Note: Descriptions are shown in the official language in which they were submitted.
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ABRASIVE ~ ; 1 ARRAY AND DISPENSER
TEC~ICAL FIELD
s The present invention relates generally to abrasive sheets, methods of
producing such sheets, and a dispenser for such sheets, and more particularly to arrays
of abrasive sheets, methods of producing such arrays of sheets, and a dispenser for
dispensing individual sheets from such an array.
10 BA~CKGROUND OF THE INVENTION
Abrasive sheets are available in many shapes and sizes, depending on the use
for which they are int~nrled Some abrasive sheets are intencled specifically for use
with powered tools, for example rotary or orbital tools and, in that case, the shape of
a sheet is determined by the particular tool with which it is to be used. Abrasive sheets
5 in a range of standard shapes and sizes, suited to most standard powered tools, are
readiiy avaiiabie and are produced by die cutt~g continuous a~rasive sheet materiai.
Because large quantities of the standard shaped sheets are required, the die cutting
operation can be carried out on a continuous basis using a rotary die cutter, and the
subsequent h~n~ling and parl~ing of the shaped sheets can be automated.
Disc-shaped sheets, for example, are very cornmonly used for powered tools,
ancl it is known to use a rotary die cutter to cut a plurality of individual discs or,
alternatively, to cut chains of connected discs which can be wound onto a roll or
folded up and packaged. See, for example, U.S. Patent No. 4,893,438. It is also
2s known ts proYid~ dispens~r~ fQr Ghains Qf çorllle~t~d a~rasive arti~les ~nd fQr non-
cormected abrasive articles provided on a continuous backing. See, for example, U.S.
Patent Nos. 3,267,623 (Block); 3,849,949 (St~inh~n~er et al.); and 4,294,357 (Stevens
et al.). Additionally, U.S. PatentNo. 5,183,479 (Grimes) discloses a method for
m~lmlf~ctllring heavy duty grinding discs by stamping a plurality of interconnected disc
30 shapes. The shapes are notched or we~k~n~d for separation. The interconnectedshapes are then covered with abrasive embedded in adhesive. While Grimes is
primarily concerned with methods of making circular discs, it also discloses that that
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abrasives may be hexagonal, octagonal, or any form for which coated abrasive on a
backing is required. U.S. Patent No. 5,197,998 (Germain) discloses an aligned row of
conl~ e~ abrasive sheets, each sheet having a main portion, an aperture formed in the
main portion, and a plurality of artn portions perimetrically spaced about the main
5 portion. The arm portion of each abrasive sheet are angularly offset with respect to
the arm portions of each immediately ~ cent sheet by one-half of the angle between
each of the arm portions.
At times, however, a limited quantity of sheets of a particular, non-standard,
10 shape and size may be required and that may not justify investment in a rotary die.
Moreover, automated h~nrlling and packing ofthe sheets may be diffcult or
impractical. In that case, the m~nl-f~ rer might use a flat-bed die cutter, which is less
costly, to cut the shaped sheets which might then be collated and packed by hand. As
a result, the production of limited quantities of such non-standard abrasive sheets will
5 be co"lpa,~ ely slow and expensive.
A problem with which the present invention is concerned is that of enabling
limited quantities of abrasive sheets, especially in non-standard shapes or sizes, to be
produced more quickly and less expensively than at present. A further problem with
20 which the invention is concerned is that of enabling limited quantities of non-standard
abrasive sheets to be p~c~ge(1 and handled more easily than at present.
SUMMARY OF T~ INVENTION . ~
One aspect of the present invention provides an abrasive sheet array. The array
25 comprises a plurality of abrasive sheets joined together and readily detachable from
each other. Each of the abrasive sheets is generally tri~n~ r and includes a narrow
end and a wide end opposite the narrow end, and the atray is generally polygonal.
In one p~ d arrangement of the above inventive array, the abrasive sheets
30 are joined together by the material from which the sheets are formed. In another
pl ere" ed atrangement of the above array each abrasive sheet comprises a substrate
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material having a first side and a second side, the substrate having abrasive material on
the first side and means for releasably ~tt~ching the abrasive sheet to a drive nnember
on the second side. In another p,erelled aL~ g~ nt of the above array, the abrasive
sheets are joined to each other at discrete locations on the edges of the sheets.
In another pl er~;ll c;d a" ~lge",ent of the above inventive array the array
comprises a plurality of abrasive sheets arranged so as to have the narrow end of each
sheet adj~c~nt the narrow end of each a-ljacçnt abrasive sheet and so as to have the
wide end of each sheet ~djac~nt to the wide end of each ~dj~cent sheet. In one
lo prere.,~d aspect ofthis arrangement, the array comprises four abrasive sheets forrning
a generally square array. In another pl t;r~" ~d aspect of this arrangement, the array
comprising five abrasive sheets forming a generally pentagonal array. In still another
plere"ed embodiment ofthis arrangement, the array comprises six abrasive sheets
forming a generally hexagonal array.
In another p. t:relled a,ll~ngel,lent of the above inventive array, the array
comprises a plurality of abrasive sheets arranged so as to have the narrow end of each
.abrasive sheet adjac~nt the wide end of each a~jac~nt abrasive sheet. In one preferred
lembodiment, the array is spirally wound so as to form a roll of abrasive sheets. In
20 anther pl~rt;lled embodiment of this arrangement, the array has a first end and a
second end opposite the first end, a longitll-lin~l axis extçn-ling in the direction from
the first end to the second end and a transverse axis perpendicular to the longinl~1in~1
axis, each abrasive sheet has at least one line of symmetry, and each abrasive sheet is
arranged so as to have its line of symmetry parallel to the transverse axis of the array
2s ][n another prere~, ~d embodiment of this arrangement, adjacçnt first and second
abrasive sheets are joined along a first line forming a first angle relative to the
~ransverse axis of the array, and a third abrasive sheet is joined to the second abrasive
sheet along a second line opposite the first line, the second line forming a second angle
relative to the transverse axis of the array. In still another pr~r~l l ed embodiment of
30 this arrangement the first and second angles are of subst~nti~lly equally magnitude and
a~re of opposite orientation relative to the transverse axis of the array.
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Another aspect of the present invention provides a dispenser for storing an
array of abrasive sheets and for separating abrasive sheets from the array. The
dispenser comprises: a box configured to store the array of sheets, the box inclu-ling a
5 first wall having an opening therein for dispensing the array from inside the box to
outside the box, the opening bounded by first and second opening edges; and abrasive
sheet separating means mounted on the first wall, the sep~ ~ g means comprising a
first separator edge oriented at a first edge angle relative to the first wall and a second
separator edge oriented at a second edge angle relative to the first wall.
In one p,ere.l ed embodiment of the above inventive dispenser, the separator
means comprises: a first abrasive sheet separator mounted on the first wall proximate
the first edge of the opening, the first separator int~ ing the first separator edge; and a
second abrasive sheet separator mounted on the first wall proxim~te the second edge
15 ofthe opening, the second separator inchl(ling the second separator edge.
In another pl ~re.. ed embodiment of the above dispenser, the first edge angle
and the second edge angle are of subst~nti~lly the sarne m~gnitude and of opposite
orientation relative to the first wall of the dispenser. In a more pl ~rel ~ ~d embodiment,
20 the first edge angle is subst~nti~lly equal to +30~ relative to the first wall and the
second edge angle is subst~nti~lly equal to -30~ relative to the second wall.
A further aspect of the present invention provides a separator for separating
individual abrasive sheets from an array of abrasive sheets. The separator is for use
25 with an array including a plurality of abrasive sheets arranged along the longitudinal
axis of the array, with the individual sheets each joined on a first side to a first
respective adjacent sheet generally along a first line at a first angle relative to the
transverse axis of the array and joined on a second side to a second respective ~djacçnt
sheet generally along a second line at a second angle relative to the transverse axis of
30 the array. The inventive separator comprises: separator means configured to receive
the array in a direction along the first axis of the separator means, the separator means
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having a second axis perpendicular to the first axis and lying in the plane defined by the
abrasive sheets as they pass through the separator means; the separator means
incl~ltlin~ a first sep~L~or edge oriente~ at a first edge angle relative to the second axis
and a second separator edge o,ienled at a second edge angle relative to the second
s ,3xis.
In one plerelled embodiment, the separator means comprises: a first abrasive
~sheet separator in~ in~ the first separator edge; and a second abrasive sheet
separator inr.ll~ding the second separator edge. The first and second separators are
0 provided opposite to one another and are configured to receive the array between the
irirst and second sep~L~ul~.
In another pl erc;. I ed embodiment of the above inventive separator the first edge
~mgle and the second edge angle are of substantially the same m~gnihlde and of
15 opposite orientation relative to the second axis. In a more p-tirell~;d embodiment, the
first edge angle is subst~nti~lly equal to +30~ relative to the second axis and the second
edge angle is sub~ lly equal to -30~ relative to the second axis ofthe array.
A still further aspect of the present invention provides a method of producing
20 an array of abrasive sheets, comprising the step of cutting, from abrasive sheet
rnaterial, an inventive array as described above. In one p~c;rell~d embodiment, the
method further comprises the step of cutting .cim~llt~nçously, from the abrasive sheet
rnaterial, a plurality of arrays. In another pl crw I ed embodiment, the method further
c:omprising the step of collating the arrays into sets.
2s
BRIEF DESCRIPTION OF THE DRAVVINGS
The present invention will be further explained with reference to the appended
Figures, wherein like structure is referred to by like numerals throughout the several
~dews, and wherein:
30 - ~~ Figure 1 shows an abrasive sheet;
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Figure 2 shows an array of the sheets shown in Figure 1 according to one
embodiment of the present invention;
Figure 3 shows, diag. an--l-~Lically, an appa~ IS for producing arrays as shown
in Figure 2;
Figure 4 shows, dia~ ;c~lly, the cutting face of the die cutter of the
app~ ~ s shown in Figure 3;
Figure 5 shows another abrasive sheet;
Figure 6 shows an array of the sheets shown in Figure 5 according to another
embodiment of the present invention;
0 Figures 7 to 13 show other embodiments of abrasive sheet arrays according to
the present invention;
Figure 14 shows a chain of the arrays shown in Figure 2 according to the
present invention;
Figure 15 shows yet another abrasive sheet;
Figure 16 shows still another abrasive sheet;
Figure 17 shows a continuous array of abrasive sheets according to a further
embodiment of the present invention;
Figure 18 shows the array of Figure 17 in a spiral-wound roll;
Fig-ure 19 shows a side elevational view of a first embodiment of a dispenser
according to the present invention for the array of Figure 17;
Figure 20 is a partial isometric view of the dispenser of Figure 19;
Figures 21A and 21B are partial top plan views ofthe dispenser of Figure 19;
Figure 22 is a partial isometric view of an alternate embodiment of a dispenser
according to the present invention; and
Figure 23 is a top plan view of the dispenser of Figure 22.
DETAILED DESCRIPTION OF THE INVENTION
Figure 1 shows an abrasive sheet l which is generally tri~n~ r in shape. The
sheet is a conventional coated abrasive comprising a substrate sheet which has abrasive
30 grit particles bonded to it on one side. The other side of the substrate sheet ls coated
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w~th a pres~w~ sensitive adhesive which is covered by a release liner. The release liner
i$ optional and can be omitted, if approp.;ate.
Coated abrasive sheets of the type shown in Figure 1 are known. The substrate
5 sheet may be any suitable material incl~lrlin~, for example, paper, polymeric film and
cloth. Likewise, the abrasive grit particles may be of any suitable type incll1-1ing, for
example, fused ~ mimlm oxide, boron carbide, silicon carbide, boron nitride, silicon
nitride, diamond, flint, silica, iron oxide, garnet, fused ~ min~ zirconia, ceramic
mimlm oxides, and co~-,binaLions ofthose materials. The abrasive sheet could also
o comprise a structured abrasive, such as of the type described in U.S. Patent No.
5,152,917 (Pieper).
The pressure-sensitive adhesive on the substrate sheet is provided to enable theabrasive sheet 1 to be mounted on a backing pad (the release liner having first been
15 removed). The backing pad can then be connected to the output shaft of a powered
tool for illlp~ Lillg a suitable movement to the abrasive sheet so that it can be used to
simd or abrade a workpiece. The use of a pressure-sensitive adhesive for that purpose
is not essl~-nti~l and any suitable alternative arrangement can be used to mount the
abrasive sheet on a backing pad inclu~1ing, for example, a hook-and-loop f~t~n;ng in
20 which case one part of the f~etening (i.e. either the hooks or the loops) would be
a~rried by the abrasive sheet.
As an alternative, the sheet 1 need not be a coated abrasive but could be a
nonwoven abrasive comprising a substrate of a porous, fibrous, nonwoven
25 construction and an abrasive comprising individual abrasive particles on one side of the
substrate. Such nonwoven abrasives are also known.
The abrasive sheet 1 shown in Figure 1 has sides which are apl)roxilllately 65
mm long and, due to its shape and size, is particularly useful in areas such as corners
30 which might be difficult to reach with a disc-shaped sheet. Sheets as shown in Figure 1
can be cut from a roll of abrasive sheet material using either a rotary die cutter or a flat
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bed die cutter but the colllp~l~Li~rely small size ofthe sheets can result in a high arnount
ofthe sheet material being wasted and can also make the individual sheets ~lifficl.lt to
handle. To reduce the wastage and the h~nrlling problems, in accordance with thepresent invention, the sheets 1 are not cut individually from the roll of abrasive sheet
s material but are cut as part of a generally polygonal array 2 of six sheets illustrated in
Figure 2. The array 2 has a .. ~x;.. cross-wise dimension of about 15.5 mm.
The array 2 comprises the six individual sheets 1 arranged to form a hexagon,
with ~djacent sheets being joined to each other by narrow connecting portions of the
o abrasive sheet material, which extend between the adjacent edges of the sheets 1.
Those connecting portions are simply locations at which one tri~n~ r sheet 1 has not
been severed completely from the ~dj?,c~-nt sheet and they are so small that they do not
show in Figure 2 although the locations themselves are inrlic~ted sch~m~tically by the
circles 3. It will be seen that there are two connecting locations 3 between the5 a~ r.~nt edges of each pair of ~dj~c~nt sheets 1, at applox;~ y 15 mm from theends of the sides. Typically, the connecting portions have a width of from 1 to 2 mm,
although the width, location and number of the connecting portions will depend on the
size and shape of the abrasive sheets 1 and of the array 2.
Alternatively, instead of being joined by discrete connecting portions, adjacentsheets 1 of the array 2 could be joined through a line of wç~kne~, for example aperforated or scored line. That line of weakness could extend the whole length of the
joined edges of the adjac~nt sheets, or only part of that length.
2s The method of producing the array 2 is illustrated in Figure 3. Abrasive sheet
material 4 (as described above for the tri~n~ r sheet 1) is pulled from a roll 5 onto
the support frame 6 of a flat-bed die cutter 7. The sheet material is brought to a halt
temporarily; the cutter 7 desc~n(lc and cuts the material beneath it into a batch of
arrays (each array being as shown in Figure 3); and the cutter then lifts again. The
sheet material 4 is then pulled forward, until a new length is located beneath the cutter
7, whereupon it is brought to a halt again and the cutter 7 desc~ncls to cut a further
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batch of the arrays 2. The cutting process continues in that way until the required
number of arrays has been cut. It should be noted that, in Figure 3, the arrays 2 are
not depicted accurately for the sake of clarity: as will be clear from the description
below, a much greater number of arrays is cut in the sheet material than is illustrated in
~ 5 ~igure 3.
The cut sheet material is pulled rOI W~l d from the support frame 6 towards a
collecting surface 8 where the arrays 2 are sepal~ted from the r~m~in~ler ofthe sheet
material (i.e. the weed 9) by pulling the latter down below the collecting surface while
0 1:he arrays 2 continue to move ~, w~l-ls and onto the collecting surface. The weed 9 is
then wound, for subsequent disposal, onto a drum (not shown) which is located below
the collecting surface 8. That drum also serves to exert the force that pulls the weed 9
ffirwards and, through it, the sheet material 4. The arrays 2 are collected by hand from
the surface 8 and stacked, and they may then be packed in that form or they may be
S broken up into the individual sheets 1 and then packed. The star-shaped center part
2A of each array (see Figure 2) is not joined to the r~m~inr~r of the array and rnay
remain in place when the array is collected, or it may fall out (or even be deliberately
removed).
The type of appdl dl~ls illustrated in Figure 3 is well known for use in the
production of cut abrasive sheets and it is believed that no further description of the
appdld~LIs is required.
The cutting face of the die cutter 7 is shown, diagrammatically, in Figure 4.
25 The die cutter extends the full width of the sheet material 4 and is conventional except
for the pattern in which the metal cutters 121 are arranged. Accordingly, only that
pattern will be described here. As shown in Figure 4, the metal cutters define
se:venteen hexagonal shapes 122 (each co~onding to an array 2 as shown in
Figure 2) arranged in two staggered rows of, respectively, eight and nine hexagonal
30 shlapes. Notches (not shown) are formed in the metal cutters 121 at the desired
locations 3 ofthe connecting portions between the sheets so that the sheet material 4
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will not be cut through at those locations. Neither the number nor the arrangement of
the hexagonal shapes 122 defined by the metal cutters 121 is restricted to that shown
in Figure 4. The cutters 121 could define a larger or smaller number of hexagonal
shapes, arranged in any app-u~l-ate manner.
It is not ess~nti~l for the die cutter 7 to extend for the full width of the sheet
material 4. It could, for example, extend for only part of the width and be moved
sideways after one cutting action so that one or more batches of arrays 2 can be cut
from the rem~ind~r of the width of the sheet material. Alternatively, two die cutters
0 could be provided side-by-side, each ~xt~nding across half the width of the sheet
material. It will be appreciated that, when a die cutter extends across part only of the
width of the sheet material, a smaller number of arrays 2 will be cut in one operation.
When a user requires an individual tri~n~ r sheet 1, the hexagonal arrays 2
15 are readily separated by tearing the conn~cting portions that hold the tri~n~ r sheets
together. The hexagonal arrays are, however, much easier to handle during production
and much easier to pack than individual tri~n~-l~r sheets. They are also easier fûr the
user to handle because the tri~n~ r sheets do not have to be separated until they are
required. In addition, the amount of the abrasive sheet material 4 that is wasted during
20 the cutting operation (Figure 3) can be reduced because it is possible to pack the
hexagonal arrays 2 more effectively on the surface of the sheet material than individual
tri~n~ r sheets.
Although Figure 3 shows only one layer of sheet material 4 being fed under the
25 die cutter 7, it is well known that several layers of material can be fed onto the support
frame 6 and cut at one time. It is also well known that the weed 9 can be pulled away
from the cut arrays 2 in an upwards direction at the collecting surface 8, rather than
downwards as shown in Figure 3. Moreover, although the above description has
referred to sheet material which is provided with some means (e.g. a pressure sensitive
30 adhesive) for attac1ling abrasive sheets to backing pads of powered tools, it would
apply also to abrasive sheet material without such ~tt~chment means.
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The collection ofthe cut arrays 2 at the surface 8 need not be done m~mlzllly
As one alternative, collecting cans may be provided at the end of the surface 8 in
suitable locations to catch the arrays as they arrive. As yet another alternative, the
S arrays could be picked up pnellm~tic~lly and transferred to a st~f~L inEg location. It is,
n1oreover, possible to use a rotary die cutter, rather than the flat bed cutter 7, to cut
the sheet material 4, in which case the material 4 would move under the cutter
continuously rather than in steps. It is also possible to laser cut the abrasive sheet
array.
It will be appreciated that sheets of other shapes could also be cut from sheet
material 4 in the form of arrays to f~cilit~te h~n-llin~ Figure 6, for example, shows an
array 10 of six sheets 1 1 (one of which is shown in Figure 5) which are also generally
tri~n~l~r but which have rounded sides. The locations at which the sheets 10 are1S joined together are in~ ted sçh~m~tically, as in Figure 2, by circles 3 and it will be
seen that, in this array, there is only one connecting location between the ~ cent
edges of each pair of ~ c~nt sheets 1. However, it will be seen that there is also a
connçcting location between the star-shaped center part 1 OA of the array and the
c~nt apex of each sheet: in other words, in this array (unlike the array shown in
Fi.gure 2) the star-shaped center part 10A is not loose and is intçn-led to remain in
place until the sheets 10 are separated. Figs S and 6 also illustrate that the abrasive
sheets 11 may be formed with apertures 12 through which dust can be removed from a
workpiece when a sheet is in use on a powered tool. Those apertures 12 can, of
course, be cut by the die cutter 7 at the same time as the array 10 is cut.
Some further abrasive sheet arrays are illustrated in Figures 7 to 13. The array13 shown in Figure 7 is another array of generally tri~n~ r sheets (in this case, ten
sheets) of the type shown in Figure 1. Figure 8 shows an array 15 of seven circlllar
sheets 16, and Figures 9 and 10 show arrays 17, 18 respectively of rect~n~-l~r sheets
19, 20 respectively. Figures 11 and 12 show further, generally polygonal, arrays 21,
23 oftri~n~-l~r sheets 22, 24 respectively, the array of Figure 11 being generally
,
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square and that of Figure 12 being generally pentagonal. Figure 13 shows an array 25
similar to that of Figure 6 except that the sheets 26 have a more elongated form. In
each of the arrays, the conn~cting locations between adj~c~nt sheets are indicated
st~h~m~tic~lly by the circles 3 (as in Figures 2 and 6), and the size, number and location
5 of those connections can be altered as applop,iale.
In general, the advantages of cutting arrays of abrasive sheets, rather than
individual sheets, will probably be most appal ell~ for sheets that have sides smaller than
120 mm (or, in the case of circular sheets, a ~ met~r of less than 120 mm). However,
o arrays of larger sheets could be cut if required. It is, moreover, not eSsenti ~l that the
arrays always be cut with other arrays ofthe same shape: it would, for example, be
possible for arrays of the type shown in Figure 8 to be cut from the same length of
sheet material as arrays of the type shown in Figure 2.
In each of the arrays described above, the a~ c~nt sheets in an array could be
spaced apart slightly instead of being contiguous although that would generally result
in a greater waste of sheet material 4. It is also possible for ~dj~cent arrays to be
joined together, for example in a line (as shown in Figure 14 for arrays ofthe type
shown in Figure 2). As already mentioned, it is known to cut abrasive discs in a chain
with ~djacçnt discs being joined by tabs, and the a~ c~nt arrays 2 in Figure 14 could
be joined in a similar manner.
Figure 15 shows another embodiment of a generally tri~n~ r abrasive sheet
31 useful with the present invention. Abrasive sheet 31 incllldes three faceted
2s comers 32 fommed by edges 33 and 34 which meet at an included angle larger than the
angle ordinarily fommed by the sides of a triangle. For example, for an equilateral
triangle, the comers would fomm an included angle of 60~, whereas edges 33 and 34
meet at any inçl~lded angle larger than 60~. In one embodiment, the edges 33 and 34
meet at apploxilllately 90~. Abrasive sheet 31 can be formed into any ofthe arrays
described above with respect to the other generally triangular sheets described herein.
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Figure 16 shows illustrative triangle 40, which is convenient for describing thei]nventive arrays described herein. As ~ c~ssed further below, it is understood that
when an array is described as inr.lllriing. a generally tri~n~ r abrasive sheet, this is
nneant to include not only sheet 40 as illustrated in Figure 16, but also the othe]r
s generally tri~n~ll~r sheets illustrated herein, such as sheet 1, 11, 22, 24, 26, and 31,
and any other form of a generally tri~n~ r abrasive sheet. Tri~n~ r sheet 40
imcl~ldes first edge 41, second edge 42, and third edge 43. Sheet 40 also inrludes first
corner 44 between edges 41 and 43, second corner 45 between edges 41 and 42, andthird corner 49 between edges 43 and 41. When tri~n~ r sheet 40 is a generally
o isosceles triangle, it inrllldes first line of symmetry 47. The term generally isosceles
triangle is understood to include generally tri~n~ r shapes having a single line of
symmetry, such as sheet 26 of Figure 13. Such generally isosceles triangles can
include rounded corners as illustrated in Figure 1, rounded edges as illustrated in
Figures 5 and 13, and faceted corners as illustrated in Figure 15. When abrasive sheet
15 40 is a generally equilateral triangle, it also inrllldes second and third lines of syrnrnetry
48 and 49. The terrn generally equilateral triangle is understood to include generally
tri~n~ r shapes having a three lines of symmetry. Such generally equilateral triangles
can include rounded corners as illustrated in Figure 1, rounded edges as illustrated in
Figures 5 and 13, and faceted corners as illustrated in Figure 15. Abrasive sheet 40
20 also inr.l~ldçs a narrow end 50 and a wide end 51 opposite from the narrow end. For a
generally tri~n~ r abrasive sheet, three opposed pairs of narrow and wide ends can
be clrfined.
Figure 17 shows continuous array 60 of abrasive sheets 40. While array 60 is
2s illustrated as inr.hl-ling tri~n~ r abrasive sheets 40, it is understood that array 60 can
be formed with any generally tri~n~ll~r abrasive sheets, inr,l~l-ling any of the generally
abrasive tri~n~ r sheets illustrated and described herein. Continuous array 60
inr.l~ldçs longit-l~lin~l axis 61 and transverse axis 62. Array 60 also incl~ldes first end
63 and second end 64. The array 60 is characterized in that adjacent sheets 40 are
30 a:rranged such that any individual sheet 40 has its narrow end 50 ~djacent the wide
e:nds 51 of the abrasive sheets immediately on either side. In this manner, the generally
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tri~,n~ ,r abrasive sheets can be efflciently pacl~ged so as to ...;~ .e waste material
in continuous sheet 4 (described above) between the adjac~nt abrasive sheets 40.When abrasive sheets 40 are generally equilateral triangles, they are preferably oriented
so as to have any of the three lines of symmetry 47, 48, 49 along the transverse axis 62
s of the array 60. When abras*e sheets 40 are generally isosceles triangles, they are
preferably oriented so as to have the single line of sym~netry 47 along the transverse
axis 62 of array 60.
The edges of adjacçnt sheets 40 can be configured as described above to
0 provide for convenient separation of the individual sheets from the array. For example,
the a~ cent sheets can be connected by connecting locations 3 as described above, or
by any we~kened line such as a score line or perforated line.
As shown in Figure 18, continuous array 60 can be provided in a spirally
wound roll 65. In the embodiment illustrated, first end of the array 63 is exposed at
the outside of roll 6~, while second end 64 of the array 60 is at the center of the
roll 65.
As each individual sheet 40 is removed from the array 60, the next ~djacent
sheet 40 then becomes available at the first end 63. As shown in Figure 17, the edge of
the abrasive sheet at the first end 63 is oriented such that exposed edge (a) is at an
angle ,B relative to the transverse axis 62 of the array 60. To remove the end sheet B,
it is n~cess~ry to separate the end sheet B from adjacent sheet C along edge (b). It is
seen that edge (b) between a-',jacent sheets B and C is at angle a relative to the
transverse axis 62. To remove the next abrasive sheet C from the array 60, it isnecessary to separate it from sheet D along edge (c). The next sheet D then separated
along edge (d), and so on. When the abrasive sheets 40 are generally equilateraltriangles, angle ~ is at an angle of-30~ relative to the transverse axis 62, while angle a
is at an angle of+30~ relative to the transverse axis 62. If the abrasive sheets are
generally isosceles triangles, then angles a and ~ will be of some angle dirrel elll than
30~, and will be of substantially equal m~gnitllde and opposite orientation. It is thus
CA 02220028 1997-10-31
WO 96/38264 PCrlUS~Iv7X36
seen that as each s~lcces.qive abrasive sheet 40 is removed from the array 60, it is
n~ce.~ry to separate sllcc~sive sheets along a first angle a relative to the trallsverse
axis 62 and then the next sheet along opposite and equal second angle 13 relati~re to the
1:ransverse axis.
s
Figure 19 shows a dispenser 66 which is particularly useful for dispensing
abrasive sheets 40 from array 60 described above. Dispenser 66 in~ dçs box 67 which
is configured to hold roll 65 within the box 67, such as on a spindle (not illustrated)
placed through the core of roll 65. Alternatively, the roll 6~ can sit loose in the box
0 67, or can be supported by any other suitable means as is well known in the art. In
another embodiment, the array 60 is "z-folded" to lay in the box 67, rather than being
ulound into a roll. Box 67 is shown as being generally rect~n~ r and being closed on
each side, although other box configurations are within the scope of the invention.
As seen in greater detail in Figure 20, box 67 includes a first wall 68 which has
therethrough an opening 69 defined by opposed first and second opening edges 70aand 70b. Opening 69 is provided for feeding the abrasive sheet array 60 out of the
d.ispenser 66. Mounted along edge 70a of the opening 69 is first abrasive sheet
separator 71 and mounted along second edge 70b of opening 69 is second abrasive
sheet separator 81. First and second separators 71, 81 provide a convenient means for
s~:pal~illg each abrasive sheet 40 from the first end 63 of the array 60. As explained
below, the first and second separators are configured to separate alternating ones of
the successive abrasive sheets 40 from the array 60.
First separator 71 in~ fles first sepal~Ling edge 72 e~on-~ing from first end 73to second end 74. First end 73 of first separating edge 72 is closer to wall 68 than is
second end 74. Therefore, first separating edge 72 is at an oblique angle relative to the
plane of first wall 68. Likewise, second separator 81 incllldçs second sepal~Lillg edge
82, e~ncling from first end 83 to second end 84. First end 83 of second separating
edge 82 is closer to wall 68 than is second end 84. Therefore, second sepal~Lil-g edge
82 is at an oblique angle relative to the plane of first wall 68. The separators 71, 81
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together define a separating means configured to receive the array 60 in direction X,
the first axis of the separator means.
In a pl~r~;lled embodiment, the first and second sepa,~Lillg edges 72, 82 are ats equal and opposite angles relative to the plane ofthe wall 68. Figure 21A is a top view
of dispenser 66, showing first separator 71 (second separator 81 is omitted fromFigure 21A for clarity). First sepal~Lillg edge 72 is at an angle a relative to the plane
of wall 68, with angle a of the sepal ~ g edge 72 corresponding to angle a at edges
(b) and (d) of the array 60 illustrated in Figure 17. Thus, to separate the end abrasive
lo sheet B from the array 60, the end abrasive sheet can be pulled upward against the first
separator 71, with edge (b) ofthe abrasive sheet aligned along first se~al~ g edge 72.
Second separator 81 is illustrated in Figure 21B (from which first separator 71 has
been omitted for clarity). Second sepal ~ g edge 82 is at angle ,~ relative to the plane
of wall 68, with angle ,1~ of the sepa~ ali--g edge 82 corresponding to angle ,13 at edges
15 (a) and (c) of the array 60 of Figure 17. The separator means has a second axis Y
perpendicular to the first axis X and parallel to the plane defined by the abrasive sheets
in the array 60 as they pass through the separators. To separate abrasive sheet C from
the array 60, sheet C is pulled downward against second separator 81, with abrasive
sheet edge (c) aligned along second sepa-~Li-lg edge 82. Abrasive sheet D can then be
20 separated from the array 60 by pulling sheet D upward against the first separator 71,
with edge (d) of the abrasive sheet aligned with first sepa-~li-lg edge 72, and so on. In
a plt;r~lled embodiment, when generally equilateral triangle abrasive sheets 40 are
used, angle a is +30~ relative to wall 68 while angle ,~ is -30~ relative to wall 68.
When the abrasive sheets of the array 60 are generally isosceles triangles, angles a and
2s ,1~ of first and second sepa- ~ling edges 72, 82, respectively, are of some magnitud
other than 30~, and are of equal m~gnit~lde and opposite orientation. Whatever the
configuration of the abrasive sheets 40, the orientations of the first and second
sepa. ~ g edges 72, 82 are chosen to correspond to the respective alternating
orientation of the edges between ~ljacçnt sheets of the array 60.
CA 02220028 1997-10-31
wo s~l~x2c I Pcr/u~ 36
Figures 22 and 23 show an alternate embodiment of the abrasive sheet
separator 91 mounted on first wall 68 of box 67. Separator 91 is mounted plo~.~ e
~, the second opening edge 70b of opening 69. Separator 91 inr.l~ldes a first se~ lg
edge 92 and a second s~ua~ g edge 93. First ~al~ , edge 92 .-.Ytçn~.c from first~ s end 94 to apex 95, and is orientated at first angle a relative to the plane of the wall 68.
'Second separator edge 93 extends forrn apex 95 to second end 96, and is oriented at
second angle ,13 relative to the plane of the wall 68. The separator receives the array in
clirection A, the first axis of the separator. The separator also has axis Y,
perplonrlicul~r to the first axis X and Iying in the plane defined by the abrasive sheets as
0 they pass by the sep~Lor. In this embodiment, abrasive sheet B is separated from
array 60 of Figure 17 by pressing sheet B down against the separator 91 with edge (b)
aligned with first sep~lor edge 92. Abrasive sheet C is then separated form the array
60 by pressing sheet C down against separator 91 with edge (c) aligned with second
sepa~ g edge 93. Abrasive sheet D is then separated form array 60 by pressing sheet
r) down against the separator 91 with edge (d) aligned with first separating edge 92,
and so on. Opening 69 and separator 91 are wide enough to allow the abrasive sheet
array 60 to be shifted back and forth so as to engage either separator edge 92, 93. In
one plerelled embodiment, slot 69 and separator 91 are ap~ xilllately twice as wide
as array 60.
Box 67 can be of any material conventionally used for such boxes, such as
cardboard, paperboard, plastic, or the like. Separators 71, 81, and 91 can be of any
suitable material such as plastic or metal, and must be strong enough to allow the
albrasive sheets to be separated. First and second separators 71, 81 are illustrated as
separate pieces; however it is understood that separators 71, 81 can be a single unit, if
desired. Separators 71, 81, and 91 can be a separate piece from the box 67, or can be
unitary with wall 68 of box 67. Sepal~ g edges 72, 82, 92, 93 can be sharp edges,
serrated edges, or any other suitable configuration.
It is also possible to use the separators 71, 81, 91 with arrangements other than
the box 67 described above. For example, an array can be mounted or stored on a
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WO 9f~3~1 PCTJUS9''(~7~36
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spool without a box 67, with the separator mounted an a suitable support to receive
the array from the spool. In one such arrangement, the dispenser is ~ rhed to the
spool by a suitable framework as is within the knowledge of those skilled in the art. In
another such arrangement, the separator is mounted on a shelf or work surface with a
s means for storing the array also mounted on the shelf behind the separator. It is
understood that many such a ,~1gel--~,.-Ls are possible and are within the knowledge of
one skilled in the art. What is common to these arrangements is that the separator 71,
81, 91 be provided in a suitable location to receive the array 60, regardless ofthe
particular means chosen to store or support the array, or the particular form of the
lo array (i.e., roll, z-fold, etc.).
The present invention has now been described with reference to several
emborlim~nt~ thereof. The foregoing detailed description and examples have been
given for clarity of unde.~ l;..g only. No llnnecess~ry limitations are to be
15 understood theleLu.--. It will be appalt;--L to those skilled in the art that many changes
can be made in the embodimrnt~ described without departing from the scope of theinvention. Thus, the scope of the present invention should not be limited to the exact
details and structures described herein, but rather by the structures described by the
l~n~-~ge ofthe claims, and the equivalents ofthose structures.
