Flocking Sanding Tool and Manufacturing Method Thereof

Abstract

A sanding tool includes a backing layer an adhesive layer and an abrasive layer. The adhesive layer is provided at the backing layer for bonding the abrasive layer at the backing layer via flocking techniques.

What is claimed is: 
     
         1 . A sanding tool, comprising:
 a backing layer;   an adhesive layer; and   an abrasive layer which is flocked onto the backing layer, extended through the adhesive layer, bonded at the backing layer via the adhesive layer, and retained at the backing layer,   wherein the backing layer and the adhesive layer of the sanding tool are made of an adhesive compound comprising:   a water-based adhesive;   a leveling agent; and   a solidifying agent, wherein the water-based adhesive, the leveling agent and the solidifying agent are physically mixed.   
     
     
         2 . The sanding tool, as recited in  claim 1 , wherein a weight ratio for the water-based adhesive, the leveling agent and the solidifying agent is 85-103:1:1.5-2 in sequence. 
     
     
         3 . The sanding tool, as recited in  claim 2 , wherein an adhesive medium of the backing layer and the adhesive layer of the sanding tool are made of the adhesive compound material. 
     
     
         4 . A manufacturing method for making a sanding tool, comprising the steps of:
 (a) configuring an adhesion material;   (b) configuring a backing layer by applying an adhesion medium at a web base and overlapping a backing cloth at the adhesion medium;   (c) drying the backing layer at a temperature ranged from 75° C. to 95° C. for about 20-30 minutes;   (d) applying the adhesion material at the backing layer at a backing cloth thereof to form an adhesive layer at the backing layer;   (e) flocking an abrasive layer at the backing layer; and   (f) shaping the sanding tool after being dried at a temperature ranged from 75° C. to 95° C. for about 20-30 minutes.   
     
     
         5 . The manufacturing method, as recited in  claim 4 , wherein the adhesion material is a compound adhesive material comprising a water-based adhesive, a leveling agent and a solidifying agent, wherein an optimal mixture for the water-based adhesive, the leveling agent and the solidifying agent is 100-103:1:1.5-3 at a weight ratio respectively. 
     
     
         6 . The manufacturing method, as recited in  claim 4 , wherein the step (a) further comprises a step of mixing a water-based adhesive, a leveling agent and a solidifying agent at a weight ratio of 100-103:1:1.5-3 respectively. 
     
     
         7 . The manufacturing method, as recited in  claim 4 , wherein the adhesion medium of the backing layer and the adhesive material forming the adhesive layer is made of the adhesion material produced in the step (a). 
     
     
         8 . The manufacturing method, as recited in  claim 4 , wherein abrasive particles of the abrasive layer is extended through the adhesive layer and retained at the backing cloth of said backing layer. 
     
     
         9 . The manufacturing method, as recited in  claim 8 , wherein the step (e) further comprises the steps of:
 (e-1) extending the abrasive particles of the abrasive layer through the adhesive layer;   (e-2) contacting the abrasive particles of the abrasive layer with the backing cloth of the backing layer; and   (e-3) retaining the abrasive particles at the backing layer via the adhesive layer.   
     
     
         10 . A sanding tool, comprising:
 a backing layer;   an adhesive layer; and   an abrasive layer which is flocked onto the backing layer, extended through the adhesive layer, bonded at the backing layer via the adhesive layer, and retained at the backing layer   
     
     
         11 . The sanding tool, as recited in  claim 10 , wherein the backing layer further comprises a web base, an adhesion medium and a backing cloth, wherein the adhesion medium is provided between the web base and the backing cloth to couple the web base and the backing cloth together. 
     
     
         12 . The sanding tool, as recited in  claim 10 , wherein said adhesive layer is made of an adhesive compound comprising a water-based adhesive, a leveling agent and a solidifying agent. 
     
     
         13 . The sanding tool, as recited in  claim 1 , wherein the abrasive layer further comprises a plurality of abrasive particles outwardly protruded from the backing layer and evenly distributed at the backing layer, wherein an even storage gap is formed between each two abrasive particles. 
     
     
         14 . The sanding tool, as recited in  claim 12 , wherein a weight ratio for the water-based adhesive, the leveling agent and the solidifying agent is 85-103:1:1.5-2 respectively. 
     
     
         15 . The sanding tool, as recited in  claim 11 , wherein the adhesive medium of the backing layer is made of an adhesive compound comprising a water-based adhesive, a leveling agent and a solidifying agent. 
     
     
         16 . The sanding tool, as recited in  claim 15 , wherein a weight ratio for said water-based adhesive, said leveling agent and said solidifying agent is 85-103:1:1.5-2 in sequence. 
     
     
         17 . The sanding tool, as recited in  claim 11 , wherein the web base is made of a material selected from the group consisting of a natural fiber, an artificial fiber and a rubber. 
     
     
         18 . The sanding tool, as recited in  claim 13 , wherein the adhesive layer is made of an adhesive compound comprising a water-based adhesive, a leveling agent and a solidifying agent. 
     
     
         19 . The sanding tool, as recited in  claim 18 , wherein a weight ratio for the water-based adhesive, the leveling agent and the solidifying agent is 85-103:1:1.5-2 respectively.