Patent Application
20240217058
The following relates to abrasive articles, and in particular, abrasive articles and their use in material removal operations.
Abrasive articles are used in various industries to machine work pieces, such as by grinding, buffing, or polishing in order to condition the surface of the workpiece to a desired condition (e.g., coating removal, surface roughness, gloss, transparency, etc.). Grinding, buffing, or polishing refers to the application of a chemical or mechanical compound to a surface using an abrasive pad. Polishing can be done by hand or with the use of a power pneumatic, in which the power is supplied by an electric motor system. Abrasive pads need to not only be strong enough to withstand the interaction between the pad and the article as the pad polishes or grinds the article but also must be able to withstand the pressure applied by the motor system. The industry continues to desire improved abrasive products, particularly those that are intended for use with electronic control systems.
According to one embodiment, an abrasive assembly can include a first abrasive body having a first diameter, a second abrasive body, and a support having an edge where the support is between the first abrasive body and the second abrasive body, and where the edge of the support extends at least 80% and at most 100% the first diameter of the first abrasive body.
In another embodiment, an abrasive assembly can include a first abrasive body, a second abrasive body, and a support between the first abrasive body and the second abrasive body, where a flexural strength as measured across the diameter of the abrasive assembly as assembled is between 1.5 MPa and 3.8 MPa as applied under 20 lbs. of force.
In still another embodiment, a support for an abrasive article can include a ring-shaped body with a first side, a second side opposite the first side, and a central opening, where the body is configured to be coupled to a first abrasive body on a first side and a second abrasive body on a second side, and where the ring-shaped body has a tensile strength of between 400 MPa and 5000 MPa.
In yet another embodiment, a method of removing material from an article can include grinding a first edge of the article using a first abrasive body of an abrasive assembly to remove material from the first edge of the article; and grinding a second edge of the article using a second abrasive body of the abrasive assembly to remove material from the second edge of the article, where the first edge of the article is opposite the second edge of the article, where the abrasive assembly includes: the first abrasive body on a first side of the assembly, where the first abrasive body has a first diameter; the second abrasive body on a second side of the assembly, where the first side is opposite the second side; and a support having an edge, where the support is between the first abrasive body and the second abrasive body, and where the edge of the support extends at least 80% and at most 100% the diameter of the first abrasive body.
The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
The use of the same reference symbols in different drawings indicates similar or identical items.
The following is directed to a nonwoven abrasive article assembly, methods of forming a nonwoven abrasive article assembly, and methods of using a nonwoven abrasive article assembly. The abrasive articles may be used in a variety of material removal operations for a variety of workpieces.
The first abrasive body 110 can be an annular ring with an opening 114 at the center of the body 110, wherein the inner annular surface of the coupling element 140 may define the opening 114. In one embodiment, at least one of the first abrasive body 110 or the second abrasive body 120 can include an attachment member protruding from a surface of the first abrasive body 110 or a surface of the second abrasive body 120 configured to attach to the support 130. In one embodiment, the coupling element 140 may assist with removably coupling of the first abrasive body 110 and the second abrasive body 120 to the support 130, and more specifically, the coupling of the assembly to a spindle.
The first abrasive body 110 can include a first diameter. In one embodiment, the first diameter of the first abrasive body 110 can be not less than 100 mm, such as not less than 150 mm, or not less than 200 mm and at most 400 mm, such as at most 350 mm, such as at most 300 mm. In another embodiment, the first abrasive body 110 can have a diameter that is between 80% and 100% the diameter of the second abrasive body 120.
The second abrasive body 120 can include the second backing plate 180. In one embodiment, the second backing plate 180 has an inner annular edge that extends farther inward that an inner annular edge of the second abrasive body 120. In one embodiment, the coupling element 140 can couple the second abrasive body 120 to both the support 130 and the first abrasive body 110 by directly attaching to the second backing plate 180. According to one embodiment, the second backing plate 180 can fit within a second recess of the support 130, where the second recess of the support 130 is on a second side of the support, and where the first side of the support 130 is opposite the second side of the support 130.
In another embodiment, as illustrated in
It will be appreciated that the backing plate may be an optional component. In one non-limiting embodiment, the first abrasive body 110 does not include a backing plate 160 and the second side 118 of the first abrasive body is directly attached to the support 130.
In one aspect, the second abrasive body 120 may have similar features as compared to the first abrasive body 110. For example, in one non-limiting embodiment,
In one embodiment, the second abrasive body 120 can have a diameter that is substantially similar to the diameter of the first abrasive body 110. In another embodiment, the second abrasive body 120 can have a diameter that is between 80% and 100% of the diameter of the first abrasive body 110. The second abrasive body 120 can be an annular ring with an opening at the center of the body 120 in which the coupling agent 140 sits. The second abrasive body 120 can include a second diameter.
In one embodiment, the second diameter of the second abrasive body 120 can be not less than 100 mm, such as not less than 150 mm, or not less than 200 mm. In one non-limiting embodiment, the second diameter can be at most 1,000 mm, such as at most 800 mm or at most 600 mm or at most 400 mm or at most 350 mm, such as at most 300 mm. It will be appreciated that the second diameter can have a value within a range including any of the minimum and maximum values noted above, including for example, but not limited to within a range of not less than 100 mm and at most 1,000 mm.
The second abrasive body 120 can have a second backing plate 180, similar to that seen in
The support 130 is between the first abrasive body 110 and the second abrasive body 120. In one embodiment, the support 130 is between the first backing plate 160 attached to the first abrasive body 110 and the second backing plate 180 attached to the second abrasive body 120.
In one embodiment, the support may have a particular construction that may facilitate improved operations of the assembly. For example, in one non-limiting embodiment, the support 130 can have a tensile strength of between 400 MPa and 5000 MPa. In another non-limiting embodiment, the support 130 can have a tensile strength of between 500 MPa and 4000 MPa. In another non-limiting embodiment, the support 130 can have a tensile strength of between 600 MPa and 3500 MPa. In another non-limiting embodiment, the support 130 can have a tensile strength of between 650 MPa and 3000 MPa. A tensile test measures the level of strength that a material possesses. A material testing laboratory usually conducts the test using a universal testing machine (UTM), which holds a specimen material in place and applies the tension stress needed to check the breaking point. The equipment is connected to an extensometer, which measures changes in the specimen's length. Tensile strength is measured in pressure units, most commonly in units of Pascal. To test the strength of a ring, a tensile strength formula can also be utilized.
In one embodiment, as seen in
The support 130 provides additional strength and stiffness to the abrasive article assembly and aids in preventing flexure of the edges of the first abrasive body 110 and the second abrasive body 120 while the assembly is in use, as described in more detail below.
The support 130 can include a material that is rated for 10,000 rpms or higher. The support can include a material selected from the group consisting of a composite polymer and metal, thermoplastic, chopped fibers, nylon, carbon fibers, and resin.
In an embodiment where the first abrasive body 110 does not contain the first backing plate 160, as in
In one embodiment, the first abrasive body 110 and/or the second abrasive body 120 can be nonwoven abrasive products, such as a nonwoven unified wheel that may be comprised of a plurality of layers of nonwoven material coated with a binder material and abrasive particles. A first layer (also called a first “slab”), a second layer (also called a second “slab”), and a third layer (also called a third “slab”) are bonded together and can each comprise a nonwoven web of fibers. The nonwoven substrate material can be compressed or densified. The nonwoven substrate material can be in the form of a unified wheel or a convolute wheel as known in the art. Unified wheels, also sometimes called unitized wheels in the art, are formed from a plurality of nonwoven webs of coated lofty staple fibers that are stacked atop each other and bonded together. A convolute wheel is formed from a nonwoven web of coated lofty staple fibers that is wrapped around a central core.
Suitable nonwoven substrate materials include any nonwoven substrate materials commonly known in the abrasives art. In an embodiment, a nonwoven substrate material is a three-dimensional web of staple fibers. The staple fibers may be bound together by one or more binder coating compositions. In one embodiment, the staple fibers can be the same. In another embodiment, the staple fibers may be a blend of fibers having one or more different fiber characteristics, including for example, but not limited to denier size, composition, and the like.
The nonwoven abrasive body can further include abrasive particles attached to the fibers using one or more binder materials.
A suitable nonwoven substrate material can have a constant or variable areal density (mass per unit area). In an embodiment, a nonwoven substrate can have an areal density in a range of at least 50 g/m2 to not greater than 1000 g/m2, such as at least 90 g/m2 to not greater than 600 g/m2. In an embodiment, a nonwoven substrate can have an areal density not greater than 1000 g/m2, such as not greater than about 900 g/m2, not greater than about 800 g/m2, not greater than about 700 g/m2, not greater than about 600 g/m2, not greater than about 500 g/m2, not greater than about 400 g/m2, not greater than about 300 g/m2, or not greater than about 250 g/m2. In an another embodiment, the nonwoven substrate can have an areal density of at least about 50 g/m2, such as at least about 60 g/m2, at least about 70 g/m2, at least about 80 g/m2, at least about 90 g/m2, at least about 100 g/m2, at least about 100 g/m2, at least about 110 g/m2, at least about 120 g/m2, at least about 130 g/m2, at least about 140 g/m2, or at least about 150 g/m2. In a non-limiting embodiment, the areal density of the nonwoven substrate can be within a range of any maximum or minimum value indicated above. In a particular embodiment, the areal density of the nonwoven substrate can be in a range of 90 grams per square meter to about 600 grams per square meter (g/m2).
In one aspect, some suitable examples of staple fibers can include natural fibers, polymer fibers, or a combination thereof. In an embodiment, natural fiber can be chosen from a kenaf fiber, a hemp fiber, a jute fiber, a flax fiber, a sisal fiber, or any combination thereof. In an embodiment, polymer fiber can be chosen from a polyamide, a polyimide, a polyester, a polypropylene, a polyethylene, or a combination thereof. In a specific embodiment, polyamide fibers can be selected from nylon fibers or aramid fibers. In a specific embodiment, nylon fibers can be nylon-6, nylon-6,6, or a combination thereof. In a particular embodiment, the fibers are polyester fibers. In another particular embodiment, the fibers are nylon fibers.
In an embodiment, the polymer fibers can have a constant or variable linear density. One measure of linear density is in denier, the mass in grams per 9,000 meters length of a single filament. For example, a nylon fiber measuring 200 deniers means that 9,000 meters of this fiber weighs 200 grams. In an embodiment, the staple fibers can have a linear density ranging from about 10 deniers to about 1200 deniers, such as about 15 deniers to about 500 deniers. In another embodiment, the staple fibers can include staple fibers having a linear density of at least about 10 deniers, at least about 15 deniers, at least about 20 deniers, at least about 30 deniers, at least about 40 deniers, at least about 50 deniers, at least about 60 deniers, at least about 80 deniers, at least about 100 deniers, at least about 200 deniers, at least about 225 deniers, or at least about 250 deniers. In another embodiment, the staple fibers can have a linear density not greater than about 1200 deniers, such as not greater than about 1000 deniers, not greater than about 800 deniers, not greater than about 600 deniers, not greater than about 500 deniers, not greater than about 400 deniers, not greater than about 300 deniers, or not greater than about 275 deniers.
A polymeric binder composition (also called a binder formulation herein) adheres the staple fibers together. Additionally, or alternatively, one or more binder compositions may adhere the abrasive particles to the staple fibers. A polymeric binder can include a curable polymeric binder. Some exemplary and non-limiting examples of suitable binder compositions can include polyvinylpyrrolidone, a polyacrylic acid, a polyacrylate, a polymethacrylic acid, a polymethacrylate, a polystyrene, a polyvinyl alcohol, a polyvinyl acetate, a polyacrylamide, a cellulose, a polyether, a phenolic resin, a melamine resin, a polyurethane, a polyurea, a polyester, a phenoxy, a latex, a fluorinated polymer, a chlorinated polymer, a siloxane, a silyl compound, a silane, or any combination thereof. In one embodiment, the binder composition may include a blocked resin.
In an embodiment, the binder material may also include one or more additives, including for example, but not limited to, fillers, solvents, plasticizers, chain transfer agents, catalysts, stabilizers, dispersants, curing agents, reaction mediators, or agents for influencing the fluidity of the dispersion. In addition to the above constituents, other components can also be added to the binder material, including, for example, anti-static agents, such as graphite, carbon black, and the like; suspending agents, such as fumed silica; anti-loading agents, such as metal stearate, including lithium, zinc, calcium, or magnesium stearate; lubricants such as wax; wetting agents; dyes; fillers, such as calcium carbonate, talc, clay and the like; viscosity modifiers such as synthetic polyamide wax; defoamers; or any combination thereof. In a particular embodiment, polymeric binder material can be located between or overlie the fibers, the abrasive particles, or a combination thereof.
As stated previously, abrasive particles can be distributed homogenously throughout the nonwoven web or the abrasive particles can be applied to a specific location or side of the non-woven web. In an embodiment, abrasive particles can be distributed homogenously throughout the nonwoven web. In another embodiment, the abrasive particles are disposed on a specific side of the non-woven web.
In a particular embodiment, the abrasive particles are blended with the binder composition to form an abrasive slurry, which is then applied to the nonwoven web. Alternatively, the abrasive grits can be applied over the binder composition (such as by gravity or by electrostatic projection) after the binder composition is coated on the nonwoven web. Optionally, a functional powder may be applied over the abrasive regions to prevent the abrasive regions from sticking to a patterning tooling. Alternatively, patterns may be formed in the abrasive regions absent the functional powder.
Abrasive particles (also called grits or grains) can be formed as individual particles or agglomerate particles. Abrasive particles can comprise any one of or a combination of abrasive materials, including silica, alumina (fused or sintered), zirconia, zirconia/alumina oxides, silicon carbide, garnet, diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide, titanium diboride, boron carbide, tin oxide, tungsten carbide, titanium carbide, iron oxide, chromia, flint, emery. For example, the abrasive grits may be selected from a group consisting of silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, or any combination thereof. Particular embodiments may include abrasive grits consisting essentially of alpha-alumina.
The abrasive grit may also have a particular shape. An example of such a shape includes a rod, a triangle, a pyramid, a cone, a solid sphere, a hollow sphere, or the like. Alternatively, the abrasive grit may be randomly shaped.
The abrasive particles can be graded coarse, medium, fine, very fine, or ultrafine. In an embodiment, the abrasive particles can have an average grit size ranging from about 24 grit to about 1000 grit according to the U.S. Coated Abrasive Manufactures Institute (“CAMI”) grading system. In another embodiment, the abrasive particles can have an average grit size from about 30 grit to about 800 grit. In yet another embodiment, the abrasive particles can have an average grit size from about 36 grit to about 600 grit. In another embodiment, the abrasive particles have an average grit size of at least about 10 microns, at least about 12 microns, or at least about 16 microns. In yet another embodiment, the abrasive particles have an average grit size not greater than about 710 microns, not greater than about 630 microns, or not greater than about 530 microns. The abrasive particles can have a Mohs hardness of at least about 8.0, such as at least about 8.5, or even at least about 9.0.
In one embodiment the abrasive particles can be surface treated. In one embodiment, the abrasive particles are silylated. In another embodiment, the surface treatment can be done by a coupling agent. The coupling agent can be a silane containing coupling agent selected from an aminoalkylsilane, an isocyanatosilane, a chloroalkysilane, or any combination thereof.
and F is the load force at the fracture point (N), L is the length of the support span, b is the width, and d is thickness. At the outside of the bend (convex face) the stress will be at its maximum tensile value. As the flexural strength improves the wear rate on the workpiece decreases. In one embodiment, a wear rate/thickness of the abrasive assembly is 1 gram of abrasive consumed/0.15 mm thickness of assembly. In another embodiment, a wear rate/thickness of the abrasive assembly is 0.9 gram of abrasive consumed/0.14 mm thickness of assembly. In one embodiment, a wear rate/thickness of the abrasive assembly is 0.8 gram of abrasive consumed/0.13 mm thickness of assembly.
The abrasive article assembly 700 can thus be used to remove material from an article. The method of use can include attaching the first abrasive body 710 and the second abrasive body 720 to the motor assembly 702. In one embodiment, the motor assembly 702 can include an arm and locking mechanism configured to fix the abrasive article assembly 700 to the arm. The method can further include grinding a first edge of an article using a first grinding surface 716 of a first abrasive body 710, grinding a second edge of the article using a second grinding surface 717 of a second abrasive body 720 of the abrasive assembly 700 to remove material from the second edge of the article. In one embodiment, the first edge of the article is opposite the second edge of the article and the abrasive assembly 700 can include the first abrasive body 710 on a first side of the assembly 700, a second abrasive body 720 on a second side of the assembly, where the first side is opposite the second side, and a support 730 having an edge between the first abrasive body 710 and the second abrasive body 720. The first abrasive body has a first diameter and the edge of the support 730 extends at least 80% and at most 100% the diameter of the first abrasive body 710. The first abrasive body 710 can work independently from the second abrasive body 720. That is to say that when grinding a surface of an article either the first abrasive body or the second abrasive body can be used. In one example, a motor assembly PUSHCorp STC 1503-BT30 can be used with a wheel speed of 10,000 rpms, a traverse speed of 400 mm/second, at an angle of 45° to the article with an applied force of between 10 and 20 pounds.
Abrasive pads need to not only be strong enough to withstand the interaction between the pad and the article as the pad polishes or grinds the article but also must be able to withstand the pressure applied by the motor system. Accordingly, the present disclosure advantageously utilizes a support that extends towards the edge of the first abrasive body and second abrasive body to increase the flexural strength of the assembly and rigidity of the abrasive assembly. Additionally, since the concave disk wear pattern is substantially reduced, the wear rate of the assembly is reduced by 50% of that of assemblies that do not utilize a support.
Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.
Embodiment 1. An abrasive assembly, including: a first abrasive body having a first diameter; a second abrasive body; and a support having an edge, wherein the support is between the first abrasive body and the second abrasive body, and wherein the edge extends at least 80% and at most 100% the first diameter of the first abrasive body.
Embodiment 2. The abrasive assembly of embodiment 1, where the first abrasive body includes a first grinding surface.
Embodiment 3. The abrasive assembly of embodiment 2, where the second abrasive body includes a second grinding surface, and where the first grinding surface is opposite the second grinding surface.
Embodiment 4. The abrasive assembly of embodiment 3, where the support is between the first grinding surface and the second grinding surface.
Embodiment 5. The abrasive assembly of embodiment 1, where the first abrasive body is configured to be used independently of the second abrasive body.
Embodiment 6. The abrasive assembly of embodiment 1, where at least one of the first abrasive body or the second abrasive body comprise an attachment member protruding from a surface of the first abrasive body or a surface of the second abrasive body.
Embodiment 7. The abrasive assembly of embodiment 6, where the support is coupled to the first abrasive body or the second abrasive body via the protrusion.
Embodiment 8. The abrasive assembly of embodiment 1, where the second abrasive body has a second diameter, and where the edge of the support extends at least 80% and at most 100% of the second diameter of the second abrasive body.
Embodiment 9. The abrasive assembly of embodiment 1, where the second abrasive body has a second diameter, and where the edge of the support extends at least 82% and at most 99% the second diameter of the second abrasive body.
Embodiment 10. The abrasive assembly of embodiment 1, where the second abrasive body has a second diameter, and where the edge of the support extends at least 87% and at most 98% the second diameter of the second abrasive body.
Embodiment 11. The abrasive assembly of embodiment 1, where the second abrasive body has a second diameter, and where the edge of the support extends at least 90% and at most 95% the second diameter of the second abrasive body.
Embodiment 12. The abrasive assembly of embodiment 1, where the first diameter of the first abrasive body is substantially the same as the second diameter of the second abrasive body.
Embodiment 13. The abrasive assembly of embodiment 1, where the first diameter of the first abrasive body is between 80% and 100% of the second diameter of the second abrasive body.
Embodiment 14. The abrasive assembly of embodiment 1, further comprising a first backing plate coupled to the first abrasive body.
Embodiment 15. The abrasive assembly of embodiment 1, further comprising a second backing plate 180 coupled to the second abrasive body.
Embodiment 16. The abrasive assembly of embodiment 1, where the edge of the support is substantially flush with an edge of the first abrasive body.
Embodiment 17. The abrasive assembly of embodiment 16, where the edge of the support is substantially flush with an edge of the second abrasive body.
Embodiment 18. The abrasive assembly of embodiment 1, where the support includes a body and the edge, and where the edge is raised away from the body.
Embodiment 19. The abrasive assembly of embodiment 1, can further include any one or more features of any of the claims and/or embodiments herein:
Embodiment 20. An abrasive assembly can include: a first abrasive body; a second abrasive body; and a support, where the support is between the first abrasive body and the second abrasive body, and where a flexural strength as measured across the diameter of the abrasive assembly as assembled is between 1.5 MPa and 3.8 MPa as applied under 20 lbs. of force.
Embodiment 21. The abrasive assembly of embodiment 20, further comprising a robotic arm assembly.
Embodiment 22. The abrasive assembly of embodiment 20, where a wear rate/thickness of the abrasive assembly is 1 gram of abrasive consumed/0.15 mm thickness of assembly.
Embodiment 23. A support for an abrasive article, can include a body including: a first side; and a second side opposite the first side, where the body is ring-shaped with a central opening, where the body is configured to be coupled to a first abrasive body on a first side and a second abrasive body on a second side, and where the body has a tensile strength of between 400 MPa and 5000 MPa.
Embodiment 24. The support of embodiment 23, where the support includes a material selected from the group consisting of a composite polymer and metal, thermoplastic, chopped fibers, nylon, carbon fibers, and resin.
Embodiment 25. The support of embodiment 23, where the support further includes a locking mechanism, and where the locking mechanism fixes the support to the first abrasive body.
Embodiment 26. The support of embodiment 25, where the locking mechanism, and where the locking mechanism fixes the support to the second abrasive body.
Embodiment 27. A method of removing material from an article, can include grinding a first edge of the article using a first abrasive body of an abrasive assembly to remove material from the first edge of the article; and grinding a second edge of the article using a second abrasive body of the abrasive assembly to remove material from the second edge of the article, where the first edge of the article is opposite the second edge of the article, where the abrasive assembly includes: the first abrasive body on a first side of the assembly, where the first abrasive body has a first diameter; the second abrasive body on a second side of the assembly, where the first side is opposite the second side; and a support having an edge, where the support is between the first abrasive body and the second abrasive body, and where the edge of the support extends at least 80% and at most 100% the diameter of the first abrasive body.
Embodiment 28. The method of removing material from the article of embodiment 27, further comprising attaching the first abrasive body and the second abrasive body to opposite sides of the support.
The above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description.
The Abstract of the Disclosure is provided to comply with Patent Law and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure.
This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description, with each claim standing on its own as defining separately claimed subject matter.
This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/477,879, filed Dec. 30, 2022, by Tony M. LANDES et al., entitled “ABRASIVE ARTICLES AND METHODS OF FORMING SAME,” which is assigned to the current assignees hereof and incorporated herein by reference in its entirety for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 63477879 | Dec 2022 | US |
