Note: Descriptions are shown in the official language in which they were submitted.
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ABRASIVES PRODUCTS WITH EDGES
TECI-INICAI,, FIELD
This disclosure, in general, relates to abrasive articles that have edges.
I3ACKGROUND ART
Abrasive articles, such as coated abrasive articles, are used in various
industries to
machine work pieces, such as by lapping, grinding, or polishing. Machining
utilizing
abrasive articles spans a wide industrial scope from optics industries,
autornotive paint repair
industries to metal t'abrication industries. In each of these examples,
manufacturing facilities
use abrasives to remove bulk material or affect surface characteristics of
products. Various
types of automated processing systems have been developed to abrasively
process articles of
various compositions and configurations. For example, coated abrasive strips,
rolls or tapes,
fed from automatic abrasive feed machines are employed to process parts, such
as automobile
and powertrain parts (e.g., crankshaft, camshaft, transmission sbaft, steering
shaft, steering
rod). Although conventional coated abrasive strips, rolls or tapes in
automatic abrasive feed
machinery systems provide abrasive coverage to the process parts, certain
process parts such
as crankshafts and camshafts, can be hard to abrade due to sharp changes in
curvature of the
parts. Manual examination and verification is time consuming and costly. Poor
abrasive
coverage on the process parts can have very deleterious results, resulting in
significant waste
during manufacture.
In some cases it can be difficult to abrade a workpiece with an abrasive
article due to
the given shape of a workpiece that might have significant amounts of
curvature and
gradients. The inability to properly abrade the entire workpiece can have very
deleterious
results, resulting in significant waste during manufacture. Prior art coated
abrasives with
sinusoidal edges or coated abrasives with slit edges have been used in the
past for improved
conformability with some level ofsuccess,
However, as should be clear from the foregoing, the abrasive industry would be
receptive to an abrasive article with improved conformability to allow niore
uniform abrasion
of a workpiece.
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DISCLOSURE OF INVENTION
In one particular embodiment, a coated abrasive includes a substrate. The
substrate has
a first surface and a second surface opposite the first surface. A plurality
of abrasive particles
are affixed to the first surface by at least one binder. The substrate has a
first edge and a first
plurality of flaps defining the first edge. Each flap of the first plurality
of flaps has an outer
contour extending to a distal end. A line intersecting the distal ends of the
first plurality of
flaps define a first outer periphery of the coated abrasive, wherein a
reference axis extending
nornial to the first outer periphery intersects a tlap of the first plurality
of flaps at two or more
discrete locations along the outer contour of the flap of the first plurality
of flaps.
in another embodiment, a coated abrasive includes a substrate. The substrate
has a first
surface and a second surface opposite the first surface. A plurality of
abrasive particles are
affixed to the first surface by at least one binder. The substrate has a first
edge and a first
plurality of flaps defining the first edge. A first flap from the first
plurality of flaps has a first
straight lateral edge projecting from a first proximal flat to a first distal
flat at an angle A
relative to a first reference axis. The first reference axis extends nonnal to
the first distal flat
at the intersection of the first straight lateral edge and the first distal
flat. A second straight
lateral edge projects from the first distal flat to a second proximal flat at
an angle B relative to
a second reference axis. The second reference axis extends normal to the first
distal flat at the
intersection of the second straight lateral edge and the first distal flat.
In another embodiment, a coated abrasive includes a substrate, The substrate
has a first
surface and a second surface opposite the first surface. A plurality of
abrasive particles are
affixed to the first surface by at least one binder. The substrate has a first
edge and a first
plurality of flaps defining the first edge. The flaps of the first plurality
of flaps are spaced
apart from each other by vaiying a non-constant distance.
In another embodiment, a coated abrasive includes a substrate. The substrate
has a first
surface and a second surface opposite the first surface. A plurality of
abrasive particles are
affixed to the first surface by at least one binder. The substrate has a first
edge and a first
plurality of flaps defining the first edge wherein the plurality of flaps bave
different shapes.
In another embodiment, a coated abrasive includes a substrate. The substrate
has a first
surface and a second surface opposite the first surface. A plurality of
abrasive particles are
affixed to the first surface by at least one binder. The substrate has a first
edge and a first
plurality of flaps defining the first edge wherein the distal edge of the
flaps are wider than a
proximal end of the flaps.
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in another embodiment, a coated abrasive includes a substrate. The substrate
has a first
surface and a second surface opposite the first surface, A plurality of
abrasive particles are
affixed to the first surface by at least one binder. The substrate has a first
edge and a first
plurality of flaps defining the first edge wherein a flap has a distal width,
a proximal width
and a median width where the median width is smaller than the distal width and
the proxima[
width.
In yet another embodiment, a coated abrasive includes a substrate. The
substrate has a
first surface and a second surface opposite the first surface. A plurality of
abrasive particles
are affixed to the first surface by at least one binder. The substrate further
has a first edge,
and a plurality of flaps defining the first edge. A first flap of the first
plurality of flaps has first
and second opposing Eatera[ sides where the first and second opposing lateral
sides have a
respective first and second rectilinear portions. The rectiaiDear portions
forming at least 20%
of an outer periphery of the flap.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure may be better understood, and its numerous features and
advantages made apparent to those skilled in the art by referencing the
accoinpanying
drawings.
FIGS. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20,
21 and 22
include diagrams illustrating exemplary abrasive articles.
The use of the same reference symbols in different drawings indicates similar
or
identical items.
DESCRIPTION OF THE E1vIBODIMENT(S)
In one particular embodiment, the disclosure is directed to a coated abrasive
including
a substrate. The substrate has a first surface and a second surface opposite
the first surface. A
plurality of abrasive particles are affixed to the first surface by at least
one binder. The
substrate has a first edge and a first plurality of flaps defining the -first
edge. The flaps can be
manufactured with different shapes and spacing between the flaps to improve
the
conformability of the coated abrasive. Improved conformability of the coated
abrasive results
in better finish of a workpiece. Improved conformability also lowers the
possibility of folding
of the edges of the coated abrasive when the coated abrasives are being used.
Finally better
conformability of a coated abrasive may result in a lower number of operations
that are
required to process a workpiece.
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In one embodiment the detailed cutting of a coated abrasive to result in
coated
abrasives with custom shaped flaps and custom spacing between the flaps can be
achieved
with a laser cutter. The beam of the laser cutter can be controlled with
mirror technology
which is usually referred to as a;alvanometer. More information on a
galvanometer can be
found at htt ://en.wiki edia.or /wiki/Galvanometer. The laser beam itself can
be of any
power, typically a few hundred watts and can be turned on or off at extremely
fast rates. The
speed of travel of the beam in the working window is typically dictated by the
material and
thickness of the coated abrasive to be cut. In contrast to the prior art that
only cut slits into a
coated abrasive, or a dye cut that formed a sinusoidal pattern, the laser cut
allows for custom
shaped flaps and custom spacing between the flaps. The flap shapes and spacing
can be
chosen to improve the conformability of the coated abrasive for the purpose of
improving the
effectiveness of the coated abrasive on a given workpiece.
FIG I shows a coated abrasive product 10 that is employed in one embodiment of
the
invention. As shown in the figure, coated abrasive product 10 has a substrate
12. The
substrate 12 has a first surface 14 and a second surface opposite the first
surface. A plurality
of particles 16 are affixed to the first surface 14 by at least one binder 18.
The substrate 12
has a first edge 20 and a first plurality of flaps 22 defining the first edge
20. Each flap of the
first plurality of flaps 22 has a first outer contour 24 extending to first
distal ends 26. A line
intersecting the first distal ends 26 defines a first outer periphery 28 of
the coated abrasive
product 10. A reference axis 30 extending normal to the first outer periphery
28 will interest
a flap of the first plurality of flaps 22 at locations 32, 34 and 36.
Coated abrasive product 10 can further include a second edge 40. Each flap of
the
second plurality of flaps 42 has a second outer contour 44 extending to second
distal ends 46.
A line intersecting the second distal ends 46 defines a first outer periphery
48 of the coated
abrasive product 10. A reference axis 50 extending normal to the first outer
periphery 48 will
interest a flap of the second plurality of flaps 42 at locations 52, 54 and
56.
FIG 2 shows a coated abrasive product I 10 that is employed in one embodiment
of the
invention. As shown in the figure, coated abrasive product 110 has a substrate
112. The
substrate 112 has a first surface 114 and a second surface opposite the first
surface. A
plurality of particles 116 are affixed to the first surface 114 by at least
one binder 118. The
substrate 112 has a first edge 120 and a first plurality of flaps 122 defining
the first edge 120.
Each flap of the first plurality of flaps 122 has a first outer contour 124
extending to first
distal ends126. A line intersecting the first distal ends 126 defines a first
outer periphery 128
of the coated abrasive product I 10. A reference axis 130 extending normal to
the first outer
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periphery 128 will interest a flap of the first plurality of flaps 122 at
locations 132, 134 and
136.
Coated abrasive product 110 can further include a second edge 140. Each flap
of the
second plurality of flaps 142 has a second outer contour 144 extending to
second distal ends
146. A line intersecting the second distal ends 146 defines a first outer
periphery 148 of the
coated abrasive product 110. A reference axis 150 extending normal to the
first outer
periphery 148 will interest a flap of the second plurality of flaps 142 at
locations 152, 154 and
156.
FIG 3 shows a coated abrasive product 210 that is employed in one embodiment
of the
invention. As shown in the figure, coated abrasive product 210 has a substrate
212. The
substrate 212 has a first surface 214 and a second surface opposite the first
surface, A
plurality of particles 216 are affixed to the first surface 214 by at least
one binder 218. The
substrate 212 has a first edge 220 and a first plurality of flaps 222 defining
the first edge 220.
Each flap of the first plurality of flaps 222 has a first outer contour 224
extending to first
distaE ends 226. A line intersecting the first distal ends 226 defines a first
outer periphery 228
of the coated abrasive product 210. A reference axis 230 extending normal to
the first outer
periphery 228 will interest a flap of the first plurality of flaps 222 at
locations 232 and 334.
Coated abrasive product 210 can further include a second edge 240. Each flap
of the
second plurality of flaps 242 has a second outer contour 244 extending ta
second distal ends
246. AÃine intersecting the second distal ends 246 defines a first outer
periphery 248 of the
coated abrasive product 210. A reference axis 250 extending normal to the
first outer
periphery 248 will interest a flap of the second plurality of flaps 242 at
locations 252 and 254.
FIG 4 shows a coated abrasive product 310 that is employed in one embodiment
of the
invention. As shown in the figure, coated abrasive product 310 has a substrate
312. The
substrate 312 has a first surface 314 and a second surface opposite the first
surface. A
plurality of particles 316 are affixed to the first surface 314 by at least
one binder 318. The
substxate 312 has a first edge 320 and a first plurality of flaps 322 defining
the first edge 320.
Each flap of the first plurality of flaps 322 has a first outer contour 324
extending to first
distal ends 326. A line intersecting the first distal ends 326 defines a first
outer periphery 328
of the coated abrasive product 310. A reference axis 330 extending normal to
tbe first outer
periphery 328 will interest a flap of the first plurality of flaps 322 at
locations 332 and 334.
Coated abrasive product 310 can further include a second edge 340. Each flap
of the
second plurality of flaps 342 has a second outer contour 344 extending to
second distal ends
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346. A line intersecting the second distal ends 346 defiiies a first outer
periphery 348 of the
coated abrasive product 310. A reference axis 350 extending normal to the
first outer
periphery 348 will interest a flap of the second plurality of flaps 342 at
locations 352 and 354.
FIG 5 shows a coated abrasive product 410 that is employed in one embodiment
of the
invention. As shown in the figure, coated abrasive product 410 has a substrate
412. The
substrate 412 has a first surface 414 and a second surface opposite the first
surface. A
plurality of particles 416 are affixed to the first surface 414 by at least
one binder 418. The
substrate 412 has a first edge 420 and a first plurality of flaps 422 defining
the first edge 420.
Each flap of the first plurality of flaps 422 has a first auter contour 424
extending to first
distal ends 426. A line intersecting the first distal ends 426 defines a first
outer periphery 428
of the coated abrasive product 410. A reference axis 430 extending normal to
the first outer
periphery 428 will interest a flap of the first plurality of flaps 422 at
locations 432 and 434.
Coated abrasive product 310 can further include a second edge 340. Each flap
of the
second plurality of flaps 342 has a second outer contour 344 extending to
second distal ends
346. A line intersecting the second distal ends 346 defines a first outer
periphery 348 of the
coated abrasive product 310. A reference axis 350 extending nortnal to the
first outer
periphery 348 will interest a flap of the second plurality of flaps 342 at
locations 352 and 354.
F1G 6 shows a coated abrasive product 510 that is employed in one embodiment
of the
invention. As shown in the figure, coated abrasive product 510 has a substrate
512. The
substrate 512 has a first surface 514 and a second surface opposite the first
surface. A
plurality of particles 516 are affixed to the first surface 314 by at least
one binder 518. The
substrate 512 has a first edge 520 and a first plurality of flaps 522 defining
the first edge 520.
Each flap of the first plurality of flaps 522 has a first outer contour 524
extending to first
distal ends 526. A line intersecting the first distal ends 526 defines a first
outer periphery 528
of the coated abrasive product 510. A reference axis 530 extending normal to
the first outer
periphery 528 will interest a flap of the first plurality of flaps 522 at
locations 532 and 534.
Coated abrasive product 510 can further include a second edge 540. Each flap
of the
second plurality of flaps 542 has a second outer contour 544 extending to
second distal ends
546. A line intersecting the secoard distal ends 546 defines a first outer
periphery 548 of the
coated abrasive product 510. A reference axis 550 extending normal to the
first outer
periphery 548 will interest a flap of the second plurality of flaps 542 at
locations 552 and 554.
FIG 7 shows a coated abrasive product 610 that is employed in one embodiment
of the
invention. As shown in the figure, coated abrasive product 610 has a substrate
612. The
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substrate 612 has a first surface 614 and a second surface opposite the first
surface, A
plurality of particles 616 are affixed to the first surface 614 by at least
one binder 618. The
substrate 612 has a first edge 620 and a first plurality of flaps 622 defining
the first edge 620.
Each flap of the first plurality of flaps 622 has a first outer contour 624
extending to first
distal ends 626. A line intersecting the first distal ends 626 defines a first
outer periphery 628
of the coated abrasive product 610. A reference axis 630 extending normal to
the first outer
periphery 628 will interest a flap of the first plurality of flaps 622 at
locations 632 and 634.
Coated abrasive product 610 can further include a second edge 640. Each flap
of the
second plurality of flaps 642 has a second outer contour 644 extending to
second distal ends
646. A line intersecting the second distal ends 646 defines a first outer
periphery 648 of the
coated abrasive product 610. A reference axis 650 extending normal to the
first outer
periphery 648 will interest a flap of the second plurality of flaps 642 at
locations 652 and 654.
The coated abrasive products shown in FIGS. 1-7 illustrate that each flap of
the first
plurality of flaps has an outer contour extending to a distal end. A line
intersecting the distal
ends of the first plurality of flaps define a first outer periphery of the
coated abrasive, wherein
a reference axis extending normal to the first outer periphery intersects a
flap of the first
plurality of flaps at two or more discrete locations along the outer contour
of the flap of the
first plurality of flaps, The flaps illustrated in FIGS. 1-7 improve the
confonnability of the
coated abrasive which results in a more consistent abrasion of a workpiece,
The coated abrasive products shown in FIGS. 1- 7 can be either belts, rolls or
sheets.
The coated abrasive products of FIGS. 1-7 can also be discs when there is only
airst edge,
FIG 8 shows a coated abrasive product 710 that is employed in one embodiment
of the
invention. As shown in the figure, coated abrasive product 710 has a substrate
712. The
substrate 712 has a first surface 714 and a second surface opposite the first
surface. A
plurality of particles 716 are affixed to the first surface 714 by at least
one binder 718. The
substrate 712 has a first edge 720 and a first plurality of flaps 722 defining
the first edge 720.
A first flap 723 from the first plurality of flaps 722 has a first straight
lateral edge 724
projecting frorn a first proximal flat 726 to a first distal flat 728 at an
angle A relative to a first
reference axis 730. The first reference axis 730 extends normal to the first
distal flat 728 at
the intersection of the first straight lateral edge 724 and the first distal
flat 728. A second
straight lateral edge 732 projects from the first distal flat 728 to a second
proximal flat 734 at
an angle B relative to a second reference axis 736. The second reference axis
736 extends
normal to the first distal flat 728 at the intersection of the second straight
lateral edge 732 and
the first distal flat 728.
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In one embodiment angle A and angle B are equal. In another einbodiment angle
A
and angle B are not equal. In yet another embodiment anglc A and angle B equal
zero.
In one embodiment the first distal flat 728 has a finite length. In one
embodiment the
length of the distal flat 728 can be larger than 20 mm. In another embodiment
the length of
the distal flat 728 can be larger than 40 mm. In another embodiment the length
of the distal
flat 728 can be larger than 80 mm. In yet another embodiment the length of the
distal flat 728
can be larger than 100 mm.
In one embodiment the first proximal flat 726 has a finite length. In one
embodiinent
the length of the proximal flat 726 can be larger than 20 mm. In another
embodiment the
length of the proximal flat 726 can be larger than 40 mm. In another
ernbodiment the length
of the proximal flat 726 can be larger than 80 mm. In yet another embodiment
the length of
the proximal flat 726 can be larger than 100 mm. In yet another embodiment the
length of the
f rst proximal flat is longer than 10% of the first distal flat length. In yet
another embodiment
the length of the first proximal flat is longer than 20% of the first distal
flat length.
The flaps are formed by removing material from the edge of the coated
abrasive. In
one embodiment this material can be removed by a laser cutter. In one
embodiment the
amount of material removed 738 between the first flap 723 and a second flap
725 of the first
plurality of flaps is greater than 10% of the first flap width. In another
embodiment the
amount of material removed 738 between the first flap 723 and a second flap
725 of the first
plurality of flaps is greater than 20% of the first flap width.
FIG. 9 shows a coated abrasive product 810 that is employed in one embodiment
of the
invention which is a variation of FIG. 8, In FIG. 9 a second straight lateral
edge 832 of flap
823 meets a first lateral edge 840 of flap 825. In the embodiment of FIG. 9
there is no
proximal flat between the second straight lateral edge 832 of flap 823 and the
first lateral edge
840 of flap 825.
FIG. 10 shows a coated abrasive product 910 that is employed in one embodiment
of
the invention which is a variation of FIG. 8. In FIG. 10 a first straight
lateral edge 924 of flap
923 rneets a second lateral edge 932 of flap 923. In the embodiment of FIG. 10
there is no
distal flat between the first straight lateral edge 924 of flap 923 and the
second lateral edge
932 of flap 923.
FIG. l I shows a coated abrasive product 1010 that is employed in one
embodiment of
the invention which is a variation of FIG. 8. In FIG. I I a first straight
lateral edge 1024 of
flap 1023 meets a second lateral edge 1032 of flap 1023. In the ernbodiment of
FIG. I 1 there
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is no distal flat between the first straight lateral edge 1024 of flap 1023
and the second lateral
edge 1032 of flap 1023. FIG. 1 I also shows the second straight lateral edge
1032 of flap 1023
meets a first lateral edge 1040 of flap 1025. In the embodiment of FIG. I 1
there is no
proximal flat between the second straight lateral edge 1032 of flap 1023 and
the first lateral
edge 1040 of flap 1025.
Referring back to FIG. 8 the coated abrasive 710 further includes a second
edge 750,
and a plurality of flaps 752 defining the second edge 750. A#irst flap 754
from the second
plurality of flaps 752 has a first straight lateral edge 756 projecting from a
first proxianal flat
758 on the second edge to a first distal flat 760 on the second edge at an
angle C relative to a
1.0 third reference axis 762. The third reference axis 762 extends normal to
the first distal flat
760 on the second edge at the intersection of the first straight lateral edge
756 and the first
distal flat 760 on the second edge. A second straight lateral edge 764
projecting from the first
distal flat 760 on the second edge to a second proximal flat 766 on the second
edge at an
angle D relative to a fourth reference axis 768. The fourth reference axis 768
extending
normal to the first distal flat on the second edge at the intersection of the
second straight
lateral edge and the first distal flat of the second edge.
In one embodiment angles A, B, C and D are equal. In another embodiment angles
A,
B, C and D are not equal. In yet another embodiment illustrated in FIG. 12 the
coated
abrasive I 110 has angles A, B, C and D equal zero because the first straight
lateral edges
1156 and the second straight lateral edges 1164 of the flaps 1154 are oriented
in a vertical
orientation.
The flaps are formed by removing material from the edge of the coated
abrasive. In
one embodiment this material can be removed by a laser cutter. In FIG. 12 the
amount of
material removed 1138 between the first flap 1123 and a second flap 125 is
greater than 10%
of the first flap 1123 width. In another embodiment the amount of material
removed 1138
between the first tlap 1123 and a second flap 1125 is greater than 20% of the
first flap 1123
widtit.
The coated abrasive products shown in FIGS. 8 - 12 can be either belts, rolls
or sheets.
The coated abrasive products of FIGS. 8-12 can also be discs when there is
only a first edge.
The coated abrasive products shown in FIGS. 8-12 have improved conformability
which will
result in more complete abrasion of a workpiece
FIG 13 shows a coated abrasive product 1210 that is employed in one embodiment
of
the invention. As shown in the figure, coated abrasive product 1210 has a
substrate 1212.
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The substrate 1212 has a'first surface 1214 and a second surface opposite the
first surface. A
plurality of particles 1216 are affixed to the first surface 1214 by at least
one binder 1218.
The substrate 1212 has a first edge 1220 and a first plurality of flaps 1222
defining the first
edge 1220, The flaps of the first plurality of flaps 1222 are spaced apart
from each other by
varying, non-constant distance. In FIG. 13 the space between flap 1224 and
flap 1226 is
larger than the distance between flap 1226 and flap 1228.
In one embodiment laser cutting allows the distance between any pair of flaps
to be set
to any desired distance. Laser cutting can allow total flexibility in the
location of the flaps in
the coated abrasive 1210. The distance between the flaps can be adjusted to
control the
amount of abrasion applied to a workpiece.
In one embodiment the distance between the flaps can be reduced to increase
the
amount of abrasion applied to a workpiece. In one embodiment the increae in
abrasion can be
for the purpose of increasing the material removal rate. Increasing the
removal rate might be
a desired first abrasion operation performed on a workpiece.
In another embodiment the distance between the flaps can be increased to
decrease the
ai-nount of abrasion applied to a workpiece. In one embodiment the purpose of
reducing the
amount of abrasion may be for the purpose a fine finishing operation to
improve the Ra of the
worksurface. A fine finishing operation might be a desired second abrasion
operation
performed on a workpiece. Other desired abrasion operations include lapping,
grinding or
polishing.
In yet another embodiment the distance between the flaps in a coated abrasive
can be
set close together for a portion of the coated abrasive to increase the amount
of abrasion
applied to the workpiece and in a different portion of the sazm coated
abrasive the flaps can
be spaced further apart to decrease the amount of abrasion applied to the
workpiece. The
coated abrasive can be manufactured with different sections in the same coated
abrasive
product where the different sections alternate between multiple abrasion
operations such as
material removal and fine finishing. Other desired abrasion operations include
lapping,
grinding or polishing.
Referring back to T'IG. 13 coated abrasive product 1210 can further include a
second
edge 1240. The #laps of the second plurality of flaps 1242 are spaced apart
from each other
by varying, non-constant distance. In FIG, 13 the space between flap 1244 and
flap 1246 is
larger than the distance between flap 1246 and flap 1248.
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FIG 14 shows a variation of coated abrasive product 1210 that is employed in
one
embodiment of the invention. Coated abrasive 1310 has a first plurality of
flaps 1322 and a
second plurality of flaps 1342 where the varying non-constant distance between
the first
pkurality of flaps 1322 and the second plurality of flaps is different.
The coated abrasive products shown in 1~'IGS: 1.3 and 14 can be either belts,
rolls or
sheets. The coated abrasive products of FIGS. 13 and 14 can also be discs when
there is only
a first edge. The coated abrasive products shown in FIGS. 13 and 14 also have
improved
conformability which will result in approved abrasion of the workpiece.
FIG 15 shows a coated abrasive product 1410 that is employed in one embodiment
of
the invention. As shown in the figure, coated abrasive product 1410 has a
substrate 1412.
The substrate 1412 has a first surface 1414 and a second surface opposite the
first surface. A
plurality of particles 1416 are affixed to the first surface 1414 by at least
one binder 1418.
The substrate 1412 has a first edge 1420 and a first plurality of flaps -nade
up of pyramid
shaped 1422 and bulb shaped flaps 1423 defining the first edge 1420. The
coated abrasive
can be manufactured to have at least two different shaped flaps in the coated
abrasive.
Coated abrasive product 1410 also has a second edge 1440 and a second
plurality of
flaps made up of pyramid shaped 1442 and bulb shaped flaps 1443 defining the
second edge
1420.
FIG. 16 illustrates another exemplary coated abrasive product 1510 which is a
variation of coated abrasive product 1440. In coated abrasive product 1510
there are three
flap shapes, narnely pyramid shaped flaps 1522, bulb shaped flaps 1523 and
triangle shaped
flaps 1524 making up a first edge 1520. The second edge 1540 is made up of
pyramid shaped
flaps 1542, bulb shaped flaps 1543 and triangle shaped flaps 1544. There can
be at least three
different shaped flaps on a coated abrasive product.
FIG. 17 illustrates alother exemplary coated abrasive product 1610 which is
another
variation of coated abrasive product 1440. In coated abrasive product 1610
there are four flap
shapes, namely pyramid shaped flaps 1624, bulb shaped flaps 1623, triangle
shaped flaps
1625 and rectangle shaped flaps 1622 making up a first edge 1620. The second
edge 1640 is
made up of pyramid shaped flaps 1644, bulb shaped flaps 1643, triangle shaped
flaps 1645
and rectangle shaped flaps 1642. There can be at least four different shaped
flaps on a coated
abrasive product.
FIG. 18 illustrates another exemplary coated abrasive product 1710 whicb is
another
variation of coated abrasive product 1440. In coated abrasive product 1710
there a first
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plurality of rectangular shaped flaps 1722 making up a first edge 1720. The
second edge
] 740 is made up of bulb shaped flaps 1742. There can be different shaped
flaps on each edge
of the coated abrasive product.
In one embodiment laser cutting allows any desired shape flap to be cut into
the coated
abrasive. Laser cutting allows total flexibility in the shape of the flaps in
the coated abrasive.
The shape of the flaps can be adjusted to control the ai-nount of abrasion
applied to a
workpiece.
In one embodiment the shape of the flaps can manufactured to increase the
amount of
abrasion applied to a worlcpiece. In one embodiment the increase in abrasion
may be for the
purpose of increasing the material removal rate. Increasing the removal rate
might be a
desired first abrasion operation performed on a workpiece.
In another embodiment the shape of the flaps can be manufactured to decrease
the
amount of abrasion applied to a workpiece. In one embodiment the purpose for
the purpose a
fine finishing operation to improve the Ra of the work surface. A fine
finishing operation
might be a desired second abrasion operation performed on a workpiece. Other
desired
abrasion operations may include lapping, grinding or polishing
In yet another embodiment the shape the flaps in a coated abrasive
manufactured for a
portion of the coated abrasive to increase the amount of abrasion applied to
the workpiece and
in a different portion of the same coated abrasive the shape of the flaps can
manufactured to
decrease the arnount of abrasion applied to the workpiece, The coated abrasive
can be
manufactured with different sections in the same coated abrasive product where
the different
sections alternate between multiple abrasion operations such as material
removal and fine
finishing.
F1G 19 shows a coated abrasive product 1810 that is employed in one
embodirxaent of
the invention. As shown in the figure, a coated abrasive 1810 comprising a
substrate 1812,
the substrate having a first surface 1814 and a second surface opposite the
first surface, and a
plurality of abrasive particles 1816 affixed to the first surface by at least
one binder 1818, the
substrate further having a first edge 1820 and a plurality of flaps 1822
defining the first edge,
wherein a distal end of the flaps 1824 is wider than the proximal end of the
flaps 1826.
In another embodiment the width of the distal end of the flap is at least 10%
wider than
a width of the proximal end of the flap. In yet another embodiment the width
of the distal end
of the flap is at least 20% wider than a width of the proximal end of the flap
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FIG 20 shows a coated abrasive product 1910 that is employed in one embodiment
of
the invention. As shown in the figure, a coated abrasive 1910 comprising a
substrate 191.2,
the substrate having a first surface 1914 and a second surface opposite the
first surface, and a
plurality of abrasive particles 1916 affixed to the first surface by at least
one binder 191 8, the
substrate further having a flrst edge 1920 and a plurality of flaps 1922
defining the first edge
1920, wherein a flap 1923 from the plurality of flaps comprises a distal width
1924, a
proxina.al width 1926 and a median width 1928 where the median width 1928 is
smaller than
the distal width 1924 and the proximal width 1926.
FIG 21 shows a coated abrasive product 2010 that is employed in one embodiment
of
the invention. As shown in the figure, a coated abrasive 2010 comprising a
substrate 2012,
the substrate having a first surface 2014 and a second surface opposite the
first surface, and a
plurality of abrasive particles 20] 6 affixed to the first surface by at least
one binder 2018, the
substrate further having a first edge 2020 and a plurality of flaps 2022
defining the first edge
2020, wherein a first flap 2023 of the first plurality of flaps has a first
and second opposing
lateral sides (2024, 2026) having a respective first and second rectilinear
portions (2028,
2030). In this embodiment the first and second rectilinear portions define the
entirety of the
lateral sides. In other embodiment the rectilinear portions define a portion
of the lateral sides.
In some embodiments the rectilinear portions forming at least 20% of an outer
periphery of the flap. In other embodiments the rectilinear portions form at
least 30% of an
outer periphery of the flap. In Fig. 21, the recti linear portions form 100%
of the outer
periphery of the flap, the outer periphery being the distance along the flap
extending from
point X to point Y.
FTG 22 shows a coated abrasive product 2110 that is employed in one embodiment
of
the invention. As shown in the figure, a coated abrasive 2110 comprising a
substrate 2112,
the substrate having a first surface 2114 and a second surface opposite the
first surface, and a
plurality of abrasive particles 2116 affixed to the first surface by at least
one binder 2118, the
substrate further having a first edge 2120 and a plurality of flaps 2122
defining the first edge
2120, wherein the first and second rectilinear portions (2128, 2130) extend
along respective
first and second lines (2132, 2134) that intersect each other at an angle E
within a range of 30
degrees to 120 degrees. In FIG 22, the first and second rectilinear portions
(2128, 2130) form
approximately 80% of the outer periphe-y of the flap, the outer periphery
being the distance
along the flap extending from point X to point Y.
Abrasive products that are employed in the invention can be in any form. In
one
embodiment the abrasive products can be a sheet or a disc. Preferably,
abrasive products are
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in a roll or belt form. More preferably, the abrasive product is a coated
abrasive roll, such as
rolls of microfinishing filrn, lapping film or finishing cloth.
Examples of suitable coated abrasive products that can be employed in the
invention
generally include a substrate, an abrasive material and at least one binder to
hold the abrasive
material to the substrate, As used herein, the term "coated abrasive product"
encompasses a
woven abrasive tool and a nonwoven abrasive tool. In one example, the coated
abrasive
product includes a substrate, which is optionally treated with a backsize coat
and/or a presize
coat opposite the backsize coat, and a make coat overlaying the optional
presize coat. The
coated abrasive product can further include abrasive particles, or an
agglomerate thercof is
attached to the maker coat or the presize coat when it is employed. A size
coat optionally can
be applied over the abrasive particles or an agglomerate. A supersize coat
optionally can also
be included in coated abrasive product. The inclusion of a backsize coat,
presize coat, size
coat, and/or supersize coat is dependent upon the abrasive product's specific
applications.
Any suitable substrate material known in the art can be employed to coat
abrasive
product 12. The substrate useful in the invention can be rigid, but generally
is flexible.
Examples include paper, cloth, film, fiber, polymeric materials, nonwoven
materials,
vulcanized rubber or fiber, etc., or a combination of one or more of these
materials, or treated
versions thereof. The choice of the substrate material generally depends on
the intended
application of the coated abrasive product to be formed. As used betein,
"nonwoven" means a
web of random or directional fibers held together mechanically, cbernically,
or physically, or
any combination of these. Examples of nonwoven materials include fibers formed
into a
nonwoven web that provides a three-dimensional integrated network structure.
Any fibers
known to be useful in nonwoven abrasive tools can be employed in the
invention. Such fibers
generally are formed from various polyiners, including polyamides, polyesters,
polypropylene, polyethylene and various copolymers thereof. Cotton, wool,
blast fibers and
various animal hairs can also be used for forming nonwoven fibers. In some
applications, the
nonwoven substrate can include a collection of loose fibers, to which abrasive
powders or
agglomerates are added to provide an abrasive web having abrasive powders or
agglomerates
throughout.
Suitable abrasive materials for use in the invention include diamond,
corundum, emery,
garnet, chert, quartz, sandstone, chalcedony, flint, quartzite, silica,
feldspar, pumice and talc,
boron carbide, cubic boron nitride, fused alumina, ceramic aluminum oxide,
heat treated
aluminum oxide, alumina zirconia, glass, silicon carbide, iron oxides,
tantalum carbide,
cerium oxide, tin oxide, titanium carbide, synthetic diamond, manganese
dioxide, zirconium
oxide, and silicon nitride. The abrasive materials can be oriented, or can be
applied to the
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substrate without orientation (i.e., randomly), depending upon the particular
desired properties
of the coated abrasive tools. In choosing an appropriate abrasive material,
characteristics,
such as size, hardness, compatibility with workpieces and heat conductivity,
are generally
considered. Abrasive materials useful in the invention typically have a
particle size ranging
from about 0.1 micrometer and about 1,500 micrometers, such as from about 10
micrometers
to about 1000 micrometers.
According to embodiments of the present invention, improved conformability,
design
flexibility, and machining performance may be achieved, relative to state of
the art coated
abrasives including those with sinusoidal shaped lateral edges. In addition,
embodiments
herein are more efficient to manufacture and consistent edge cutting through
laser patterning
techniques ensures low flap to flap shape variance and improved precision, in
contrast to state
of the art techniques that rely on cutting with a die roll.
The above-disclosed subject matter is to be considered illustrative, and not
restrictive,
and the appended claims are intended to cover all such modiftcations,
enhancements, and
other embodiments, which fall within the true scope of the present invention.
Thus, to the
rnaximum extent allowed by law, the scope of the present invention is to be
determined by the
broadest permissible interpretation of the following ciaims and their
equivalents, and shal E not
be restricted or limited by the foregoing detailed description.
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