CA1317466C - Abrasive product and method - Google Patents
Abrasive product and methodInfo
- Publication number
- CA1317466C CA1317466C CA000556049A CA556049A CA1317466C CA 1317466 C CA1317466 C CA 1317466C CA 000556049 A CA000556049 A CA 000556049A CA 556049 A CA556049 A CA 556049A CA 1317466 C CA1317466 C CA 1317466C
- Authority
- CA
- Canada
- Prior art keywords
- pellets
- holes
- flexible
- mask
- abrasive product
- 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
Abstract
ABSTRACT OF THE DISCLOSURE
A method of making a flexible abrasive product comprises bonding a conductive sheet to a flexible substrate, applying a surface mask to said sheet to define a multitudinous pattern of holes having a predetermined shape, and electrodepositing metal onto said conductive sheet through said holes in the presence of particulate abrasive material to form metal pellets carrying said particulate abrasive material. The product has excellent abrasive properties, good flexibility, and durability.
A method of making a flexible abrasive product comprises bonding a conductive sheet to a flexible substrate, applying a surface mask to said sheet to define a multitudinous pattern of holes having a predetermined shape, and electrodepositing metal onto said conductive sheet through said holes in the presence of particulate abrasive material to form metal pellets carrying said particulate abrasive material. The product has excellent abrasive properties, good flexibility, and durability.
Description
` ~17~66 This invention relates to a m~thod of making a ~lexible abrasive product.
An abrasive product has been proposed in which abrasive particles, such a diamond grit, are embedded in nickel pellets carried on a substrate. Such a product is made by electro-depositing nickel through holes formed in a mask applied to the surface of the substrate, which can be a fabric rendered conductive.
An object of the invention is to improve the technique for manufacturing such a product.
According to the present invention there is provided a method of making a flexible abrasive product comprising: a) bonding a conductive sheet to a flexible substrate; b) applying a surface mask to said sheet to define a multitudinous pattern of shaped holes, and c) electrodepositing metal onto said conductive sheet through said holes in the presence of particulate abrasive material to form shaped metal pellets carrying said particulate abrasive material.
The holes are preferably crescent-shaped and arranged in a regular pattern, with the convex edges of the crescent facing the intended direction of movement of the abrasive product.
The flexible substrate preferably comprises a KevlarTM
fabric bonded to a sheet of copper foil by LomodTM resin.
The mask is preferably in the form of a photo-resist material applied to the copper foil. The holes can be defined photographically and subsequently exposed upon development of the photo-resist material.
~ lternatively, the holes can be defined by means of a silk-screen process.
t317~
The invention also provides a flexible abrasive product comprising a flexible substrate having a multitude of metal pellets bearing particulate abrasive material attached thereto, said pellets being arranged in a pattern and having a predetermined shape.
The pellets preferably have a crescent-shape.
The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which:-Figure 1 shows a laminated substrate bearing a surface mask defining a regular pattern of crescent-shaped holes;
Figure 2a shows a detail of one of the shaped holes;
and Figure 2b shows a detail of a group of holes.
The laminate 1, shown in figure 1, comprises a KevlarTM
fabric resin bonded to a copper sheet 2 covered with a surface mask 3 of photo-resist material defining crescent-shaped holes 4 through which electrodeposition occurs. The laminate shown in Figure 1 is subsequently placed in an electrolytic tank to permit deposition of nickel in the presence of diamond grit through the shaped holes 4. This process produces crescent-shaped pellets at the locations of the holes with diamond grit embedded in the nickel.
After removal from the tank, the mask and exposed copper are striped from the KevlarTM to leave a sheet consisting of a regular pattern of crescent-shaped pellets firmly attached to the KevlarTM backing. Each pellet consists of an electrodeposit of nickel bearing the diamond grit carried on a crescent-shaped segment of copper bonded to the underlying fabric.
Figure 2a shows in detail the shape of the holes. The crescent-shapes are defined by overlapping circles of slightly ; `"
1317~6~
different radii. Figure 2b shows how the holes are arranged in a symmetrical arrangement.
The manufactured sheet is subsequently cut into strips, which in turn are formed into belts. The use of crescent-shapes makes the belts unidirectional, in that the convex edge has to face the direction of movement a of the belt.
The use of crescent-shapes, permits significant savings in diamond grit without deterioration in the abrasive properties since the surface area of the pellets is less than for circular pellets. Furthermore, the removal of a braided matter is improved.
The holes can have other shapes. For exam~le, honeycomb shapes provide the belt with greater rigidity.
The spacing and size of the pellets can be varied to change the properties of the abrasive product. For rough grinding purposes, the pellets are spaced further apart and larger diamonds employed. For smooth grinding applications, the pellets are brought closer together and smaller diamonds used .
KevlarTM is a particularly useful material for making abrasive belts. For disks on the other hand, the copper foil can be bonded onto fiberglass or other semi-rigid material and the fiberglass then laminated onto a firm backing, for example a polyester backing.
_ 3 --1317l~6~
EXAMPLE
A sheet of 10 ounce KevlarTM (a trade mark for p-poly-phenyleneterephthalamide yarn) 24 by 24 fabric was bonded under heat and pressure with LomodTM (available from General Electric) resin to a copper sheet having a surface density of one ounce per square foot. KevlarTM is a polyaramid fabric.
The surface of the copper sheet was cleaned and scrubbed with an abrasive brush in a scrubbing machine.
- 3a -.~
13~7~
The cleaned laminate was passed through a dry film laminator made by Thio~ol/Dynachem Company (Model 30) to apply a Riston (a trade mark of DuPont) photo-resist film (an alternative is Dynachem film).
Laminate with the applied photo-resist film was placed in a Scannex II exposure unit with a template defining the desired pattern. This template can be produced photographically.
After exposure to ultra violet light, the image was developed and the protective Mylar film, applied by the laminator, removed. The laminate was then plated in a plating bath as described, for example, in our co-pending application Serial No. 518,201 filed on September 15, 1986.
The plating took place in the presence of diamond grit, although other abrasives particulate material can be employed, to form crescent-shaped diamond grit embedded nickel pellets.
After plating, the dry film and exposed copper were removed with an alkyline stripping and etching solution.
The product was then roller coated with polyurethane protective resin, having the trade designation UR 2139X-l and UR
2139X-lA by Elecbro Inc.
The sheet was then cut into strips, and the strips formed into belts ready for use as an abrasive.
Instead of using photo-resist materials to form the mask, the mask can be applied by a silk screening process. In this case, the mask is made of enplate UR 2311B silk screening material which is UV cured after silk-screening.
An abrasive product has been proposed in which abrasive particles, such a diamond grit, are embedded in nickel pellets carried on a substrate. Such a product is made by electro-depositing nickel through holes formed in a mask applied to the surface of the substrate, which can be a fabric rendered conductive.
An object of the invention is to improve the technique for manufacturing such a product.
According to the present invention there is provided a method of making a flexible abrasive product comprising: a) bonding a conductive sheet to a flexible substrate; b) applying a surface mask to said sheet to define a multitudinous pattern of shaped holes, and c) electrodepositing metal onto said conductive sheet through said holes in the presence of particulate abrasive material to form shaped metal pellets carrying said particulate abrasive material.
The holes are preferably crescent-shaped and arranged in a regular pattern, with the convex edges of the crescent facing the intended direction of movement of the abrasive product.
The flexible substrate preferably comprises a KevlarTM
fabric bonded to a sheet of copper foil by LomodTM resin.
The mask is preferably in the form of a photo-resist material applied to the copper foil. The holes can be defined photographically and subsequently exposed upon development of the photo-resist material.
~ lternatively, the holes can be defined by means of a silk-screen process.
t317~
The invention also provides a flexible abrasive product comprising a flexible substrate having a multitude of metal pellets bearing particulate abrasive material attached thereto, said pellets being arranged in a pattern and having a predetermined shape.
The pellets preferably have a crescent-shape.
The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which:-Figure 1 shows a laminated substrate bearing a surface mask defining a regular pattern of crescent-shaped holes;
Figure 2a shows a detail of one of the shaped holes;
and Figure 2b shows a detail of a group of holes.
The laminate 1, shown in figure 1, comprises a KevlarTM
fabric resin bonded to a copper sheet 2 covered with a surface mask 3 of photo-resist material defining crescent-shaped holes 4 through which electrodeposition occurs. The laminate shown in Figure 1 is subsequently placed in an electrolytic tank to permit deposition of nickel in the presence of diamond grit through the shaped holes 4. This process produces crescent-shaped pellets at the locations of the holes with diamond grit embedded in the nickel.
After removal from the tank, the mask and exposed copper are striped from the KevlarTM to leave a sheet consisting of a regular pattern of crescent-shaped pellets firmly attached to the KevlarTM backing. Each pellet consists of an electrodeposit of nickel bearing the diamond grit carried on a crescent-shaped segment of copper bonded to the underlying fabric.
Figure 2a shows in detail the shape of the holes. The crescent-shapes are defined by overlapping circles of slightly ; `"
1317~6~
different radii. Figure 2b shows how the holes are arranged in a symmetrical arrangement.
The manufactured sheet is subsequently cut into strips, which in turn are formed into belts. The use of crescent-shapes makes the belts unidirectional, in that the convex edge has to face the direction of movement a of the belt.
The use of crescent-shapes, permits significant savings in diamond grit without deterioration in the abrasive properties since the surface area of the pellets is less than for circular pellets. Furthermore, the removal of a braided matter is improved.
The holes can have other shapes. For exam~le, honeycomb shapes provide the belt with greater rigidity.
The spacing and size of the pellets can be varied to change the properties of the abrasive product. For rough grinding purposes, the pellets are spaced further apart and larger diamonds employed. For smooth grinding applications, the pellets are brought closer together and smaller diamonds used .
KevlarTM is a particularly useful material for making abrasive belts. For disks on the other hand, the copper foil can be bonded onto fiberglass or other semi-rigid material and the fiberglass then laminated onto a firm backing, for example a polyester backing.
_ 3 --1317l~6~
EXAMPLE
A sheet of 10 ounce KevlarTM (a trade mark for p-poly-phenyleneterephthalamide yarn) 24 by 24 fabric was bonded under heat and pressure with LomodTM (available from General Electric) resin to a copper sheet having a surface density of one ounce per square foot. KevlarTM is a polyaramid fabric.
The surface of the copper sheet was cleaned and scrubbed with an abrasive brush in a scrubbing machine.
- 3a -.~
13~7~
The cleaned laminate was passed through a dry film laminator made by Thio~ol/Dynachem Company (Model 30) to apply a Riston (a trade mark of DuPont) photo-resist film (an alternative is Dynachem film).
Laminate with the applied photo-resist film was placed in a Scannex II exposure unit with a template defining the desired pattern. This template can be produced photographically.
After exposure to ultra violet light, the image was developed and the protective Mylar film, applied by the laminator, removed. The laminate was then plated in a plating bath as described, for example, in our co-pending application Serial No. 518,201 filed on September 15, 1986.
The plating took place in the presence of diamond grit, although other abrasives particulate material can be employed, to form crescent-shaped diamond grit embedded nickel pellets.
After plating, the dry film and exposed copper were removed with an alkyline stripping and etching solution.
The product was then roller coated with polyurethane protective resin, having the trade designation UR 2139X-l and UR
2139X-lA by Elecbro Inc.
The sheet was then cut into strips, and the strips formed into belts ready for use as an abrasive.
Instead of using photo-resist materials to form the mask, the mask can be applied by a silk screening process. In this case, the mask is made of enplate UR 2311B silk screening material which is UV cured after silk-screening.
Claims (12)
1. A method of making a flexible abrasive product comprising:
a) bonding a conductive sheet to a flexible substrate;
b) applying a surface mask to said sheet to define a multitudinous pattern of shaped holes: and c) electrodepositing metal onto said conductive sheet through said holes in the presence of particulate abrasive material to form shaped metal pellets carrying said particulate abrasive material.
a) bonding a conductive sheet to a flexible substrate;
b) applying a surface mask to said sheet to define a multitudinous pattern of shaped holes: and c) electrodepositing metal onto said conductive sheet through said holes in the presence of particulate abrasive material to form shaped metal pellets carrying said particulate abrasive material.
2. A method as claimed in claim 1 wherein said holes form a regular pattern in said mask.
3. A method as claimed in claim 2 wherein said holes are crescent-shaped.
4. A method as claimed in any of claims 1 to 3 wherein said conductive sheet is copper foil, said substrate is a polyaramid fabric resin bonded to said copper foil, said metal is nickel, and said abrasive particulate material is diamond grit.
5. A method as claimed in any of claims 1 to 3 wherein said mask is silk-screend onto said conductive sheet.
6. A method as claimed in any of claims 1 to 3 wherein said mask comprises a photoresist material which is exposed and developed to define the shaped holes.
7. A method as claimed in any of claims 1 to 3 wherein said mask and exposed copper foil are removed by etching after said electrodeposition.
8. A flexible abrasive product comprising a flexible substrate having a multitude of metal pellets bearing particulate abrasive material attached thereto, said pellets being arranged in a pattern and having a predetermined shape.
9. A flexible abrasive product as claimed in claim 8 wherein said pellets are crescent-shaped.
10. A flexible abrasive product as claimed in claim 9 wherein said pellets are arranged in a regular pattern.
11. A flexible abrasive product as claimed in any of claims 8 to 10 wherein said pellets comprise electrodeposited metal on copper segments resin-bonded to said substrate.
12. A flexible abrasive product as claimed in any of claims 8 to 10 wherein the substrate is a polyaramid fabric.
Priority Applications (15)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000556049A CA1317466C (en) | 1988-01-07 | 1988-01-07 | Abrasive product and method |
| AU12157/88A AU1215788A (en) | 1987-02-27 | 1988-02-24 | Flexible abrasives |
| FI880894A FI880894A (en) | 1987-02-27 | 1988-02-25 | BOEJLIGA SLIPMEDEL. |
| DK099288A DK99288A (en) | 1987-02-27 | 1988-02-25 | GRINDING TOPIC |
| JP63044072A JPS6458480A (en) | 1987-02-27 | 1988-02-26 | Abrasive member and manufacture thereof |
| AT88810118T ATE93438T1 (en) | 1987-02-27 | 1988-02-26 | FLEXIBLE ABRASIVES. |
| BR888800891A BR8800891A (en) | 1987-02-27 | 1988-02-26 | METHOD OF MAKING A FLEXIBLE ABRASIVE ELEMENT AND FLEXIBLE ABRASIVE ELEMENT |
| AU12356/88A AU613895B2 (en) | 1987-02-27 | 1988-02-26 | Flexible abrasives |
| EP88810118A EP0280657B2 (en) | 1987-02-27 | 1988-02-26 | Flexible abrasives |
| DE3883403T DE3883403T3 (en) | 1987-02-27 | 1988-02-26 | Flexible abrasives. |
| KR1019880002114A KR880009734A (en) | 1987-02-27 | 1988-02-27 | Flexible abrasive member, abrasive and molding method |
| CN88101108A CN88101108A (en) | 1986-09-15 | 1988-02-27 | Flexible abrasives |
| NO880876A NO880876L (en) | 1987-02-27 | 1988-02-29 | FLEXIBLE GRINDING ELEMENT AND PROCEDURE FOR MANUFACTURING A GRINDING ELEMENT. |
| US07/161,940 US4874478A (en) | 1987-02-27 | 1988-02-29 | Method of forming a flexible abrasive |
| US07/398,335 US5066312A (en) | 1987-02-27 | 1989-08-25 | Flexible abrasives |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000556049A CA1317466C (en) | 1988-01-07 | 1988-01-07 | Abrasive product and method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1317466C true CA1317466C (en) | 1993-05-11 |
Family
ID=4137205
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000556049A Expired - Lifetime CA1317466C (en) | 1986-09-15 | 1988-01-07 | Abrasive product and method |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1317466C (en) |
-
1988
- 1988-01-07 CA CA000556049A patent/CA1317466C/en not_active Expired - Lifetime
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKLA | Lapsed | ||
| MKEC | Expiry (correction) |
Effective date: 20121205 |