Flexible grinding tool and process for producing it

Claim 2

A flexible abrasive comprising: a grain layer having a grain binder which carries abrasive grain; a fibrous backing layer defining a front surface bearing on the grain layer and a rear surface facing away from the grain layer, the fibrous material of the backing layer having surface depressions on at least one of the front or rear surfaces; and a finish forming part of the backing layer and at least partially filling the depressions on said at least one surface, the finish material being a foam solidified from a flowable state, whereby said surface is rendered smooth.

Claim 3

A flexible abrasive comprising: a grain layer having a grain binder which carries abrasive grain; a fibrous backing layer defining a front surface bearing on the grain layer and a rear surface facing away from the grain layer, the fibrous material of the backing layer front surface having large depressions including interspaces between the fibers; and a finish material forming part of the backing layer and at least partially filling the depressions on the front surface, the finish material being solidified from a flowable foam, whereby the front surface is rendered smooth.

Claim 4

A flexible abrasive comprising: a grain layer having a grain binder which carries abrasive grain; a fibrous backing layer defining a front surface bearing on the grain layer and a rear surface facing away from the grain layer, the fibrous material of the backing layer front surface having large depressions including interspaces between the fibers; and a finish material forming part of the backing layer and at least partially filling the depressions on the front surface, the finish material being solidified from a flowable foam, whereby the front surface is rendered smooth.

Claim 5

The abrasive of claim 2, wherein the fibers associated with the backing layer front surface protrude relative to the depressions, the protruding portions of the fibers defining a front plane of the backing, and the depressions on the front surface are filled with solidified foamed resin finish material up to but not substantially beyond the front plane, whereby the protruding portions and the finish material form a generally smooth front surface.

Claim 6

A flexible abrasive comprising: a grain layer having a grain binder which carries abrasive grain; a fibrous backing layer defining a front surface bearing on the grain layer and a rear surface facing away from the grain layer, the fibrous material of the backing layer rear surface having depressions including interspaces between the fibers; and a finish material forming part of the backing layer and at least partially filling the depressions on the rear surface, the finish material being solidified from a flowable foam, whereby the rear surface is rendered smooth.

Claim 7

A flexible abrasive comprising: a grain layer having a grain binder which carries abrasive grain; a fibrous backing layer defining a front surface bearing on the grain layer and a rear surface facing away from the grain layer, the fibrous material of the backing layer rear surface having depressions including interspaces between the fibers; and a finish material forming part of the backing layer and at least partially filling the depressions on the rear surface, the finish material being solidified from a flowable foam, whereby the rear surface is rendered smooth.

Claim 8

The flexible abrasive as claimed in claim 1, wherein the density of the foamed finish is greater at the contact of the finish with the fibers on said surface of the backing than at a distance from such contact.

Claim 9

The flexible abrasive as claimed in claim 1, wherein the backing has spaced apart fiber strands between which are located interspaces which define the depressions and which are substantially filled by the foamed finish.

Claim 10

The flexible abrasive as claimed in claim 6, wherein the foamed finish is arranged on the rear side of the backing substantially only between the fiber strands without any appreciable finish thickness on the fiber strands, and wherein the height of the foamed finish between the fiber strands in the non-loaded operating state is greater than the height of the fiber strands.

Claim 11

The flexible abrasive as claimed in claim 7, wherein the foamed finish is compressible under the loaded operating state to at least the height of the fiber strands.

Claim 12

The flexible abrasive as claimed in claim 1, wherein the foamed finish forms a layer covering the backing substantially completely.

Claim 13

The flexible abrasive as claimed in claim 9, wherein the pressure necessary for compressing the foam finish to half its thickness is at least 700 kPa.

Claim 14

The flexible abrasive as claimed in claim 1, wherein the foamed finish is located on the front side of the backing and is essentially incompressible under the grinding pressure.

Claim 15

The flexible abrasive as claimed in claim 1, wherein the foamed finish forms a smooth surface.

Claim 16

The flexible abrasive as claimed in claim 12, wherein the finish is on the rear surface and the density of the foamed finish is greater near its free surface facing away from the grain layer.

Claim 17

The flexible abrasive as claimed in claim 11, wherein the density of the foamed finish is is on average more than approximately 0.5 g/cm 3 .

Claim 18

The flexible abrasive as claimed in claim 14, wherein the density of the foamed finish is on average less than approximately 0.9 g/cm 3 .

Claim 19

The flexible abrasive as claimed in claim 11, wherein the foamed finish on the surface of the backing is covered by another layer of material having a higher strength than the finish.

Claim 20

A process for filling and finishing a flexible abrasive having a grain layer and a fibrous backing layer which has front and rear surfaces defining fiber interspaces, comprising the steps of applying a resin containing a foaming agent to at least one of the front or rear surfaces of the backing layer to at least partially fill the fiber interspaces, and hardening the resin foaming agent to form said finish.

Claim 21

A process for filling and finishing a flexible abrasive having a grain layer and a fibrous backing layer which has front and rear surfaces defining fiber interspaces, comprising the steps of applying a resin containing a foaming agent to at least one of the front or rear surfaces of the backing layer to at least partially fill the fiber interspaces, and hardening the resin foaming agent to form said finish.

Claim 22

The process as claimed in claim 17, wherein the foaming takes place at least partially after the introduction of the mass into the backing.

Claim 23

The process as claimed in claim 7, wherein the applied mass defines an exposed surface and the exposed surface of the mass is smoothed level with the highest elevations of the fibrous structure of the backing.

Claim 24

The process as claimed in claim 19, wherein the smoothing takes place after the end of foaming.

Claim 25

The process as claimed in claim 19, wherein the smoothing takes place before the end of foaming.

Claim 26

The process as claimed in claim 17, wherein foam layer applied to the rear surface is calendered after foaming.