Flap wheel

Abstract

Abrasive particles are adhered on a first surface of a backing member to define a flap. These particles are removed from support portions of a plurality of flaps. The flaps are stacked and compressed so that the inner ends of the support surfaces on contiguous flaps abut and so that the abrasive particles at the juncture between the support portion and a working portion on each flap abut the second surface of the contiguous flap. This causes a controlled spacing (e.g. wedge-shaped) to be produced between the support portions of contiguous flaps with the flaps uniformly separated at their outer ends. These controlled spacings may be at least partially filled with an adhesive compatible with the adhesive on the first flap surfaces to form the flaps into an array or pack. An anchor may be attached to the pack and may be constructed to couple the pack to a rotary member. The anchor may have an arm attached to the flap support portions with an enlarged portion at its inner end for coupling to the rotary member. Alternatively, the anchor may have a pair of spaced arms attached to the flap support portions and a portion integrating the arms and coupled to the rotary member or may be attached to the inner ends of the support portions be disposed in a socket with a restricted neck in the rotary member. Alternatively, the flaps may be packed tightly into an annulus to define a central hole, potted with an adhesive.