Thermoplastic sheet abrasives and methods of making the same

Abstract

The present invention provides sheet abrasives that include a plurality of abrasive particles dispersed within a thermoplastic polymer. The present invention also provides methods for producing sheet abrasives.

1 . A sheet abrasive comprising: 
 a thermoplastic polymer layer; and    a plurality of abrasive particles dispersed therein.    
   
   
       2 . The sheet abrasive of  claim 1 , wherein the thermoplastic polymer layer is selected from the group consisting of polyamides, polyurethanes, acetals, thermoplastic polyimides, liquid crystal polymers, polyphenylene sulfides, polyetheramides, polyetheresters, and polyethylene.  
   
   
       3 . The sheet abrasive of  claim 1 , wherein the plurality of abrasive particles is selected from the group consisting of silicon carbide, aluminum oxide, diamond, ceramic aluminum oxide, ceramic, zirconia aluminum, garnet, cubic boron nitride, and talc.  
   
   
       4 . The sheet abrasive of  claim 1 , wherein the polymer layer has a thickness from about 0.001 inch to about 0.25 inch.  
   
   
       5 . The sheet abrasive of  claim 1 , wherein the plurality of abrasive particles is dispersed substantially uniformly within the thermoplastic polymer layer.  
   
   
       6 . The sheet abrasive of  claim 1 , wherein the thermoplastic polymer layer is an extruded thermoplastic polymer layer.  
   
   
       7 . The sheet abrasive of  claim 6 , wherein the extruded thermoplastic polymer layer is uni-axially oriented.  
   
   
       8 . The sheet abrasive of  claim 6 , wherein the extruded thermoplastic polymer layer is bi-axially oriented.  
   
   
       9 . The sheet abrasive of  claim 1 , wherein the thermoplastic polymer layer is an injection-molded thermoplastic polymer layer.  
   
   
       10 . The sheet abrasive of  claim 1 , wherein the thermoplastic polymer layer comprises a foamed thermoplastic polymer.  
   
   
       11 . The sheet abrasive of  claim 1 , wherein the abrasive particles comprise from about 1% to about 30% by volume of the sheet abrasive.  
   
   
       12 . The sheet abrasive of  claim 1 , wherein the abrasive sheet is adapted to form a continuous belt.  
   
   
       13 . The sheet abrasive of  claim 1 , wherein the abrasive sheet is adapted to form a flap wheel.  
   
   
       14 . The sheet abrasive of  claim 1 , further comprising a second layer adjacent to the thermoplastic polymer layer.  
   
   
       15 . The sheet abrasive of  claim 14 , wherein the second layer comprises a polymer.  
   
   
       16 . The sheet abrasive of  claim 14 , wherein the second layer further comprises a plurality of abrasive particles.  
   
   
       17 . The sheet abrasive of  claim 14 , further comprising an adhesive layer disposed between the thermoplastic polymer layer and the second layer.  
   
   
       18 . The sheet abrasive of  claim 14 , wherein the abrasive sheet is adapted to form a continuous belt.  
   
   
       19 . The sheet abrasive of  claim 14 , wherein the abrasive sheet is adapted to form a flap wheel.  
   
   
       20 . A method of forming a sheet abrasive comprising the steps of: 
 dispersing a plurality of abrasive particles in a molten thermoplastic polymer; and    extruding the molten thermoplastic polymer to form a sheet abrasive,    wherein the sheet abrasive comprises an extruded thermoplastic polymer layer and the plurality of abrasive particles dispersed therein.    
   
   
       21 . The method of  claim 20 , wherein the thermoplastic polymer is extruded to form an extruded thermoplastic layer having a thickness from about 0.001 inch to about 0.25 inch.  
   
   
       22 . The method of  claim 20 , comprising orienting the extruded thermoplastic polymer layer in a uni-axial or bi-axial direction.  
   
   
       23 . The method of  claim 22 , wherein the orienting step comprises stretching the extruded thermoplastic polymer layer.  
   
   
       24 . The method of  claim 20 , further comprising the step of providing a second layer adjacent to the extruded thermoplastic polymer layer.  
   
   
       25 . The method of  claim 24 , wherein the second layer further comprises a plurality of abrasive particles.  
   
   
       26 . The method of  claim 24 , wherein the second layer comprises a polymer.  
   
   
       27 . The method of  claim 26 , wherein providing the second layer comprises co-extruding the extruded thermoplastic polymer layer and the second layer.  
   
   
       28 . The method of  claim 24 , wherein providing the second layer comprises adhering the second layer to the extruded thermoplastic polymer layer with an adhesive.  
   
   
       29 . A method of forming a sheet abrasive comprising the steps of: 
 dispersing a plurality of abrasive particles in a thermoplastic polymer; and    injecting the thermoplastic polymer into a mold to form a sheet abrasive,    wherein the sheet abrasive comprises an injection-molded thermoplastic polymer layer and the plurality of abrasive particles dispersed therein.