Laminated flexible resilient abrasive article

Abstract

A sheet-like abrasive article includes a resilient backing sheet having opposed major surfaces and a continuous abrasive sheet affixed to the backing sheet. The abrasive sheet includes an abrasive support layer with abrasive particles arranged thereon, thereby defining an abrasive surface. A sanding tool assembly including such a sheet-like abrasive article is also disclosed.

1 . A flexible sheet-like abrasive article for hand-held, manually-operated sanding, comprising: 
 (a) a flexible resilient backing sheet having opposed major surfaces;    (b) a flexible continuous abrasive sheet affixed to at least one surface of the backing sheet, the abrasive sheet comprising a continuous abrasive support layer with abrasive particles deposited thereon, thereby defining an abrasive surface comprising protruding abrasive particles.    
   
   
       2 . An abrasive article as defined in  claim 1 , wherein the resilient backing sheet comprises a closed-cell foam.  
   
   
       3 . An abrasive article as defined in  claim 1 , wherein the backing sheet is a discontinuous sheet formed by a plurality of separated resilient bodies held together in a pattern so as to provide openings between each adjacent separated body yet connected to one another at contact points.  
   
   
       4 . An abrasive article as defined in  claim 3 , wherein the backing sheet comprises a polyvinylchloride foam material.  
   
   
       5 . An abrasive article as defined in  claim 1 , wherein the backing sheet comprises a foamed latex rubber material.  
   
   
       6 . An abrasive article as defined in  claim 1 , wherein the backing sheet comprises a nonwoven material.  
   
   
       7 . An abrasive article as defined in  claim 1 , wherein the backing sheet has a thickness of no greater than about 8 mm.  
   
   
       8 . An abrasive article as defined in  claim 1 , wherein the backing sheet includes a generally flat surface bonded with the abrasive support layer and further includes a textured surface opposite the flat surface defining a gripping surface opposite the abrasive surface which is engaged by the user to manually actuate the abrasive article.  
   
   
       9 . An abrasive article as defined in  claim 1 , wherein the abrasive support layer comprises a cloth material.  
   
   
       10 . An abrasive article as defined in  claim 9 , wherein the abrasive support layer is a J-weight woven cloth.  
   
   
       11 . An abrasive article as defined in  claim 1 , wherein the abrasive sheet and backing sheet are adhesively bonded together.  
   
   
       12 . A hand-held, manually-operated sanding tool assembly including a replaceable sheet-like abrasive material, the sanding tool assembly comprising: 
 (a) a sanding tool comprising: 
 (i) a base member having first and second opposed ends and a generally planar bottom surface extending between the first and second ends, and at least one inclined upper contact surface opposite the bottom surface adjacent one of the first and second ends arranged to form an acute angle with the bottom surface relative to the associated adjacent end; and  
 (ii) a clamping mechanism pivotally connected with the base member, the clamping mechanism being movable between an open position wherein the clamping mechanism is spaced from the base member contact surface, thereby defining a gap between the base member upper contact surface and the clamping mechanism for receiving an end portion of the sheet of abrasive material, and a closed position wherein the clamping mechanism is moved toward the contact surface and is arranged adjacent the base member contact surface, the clamping mechanism including a tensioning member arranged to slidably engage the contact surface, whereby when an end portion of the sheet of abrasive material is inserted into the gap between the base member and the clamping mechanism, and the clamping mechanism is moved from the open position to the closed position, the tensioning member engages the sheet of abrasive material, and as the clamping mechanism is further urged toward the contact surface, the tensioning member and abrasive sheet move upwardly along the inclined contact surface away from the associated end, thereby tightening the fit of the abrasive sheet against the bottom surface of the base member; and  
   (b) a flexible sheet-like abrasive article, comprising: 
 (i) a flexible resilient backing sheet having opposed major surfaces;  
 (ii) a flexible continuous abrasive sheet affixed to at least one surface of the backing sheet, the abrasive sheet comprising a continuous abrasive support layer with abrasive particles deposited thereon, thereby defining an abrasive surface comprising protruding abrasive particles.  
   
   
   
       13 . The sanding tool assembly as defined in  claim 12 , wherein the tensioning member comprises a flexible metal leaf spring.  
   
   
       14 . The sanding tool assembly as defined in  claim 13 , wherein the tensioning member extends the width of the clamping mechanism.  
   
   
       15 . The sanding tool assembly as defined in  claim 12 , wherein the tensioning member includes a gripping surface for increasing the frictional force between the tensioning member and the sheet of abrasive material.  
   
   
       16 . A sanding tool as defined in  claim 15 , wherein the gripping surface comprises a plurality of projections.  
   
   
       17 . A method of sanding, comprising: 
 (a) providing a flexible sheet-like abrasive article, comprising: 
 (i) a flexible resilient backing sheet having opposed major surfaces; and,  
 (ii) a flexible continuous abrasive sheet affixed to at least one surface of the backing sheet, the abrasive sheet comprising a continuous abrasive support layer with abrasive particles deposited thereon, thereby defining an abrasive surface comprising protruding abrasive particles;  
   (b) providing a hand-held, manually-operated sanding tool comprising: 
 (i) a base member having first and second opposed ends and a generally planar bottom surface extending between the first and second ends, and at least one inclined upper contact surface opposite the bottom surface adjacent one of the first and second ends arranged to form an acute angle with the bottom surface relative to the associated adjacent end; and  
 (ii) a clamping mechanism pivotally connected with the base member, the clamping mechanism being movable between an open position wherein the clamping mechanism is spaced from the base member contact surface, thereby defining a gap between the base member upper contact surface and the clamping mechanism for receiving an end portion of the abrasive article, and a closed position wherein the clamping mechanism is moved toward the contact surface and is arranged adjacent the base member contact surface, the clamping mechanism including a tensioning member arranged to slidably engage the contact surface, whereby when an end portion of the sheet of abrasive material is inserted into the gap between the base member and the clamping mechanism, and the clamping mechanism is moved from the open position to the closed position, the tensioning member engages the sheet of abrasive material, and as the clamping mechanism is further urged toward the contact surface, the tensioning member and abrasive sheet move upwardly along the inclined contact surface away from the associated end, thereby tightening the fit of the abrasive sheet against the bottom surface of the base member;  
   (c) securing the flexible sheet-like abrasive article to the sanding tool by means of the clamping mechanism, and,    (d) manually operating the sanding tool to abrade a work surface.    
   
   
       18 . The method of  claim 17 , wherein the tensioning member comprises a flexible metal leaf spring.  
   
   
       19 . The method of  claim 17 , wherein the backing sheet is a discontinuous sheet formed by a plurality of separated resilient bodies held together in a pattern so as to provide openings between each adjacent separated body yet connected to one another at contact points.  
   
   
       20 . The method of  claim 17 , wherein the abrasive support layer is a J-weight woven cloth.