Abrasive articles and methods for making them

Abstract

An abrasive article for personal grooming includes an abrasive layer attached to a foam or other base layer. The abrasive layer includes abrasive material, binder material, pigment, and/or a blowing agent, e.g., to provide a three-dimensional decorative pattern extending from the base layer. In another embodiment, the abrasive article includes a translucent or transparent abrasive layer, an adhesive layer for attaching the abrasive layer to a base layer, and a decorative pattern printed between the adhesive layer and the base layer, e.g., on a lower surface of the adhesive layer and/or on an upper surface of the base layer. Alternatively, a decorative pattern may be printed within the abrasive layer, e.g., on a plastic sheet to which abrasive material and binder material are attached over the decorative pattern. The abrasive and adhesive layers are translucent or transparent such that the decorative pattern is visible through the abrasive material.

1 . An abrasive article for personal grooming, comprising: 
 a base layer comprising an upper surface; and    an abrasive layer on the upper surface of the base layer, the abrasive layer including a first region comprising abrasive material and a blowing agent, and a second region comprising abrasive material such that the first region has a thickness greater than the second region, thereby creating a three-dimensional decorative pattern extending from the upper surface of the base layer.    
   
   
       2 . The abrasive article of  claim 1 , wherein the first region further comprises one or more pigments such that the decorative pattern comprises a colored pattern.  
   
   
       3 . The abrasive article of  claim 2 , wherein the second region further comprises one or more pigments.  
   
   
       4 . The abrasive article of  claim 3 , wherein the abrasive layer further comprises a third region separate from the first and second regions, the third region comprising abrasive material and at least one of a blowing agent and one or more pigments that are different than the first and second regions.  
   
   
       5 . The abrasive article of  claim 1 , wherein the first region covers only a portion of the upper surface of the base layer, and wherein the second region substantially covers a remainder of the upper surface of the base layer.  
   
   
       6 . The abrasive article of  claim 1 , wherein each of the first and second regions comprises a resin carrying the abrasive material.  
   
   
       7 . The abrasive article of  claim 1 , further comprising a decorative pattern between the abrasive layer and the base layer, the abrasive layer comprising translucent or substantially transparent material such that the decorative pattern is visible through the abrasive layer.  
   
   
       8 . The abrasive article of  claim 1 , wherein the base layer comprises a second surface, the abrasive article further comprising a second abrasive layer on the second surface of the base layer, the second abrasive layer including a region comprising abrasive material and a blowing agent, and a region comprising abrasive material such that the second abrasive layer has a varying thickness between the regions, thereby creating a three-dimensional decorative pattern extending from the second surface of the base layer.  
   
   
       9 . A method for manufacturing an abrasive article, comprising: 
 providing a base layer comprising an upper surface;    mixing abrasive material with binder material, one or more pigments, and a blowing agent to provide a first abrasive mixture;    applying the first abrasive mixture to one or more regions of the upper surface of the base layer in a predetermined pattern; and    curing the first abrasive mixture such that the blowing agent is activated to create an expanded abrasive layer on the upper surface of the base layer.    
   
   
       10 . The method of  claim 9 , further comprising: 
 mixing abrasive material with binder material to provide a second abrasive mixture; and    applying the second abrasive mixture to one or more regions of the upper surface of the base layer.    
   
   
       11 . The method of  claim 10 , wherein the second abrasive mixture is applied to one or more regions adjacent the one or more regions to which the first abrasive mixture is applied.  
   
   
       12 . The method of  claim 11 , wherein the second abrasive mixture does not include a blowing agent such that the one or more regions to which the second abrasive mixture is applied define a height that is less than the one or more regions to which the first abrasive mixture is applied.  
   
   
       13 . The method of  claim 10 , wherein one or more pigments are mixed with the abrasive material to provide the second abrasive mixture.  
   
   
       14 . The method of  claim 9 , wherein the first abrasive mixture is applied to the upper surface of the base layer to create a decorative pattern thereon.  
   
   
       15 . The method of  claim 9 , further comprising applying an abrasive layer to another surface of the base layer.  
   
   
       16 . An abrasive article for personal grooming comprising: 
 a base layer comprising an upper surface; and    an abrasive layer on the upper surface to provide an abrasive surface;    the upper surface comprising a three-dimensional pattern therein.    
   
   
       17 . The abrasive article of  claim 16 , further comprising a three-dimensional object embedded between the abrasive layer and the base layer, the object at least partially creating the three-dimensional pattern in the abrasive surface.  
   
   
       18 . The abrasive article of  claim 17 , wherein the object comprises a decorative pattern thereon, the abrasive layer being at least translucent to allow the decorative pattern to be visible therethrough.  
   
   
       19 . The abrasive article of  claim 16 , wherein the abrasive layer comprises a blowing agent mixed with a resin, the blowing agent expanded to at least partially create the three-dimensional pattern in the abrasive surface.  
   
   
       20 . The abrasive article of  claim 16 , wherein the base layer comprises a blowing agent mixed with a resin, the blowing agent being expanded to at least partially create the three-dimensional pattern in the abrasive surface.  
   
   
       21 . An abrasive article for personal grooming, comprising: 
 a base layer comprising an upper surface;    a translucent or substantially transparent abrasive layer comprising a lower surface, and an upper surface comprising abrasive material;    a layer of adhesive attaching the lower surface of the abrasive layer to the upper surface of the base layer; and    a decorative pattern printed on the adhesive layer such that the decorative pattern is visible through the abrasive layer.    
   
   
       22 . An abrasive article for personal grooming, comprising: 
 a base layer including a foam layer comprising an upper surface;    a decorative pattern printed on the upper surface of the foam layer; and    a translucent or substantially transparent abrasive layer attached to the upper surface of the foam layer over the decorative pattern such that the decorative pattern is visible through the abrasive layer.    
   
   
       23 . The abrasive article of  claim 22 , further comprising a white base coat on the upper surface of the foam layer beneath the decorative pattern.  
   
   
       24 . An abrasive article for personal grooming, comprising: 
 a base layer comprising an upper surface; and    an abrasive layer attached to the upper surface of the base layer, the abrasive layer comprising a plastic sheet, a decorative pattern printed on the sheet, and abrasive material attached to the sheet over the decorative pattern, the abrasive material being translucent or substantially transparent such that the decorative pattern is visible through the abrasive particles.    
   
   
       25 . The abrasive article of  claim 24 , wherein the abrasive layer comprises a bonding enhancement layer on the upper surface of the sheet, the decorative pattern being printed on the bonding enhancement layer.  
   
   
       26 . The abrasive article of  claim 25 , wherein the bonding enhancement layer comprises solid particles carried by a binder material.  
   
   
       27 . The abrasive article of  claim 25 , wherein the decorative pattern comprises multiple colors printed onto the bonding enhancement layer.  
   
   
       28 . The abrasive article of  claim 24 , wherein the decorative pattern comprises one or more water-based inks or dyes.  
   
   
       29 . The abrasive article of  claim 24 , wherein the sheet comprises a polyester film.  
   
   
       30 . The abrasive article of  claim 24 , wherein the base layer comprises a core layer, and a foam layer on the core layer, the foam layer comprising the upper surface.  
   
   
       31 . A method for manufacturing an abrasive article having a decorative pattern, comprising: 
 providing a plastic sheet having an upper surface;    applying a bonding enhancement layer to the upper surface of the sheet;    printing a decorative pattern onto the bonding enhancement layer; and    bonding abrasive material over the decorative pattern, the abrasive material being translucent or substantially transparent such that the decorative pattern is visible through the abrasive material.    
   
   
       32 . The method of  claim 31 , wherein the sheet comprises a polyester film.  
   
   
       33 . The method of  claim 31 , wherein the bonding enhancement layer comprises solid particles carried by binder material.  
   
   
       34 . The method of  claim 31 , wherein the decorative pattern is printed by simultaneously printing multiple colors onto the bonding enhancement layer.  
   
   
       35 . The method of  claim 31 , wherein the decorative pattern is printed by successively printing multiple colors onto the bonding enhancement layer.  
   
   
       36 . The method of  claim 31 , wherein the decorative pattern comprises one or more water-based inks or dyes.