CA1317465C - Method of making abrasive articles with metallized backing fabric and articles made thereby - Google Patents
Method of making abrasive articles with metallized backing fabric and articles made therebyInfo
- Publication number
- CA1317465C CA1317465C CA000542562A CA542562A CA1317465C CA 1317465 C CA1317465 C CA 1317465C CA 000542562 A CA000542562 A CA 000542562A CA 542562 A CA542562 A CA 542562A CA 1317465 C CA1317465 C CA 1317465C
- Authority
- CA
- Canada
- Prior art keywords
- fabric
- metal
- coating
- abrasive
- vaporized
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Landscapes
- Polishing Bodies And Polishing Tools (AREA)
Abstract
ABSTRACT
A method is disclosed for making abrasive articles having abrasive particles embedded in elecrodeposits of metal provided at a multitude of discrete locations on a backing fabric. The backing fabric is first coated with a vaporized metal such that the vaporized metal becomes firmly attached to the fabric to provide a conductive coating. The coating is masked at the discrete locations. Then metal is deposited elctrolytically at the discrete locations in the presence of the abrasive particles so that the abrasive particles become embedded in the metal. The method permits the manufacture of an abrasive strip that is ready for use, without the need to bond it unto a backing material.
A method is disclosed for making abrasive articles having abrasive particles embedded in elecrodeposits of metal provided at a multitude of discrete locations on a backing fabric. The backing fabric is first coated with a vaporized metal such that the vaporized metal becomes firmly attached to the fabric to provide a conductive coating. The coating is masked at the discrete locations. Then metal is deposited elctrolytically at the discrete locations in the presence of the abrasive particles so that the abrasive particles become embedded in the metal. The method permits the manufacture of an abrasive strip that is ready for use, without the need to bond it unto a backing material.
Description
131 7~6~
This invention relates to a method of making abrasive articles having abrasive particles embedded in electrodeposits of metal at discrete locations, and to an article made thereby.
Various proposals have been made relatlng to the manufacture of abrasive articles employing diamond particles embedded in electrodeposits of nickel on a conductive substrate.
For example, our copending application Serial No. 518,201, filed September 15, 1986, discloses a technique whereby a mask is formed on a conductive mesh and nickel bearing diamond particles i8 deposited on the mesh at discrete locations defined by the mask. For use in industrial applications, the mesh generally needs to be bonded onto a backing material, which may, for example, be a supporting disk or a fabric belt, the latter being an important application for the abrasive material. The problem with bonding the conductive mesh onto a backing fabric is that a two-stage process is involved. The abrasive material is manufactured in an electrolytic tank, and it must then be cut to ~ize and laminated onto the backing fabric with a suitable material. This process is labour intensive and furthermore the requirements on the adhesive to withstand heat and water, used for cooling purposes, are stringent.
An ob~ect of the invention is to provide a improved manufacturing technique.
According to the present invention there is provided a method of making an abrasive article having abrasive particles embedded in electrodeposits of metal provided at a multitude of discrete locations, comprising coating a backing fabric with a vaporized metal such that the vaporized metal becomes firmly attached to the fabric to provide a conductive coating, masking said conductive coating to expose only said discrete locations, and electrodepositing said metal and said coating at said discrete locations, using said coating as an electrode, in the presence of abrasive particles such that said particles become -1317~
embedded therein.
The above described method permits the complete elimination of the lamination stage and the fabrication of an abrasive belt directly onto the backing fabric. The backing fabric is preferably made of polyaramid yarn, such as p-poly(phenylene) trephthalamide and sold by Dupont under the trademark Kevlar.
The fabric is preferably made of scoured 1500 denier yarn having a balanced weave.
The invention also provides an abrasive article comprising a backing fabric, a coating of vaporized metal deposited in said fabric and firmly attached thereto, and a multitude of metal deposits having abrasive particles embedded therein provided at discrete locations on said metal coating.
The abrasive particles are preferably diamond grit.
The coating metal can be copper and the electrodeposition metal nickel.
The invention will now be described in more detail, by way of example only in which:-Figure 1 is a plan view of a section of fabric bearingnickel deposits;
Figure 2 is a cross section of a small length of the fabric shown in Figure l; and Figure 3 is a perspective view of an abrasive belt made according to the invention.
In the accompanying drawings, Figure 1 shows a strip of Kevlar fabric (Kevlar is a trademark of Dupont for P poly (phenylene terephthalmide) yarn having deposited thereon, at discrete locations and in a uniform pattern, roughly circular "~_ - ~' 1317 ~G~
deposits 2 of nickel, the deposits bearing abrasive particles formed of diamond grit. The deposits 2 can be seen more clearly in Figure 2, which shows in enlarged cross section, a small length of the fabric shown in Figure 1. The diamond particles are referenced 3.
The nickel deposits 2 are formed on a vaporized copper coating 4 firmly attached to the Kevlar fabric.
As shown in Figure 3, the strip of Kevlar fabric is folded over to form a belt 5, with the two ends being lap jointed along a wav-y line 6 and held together by means of an overlying adhesive strip 7.
Unlike the previous proposals, the nickel deposits 3 are formed, by means of the copper coating 4, directly onto the Kevlar backing fabric.
The abrasive belt is made from a Barrday F-2160/175 Kevlar 29-1500 denier scoured fabric. The fabric is then coated with a layer of vaporized copper, which has maximum compatability with nickel in an electrodeposition process. The copper should be fir~ly attached to the fibers making up the Kevlar fabric.
This is achieved by Tpraying the vaporized copper onto the Kevlar fabric with a Metco~type 12 E 4-arc all purpose metalizing spray gun. The arc spray gun forms an arc between a pair of copper electrodes and blows the vaporized copper onto the fabric by means of an air jet.
With this technique, approximately one square foot of fabric can be coated to a thickness of 2 mils in 10 seconds. To ensure good penetration, the fabric should be stretched out on a flat surface and the arc spray gun uniformly moved over the fabric.
Other techniques for coating the fabric have also been successful. A less coarse deposit can be achieved with the Metco nova advanced plasma gun, and it is also possible to use a copper 1317~
wire vaporized by means of an oxy-acetalyne flame. The latter technique, however, leads to a coarser deposit, which in turn can render the subsequent masking step, to be described, more difficult. Other techniques, such a vacuum deposition, electroless deposition, spraying, and painting can be employed to coat the fabric with a conductive surface, but the preferred technique for adhesion, fineness, and uniformity of attachment is the arc spray gun.
When a suitable copper coating has been built up on thè
Kevlar fabric, with good penetration of the copper into the fabric fibres, a mask, such as a polyvinyl coride mask, having symmetrically disposed therein a very large number of holes (approximately 90 per square inch) of about 1/16 inch in diameter, and the mask being of a thickness of about 3/4 of thousand of an inch, is applied to the copper coating. The mask can be laminated to the mesh from a silicone release paper, undera heat and pressure at 350 degrees F and 85 PSI. Tthe mask is first formed on the silicone release paper by a silk screen or other suitable process. The mask is preferably applied to the silicone release paper in the form of a plastisol.
Once the mask has been applied to the copper coated Kevlar fabric, the laminate is then placed in an electrolytic tank, for example the commercial nickel sulfamate bath supplied under the trademark SNRT24 by Hansing operated at 170 amps and 9 volts DC and at a temperature of 140 degrees F. The bath has a nickel anode, and the copper coating is made the cathode. As a result, nickel deposits build up on the portions of the copper coating exposed through the holes in the mask. During the build up of nickel, abrasive diamond particles are distributed over the fabric 80 as to become firmly embedded in the nickel deposits.
The electrodeposition process can be carried in a manner similar to the described in our copending application Serial NQ. 518,201, with the coated Kevlar fabric in effect 1317~6~
taking the place of the conductive mesh.
It is because the ma8k hag to be applied to the copper coating that the coarseness of the coating is important. As mentioned above, the arc spray gives a reasonably uniform coating, in which the mask can be attached. If the coating is too coarse, the coarse particles Will tend to penetrate the mask causing nickel to be deposited on them at unwanted locations during the deposition process.
The treated fabric, when it emerges from the bath, can be cut to size and is ready for use as an abrasive without the need to have it laminated onto a backing material. The Kevlar fabric is extremely strong and well suited to most industrial applications.
The fabric is pr~ferably coated on the back with an A adhesive, such as Bostik 7070 adhesive, to reduce fraying at the edges. The two ends are preferably joined together in a wavy lap joint, as illustrated in Figure 1, and overlayed on the inside with a strip of fabric. The same Bostik~7070 adhesive can be employed.
In order to increase the strength of the belt further, the strip can be stitched to the fabric with Kevlar thread.
This invention relates to a method of making abrasive articles having abrasive particles embedded in electrodeposits of metal at discrete locations, and to an article made thereby.
Various proposals have been made relatlng to the manufacture of abrasive articles employing diamond particles embedded in electrodeposits of nickel on a conductive substrate.
For example, our copending application Serial No. 518,201, filed September 15, 1986, discloses a technique whereby a mask is formed on a conductive mesh and nickel bearing diamond particles i8 deposited on the mesh at discrete locations defined by the mask. For use in industrial applications, the mesh generally needs to be bonded onto a backing material, which may, for example, be a supporting disk or a fabric belt, the latter being an important application for the abrasive material. The problem with bonding the conductive mesh onto a backing fabric is that a two-stage process is involved. The abrasive material is manufactured in an electrolytic tank, and it must then be cut to ~ize and laminated onto the backing fabric with a suitable material. This process is labour intensive and furthermore the requirements on the adhesive to withstand heat and water, used for cooling purposes, are stringent.
An ob~ect of the invention is to provide a improved manufacturing technique.
According to the present invention there is provided a method of making an abrasive article having abrasive particles embedded in electrodeposits of metal provided at a multitude of discrete locations, comprising coating a backing fabric with a vaporized metal such that the vaporized metal becomes firmly attached to the fabric to provide a conductive coating, masking said conductive coating to expose only said discrete locations, and electrodepositing said metal and said coating at said discrete locations, using said coating as an electrode, in the presence of abrasive particles such that said particles become -1317~
embedded therein.
The above described method permits the complete elimination of the lamination stage and the fabrication of an abrasive belt directly onto the backing fabric. The backing fabric is preferably made of polyaramid yarn, such as p-poly(phenylene) trephthalamide and sold by Dupont under the trademark Kevlar.
The fabric is preferably made of scoured 1500 denier yarn having a balanced weave.
The invention also provides an abrasive article comprising a backing fabric, a coating of vaporized metal deposited in said fabric and firmly attached thereto, and a multitude of metal deposits having abrasive particles embedded therein provided at discrete locations on said metal coating.
The abrasive particles are preferably diamond grit.
The coating metal can be copper and the electrodeposition metal nickel.
The invention will now be described in more detail, by way of example only in which:-Figure 1 is a plan view of a section of fabric bearingnickel deposits;
Figure 2 is a cross section of a small length of the fabric shown in Figure l; and Figure 3 is a perspective view of an abrasive belt made according to the invention.
In the accompanying drawings, Figure 1 shows a strip of Kevlar fabric (Kevlar is a trademark of Dupont for P poly (phenylene terephthalmide) yarn having deposited thereon, at discrete locations and in a uniform pattern, roughly circular "~_ - ~' 1317 ~G~
deposits 2 of nickel, the deposits bearing abrasive particles formed of diamond grit. The deposits 2 can be seen more clearly in Figure 2, which shows in enlarged cross section, a small length of the fabric shown in Figure 1. The diamond particles are referenced 3.
The nickel deposits 2 are formed on a vaporized copper coating 4 firmly attached to the Kevlar fabric.
As shown in Figure 3, the strip of Kevlar fabric is folded over to form a belt 5, with the two ends being lap jointed along a wav-y line 6 and held together by means of an overlying adhesive strip 7.
Unlike the previous proposals, the nickel deposits 3 are formed, by means of the copper coating 4, directly onto the Kevlar backing fabric.
The abrasive belt is made from a Barrday F-2160/175 Kevlar 29-1500 denier scoured fabric. The fabric is then coated with a layer of vaporized copper, which has maximum compatability with nickel in an electrodeposition process. The copper should be fir~ly attached to the fibers making up the Kevlar fabric.
This is achieved by Tpraying the vaporized copper onto the Kevlar fabric with a Metco~type 12 E 4-arc all purpose metalizing spray gun. The arc spray gun forms an arc between a pair of copper electrodes and blows the vaporized copper onto the fabric by means of an air jet.
With this technique, approximately one square foot of fabric can be coated to a thickness of 2 mils in 10 seconds. To ensure good penetration, the fabric should be stretched out on a flat surface and the arc spray gun uniformly moved over the fabric.
Other techniques for coating the fabric have also been successful. A less coarse deposit can be achieved with the Metco nova advanced plasma gun, and it is also possible to use a copper 1317~
wire vaporized by means of an oxy-acetalyne flame. The latter technique, however, leads to a coarser deposit, which in turn can render the subsequent masking step, to be described, more difficult. Other techniques, such a vacuum deposition, electroless deposition, spraying, and painting can be employed to coat the fabric with a conductive surface, but the preferred technique for adhesion, fineness, and uniformity of attachment is the arc spray gun.
When a suitable copper coating has been built up on thè
Kevlar fabric, with good penetration of the copper into the fabric fibres, a mask, such as a polyvinyl coride mask, having symmetrically disposed therein a very large number of holes (approximately 90 per square inch) of about 1/16 inch in diameter, and the mask being of a thickness of about 3/4 of thousand of an inch, is applied to the copper coating. The mask can be laminated to the mesh from a silicone release paper, undera heat and pressure at 350 degrees F and 85 PSI. Tthe mask is first formed on the silicone release paper by a silk screen or other suitable process. The mask is preferably applied to the silicone release paper in the form of a plastisol.
Once the mask has been applied to the copper coated Kevlar fabric, the laminate is then placed in an electrolytic tank, for example the commercial nickel sulfamate bath supplied under the trademark SNRT24 by Hansing operated at 170 amps and 9 volts DC and at a temperature of 140 degrees F. The bath has a nickel anode, and the copper coating is made the cathode. As a result, nickel deposits build up on the portions of the copper coating exposed through the holes in the mask. During the build up of nickel, abrasive diamond particles are distributed over the fabric 80 as to become firmly embedded in the nickel deposits.
The electrodeposition process can be carried in a manner similar to the described in our copending application Serial NQ. 518,201, with the coated Kevlar fabric in effect 1317~6~
taking the place of the conductive mesh.
It is because the ma8k hag to be applied to the copper coating that the coarseness of the coating is important. As mentioned above, the arc spray gives a reasonably uniform coating, in which the mask can be attached. If the coating is too coarse, the coarse particles Will tend to penetrate the mask causing nickel to be deposited on them at unwanted locations during the deposition process.
The treated fabric, when it emerges from the bath, can be cut to size and is ready for use as an abrasive without the need to have it laminated onto a backing material. The Kevlar fabric is extremely strong and well suited to most industrial applications.
The fabric is pr~ferably coated on the back with an A adhesive, such as Bostik 7070 adhesive, to reduce fraying at the edges. The two ends are preferably joined together in a wavy lap joint, as illustrated in Figure 1, and overlayed on the inside with a strip of fabric. The same Bostik~7070 adhesive can be employed.
In order to increase the strength of the belt further, the strip can be stitched to the fabric with Kevlar thread.
Claims (13)
1. A method of making an flexible abrasive article having abrasive particles embedded in electrodeposits of metal provided at a multitude of discrete locations, comprising coating a backing fabric with a vaporized metal such that the vaporized metal becomes firmly attached to the fabric to provide a conductive coating, masking said conductive coating and to expose only said discrete locations, and electrodepositing said metal and said coating at said discrete location, using said coating as an electrode, in the presence of said abrasive particles such that said particles become embedded therein.
2. A method as claimed in claim 1 wherein said vaporized metal is sprayed onto said fabric.
3. A method as claimed in claim 2 wherein said vaporized metal is sprayed with an arc spray gun.
4. A method as claimed in claim 2 wherein said vaporized metal is sprayed with a plasma spray gun.
5. A method as claimed in any one of claims 2, 3, or 4 wherein said electrodeposited metal is nickel and said vaporized metal is copper.
6. A method as claimed in Claim 1 wherein said fabric is made of a scoured polyaramic yarn.
7. A method as claimed in Claim 6 wherein the yarn is made of p-poly(pheneylene) terephthalamide fibre.
8. A method as claimed in Claim 7 wherein the fabric is about 1500 denier.
9. A method as claimed in Claim 1 wherein the mask is a plastisol mask applied by a silk screen process.
10. An flexible abrasive article comprising a backing fabric, a coating of vaporized metal deposited on said fabric and firmly attached thereto, and a multitude of metal deposits having abrasive particles embedded therein provided at discrete locations on said metal coating.
11. An abrasive article as claimed in Claim 10, wherein said metal coating is copper and said metal deposits are nickel.
12. An abrasive article as claimed in Claim 10 or 11, wherein said abrasive particles are diamond grit.
13. An abrasive article as claimed in Claim 10, wherein said abrasive article comprises a strip of said fabric formed into a belt.
Priority Applications (11)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000542562A CA1317465C (en) | 1987-07-21 | 1987-07-21 | Method of making abrasive articles with metallized backing fabric and articles made thereby |
| AU78154/87A AU613584B2 (en) | 1986-09-15 | 1987-09-08 | A flexible abrasive coated article and method of making it |
| NO873745A NO873745L (en) | 1986-09-15 | 1987-09-08 | FLEXIBLE GRINDING ELEMENT AND PROCEDURE FOR MANUFACTURING SUCH ITEMS. |
| FI873967A FI873967A (en) | 1986-09-15 | 1987-09-11 | BOYJLIGT STYCKE BELAGT MED SLIPMEDEL OCH FOERFARANDE FOER FRAMSTAELLNING AV DETTA. |
| BR8705173A BR8705173A (en) | 1986-09-15 | 1987-09-15 | ABRASIVE FLEXIBLE ELEMENT AND METHOD FOR MANUFACTURING IT |
| CN198787106418A CN87106418A (en) | 1986-09-15 | 1987-09-15 | Flexible abrasive product and the manufacture method thereof covered |
| EP87810529A EP0263785B1 (en) | 1986-09-15 | 1987-09-15 | A flexible abrasive coated article and method of making it |
| DE8787810529T DE3768408D1 (en) | 1986-09-15 | 1987-09-15 | FLEXIBLE COATED ABRASIVE AND METHOD FOR PRODUCING THE SAME. |
| DK484887A DK484887A (en) | 1986-09-15 | 1987-09-15 | FULLY COATED ARTICLE AND PROCEDURE FOR PREPARING THE SAME |
| AT87810529T ATE61268T1 (en) | 1986-09-15 | 1987-09-15 | FLEXIBLE COATED ABRASIVE AND METHOD OF PRODUCTION. |
| KR1019880001695A KR880009733A (en) | 1987-02-27 | 1988-02-15 | Flexible abrasive coated article and method for manufacturing same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000542562A CA1317465C (en) | 1987-07-21 | 1987-07-21 | Method of making abrasive articles with metallized backing fabric and articles made thereby |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1317465C true CA1317465C (en) | 1993-05-11 |
Family
ID=4136112
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000542562A Expired - Lifetime CA1317465C (en) | 1986-09-15 | 1987-07-21 | Method of making abrasive articles with metallized backing fabric and articles made thereby |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1317465C (en) |
-
1987
- 1987-07-21 CA CA000542562A patent/CA1317465C/en not_active Expired - Lifetime
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKLA | Lapsed | ||
| MKEC | Expiry (correction) |
Effective date: 20121205 |