GB2223966A

GB2223966A - Making flexible abrasive member

Info

Publication number: GB2223966A
Application number: GB8812612A
Authority: GB
Inventors: David James Smart
Original assignee: D K HOLDINGS Ltd
Current assignee: D K HOLDINGS Ltd
Priority date: 1988-05-27
Filing date: 1988-05-27
Publication date: 1990-04-25
Anticipated expiration: 2008-05-27
Also published as: GB8812612D0; GB2223966B

Abstract

A method of making a flexible abrasive member comprises applying an electrically non-conductive mask 2 to regions of a surface of an electrically conductive, flexible mesh material 1 so as to leave unmasked regions 3 thereon, mounting the mesh material on an electrically non-conductive carrier 4, electro-depositing a coating of metal onto the unmasked regions 3 of the mesh material 1 in the presence of abrasive particles so that the coating of metal penetrates at least partially through the mesh material 1 towards the carrier 4 and abrasive particles are embedded in the metal coating, and demounting the coated mesh material from the carrier 4. <IMAGE>

Description

METHOD OF MAKING A FLEXIELL ABRASIVE MEMBER The present invention relates to a flexible abrasive menber and a method of raking the same.

The flexible abrasive members produced by the method of the invention find application in the grinding, wearing or smoothing of objects made of glass, metal, plastics and other materials.

The invention is particularly concerned with a method of making a flexible abrasive member comprising an electrically conductive mesh having abrasive regions on the surface thereof.

It is known from EP ro. C013466 to electro-deposit metal and abrasive particles on an electrically non-conductive mesh material mounted on an electrically conductive carrier. This disclosure specifically relates to electrically non-conductive mesh materials, such as woven fabric, there being no suggestion of the use of electrically conductive mesh 'materials.

US 4047902 discloses the deposition of metal and abrasive on a substrate by various technicues, including electro-deposition on a conductive material such as a metal sheet. There is, however, no suggestion that the conductive substrate may be a mesh 'material. In addition, there is no disclosure of an electrically non-conductive carrier for supporting the substrate during the electro-deposition process.

It is also known, for example from GB 1229980 and GE 1498689, to electrodeposit abrasive in a metal matrix onto rigid metal substrates forming part of a core drill and cutting disc respectively. The rigid substrates may be metal wire meshes. The resulting abrasive members are inflexible, so that any flexing will give rise to cracking and breaking away of the deposited metal. Again there is'no disclosure of mounting the metal substrate on a carrier prior to the deposition process.

According to the present invention there is provided a method of making a flexible abrasive ember comprising applying an electrically non-conductive mask to regions of a surface of an electrically conductive, flexible mesh material so as to leave unmasked regions thereon, mounting the mesh material on an electrically non-conductive carrier; electro-depositing a coating of metal onto the unmasked regions of the mesh material in the presence of abrasive particles so that that the coating of metal penetrates at least partially through the mesh material towards the carrier and abrasive particles are embedded in the metal coating, ano demounting the coated mesh material from. the carrier.

The penetration of the deposited metal through the mesh material ensures a strong bonding of the metal and abrasive to the mesh material, increasina the durability of the resultant abrasive member.

It is also preferred that the said unmasked regions are discrete and spaced apart from one another over the surface of the mesh material.

In a preferred embodiment of the invention, a flexible backing raterial such as fabric or foam plastics material is applied to the coated mesh material after demounting from the carrier.

The masking process may be carried out using any convenient technique, for example using masking tape, silk screening materials or a photoresist ink.

It will be appreciated that the invention extends to a flexible abrasive member made by a method according to the invention as described above.

The following is a description by way of example only and with reference to the accompanying drawings of a presently preferred embodiment of the invention.

Figure 1 is a cross-section through a portion of a masked electrically conductive flexible mesh material mounted on a carrier.

Figure 2 is a cross-section through a portion of a flexible abrasive member mounted on a carrier; and Figure 3 is a plan view of a portion of a preferred form of flexible abrasive member, with the mesh indicated in part.

A surface of an electrically conductive, flexible mesh material 1 is masked by a silk screen or other mask 2 leaving discrete, spaced apart, unmasked regions 3 on the surface of the mesh 1. The masked mesh material is then mounted on an electrically non-conductive carrier 4, as shown in Figure 1.

The carrier 4 may have a curved or planar surface, but is conveniently in the form of a cylindrical drum around which the masked mesh material is stretched to achieve good contact between the mesh and the surface of the carrier. The carrier may be made of any suitable electrically non-conductive material.

The carrier 4 with the mesh 1 mounted thereon is then submerged in an electrolyte bath, and a coating of metal is electro-deposited on the unmasked surface regions 3 of the mesh 1 in the presence of abrasive particles.

As seen in Figure 2, the electro-deposition process results in discrete, spaced apart regions 5 of abrasive particles in a metal matrix bonded to the mesh material 1.

During the electro-deposition process, the metal penetrates at least partially through the mesh 1 towards the carrier 4. This penetration results in a strong bonding of the regions 5 of metal and abrasive particles to the mesh 1, and hence a more durable abrasive member is produced.

After removal of the photoresist mask if required, and demounting of the coated mesh material from the carrier, the resultant flexible abrasive member may be used or may be trimmed and shaped for a particular application. In particular, a flexible backing material, for example of foarr plastics or rubber, may be applied to the coated mesh arterial so as to increase the durability of the flexible abrasive member.

Figure 3 is a plan view of a preferred arrangement of the metal and abrasive regions 5 on the mesh 1. The regions 5 may be of any desired shape, for example circular, and the specific size and separation of these regions may be varied depending on the intended application of the abrasive member.

The uncoate regions 6 of the mesh between the regions 5 of metal and abrasive increase the flexibility of the abrasive member, and the strong bonding of the metal and abrasive regions 5 to the mesh 1 inhibits detachment of the metal and abrasive during flexing of the abrasive member.

Another important function of the uncoated regions 6 of the mesh is to provide channels for the passage of fluid during use. Such fluid may be used both to cool the surface of the abrasive member, and to flush away debris resulting from grinding or wearing of the object to which the abrasive member is applied in use.

The size of the abrasive particles and the thickness of the metal and abrasive coating may also be varied according to the intended application of the abrasive merger. However, the coated regions 5 preferably have a thickness of 0.1 to 1 rm. Ey way of example, in the embodiment shown in Figures 2 and 3 the coated regions 5 have a thickness above the surface of the mesh of approximately C.3 mm, and have a length of approximately 7mm.

Although the metal plating for bonding the abrasive particles to the mesh may be any suitable metal, a nickel plating is preferred. The abrasive particles may be of, for example, cubic boron, nitride, silicon, diamond or glass or other suitable material.

The electrically conductive mesh material may again be made of any suitable metal.

It will be appreciated that further variations and modifications to the details of the invention described above may be made without departing from the scope of the invention as defined in the following clains.

Claims

CLAIt:C

1. A method of making a flexible abrasive member comprising applying an electrically non-conductive mask to regions of a surface of an electrically conductive, flexible mesh material so as to leave unmasked regions thereon, mounting the mesh material on an electrically non-conductive carrier, electro-depositing a coating of metal onto the unmasked regions of the mesh material in the presence of abrasive particles so that the coating of metal penetrates at least partially through the mesh material towards the carrier and abrasive particles are embedded in the metal coating, and demounting the coated mesh material from the carrier.

2. A method as claimed in Claim 1, wherein the said unmasked regions are discrete and spaced apart from one another over the surface of the mesh material.

3. A method as claimed in Claim 1 or Claim 2 including applying a flexible backing material to the coated mesh material after demounting from the carrier.

4. A method as claimed in Claim 3, wherein the flexible backing material is a fabric or foam plastics material.

5. A method as claimed in any one oç the preceding claims, wherein the metal coating is a nickel coating.

6. A method as claimed in any one of the preceding claims wherein the said mask is produced using a silk screen mask.

7. A method of making a flexible abrasive member substantially as hereinbefore described with reference to the accompanying drawings.

8. A flexible abrasive member made by a method as claimed in any one of the preceding claim.

9. A flexible abrasive member substantially as hereinbefore described with reference to the accompanying drawings.