KR101832124B1 - Coated abrasive article based on a sunflower pattern - Google Patents

Abstract

The abrasive article has a plurality of abrasive areas arranged in a non-uniform distribution pattern, the pattern being a spiral or postcard pattern, such as a spiral lattice, and in particular a pattern described in a Vogelian pattern, such as a sunflower pattern.

Description

TECHNICAL FIELD [0001] The present invention relates to a COATED ABRASIVE ARTICLE BASED ON A SUNFLOWER PATTERN,

The present invention relates generally to coated abrasive articles having abrasive parts, in particular discrete, continuous, semicontinuous and combinations thereof, with a sunflower pattern-based abrasive part.

Abrasive articles, such as coated abrasive articles, are applied to various industries for workpiece polishing or machining, e.g., by lapping, grinding, or polishing. Machining using abrasive articles covers a wide range of industries, from optics, automotive sheet metal painting and welding to construction and woodworking. Machining by hand or by commonly available tools such as orbital polishers (both random and stationary), and belts and vibrating sanders are also commonly used by consumers in domestic applications Is done. In each of these cases, abrasives are used to remove the material surface and affect the abrasive surface properties (e.g., flatness, surface roughness, gloss). In addition, various types of automated processing systems have been developed for grinding of articles of various compositions and configurations.

Surface properties include, among other things, gloss, texture, gloss, surface roughness and uniformity. In particular, surface properties such as roughness and gloss are applied to quality determination. For example, when applying or painting a surface, certain defects or surface defects are generated during the application or curing process. Such surface defects or surface defects include entangled marks, " orange fill " textures, " spots ", or encapsulated bubble and dust defects. Typically, these defects on the coating surface are first removed by grinding with a crude particle abrasive, followed by grinding with a finer particle abrasive, and even by buffer grinding with a wool or foam pad until smoothness is achieved. Thus, the properties of the abrasive articles used comprehensively affect the surface quality.

In addition to the surface properties, the industry is also sensitive to abrasive machining costs. Factors that affect the processing cost include the surface treatment rate and the material cost used for such surface treatment. Typically, the industry wants a cost-effective material with a high grinding rate.

However, abrasives exhibiting high grinding ratios are sometimes poor in achieving desirable surface properties. Conversely, abrasives that can achieve desirable surface properties often exhibit low grinding rates. For this reason, surface treatment often consists of multi-step operations using abrasive sheets of various grades. Typically, surface defects (e.g., scratches) that occur in one step are repaired (e. G., Removed) with finer particle abrasives in one or more subsequent steps. Thus, the abrasive that generates scratches and surface defects requires time, effort, and consumes material in subsequent processing steps, resulting in a high overall processing cost.

Another factor affecting the grinding rate and surface quality is that the workpiece surface is ground so that " swabs " that can accumulate on and between the surfaces of the abrasive particles are "loaded" onto the abrasive article. The loading phenomenon is typically undesirable because it lowers the abrasive product efficiency and may also adversely affect surface properties by increasing the probability of scratch defects.

Various efforts have been made to reduce the accumulation of swarf such as applying a vacuum system to remove the swarf by introducing the fluid to the surface of the workpiece and removing the swarf when the swarf is generated. However, cost-effective polishing There is still a need for improvements to articles, processes and systems.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention may be better understood by reference to the accompanying drawings, and numerous features and advantages thereof may become apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an exemplary coating polishing disc with a pattern of a controlled nonuniform polishing region (so-called spot) according to the present invention and without any openings.
Figure 2 illustrates an exemplary coating abrasive having a multi-spiral arm-shaped abrasive region passing through points consistent with the Vogel model.
Figure 3 shows an exemplary coated abrasive disc with a phyllotactic spiral pattern with clockwise and counterclockwise parasitic spirals according to the invention, in particular without any openings, with a grinding area in the form of a spiral grating .
Figure 4 shows an exemplary coated abrasive disc with no opening and with a grinding area in the form of a postcard spiral pattern with clockwise and counterclockwise yarn lines according to the present invention.
Figure 5 is a schematic diagram of a postcard spiral pattern with clockwise and counterclockwise quadrature lines in which circular sweep areas intersecting quadrature lines are combined according to the present invention, The disc is shown.
Figure 6 shows a Vogel model for polishing area placement according to the present invention.
FIG. 7 shows another Vogel model according to the present invention showing a polishing region arrangement sequence.
Figures 8A-8C illustrate postcard spiral patterns for polishing area placement in a coating abrasive consistent with the Vogel model with different divergence angles according to the present invention.
FIG. 9 is a schematic diagram of a postcard spiral pattern having clockwise and counterclockwise quadratic lines in which circularly polished regions of various sizes intersecting quadrature lines are combined according to the present invention, The disc is shown.
10 illustrates another exemplary coating grinding master having a postcard spiral patterned grinding area with a diagonal thread line in which various sizes of circular grinding areas are diverged by the present invention.
Figure 11 illustrates another exemplary coating grinding master having a postcard spiral patterned grinding area with a diagonal clockwise grating area in which various sizes of circular grinding areas are diverged by the present invention according to the present invention.
12 illustrates another exemplary coating grinding master having a grinding region of a postcard spiral pattern having a branch clockwise direction and a counterclockwise grating line in which diagonal circular grinding regions diverging quadriceps are branched according to the present invention will be.
Figure 13 shows another exemplary coating grinding master having a postcard spiral patterned grinding area with a diagonal thread line in which various sizes of circular grinding areas are diverged by the present invention according to the present invention.
Figure 14 illustrates another exemplary coating grinding master having a postcard spiral patterned grinding area with a diagonal thread line in which various sizes of circular grinding areas are diverged by the present invention according to the present invention.
15 is a graphical image of an exemplary abrasive area pattern having 148 abrasive areas according to the present invention.
16 illustrates an example of an alternative polishing pattern according to the present invention that is a transpose of the polishing area pattern of Fig.
Figure 17 shows an exemplary abrasive area in the form of a spiral and an arc based on the pattern of Figure 16;
18 is a graphical image of an exemplary abrasive area pattern having 344 abrasive areas according to the present invention.
FIG. 19 shows an example according to the present invention, which is the transposition of the polishing area pattern of FIG.
Figure 20 illustrates an example of the present invention, which is a support pad combined with the opening pattern of Figure 19;
21 is a cross-sectional view of an exemplary coating abrasive according to the present invention.
In the drawings, the same reference numerals denote the same or similar parts.

In an embodiment, the abrasive article comprises a coating abrasive having a plurality of abrasive areas arranged in a controlled, non-uniform distribution pattern. The pattern may be any pattern having a controlled non-uniform distribution comprising a radiation pattern, a spiral pattern, a postcard pattern, an asymmetric pattern, or a combination thereof. An example of a combination pattern is a spiral grid pattern. The pattern is partially, substantially, or completely asymmetric. The pattern may cover the entirety of the article to be polished (i.e., distributed throughout), cover substantially the entirety of the article to be polished (i.e., greater than 50% to less than 100%), cover various portions of the article, Only.

A controlled " non-uniform distribution " means that the pattern has a controlled asymmetry (i.e., adjusted randomness) and the distribution of the abrasive regions is described or predicted, for example, by radiation, spiral, At least some of the asymmetry is shown.

The modulated asymmetry can be controlled asymmetry (so-called mirror symmetry, line symmetry, and bilateral symmetry), controlled rotational asymmetry, controlled translational symmetry, controlled sliding reflection symmetry, or a combination thereof. The non-uniform distribution includes an order of one rotational symmetry, that is, a radiation, a spiral, or a postcard opening pattern in which the pattern is not rotationally symmetric because it overlaps only when the pattern itself rotates 360 degrees around the center. That is, when two copies of a completely identical pattern overlap each other, one copy is fixed and the other copy is rotated 360 degrees around the center, all of the abrasive areas of both copies are aligned only once in a 360 degree rotation process.

Typically, all of the abrasive areas (i.e., the entire pattern) of the pattern have a controlled asymmetry. However, the patterns according to the embodiments include asymmetric patterns in which only a part (i.e., a part of the pattern) of the total number of polishing regions of the pattern is adjusted. In this case, only a part of the polishing regions of the pattern formed and generated when the uniform distribution pattern or a part of the completely random pattern is combined with or replaced with the pattern of the uneven distribution to be controlled has a regulated non-uniform distribution. Some of the total abrasive areas with controlled non-uniformity are quantified as a discrete number, or a fraction, percentage, or ratio of abrasive areas in the pattern. In embodiments, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 80%, at least 85%, at least 90%, at least 95%, at least 96%, at least 97% At least 98%, at least 99%, at least 99.5%, at least 99.9% of the polishing regions have controlled asymmetry. Some of the asymmetric controlled polishing regions of the pattern may be in the range of any pair of the upper and lower limits. In certain embodiments, from about 50% to about 99.9%, from about 60% to about 99.5%, from about 75% to about 99% of the pattern have a controlled non-uniform distribution.

In another embodiment, the pattern comprises at least about 5 abrasive regions, at least about 10 abrasive regions, at least about 15 abrasive regions, at least about 20 abrasive regions, at least about 25 abrasive regions, or at least about 50 abrasive regions Asymmetry controlled across. In other embodiments, the pattern may be less than or equal to about 100,000 polishing regions, less than or equal to about 10,000 polishing regions, less than or equal to about 5,000 polishing regions, less than or equal to about 2,500 polishing regions, less than or equal to about 1,000 polishing regions, Has asymmetry regulated over about 500 polishing zones. The number of polishing regions having controlled asymmetry may be in the range of any pair of the upper and lower limits.

As described above, the pattern of the embodiments may be any pattern having a controlled non-uniform distribution including a radiation pattern, a spiral pattern, a postcard pattern, an asymmetric pattern, or a combination thereof. An example of a combination pattern is a spiral grid pattern. It should be understood that helical lattice patterns can be classified into radiation patterns, spiral patterns, postcard patterns, and asymmetric patterns. The radiation pattern is any pattern that appears radially at the center point, e.g., spokes, at the center of the wheel.

In an embodiment, the helical pattern is any curve, or a set of curves, that diverges from the center point of the article to be polished and gradually extends outward as it rotates about the center point. The center point is located at or near the center of the item to be polished, or, alternatively, lies outside the center of the item to be polished. There may be a single spiral or multiple spirals (i.e., multiple spirals). The spirals can be individually or sequentially, separated or connected. The split spirals can be diverged at different center points (i.e., each spiral has its own center point), can be diverged at a common center point (i.e., each spiral shares a center point), or a combination thereof have. The spiral patterns are: Archimedes spiral; Euler helix, corundum helix, or clozoid; Fermat spiral; Hyperbolic helix; Litus; Algebraic helix; Fibonacci spiral; Golden spiral; Or a combination thereof.

In an embodiment, the pattern may be a postcard pattern. As used herein, " postcard pattern " means a pattern associated with the leaf turn. Leaf turn is an arrangement of leaves, flowers, scales, flowers, and seeds in lateral organs, for example many kinds of plants. Many postcard patterns appear as spontaneous phenomena of remarkable patterns with arcs, spirals, and whorls. The pattern of seeds in the sunflower head is an example of this phenomenon. As shown in Figs. 3 and 4, the multiple arcs or spirals, also referred to as quadrants, originate at midpoint C and extend outward, while the other spirals are derived to fill the spacing left by internal spirals. Jean ' s Phyllotaxis Systemic Study in Plant Morphogenesis at p. 17. Frequently, spiral-pattern arrays can be observed to outwardly radiate both clockwise and counterclockwise. As shown in Fig. 4, these types of patterns can be observed with pairs of oppositely arranged hot lines labeled as (m, n), where the number of spirals or arcs at a distance from the center point radiating in the clockwise direction is " m ", and the number of spirals or arcs emitting in a counterclockwise direction is " n ". Also, the angle between two consecutive spirals or arcs in the center is referred to as the divergence angle " a ". The present inventors have surprisingly found that postcard patterns are useful for forming new patterns of abrasive articles, especially coated abrasive articles.

In an embodiment, the pattern has a plurality of clockwise spirals and a plurality of counter-clockwise spirals, wherein the number of clockwise spirals and the number of counter-clockwise spirals is a multiple of Fibonacci numbers or Fibonacci numbers. In a particular embodiment, the number of clockwise spirals and the number of counterclockwise spirals is: (3, 5), (5,8), (8,13), (13,21) , (21, 34), (34, 55), (55, 89), (89, 144) or a multiple of these pairs. In another embodiment, the number of clockwise spirals and the number of counterclockwise spirals is a multiple of the number of Lucas numbers. In a particular embodiment, the number of clockwise spirals and the number of counterclockwise spirals can be determined as pairs (m, n): (3, 4), (4, 7), (7, 11) , (18, 29), (29, 47), (47, 76), or (76, 123), or a multiple of such pairs. In another embodiment, the number of clockwise spirals and the number of counterclockwise spirals are any number of ratios converging to the golden ratio, where the golden ratio is the sum of one plus root 5, division 2, (1 +? 5) / 2, and is approximately 1.6180339887. In certain embodiments, the ratio of clockwise spirals to counterclockwise spirals is approximately equal to the golden ratio.

As described above, sunflower seeds are arranged in a spiral postcard pattern. In an embodiment, the pattern is a sunflower pattern.

The sunflower pattern is described by the Vogel model, which is the "Fibonacci helix" or divergence angle between consecutive points of 137 . It is a spiral type with a fixed Fibonacci angle approaching a golden angle of 508 °.

Figures 6 and 7 show the following Vogel model:

(식 1)

(Equation 1)

        Where:

n is the order of the number of the spots when counting from the center to the outward;

φ is the angle between the position vector of the nth field in the polar coordinate system starting from the reference direction and the capitulum center, and the divergence angle α between the position vectors of any two consecutive fields in the sunflower pattern is 137 . Lt; / RTI >

r is the distance between the central center of the pyramid and the center of the nth circle;

c is a constant conversion factor.

In an embodiment, the pattern is described as a Vogel model or a Vogel model variant. In certain embodiments, the aperture pattern is described as a Vogel model:

n is the order of the polishing area counted from the center of the pattern to the outward;

Phi is the angle between the position vector of the n-th abrasive area in the reference direction and the polar coordinate system starting at the pattern center, so that the divergence angle between the position vectors of any two consecutive abrasive areas is a constant angle alpha;

r is the distance from the center of the pattern to the center of the n-th polishing region;

c is a constant conversion factor.

As noted above, all, substantially all, or some of the polishing regions of the pattern are described in the Vogel model (i.e., consistent with the model). In an embodiment, all of the abrasive areas of the pattern are described by the Vogel model. In other embodiments, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, at least 99% of the polishing regions are described by the Vogel model.

In another embodiment, a suitable spiral or postcard pattern may be any postcard pattern, such as a Vogel model, or other suitable pattern having a controlled non-uniform distribution, such as a radiation pattern, a spiral pattern, a postcard pattern, And the x and y coordinates of x and y . In an embodiment, the x and y coordinates of the spiral or postcard pattern are transposed and rotated to form the x ' and y' coordinates of the spiral or postcard pattern, where θ is π / n degrees and n is any integer:

(식 2)

(Equation 2)

The transposed and rotated production coordinates (x 'and y') are shown, for example, using computer-aided design (CAD) software to form a spiral or postcard pattern. Certain embodiments of transposed postcard patterns are shown in Figure 16, which is the transposition of the postcard pattern in Figure 15, and Figure 19 is the transposition of the postcard pattern in Figure 18.

Surprisingly, the inventors have found that postcard patterns are useful in creating new patterns to improve abrasive article performance, including, for example, bonded abrasive articles and fixed abrasive articles such as coated abrasive articles. In particular, postcard patterns are useful for generating new abrasive area patterns of coated abrasive articles. The postcard patterns can achieve acceptable surface quality while achieving high surface grinding ratios, helping to resolve conflicting problems, reduce the amount of swarf loading on the abrasive surface, and maintain high durability and long life of the abrasive article. These results are, at least in part, surprising in terms of: First, the postcard patterns of the embodiments improve the unexpectedly good swarf removal range, and even though the total abrasive area is less than the total abrasive area of the newest pattern, more fully associated swab extraction areas (E.g., open area paths and / or channels) and polishing areas (e.g., individual polishing spots, long nodes, semi-continuous arcs, swirls, spirals, and combinations of these, . Second, the postcard patterns of these embodiments provide excellent abrasive performance (e.g., cumulative amount of cut) that is unexpectedly at least equal, even if the total area of polishing is less than the latest patterns, do. Third, as will be discussed in greater detail herein, the efficiency and performance of these embodiments are further enhanced when coupled with the combined support pad and vacuum system.

Important aspects in the pattern design of coated abrasive articles are the percentage of abrasive total surface area of the coated abrasive article, the ratio of the total abrasive surface area to the open area, when the abrasive article is used (e.g., rotational movement in an orbital sander, Motion and continuous sideways movement in the belt sander) The position and range covered by the predicted abrasive area, the conversion factor, the number of abrasive areas, the divergence angle between the abrasive areas, the size and shape of the abrasive areas, the distance between adjacent abrasive areas, And outermost abrasive regions and edges, or distances between edges.

Abrasive disc size

There are various sizes of abrasive products commonly used by industry and commercial consumers, typically ranging from fractions of a few inches in diameter to feet. These patterns are suitable for use with most any size abrasives, including abrasive discs of various standard sizes (e.g., 3 inches to 20 inches). In an embodiment, the abrasive article is a circular disk and has a diameter of at least about 0.25 inches, at least about 0.5 inches, at least about 1.0 inches, at least about 1.5 inches, at least about 2.0 inches, at least about 2.5 inches, or at least about 3.0 inches. In another embodiment, the abrasive article is a circular disk and has a diameter of about 72 inches or less, about 60 inches or less, about 48 inches or less, about 36 inches or less, about 24 inches or less, about 20 inches or less, about 18 inches or less, about 12 About 10 inches or less, about 9 inches or less, about 8 inches or less, about 7 inches or less, or about 6 inches or less. In another embodiment, the size of the abrasive article is from about 0.5 inches to about 48 inches in diameter, from about 1.0 inches to about 20 inches in diameter, from about 1.5 inches to about 12 inches.

Potential total surface area

The size and shape of the abraded article determines the potential total surface area of the abraded article. By way of example, a 1 inch diameter abrasive disc has a potential total surface area of 0.7854 in ² . As another example, the potential total surface area of a 2 inch * 3 inch rectangular polishing sheet is 6 in ² .

Total open area

The total open area affects the amount of swarf extraction. Typically, as the open area increases, the amount of swarf extraction increases and thus the grinding rate (i.e., " cutting ") of the abrasive article during use is maintained or sometimes improved. However, increasing the open area also directly reduces the available grinding area, which reduces the grinding rate at a given point. In an embodiment, the total open area is the sum of all open areas at the front of the abraded article. That is, the total open area is equal to the potential total surface area of the abraded article minus the total abrading area (i. E., The sum of all abrading areas). Thus, the total open area is from about 15% to about 95.5% of the potential total surface area, depending on the desired area of abrasion. In embodiments, the total open area is at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45% At least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%. In another embodiment, the total open area comprises no more than about 95.5%, no more than about 95%, no more than about 94.5%, no more than about 94%, no more than about 93.5%, no more than about 93%, no more than about 92.5% , About 91.5%, about 91%, about 90.5%, about 90% or less. The total open area may be in the range consisting of any pair of the upper and lower limits. In another embodiment, the total open area ranges from about 65% to about 93%, from about 70% to about 92%, from about 75% to about 91%, or from about 80% to about 90%. The total open area can be considered as an individual value rather than a ratio. For example, the total open area of the 5 inch polishing disc is about 2.95 in ² to about 18.75 in ² .

Abrasive total surface area

The polishing total surface area affects the amount of surface material removed. Typically, as the polishing total surface area increases, the amount of surface material removed increases. Also, typically, as the amount of surface material removed increases, the tendency to form swarf increases and the surface roughness tends to increase. In an embodiment, the polishing total surface area of the coating abrasive will limit the total open area (i.e., the sum of all open areas) at the potential total surface area of the abrasive article (i.e., the polishing surface area in the apertures). Thus, the polishing total surface area is from about 4.5% to about 85% of the total potential surface area depending on the desired open area.

In embodiments, the polishing total surface area is at least about 4%, at least about 4.5%, at least about 5%, at least about 5.5%, at least about 6%, at least about 7.5%, at least about 8% , At least about 8.5%, at least about 9%, at least about 9.5%, or at least about 10%. In yet another embodiment, the polishing total surface area is less than or equal to about 85%, less than or equal to about 80%, less than or equal to about 75%, less than or equal to about 70%, less than or equal to about 65%, less than or equal to about 60%, less than or equal to about 55% About 45% or less, about 40% or less, about 35% or less, about 30% or less, about 25% or less, or about 20% or less. The polishing total surface area may be in the range comprised of any pair of the upper and lower limits. In another embodiment, the total surface area of the abrasive is from about 7% to about 35%, from about 8% to about 30%, from about 9% to about 25%, or from about 10% to about 20%. The total surface area of the abrasive can be considered as an individual number rather than a ratio. For example, the polishing total surface area of a 5 inch polishing disc is about 0.88 in ² to about 16.69 in ² .

The ratio of the total surface area of the abrasive to the total open area

In an embodiment, the ratio of the total surface area of polishing to the total open area is at least about 1: 199, at least about 1:99, at least about 1: 65.7; At least about 1:49, at least about 1:39, at least about 1:29, at least about 1:19, or at least about 1: 9. In another embodiment, the ratio of the total polishing surface area to the total open area is less than about 1: 0.05, less than about 1: 0.1, less than about 1: 0.2, less than about 1: 0.3, 0.5 or less, about 1: 0.6 or less, about 1: 0.7 or less, about 1: 0.8 or less, about 1: 0.9 or less, or about 1: The ratio of the total surface area of polishing to the total open area may be in the range consisting of any pair of said upper and lower limits.

Number of polishing areas

The number of polishing regions affects the total open area and the total polishing area. In addition, the number of polishing regions affects the density and distribution of the polishing range at the surface of the polishing article, which again directly affects the material cutting rate and swab extraction efficiency of the polishing article. In an embodiment, the number of polishing regions is at least about 5, at least about 10, at least about 15; At least about 18, or at least about 21. In another embodiment, the number of polishing regions is about 100,000 or less; About 50,000 or less; About 10,000 or less; About 1,000 or less; About 800 or less; About 750 or less; About 600 or less; Or about 550 or less. The number of polishing regions may be in the range consisting of any pair of the upper and lower limits. In another embodiment, the number of polishing regions is from about 21 to about 10,000; From about 25 to about 1,000; From about 30 to about 750; Or from about 35 to about 550. In certain embodiments, the number of polishing regions is from about 21 to about 550.

Divergence angle

The divergence angle a increase / decrease affects the shape in which the polishing regions are arranged in the pattern and the shape of the clockwise and counterclockwise spirals. The divergence angle is equal to the 360 ° division constant or variable, so the divergence angle is constant or variable. We found that changing the divergence angle slightly can change the pattern considerably. Figures 8a, 8b and 8c show different postcard patterns only in divergence angle values. The divergence angle in FIG. 8A is 137.3 DEG. The divergence angle in FIG. 8B is 137.5 DEG. The divergence angle in FIG. 8C is 137.6 degrees. In an embodiment, the divergence angle is at least about 30 degrees, at least about 45 degrees, at least about 60 degrees; At least about 90 degrees, or at least about 120 degrees. In another embodiment, the divergence angle is less than 180 degrees, such as less than about 150 degrees. The divergence angle may be in the range consisting of any pair of the upper and lower limits. In other embodiments, the divergence angle is from about 90 degrees to about 179 degrees, from about 120 degrees to about 150 degrees, from about 130 degrees to about 140 degrees, or from about 135 degrees to about 139 degrees. In an embodiment, the divergence angle is determined by a 360 degree division number. In a particular embodiment, the divergence angle is determined by a 360 deg. Golden ratio. In certain embodiments, the divergence angle is from about 137 degrees to about 138 degrees, such as from about 137.5 degrees to about 137.6 degrees, such as from about 137.50 degrees to about 137.5 degrees. In certain embodiments, the divergence angle is 137.508 degrees.

Distance to edge of abrasive

Depending on the structure and use of the abrasive article, the overall pattern dimension is determined. The distance from the pattern center to the outermost polishing regions extends to a distance in contact with the edge of the polishing article. Thus, the edges of the outermost abrasive regions extend or cross to the edge of the abrasive article. Alternatively, the distance from the pattern center to the outermost abrasive regions may be extended such that there are no abrasive regions in a predetermined space between the edges of the outermost abrasive regions and the edge of the abrasive article. The minimum distance from the edges of the outermost polishing regions is specified if desired. In an embodiment, the minimum distance from the edges of the outermost polishing regions to the outer edge of the abrasive article is a specific distance and is expressed as a ratio of the individual article length or the abrasive article front distance at which the pattern appears. In embodiments, the minimum distance from the corners of the outermost polishing regions to the outer edge of the polishing article is at least about zero (i.e., the edges of the outermost polishing regions intersect or abut the corners of the polishing article) to about 15 %to be.

Size of polishing areas

The size of the abrasive areas is determined, at least in part, by the desired abrasive total surface area for the abrasive article. The size of the polishing regions is constant across the pattern or variable within the pattern. In an embodiment, the size of the polishing regions is constant. In another embodiment, the size of the polishing regions varies with the distance of the polishing regions from the pattern center.

Conversion factor

The conversion factor affects the overall size and dimensions of the pattern. The conversion factor is adjusted so that the edges of the outermost abrasive areas are within a desired distance of the outer edge of the abrasive article.

Distance between nearest abrasive areas

Considering the number and size of the polishing regions, the distance between the centers of the nearest polishing regions is determined. The distance between centers of any two polishing regions is a function of other design considerations. In an embodiment, the shortest distance between any two centers of abrasion is not repetitive (i.e., the center-to-center spacing is not the same distance). This type of spacing is also an example of regulated asymmetry.

 Pattern range - acceptable anomalies

It is clear that the pattern need not be applied to the abrasive article in whole or in succession. Some of the patterns may be applied or omitted so that the various subdivisions or sections in the front of the abraded article may not have a complete opening pattern. In an embodiment, half, 1/3, 1/4, 1/5, 1/6, 1/7, 1/8, 1/9, 1/10 of the pattern may be omitted. In another embodiment, the pattern may be applied only to one or more concentric annular zones of the abrasive article. In other embodiments, one or more of the series of abrasive regions, which typically appear along the individual arcs or spiral arms of the pattern, may be omitted. In an embodiment, all nth, or all nth, multiple may be omitted. In other embodiments, individual polishing regions, groups of polishing regions, or polishing regions according to a particular sequence may be omitted. Conversely, certain additional polishing areas may be included in the pattern. The addition or removal of polishing regions is regarded as an anomaly for the pattern, and a predetermined anomaly of the pattern, plus or minus, is acceptable. In an embodiment, the allowable pattern anomaly is 0.1% to 10% of the total polishing area for the abraded article.

Shape of polishing areas

The range is affected by the shape of the polishing regions. The shape of the abrasive regions may be regular or irregular. In an embodiment, the shape of the abrasive regions may be discrete lines, regular polygons, irregular polygons, ellipses, circles, arcs, spirals, vortices, gratings, or a combination thereof. In certain embodiments, the shape of the polishing regions is circular. In other embodiments, the abrasive region shape may be in the form of one or more lines, arcs, spirals, or vortices having the controlled non-uniform distribution described herein. One or more lines, arcs, spirals, or vortices may intersect multiple lines.

The polishing area is configured to allow sufficient swab removal regardless of the application of vacuum to the abrasive article back. In an embodiment, the abrasive region is in the form of a spiral or quadrilateral extending radially outwardly from the center of the abrasive article. The helical or quadrature lines are configured to create an open flow air flow channel between the polishing regions. In another embodiment, the polishing regions are formed similar to a helical grating. Openings are arranged in an open area surrounded by a grating. It is determined that swarf removal is facilitated by the presence of an open area in fluid communication with the outer edge of the abrasive article, or in fluid communication with the apertures in the abrasive article that is open to the vacuum source, or both. Such an abrasive area and an open area constituted to create an air flow path guide the swab and discharge it from the abrasive area by centrifugal force or directly into the vacuum system hole so that the abrasive area in front of the abrasive article and any open Thereby preventing the swelling of the fibrous layer, for example, the hook and the rope material layer.

In an embodiment, the abrasive area pattern is comprised of regular polygons, irregular polygons, ellipses, arcs, spirals, postcard patterns, or a combination thereof. The pattern of abrasive areas consists of radial arcs, radial spirals, or a combination thereof. The pattern of polishing areas consists of a combination of clockwise radial spirals and counterclockwise radial spirals. The abrasive regions are either separate or discontinuous. Alternatively, the at least one polishing region is fluidly coupled.

The number of radial arcs, radial spirals, or combinations thereof is variable. In embodiments, the number of radial arcs, radial spirals, or combinations thereof is no greater than 1000, such as no greater than 750, no greater than 500, no greater than 250, no greater than 100, no greater than 90, no greater than 80, In embodiments, the number of radial arcs, radial spirals, or combinations thereof is at least 2, such as at least 3, at least 5, at least 7, at least 9, at least 11, at least 15, In an embodiment, the number of radial arcs, radial spirals, or combinations thereof is 2 to 500, such as 2 to 100.

The width of the polishing regions is variable. The widths of the polishing regions are constant or variable, or a combination thereof. In an embodiment, the widths of the polishing regions are in the range of fixed lengths. In an embodiment, the widths of the polishing regions are from 0.1 mm to 10 cm. In another embodiment, the widths of the abrasive regions are associated with the desired size of the adjacent open region of the abrasive article. In embodiments, the widths of the abrasive regions may be at least one tenth of the size of the open area of the abrasive article, e.g., 1/8, 1/6, 1/5, 1/4, 1/3, Or more than 1/2. In embodiments, the widths of the abrasive regions may be less than 10 times the size of the coated abrasive article open area, e.g., less than 8 times, 6 times, 5 times, 4 times, 3 times, 2 times Or less. In an embodiment, the widths of the polishing regions are approximately equal to the size of the coating abrasive article open area.

In another embodiment, the polishing regions are configured and configured to produce a plurality of air flow paths disposed in a pattern. The air flow patterns include regular polygons, irregular polygons, ellipses, arcs, spirals, postcard patterns, or combinations thereof. The air flow paths pattern is comprised of radial curved paths, radial spiral paths, or a combination thereof. The air flow paths pattern consists of a combination of internal radial spiral paths and external radial spiral paths. The air flow patterns consist of a combination of clockwise radial spiral paths and counterclockwise radial spiral paths. The air channels are either separate or discontinuous. Alternatively, the one or more air channels are fluidly connected.

The number of radial curved paths (" arcs "), radial spiral paths, or combinations thereof is variable. In embodiments, the number of radial curved paths, radial helical paths, or combinations thereof is no greater than 1000, such as up to 750, up to 500, up to 250, up to 100, up to 90, up to 80, In embodiments, the number of radial curved paths, radial helical paths, or combinations thereof is at least 2, such as at least 3, at least 5, at least 7, at least 9, at least 11, at least 15, In an embodiment, the number of radial curved paths, radial helical paths, or combinations thereof is 2 to 500, such as 2 to 100.

The widths of the air channels are variable. The widths of the air flow paths are constant or variable, or a combination thereof. In an embodiment, the widths of the air channels are in the range of fixed lengths. In an embodiment, the width of the air channels is from 0.1 mm to 10 cm. In another embodiment, the width of the air channels is related to the size of the polishing areas of the coating abrasive. In embodiments, the width of the air channels is at least 1/10 of the size of the polishing areas of the coating abrasive, such as 1/8, 1/6, 1/5, 1/4, 1/3 , Or more than 1/2. In embodiments, the width of the air channels may be less than 10 times the size of the abrasive areas of the coating abrasive, such as less than 8 times, 6 times, 5 times, 4 times, 3 times, 2 times or less. In an embodiment, the width of the air flow paths is approximately equal to the size of the abrasive areas of the coating abrasive.

The air flow paths have one or more cavities, orifices, paths, holes, openings, or combinations thereof disposed along or within the air flow paths extending through the abrasive article body. In an embodiment, each air passage is disposed within the air passage with at least one hole extending through the polishing article body.

Abrasive article shape and structure

The abrasive article may be of any shape that accommodates the desired abrasive area pattern and is suitable for the polishing process and constituent material. In an embodiment, the abrasive article is a bonded abrasive article. In another embodiment, the abraded article is a coated abraded article. In certain embodiments, the abrasive article is one of a sheet, a belt, or a disc.

1 shows a top view of a coated abrasive article 100 in which a plurality of abrasive areas 101 are arranged in a pattern of non-uniform distribution, the pattern being a postcard spiral coincident with a Vogel model (commonly referred to as a 'sunflower' pattern) Pattern. The open areas 103 surround the abrasive areas. The coating abrasive is substantially planar (i.e., substantially flat) disc-shaped.

21 is a side view of the coated abrasive article 2100 and includes a support 2101 having a first major surface 2103 and a second major surface 2105. The polishing layer 2107 is laminated on the first main surface of the support. The abrasive layer is comprised of multiple layers and includes a binder layer 2109, also referred to as a make coat. A plurality of abrasive grains 2111 are dispersed, penetrated, or settled within the binder layer, or a combination thereof. A pattern of polishing areas 2113 is present on the surface of the support. One or more open regions 2115 are adjacent to the polishing regions. The size coat 2117 is selectively laminated on the binder layer. The super-size coat 2119 is optionally stacked on a size coat. The back coat 2121 is laminated to the second main surface (i.e., non-polishing side) of the support layer. The fastener layer 2123 is laminated to the backcoat or, alternatively, is directly laminated to the second major surface of the support. In certain embodiments, the coated abrasive article 2100 is optionally attached to a support pad (not shown) or a vacuum system (not shown).

Backing

The support may be flexible or rigid. The support is made of a variety of materials including a support commonly used in coating abrasives. Exemplary flexible supports include, but are not limited to, polymer films (e.g. prime treated films) such as polyolefin films (e.g., polypropylene including biaxially oriented polypropylene), polyester films (e.g., polyethylene terephthalate) Film, or cellulose ester film; Metal foil; Mesh; Foams (e. G., Natural sponge materials or polyurethane foams); Fabrics (for example, fabrics made of polyester, nylon, silk, cotton, poly-cotton or rayon, or yarns made of yarn); paper; Hardened paper; Vulcanized rubber; Cured fiber; Nonwoven materials; Combinations thereof; Or treating them. The fabric support may be knitted or stitched. As a specific example, the support is selected from the group consisting of paper, polymer film, cloth, cotton, polycotton, rayon, polyester, poly-nylon, vulcanized rubber, cured fiber, metal foil and combinations thereof. As another example, the support comprises a polypropylene film or a polyethylene terephthalate (PET) film.

The support optionally has at least one of a saturant, a presize layer or a backsize layer. The purpose of these layers is typically to seal the support or to protect the yarn or fibers of the support. If the support is a fabric material, typically at least one of these layers is used. Adding a free-sized layer or a back-sized layer can also provide a more "smooth" surface at the front or back of the support. Other optional layers known in the art may also be used (e.g., a tie layer; see U.S. Patent No. 5,700,302 (Stoetzel et al.), Incorporated herein by reference).

An antistatic agent may be included in the cloth material. With the addition of antistatic agents, the coated abrasive article can lower the electrostatic storage tendency when grinding wood or wood-like materials. Additional details relating to antistatic support and support treatments may be found, for example, in U.S. Patent No. 5,108,463 (Buchanan et al.), Which is incorporated herein by reference; 5,137,542 (Buchanan et al.); No. 5,328,716 (Buchanan); And 5,560,753 (Buchanan et al.).

The support is, for example, a fiber reinforced plastic as described in U.S. Patent No. 5,417,726 (Stout et al.), Which is incorporated herein by reference, or a non-spindle infinite belt as described, for example, in U.S. Patent No. 5,573,619 (Benedict et al. Similarly, the support is a polymeric substrate having a hooking stem as described, for example, in U.S. Patent No. 5,505,747 (Chesley et al.), Which is incorporated herein by reference. Similarly, the support is, for example, a loop fabric as described in U.S. Patent No. 5,565,011 (Follett et al.), Which is incorporated herein by reference.

Abrasive layer

The abrasive layer is formed of one or more coats and a plurality of abrasive particles. For example, the abrasive layer comprises a make coat and optionally a size coat or a super-size coat. The abrasive layers generally comprise abrasive particles that are laminated, buried, dispersed, or formed in combination in the binder or in the binder.

Abrasive particles

The abrasive particles include substantially single-phase inorganic materials such as alumina, silicon carbide, silica, ceria, and harder, high performance superabrasive particles such as cubic boron nitride and diamond. The abrasive particles may also comprise composite particulates. These materials include agglomerates which are formed by slurry treatment processes which volatilize or evaporate to remove the liquid carrier to leave green agglomerates and optionally subsequent high temperature treatment (i.e., firing) to form unstable fired agglomerates do. Further, the abrasive includes an engineering abrasive including macro-structure and specific three-dimensional structure.

In an exemplary embodiment, the abrasive particles are mixed with the binder formulation to form an abrasive slurry. Alternatively, abrasive particles are applied to the binder formulation after the binder formulation is applied to the support. Optionally, a functional powder is applied to the polishing regions such that the polishing regions do not adhere to the patterning tool. Alternatively, the patterns are formed in the polishing regions in the functional powder member.

The abrasive particles may be selected from the group consisting of silica, alumina (fused or sintered), zirconia, zirconia / alumina oxide, silicon carbide, garnet, diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide, titanium diboride, boron carbide, tin oxide, Titanium oxide, iron carbide, iron oxide, chromia, flint, and emery, or a combination thereof. For example, the abrasive particles may be formed of a material selected from the group consisting of silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, eutectic alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, . Certain embodiments using dense abrasive particles consisting predominantly of alpha-alumina are described.

The abrasive particles also have a specific shape. Examples of such shapes include rod-shaped, triangular, pyramidal, conical, solid spherical, hollow spherical, or the like. Alternatively, the abrasive particles may have a random shape.

In embodiments, the average particle size of the abrasive particles is less than 800 microns, such as less than about 700 microns, less than 500 microns, less than 200 microns, or less than 100 microns. In another embodiment, the abrasive particle size is at least 0.1 micron, at least 0.25 micron, or at least 0.5 micron. In another embodiment, the size of the abrasive particles is from about 0.1 micron to about 200 microns, and more typically from about 0.1 micron to about 150 microns or from about 1 micron to about 100 microns. The particle size of the abrasive particles is typically specified as the longest dimension of the abrasive particles. Generally, there is a range of particle size distribution. In some embodiments, the particle size distribution is tightly regulated.

Make coat - binder

The binder of the make coat or the size coat is formed of a homopolymer or a mixture of polymers. For example, the binder is formed of an epoxy, an acrylic polymer, or a combination thereof. Additionally, the binder includes a filler, such as a combination of a nano-sized filler or a nano-sized filler and a micron-sized filler. In certain embodiments, the binder is a colloidal binder and the formulation that is cured to form the binder comprises a particulate filler as a colloidal suspension. Alternatively, or in addition, the binder is a nanocomposite binder and comprises a particulate filler of 1 micron or less.

The binder generally comprises a polymeric base which bonds the abrasive particles to a support or, if present, a flexible coat. Typically, the binder is formed from a curable binder formulation. In one exemplary embodiment, the binder formulation comprises a polymer component and a dispersed phase.

The binder formulation includes one or more reactive components or polymeric components for making the polymer. Polymeric components include monomeric molecules, polymeric molecules, or combinations thereof. The binder formulation further comprises components selected from solvents, plasticizers, chain transfer agents, catalysts, stabilizers, dispersants, curing agents, reaction modifiers and dispersing flow control agents.

The polymeric components form a thermoplastic or thermoset polymer. For example, the polymeric components may be selected from the group consisting of polyurethanes, polyureas, polymeric epoxies, polyesters, polyimides, polysiloxanes (silicones), polymeric alkyds, styrene-butadiene rubbers, acrylonitrile-butadiene rubbers, polybutadiene- Resins, or reactive resins for the production of thermoset polymers in general. Other examples include acrylate or methacrylate polymer components. The precursor polymeric components are typically combined with a curable organic material (i. E., By exposure to polymeric monomers or heat or other energy sources such as electron beams, ultraviolet light, visible light or the like, or with the addition of other auxiliaries which cure or polymerize the chemical catalyst, Polymerizable or crosslinkable material). Examples of precursor polymeric components include amino polymers or aminoplast polymers such as alkylated urea-formaldehyde polymers and alkylated benzoguanamine-formaldehyde polymers; Acrylate polymers such as acrylate and methacrylate polymers, alkyl acrylates, acrylate epoxies, acrylate urethanes, acrylate polyesters, acrylate polyethers, vinyl ethers, acrylated oils, or acrylate silicon; Alkyd polymers such as urethane alkyd polymers; Polyester polymers; Reactive urethane polymers; Phenolic polymers such as resole and novolac polymers; Phenol / latex polymer; Epoxy polymers such as bisphenol epoxy polymers; Isocyanate; Isocyanurate; Polysiloxane polymers such as alkylalkoxy silane polymers; Or a reactive vinyl polymer forming reactive component. The binder formulation includes monomers, oligomers, polymers, or combinations thereof. In certain embodiments, the binder formulation comprises at least two types of polymeric monomers that crosslink when cured. For example, the binder formulation includes epoxy components and acrylic components that, when cured, form an epoxy / acrylic polymer.

Additives - grinding aid (Aid)

The abrasive layer also includes a grinding aid to increase the grinding efficiency and the cutting rate. Useful grinding aids include inorganic based, such as halogen salts, such as sodium cryolite, and potassium tetrafluoroborate; Or organic based, such as chlorinated waxes, such as polyvinyl chloride. Certain embodiments include cryolite and potassium tetrafluoroborate having a particle size of 1 micron to 80 microns, most typically 5 microns to 30 microns. The super-size coat is a polymer layer applied to abrasive particles to impart anti-glazing and anti-loading properties.

Back Coat - Flexible Coat

The coated abrasive article optionally includes a flexible and backcoat (not shown). These coats may perform the functions described above and may be formed of a binder composition.

Coated abrasive article manufacturing method

In a process for producing a coated abrasive article having an abrasive area pattern, the support is dispensed from a roll, and the support is applied with a binder formulation dispensed from the coating apparatus. An exemplary coating apparatus includes a drop die coater, a knife coater, a curtain coater, a vacuum die coater or a die coater. The coating method is contact type or non-contact type. Such methods include two rolls, three roll reversals, knife over rolls, slot die, gravure, rotary printing, extrusion or spray coating, or combinations thereof.

In an embodiment, the binder formulation is provided as a slurry including formulations and abrasive particles. In an alternative embodiment, the binder formulation is dispensed separately from the abrasive particles. The abrasive particles are provided after coating the support with a binder, after hardening the binder formulation part, after patterning the binder formulation, or after the binder formulation is fully cured, if possible. The abrasive particles are applied, for example, by electrostatic coating, drop coating, or mechanical projection.

In another embodiment, the support coated with the binder and abrasive particles may be formed in the form of a coating abrasive (i. E., A disc) or a pattern of apertures through the coating abrasive, if desired, by stamping, spinning, laser cutting, do. In another embodiment, the support is selectively coated with a binder to leave the uncoated areas and apply the abrasive particles thereto to form the abrasive areas. For example, the binder is printed on a support, for example, by screen printing, offset printing, or flexographic printing. In another embodiment, the binder is selectively applied with a gravure coating, a slot die coating, a mask spray coating, or the like. Alternatively, a photothermographic or UV curable mask is applied to the support through, for example, photolithography and development to block some of the support. In another embodiment, non-spin finish is applied to the support before application of the binder.

How to use - Workpiece polishing

In the workpiece polishing method, the workpiece is brought into contact with the coating abrasive. The coating abrasive is rotated relative to the workpiece. For example, a coating abrasive is mounted on an orbital sander and brought into contact with the workpiece. When the workpiece is polished, the polished material from the workpiece accumulates between the polishing regions or adjacent open regions. The accumulating material is discharged from the front side of the coating abrasive during transportation while using the coating abrasive. Alternatively, a vacuum system is provided on the abrasive article. The vacuum system includes support pads configured to interact with the abrasive article.

Support pads

It will be appreciated that the support pads corresponding to the coating abrasive having a controlled non-uniform abrasive particle distribution can be used successfully in combination with a conventional coating abrasive as well as a specific coating abrasive with controlled non-uniform polishing areas. The inventors have surprisingly found that applying the support pad embodiments can provide superior swab removal and improve abrasive performance with conventional abrasives.

In an embodiment, the support pad has a pattern of air flow paths that can be operated interlockingly in combination with a coating abrasive having a controlled non-uniform distribution pattern. As noted, these support pads are used in combination with conventional perforated coating abrasives to improve swarf removal and abrasive performance.

In an embodiment, the support pads include a pattern of air flow paths, and the pattern of air flow paths is created with the x and y coordinates of the controlled non-uniform distribution pattern. The controlled non-uniform distribution pattern used to create the support pad air flow pattern may be the same as or different from the coating abrasive pattern used with the support pad. In an embodiment, the controlled non-uniform distribution pattern is the same as the coating abrasive pattern used with the support pads. In another embodiment, the controlled non-uniform distribution pattern is different from the coating abrasive pattern used with the support pads.

In an embodiment, the support pad is interlocked in combination with a coating abrasive having postcard patterns by the coating abrasive embodiments described herein. The support pad is combined with a coating abrasive having postcard patterns, and the support pad comprises a plurality of openings, a plurality of cavities, a plurality of channels, a plurality of paths, or a combination thereof, Is formed in a pattern that is configured to facilitate suction and sweep removal from the workpiece surface during polishing through the apertures of the abrasive article. The openings, cavities, channels, paths, or combinations thereof, form air channels, which are disposed in or through the support pads, or a combination thereof. The air channels facilitate suction and swab removal through the coating abrasive openings from the workpiece surface during the polishing process. In an embodiment, the apertures pattern, cavities, channels, paths, or combinations thereof may be in the form of regular polygons, irregular polygons, ellipses, arcs, spirals, postcard patterns, or combinations thereof . In another embodiment, the air channels can be in the form of regular polygons, irregular polygons, ellipses, arcs, spirals, postcard patterns, or a combination thereof.

Patterns to form radial curvature and helical channels as well as annular channels that intersect the curved and spiral channels, or a combination thereof. Annular, curved, helical, or combinatorial channels are cut into a suitable material in the form of, for example, grooves, cavities, orifices, paths, or other paths to form a combined support pad.

In certain embodiments, the air channels of the support pad are partially, completely, coincident with the coating abrasive openings. It is to be understood that the air flow path coincides with the opening when at least a portion of the opening area coincides with or is aligned with a part of the air flow path. In an embodiment, the air channels of the corresponding support pad correspond to openings of at least 5%, at least 10%, at least 15%, at least 20%, at least 25%. In embodiments, the air channels of the corresponding support pad may comprise at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 55% , At least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 100% of the coating abrasive openings.

It should be understood that certain support pad spiral and postcard air flow patterns exhibit a certain degree of alignment with the opening pattern of the coating abrasive, particularly when the air flow path pattern is based on transposition and rotation of the abrasive areas coordinates of the coating abrasive. In an embodiment, the air flow pattern of the support pad coincides with most nearly all of the coating abrasive openings when the support pad is in a particular phase, or rotation, relative to the coating abrasive. When the support pad air flow paths coincide with the coating abrasive openings, the support pad rotates 90 or 180 degrees compared to the coating abrasive and when almost all of the coating abrasive openings coincide with at least one air flow paths of the support pad, Is called a single-alignment (also called a so-called two-stage alignment) support pad.

In an embodiment, the support pad may be configured to include or include an alignment indicator. The alignment indicator may be indicia, a tool, a notch, an attachment, a collar, a projection, or a combination thereof, indicative of a support pad alignment with the coating abrasive. In certain embodiments, the alignment indicator may be marking.

While the embodiments of the abrasive articles described herein are described in combination, such support pads may also be used with standard standard perforated coating abrasives. Support pads having multiple openings, multiple cavities, multiple channels, or a combination thereof that form unexpectedly helix or postcard pattern air channels can improve the swarf removal rate, improve abrasive cutting performance, Coating abrasive, and coating abrasive having both postcard boring patterns.

The support pad may be flexible or rigid. The support pads may be made of any of a variety of materials, including those used in making conventional support pads, or a combination of materials. The support pads may be fabricated from a single piece, an integral assembly, or a multi-piece assembly, such as a multi-layer assembly or a co-extrusion assembly. The support pad is preferably an elastic material such as a flexible foam. Suitable foams include polyurethanes, polyesters, polyester-urethanes, polyetherurethanes; Natural or synthetic rubbers such as polybutadiene, polyisoprene, EPDM polymers, polyvinyl chloride (PVC), polychloroprene, or styrene / butadiene copolymers; Or a combination thereof. Foaming may be an open or closed cell. Additives, such as binders, reinforcing agents, hardeners, antioxidants, reinforcing materials, and the like, are added to the foam formulation to achieve the desired properties. Dyes, pigments, fillers, antistatic agents, flame retardants, and scrims are also added to the foam or other resilient material to form support pads.

Particularly useful foams include TDI (toluene diisocyanate) / polyester and MDI (methylenediphenyl diisocyanate) / polyester foams. In an embodiment, the support pads are made of an elastic, developed cell polyurethane foam, which is formed from the reaction product of a polyether polyol and an aromatic polyisocyanate. In other embodiments, the support pads can be foam, vulcanized rubber, or any combination thereof.

It is to be understood that not all of the acts described above in the broad description or embodiments are required, that some of the specific acts may not be required, and that one or more other acts may be practiced in addition to those described. In addition, the order in which the actions are listed does not have to be the order in which they are executed.

In the foregoing specification, the concepts have been described with reference to specific embodiments. However, those of ordinary skill in the art will recognize that various modifications and variations are possible without departing from the scope of the present invention as set forth in the following claims. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention.

As used herein, the terms "comprises", "comprising", "includes", "including", "has", "having" Any other variation of these is intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features need not necessarily be limited to such features, It should be understood that the phrase "or" is used in an inclusive sense to refer to a "or" in an inclusive sense, For example, condition A or B is satisfied by any of the following: A is true (or exists), B is false (or does not exist), and A False (or nonexistent) B is True (or present), and both A and B are true (or present).

Also, "a" or "an" is used to describe the elements and components described herein. This is done merely for convenience and to give the general meaning of the scope of the present invention. This description should be read to include one or at least one, and the singular also includes the plural unless it is expressly meant to mean differently.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, it is to be understood that advantages (s), advantages, solutions to problems, and any feature (s) that may cause or may cause any benefit, advantage, , Nor should it be interpreted as a required or essential feature.

After reading the specification, skilled artisans will appreciate that any feature described herein in connection with each of the embodiments for clarity may also be provided in combination in a single embodiment. Conversely, various features described in connection with a single embodiment for brevity may also be provided separately or in any subcombination. Also, reference to values described in ranges includes each value and all values within this range. When the term " about "or" approximately " precedes this number, for example, when describing a numerical range, the exact numerical value is also included. For example, a numerical range beginning with "about 25 " also includes a range beginning exactly 25.

Item 1. A polishing article comprising a coating abrasive comprising a plurality of abrasive regions arranged in a pattern having a controlled non-uniform distribution, the pattern comprising a radiation pattern, a spiral pattern, a postcard pattern, an asymmetric pattern, At least one abrasive article.

Item 2. The abrasive article according to item 1, wherein the pattern is a spiral pattern.

Item 3. In the second item, the helical pattern is one of an Archimedes spiral, an Euler spiral, a Fermat spiral, a hyperbolic spiral, a lithus, an algebraic spiral, a Fibonacci spiral, a golden spiral, or a combination thereof.

Item 4. In the third item, the pattern has a controlled asymmetry.

Item 5. The article of item 4, wherein the adjusted asymmetry is at least partially rotationally asymmetric around the pattern center.

Item 6. The article of item 5, wherein the rotational asymmetry extends to at least 51%, at least 70%, or at least 85% of the patterned areas of the pattern.

Item 7. The article of 5, wherein the rotational asymmetry extends at least 20 of the abrasive areas of the pattern, at least 50 of the abrasive areas, or at least 100 of the abrasive areas.

Item 8. The article of item 5, wherein the pattern is rotationally asymmetric about the center of the pattern.

Item 9. The abrasive article of item 1, wherein the pattern is a postcard pattern.

Item 10. The article of item 9, wherein the pattern is a spiral postcard pattern.

Item 11. The method of item 10, wherein the pattern has a plurality of clockwise spirals and a plurality of counterclockwise spirals, the number of clockwise spirals and the number of counterclockwise spirals is a Fibonacci number or a multiple of the Fibonacci number, article.

Item 12. The article of item 11, wherein the number of clockwise spirals and the number of counterclockwise spirals is a number of LUCAS or a multiple of LUCAS.

Item 13. The article of item 11, wherein the number of clockwise spirals and the number of counterclockwise spirals converge to a golden ratio.

Item 14. The article of Paragraph 10, wherein the spiral postcard pattern has a controlled asymmetry.

Item 15. The article of item 10, wherein the screw postcard pattern is a sunflower pattern.

Item 16. The article of item 11, wherein the pattern is described in polar coordinates by an equation.

(식 1)

(Equation 1)

Where:

n is the order of the polishing area when counting from the center of the pattern to the outward;

Phi is the angle between the position vector of the n-th abrasive area in the reference direction and the polar coordinate system starting at the pattern center, so that the divergence angle between the position vectors of any two consecutive abrasive areas is a constant angle alpha;

r is the distance from the center of the pattern to the center of the n-th polishing region;

c is a constant conversion factor.

Item 17. The article of Paragraph 16, wherein at least about 51%, at least about 70%, and at least about 85% of the abrasive areas conform to Formula 1.

Item 18. The article of Paragraph 16, wherein the pattern has a divergence angle from about 100 DEG to about 170 DEG in polar coordinates.

Item 19. The article of Paragraph 16, wherein the pattern has a divergence angle of 137.508 degrees.

Item 20. The article of Paragraph 16, wherein the total abrasive area of at least about 80%, at least about 85%, at least about 90%, is according to Formula 1.

Item 21. The article of Paragraph 16, wherein the range of the plurality of polishing regions is from about 5/10/20 polishing regions to about 500/1000/10 thousand polishing regions.

Item 22. The article of Paragraph 16, wherein the pattern substantially covers the entire front surface of the article to be polished.

Item 23. The article of Paragraph 16, wherein the edge of the outermost abrasive region of the pattern intersects the edge of the abrasive article.

Item 24. The article of Paragraph 16, wherein the edge of the outermost abrasive region of the pattern is at least a specific distance from the edge of the abrasive article.

Item 25. The article of Paragraph 16, wherein the pattern covers only a part of the front surface of the article to be polished.

Item 26. The article of Paragraph 16, wherein the pattern covers a repetitive portion of the front surface of the article to be polished.

Item 27. The abrasive article of Item 16, wherein the total open area of the pattern is from about 15% to about 99.5% of the potential surface area of the abrasive article.

Item 28. The abrasive article of Item 16, wherein the polishing total surface area is from about 4.5% to about 85% of the total potential surface area.

Item 29. The abrasive article of Item 16, wherein the article has a disc shape.

Item 30. The method of item 16, wherein the shape of the abrasive regions is selected from one of a single line region, polygons, ellipses, circles, arcs, spirals, vortices, spiral gratings, .

Item 31. A coated abrasive article,

A support layer having a first major surface and a second major surface; And

And an abrasive layer stacked on the first major surface of the support layer,

Wherein the polishing layer comprises a plurality of polishing regions arranged in a pattern having a controlled non-uniform distribution, the pattern being at least one of a radiation pattern, a spiral pattern, a postcard pattern, an asymmetric pattern, or a combination thereof.

Item 32. A method for manufacturing an abrasive article,

Laminating an abrasive layer on a support,

Wherein the polishing layer comprises a plurality of polishing regions arranged in a pattern having a controlled non-uniform distribution, wherein the pattern is at least one of a radiation pattern, a spiral pattern, a postcard pattern, an asymmetric pattern, or a combination thereof.

Item 33. A coated abrasive article, comprising: a plurality of abrasive areas stacked on a major surface of a coated abrasive article, the abrasive areas configured to form a plurality of air flow paths, the air flow path including arcs, spirals, whorls, postcard patterns, or a combination thereof.

Item 34. The coated abrasive article of Item 34, wherein the air flow patterns are comprised of radial curved paths, radial spiral paths, or a combination thereof.

Item 35. The coated abrasive article of Item 34, wherein the air flow patterns are comprised of a combination of internal radial spiral paths and external radial spiral paths.

Item 36. The coated abrasive article of Item 34, wherein the air flow patterns are composed of a combination of clockwise radial spiral paths and counterclockwise radial spiral paths.

Item 37. The coated abrasive article of Item 34, wherein the pattern of air flow paths further comprises an annular air flow passage intersecting radial curved paths or radial spiral paths, or a combination thereof.

Item 38. A coated abrasive article, comprising: a pattern of air flow paths, the pattern of air flow paths being generated from x and y coordinates of a controlled non-uniform distribution pattern.

Item 39. The method according to item 38, wherein the x and y coordinates of the adjusted non-uniform distribution pattern are transposed and rotated according to equation (2) to determine the x ' and y ' coordinates of the air flow patterns, / n, where n is an arbitrary integer.

식 (2)

Equation (2)

Item 40. The coated abrasive article of Item 39, wherein the controlled non-uniform distribution pattern is a postcard pattern.

Item 41. The coated abrasive article of Item 40, wherein the controlled non-uniform distribution pattern is Vogel's equation.

Item 42. The coated abrasive article of Item 41, wherein n is an arbitrary integer of 1 to 10.

Item 43. The coated abrasive article of Item 42, wherein n is 1, 2, 3, 4, 5, or 6.

Item 44. The coated abrasive article of Item 39, wherein the air flow patterns are comprised of a plurality of openings, cavities, channels, paths, or a combination thereof.

Item 45. A polishing system comprising:

Coating abrasive; And

Comprising a support pad,

Wherein the coating abrasive is constituted by a distribution pattern of controlled nonuniform polishing areas,

Wherein the support pad comprises a plurality of air channels arranged in a pattern configured to coincide with the abrasive areas of the coating abrasive.

Claims (45)

In a polishing article,
A coating abrasive comprising a plurality of abrasive areas and adjacent open areas arranged in a pattern having a controlled non-uniform distribution, the pattern being a spiral postcard pattern, the pattern comprising a plurality of clockwise spirals and a plurality of counter- , The number of clockwise spirals and the number of counterclockwise spirals is a Fibonacci number or a multiple of the Fibonacci number,
The pattern is described in polar coordinates by the following equation,

(Equation 1)
In the above equation,
n is the order number of the polishing region counted outward from the center of the pattern,

Is the angle between the position vector of the n-th abrasive region in the reference direction and the polar coordinate system starting at the pattern center, so that the divergence angle between the position vectors of any two consecutive abrasive regions is a certain angle a,
r is the distance from the center of the pattern to the center of the n-th polishing region,
c is a constant conversion factor,
The pattern has divergent angles ranging from 100 ° to 170 ° in polar coordinates,
The total open area of the pattern is 65% to 99.5% of the total potential surface area of the abrasive article,
Each of the abrasive regions having a width of at least 1/10 and no more than 10 times the size of adjacent open regions of the abrasive article,
Each of the polishing regions having a width ranging from 0.1 mm to 10 cm. The abrasive article of claim 1, wherein at least 51% of the abrasive areas conform to formula (1). delete 8. The abrasive article of claim 1, wherein the pattern has a divergence angle of 137.508 degrees. The abrasive article of claim 1, wherein at least 80% of the total abrasive area follows equation (1). The abrasive article of claim 1, wherein the range of the plurality of abrasive areas is from 5 to 10,000 abrasive areas. The abrasive article of claim 1, wherein the pattern covers the entire front surface of the abrasive article. The abrasive article of claim 1 wherein the edge of the outermost abrasive region of the pattern intersects the edge of the abrasive article. The abrasive article of claim 1 wherein the edge of the outermost abrasive region of the pattern is at least a specific distance from the edge of the abrasive article. The abrasive article of claim 1, wherein the pattern covers only a portion of the front surface of the abrasive article. delete The abrasive article of claim 1, wherein the total open area of the pattern is between 80% and 95.5% of the total potential surface area of the abraded article. The abrasive article of claim 1, wherein the polishing total surface area is between 4.5% and 35% of the total potential surface area. The abrasive article of claim 1, having a disc shape. The method of claim 1, wherein the shape of the polishing regions is selected from one of a short line region, polygons, ellipses, circles, arcs, spirals, vortices, spiral gratings, article. delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete

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