TW201500148A - Coated abrasive article based on a sunflower pattern - Google Patents

Abstract

An abrasive article having a plurality of abrasive areas arranged in a non-uniform distribution pattern, wherein the pattern is spiral or phyllotactic, such as a spiral lattice, and in particular those patterns described by the Vogel model, such as a sunflower pattern.

Description

Abrasive article with a coating of sunflower pattern

The present invention relates generally to abrasives, and more particularly to abrasive articles having a coating having abrasive regions that are discrete, continuous, semi-continuous, and combinations thereof, depending on the pattern of the sunflower. set.

Abrasive articles, such as coated abrasive articles, are used in a variety of industries to polish workpieces by hand or mechanical processes, such as by lapping, grinding, or polishing. The use of abrasive products spans a wide range of industries and consumer applications, from the optical industry, the automotive refinish industry, and the metal manufacturing industry to construction and carpentry. Processing, for example, by hand or using commonly used tools such as track polishers (random and fixed shafts), and belt and vibratory sanders, is often used by consumers in the home. In each case, the abrasive is the material used to remove the surface and affect the surface characteristics of the ground surface (eg, flatness, surface roughness, gloss). In addition, various types of automated processing systems have been developed to process abrasive articles of various compositions and configurations.

Surface characteristics include, but are not limited to, gloss, texture, gloss, surface roughness, and uniformity. In particular, surface characteristics, such as roughness and gloss, can be measured to determine quality. For example, when painting or painting a surface, some imperfections or surface defects of the surface may occur during application or curing. Such surface imperfections or surface defects may include defects such as pitting, "orange peel" texture, "fisheye", or enveloped bubbles and dust. Typically, such defects in the painted surface can be removed, first by sanding with coarse abrasives, followed by sanding with a tapered abrasive, and even with wool or foam pads until the desired smoothness is achieved. degree. Therefore, the properties of the abrasive article used generally affect the surface quality.

In addition to surface characteristics, the cost of grinding operations is important to the industry. Factors that affect the cost of operation include the speed at which the surface is prepared and the cost of the materials used to make the surface. Under normal circumstances, the industry seeks cost-effective materials with high material removal rates.

However, abrasives with higher removal rates tend to exhibit poor performance in achieving desired surface characteristics. Conversely, abrasives that produce desirable surface characteristics typically have lower material removal rates. For this reason, the preparation of the surface is generally a multi-step process using various grades of abrasive paper. Typically, surface imperfections (such as scratches) introduced by a single step can be repaired (e.g., removed) using abrasives of tapered particles in one or more subsequent steps. Thus, the introduction of scratches and surface imperfections can result in an increase in time, effort, and material cost, and overall processing cost in subsequent processing steps.

Another factor affecting material removal rate and surface quality is the "load" of "chips", that is, materials that are worn from the surface of the workpiece, which tend to accumulate on the surface of the abrasive particles and accumulate between the abrasive particles. The load is undesirable because it generally reduces the effectiveness of the abrasive product and increases the likelihood of scratching defects with a negative impact on surface characteristics.

Various efforts have been made to reduce the accumulation of chips, such as the introduction of fluid onto the surface of the workpiece to wash away the chips, and the application of the vacuum system to carry it away as the chips are produced, but still require cost-effective improvements, grinding Products, processes, and systems to promote effective grinding and improved surface properties.

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In one embodiment, an abrasive article comprising a coated abrasive having a plurality of abrasive regions arranged in a controlled non-uniformly distributed pattern. The pattern can be any pattern having a controlled non-uniform distribution, including a radial pattern, a spiral pattern, a leaf pattern, an asymmetric pattern, or a combination thereof. An example of a combined pattern is a spiral lattice pattern. The pattern may be partially, substantially, or completely asymmetrical. The pattern may cover (ie, may be distributed over) the entire abrasive article, may cover substantially the entire abrasive article (ie, greater than 50% but less than 100%), may cover portions of the abrasive article, or may only cover the abrasive Part of the product.

A controlled "non-uniform distribution" means that the pattern has a controlled asymmetry (ie, controlled randomness) such that although the distribution of the abrasive regions can be described by a formula, or predicted by a formula, for example The pattern can still exhibit at least partial to complete asymmetry in a radial, spiral, or leaf-like formula.

The controlled asymmetry can be a controlled reflection asymmetry (also known as mirror symmetry, line symmetry, and bilateral symmetry), controlled rotational asymmetry, controlled translational symmetry, controlled slippage Reflective symmetry, or a combination thereof. An example of a non-uniform distribution may prove to have a first-order rotational symmetry for a radial, spiral, or phyllotactic pattern, which means that the pattern has no rotational symmetry because the pattern rotates around its center At 360 °, the pattern repeats itself only once. In other words, if two copies of exactly the same pattern are placed directly on each other, one copy remains the same, and the second copy rotates 360 degrees around its center, then two copies are rotated at 360° All of the abrasive areas will be aligned only once.

Under normal circumstances, all abrasive regions of a pattern (i.e., the entire pattern) will have a controlled asymmetry. However, it is contemplated that the pattern according to the present embodiment also includes such a pattern that only a portion (i.e., a portion of the pattern) of the total number of abrasive regions of the pattern has a controlled asymmetry. For example, a portion of the uniformly distributed pattern or a completely random pattern may be combined or replaced in a pattern having a controlled non-uniform distribution such that only a portion of the resulting region of the resulting pattern has a controlled non- Uniform distribution, such as a controlled non-uniform distribution. The portion of the total abrasive region that has a controlled non-uniform distribution can be quantified as a discrete number, or as a fraction, a percentage, or a ratio of the total number of abrasive regions of the pattern. In one embodiment, 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% of the abrasive region of the pattern , at least 97%, at least 98%, at least 99%, at least 99.5%, and at least 99.9% have controlled asymmetry. The portion of the abrasive region having a controlled asymmetric pattern may be within the range of the aforementioned upper and lower limits including any pair. In a particular embodiment, from about 50% to about 99.9%, from about 60% to about 99.5%, from about 75% to about 99% of the pattern has a controlled non-uniform distribution.

In another embodiment, the pattern has a controlled asymmetry of 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 zones. In another embodiment, the pattern has a controlled asymmetry of no greater than about 100,000 abrasive regions, no greater than about 10,000 abrasive regions, no greater than about 5,000 abrasive regions, no greater than about 2,500 abrasive regions, and no greater than about 1,000 An abrasive region, no greater than about 750 abrasive regions, or no greater than about 500 abrasive regions. The number of abrasive regions having a controlled asymmetry may range from any of the aforementioned upper and lower limits.

As described above, the pattern in the present embodiment may have a controlled non-uniform distribution including a radial pattern, a spiral pattern, a leaf pattern, an asymmetrical pattern, or a combination thereof. An example of a combined pattern is a spiral lattice pattern. It can be recognized that the spiral lattice pattern can be classified into a radial pattern, a spiral pattern, a leaf pattern, and an asymmetrical pattern. The radial pattern may be any pattern that radiates from a central point to the periphery, such as from the spokes of the wheel hub.

In one embodiment, the spiral pattern can be any curve, or a set of curves that diverge from the center point of the abrasive article and extend away from the center point around which it surrounds. The center point can be located at or near the center of the abrasive article, or away from the center of the abrasive article. There can be a single helix or multiple helices (ie, multiple helices). The helix may be discrete or continuous, separate or connected. Individual spirals can be diverged from different central points (ie, each spiral has its own central point), or it can be diverged from a common central point (ie, each spiral shares a central point), or they The combination. The spiral pattern may include: an Archimedean spiral; an Euler spiral, a Cornu spiral, or a clothoid; a Fermat spiral; a hyperbolic spiral; Lituus); logarithmic spiral; Fibonacci spiral; golden spiral; or a combination thereof.

In one embodiment, the pattern may be a leaf pattern. As used herein, "leaf pattern" refers to a pattern associated with the ordering of leaves. Leaf order is the arrangement of leaves, flowers, scales, florets and seeds of lateral organs such as many plants. Many leaf-sequence patterns have naturally occurring patterns such as arcs, spirals, and turns. The pattern of the seeds of the sunflower head is an example of this phenomenon. As shown in Figures 3 and 4, multiple arcs or spirals, also known as parasitic lines, can have their own origin at a central point (C) and progress outward, while other spirals Then fill the gap left by the inner spiral. Please refer to Jean's Phyllotaxis A Systemic Study in Plant Morphogenesis at p. 17. In the usual case, the arrangement of the spiral pattern can be seen as radiating outward in the clockwise and counterclockwise directions. As shown in Figure 4, these types of patterns have opposite diagonal line pairs, which can be represented by (m, n), where m is a spiral or arc that is radiated from the center point in a clockwise direction. The value, and n is the value of the spiral or arc radiated counterclockwise. Furthermore, the angle between the two consecutive spirals or arcs at the center is called the divergence angle "d". Surprisingly, the inventors have discovered that a leaf pattern can be used to create new patterns of abrasive articles, particularly abrasive articles having a coating.

In one embodiment, the pattern has a number of clockwise spirals and a number of counterclockwise spirals, wherein the number of clockwise spirals and the number of counterclockwise spirals are Fibonacci numbers or Fibonacci ( Fibonacci) A multiple of the number. In a particular embodiment, the numbers of the clockwise and counterclockwise spirals become a pair (m, n): (3, 5), (5, 8), (8, 13), (13, 21), (21 , 34), (34, 55), (55, 89), (89, 144) or a multiple of the pair of numbers. In another embodiment, the number of clockwise spirals and the number of counterclockwise spirals are Lucas numbers, or multiples of Lucas numbers. In a particular embodiment, the numbers of the clockwise and counterclockwise spirals become a pair of (m,n): (3,4), (4,7), (7,11), (11,18), ( 18, 29), (29, 47), (47, 76) or (76,123), or a multiple of these pairs of numbers. In another embodiment, the ratio of the number of the clockwise spiral to the number of the counterclockwise spiral converges to a numerical ratio of the golden ratio, wherein the golden ratio is equal to 1 plus the square root of 5 divided by two, (1+ Ö5)/2, approximately equal to 1.6180339887. In a particular embodiment, the ratio of the clockwise helix to the counterclockwise helix is approximately equal to the golden ratio.

As already mentioned above, the seeds of sunflower plants observed in nature are arranged in a spiral leaf pattern. In one embodiment, the pattern is a sunflower pattern.

The sunflower pattern has been described by the Vogel model, which is a type of "Fibonacci spiral" or "spiral" in which the divergence angle between successive points is A fixed Fibonacci angle that is close to the golden angle and equals 137.508 °.

Figures 6 and 7 show the Vogel model, which is: φ = n ∗a, r = c√n (Formula 1) where: n is the sequence number of the florets, counting from the center outward; φ In the polar coordinate system, the angle between the reference direction and the position vector of the nth florets from the center of the inflorescence, so that the angle between the divergence angle a and the position vectors of any two consecutive florets remains fixed. For the sunflower pattern, it is 137.508 ^° ; r is the distance between the center of the inflorescence and the center of the nth floret; and c is a constant scale factor.

In one embodiment, the pattern is described by a variant of the Vogel model or the Vogel model. In a particular embodiment, the pattern is described by a Vogel model, where: n is the sequential number of abrasive regions, counting outward from the center of the pattern; φ is the reference direction and the nth in the polar coordinate system The angle between the position vectors of the abrasive region from the center of the pattern such that the divergence angle between the position vectors of any two consecutive abrasive regions is a constant angle a; r is from the center of the pattern to the center of the nth abrasive region Distance; and c is a constant scale factor.

As noted above, all, or substantially all, or a portion of the abrasive regions of the pattern are described in a Vogel model (ie, in accordance with Vogel's model). In one embodiment, all of the abrasive regions of the pattern are described by the Vogel model. In another embodiment, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, at least 99% of the abrasive region is described by a Vogel model.

In another embodiment, a suitable spiral or leaf pattern may be generated from the x and y coordinates of any of the leaf pattern, such as a Vogel model, or other suitable pattern with a controlled non-uniform distribution. , including radial patterns, spiral patterns, leaf pattern patterns, asymmetric patterns, or combinations thereof. In one embodiment, the x and y coordinates of the spiral or lobed pattern are transposed and rotated according to the following formula to obtain the x' and y' coordinates of the spiral or phyllotype pattern, where q is equal to p /n radians, and n is an arbitrary integer: éx' ù écosq - sin qù éxù (Equation 2) = ë y' û ë sin q cosqû ëyû The coordinates (x' and y') obtained by transposition and rotation can be Drawing, for example using a computer aided drawing (CAD) software, to produce a spiral or leaf pattern. A specific embodiment of the transposed leaf pattern is shown in Fig. 16, which is the transposition of the leaf pattern of Fig. 15; and Fig. 19 is the transposition of the leaf pattern of Fig. 18.

The inventors have surprisingly discovered that the leaf pattern can be used to create new patterns that enhance the performance of the abrasive article, including fixed abrasive articles such as bonded abrasive articles and coated abrasive articles. In particular, the leaf pattern can be used to create a pattern of new abrasive areas of the coated abrasive article. The leaf pattern helps solve competitive problems, achieving high removal rates of surface materials while still having acceptable surface quality, reducing the amount of chips on the abrasive surface, and maintaining high durability, and long abrasive use. life. To some extent, at least the following aspects are surprising. First, the leaf pattern of the embodiment of the present invention unexpectedly improves the chip removal coverage compared to the prior art abrasive pattern, even in the case where the total polishing area of ​​the embodiment of the present invention is smaller than the total polishing area of ​​the prior art. And having a more fully mixed distribution of chip extraction locations (eg, empty regions, channels, and/or channels) and abrasive regions on the surface of the abrasive (eg, individual grinding points as described and illustrated herein, elongated nodes, Semi-continuous arcs, vortices, spirals, and combinations thereof). Secondly, the leaf-sequence pattern of the embodiment of the present invention is unexpectedly provided, compared to the prior art abrasive pattern, whether or not vacuum is utilized, even in the case where the total abrasive area of ​​the embodiment of the present invention is smaller than the total abrasive area of ​​the prior art. Excellent abrasive performance (for example, cutting of accumulated material) at least comparable. Third, as discussed in more detail in later applications, the effectiveness and performance of this embodiment can be further enhanced with pairing with cooperating support pads and vacuum systems.

It will be appreciated that important factors for the design of the coated abrasive article include the percentage of total abrasive surface area, the ratio of total abrasive surface area to empty area, when the abrasive article is used (eg, track sander Rotational motion, oscillating motion of sheet sander, continuous lateral movement of belt sander), extensive coverage of abrasive area and predicted position, scale factor, number of abrasive areas, divergence angle between abrasive areas The size and shape of the abrasive region, the distance between adjacent abrasive regions, and the distance between the outermost abrasive region and the edge of the coated abrasive article. Grinding disc size

Abrasive discs, which are commonly used by industrial and commercial consumers, come in a variety of sizes and are typically less than one inch to foot in diameter. This pattern is suitable for abrasive discs of almost any size, including various standard size grinding discs (eg, 3" to 20"). In one embodiment, the abrasive article is a disk having 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 disk having a diameter of no greater than about 72 inches, no greater than about 60 inches, no greater than about 48 inches, no greater than about 36 inches, no greater than about 24 inches, and no greater than about 20 Inches, no greater than about 18 inches, no greater than about 12 inches, no greater than about 10 inches, no greater than about 9 inches, no greater than about 8 inches, no greater than about 7 inches, or no greater than about 6 inches. In another embodiment, the abrasive article has a diameter ranging from about 0.5 inches to about 48 inches, from about 1.0 inches to about 20 inches, and from about 1.5 inches to about 12 inches. Total potential surface area

The size and shape of the abrasive article determines the overall potential surface area of the abrasive article. For example, a 1 inch diameter abrasive disk has a total potential surface area of 0.7854 square inches. As another example, a 2 inch by 3 inch rectangular abrasive sheet will have a total potential surface area of 6 square inches. Total empty area

The total empty area affects the amount of chip extraction. Typically, as the area of the void increases, the amount of chip extraction also increases, thereby facilitating maintenance, or sometimes increasing the material removal rate (i.e., "cutting" rate) of the abrasive article during use. However, increasing the amount of empty area also reduces the amount of directly available abrasive area, which reduces the rate of material removal at a certain critical point. In one embodiment, the total empty area is equal to the sum of the areas of all empty areas of the surface of the abrasive article. In other words, the total empty area is equal to the total potential surface area of the abrasive article minus the total abrasive area (ie, the sum of all abrasive areas). Thus, the amount of total empty area can range from about 15% to about 95.5% of the total potential surface area, depending on the amount of abrasive area desired. In one embodiment, the total empty 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 40% of the total potential surface area. 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 empty area is no greater than about 95.5%, no greater than about 95%, no greater than about 94.5%, no greater than about 94%, no greater than about 93.5%, no greater than about 93%, no greater than About 92.5%, no more than about 92%, no more than about 91.5%, no more than about 91%, no more than about 90.5%, or no more than about 90%. The amount of total empty area may be within the range of any of the aforementioned upper and lower limits. In another embodiment, the total empty area is 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 empty area can be thought of as a discrete quantity, not a percentage. For example, a five-inch abrasive disc can have a total empty area ranging from about 2.95 square inches to about 18.75 square inches. Total surface area of the abrasive

The total surface area of ​​the abrasive affects the amount of surface material removed. Typically, the amount of surface area of ​​the total abrasive increases and the amount of surface material removed increases. Moreover, typically, as the amount of surface material removed increases, the accumulation of chips and surface roughness also increase. In one embodiment, the total abrasive surface area of ​​the coated abrasive is equal to the total potential surface area of ​​the abrasive article (ie, the surface area of ​​the abrasive, if there are no holes) minus the total empty area (ie, all The sum of the empty areas). Thus, the amount of surface area of ​​the total abrasive can range from about 4.5% to about 85% of the total potential surface area, depending on the amount of empty area desired. In one embodiment, the total abrasive surface area may be 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% of the total potential surface area, At least about 8%, at least about 8.5%, at least about 9%, at least about 9.5%, or at least about 10%. In another embodiment, the total abrasive surface area may be no greater than about 85%, no greater than about 80%, no greater than about 60%, no greater than about 75%, no greater than about 70% of the total potential surface area. , not more than about 65%, not more than about 55%, not more than about 50%, not more than about 45%, not more than about 40%, not more than about 35%, not more than about 30%, not more than about 25%, or Not more than about 20%. The surface area of ​​the total abrasive can be in the range of any of the aforementioned upper and lower limits. In another embodiment, the total abrasive surface area ranges 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 abrasive surface area can be thought of as a discrete amount rather than a percentage. For example, a 5-inch abrasive disc can have a total abrasive surface area ranging from about 0.88 square inches to about 16.69 square inches. Ratio of total abrasive surface area to total empty area

In one embodiment, the ratio of the total abrasive surface area to the total empty 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 abrasive surface area to the total empty area is no greater than about 1:0.05, no greater than about 1:0.1, no greater than about 1:0.2, no greater than about 1:0.3, no. Greater than about 1:0.4, no greater than about 1:0.5, no greater than about 1:0.6, no greater than about 1:0.7, no greater than about 1:0.8, no greater than about 1:0.9, or no greater than about 1:1. The ratio of the total abrasive surface area to the total empty area can be within any of the aforementioned upper and lower limits. Number of abrasive areas

The amount of abrasive area affects the amount of total empty area and the amount of total abrasive area. In addition, the amount of abrasive region affects the density and distribution of the abrasive covering the surface of the abrasive article, which in turn directly affects the removal rate of the surface material of the abrasive article and the efficiency of chip extraction. In one embodiment, the amount of abrasive 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 abrasive regions is no greater than about 100,000, no greater than about 50,000, no greater than about 10,000, no greater than about 1000, no greater than about 800, no greater than about 750, no greater than about 600, or no greater than about 550. The number of abrasive zones can be in the range of any of the aforementioned upper and lower limits. In another embodiment, the amount of abrasive regions ranges 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 a particular embodiment, the amount of abrasive regions ranges from about 21 to about 550. Divergence angle

Increasing or decreasing the divergence angle α affects how the abrasive regions are placed in the pattern, and the shape of the clockwise and counterclockwise spirals. The divergence angle is equal to 360° divided by a constant or variable value, so the divergence angle can be a constant value, or it can vary. It has been observed that small changes in the divergence angle can significantly alter the pattern. Figures 8a, 8b, and 8c show leaf-sequence patterns that differ only in the divergence angle. The divergence angle of Figure 8a is 137.3°. The divergence angle shown in Figure 8b is 137.5°. The divergence angle of Figure 8C is 137.6°. In one embodiment, the divergence angle is at least about 30°, at least about 45°, at least about 60°, at least about 90°, or at least about 120°. In another embodiment, the divergence angle is less than 180°, such as no greater than about 150°. The divergence angle can be within the range of any of the aforementioned upper and lower limits. In another embodiment, the divergence angle ranges from about 90° to about 179°, from about 120° to about 150°, from about 130° to about 140°, or from about 135° to about 139°. In one embodiment, the divergence angle is determined by dividing 360° by an irrational number. In a particular embodiment, the divergence angle is determined by dividing 360° by the golden ratio. In a particular embodiment, the divergence angle is from about 137 to about 138, such as from about 137.5 to about 137.6, such as from about 137.50 to about 137.51. In a particular embodiment, the divergence angle is 137.508°. Distance to the edge of the abrasive

The overall size of the pattern can be determined depending on the geometry of the abrasive article and its intended use. The distance from the center of the pattern to the outermost abrasive region can extend to a distance from the edge of the abrasive article. Thus, the edges of the outermost abrasive regions can extend to the intersection with the edges of the abrasive article. Alternatively, the distance from the center of the pattern to the outermost abrasive region may extend to a distance such that there is a certain amount of space between the edge of the outermost abrasive region and the edge of the abrasive article, wherein there is no abrasive region. The minimum distance from the edge of the outermost abrasive region can be specified as needed. In one embodiment, the minimum distance from the edge of the outermost abrasive region to the outer edge of the abrasive article is a specific distance, which may be a discrete length, or the length of the surface of the pattern that the abrasive article has. percentage. In one embodiment, the minimum distance from the edge of the outermost abrasive region to the outer edge of the abrasive article can be at least about zero (ie, the edge of the outermost abrasive region intersects the outer edge of the abrasive article or is co-terminal ), the range of which is about 15% of the length of the surface of the abrasive article. Size of the abrasive area

The size of the abrasive region is determined, at least in part, by the total amount of abrasive region required to grind the article. The size of the abrasive region may be fixed throughout the pattern, or it may vary within the pattern. In one embodiment, the size of the abrasive region is constant. In another embodiment, the size of the abrasive region varies with the distance of the abrasive region from the center of the pattern. Scale Factor

The scale factor affects the size and total size of the pattern. The scale factor can be adjusted such that the edge of the outermost abrasive region is within a desired distance of the outer edge of the abrasive article. Distance between nearest adjacent abrasive regions

When considering the number and size of the abrasive regions, the distance between the centers of the nearest adjacent abrasive regions can be determined. The distance between the centers of any two abrasive regions is a function of other design considerations. In one embodiment, the shortest distance between the centers of any two abrasive regions is never repeated (ie, the center-to-center spacing is never exactly the same distance). This type of spacing is also an example of controlled asymmetry. Pattern coverage - anomalous acceptable amount

It will be apparent below that the pattern need not be applied to all or in a continuous manner of the abrasive article. Portions of the pattern can be applied or skipped such that different regions of the face of the abrasive article do not have a complete pattern. In one embodiment, one half of the pattern, one third, one quarter, one fifth, one sixth, one seventh, one eighth, one fifth, or one tenth May be skipped. In another embodiment, the pattern can be applied to only one or more concentric annular regions of the abrasive article. In another embodiment, it is possible to skip one or more abrasive regions that typically occur in a series of abrasive regions along individual arcs or arms of the pattern. In one embodiment, each nth, or each nth, of each nth may be skipped. In another embodiment, a separate abrasive zone, a group of abrasive zones, or an abrasive zone corresponding to a particular series of values ​​can be skipped. Conversely, the pattern may also contain a certain amount of additional abrasive area. The addition and subtraction of the abrasive region can be regarded as an abnormality of the pattern, and a certain amount of an abnormal pattern, more or less, is acceptable. In one embodiment, the acceptable amount of the anomalous pattern may range from 0.1% to 10% of the total abrasive area of ​​the abrasive article. Shape of the abrasive area

The shape of the abrasive area affects the coverage. The shape of the abrasive region can be regular or irregular. In one embodiment, the shape of the abrasive region can be a short line, a regular polygon, an irregular polygon, an ellipse, a circle, an arc, a spiral, a vortex, a lattice, or a combination thereof. In a specific embodiment, the abrasive region has a rounded shape. In another embodiment, the shape of the abrasive region can be one or more lines, arcs, spirals, or vortices having a controlled non-uniform distribution as described herein. One or more lines, arcs, spirals, or vortices may have multiple lines intersecting.

The abrasive region can be configured such that whether or not a vacuum is installed on the back of the abrasive article is sufficient to eliminate possible chips. In one embodiment, the abrasive region is in the shape of a spiral or a diagonal line that extends radially outward from the center of the abrasive article, and the helical or oblique line may be configured such that it is empty between the abrasive regions. The area forms an air flow passage. In another embodiment, the abrasive region is formed similar to a spiral lattice. The opening can be located in an empty area surrounded by the grid. It is believed that the removal of the chips can be enhanced by the use of empty areas that are fluidly connected to the outer edges of the abrasive article, or fluidly connected to the apertures of the abrasive article, or both, the apertures of the abrasive article can be connected to the vacuum source. The abrasive region and the empty region thus configured to form an air flow path can guide the chips, eject the chips from the abrasive region by centrifugal force, or directly enter the holes of the vacuum system, thereby preventing the accumulation of chips on the surface of the abrasive article. The area, as well as any open fibrous layers, such as hook-and-loop material layers, may adhere to the back of the abrasive article.

** In one embodiment, the pattern of abrasive regions may include regular polygons, irregular polygons, ellipses, arcs, spirals, leaf pattern, or combinations thereof. The pattern of the abrasive region can include a radiation arc, a radiation spiral, or a combination thereof. The pattern of abrasive regions may include a combination of inwardly radiating helix and outwardly radiating helix. The pattern of the abrasive region may comprise a combination of a spiral of clockwise radiation and a spiral of counterclockwise radiation. The abrasive regions can be discrete or discontinuous from one another. Alternatively, one or more abrasive regions may be fluidly connected.

The number of radiation arcs, radiation spirals, or combinations thereof can vary. In one embodiment, the number of radiation arcs, radiation spirals, or a combination thereof may be no more than 1000, such as no more than 750, no more than 500, no more than 250, no more than 100, no more than 90, no more than 80, or , not more than 75, in one embodiment, the number of radiation arcs, radiation spirals, or a combination thereof may be not less than 2, such as not less than 3, not less than 5, not less than 7, not less than 9, not less than 11, Not less than 15, or not less than 20. In one embodiment, the number of radiation arcs, radiation spirals, or a combination thereof may be from 2 to 500, such as from 2 to 100.

The width of the abrasive region can vary. The width of the abrasive region can be constant, or varied, or a combination thereof. In one embodiment, the width of the abrasive region can be within a fixed length range. In one embodiment, the abrasive region may have a width of from 0.1 mm to 10 cm. In another embodiment, the width of the abrasive region is related to the size required for adjacent empty regions of the abrasive article. In one embodiment, the width of the abrasive region is not less than 1/10 of the size of the empty region of the abrasive article, such as not less than 1/8, 1/6, 1/5, 1/4, 1 / 3, or 1 /2. In one embodiment, the width of the abrasive region is no more than 10 times the size of the area of the empty region of the coated abrasive, such as no more than 8 times, no more than 6 times, no more than 5 times, no more than 4 times, no More than 3 times, no more than 2 times. In one embodiment, the width of the abrasive region is approximately equal to the size of the area of the empty region of the coated abrasive.

In another embodiment, the abrasive region can be formed and configured to form a plurality of air flow passages in the pattern. The pattern of air flow channels may include regular polygons, irregular polygons, ellipses, arcs, spirals, leaf pattern, or a combination thereof. The pattern of air flow channels may include a path of a radial arc, a path of a radiation spiral, or a combination thereof. The pattern of air flow channels may include a combination of an inward radial spiral path and an outward spiral radiation path. The pattern of air flow channels may include a combination of a clockwise spiral radiation path and a counterclockwise spiral radiation path. The air flow channels may be discrete or discontinuous from one another. Alternatively, one or more of the air flow channels may be fluidly connected.

The number of radiating arcuate paths ("arcs"), radiating spiral paths, or a combination thereof can vary. In one embodiment, the number of the radiation arc path, the radiation spiral path, or a combination thereof may be not more than 1000, such as not more than 750, not more than 500, not more than 250, not more than 100, not more than 90, not more than 80, or not more than 75, in one embodiment, the radial arc path, the radiation spiral path, or the number of combinations thereof may be not less than 2, such as not less than 3, not less than 5, not less than 7, not less than 9, Not less than 11, not less than 15, or not less than 20, in one embodiment, the number of radiating arc paths, radiating spiral paths, or a combination thereof may be from 2 to 500, such as from 2 to 100.

The width of the air flow passage can vary. The width of the air flow passages may be constant or varied, or a combination thereof. In one embodiment, the width of the air flow passage may be within a fixed length range. In one embodiment, the width of the air flow passage can vary from 0.1 mm to 10 cm. In another embodiment, the width of the air flow passage is related to the size of the abrasive region having the coating. In one embodiment, the width of the air flow passage is not less than 1/10 of the size of the abrasive region having the coating, such as not less than 1/8, 1/6, 1/5, 1/4, 1/3, or 1/2. In one embodiment, the width of the air flow channel is no more than 10 times the size of the abrasive region having the coating, such as no more than 8 times, no more than 6 times, no more than 5 times, no more than 4 times, no more than 3 times , no more than 2 times. In one embodiment, the width of the air flow passage is approximately equal to the size of the abrasive region having the coating.

The air flow passages may have one or more cavities, holes, passages, holes, openings, or combinations thereof, along or within the air flow passage, the air flow passages extending through the body of the abrasive article. In one embodiment, each air flow passage has at least one aperture disposed in an air flow passage extending through the body of the abrasive article. Shape and structure of the abrasive article

The shape of the abrasive article can be any shape that conforms to the pattern of the desired abrasive region and is determined by the desired abrasive construction process and construction material. In one embodiment, the abrasive article is a bonded abrasive article. In another embodiment, the abrasive article is an abrasive article having a coating. In a particular embodiment, the abrasive article is a sheet, tape, or disk.

1 shows a top view of one embodiment of a coated abrasive article 100 having a plurality of non-uniformly distributed patterned abrasive regions 101, wherein the pattern is a corrugated spiral pattern conforming to a Vogel model. (often referred to as the "sunflower" pattern). An empty area 103 surrounds the abrasive area. The shape of the coated abrasive article is substantially a planar (i.e., substantially flat) disk.

21 shows a side view of a coated abrasive article 2100 that includes a backing pad 2101 having a first major surface 2103 and a second major surface 2105. An abrasive layer 2107 is disposed on the first major surface of the backing pad. The abrasive layer can comprise a plurality of layers, including an adhesive layer 2109, also referred to as a make coat. The plurality of abrasive particles 2111 can be dispersed within the adhesive layer, penetrating the adhesive layer, or on the adhesive layer, or a combination thereof. The pattern of the abrasive region 2113 can appear on the surface of the backing pad. One or more empty regions 2115 are adjacent to the abrasive region. The size coating 2117 can be selectively disposed on the adhesive layer. The oversized coating 2119 can be selectively disposed on the size coating. The back coating 2121 may be disposed on the second major surface (ie, the non-abrasive surface) of the backing layer. The pinned layer 2123 can be disposed on the backside coating or can be disposed directly on the second major side of the backing pad. In a particular embodiment, the coated abrasive article 2100 can be selectively attached to a support pad (not shown) or a vacuum system (not shown). Back cushion

The back pad can be flexible or rigid. The backing pad can be made from any number of materials, including those conventionally used as backing pads for coated abrasive articles. Exemplary flexible backing pads include polymeric films (eg, primer films) such as polyolefin films (eg, polypropylene, including biaxially oriented polypropylene), polyester films (eg, polyethylene terephthalate) a glycol ester), a polyamide film, or a cellulose ester film; a metal foil; a mesh; a foam (for example, a natural sponge material or a polyurethane foam); a cloth (for example, a cloth woven from fibers or yarns, including poly Ester, nylon, silk, cotton, polycotton, or rayon); paper; vulcanized paper; vulcanized rubber; vulcanized fiber; nonwoven material; or a combination thereof; or a treated variant thereof. The back pad of the cloth can be woven or stitched. In a specific embodiment, the backing pad is selected from the group consisting of paper, polymer film, cloth, cotton, polycotton, rayon, polyester, polynylon, vulcanized rubber, vulcanized fiber, metal foil, and The combination. In other embodiments, the backing pad comprises a polypropylene film or a polyethylene terephthalate (PET) film.

The backing pad can optionally have at least one impregnating agent, a front side layer or a back side layer. The purpose of these layers is to seal the backing pad or to protect the yarn or fiber of the backing pad. If the backing pad is the material of the cloth, at least one of these layers is typically used. The addition of the front side layer or the back side layer allows the front and back sides of the back pad to have a "smoother" surface. Other optional layers known in the art can also be used (e.g., a tie layer; see U.S. Patent No. 5,700,302 (Stoetzel et al.), the disclosure of which is incorporated herein by reference.

Antistatic materials can be included in the cloth treatment material. The addition of an antistatic material allows the coated abrasive article to reduce accumulated static electricity when sanded with wood or wood-based materials. Further details regarding the treatment of antistatic backing pads and backing pads can be found, for example, in U.S. Patent No. 5,108,463 (Buchanan et al.); 5,137,542 (Buchanan et al.); 5,328,716 (Buchanan); and 5,560,753 (Buchanan). The disclosure of which is incorporated herein by reference.

The backing pad may be a fiber reinforced thermoplastic material, for example, as described in U.S. Patent No. 5,417,726 (Stout et al.), or a ring-shaped endless belt, for example, as disclosed in U.S. Patent No. 5,573,619 (Benedict et al.). The content is incorporated herein by reference. Likewise, the backing pad can be a polymeric matrix having a hook, for example, as described in U.S. Patent No. 5,505,747 (Chesley et al.), the disclosure of which is incorporated herein by reference. Similarly, the backing pad can be a terry fabric, for example, as described in U.S. Pat. No. 5,556,011 (Follett et al.), the disclosure of which is incorporated herein by reference. Abrasive layer

The abrasive layer can be composed of one or more coatings and a plurality of abrasive particles. For example, the abrasive layer includes a make coat 2109 and may optionally include a size coating or a large size coating. The abrasive layer typically comprises abrasive particles disposed in the adhesive, or embedded within the adhesive, or dispersed in the adhesive, or a combination thereof. Abrasive grain

The abrasive particles can include substantially single phase inorganic materials such as alumina, tantalum carbide, cerium oxide, cerium oxide, and relatively hard, high performance superabrasive particles such as cubic boron nitride and diamond. Additionally, the abrasive particles can comprise a composite particulate material. Such materials may include aggregates that may be formed via a slurry treatment route, including removal of the liquid carrier via volatilization or evaporation, leaving the embryo body aggregates, followed by selective high temperature processing (eg, roasting) to form a useful , fired aggregates. Additionally, the abrasive region can include engineered abrasives including macrostructures and unique three-dimensional structures.

In an exemplary embodiment, the abrasive particles are mixed with a binder to form an abrasive slurry. Alternatively, the abrasive particles are applied to the adhesive after the adhesive is applied to the backing pad. Alternatively, a functional powder can be applied to the abrasive region to prevent the abrasive region from adhering to the patterned mold. Alternatively, the pattern can be formed on an abrasive region without functional powder.

The abrasive region can be formed from any one of abrasive particles or a combination thereof, the abrasive particles including cerium oxide, aluminum oxide (melted or sintered), zirconia, zirconia/alumina oxide, tantalum carbide, garnet, diamond, cubic Boron nitride, tantalum nitride, hafnium oxide, titanium dioxide, titanium diboride, boron carbide, tin oxide, tungsten carbide, titanium carbide, iron oxide, chromium oxide, vermiculite, silicon carbide. For example, the abrasive particles can be selected from the group consisting of cerium oxide, aluminum oxide, zirconium oxide, tantalum carbide, tantalum nitride, boron nitride, garnet, diamond, eutectic alumina zirconia, Cerium oxide, titanium diboride, boron carbide, vermiculite, silicon carbide, aluminum oxide nitride, and blends thereof. Particular embodiments have been produced via the use of dense abrasive particles comprising primarily alpha-alumina.

The abrasive particles can also have a particular shape. Examples of such shapes include rods, triangles, prisms, cones, solid balls, hollow spheres, or the like. Alternatively, the abrasive particles can have a random shape.

In one embodiment, the abrasive particles can have an average particle size of no greater than 800 microns, such as no greater than about 700 microns, no greater than 500 microns, no greater than 200 microns, or no greater than 100 microns. In another embodiment, the abrasive particle size is at least 0.1 microns, at least 0.25 microns, or at least 0.5 microns. In another embodiment, the abrasive particles have a size from about 0.1 microns to about 200 microns, more typically from about 0.1 microns to about 150 microns, or from about 1 micron to about 100 microns. The size of the abrasive particles generally refers to the longest dimension of the abrasive particles. Typically, the size of the abrasive particles has a range distribution. In some cases, the particle size distribution is strictly controlled. Making a coating - binder

The binder from which the coating or size coating is made can be formed from a single polymer or a blend of polymers. For example, the binder can be selected from the group consisting of epoxy resins, acrylic polymers, or combinations thereof. Further, the binder may include a filler such as a nano-sized filler or a combination of a nano-sized filler and a micro-sized filler. In a particular embodiment, the adhesive is a colloidal adhesive wherein the adhesive is cured to form a colloidal suspension containing particulate filler. Alternatively, or in addition, the binder may be a binder of a nanocomposite comprising a submicron particulate filler.

The binder typically comprises a polymeric matrix that bonds the abrasive particles to the backing pad or, if present, to the compliant coating. Typically, the adhesive is made by curing the adhesive formulation. In an exemplary embodiment, the adhesive formulation includes a polymer component and a dispersed phase.

The binder formulation may include one or more reactive ingredients or a polymer component from which the polymer is prepared. The polymer component can include monomer molecules, polymer molecules, or a combination thereof. The binder preparation may further comprise a group selected from the group consisting of a solvent, a plasticizer, a chain transfer agent, a catalyst, a stabilizer, a dispersant, a curing agent, a reaction medium, and a fluidity for influencing the dispersion. Ingredients.

The polymer component can form a thermoplastic or a thermoset plastic. For example, the polymer component may include polyurethane, polyurea, polyepoxy, polyester, polyimide, polyoxyalkylene (organoanthracene), polyalkyd resin, styrene-butadiene. A rubber, acrylonitrile-butadiene rubber, a monomer and resin of polybutadiene, or, in general, a reactive resin for producing a thermosetting polymer. Another example includes an acrylate or methacrylate polymer composition. The precursor polymer component is typically a curable organic material (ie, when exposed to heat or other sources of energy, such as electron beams, ultraviolet light, visible light, etc., or sometimes a chemical catalyst, water vapor, can polymerize the polymer or Crosslinked monomers or materials, or other agents that can cause the polymer to cure or polymerize). Examples of precursor polymer components include reactive components that form amino polymer or aminoplast polymers, such as alkylated urea-formaldehyde polymers, melamine-formaldehyde polymers, and alkylated benzoguanamines. - Formaldehyde polymers; Acrylate polymers including acrylate and methacrylate polymers, alkyl acrylates, acrylated epoxies, acrylated urethanes, acrylated polyesters, acrylics Polyether, vinyl ether, acrylated oil, or acrylated polyoxyalkylene; alkyd resin such as polyurethane alkyd polymer; polyester polymer; reactive polyurethane polymer; such as phenolic resin A phenolic polymer of a novolak polymer; a phenolic/latex polymer; an epoxy polymer such as a bisphenol epoxy polymer; an isocyanate; an isocyanurate; a polyfluorene comprising an alkyl alkoxy decane polymer An oxane polymer; or a reactive vinyl polymer. The binder formulation can include monomers, oligomers, polymers, or combinations thereof. In a particular embodiment, the adhesive formulation comprises monomers of at least two types of polymers that are crosslinkable upon curing. For example, the adhesive formulation can include an epoxy resin component and an acrylic component that, upon curing, can form an epoxy/acrylic polymer. Additive - grinding aid

The abrasive layer may also include a grinding aid to increase grinding efficiency and cutting rate. Useful grinding aids can be inorganic, such as halide salts, such as sodium cryolite, and potassium tetrafluoroborate; or organic, such as chlorinated waxes, such as polyvinyl chloride. A particular embodiment includes cryolite and potassium tetrafluoroborate having a particle size ranging from 1 micron to 80 microns, and most typically from 5 microns to 30 microns. The large size coating can be a polymer layer applied to the abrasive particles to provide glaze resistance and load resistance. Back coating - compliant coating

The coated abrasive article can optionally include a compliant and back coating (not shown). These coatings function as described above and can be formed from a binder component. Method of manufacture - coated abrasive articles

Turning to a method of making a coated abrasive article having a pattern of abrasive regions, the backing pad can be distributed by a roller, and the backing pad can be coated with an adhesive formulation by a coating apparatus Delivery. An exemplary coating apparatus includes a droplet die coater, a knife coater, a curtain coater, a vacuum die coater or a die coater. The coating method can include a contact or non-contact method. Such methods include two rolls, three roll inversion, roll doctor, slot die, gravure, rotary printing, extrusion, spray application, or combinations thereof.

In one embodiment, the adhesive formulation can be provided as a slurry comprising the formulation and abrasive particles. In another embodiment, the adhesive formulation can be dispensed as separate abrasive particles. The abrasive particles can be provided after the adhesive formulation is partially cured, or after the adhesive formulation pattern is formed, if any, or after the adhesive formulation is fully cured, after the backing pad is coated with the adhesive. Abrasive particles can be applied by techniques such as electrostatic spraying, dispensing, or mechanical casting.

In another embodiment, a backing pad coated with a binder and abrasive particles can be formed into a shape of a coated abrasive using a stamp, die cutting, laser cutting, or a combination thereof (eg, a circular disk). Or the pattern of holes (if any) that cut through the coated abrasive.

In another embodiment, the backing pad can be selectively coated with an adhesive leaving an uncoated area, and the uncoated areas are coated with abrasive particles to form an abrasive region. For example, the adhesive can be printed onto a backing pad, such as via screen printing, offset printing, rotary printing, or flexographic printing. In another embodiment, the adhesive can be selectively coated using gravure coating, slot die coating, barrier spray coating, or the like. Alternatively, a photoresist or UV curable mask can be applied to the backing pad and developed, for example via photolithography, to cover portions of the backing pad. In another example, the dehumidifying compound can be applied to the backing pad beforehand before applying the adhesive. Use - grinding workpiece

Turning to the method of grinding the workpiece, the workpiece can be in contact with the coated abrasive. The coated abrasive can be rotated relative to the workpiece. For example, a coated abrasive can be mounted on an orbital grinder and in contact with the workpiece. When the workpiece is abraded, the material that has worn away from the workpiece will accumulate in an empty area between the abrasive regions or accumulate beside the abrasive region. The accumulated material can be discharged from the surface of the coated abrasive due to the movement of the coated abrasive during use. Alternatively, the vacuum system can be equipped onto the abrasive article. The vacuum system can include a support pad that is used to function in cooperation with the abrasive article. Support pad

It should be understood that the support mat is designed to correspond to a coated abrasive having a controlled non-uniform distribution of abrasive regions, so that it can be successfully used with conventional coated abrasives, as well as with controlled non-uniformity. A unique coated abrasive that distributes the abrasive area. The inventors have surprisingly discovered that embodiments of the support pad can provide superior chip removal and can promote improved abrasive performance of conventional abrasives. In one embodiment, the support pad can have a pattern of air flow channels that are adapted to operate in cooperation with the coated abrasive having a controlled non-uniform distribution pattern. As previously mentioned, such support pads can be used cooperatively in conventional porous coated abrasives to promote chip removal and grinding performance.

In one embodiment, the support pad can include a pattern of air flow channels, wherein the pattern of air flow channels is generated from the x and y coordinates of the controlled non-uniformly distributed pattern. The controlled non-uniformly distributed pattern of air flow patterns used to create the support pads may be the same as or different from the pattern of coated abrasives used with the support pads. In one embodiment, the controlled non-uniformly distributed pattern is the same as the pattern of coated abrasive used with the support mat. In another embodiment, the controlled non-uniformly distributed pattern is different from the pattern of coated abrasive used with the support mat.

In one embodiment, the support pad can operate in conjunction with a coated abrasive having a kerf pattern according to the embodiment of the coated abrasive described herein. When the support pad comprises a plurality of openings, a plurality of cavities, a plurality of channels, a plurality of channels, or a combination thereof, the support pad can be operated in cooperation with the coated abrasive having a kerf pattern, which is configured In the pattern, it is possible to facilitate inhalation and to remove chips on the surface of the workpiece through the holes of the coated abrasive having a flaky pattern during the grinding process. The openings, cavities, channels, channels, or combinations thereof may define air flow channels that are positioned along the support pads, or within the support pads, or through the support pads, or a combination thereof. The air flow passages can be used to facilitate inhalation and to remove chips on the work surface via the holes of the coated abrasive having a kerf pattern during the grinding process. In one embodiment, the pattern of openings, cavities, channels, channels, or combinations thereof may be regular polygons, irregular polygons, ellipses, arcs, spirals, leaf-like patterns, or combinations thereof. In another embodiment, the air flow channels may be regular polygons, irregular polygons, ellipses, arcs, spirals, leaf pattern, or combinations thereof.

The pattern can be used to define curved and spiral channels of radiation, as well as annular channels that can intersect curved and spiral channels, or a combination thereof. Then, the annular passage, the curved passage, the spiral passage, or a combination thereof may be formed in a suitable material such as a groove, a cavity, a hole, a passage, or other path to form Synergistic support pads.

In certain embodiments, the air flow passages of the support pads will partially or even completely match the holes of the coated abrasive. It should be understood that the matching of the air flow passages with the openings of the coated abrasive means that at least a portion of the aperture area coincides with or is aligned with a portion of the air flow passage. In one embodiment, the air flow passages corresponding to the support pads are matched to the holes by at least 5%, at least 10%, at least 15%, at least 20%, at least 25%. In one embodiment, the air flow passage corresponding to the support pad is matched to the hole by 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 50%, 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%.

It should be understood that the spiral and scalloped air flow channel patterns of certain support pads are aligned with the pattern of coated abrasive holes, particularly when the air flow channel pattern is based on a coated abrasive. The coordinates of the area are transposed and rotated to produce the time. In one embodiment, the air flow channel pattern will match substantially or nearly all of the coated abrasive aperture when the support pad has a particular phase, or angle of rotation, relative to the coated abrasive. . When the support pad is rotated 90° or 180° relative to the coated abrasive, the air flow channel pattern of the support pad matches the hole of the coated abrasive, and most or almost all of the holes of the coated abrasive match In the case of at least one air flow channel of the support pad, the support pad is referred to as a single alignment (also referred to as 2 realignment) support pad.

In one embodiment, the support pad can include or be adapted to include an alignment indicator. The alignment indicator can be a marker, device, slit, attachment, neck ring, protrusion, or combination thereof to indicate the degree of alignment of the support pad with the coated abrasive. In a specific embodiment, the alignment indicator can be a marker.

While described in the context of embodiments of the abrasive articles described herein, such support pads can also be used with standard porous coated abrasives of the state of the art. It has been unexpectedly discovered that if the support pad has a plurality of openings for forming a spiral or scalloped pattern of air flow channels, a plurality of cavities, a plurality of channels, or a combination thereof, the standard for prior art states Porous coated abrasives and coated abrasives with kerf-shaped holes can improve chip removal, promote abrasive cutting performance, and abrasive life.

The support pads can be flexible or rigid. The support pads can be formed from any number of materials, or combinations of materials, including those conventionally used to make the support pads. The support pad can be made in a one-piece, unitary structure, or in a multi-piece construction, such as a multi-layer structure or a concentric layer structure. The support pad is preferably made of an elastic material such as a flexible foam. Suitable foam materials may be polyurethane, polyester, polyester polyurethane, polyether polyurethane; natural or synthetic rubber such as polybutadiene, polyisoprene, EPDM polymer, polyvinyl chloride (PVC), poly Chlorobutene, or a styrene/butadiene copolymer; or a combination thereof. The foam can be open or closed. Additives such as coupling agents, toughening agents, curing agents, antioxidants, reinforcing materials, and the like can be added to the foam formulation to achieve the desired characteristics. Dyes, pigments, fillers, antistatic agents, flame retardants, and woven fabrics can also be added to foams or other elastomeric materials used to form the support pads.

Particularly useful foams include TDI (toluene diisocyanate) / polyester and MDI (diphenylmethane diisocyanate) / polyester foam. In one embodiment, the support pad is formed from an elastic, open-celled polyurethane foam formed from the reaction product of a polyether polyol and an aromatic polyisocyanate. In another embodiment, the support pad can be a foam, a vulcanized rubber, or any combination thereof.

It should be noted that not all of the functions described in the general description or embodiments above are required, that is, a particular effect of a portion thereof is not required, and one or more other effects may be added to the The role of it. Further, the order in which these effects are listed is not necessarily the order in which they are performed.

In the above description, these concepts have been described with reference to specific embodiments. However, it will be apparent to those skilled in the art that various modifications and changes can be made in the present invention without departing from the spirit and scope of the invention. Accordingly, the specification and drawings are to be regarded as illustrative and not restrict

As used herein, the terms "comprises", "comprising", "includes", "including", "has" ("has") , "having" or any other variation thereof is used to cover a non-exclusive meaning. For example, a process, a method, an article, or an apparatus that includes a list of features is not necessarily limited to these features, but may include features not explicitly listed or otherwise Or a feature inherent in a process, a method, an article, or an appratus. In addition, unless expressly stated to the contrary, “or” (“or”) means an inclusive or non-exclusive. For example, condition A or B satisfies any of the following statements: A is true (or exists) and B is false (or non-existent), A is false (or non-existent), and B is true (or exists), Both A and B are true (or exist).

In addition, "a" or "an" is used to describe the elements and components described herein. This is for convenience only and gives the general meaning of the scope of the invention. This description is to be understood as inclusive, and the singular

The benefits of the present invention, other advantages, and solutions to problems have been described above in the specific embodiments. However, the benefits, advantages, problems of the invention, and any features that may occur or become more apparent that may result in any benefit, advantage, or problem solving should not be construed as being any or all of the scope of the patent application. Critical, required, or necessary features.

Certain features that are described in the context of the various embodiments may be combined in a single embodiment for the purpose of clarity. Conversely, various features that are described in the context of a single embodiment for the sake of simplicity may also be provided separately or in any sub-combination.

In addition, values expressed in ranges include individual values and each value within the range. When the term "about" or "approximately" is placed before a numerical value, for example, when describing a numerical range, the precise numerical value is also included. For example, a range of values starting at "about 25" is also meant to include a range starting at exactly 25.

100‧‧‧Abrased products
101‧‧‧Abrasive area
103‧‧‧empty area
2100‧‧‧Abrased products
2101‧‧‧Back cushion
2103‧‧‧ first major surface
2105‧‧‧Second major surface
2107‧‧‧Abrasive layer
2109‧‧‧Adhesive layer
2111‧‧‧Abrasive particles
2113‧‧‧Abrasive area
2115‧‧‧empty area
2117‧‧‧ size coating
2119‧‧‧Oversized coating
2121‧‧‧Back coating
2123‧‧‧Fixed layer

The invention may be better understood, and many of the features and advantages of the invention will become apparent to those skilled in the art. 1 is an embodiment of a coated disc having no holes, having a pattern of controlled non-uniformly distributed abrasive regions (ie, dots) in accordance with the present invention. Figure 2 is a schematic illustration of an embodiment of a coated abrasive having an abrasive region in the shape of a plurality of spirals that pass through a Vogel model. Figure 3 is a schematic illustration of an embodiment having a coating without any pores, the abrasive region corresponding to a spiral pattern of the leaf order, in particular a type of spiral having a clockwise and counterclockwise oblique line according to the present invention. lattice. Figure 4 is a schematic illustration of another embodiment having a coating without any pores, the shape of the abrasive region being a spiral pattern of a leaf order having a clockwise and counterclockwise oblique line in accordance with the present invention. Figure 5 is a schematic illustration of another embodiment of a coated abrasive disk having an abrasive region corresponding to a helical pattern of a blade sequence, particularly a type of spiral lattice having a clockwise and counterclockwise shape in accordance with the present invention. A diagonal line, and a circular abrasive area that intersects the oblique line. Figure 6 is a schematic illustration of a Vogel model in accordance with the present invention for configuring an abrasive region. Figure 7 is a schematic illustration of another Vogel model in accordance with the present invention showing numbers of configured abrasive regions. 8A-8C are schematic illustrations of a spiral pattern of a leaf pattern in accordance with the present invention for configuring abrasive regions having a coating that conforms to a Vogel model having different divergence angles. Figure 9 is a schematic illustration of another embodiment of a coated abrasive disc according to the present invention, the abrasive region corresponding to a spiral pattern of a leaf pattern, particularly a type of spiral lattice having a clockwise and counterclockwise slope Column lines, and different sizes of round abrasive areas at the intersection of the diagonal lines. Figure 10 is a schematic illustration of another embodiment of a coated abrasive disk according to the present invention, the abrasive region corresponding to a helical pattern of a leaf sequence having a branched oblique line and at the bifurcation of the oblique line Round abrasive areas of different sizes. Figure 11 is a schematic illustration of another embodiment of a coated abrasive disk in accordance with the present invention, the abrasive region corresponding to a helical pattern of a leaf sequence having a clockwise oblique line of the branches, and a diagonal line in the oblique line Round abrasive areas of different sizes at the crotch. Figure 12 is a schematic illustration of another embodiment of a coated abrasive disk according to the present invention, the abrasive region corresponding to a helical pattern of a leaf sequence having a clockwise and counterclockwise oblique line, and an oblique Different sizes of round abrasive areas at the branch line. Figure 13 is a schematic illustration of another embodiment of a coated abrasive disk according to the present invention, the abrasive region corresponding to a helical pattern of a leaf sequence having a branched oblique line and at the bifurcation of the oblique line Round abrasive areas of different sizes. Figure 14 is a schematic illustration of another embodiment of a coated abrasive disk in accordance with the present invention, the abrasive region corresponding to a helical pattern of a leaf sequence having a branched oblique line and at the bifurcation of the oblique line Round abrasive areas of different sizes. Figure 15 is a schematic illustration of an abrasive region in accordance with the present invention having 148 abrasive regions. Figure 16 is a schematic illustration of an embodiment of a different abrasive pattern in accordance with the present invention, which is a transposition of the abrasive pattern of Figure 15. Figure 17 is a schematic illustration of an embodiment of an abrasive region in the form of a spiral and a circular arc in accordance with the pattern of Figure 16. Figure 18 is a diagram of an exemplary embodiment of an abrasive region pattern having 344 abrasive regions in accordance with the present invention. Figure 19 is a schematic illustration of an exemplary embodiment of the present invention, which is a transposition of the abrasive region pattern of Figure 18. Figure 20 is a schematic illustration of an exemplary embodiment of a support pad in cooperation with the opening pattern of Figure 19, in accordance with the present invention. Figure 21 is a cross-sectional view of an embodiment of a coated abrasive in accordance with the present invention.

The same reference numbers are used in the different drawings to refer to the same or the same items.

100‧‧‧Abrased products

101‧‧‧Abrasive area

103‧‧‧empty area

Claims (45)

An abrasive article comprising: a coated abrasive having a plurality of regions arranged in a pattern of abrasive, wherein the pattern has a controlled non-uniform distribution, and wherein the pattern is at least radially A pattern, a spiral pattern, a leaf pattern, an asymmetrical pattern, or a combination thereof. The abrasive article of claim 1, wherein the pattern is a spiral pattern. The abrasive article of claim 2, wherein the spiral pattern is an Archimedes spiral, Eulerspiral, Fermat's spiral, hyperbolic Hyperbolic spiral, lituus, logarithmic spiral, Fibonaccispiral, golden spiral, or a combination thereof. The abrasive article of claim 3, wherein the pattern has a controlled asymmetry. The abrasive article of claim 4, wherein the controlled asymmetry is a rotational asymmetry for at least a portion of a center of the pattern. The abrasive article of claim 5, wherein the asymmetric of the rotation extends to at least 51%, at least 70%, or at least 85% of the abrasive region of the pattern. The abrasive article of claim 5, wherein the asymmetric of the rotation extends to at least 20, at least 50, or at least 100 of the abrasive regions of the pattern. The abrasive article of claim 5, wherein the pattern is rotationally asymmetrical to the center of the pattern. The abrasive article of claim 1, wherein the pattern is a leaf pattern. The abrasive article of claim 9, wherein the pattern is a spiral leaf pattern. The abrasive article of claim 10, wherein the pattern has a plurality of clockwise spirals and a plurality of counterclockwise spirals, wherein the number of clockwise spirals and the number of counterclockwise spirals are Fibonacci numbers ( Fibonacci numbers) or multiples of Fibonacci numbers. The abrasive article of claim 11, wherein the number of clockwise spirals and the number of counterclockwise spirals are multiples of Lucas numbers or Lucas numbers. The abrasive article of claim 11, wherein the ratio of the number of clockwise spirals to the number of counterclockwise spirals is a ratio that converges to the golden ratio. The abrasive article of claim 10, wherein the spiral leaf pattern has a controlled asymmetry. The abrasive article of claim 10, wherein the spiral leaf pattern is a sunflower pattern. The abrasive article according to claim 11, wherein the pattern is described in a polar coordinate system by the following formula: φ = n ∗ a, r = c√n (Formula 1) wherein: n is an abrasive region The number of orders, which counts outward from the center of the pattern; φ is the angle between the reference direction and the position vector of the nth abrasive region, and the position vector starts at the center of the pattern in the polar coordinate system, thus making any two The divergence angle between the position vectors of successive lap regions is a constant angle a; r is the distance from the center of the pattern to the center of the nth abrasive region; and c is a constant scale factor. The abrasive article of claim 16 wherein at least about 51%, at least about 70%, and at least about 85% of the abrasive region conforms to formula (1). The abrasive article of claim 16, wherein the pattern has a divergence angle in the polar coordinate system ranging from about 100° to about 170°. The abrasive article of claim 16, wherein the pattern has a divergence angle of 137.508°. The abrasive article of claim 16 wherein at least about 80%, at least about 85%, and at least about 90% of the total abrasive region conforms to formula (1). The abrasive article of claim 16, wherein the plurality of abrasive regions ranges from about 5/10/20 abrasive regions to about 500/1000/10,000 abrasive regions. The abrasive article of claim 16, wherein the pattern substantially covers the entire face of the abrasive article. The abrasive article of claim 16 wherein the edges of the outermost abrasive regions of the pattern intersect at the edges of the abrasive article. The abrasive article of claim 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. The abrasive article of claim 16 wherein the pattern covers only a portion of the face of the abrasive article. The abrasive article of claim 16, wherein the pattern covers a portion of a period of the face of the abrasive article. The abrasive article of claim 16 wherein the total empty area is from about 15% to about 99.5% of the total potential surface area of the abrasive article. The abrasive article of claim 16 wherein the total abrasive surface area is from about 4.5% to about 85% of the total potential surface area of the abrasive article. An abrasive article according to claim 16 which has the shape of a disk. The abrasive article of claim 16, wherein the shape of the abrasive region is selected from one of the following shapes: a short segment, a polygon, an ellipse, a circle, an arc, a spiral, a vortex, a spiral lattice, or a combination thereof. . A coated abrasive article comprising: a backing layer having a first major end surface and a second major end surface: and an abrasive layer disposed on the first major end surface of the backing layer, wherein the abrasive layer comprises a plurality The abrasive region, the plurality of abrasive regions are arranged to have a controlled non-uniform distribution pattern, and the pattern is a radial pattern, a spiral pattern, a leaf pattern, an asymmetric pattern, or a combination thereof. A method of making an abrasive article, comprising: disposing an abrasive layer on a backing layer; wherein the abrasive layer comprises a plurality of abrasive regions, the plurality of abrasive regions being arranged to have a controlled non-uniform distribution pattern, and the pattern is radial At least one of a pattern, a spiral pattern, a leaf pattern, an asymmetrical pattern, or a combination thereof. A coated abrasive article comprising: a plurality of abrasive regions disposed on a surface of a coated abrasive article, wherein the abrasive regions are configured to form a plurality of air flow channels, the pattern of air flow channels comprising a circular arc , spiral, spiral, leaf pattern, or a combination thereof. The coated abrasive article of claim 34, wherein the pattern of air flow channels comprises a radial arcuate path, a radial helical path, or a combination thereof. The coated abrasive article of claim 34, wherein the pattern of air flow channels comprises a combination of an inner radial helical path and an outer radial helical path. The coated abrasive article of claim 34, wherein the pattern of air flow channels comprises a combination of a clockwise radial helical path and a counterclockwise radial helical path. The coated abrasive article of claim 34, wherein the pattern of air flow passages further comprises an annular air flow passage that intersects the radial circular path or the radial helical path, or a combination thereof. A coated abrasive article comprising a pattern of air flow channels, wherein the pattern of air flow channels is produced from x and y coordinates of a controlled non-uniformly distributed pattern. The coated abrasive article according to claim 38, wherein the x and y coordinates of the controlled non-uniformly distributed pattern are transposed and rotated according to the formula (Equation 2) shown below to determine the air. The x' and y' coordinates of the flow channel, where q is equal to p/n radians and n is an arbitrary integer: é x' ù écosq - sin qù é x ù (formula 2) = ë y' û ë sin q cosqû ë y û The coated abrasive article of claim 39, wherein the controlled non-uniformly distributed pattern is a leaf-like pattern. The coated abrasive article of claim 40, wherein the controlled non-uniform distribution pattern is described by a Vogel equation. A coated abrasive article according to claim 41, wherein n is any integer from 1 to 10. A coated abrasive article according to claim 42 wherein n is 1, 2, 3, 4, 5, or 6. The coated abrasive article of claim 39, wherein the pattern of air flow channels comprises a plurality of openings, cavities, channels, channels, or combinations thereof. A grinding system comprising: a coated abrasive; and a support pad, wherein the coated abrasive comprises a controlled non-uniformly distributed pattern of abrasive regions, and wherein the support pad comprises a plurality of air The flow channels, the air flow channels, are arranged in a pattern to fit the corresponding abrasive region of the coated abrasive.