Sanding element and method for manufacturing a sanding element

A method for manufacturing a disc-shaped sanding element with a circular circumference having at least two bonded layers containing abrasive grains, wherein the at least two bonded layers extend parallel to each other, while the at least two bonded layers extend at least to the circumference of the sanding element so as to form a sanding edge on the circumference for processing a workpiece, wherein the method comprises:

• forming the first layer, the forming of the first layer comprising placing one or several thread or fibre blankets with an open three-dimensional structure in which is distributed a synthetic resin with abrasive grains on a bottom plate of a press to form a stack of said blankets extending practically parallel to each other,
• subsequently compressing the stack of said blankets so as to bond the blankets together and to produce a sheet whose thickness is smaller than the thickness of said stack, in which said blankets form a whole with a higher density than an average density of said blankets before they were compressed,
• curing said sheet,
• subsequently placing one or several additional thread or fibre blankets with an open three-dimensional structure against at least one side of said sheet, wherein the blankets comprise a synthetic resin with abrasive grains distributed therein, said additional blankets forming a second layer, wherein the additional blankets are stacked practically parallel to each other to form a second stack of blankets,
• compressing said second stack against said sheet to form said second layer which adheres to said sheet, in which said additional blankets, together with the sheet, form a whole having a higher density than an average density of said additional blankets before they were compressed,
• curing said whole,
• cutting a circular disc from said whole, wherein said circular disc forms the sanding element.

A Method for manufacturing a disc-shaped sanding element with a circular circumference having at least three bonded layers containing abrasive grains, wherein the at least three bonded layers extend parallel to each other, while the at least three bonded layers extend at least to the circumference of the sanding element so as to form a sanding edge on the circumference for processing a workpiece, wherein the method comprises:

• forming the first layer, the forming of the first layer comprising placing one or several thread or fibre blankets with an open three-dimensional structure in which is distributed a synthetic resin with abrasive grains on a bottom plate of a press to form a stack of said blankets extending practically parallel to each other,
• subsequently compressing the stack of said blankets so as to bond the blankets together and to produce a sheet whose thickness is smaller than the thickness of said stack, in which said blankets form a whole with a higher density than an average density of said blankets before they were compressed,
• curing said sheet,
• placing one or several additional thread or fibre blankets with an open three-dimensional structure against both sides of said sheet, wherein the blankets comprise a synthetic resin with abrasive grains distributed therein, said additional blankets forming a layer on each side of the sheet, wherein the additional blankets are stacked practically parallel to each other to form a stack of blankets on both opposite sides of the sheet,
• compressing both stacks against said sheet to form a second and a third layer which adheres to said sheet on either side of the sheet, in which said additional blankets, together with the sheet, form a whole having a higher density than an average density of said additional blankets before they were compressed,
• curing said whole,
• cutting a circular disc from said whole which forms the sanding element.