Sanding disc

Abstract

A sanding disc comprising an integral structure having a plurality of layers. The layers include a foam backing layer, a middle semi-resilient layer and an abrasive screen layer.

What is claimed is:  
     
         1 . A sanding disc comprising: 
 a backing layer of a porous, resilient material;    a middle layer of a nonporous, semi-resilient material bonded to said backing layer; and    an abrasive screen layer bonded to said middle layer.    
     
     
         2 . The sanding disc of  claim 1  wherein said backing layer is a foam pad.  
     
     
         3 . The sanding disc of  claim 1  wherein said middle layer is cardboard.  
     
     
         4 . The sanding disc of  claim 1  wherein said abrasive screen layer is a screen cloth having an open mesh design wherein said screen cloth is coated with an abrasive material.  
     
     
         5 . The sanding disc of  claim 4  wherein said abrasive material is silicon carbide.  
     
     
         6 . The sanding disc of  claim 1  wherein said abrasive screen layer is a silicon carbide sanding screen.  
     
     
         7 . The sanding disc of  claim 1  wherein said backing layer has a thickness of about 0.75 inches.  
     
     
         8 . The sanding disc of  claim 1  wherein said sanding disc has a maximum outside diameter of about 9 inches.  
     
     
         9 . The sanding disc of  claim 1  wherein said backing layer has an outside diameter of about 8.5 inches.  
     
     
         10 . The sanding disc of  claim 1  wherein said sanding disc has a central opening.  
     
     
         11 . The sanding disc of  claim 1  wherein said abrasive layer has an inside diameter of about 3 inches.  
     
     
         12 . The sanding disc of  claim 1  wherein said middle layer is bonded to said top layer and said abrasive layer with adhesive.  
     
     
         13 . A method of making a sanding disk for a motorized drywall sander, said method comprising: 
 forming a foam backing layer in the shape of a disc having an inside and an outside diameter;    attaching a nonporous, semi-resilient middle layer in the shape of a disc having an outside diameter larger than said outside diameter of said foam support layer; and    securing an abrasive screen to said middle layer, said abrasive screen having an outside diameter substantially similar to said outside diameter of said middle layer.    
     
     
         14 . The method of  claim 13  further comprising forming an adhesive layer between said foam support layer and said middle layer.  
     
     
         15 . The method of  claim 13  further comprising forming an adhesive layer between said abrasive screen and said middle layer.  
     
     
         16 . A high speed sanding disc for sanding drywall joints, said sanding disc comprising: 
 an integral structure having a plurality of layers, said plurality of layers comprising: 
 an abrasive screen;  
 a nonporous, semi-resilient layer bonded to said abrasive screen; and  
 a foam pad bonded to said nonporous layer wherein said abrasive screen, said nonporous layer and said foam pad form said integral structure.  
   
     
     
         17 . The sanding disc of  claim 16  wherein said integral structure has a central opening therethrough forming an inside diameter of said integral structure.  
     
     
         18 . The sanding disc of  claim 16  wherein said abrasive screen and said nonporous layer are thinner than said foam pad.  
     
     
         19 . The sanding disc of  claim 16  wherein said abrasive screen and said nonporous layer each have an outside diameter larger than said foam pad.  
     
     
         20 . The sanding disc of  claim 16  wherein said abrasive screen has an inside diameter larger than said middle layer.