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Thermoplastic sheet abrasives and methods of making the same

Inactive Publication Date: 2005-07-28
SOELCH RICHARD ROBERT +3
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0006] The present invention provides a sheet abrasive that includes a plurality of abrasive particles dispersed within a thermoplastic polymer layer. The thermoplastic polymer layer preferably is an extruded thermoplastic polymer layer or an injection-molded thermoplastic polymer layer. The thermoplastic polymer layer makes the sheet abrasive strong yet flexible, and the abrasive particles are held firmly in place within the polymer layer without the need for an additional bonding material. Furthermore, because the abrasive particles are dispersed throughout the thickness of the thermoplastic polymer layer, not just on its surface, the sheet abrasive maintains its abrasive qualities even after its topmost layer has been worn away.

Problems solved by technology

These types of coated sheet abrasives, however, suffer from several disadvantages.
Thus, the useful life of these types of sheet abrasives is limited by the thickness of the abrasive particle layer and by the strength of the bond between the abrasive particles and the base material.
In addition, the flexibility of conventional coated sheet abrasives is limited because bending or stretching the sheets can dislodge the abrasive particles from the base material and crack, crease, or otherwise damage the sheet.
Storing, handling, and transporting the organic solvents used in this process pose a significant inconvenience and health hazard to operators.
Furthermore, evaporating the organic solvents can make the process more costly and time consuming.
The compression molding process is time consuming because the process in non-continuous, i.e., each mold can only produce one abrasive pad at a time.

Method used

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  • Thermoplastic sheet abrasives and methods of making the same
  • Thermoplastic sheet abrasives and methods of making the same
  • Thermoplastic sheet abrasives and methods of making the same

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0050] All examples were produced using the extruder 30 illustrated schematically in FIG. 4. The polymer starting materials were added to the rear of the extruder 30 through primary feeder 32, and the abrasive particles were added through secondary feeder 34. The extrudate 36 exited the die 38 vertically downward into a water quench bath 40 where the extrudate 36 was solidified. A standard 6 inch film type die 38 with an adjustable die gap (Extrusion Dies Inc., Chippewa Falls, Wis.) was used. The die gap was set at 0.058 inch for all examples. The extrudate 36 was pulled by a set of slow group orientation rolls 42, and was passed through an orientation oven 44 and then onto a set of fast group orientation rolls 46. Next, the extrudate 36 was passed through a relaxation oven 48, a set of crimp rolls 50 to provide crimp, and then through a set of lube rolls 52 coated with a lubricant. The extrudate 36 then was passed onto a set of relaxation group rolls 54, which were set at the same ...

example 2

[0054] A two layer sheet abrasive sample was prepared by adhering a control sheet made of nylon 6 onto sample F using hot melt glue. The resulting two-layer sheet abrasive sample could not be torn by hand, while Sample E, which did not contain a second layer, could be torn with moderate effort. This experiment demonstrates sheet abrasives that include two or more layers can exhibit improved mechanical properties, such as improved tensile strength.

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Abstract

The present invention provides sheet abrasives that include a plurality of abrasive particles dispersed within a thermoplastic polymer. The present invention also provides methods for producing sheet abrasives.

Description

FIELD OF THE INVENTION [0001] The present invention relates generally to the field of sheet abrasives. More particularly, the invention relates to sheet abrasives comprising abrasive particles dispersed within a thermoplastic polymer and methods for making the same. BACKGROUND [0002] Conventional sheet abrasives generally consist of abrasive particles bonded to the surface of a paper or cloth base material. These types of coated sheet abrasives, however, suffer from several disadvantages. Typically, a coated sheet abrasive contains a single layer of abrasive particles coated on the base material, which itself is non-abrasive. During use, the abrasive particles are either worn down or become detached from the surface of the base material, leaving only bare base material in contact with the work surface. Thus, the useful life of these types of sheet abrasives is limited by the thickness of the abrasive particle layer and by the strength of the bond between the abrasive particles and t...

Claims

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Application Information

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IPC IPC(8): B24B21/00B24D3/00B24D3/20B24D11/00B24D99/00
CPCB24D3/002B24D11/001B24D3/20
Inventor SOELCH, RICHARD ROBERTKRUEGLER, GERALD F.AGARWAL, AMIT RAMESHMAINER, RAYMOND GEORGE
Owner SOELCH RICHARD ROBERT