Coated abrasive sheet material with loop material for attachment incorporated therein

A method for forming a coated abrasive material comprising a backing having front and rear surfaces, a layer of abrasive grains adhered to said front surface by a layer of bonding resin and a multiplicity of loops projecting from said rear surface, a sheet of which coated abrasive material can be releasably attached to a pad having a support surface and a multiplicity of hooks projecting from the support surface by releasable engagement between the loops and the hooks while the sheet of coated abrasive material is driven by the pad to abrade a workpiece, said method comprising:

• providing a sheet of fibers;
• corrugating the sheet of fibers to have arcuate portions projecting in the same direction from spaced anchor portions of the sheet of fibers;
• forming a layer of liquid polymeric bonding material;
• immersing the anchor portions of the sheet of fibers in the layer of liquid polymeric bonding material;
• solidifying the layer of liquid polymeric bonding material to form at least a portion of the backing around the spaced anchor portions of the sheet of fibers with the arcuate portions of the sheet of fibers projecting from the rear surface of the backing;
• and
• adhering a layer of abrasive grains to a front surface of the backing with a layer of bonding resin;
• said method further including the steps of:
• providing a sheet of backing material having a major surface;
• and
• positioning said major surface of the sheet of backing material closely adjacent the spaced anchor portions;
• and
• in said forming step of the liquid polymeric bonding material is deposited either onto the anchor portions of the fibers, onto the major surface of the sheet of backing material, or onto both the anchor portions of the fibers and the major surface of the sheet of backing material, and said method includes the step of positioning the major surface of the sheet of backing material and the anchor portions of the fibers close together with the liquid polymeric bonding material therebetween to provide said immersing step and so that after said solidifying step the polymeric bonding material adheres the anchor portions of the fibers to the sheet of backing material
• said sheet of backing material is of paper and has a layer of polyethylene along said major surface, said liquid polymeric bonding material is polyethylene, said step of forming a layer of liquid polymeric bonding material comprises extruding said polyethylene, said step of positioning the major surface of the sheet of backing material and the anchor portions of the fibers close together with the liquid polymeric bonding material therebetween to provide said immersing step positions the polyethylene coating on the paper adjacent the anchor portions of the fibers so that the extruded liquid polyethylene softens and fuses to or mixes with the polyethylene coating on the paper, and said step of solidifying the layer of liquid polymeric bonding material comprises the step of cooling the layer of liquid polyethylene bonding material so that after said solidifying step the polyethylene bonding material firmly adheres the anchor portions of the fibers to the sheet of paper backing material.

A method for forming a coated abrasive material comprising a backing having front and rear surfaces, a layer of abrasive grains adhered to said front surface by a layer of bonding resin and a multiplicity of loops projecting from said rear surface, a sheet of which coated abrasive material can be releasably attached to a pad having a support surface and a multiplicity of hooks projecting form the support surface by releasable engagement between the loops and the hooks while the sheet of coated abrasive material is driven by the pad to abrade a workpiece, said method comprising:

• providing a sheet of fibers;
• corrugating the sheet of fibers to have arcuate portions projecting in the same direction from spaced anchor portions of the sheet of fibers;
• forming a layer of liquid polymeric bonding material;
• immersing the anchor portions of the sheet of fibers in the layer of liquid polymeric bonding material;
• solidifying the layer of liquid polymeric bonding material to form at least a portion of the backing around the spaced anchor portions of the sheet of fibers with the arcuate portions of the sheet of fibers projecting from the rear surface of the backing;
• and
• adhering a layer of abrasive grains to a front surface of the backing with a layer of bonding resin;
• and
• the sheet of fibers provided in said providing step has a plurality of the fibers extending in a first direction along the sheet, and said forming step forms the sheet of fibers so that the anchor portions of the sheet of fibers are parallel and elongate in a second direction along the sheet of fibers that is generally at a right angle to the first direction in which the plurality of the fibers extend along the sheet.

A method for forming a coated abrasive material comprising a backing having front and rear surfaces, a layer of abrasive grains adhered to said front surface by a layer of bonding resin and a multiplicity of loops projecting from said rear surface, a sheet of which coated abrasive material can be releasably attached to a pad having a support surface and a multiplicity of hooks projecting from the support surface by releasable engagement between the loops and the hooks while the sheet of coated abrasive material is driven by the pad to abrade a workpiece, said method comprising:

• providing a sheet of fibers;
• corrugating the sheet of fibers to have arcuate portions projecting in the same direction from spaced anchor portions of the sheet of fibers;
• forming a layer of liquid polymeric bonding material;
• immersing the anchor portions of the sheet of fibers in the layer of liquid polymeric bonding material;
• solidifying the layer of liquid polymeric bonding material to form at least a portion of the backing around the spaced anchor portions of the sheet of fibers with the arcuate portions of the sheet of fibers projecting from the rear surface of the backing;
• and
• adhering a layer of abrasive grains to a front surface of the backing with a layer of bonding resin;
• and
• the sheet of fibers provided in said providing step is elongate;
• and
• said corrugating step comprises the steps of:
• providing a corrugating member including a plurality of elongate, parallel, spaced ridges defining the periphery of the corrugating member, the ridges defining spaces between the ridges;
• and
• feeding the sheet of fibers longitudinally along the ridges in a direction generally parallel to the ridges while generally conforming the sheet of fibers to the periphery of the corrugating member to form the arcuate portions of the fibers in the spaces between the ridges of the corrugating member and the anchor portions of the sheet of fibers along the ridges of the corrugating member.

A method for forming a coated abrasive material comprising a backing having front and rear surfaces, a layer of abrasive grains adhered to said front surface by a layer of bonding resin and a multiplicity of loops projecting from said rear surface, a sheet of which coated abrasive material can b releasably attached to a pad having a support surface and a multiplicity of hooks projecting from the support surface by releasable engagement between the loops and the hooks while the sheet of coated abrasive material is driven by the pad to abrade a workpiece, said method comprising:

• providing a sheet of fibers;
• corrugating the sheet of fibers to have arcuate portions projecting in the same direction from spaced anchor portions of the sheet of fibers;
• forming a layer of liquid polymeric bonding material;
• immersing the anchor portions of the sheet of fibers in the layer of liquid polymeric bonding material;
• solidifying the layer of liquid polymeric bonding material to form at least a portion of the backing around the spaced anchor portions of the sheet of fibers with the arcuate portions of the sheet of fibers projecting from the rear surface of the backing;
• and
• adhering a layer of abrasive grains to a front surface of the backing with a layer of bonding resin;
• said step of providing a sheet of fibers comprising the steps of:
• providing a majority of polyester fibers having a first softening temperature, and a minority of fibers which comprise portions that soften at a significantly lower temperature than the polyester fibers;
• and thermally bonding the sheet of fibers at a temperature that will soften the portions of the minority of the fibers so that the portions of the minority of the fibers soften and bond together the polyester fibers causing the sheet of fibers to have enough internal strength to remain intact during said corrugating step.

A method for forming a coated abrasive material comprising a backing having front and rear surfaces, a layer of abrasive grains adhered to said front surface by a layer of bonding resin and a multiplicity of loops projecting from said rear surface, a sheet of which coated abrasive material can be releasably attached to a pad having a support surface and a multiplicity of hooks projecting from the support surface by releasable engagement between the loops and the hooks while the sheet of coated abrasive material is driven by the pad to abrade a workpiece, said method comprising:

• providing a sheet of fibers;
• corrugating the sheet of fibers to have arcuate portions projecting in the same direction from spaced anchor portions of the sheet of fibers;
• forming a layer of liquid polymeric bonding material;
• immersing the anchor portions of the sheet of fibers int he layer of liquid polymeric bonding material;
• solidifying the layer of liquid polymeric bonding material to form a portion of the backing around the space anchor portions of the sheet of fibers with the arcuate portions of the sheet of fibers projecting from the rear surface of the portion of the backing;
• providing a layer of backing material having a layer of abrasive grains adhered to one surface by a layer of bonding resin;
• and
• adhering the surface of the portion of the backing opposite the sheet of fibers to the surface of the layer of backing material opposite the layer of abrasive grains;
• and
• said corrugating step comprises the steps of:
• providing first and second generally cylindrical corrugating members each having an axis and including a plurality of spaced ridges defining the periphery of the corrugating member, the ridges having outer surfaces and defining spaces between said ridges adapted to receive portions of the ridges of the other corrugating member in meshing relationship with the sheet of fibers therebetween;
• mounting the corrugating members in axially parallel relationship with portions of the ridges in meshing relationship;
• rotating at least one of the corrugating members;
• and
• feeding the sheet of fibers between the meshed portions of the ridges to generally conform the sheet of fibers to the periphery of the first corrugating member and form the arcuate portions of the fibers in the spaces between the ridges of the first corrugating member and the anchor portions of the sheet of fibers along the outer surfaces of the ridges of the first corrugating member.

A method for forming a coated abrasive material comprising a backing having front and rear surfaces, a layer of abrasive grains adhered to said front surface by a layer of bonding resin and a multiplicity of loops projecting from said rear surface, a sheet of which coated abrasive material can be releasably attached to a pad having a support surface and a multiplicity of hooks projecting from the support surface by releasable engagement between the loops and the hooks while the sheet of coated abrasive material is driven by the pad to abrade a workpiece, said method comprising:

• providing a sheet of fibers;
• corrugating the sheet of fibers to have arcuate portions projecting in the same direction from spaced anchor portions of the sheet of fibers;
• forming a layer of liquid polymeric bonding material;
• immersing the anchor portions of the sheet of fibers in the layer of liquid polymeric bonding material;
• solidifying the layer of liquid polymeric bonding material to form a portion of the backing around the spaced anchor portions of the sheet of fibers with the arcuate portions of the sheet of fibers projecting from the rear surface of the portion of the backing;
• providing a layer of backing material having a layer of abrasive grains adhered to one surface by a layer of bonding resin;
• and
• adhering the surface of the portion of the backing opposite the sheet of fibers to the surface of the layer of backing material opposite the layer of abrasive grains;
• the sheet of fibers provided by said providing step is elongate and
• said corrugating step comprises the steps of:
• providing a corrugating member including a plurality of elongate, parallel, spaced ridges defining the periphery of the corrugating member, the ridges defining spaces between the ridges;
• and
• feeding the sheet of fibers longitudinally along the ridges in a direction generally parallel to the ridges while generating conforming the sheet of fibers to the periphery of the corrugating member to form the arcuate portions of the fibers in the spaces between the ridges of the corrugating member and the anchor portions of the sheet of fibers along the ridges of the corrugating member.

A method for forming a loop fastener portion comprising a backing having front and rear surfaces, and a multiplicity of loops projecting from said rear surface adapted for releasable engagement with a plurality of hooks, said method comprising:

• providing an elongate sheet of fibers in which sheet of fibers the majority of the fibers are aligned longitudinally in the sheet of fibers;
• corrugating the sheet of fibers to have arcuate portions projecting in the same direction from spaced anchor portions of the sheet of fibers, said corrugating step comprising the steps of:
• providing a corrugating member including a plurality of elongate, parallel, spaced ridges defining the periphery of the corrugating member, the ridges defining spaces between the ridges;
• and
• feeding the sheet of fibers longitudinally along the ridges in a direction generally parallel to the ridges while generally conforming the sheet of fibers to the periphery of the corrugating member to form the arcuate portions of the fibers in the spaces between the ridges of the corrugating member and the anchor portions of the sheet of fibers along the ridges of the corrugating member to form a first set of elongate parallel anchor portions extending longitudinally of the sheet of fibers,;
• forming a layer of liquid polymeric bonding material;
• immersing the anchor portions of the first set of anchor portions on the sheet of fibers in the layer of liquid polymeric bonding material;
• solidifying the layer of liquid polymeric bonding material to form at least a portion of the backing around the spaced anchor portions of the sheet of fibers with the arcuate portions of the sheet of fibers projecting from the rear surface of the backing;
• said providing
• forming a second set of anchor portions transverse to the first set and to the first direction,
• embedding the second set of anchor portions in the polymeric bonding material prior to completion of said solidifying step to provide, after the solidifying step, bonding locations including first and second elongate, generally parallel portions disposed in a pattern to provide areas of said arcuate portions along said rear surface of said backing.