Molded and shaped thermoset abrasive discs

Abstract

An abrasive disc that fits on a sander over all of the edges of the back up pad such that the disc itself does not have a sharp edge which can cause injuries or damage parts.

Description

Abstract: An added molding and shaping process to flexible abrasive sanding discs slightly oversized compared to the backup pad. Possible configurations include sizes of 2″,3″,5″,6″,8″, and 11″ outside diameter. Possible grit configurations include

24, 36, 40, 50, 60, 80, 100, 120, 150, 180, 220, 320, 400, 600, 800, 1000, 1200, 1500, 2000 and 3000.

Background: In my 25 year experience in distribution of coated abrasive products, no company has come up with a safe solution for the following problems while either hand sanding or using pneumatic random orbital sander for flexible disc sanding of wood, metals, composites, or other substrates.

Description: Taking an existing flat abrasive disc or punching discs from jumbo rolls and shaping it slightly so the outer diameter of the forms to the outside diameter of the backup pad with a tapered edge. This tapered edge will greatly reduce the chance of the disc cutting body parts or work pieces due to spreading the force of the dangerous sharp disc edge, so it sands instead of cuts.

I want to manufacture and market a safer line of abrasive sanding discs.

The problems of current discs on the market include:

1. Film backed discs being very sharp on the edges leading to injury while accidentally touching the discs while the pneumatic random orbital sander spins at 12,000 rpm. This usually occurs when the sander is set down after use and accidental contact is made while the disc is still spinning. Safety is a major concern for all manufacturers as it should be. In the last week, I have asked 6 different professional sanders about hand injuries and 100% described horrific injuries. Some required stiches.

2. While sanding a variety of surfaces that have a 90 degree angle to them, the sharp disc contacts the edge of where the parts meet and gouges the workpiece.

3. This can also occur and flat work pieces when the sander is set down at a slight angle.

4. When a back up pad (the part the disc attached to), gets worn or loaded, it can make the discs fly off at high speed. This turns them into high speed cutting devices as they fly, very dangerous.

A new design of the shape of abrasive sanding discs that features a slightly oversized, tapered molded edge that curves up over the backing pad will solve the problems listed above. The discs will not have the sharp edges that lead to injuries and damage of parts in manufacturing. These can have a hook and loop backing or a pressure sensitive adhesive backing. Possible backing methods include pressure sensitive adhesive and hook and loop material.

The advantages of my design are:

Operator safety
Lessening the risk of work surface damage
Longer disc pad life
Longer disc life
Much shorter distance of travel if they accidentally fly off

DESCRIPTION OF DRAWINGS

FIG. 1—A side view of the disc as it would sit on a flat surface

FIG. 2—A side view of the disc as it would sit on a flat surface

FIG. 3—A 3D view of the disc as it would sit flat

FIG. 4—A top view of the disc

FIG. 5—A bottom view of the disc

DETAILED DESCRIPTION OF INVENTION

By specifying new disc sizes from the abrasive manufacturer plant or laser cutting or die stamping new, oversized discs, this gives and extra edge to work with. Example: A typical sanding disc is 5″ OD going on to a 4⅞″ OD back up pad. In that situation, I will start with a 5½″ OD disc and form the edges so the edges extend over the back up pad.

I will accomplish that by starting with an oversized tube press with internal, thin, welded pieces of metal that conform the individual discs with a pattern. As the discs move down the tubes (with consistent heat added), the outside edges will conform and therefore make a tight seal over the intended back up pad when used.

Claims

1. A molded and shaped circular abrasive disc comprising:

A formed shape that is flat on the surface of the back up pad and extends up over part or all of the edges of the back up pad.