US4930266A — Abrasive sheeting having individually positioned …

Claim 1

Independent Claim 66 words

Abrasive sheeting comprising a backing carrying a binder layer of substantially uniform thickness in which individually positioned abrasive granules are strongly bonded and lie substantially in a plane and at a predetermined lateral spacing between granules, said granules being of substantially equal size and passing a screen with 300 μm openings, and a portion of virtually every granule protruding from the surface of the binder layer.

Claim 2

Dependent Claim 66 words

Abrasive sheeting comprising a backing carrying a binder layer of substantially uniform thickness in which individually positioned abrasive granules are strongly bonded and lie substantially in a plane and at a predetermined lateral spacing between granules, said granules being of substantially equal size and passing a screen with 300 μm openings, and a portion of virtually every granule protruding from the surface of the binder layer.

Claim 3

Dependent Claim 17 words

Abrasive sheeting as defined in claim 1 wherein the binder layer forms a meniscus at each granule.

Claim 4

Dependent Claim 31 words

Abrasive sheeting as defined in claim 2 wherein substantially every granule is equiax and of substantially the same diameter, and each granule protrudes from the binder to substantially the same extent.

Claim 5

Dependent Claim 16 words

Abrasive sheeting as defined in claim 1 wherein single granules are aligned in uniformly spaced rows.

Claim 6

Dependent Claim 39 words

Abrasive sheeting as defined in claim 4, a great length of which is wound upon itself in roll form, said granules being in a predetermined pattern that repeats a large number of times over the length of the sheet.

Claim 7

Dependent Claim 47 words

Abrasive sheeting as defined in claim 5 wherein said predetermined pattern leaves areas of the binder layer free from abrasive granules in positions to be contacted by a tool for cutting the sheeting into articles of desired shapes, thus protecting the cutting tool from contacting abrasive granules.

Claim 8

Dependent Claim 51 words

Abrasive sheeting as defined in claim 1 wherein additional abrasive granules of substantially equal size different from the size of the first-mentioned abrasive granules are individually positioned in a second predetermined pattern and an uncoated portion of virtually every of said additional granules protrudes from the surface of the binder layer.

Claim 9

Dependent Claim 30 words

Abrasive sheeting as defined in claim 1 wherein said abrasive granules have irregular shapes, and the major axis of each granule lies substantially in a plane parallel to the backing.

Claim 10

Dependent Claim 19 words

Abrasive sheeting as defined in claim 1 and having a size coat covering the granules and the binder layer.

Claim 11

Dependent Claim 16 words

Abrasive sheeting as defined in claim 1 wherein a portion of virtually every granule is uncoated.

Claim 12

Dependent Claim 70 words

Abrasive sheeting comprising a backing carrying a binder layer in which individually positioned abrasive granules are bonded and lie substantially in a plane and at a predetermined lateral spacing between granules, said granules being of substantially equal size and passing a screen with 300 μm openings, a portion of virtually every granule protruding from the surface of the binder layer, and a size coat covering the granules and binder layer.

Claim 13

Dependent Claim 70 words

Abrasive sheeting comprising a backing carrying a binder layer in which individually positioned abrasive granules are bonded and lie substantially in a plane and at a predetermined lateral spacing between granules, said granules being of substantially equal size and passing a screen with 300 μm openings, a portion of virtually every granule protruding from the surface of the binder layer, and a size coat covering the granules and binder layer.

Claim 14

Dependent Claim 31 words

Abrasive sheeting defined in claim 11 wherein substantially every granule is equiax and of substantially the same diameter, and each granule protrudes from the binder layer to substantially the same extent.

Claim 15

Dependent Claim 60 words

Abrasive sheeting comprising a backing carrying a binder layer of substantially uniform thickness in which abrasive granules are strongly bonded and lie substantially in a plane, said granules being of substantially equal size to pass a screen with 300 μm openings, the granules having individual positions that are uniformly spaced laterally, there being only one granule at almost every position.

Claim 16

Dependent Claim 60 words

Abrasive sheeting comprising a backing carrying a binder layer of substantially uniform thickness in which abrasive granules are strongly bonded and lie substantially in a plane, said granules being of substantially equal size to pass a screen with 300 μm openings, the granules having individual positions that are uniformly spaced laterally, there being only one granule at almost every position.

Claim 17

Dependent Claim 18 words

Abrasive sheeting as defined in claim 13 and having a size coat covering the granules and binder layer.

Claim 18

Dependent Claim 60 words

Method of making abrasive sheeting by the sequential steps of (1) attracting small abrasive granules only to dots laterally spaced in a predetermined pattern on a carrier, (2) while advancing a backing that carries a tacky binder layer in synchronism with said carrier, transferring the attracted granules into the binder layer in said pattern, and (3) rendering the binder nontacky.

Claim 19

Dependent Claim 60 words

Method of making abrasive sheeting by the sequential steps of (1) attracting small abrasive granules only to dots laterally spaced in a predetermined pattern on a carrier, (2) while advancing a backing that carries a tacky binder layer in synchronism with said carrier, transferring the attracted granules into the binder layer in said pattern, and (3) rendering the binder nontacky.

Claim 20

Dependent Claim 19 words

Method as defined in claim 15, in step 2 of which the granules are pressed into the binder layer.

Claim 21

Dependent Claim 32 words

Method as defined in claim 16 wherein said carrier covers the cylindrical exterior of a rotating drum, and in step (1) the drum is rotated through a fluidized bed of said granules.

Claim 22

Dependent Claim 29 words

Method as defined in claim 15 wherein said dots are roughly circular, each having a diameter within the range of 30-90% of the mean dimension of the abrasive particles.

Claim 23

Dependent Claim 36 words

Method as defined in claim 15 and comprising subsequent to step (2) an additional step of causing the binder to flow to form a meniscus at each granule, thus strongly binding the granules to the backing.

Claim 24

Dependent Claim 138 words

Method of making abrasive sheeting comprising a backing carrying a binder layer in which abrasive granules of substantially uniform thicknesses are individually embedded in a predetermined pattern, said method comprising the steps of (1) coating one face of a metal foil with rubber and the other face with a photoresist, (2) exposing the photoresist to light in a predetermined pattern, (3) removing areas of the photoresist corresponding to said pattern, (4) removing areas of the metal foil, to expose the rubber in said pattern, (5) attracting abrasive granules to the exposed rubber areas, (6) while moving the tacky binder layer in synchronism with the exposed rubber areas, pressing the attracted granules into the binder layer in said pattern, and (7) rendering the binder nontacky, thereby producing abrasive sheeting, the individual abrasive granules of which lie in said pattern.

Claim 25

Dependent Claim 138 words

Method of making abrasive sheeting comprising a backing carrying a binder layer in which abrasive granules of substantially uniform thicknesses are individually embedded in a predetermined pattern, said method comprising the steps of (1) coating one face of a metal foil with rubber and the other face with a photoresist, (2) exposing the photoresist to light in a predetermined pattern, (3) removing areas of the photoresist corresponding to said pattern, (4) removing areas of the metal foil, to expose the rubber in said pattern, (5) attracting abrasive granules to the exposed rubber areas, (6) while moving the tacky binder layer in synchronism with the exposed rubber areas, pressing the attracted granules into the binder layer in said pattern, and (7) rendering the binder nontacky, thereby producing abrasive sheeting, the individual abrasive granules of which lie in said pattern.

Claim 26

Dependent Claim 21 words

The method of claim 20 including the further step of removing any remaining areas of photoresist between steps (4) and (5).

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1993-06-04	1993-12-04	1994-06-05	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1997-06-04	1997-12-04	1998-06-05	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2001-06-04	2001-12-04	2002-06-05	$7700.00	Window Closed / Lapsed

Abrasive sheeting having individually positioned abrasive granules

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