form of a disc wherein the disc is attached to a back up
pad of an orbital sander and the back up pad has hooks of the hook
and loop attachment system. At least one vacuum hole 100 may align
with at least one vacuum hole in the back up pad of the orbital
sander. It should be noted that the abrasive sheet 98 may have any
attachment means fixed to the backing of the abrasive sheet and not
only loop material for example adhesive may alternately be used as
an attachment means. It would be preferable to have a vacuum hole
pattern in the loop material 40 that corresponds to the hole
pattern in the back up pad of the orbital sander, for example a
five or 8 hole pattern is common in back up pads of orbital
sanders. The holes in the loop material may extend through the
second sheets and through the first sheet of material 12 and
through the abrasive surface 102. In this manner the holes in the
abrasive sheet may easily be aligned with the holes in the back up
pad of the orbital sander. When the abrasive sheet is attached to
the back up pad and in contact with a work surface all holes in the
abrasive sheet would be substantially closed off by the work
surface thereby vacuum would be distributed throughout the pathways
30 accessing all the apertures in the abrasive sheet and not only
the vacuum holes that are aligned with the holes in the back up
pad. Intake air would be provided through the side vents 104 of the
abrasive sheet and also between the abrasive surface and the work
surface. The side vents 104 are peripherally located on the
abrasive sheet where the pathways 30 exit the sidewalls 106 of the
abrasive sheet. Air is sucked into the pathways from outside the
abrasive sheet, through side vents 104 and into the network of
pathways 30. In this manner vacuum may be distributed to apertures
positioned throughout the abrasive sheet via vacuum pathways
located on the abrasive sheet opposite the abrasive surface.
[0058] An abrasive sheet may be made in this manner wherein side
vents do not exist and a network of pathways form an enclosed
chamber as described previously in FIGS. 7 and 8. For example an
abrasive disc may have pathways opposite the abrasive surface
wherein the pathways do not exit the sidewalls of the abrasive disc
and form an enclosed network of pathways. It may be preferable that
a limited number of pathways may exit the sidewalls thereby
providing a vent in the sidewalls for intake air. The number of
pathways allowed to exit the sidewalls would be determined by the
amount of vacuum, the size of the vents and the area of the vacuum
chamber as shown in FIGS. 7 and 8. It is preferable that the number
of vents is such that a negative pressure is obtained in the vacuum
chamber thereby a greater vacuum is distributed to the apertures in
the abrasive sheet thus improving the efficiency of dust
collection. In an alternate
[0059] FIG. 20 is a top planar view of an abrasive disc 108 having
a support sheet 110 that is circular. The circular support sheet
110 supports concentric second sheets 112, 114, and 116 affixed to
the circular support sheet 110 and shown in hidden lines. The
concentric second sheets have abrasive material coated onto the
surface opposite the side affixed to the support sheet 110
providing an abrasive major surface 128 on the second sheets. A
cross sectional view of the abrasive disc 108 is shown in FIG. 21.
The support sheet 110 has longitudinal slots 118 that extend
through the thickness of the support sheet and are arranged in a
radial pattern. The concentric second sheets 112, 114, 116 are
sized and arranged so that when the second sheets are affixed to
the support sheet 110, a plurality of concentric gaps or vacuum
pathways 120 exists between the concentric second sheets. The
concentric pathways 120 intersect and are in flow communication
with the radial slots 118 in the support sheet 110. A fastener may
be applied to the back of the abrasive disc for attaching the disc
to a back up pad. Fasteners that may be used include hook and loop
material of the hook and loop fastening system or adhesive, or any
known fastener that serves to attach abrasive sheet to a back up
pad. Loop material of the hook and loop fastening system is
preferably used.
[0060] The outermost concentric second sheet 112 may be segmented
into sections wherein each section is separated by a gap 122 and
wherein the gap is a pathway that serves as an air intake port so
that air may be sucked into the pathways 120 from the periphery of
the abrasive sheet. Apertures 124 may be positioned on the support
sheet and coincide with and occupy at least part of the space that
forms the slots 118. The slots and apertures at least partially
share a common space so that at least one slot communicates with at
least one aperture. The apertures 124 extend through the thickness
of at least the support sheet 110. from
[0061] For economy and simplicity in making the abrasive disc it is
preferable that the apertures 124 are formed after the concentric
second sheets are affixed to the support sheet and coated with
abrasive particles. loop material 126 of hook and loop attachment
system may be applied to the backing of the abrasive disc 108. If
apertures are formed after support sheets 110 and second sheets
112,114, and 116 and loop material are laminated together, the
apertures would extend through the thickness of the disc 108,
extending through the loop material 126, support sheet 110 and
second sheets 112, 114, and 116 and through the abrasive major
surface.
[0062] Apertures may be formed by a punching or die cutting
process. Additional curved slots 130 may be formed in the support
sheet wherein the curved slots are segments of a circular slot
having a diameter that allows the curved slots to communicate with
vacuum holes in a back up pad irrespective of the alignment of the
apertures 124 with the back up pad vacuum holes. For example if the
abrasive disc 108 is attached to the back up pad of an orbital
sander without considering alignment of apertures 124 with the
holes in the back up pad, the curved slots 136 would have an
increased chance of overlaying the holes in the back up pad.
[0063] FIGS. 22 and 23 show a top planar view and a cross sectional
view of an alternate embodiment of an abrasive disc 132 comprising
a substrate 134 having indented or embossed vacuum pathways 136
that are indented and recessed below the abrasive surface. In this
embodiment the substrate is a non resilient material preferably
paper. The abrasive disc 132 having embossed pathways is similar to
the above described abrasive discs with the exception that the
pathways are not formed by laminating second sheets to a first
sheet rather the present embodiment comprises only one sheet that
is a substrate for attaching abrasive particles thereby making an
abrasive sheet or disc. The abrasive disc 132 has vacuum pathways
136 in a grid formation creating raised square surfaces that are
coated with abrasive 140. Pathway apertures 138 are located in the
pathways 136.
[0064] FIGS. 24 and 25 show a top planar view and a cross sectional
view of a disc having indented vacuum pathways that do not exit the
side of the abrasive disc as shown and described in FIGS. 7 and 8
above. FIG. 25 shows a cross sectional view of the abrasive disc in
contact with a work surface 114
[0065] FIG. 26 shows a cross sectional view of an alternate
embodiment of an abrasive disc 140 similar to the abrasive disc
shown and described in FIGS. 22 and 23 with the exception that the
abrasive surface is on the opposite side of the substrate that the
pathways are indented or embossed into. The abrasive disc may be
configured and arranged with pathways in any of the configurations
previously described with the exception that they are indented or
embossed into a substrate rather than formed by a kiss cutting and
lamination process involving more than one sheet of material
laminated together. Although an abrasive disc is shown it should be
noted that an abrasive sheet in any of the above mentioned forms
may be made using the embossing or indenting process to provide
pathways to the abrasive surface or to the backing of the abrasive
material opposite the abrasive surface. Although embossing and
indenting an abrasive surface is not unknown in the prior art it is
the intention to provide a new use for embossed abrasive articles
wherein the embossed or indented portion provides pathways used for
the purpose of dust collection wherein the pathways may be embossed
in the surface that is to be coated with abrasive or the abrasive
surface is embossed or indented after coating with abrasive. It is
also the intent to provide an embossed or indented surface to the
backing of an abrasive article wherein the embossed or indented
portion provides pathways opposite the abrasive surface for the
purpose of dust collection.
[0066] A method of forming the abrasive sheet material 10
comprises: Providing an abrasive sheet material comprising a first
sheet having a first major surface and a second major surface and
second sheets having first major surfaces and second major surfaces
wherein the second major surfaces of the second sheets are affixed
to the first major surface of the first sheet and spaces exist
between the second sheets wherein said spaces form pathways that
interweave between the second sheets wherein the pathways
communicate with each other and form a network of pathways. At
least one aperture extends from at least the first major surface of
the first sheet to the second major surface of the first sheet and
communicates with at least one of the pathways. Abrasive particles
are coated onto at least the first major surface of the second
sheets forming an abrasive first major surface. When air moves
through the pathways by a vacuum source said pathways channel air
across and parallel to the work surface while the air is in contact
with the work surface thereby providing a sweeping movement of air
across the work surface carrying dust with the air for the purpose
of vacuuming dust from the work surface.
General Method of Making
[0067] Abrasive sheet product is made by providing a first sheet of
material having a plurality of second sheets of material laminated
to the first sheet of material wherein the second sheets of
material are individual second sheets that are spaced apart and
adjacent to each other thereby forming pathways or channels between
the second sheets wherein the pathways form conduits for the
passage of air and debris when the abrasive sheet product is in
contact with a work surface and a suction or blowing air is
directed into the pathways via apertures in the first sheet of
material. Positive or negative air pressure may be directed into
the pathways via a vacuum or air blowing device such as a fan, a
vacuum is preferable.
[0068] In greater detail a plurality of second sheets of material
are first formed by a method commonly known and used in making for
example adhesive backed labels such as those sold in office supply
stores. One example is a method of making Color Coding Labels such
as those sold by Avery Dennison Corporation, product number 05795
wherein small 1/4'' disc shaped labels are formed through a process
of kiss cutting.
[0069] A second sheet of material is adhesively laminated to a
first sheet of material. The second sheet of material being label
material and the first sheet a releasable material that is
releasably attached to the second sheet of material. The labels are
formed into the second sheet of material by cutting through the
second sheet of paper or the label material and not through the
first sheet or the releasable material. The process of cutting only
the second sheet and not the first sheet of material is a process
called kiss cutting wherein the cutting blades of the machine cut
through the second sheet and only touch or kiss the first sheet
without cutting through it. Labels are now formed into the second
sheet material forming individual second sheets that are spaced
apart from each other. The second sheet material that is waste and
not to be used as labels is removed from or delaminated from the
first sheet material thereby leaving only individual second sheets
or labels releasably attached to the first sheet and are adjacent
to each other and spaced apart from each other wherein the spaces
form pathways or channels between the second sheets or labels and
wherein the pathways interconnect with each other and form a
network of interconnected pathways that are in flow communication
with each other. The space comprising the pathways or channels was
previously occupied by the now removed waste material of the second
sheet.
[0070] The abrasive sheet material of the present invention is made
using the kiss cutting process described above wherein a second
sheet of material is laminated to a first sheet of material wherein
the first and second sheets of material are suitable materials for
making a substrate for the purpose of coating the substrate with
abrasive particles thereby forming an abrasives sheet material.
[0071] It should be noted that the above description is for the
purpose clarifying the kiss cutting process in making labels and
demonstrating how kiss cutting a second sheet of material laminated
to a first sheet of material may be used in making a substrate for
coating with abrasive particles wherein the substrate has pathways
that are recessed below an abrasive surface or surfaces. The
pathways are for the purpose of dust collection as will be further
described.
[0072] It is the object of the present invention to use the process
of kiss cutting to form an abrasive sheet substrate having a first
sheet and separated second sheets laminated to the first sheet and
pathways formed between the separated second sheets. Although it is
the intention to use the process of kiss cutting in making the
abrasive sheet material of the present invention some modifications
or additional processes may be used in addition to the above
process in making the abrasive sheet material and such
modifications or additional processes are described below. In all
such modified versions of making the abrasive sheet the common
process of kiss cutting the second sheets is used. For example in
some processes the second sheets may be kiss cut and delaminated
from a releasable first sheet material to a first sheet of material
that is not releasable thereby making the second sheets permanently
affixed to the first sheet of material. In other embodiments the
second sheets of material may remain on the releasable material and
become more permanently affixed to the first sheet of releasable
material by a make coat of adhesive used in the abrasive coating
processes. Or the adhesive that bonds the second sheet to the
releasable first sheet may be a releasable bond for a short period
of time and become more permanent over a longer period of time
thereby making the bond between the first sheet of material and the
second sheets a permanent bond over time.
[0073] In the preferred method of making the abrasive sheet
material a second sheet of material is laminated to a first sheet
of material. A plurality of second sheets are formed from the
second sheet material by kiss cutting the second sheet. The waste
material of the second sheet is removed leaving a plurality of the
desired second sheets releasably attached to the first sheet with
pathways formed between the plurality of second sheets. The second
sheets are then delaminated from the releasable sheet material and
relaminated to a first sheet of material that is not releasable. It
is also the object of the present invention to delaminate the
second sheets of material after being kiss cut and relaminate the
second sheets to a first sheet that is not releasable wherein the
second sheets are in substantially the same pattern and arrangement
as they were after being kiss cut and before delamination. In this
manner any arrangement or pattern or formation of second sheets may
be delaminated from one sheet and relaminated to a different sheet
of material while maintainting substantially the same pattern and
arrangement from one sheet to another sheet. It is the objective to
keep the integrity of the positioning of second sheets in tact
during the delamination and relamination process, it should be
noted that a certain degree of misalignment or difference in
positioning of second sheets when relaminated would not generally
effect the performance of the abrasive sheet wherein the pathways
provide a means of channeling vacuum to a work surface.
[0074] The delamination of the second sheets from the releasable
liner and relamination to a first sheet that is not releasable
material may be done by known machinery used in the paper
converting industry and generally refered to as applicators. Such
known applicators includes those made by Label-aire company Located
in Fullerton, Calif. Preferable applicator machines that may be
used for the delamination and relamination of second sheets are
Label-Aire Model numbers 3115 wipe on, model 3135 wipe on, model
3114 Tamp Blow, model 3111 Air-Blow, 3125 wipe on, and 3155 wipe
on. The wipe on applicators are more preferable. Although the
company mentioned above and the applicator model numbers are
preferable, the present invention and process of delaminating and
relaminating sheets of material should not be limited to only these
models, rather should include any known machinery used for
delaminating a sheet of material from one sheet and relaminating
the sheet of material to another sheet.
[0075] Machinery used for kiss cutting may be purchased from
Manufacturers supply company in Cincinatti Ohio and includes such
kiss cutting systems as the Guidolin Davide Systems model numbers
GD151 Kisscut, GD301 Kisscut, GD401 Kisscut, GD654 Kisscut,
Guillotine GDX1 and Rotary Die Kisscut. Rotary Die kiss cut is
preferable for kiss cutting the second sheets of the present
invention. The present invention may be made in two separate
processes, the first process involves laminating the second sheets
to a liner and kiss cutting the second sheets with a kisscutter
machine then removing the waste material and winding the second
sheets while on the liner into a roll. The second step involves
putting the roll on an applicator machine described above and
delaminating and relaminating the second sheets onto a first sheet
of material for making a substrate with pathways as described. It
should be noted that machinery as described above may be configured
and arranged in a manner that combines the steps mentioned above
into one step wherein a lamination of second sheets on a liner may
be kiss cut then fed into an applicator wherein the second sheets
are delaminated from the liner and relaminated to a first sheet
wherein all steps are a continuous operation.
[0076] It is the intent of the present invention to use such
machinery and processes as described above to efficiently and
effectively make a laminated substrate having pathways used for
dust collection and coating the substrate with abrasive particles
to form an abrasive sheet material that has dust collection
pathways. Through the process of kiss cutting, delamination and
relamination, pathways are formed into the laminated substrate for
the purpose of coating the substrate with abrasive material making
an abrasive sheet material having dust collection pathways. Holes
may be formed into the abrasive sheet wherein the holes direct
vacuum to the pathways.
[0077] The second sheets of material may be of different shapes so
as to form any configuration of pathways or form any pattern. For
example second sheets of material may have a combination of shapes
wherein some are rectangular and some are round, or some are curved
and some are linear, and these combinations of shapes may form a
pattern wherein that pattern serves a function and wherein that
pattern is repetitively place or duplicated on an abrasive sheet
material. individual abrasive products having a particular pattern
of second sheets or sheet may be cut from the abrasive sheet
wherein the abrasive sheet has a particular pattern duplicated on
the abrasive sheet. It should also be noted that the second sheets
provide individual cutting edges that increase the cut rate of the
abrasive product and the particular shape of the second sheets may
be of a shape that provides greater cutting efficiency by having
many cutting edges. For example the second sheets of material may
be star shaped, or have a wave pattern. The second sheets of
material may have any imaginable shape including but not limited to
circular, square, rectangular, octagonal, hexagonal, irregular,
diamond, triangular, oval waved, curved, spiral, linear, non linear
or any combination of these shapes including star shapes or
concentric circles or any of these shapes wherein they are
positioned to be concentric to each other.
[0078] Other devices may be devised and used to delaminate the
second sheets from liner material and relaminate them to a first
sheet material. It is the object of the present invention to
include within its scope any and all devices that may be utilized
for kiss cutting the second sheets that are laminated to a
releasable liner material and delaminateing the second sheets from
the releasable liner material and relaminating the second sheets of
material to a first sheet of material wherein pathways or gaps
exist between the second sheets when relaminated onto the first
sheet material and wherein the first sheet and second sheets
together form a substrate suitable for coating with abrasive
particles thereby forming an abrasive sheet material and wherein
the pathways of the abrasive sheet material may be used for
directing vacuum to a work surface during sanding operations.
Furthermore it is necessary that the first sheet of material is
suitable as a substrate for an abrasive sheet.
[0079] The first sheet of material may serve as a backing layer or
a support member or a first substrate or a connecting support
member to which the second sheets are fixedly attached and that in
the process of delaminating the second sheets from the releasable
liner material and relaminating the second sheets to the first
sheet material the integrity or positioning of the second sheets is
maintained in substantially the same position they were in when
kiss cut on the releasable liner material. The method of making the
abrasive sheet described above provides unlimited possibilities of
different configurations and arrangements of pathways that
interweave between raised abrasive surfaces on an abrasive sheet
wherein the raised surfaces are surfaces of the second sheets of
material. It should be noted that the raised surfaces or second
sheets may also not be coated with abrasive particles and the
raised surfaces or second sheets may serve to retain an abrasive
sheet material wherein the abrasive sheet material overlays the
pathways and wherein the abrasive sheet material may have apertures
that communicate with the pathways for the purpose of collecting
dust.
[0080] An alternate method of making an abrasive sheet material of
the present invention is similar the method described above with
the exception that the second sheets are not delaminated from the
first sheet of liner material after being kiss cut, and the first
sheet of liner material is such that the second sheets may be
releasable from the first sheet of liner material for a period of
time then not releasable after a longer period of time wherein the
second sheets over time become permantently attached to first sheet
of liner material. For example the first sheet of liner material
may be a sheet of material suitable as a substrate for coating with
abrasive particles. The second sheet of material would be
adhesively attached to the first sheet of liner material with an
adhesive that for a short period of time allows the second sheet
material to be releasable from the first sheet, herein after
referred to as the releasable period. In this manner the second
sheets may be kisscut and the waste material removed via a
releasable attachment during the releasable period. After the waste
material is removed a longer period of time passes and the second
sheets become more permanently affixed to the first sheet of
material. It is preferred that the second sheets become permanently
attached to the first sheet of material before coating the
substrate with abrasive particles. The second sheets however need
not be permanently affixed to the first sheet and the adhesive bond
may be made more secure during the abrasive coating process wherein
a make coat of glue is coated onto the substrate covering the first
major surface 22 of second sheets, the pathways 30, pathway
sidewalls 32, and first major surface of first sheet 14 or pathway
bottom 36. By coating all surfaces with glue, a secure bond holding
the second sheets to the first sheet is achieved. The bond may be
further strengthened by adding coats of glue during the abrasive
coating process such as super make coats or any additional coat of
glue otherwise used in the abrasive coating process.
[0081] It is well known that abrasive sheets are commonly
releasably attached to back up pads by means of a pressure
sensitive adhesive coating on the backing of the abrasive sheet.
Although it is not the intent to make the second sheets releasably
attached to the first sheet it should be included within the scope
of the invention that a bond between the first sheet and the second
sheets need not be permanent and that it may be of benefit to have
the second sheets irremovably attached to the first sheet in
certain instances.
[0082] Further modification of the invention herein disclosed will
occur to those skilled in the respective arts and all such
modifications are deemed to be within the scope of the
invention
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