Resilient abrasive article and method of manufacture

Abstract

The present invention provides a resilient hand-held abrasive article comprising a flexible and/or conformable grip comprising a top surface, a bottom surface and individual small high-grip pads attached to each other in a pattern that leaves voids therebetween, the individual small high-grip pads comprising a top and a bottom. The top surface of a sanding article is attached, and in certain embodiments removably attached, to the bottom of the high-grip pads and a bottom surface having abrasive particles coated thereon. In certain embodiments, the flexible and/or conformable grip may not comprise voids.

1 . A hand-held abrasive article, comprising:
 a flexible grip comprising a top surface, a bottom surface and individual small high-grip pads attached to each other in a pattern that leaves voids therebetween, the individual small high-grip pads comprising a top and a bottom;   a sanding article having a top surface attached to the bottom of the high-grip pads and a bottom surface having abrasive particles coated thereon.   
   
   
       2 . The hand-held abrasive article of  claim 1 , wherein the sanding article comprises a sanding sponge. 
   
   
       3 . The hand held abrasive article of  claim 1 , wherein the sanding article comprises an abrasive sheet. 
   
   
       4 . The hand-held abrasive article of  claim 1 , wherein the top of the high-grip pads are convex. 
   
   
       5 . The hand-held abrasive article of  claim 1 , wherein the bottom of the high-grip pads are substantially flat. 
   
   
       6 . The hand-held abrasive article of  claim 1 , wherein the high-grip pads are substantially uniform in size and shape. 
   
   
       7 . The hand-held abrasive article of  claim 1 , wherein the high-grip pads comprise a foam material. 
   
   
       8 . The hand-held abrasive article of  claim 1 , wherein the flexible grip is substantially without voids. 
   
   
       9 . A resilient, hand-held abrasive article, comprising:
 (a) a flexible conformable backing layer having opposed first and second major surfaces, the backing layer comprising a multiplicity of separated resilient bodies connected to each other in an array that provides open spaces between adjacent connected bodies, each body having a first surface and an opposite second surface; and   (b) a flexible reinforcing layer having a first major surface affixed to the first surface of the separated resilient bodies, and a second opposed major surface having abrasive particles arranged thereon, thereby defining an abrasive surface.   
   
   
       10 . The abrasive article of  claim 9 , wherein each of the resilient bodies has a size and shape that is substantially uniform. 
   
   
       11 . The abrasive article of  claim 9 , wherein the flexible reinforcing layer is an abrasive sheet. 
   
   
       12 . The abrasive article of  claim 9 , wherein the flexible reinforcing layer is a continuous film. 
   
   
       13 . The abrasive article of  claim 10 , wherein the first surface of each resilient body is dome-shaped. 
   
   
       14 . The abrasive article of  claim 13 , wherein the resilient bodies comprise a foam material. 
   
   
       15 . A method for manufacturing a resilient hand-held abrasive article, comprising:
 providing a flexible conformable backing layer having opposed first and second major surfaces, the backing layer comprising a multiplicity of separated resilient bodies connect to each other in an array that provides open spaces between adjacent connected bodies, each body having a first surface and an opposite second surface;   providing a flexible reinforcing layer having a first major surface and a second opposed major surface;   fixedly attaching the first major surface of the flexible reinforcing layer to the first surface of the separated resilient bodies; and   coating the second major surface of the flexible reinforcing layer with abrasive particles.   
   
   
       16 . The method of  claim 15 , wherein the flexible reinforcing layer comprises a sanding sponge. 
   
   
       17 . The method of  claim 15  wherein the flexible reinforcing layer comprises an abrasive sheet. 
   
   
       18 . The method of  claim 15 , further comprising providing the separated resilient bodies with convex top surfaces. 
   
   
       19 . The method of  claim 15 , further comprising providing the separated resilient bodies with substantially flat bottom surfaces. 
   
   
       20 . The method of  claim 15 , further comprising irremovably attaching the first major surface of the flexible reinforcing layer to the first surface of the separated resilient bodies. 
   
   
       21 . A hand-held abrasive article, comprising:
 a flexible grip comprising a top surface, a bottom surface and individual small high-grip pads attached to each other in a pattern that leaves voids therebetween, the individual small high-grip pads comprising a top and a bottom;   a sanding article having a top surface that is irremovably attached to the bottom of the high-grip pads and a bottom surface coated with abrasive particles.   
   
   
       22 . The hand-held abrasive article of  claim 21 , wherein the sanding article comprises a sanding sponge. 
   
   
       23 . The hand-held abrasive article of  claim 21 , wherein the sanding article comprises an abrasive sheet. 
   
   
       24 . The hand-held abrasive article of  claim 21 , further comprising pressure sensitive adhesive on the bottom of the high-grip pads and a removable liner thereon, wherein removal of the liner exposes the pressure sensitive adhesive to which the top surface of the sanding article may then be affixed. 
   
   
       25 . The hand-held abrasive article of  claim 21 , further comprising one part of a hook and loop attachment system attached to the bottom of the high-grip pads and a second part of the hook and loop attachment system attached to the top surface of the sanding article. 
   
   
       26 . The hand-held abrasive article of  claim 21 , further comprising the sanding article being disk-shaped. 
   
   
       27 . The hand-held abrasive article of  claim 21 , wherein the top of the high-grip pads are convex. 
   
   
       28 . The hand-held abrasive article of  claim 21 , wherein the bottom of the high-grip pads are substantially flat. 
   
   
       29 . The hand-held abrasive article of  claim 21 , wherein the high-grip pads are substantially uniform in size and shape. 
   
   
       30 . The hand-held abrasive article of  claim 21 , wherein the high-grip pads comprise a foam material. 
   
   
       31 . An improved sanding block comprising:
 a sanding sponge having a plurality of exterior surfaces, including one abrasive first major surface and one second major surface and side surfaces and abrasive material coated onto at least the one abrasive first major surface; and   apertures that extend from the one abrasive first major surface to the one second major surface.   
   
   
       32 . A sanding system comprising:
 a sanding sponge having a plurality of exterior surfaces, including an abrasive first major surface and a second major surface and side surfaces and abrasive material coated onto at least the abrasive first major surface;   a multiplicity of apertures that extend from the abrasive first major surface to the second major surface, wherein the flexible resilient core is configure and arranged to be operatively connected to a suction device; and   a holder configured and arranged to hold the sanding sponge, the holder being configured and arranged to be operatively connected to a suction device.