Sanding Cloths

Abstract

A sanding cloth comprising a substrate sheet of flexible and pliable material having a first side and a second side. An amount of first adhesive is applied to the first side of the sheet. A first grit material is applied to the first adhesive wherein the sheet is flexible and easily pliable and conformable to tight fine spaces that are sanded when preparing trim moldings, furniture refinishing and similar finish applications. Adhesive and grit can be applied to one or both sides of the cloth.

Description

CLAIM OF PRIORITY

This patent application is a continuation-in-part patent application of U.S. Utility patent application Ser. No. 14/834,148, filed Aug. 24, 2015, which claims priority under 35 USC 119 (1) from U.S. Provisional Patent Application Ser. No. 62/042,206 filed Aug. 8, 2014, of common inventorship herewith entitled, “Sanding Cloths,” both of which are incorporated herein by reference as though the same were set forth in their entirety.

Field of the Invention

The present invention pertains to the field of building materials, and more specifically to the field of sanding materials.

Background of the Invention

Preparation is the primary component when it comes to painting, varnishing, staining and refinishing. The old paint, stain or varnish is removed completely and the bare surface of the object is sanded before application of a staining or sealing agent can be applied. A conscientious craftsman lightly sands the surface between successive coats. And while some surfaces are flat and continuous, allowing the use of a belt or orbital electric sander, most fine work requires hand sanding and lots of it. Like electric sanders, manual sanding blocks are useful only on flat continuous surfaces. When faced with uneven surfaces, complicated moldings or edges and generally intricate construction designs, the craftsman must resort to sanding with sandpaper which presents its own problems. Sandpaper is stiff, tending to fold or crack when forced into tight flutings and contours. For tight spaces and fancy detailed woodwork or furniture, the sheets generally are cut into smaller, more manageable pieces prior to use. A sanding sponge is somewhat pliable, but usually too thick to reach tight spaces and conform to fine details.

The prior art has put forth several designs for sand paper materials. Among these are:

U.S. Pat. No. 4,867,760 to Walter A. Yarbrough describes a stitch bonded fabric or other arrays of substantially coplanar and co-parallel yarns that are non-interlaced with other yarns and employed to reinforce the backing for coated abrasive products. A preferred construction with continuous filament polyester yarns is described, together with the cloth finishing process employed to prepare a backing for coating with abrasive grain. This invention is particularly suitable for making coated abrasive belts.

U.S. Pat. No. 3,732,652 to Henry P. Furgal, Pasquale J. Falivene and Cesare N. Marchesani describes a heavy duty scouring cloth suitable for cleaning, dusting, or waxing. With an inner sponge layer laminated between outer non woven fabric layers, this cloth is especially adapted for use as a bathroom mat, table pad or place mat. The fabric layers are formed of laminates of aligned fibers.

U.S. Pat. No. 2,288,649 to Norman P. Roble describes a flexible abrasive article comprising a layer of abrasive particles bonded to a backing of multiple cloth made up of a plurality of layers of parallel longitudinal threads and of transverse threads which draw the multiple layers and the parallel longitudinal threads close together. The strength of the cloth is substantially greater in a direction parallel to the longitudinal threads than in a transverse direction. The invention is a flexible abrasive belt comprising a layer of abrasive particles bonded to a backing of multiple cloths in which the parallel threads constituting the principal threads of the parallel layers of cloth are disposed parallel to the direction of motion of the belt. The strength of the sheet per unit length is at least fifty per cent greater in a direction parallel to the longitudinal threads than in a transverse direction. The flexible abrasive belt comprises a layer of abrasive particles adhesively attached to a backing of multiple cloth in which the stronger threads of the parallel layers of cloth lie parallel to the direction of travel of the belt.

None of these prior art references describe the present invention.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a line of soft flexible abrasive cloths that are graded like sandpaper in their degree of coarseness, but are easily pliable and conformable to tight fine spaces that are sanded when preparing trim moldings furniture refinishing and similar finish applications.

The present invention is a sanding cloth. The sanding cloth comprises a sheet of pliable material having a first side and a second side. An amount of adhesive is applied to the first side of the sheet to form an adhesive layer. A first grit material is applied to the first adhesive layer to form an abrasive layer wherein the sheet is easily pliable and conformable to tight fine spaces that are sanded when preparing trim moldings, furniture refinishing and similar finish applications.

In addition, the present invention includes a method for constructing a sanding cloth. The method comprises providing a sheet of pliable material having a first side and a second side, applying an amount of first adhesive to the first side of the sheet to form a first adhesive layer, applying a first grit material to the first adhesive layer to form a first abrasive layer, and conforming the sheet to tight fine spaces that are sanded when preparing trim moldings, furniture refinishing and similar finish applications.

The present invention further includes a sanding cloth. The sanding cloth comprises a single sheet of pliable, porous material having a first side and a second side An amount of first adhesive is applied to the first side of the sheet to form a first adhesive layer and a first grit material is applied to the first adhesive layer to form a first abrasive layer. Further, an amount of second adhesive is applied to the second side of the sheet to form a second adhesive layer and a second grit material is applied to the second adhesive layer to form a second abrasive layer wherein the sheet is easily pliable and conformable to tight fine spaces that are sanded when preparing trim moldings, furniture refinishing and similar finish applications.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view illustrating a sanding cloth, constructed in accordance with the present invention.

FIG. 2 is a diagrammatic side view, not to scale, of the layers of materials comprising the sanding cloth of the present invention having one abrasive surface.

FIG. 3 is a diagrammatic side view, not to scale, of the layers of materials comprising the sanding cloth of the present invention having two abrasive surfaces.

FIG. 4 is a representation showing the flexibility of the sanding cloth of the present invention, showing that the sanding cloth has been cut to an appropriate size and wrapped around a contoured element.

FIG. 5 is a representation showing the flexibility of the sanding cloth of the present invention, showing the fingers and thumb of a user's hand holding the sanding cloth wrapped around the slat of a wooden window blind and both sides of the slat are being sanded simultaneously.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “flexible” is intended to mean having the ability to conform to a user's hand and fingers allowing the user's hand and fingers to become the sanding tool and aid in maneuvering and guiding the sanding cloth through and around tight, fine and fancy detailed woodwork that includes flutings, trim moldings, stair systems, ballasts, rails and furniture.

As used herein the term “substrate” is intended to mean a thin. strong, resilient, pliable, material that will return to its original shape after being twisted, folded, rolled or balled to conform to any shape or contour, capable of receiving adhesive.

As illustrated in FIGS. 1-5, the present invention, hereinafter referred to as sanding cloths, indicated generally as 10, is a line of soft flexible abrasive cloths 10 that are graded like sandpaper in their degree of coarseness, but are easily pliable and conformable to tight fine spaces that are sanded when preparing trim moldings, furniture refinishing and similar finish applications. The sanding cloths 10 of the present invention are available in varying sizes coarseness, and flexibility of the present invention.

The sanding cloths 10 of the present invention comprise a thin backing layer 14, also called substrate layer, onto which is applied an adhesive to form an adhesive layer 16, on top of or imbedded into which is grit to form an abrasive layer 12. Substrate layer 14 is made of any suitable material. Examples of suitable substrate material include: natural fiber fabrics such as cotton, hemp, cellulose, wool, paper product, or cheesecloth, for example. Examples of suitable substrate material further include manmade fibers such as nylon, polyester, rayon, cellulose, for example. This substrate layer 14 is approximately 0.5 mm to 2 mm in thickness. In an alternative embodiment, the substrate layer 14 is from approximately 0.75 mm to 1.5 in thickness. This layer of material 14 is infused, impregnated or overlain with abrasive grit 12 such as silica sand and the like. Grit 12 can be applied to substrate layer 14 by any suitable means such as flexible adhesive, or other flexible adhesion means. Examples of abrasive grit suitable for use in the present invention include, for example, fused aluminum oxide, oxide, heat treated aluminum oxide, alumina-based ceramics, silicon carbide, zirconia, alumina-zirconia, garnet, diamond, ceria, cubic boron nitride, ground glass, quartz, titanium diboride, sol gel abrasives and combinations thereof. Additional grit materials also include silica, silica sand, garnet, emery, and diamond, for example. Coarseness of grit can be varied, for example, from coarse to extra fine. The abrasive layer 12 is approximately 0 5 mm to 1.5 mm thick. In an alternative embodiment, the abrasive layer 12 is approximately 75 mm to 2.75 mm in thickness.

Alternatively, the backing layer 14 can be coated with adhesive 16 to ensure the adhesion of the grit 1 to the substrate, or backing layer 14. The adhesive can be applied by any suitable technique, such as knife coating, spray coating, roll coating, rotogravure coating, curtain coating and the like. Suitable adhesives include any flexible adhesive such as No-Wrinkle Rubber Cement by Elmer's Products, Inc., 6655 Peachtree Dunwoody Road, NE Atlanta. Ga. 30328, or other bonding agent. The sanding cloths 10 are manufactured in grades from Coarse to Extra Fine. The adhesive layer 16 is approximately 0.5 mm to 1.5 mm thick. In alternative embodiment the adhesive layer 16 is approximately 0.75 mm to 2.25 mm in thickness.

In an embodiment, the sanding cloths 10 measure approximately eight inches in width and ten inches in length and vary total thickness from 1.5 mm to 5 mm. The sanding cloth of the present invention can be sized appropriately for its intended purpose. The thickness of the sanding cloth 10 and type of grit 12 applied will vary according to end users, such as raw wood products, wood requiring refinishing, stripped of paint and/or varnish, fiberglass and metal, and for in-between coat sanding, but is contemplated to be approximately 1.5 mm to 5 mm in total thickness.

Although it is acknowledged that dimensions are not necessarily constitute a patentable distinction, in the present invention, the dimensions of the layers of the cloth are critical to the functionality of the flexibility of the cloth.

The sanding cloths 10 are flexible and easily pliable and comfortable. They have the ability to conform to the user's hand and fingers allowing the user's hand and fingers to become the sanding tool and aid in maneuvering and guiding the sanding cloth through and around tight, fine and fancy detailed woodwork that includes flutings, trim moldings, systems, ballasts, rails and furniture. Being soft and pliable, the sanding cloth 10 of the present invention can ball up in one's hand to allow the abrasive surface 12 of this easily gripped ball to conform neatly to details of fancy woodwork such as trim moldings and scrollwork, balusters and finials, fluted posts and columns, window shutters and louvers, lattice work, furniture trim and detailing and bright work on boats. Of course, the sanding cloth of the present invention also functions on flat surfaces, as well.

Because the sanding cloth 10 is soft, and can comprise a perimeter edge, the edges remain intact and flexibly with no cracking. In an embodiment, the sanding cloths 10 are fabricated in an environmentally benign, biodegradable, disposable woven natural fabric such as cotton or hemp or from a blend of fabrics such as cotton, paper, paper products, embossed or not embossed, cellulose, etc. In a preferred embodiment, the sanding cloth 10 is constructed from a porous fabric allowing the sanding cloth to receive the proper adhesive for the abrasive grit 12. Furthermore, in an embodiment it is contemplated that both sides of the sanding cloth 10 have the abrasive grit 12. In an alternative embodiment, the substrate 14 can be comprised of textured paper product, cellulose or textured fabric, in order to facilitate adhesion of the grit to the substrate and increase strength of the cloth and increase sanding surface area.

Due to their softness, flexibility and pliability, the sanding cloths 10 of the present invention are foldable or ballable into needed sizes. Cloths can be cut with scissors or a utility knife. Alternatively the cloths can be supplied on a roll and the sanding cloths can be perforated at desired intervals allow for ease in separating without having to use scissors to cut the cloth, by tearing along the perforations. An alternative embodiment of the sanding cloths 10 is produced for use in auto painting, refinishing, and detailing. In an embodiment, the sanding cloths are suitable for wet sanding. The sanding cloths 10 provide superior performance and results, are more flexible, easier to use, and save both time and expense when compared to conventional sandpapers.

FIG. 4 shows a sanding cloth of the present invention which has been custom cut and is wrapped around a curved, contoured element, and the sanding cloth conforms to the curved contour of the surface being sanded.

In an embodiment, the substrate backing for the sanding cloths 10 of the present invention can receive the adhesive coatings 16 and abrasive coatings 12 on both sides of the cloth 10 which allows the cloth 10 to be held in any way necessary to completely sand any surface in a time efficient and thorough manner, as shown in FIG. 5, wherein both sides of the wooden window blind slat are being sanded simultaneously. The sanding cloth 10 can be made to conform to the trickiest and finest detail work on trim, or furniture. The cloths 10 vary in thickness approximately from 1.5 mm to 5 mm. In an alternative embodiment, the total thickness of the cloth is approximately from 2.25 mm to 6.5 mm in thickness.

The sanding cloths 10 of the present invention can be packaged individually or several (five, for example) to a package. Alternatively, the sanding cloths 10 can be distributed in rolls for contractors that range between ten inches to twelve inches in width and twenty-five to fifty feet in length, allowing the cloth 10 to be cut to size. Alternatively, if in a roll, the sanding cloths can be perforated at desired intervals to allow for ease tearing the desired amount of sanding cloth from the roll.

The sanding cloths 10 of the present invention can be a large diversified product that will naturally cross over with a high demand into many trades and industries including painting, restoration, construction auto body, marine, metal fabrication. The professional, craftsman, handyman, homeowner and hobbyist will use the sanding cloths. The sanding cloths 10 will save the user time when sanding any detailed object or project.

Basically, the sanding cloths 10 of the present invention are a line of soft flexible abrasive cloths that are graded like sandpaper in their degree of coarseness, but are easily pliable and conformable to tight fine spaces that are sanded when preparing trim moldings, furniture refinishing and similar finish applications.

Although this invention has been described with respect to specific embodiments, it is not intended to be limited thereto and various modifications which will become apparent to the person of ordinary skill in the art are intended to fall within the spirit and scope of the invention as described herein taken in conjunction with the accompanying drawings and the appended claims.

Claims

1. A sanding cloth comprising:

a sheet of flexible material having a first side and a second side, the sheet having a perimeter edge forming a substrate layer;

an amount of first adhesive applied to the first side of the sheet to form an adhesive layer; and

a first grit material applied to the first adhesive layer to form an abrasive layer;

wherein the sheet is flexible and easily pliable and conformable to tight fine spaces that are sanded when preparing trim moldings, furniture refinishing and similar finish applications and

wherein the perimeter edge remains intact and flexible with no cracking.

2. The sanding cloth of claim 1 wherein the grit material is selected from the group consisting of: fused aluminum oxide, heat treated aluminum oxide, alumina-based ceramics, silicon carbide, zirconia, alumina-zirconia, garnet, diamond, ceria, cubic boron nitride, ground glass, quartz, titanium diboride, sol gel abrasives, silica, silica sand, garnet, emery, and diamond and combinations thereof.

3. The sanding cloth of claim 1 wherein the sheet is from approximately 0.5 mm to 2.0 mm in thickness.

4. The sanding cloth of claim 1 wherein the sheet is constructed from an environmentally benign, biodegradable, disposable woven natural fiber fabric material selected from the group consisting of: cotton, hemp, cellulose, wool, paper product, viscose, and cheesecloth.

5. The sanding cloth of claim 1 wherein the sheet is constructed from nylon, polyester, rayon, viscose, or other manmade fiber.

6. The sanding cloth of claim 1 wherein the abrasive layer is approximately 0.5 mm to 1.5 mm in thickness.

7. The sanding cloth of claim 1 wherein the adhesive layer is from 0.5 mm to a 5 mmin thickness.

8. The sanding cloth of claim 1 wherein the sheet is constructed in gradations of coarseness from Coarse to Extra Fine.

9. The sanding cloth of claim 1 and further comprising:

an amount of second adhesive applied to the second side of the sheet to form a second adhesive layer: and

a second grit material applied to the second adhesive layer to form a second abrasive layer.

10. The sanding cloth of claim 1 made in a roll with perforations at regular intervals for tearing without having to use scissors to cut the cloth.

11. A method for constructing a sanding cloth, the method comprising:

providing a sheet of flexible and pliable material having a first side and a second side, the sheet having a perimeter edge:

applying an amount of first adhesive to the first side of the sheet;

applying a first grit material to the first adhesive;

conforming the sheet to tight fine spaces that are sanded when preparing trim moldings, furniture refinishing and similar finish applications; and

maintaining the perimeter edge intact arid flexible with no cracking.

12. The method of claim 11 and further comprising:

applying an amount of second adhesive to the second side of the sheet; and

applying a second grit material to the second adhesive.

13. A sanding cloth comprising:

a single sheet of pliable, porous material having a first side and a second side, the sheet having a perimeter edge,

an amount of first adhesive applied to the first side of the sheet;

a first grit material applied to the first adhesive;

an amount of second adhesive applied to the second side of the sheet; and

a second grit material applied to the second adhesive;

wherein the sheet is easily pliable and conformable to tight fine spaces that are sanded when preparing trim moldings, furniture refinishing and similar finish applications; and

wherein the perimeter edge remains intact and flexible with no cracking.

14. A sanding cloth comprising:

a single sheet of pliable, porous material having a first side and a second side to form a substrate layer;

an amount of first adhesive applied to the first side of the sheet to form an adhesive layer;

a first grit material applied to the first adhesive to form an abrasive layer;

an amount of second adhesive applied to the second side of the sheet to form a second adhesive layer: and

a second grit material applied to the second adhesive to form a second adhesive layer,

wherein the sheet is flexible, easily pliable and conformable to tight fine spaces that are sanded when preparing trim moldings, furniture refinishing and similar finish applications.

15. The sanding cloth of claim 14 wherein the sanding cloth is graded in degree of coarseness and manufactured in grades from Coarse to Extra Fine.

16. The sanding cloth of claim 14 wherein the sanding cloth is constructed in varying sizes, coarseness, and flexibility.

17. The sanding cloth of claim 14 wherein the sheet is constructed from an environmentally benign, biodegradable, disposable woven natural fabric material selected from the group cotton and hemp.

18. The sanding cloth of claim 14 wherein he abrasive grit is silica sand.

19. The sanding cloth of claim 14 wherein the sheet has a perimeter edge wherein the perimeter edge remains intact and flexible with no cracking.

20. The sanding cloth of cam 14 wherein the sheet is foldable and ballable into needed sizes without having to use scissors to cut the cloth