Abstract: A flap disc for use with a rotary surface finishing tool, the flap disc includes a backing plate which attaches to and is rotated by the finishing tool. The backing plate has a mounting flange on which a plurality of abrasive flaps are radially disposed. The abrasive flaps are each adhesively attached to the mounting flange and positioned so as to overlap an adjacent flap. Each abrasive flap has a finishing layer which comprises abrasive particles intermixed in a resin binder. Attached to the finishing layer is a substrate which includes a resin binder. In one embodiment of the invention, the substrate is made from fiber material onto which the abrasive particle/resin mixture is adhesively attached. Alternately, the substrate may comprise a non-woven fibrous material onto which the abrasive particle/resin mixture is adhesively bonded. The mounting flange may comprise a plurality of fiberglass plies intermixed in a resin matrix.

Abstract: A method is disclosed for making a brushing tool having a hub and a plurality of bristles extending from the hub. A mold defines a cavity which is divided into a closable mold cavity and a bristle cavity. At least one bristle locating pin is disposed within the bristle cavity. At least one bundle of bristles is inserted into the bristle cavity adjacent to the at least one bristle locating pin so that one end of the bristles is disposed within the mold cavity. The mold cavity is then closed so that the ends of the bristles within the mold cavity are generally clamped together near the interface of the mold cavity and the bristle cavity. A thixotropic material in liquid form is injected into the mold cavity so that a portion of each bristle disposed within the mold cavity is surrounded by the thixotropic material. When the thixotropic material hardens, the portion of each bristle on the mold cavity becomes embedded in the hardened material, the hardened material thereby forming the hub of the brushing tool.

Abstract: A brushing tool for metal working has a circular disc perforated adjacent the rim with a plurality of holes through which wire bundles are passed and then twisted to form radially-extending knots. A plurality of notches are provided in the rim adjacent the holes to provide support for the knots and to limit pivotal movement of the knots in the plane of the disc during use without the need for side plates.

Abstract: A brushing tool for metal working has a circular disc perforated adjacent the rim with a plurality of holes through which wire bundles are passed and then twisted to form radially-extending knots. A plurality of notches are provided in the rim adjacent the holes to provide support for the knots and to limit pivotal movement of the knots in the plane of the disc during use without the need for side plates.

Abstract: An industrial cup-shaped brush in which both inward and outward pivotal movements of the wire bristles caused by scrubbing or rotary motions is effectively resisted by providing elongated supports on the knot plate for the wire bristles and anchoring the bristles to the elongated supports by elongated loops of generally complementary shape to the elongated supports.