Dry Sanding Surfaces Having High Abrasive Loading

Abstract

Abrasive articles are disclosed that may be used in dry sanding applications. The abrasive articles disclosed may be made entirely from abrasive materials or alternatively may be made by fastening abrasive surfaces to handles or tools. The abrasive articles of the present invention have abrasive surfaces with controlled wear rates that renew themselves during use. The self renewing abrasive surfaces of the present invention may be prepared by pressing a mixture of abrasive particles and a minimal amount of a foam binder together into a mold and subsequently allowing the mixture to foam, break down, and harden. Alternatively, high loading densities of abrasive with larger amounts of foam binder may be employed that retain their foam integrity. The resulting abrasive articles are long lasting and may be made low in cost.

1 . A composition of matter for dry sanding applications comprising: (a) from about 1 part by weight of polymeric foam with a density of at least 8 pounds per cubic foot; and (b) from about 2.7 to about 8 parts by weight of abrasive particles, whereby said composition of matter has structural integrity. 
   
   
       2 . The composition of matter of  claim 1  wherein said polymeric foam is polyurethane. 
   
   
       3 . A composition of matter for dry sanding applications comprising: (a) about 1 part by weight of polymeric foam; and (b) at least 8 parts by weight of particles, whereby loading density of said particles causes disruption of said foam. 
   
   
       4 . The composition of matter of  claim 3  wherein said particles is comprised of abrasive particles. 
   
   
       5 . The composition of matter of  claim 3  further comprising of void spaces between said particles of less than about 70% by volume. 
   
   
       6 . The composition of matter of  claim 3  wherein said polymeric foam is polyurethane. 
   
   
       7 . An abrasive article for dry sanding applications comprised of a dense abrasive composition. 
   
   
       8 . The abrasive article of  claim 7  further comprising a Velcro attachment. 
   
   
       9 . The abrasive article of  claim 8  wherein said Velcro attachment is used to attach said abrasive article to a dual action sander. 
   
   
       10 . The abrasive article of  claim 8  wherein said Velcro attachment is used to attach said abrasive article to a hand sander. 
   
   
       11 . The abrasive article of  claim 8  wherein said Velcro attachment is used to attach said abrasive article to a straight line sander.