ABRASIVE MATERIAL, ACCESSORIES FOR A TOOL CONTAINING SUCH ABRASIVE MATERIAL AND METHOD OF MANUFACTURING SUCH ABRASIVE MATERIAL

Abstract

Abrasive material, characterised in that the abrasive material (1) includes a double layer of fabric (2) with connection (3) cut in the middle to form hairs (4) or fibres (4) on the first side (5) of the abrasive material (1), where the hairs (4) are post-treated so that the shape of the hairs (4) is permanently changed, and where the hairs (4) are equipped with abrasive particles (8).

Claims

1-16. (canceled)

17. An abrasive material comprising a double-layered fabric having a wired connection cut in a middle of the double-layered fabric to form hairs or fibers on a first side of the abrasive material, wherein: the wires are composite wires with multiple hairs or fibers; the wires that form the connection in the double-layer tissue are connected by a W-connection to the layers of the double-layer tissue; the hairs are post-treated so that a shape of the hairs is permanently changed; and the hairs are equipped with abrasive particles.

18. The abrasive material of claim 17, wherein the wires are composite wires with fibers of a rigid plastic.

19. The abrasive material of claim 18, wherein the rigid plastic comprises nylon.

20. The abrasive material of claim 17, wherein the abrasive particles are attached to the hairs or fibers with a binder.

21. The abrasive material of claim 17, wherein the hairs or fibers have a curly shape, a round spiral shape, an angular spiral shape, or a zigzag shape.

22. The abrasive material of claim 17, wherein the hairs or fibers extend in multiple directions in an upright space on a second side of the abrasive material opposite the first side.

23. The abrasive material of claim 17, wherein at least part of the hairs or fibers is directed at an angle from 45 to 135 relative to the first side of the abrasive material.

24. The abrasive material of claim 17, further comprising a layer of a nonwoven or textile applied on a second side of the abrasive material opposite the first side.

25. The abrasive material of claim 17, wherein a length (L) of the hairs or fibers is from 3 millimetres to 80 millimetres.

26. The abrasive material of claim 17, wherein the double-layer fabric is fitted with a weft yarn of boucl yarn.

27. The abrasive material of claim 17, wherein the hairs or fibers are grouped in brush rows.

28. The abrasive material of claim 17, wherein the hairs or fibers are made of a heat- resistant material.

29. A method of manufacturing of an abrasive material, the method comprising: (A) providing a connection to a double layer fabric; (B) cutting the connection to form hairs or fibers on a first side of the abrasive material; (C) treating the hairs or fibers so that a shape of the hairs is changed; and (D) applying abrasive particles to the hairs.

30. The method of claim 29, further comprising, after (C) applying a layer of a nonwoven or textile onto a second side of the abrasive material opposite the first side.

31. The method of claim 29, wherein (D) further comprises applying a binder to the hairs to attach the abrasive particles to the hairs.

32. The method of claim 29, further comprising: (E) thermally compressing the abrasive material obtained after (D).

33. An accessory comprising an abrasive material according to claim 17, the accessory having a three-dimensional design.

34. The accessory of claim 33, wherein: the accessory is selected from an abrasive brush pad, cleaning pad, a sanding pad, a polishing pad, or a roller brush; and the accessory is fitted with a sanding surface or a polishing surface.

Description

[0080] With the insight to better demonstrate the characteristics of the invention, a few preferential variants of an abrasive material are described here according to the invention, an accessory to an instrument containing such abrasive material and the method of manufacturing such abrasive material, with reference to the accompanying drawings, in which:

[0081] FIG. 1 schematically represents a cross-section of an abrasive material according to the invention;

[0082] FIGS. 2 to 6 show the consecutive steps of the method according to the invention;

[0083] FIG. 7 shows an accessory according to the invention;

[0084] FIG. 8 shows an alternative of FIG. 7;

[0085] FIG. 9 schematically represents a cross-section of an abrasive material according to the invention;

[0086] FIG. 1 schematically represents a cross-section of an abrasive material 1 according to the invention.

[0087] It comprises half of a double layer fabric 2 with connection 3 that is cut in the middle as shown in FIG. 2. In the example shown, this connection 3 is a so-called W-connection 3 through a first side 5 and opposite second side 9 of each layer from which the double layer fabric is constructed.

[0088] The connection 3 is therefore a wire 3 that is woven or stitched through both layers (top and bottom in FIG. 2) of the double layer fabric 2 and connected by a W-connection to the first (5) and an opposite second side (9) of the abrasive material.

[0089] The connection 3 of the double layer fabric 2, more specifically the wire 3 with which this connection 3 is made, is in this case, but not necessarily, made of a heat-resistant material. In a preferred form, the wire is a composite wire containing multiple hairs or fibres.

[0090] By cutting this connection 3, hairs 4 or fibres 4 are formed on the first side 5 of the abrasive material 1. In this embodiment in which the wires are composed, the fibres will open spatially after cutting as shown in FIG. 9.

[0091] The fibres 4 are preferably grouped in so-called brush rows 6. The open spaces 7 between these brush rows 6 are also called rills 7.

[0092] The fibres 4 or hairs 4 thus created have been treated, resulting in permanent changes to their shape.

[0093] In this case, the shape of the fibres 4 is a curl shape, but this can also be a round spiral shape, angular spiral shape, a zigzag shape or the like.

[0094] The length L of these hairs 4 is in this case five millimetres, but this could also be ten, fifteen, thirty or, for example, fifty millimetres. Preferably the length L of the hairs 4 is between three millimetres and eighty millimetres.

[0095] According to the invention, the hairs 4 have sanding particles 8.

[0096] In this case the hairs 4 have a binder to attach the sanding particles 8 to the hairs 4. This binder is not shown on the figures.

[0097] Although in FIG. 1 all hairs 4 are represented as perpendicular to the first side 5 of the abrasive material 1, it must be taken into account that this is only a schematic representation. As described above, this upright orientation of the hairs means that they focus spatially in line with the umbel (umbella) inflorescence of a plant, as shown, for example, in FIG. 9.

[0098] In practice, not all hairs 4 will be oriented perpendicular to the first side 5.

[0099] Preferably, at least part of the hairs 4 is directed mainly at an angle between 45 and 135 with respect to the aforementioned first side 5 of the abrasive material 1.

[0100] This property can be obtained by the post-treatment of the hairs 4 or fibres 4, including the cutting of a composite thread, where the post-treatment also involves relaxation of the fibres from which the wire connection is made. This leads to the straightening of the hairs or fibres similar to the umbel inflorescence of a plant as shown, for example, in FIG. 9.

[0101] The aforementioned part is preferably at least 15%, or better at least 25% or at least 35% of the hairs 4 upright oriented on the front of the first side 5 or the abrasive material sanding surface.

[0102] The second side 9 of the abrasive material 1 is in this case, but not necessary for the invention, provided with a layer nonwoven 10. This can also be a layer of textiles or the like.

[0103] The method for manufacturing the abrasive material 1 is very simple and as follows.

[0104] FIGS. 2 to 6 show the successive steps.

[0105] Starting from one double layer fabric 2 with connection 3. In this case, this connection is a W-connection 3, which can be derived from the stitching of the connection 3.

[0106] In this case, the connection 3, as already mentioned, is made using a heat-resistant material.

[0107] The connection of this double layer of tissue 2 is cut, as shown schematically in FIG. 2.

[0108] This forms the hairs 4 on the first side 5.

[0109] In a possible next step, as shown in FIG. 3, the connection 3 is fixed. This can be done, for example, by stitching the tissue 2.

[0110] FIG. 4 shows the next step, in which the hairs 4 are treated so that the shape of the hairs 4 is changed.

[0111] The shape of the hairs 4 is curly after treatment. This gives the hairs 4 a resilience.

[0112] The above treatment can be thermal or chemical, with the hairs 4 permanently deformed.

[0113] In another embodiment, the wires 3 are made of a composite wire with multiple fibres of a rigid plastic such as nylon. The fibres in such a composite wire are subject to a torsion tension that is released when cutting such a composite wire so that the constituent fibres detach completely or partially and open up spatially similar to the umbel (umbella) inflorescence of a plant. This relaxation step replaces or forms part of the aforementioned thermal or chemical treatment and gives rise to a material as shown in FIG. 9.

[0114] The next step shown in FIG. 5 is an optional additional step where a layer of nonwoven 10, but this may also be textile or similar, is applied to the second side 9 of the abrasive material 2.

[0115] Then, in an optional step not shown in the figures, a binder is applied to the hairs 4. This binder will allow sanding particles 8 to attach to the hairs 4.

[0116] The binder is a resin, for example.

[0117] The nonwoven layer 10 from the previous step will stop the resin from coming through the abrasive material 1. FIG. 6 shows the last step where the abrasive particles 8 are applied to the hairs 4.

[0118] For example, these abrasive particles 8 are diamond particles.

[0119] In this way, the abrasive material 1 is manufactured and ready for use.

[0120] A possible application for the use of abrasive material 1 is shown in FIGS. 7 and 8.

[0121] FIG. 7 shows an accessory 11 to a tool 12 containing an abrasive material 1 according to the invention.

[0122] The accessory 11 has a three-dimensional design and in this case concerns a pad 11, for example a brushing, cleaning, sanding or polishing pad.

[0123] The pad 11 has a disc shape and is covered with the abrasive material 1.

[0124] To this end, the pad 11 is equipped with, for example, Velcro hooks which can attach to the nonwoven 10 on the second side 9 of the abrasive material 1, so that the abrasive material 1 can attach to the pad 11.

[0125] By applying the abrasive material 1, the pad 11 has a sanding or polishing surface 13.

[0126] The tool 12 on which the pad 11 is applied will allow the pad 11 to rotate at high speed.

[0127] The tool 12 can then be placed on a surface to be sanded, brushed, cleaned or polished.

[0128] The resilient hairs 4 will be able to sand, brush, clean or polish in the depth of the surface. The particles thus removed from the surface will be removed via the rills 7 and will not accumulate between the surface and the polishing surface 13 of the pad 11.

[0129] FIG. 8 shows a variant of an accessory 11 according to FIG. 7, in which case the shape of the pad 11 is changed.

[0130] After all, it will be possible to give a specific shape to pad 11, which will allow for the sanding, brushing, cleaning or polishing of corners or special shapes.

[0131] By giving the pad 11 a complementary shape according to the surface to be treated, special non-flat surfaces can also be treated.

[0132] The sanding and polishing surface 13 will exert an equal force throughout the surface due to its shape, so that the treatment will take place uniformly over the entire surface.

[0133] The present invention is by no means limited to the embodiments described as examples and shown in the figures, but an abrasive material according to the invention, an accessory to an instrument containing such abrasive material and the method of manufacturing such abrasive material can be achieved according to different variants without acting outside the scope of the invention.

EXPERIMENTAL COMPARISON

[0134] A characteristic of the abrasive according to the invention has to do with the upright orientation of the hairs, and in particular an orientation similar to the umbel (umbella) inflorescence of a plant.

[0135] A number of tests compared the effects of the abrasive material according to the invention (Ecoforce Green) with a classic nylon abrasive brush with stiff hairs without abrasives, and a nonwoven abrasive material with a horizontal open cell structure with silica, diamond and alum oxide as abrasives.

1. Wet Cleaning of a Wooden Surface

[0136]

TABLE-US-00001 Nylon Brush Nonwoven pad Ecoforce green Teak 3 min/ Teak 3 min/ Teak 3 min/ rotation/water rotation/water rotation/water Remove surface Remove surface Good surface area contamination contamination and deep cleaning No deep cleaning Limited visual No visible No material damage damage to materials damage to materials Result after 3 min Result after 3 min Result after 3 min idle cleaning idle cleaning idle cleaning The brush only Abrasion is obtained. Good surface area removes dirt on the Visible damage to and deep cleaning surface the material No visible No deep cleaning damage to materials No material damage

2. Wet Cleaning of a Linoleum Surface

[0137]

TABLE-US-00002 Nylon Brush Nonwoven pad Ecoforce green Linoleum 3 min/ Linoleum 3 min/ Linoleum 3 min/ rotation/water rotation/water rotation/water No visible effect A superficial effect, A clear cleaning effect on this material. with hints of abrasion both at the surface and on the treated material. in depth without leaving sanding stripes. Visually renovated effect for the treated material.

3. Wet Cleaning of Ceramic Floor Tiles and Joints

[0138]

TABLE-US-00003 Nylon Brush Nonwoven pad Ecoforce green Floor tiles 3 min/ Floor tiles 3 min/ Floor tiles 3 min/ rotation/water rotation/water rotation/water Surface cleaning of Surface cleaning of Surface cleaning of the tiles. the tiles. the tiles. No effect on joints. No effect on joints Deep cleaning of the joints.

4. Wet Cleaning of a Granite Surface

[0139]

TABLE-US-00004 Nylon Brush Nonwoven pad Ecoforce green Granite top 3 min/ Granite top 3 min/ Granite top 3 min/ rotation /water rotation /water rotation /water Surface cleaning. Visible effect after Visible effect after No deep cleaning. a few minutes. a few minutes. Fast pad wear. No visible pad wear. Limited deep Deep cleaning without cleaning and additional chemicals. requires additional Visually renovated effect chemicals for this. for the treated material
The above experiments show that the abrasive material according to the invention, can add value to the various applications where typical nonwovens and brush hairs are used today. We have found that because of the upright fibre form, its resilience really allows for better penetration in depth and more effective cleaning without compromising on chemical agents, like ordinary waste deposits. The slightly abrasive grains applied to the fibres help loosen dirt on the material to be cleaned.

[0140] The shape, structure, and upright orientation of the bristles provide the necessary resilience, which we can also call brush power, as we zoom more closely into function and resilience, we see that because of the spatial orientation of the fibre ends, the strength is not only developed on the upper surface, but also in lower sections of the ecoforce, this in contrast to the classic sanding brushes and nonwoven open cell structures that generate these forces only at the front, at the highest points of their surface.

[0141] The tests also showed that the resilience ensures that the structure of a surface is not affected and only the dirt is detached, unlike the other materials tested.

[0142] The tests have also shown that the length and resilience of the hairs ensures that sanding is not possible or only to a limited extent, even with coarse grains. (data not shown). To achieve an abrasive effect, the fibres must be shortened.

[0143] The Ecoforce pad thus overlaps the current operation of the nonwovens and the brush pads and has unique properties with completely different end results without damaging the surface.