TWI589406B - Abrasive article having a dross ridge and method of forming same - Google Patents

Description

Abrasive article with scum ridge and method of forming same

The following is directed to an abrasive article, particularly an abrasive article having a scum ridge formed on the edge of the surface of the abrasive article.

Abrasive articles have been used to grind and polish the surface of the workpiece. Applications suitable for the use of abrasive articles include high-cutting of workpieces such as wood and metal, as well as fine polishing of ophthalmic lenses, optical fibers, and computer heads. In general, abrasive articles include a plurality of abrasive particles bonded together (eg, bonded abrasive or abrasive wheels) or bonded to a backing pad (eg, a coated abrasive article). For coated abrasive articles, there is typically a single layer or sometimes multiple layers of abrasive particles bonded to the backing pad. These abrasive particles can be applied as a "make" coat and a "size" coat, or as a slurry coating to the backing pad. Further, a supersize coat can be applied over the make coat or size coat to help extend the life of the abrasive particles.

Various configurations of known abrasive articles are, for example, discs, rings Belts, sanding sponges, etc. The configuration of the abrasive particles will affect the intended use of the article. For example, some abrasive articles are configured to be attached to a vacuum source during use to remove dust and debris from the abrasive surface.

For typical coated abrasive articles, the exposed tips of the abrasive particles can wear the workpiece during use. The surface of the new abrasive particles is constantly exposed to extend the life of the abrasive article. After a certain time, the abrasive particles no longer have a sufficient amount of sharp abrasive surface, so the coated abrasive article is considered to have worn out and then is usually discarded.

While coated abrasive articles that are perforated or cut using laser light are known in their manufacture and processes, there is still a need for improved coating in the field of using such improved laser cutting methods to form such abrasive articles. Abrasive article and method of making the same.

100, 200, 300, 400‧‧‧ grinding products

101, 201‧‧‧ first surface

102, 332‧‧‧ edge

103, 330a, 330b, 430a, 430b, 502, 602‧‧ ‧ scum ridge

104‧‧‧ average width

105‧‧‧ Height of scum ridge

106‧‧‧ holes

107‧‧‧around

108, 208‧‧‧ second surface

150, 250‧‧ ‧ laser light

206‧‧‧Conical hole

209, 210‧‧‧ surface

211‧‧‧ first edge

212‧‧‧ second edge

310, 410‧‧‧ Back cushion

314, 414‧‧‧ abrasive layer

315, 415‧‧‧ first major surface

316‧‧‧Making coating

317‧‧‧ size coating

318‧‧‧Abrasive granules

319, 419‧‧‧ oversize coating

325‧‧‧Second major surface

360‧‧‧ Pressure sensitive adhesive

370, 470‧‧‧ peeling liner

Edge of 432‧‧

434‧‧‧ holes (perforations)

450‧‧‧Adhesive

460‧‧‧ Pressure sensitive adhesive layer

The invention will be better understood, and many of the features and advantages of the invention will become apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a cross-sectional side elevational view of an abrasive article in accordance with one embodiment of the present invention.

2 is a cross-sectional side elevational view of an abrasive article in accordance with one embodiment of the present invention.

3 is a cross-sectional side elevational view of an abrasive article in accordance with one embodiment of the present invention.

Figure 4 is a cross-sectional side view of an abrasive article in accordance with one embodiment of the present invention. schematic diagram.

Figure 5 is a top plan view of a portion of an abrasive article in accordance with one embodiment of the present invention.

Figure 6 is a top plan view of a portion of an abrasive article in accordance with one embodiment of the present invention.

The following are procedures suitable for forming abrasive articles that can be used in a variety of different applications. In addition, the following includes a description of coated abrasive articles that can be used in some applications, including, for example, high-cutting of workpieces such as wood and metal, as well as precision for ophthalmic lenses, optical fibers, and computer heads. polishing.

In particular, the following is directed to the process of forming an abrasive article having edges on its surface. Forming the edge can include forming a splash ridge or scum ridge that extends from at least a portion of the rim. As used herein, a splash ridge is defined as a residue of a resolidified melt that is on the impact edge (i.e., into the edge) of the cut on the abrasive article or within the abrasive article. As used herein, a dross ridge is defined as a residue of a resolidified melt that is attached to the edge of the cut (i.e., exiting the edge) of the cut in the abrasive article or in the abrasive article.

According to embodiments herein, edges and splash ridges or scum ridges are formed It may include the use of laser light. Laser devices considered suitable for use in accordance with embodiments herein include tunable, fixed wavelength, pulsed, continuous wave (CW) laser devices, or combinations thereof. In certain embodiments, suitable laser devices may include gas laser devices (eg, neon, argon, xenon, xenon, nitrogen, carbon dioxide, carbon monoxide, excimer, etc.), chemical laser devices (eg, Hydrogen fluoride, antimony fluoride, chemical oxygen iodine, full-gas iodine and other laser devices), dye laser devices, metal vapor laser devices (such as barium cadmium, barium mercury, barium selenium, barium silver, barium vapor, barium copper, Copper vapor, gold vapor and other laser devices), solid-state laser devices (eg, ruby, yttrium/yttrium aluminum garnet, yttrium-chromium-aluminum garnet, yttrium: yttrium aluminum garnet, yttrium: lithium lanthanum fluoride, 钕: Barium vanadate, barium: barium calcium borate, titanium: sapphire, barium: yttrium aluminum garnet, barium: yttrium aluminum garnet and other laser devices), semiconductor laser device (semiconductor laser diode, gallium nitride, nitrogen Laser devices such as indium gallium arsenide, aluminum gallium phosphide indium, lead salts, vertical cavity surface emission, quantum cascade, mixed germanium, and the like. In some instances, suitable laser devices include water jets, fiber optics, free electrons, and gas dynamics. In some embodiments, suitable laser devices can include pulsed infrared or ultrafast pulsed laser devices and the like.

Laser devices such as argon ions, carbon monoxide, and metal ions are gas laser devices that can generate wavelengths of far ultraviolet rays such as 氦-silver (He-Ag) 224 nm and neodymium-copper (Ne-Cu) 248 nm. Laser device. These laser devices have a particularly narrow oscillating linewidth of less than 3 GHz (0.5 picometers).

Chemical lasers are powered by chemical reactions and can achieve high power continuous operation. For example, in a hydrogen fluoride laser device (2700 to 2900 nm), a krypton fluoride laser device (3800 nm), the reaction is hydrogen or A combination of helium and ethylene in the combustion products of nitrogen trifluoride.

Excimer lasers represent laser technology in the ultraviolet partial spectrum, which provides pulsed short-wave laser light with high peak power. One of the most typical examples of excimer lasers is a cesium fluoride laser device.

Solid-state laser devices and dye-based laser devices represent laser technologies that span infrared light to the ultraviolet portion of the spectrum, and also provide high peak power and high continuous power. An example of a laser device of this type is yttrium: yttrium vanadate or ytterbium-doped yttrium vanadate laser, and its shorter wavelength harmonic device.

Abrasive article of the laser device in a specific embodiment, described herein is used to form the carbon dioxide laser or an infrared device (i.e., CO ₂₎ is.

In accordance with embodiments herein, a laser device can be used to cut, penetrate, perforate, or otherwise turn an abrasive article into a final product. The laser can be operated via flame cutting, melt cutting, ablation (ie, vaporization, whether by evaporation or sublimation of a portion of the article of abrasive article), or a combination thereof. In some cases, when laser light is used to form the edge of the abrasive article, a hardened, raised, and/or sharp edge is formed on the surface of the abrasive article adjacent to the edge of the laser beam. In some cases, when laser light is used to form the abrasive article, splash ridges or scum ridges of residual particles may be formed which have been melted by the laser light and resolidified on the edge of the abrasive article.

In some cases, a laser device can produce a beam of long-infrared (LWIR) light having a dominant wavelength between about 9 and about 12 microns. In one embodiment, the laser device can produce wavelengths no greater than about 12 microns, such as no greater than about 11 microns, no greater than about 10.6 microns, and no greater than about 10.4. Micron, no greater than about 10.2 microns, no greater than about 10 microns, no greater than about 9.8 microns, no greater than about 9.7 microns, no greater than about 9.6 microns, or even no greater than about 9.4 microns. In one embodiment, the laser device can produce a wavelength of at least about 9 microns, such as at least about 9.2 microns, at least about 9.3 microns, at least about 9.4 microns, at least about 9.5 microns, at least about 9.6 microns, at least about 9.7 microns, at least About 9.8 microns, at least about 9.9 microns, at least about 10 microns, at least about 10.2 microns, at least about 10.4 microns, or even at least about 10.5 microns. In a specific embodiment, the laser device can produce a wavelength of about 10.6 microns. In another embodiment, the laser device can produce a wavelength of about 9.2 microns. It will be appreciated that the laser device can produce wavelengths in the range including any of the aforementioned upper and lower limits as desired.

In one embodiment, a laser device suitable for forming the abrasive article described herein can include a particular average power. For example, a suitable laser device can include an average power of at least about 1000 watts (W), such as at least about 1250 W, at least about 1500 W, at least about 1750 W, at least about 2000 W, or even at least about 2250 W. Nonetheless, in other embodiments, suitable laser devices can include an average power of no greater than about 2500 W, such as no greater than about 2250 W, no greater than about 2000 W, no greater than about 1750 W, no greater than about 1500 W, or even no greater than about. 1250W. It should be understood that suitable laser devices include an average power that can be within any of the aforementioned upper and lower limits.

In one embodiment, the cross-section (i.e., spot size) of the laser beam impinging on the substrate being cut has a particular size, typically a region. For example, the laser beam can be focused to a point that is the point of contact of the laser beam with the abrasive article such that all portions of the total contact point have an intensity that is at least half of the average beam intensity and has an area less than or equal to 0.3. Square millimeters (mm ² ), less than about 0.1 square millimeters, or even less than about 0.01 square millimeters. In one embodiment, the trace rate of the laser light (i.e., the rate at which the beam sweeps across the substrate) can be at least about 10 millimeters per second, such as at least about 20 millimeters per second.

Laser ablation of the material of the coated abrasive article may use a single trace (ie, single pass) of the laser beam or multiple superimposed traces (ie, multiple passes in the same space) of the laser The beam is achieved. Alternatively, multiple laser beams can be used simultaneously or sequentially. If multiple laser beams are used, they may have the same or different wavelengths. In one embodiment, the individual components of the coated abrasive article can be sequentially removed with a laser beam, each of which can be adjusted to an absorption band of each component (eg, a backing pad, an abrasive layer, or a combination thereof). . In another embodiment, the various components of the abrasive article are simultaneously removed using a plurality of laser beams that are adjusted to various components of the abrasive article (eg, a backing pad, an abrasive layer, or a combination thereof) Absorption band.

Additional laser light can also be used, for example, if additional components are present, such as multiple layers of an abrasive article. If multiple laser beams are used, their traces are usually superimposed to achieve maximum benefit, although this is not required.

In a specific embodiment, a single laser light is used in which a single trace or multiple traces are formed. In another embodiment, a plurality of laser lights are used, wherein each of the laser lights performs a single trace or a plurality of traces.

Laser ablation can be done in such a way that it does not penetrate completely Coated abrasive article. In some instances, laser ablation can be performed on an abrasive article that does not completely wear the abrasive article. Additionally, laser ablation can be performed from any direction, for example, from a "front" surface (ie, a polished surface) to a "back" surface (non-abrasive surface), or vice versa. In one embodiment, laser ablation can be performed from the back side of the abrasive article such that the laser light can illuminate or pass through the back surface before illuminating or passing the front or upper surface (ie, the first surface of the abrasive article) (ie, grinding the second surface of the article). In some cases, the laser light can form at least one aperture through the abrasive article (ie, from the second surface of the abrasive article to the first surface of the abrasive article).

According to one embodiment, a method of forming an abrasive article described herein can be initiated in a first step comprising: providing an abrasive article having a first surface and a second surface, the second surface being spaced apart from the first surface. FIG. 1 is a cross-sectional side view of an abrasive article 100 in accordance with one embodiment. As shown, the first surface 101 can be the top surface of an abrasive article that is defined to contact the workpiece for cutting, sanding, grinding, or the like. As described herein, the first surface 101 can be an abrasive layer (ie, a make coat having abrasive particles dispersed within the make coat - "abrasive slurry", or disposed on the surface from which the coating is made), size coated Layer, oversize coating, or a combination thereof. In one particular example, the first surface comprises an oversized coating.

As also shown in FIG. 1, the second surface 108 of the abrasive article 100 is spaced from the first surface 101 of the abrasive article 100, and the second surface 108 can be substantially parallel to the first surface 101. As described herein, the second surface can include a backing pad, an adhesive layer, a joining system as described herein, or the like.

According to one embodiment, a method of forming an abrasive article can include The laser light 150 is directed to the abrasive article 100 to illuminate the second surface 108 prior to illuminating the first surface 101. Laser light 150 as used herein may be referred to as a laser beam that may be directed to the back surface (or second surface 108) or to the abrasive article 100 such that it illuminates or passes through the surface (or first surface 101) of the article prior to illumination. Previously, the surface (or second surface 108) of the article after it has been illuminated or passed through. Referring briefly to Figure 2, the laser light 250 can be directed to the rear surface (or second surface 208) or to the abrasive article 200 such that it is illuminated or worn prior to illuminating or passing through the surface (or first surface 201) prior to the abrasive article. The surface (or second surface 208) after grinding the article. As described herein, and it should be understood that the laser light 250 can include a focused beam of light that can form a surface, such as surfaces 209 and 210, which can define a particular taper, such as a tapered aperture 206.

According to one embodiment, a method of forming an abrasive article can include forming an edge on a first surface of the abrasive article. For example, as shown in FIG. 1, the edge 102 can be formed on the first surface 101 of the abrasive article 100. In one embodiment, the edge 102 can define at least a portion of the perimeter 107 of the abrasive article 100, it being understood that the perimeter 107 may define the circumference of the abrasive article 100. According to one embodiment, a method of forming an abrasive article can include forming one or more scum ridges 103 extending from edge 102 of perimeter 107 and/or at least a portion of aperture 106, as described herein.

After the forming process is completed, the abrasive article is formed. The abrasive article can have certain characteristics that will be described in more detail in accordance with the embodiments described herein.

For example, referring back to FIG. 1 in accordance with an embodiment described herein, the edge 102 can define a hole formed in at least a portion of the abrasive article 100. 106. In some examples, the abrasive article 100 can include a plurality of apertures 106. According to one embodiment, the number and configuration of the holes depends on the application of the abrasive article and the size of the abrasive article. For example, the number of apertures disposed on the abrasive article can be no greater than about 500, no greater than about 400, no greater than about 300, no greater than about 200, no greater than about 100, no greater than about 50, or even no greater than about 40. In one embodiment, the number of apertures disposed on the abrasive article can be at least about 40, at least about 50, at least about 10, at least about 200, at least about 300, at least about 400, or even at least about 500. It should be understood, however, that the number of holes 106 can be within the range of any of the foregoing upper and lower limits.

According to one embodiment, the abrasive article can be a circular disc and the shape of the plurality of apertures can comprise a circular shape. However, other shapes of abrasive articles and/or apertures are considered to be within the scope of the embodiments described herein. For example, the abrasive article can comprise a disc, a circular, elliptical, rectangular, polygonal two-dimensional shape, an annular band, or a combination of peripheral edges defined by the shape.

According to one embodiment, the edges defining the one or more apertures may comprise a circular, rectangular, elliptical, curved, polygonal two-dimensional shape, or a combination thereof.

One or more apertures may be placed anywhere within the abrasive article and they may occupy a particular percentage of the open area of the top surface (ie, the first surface) of the abrasive article. In some examples, the one or more apertures can occupy at least about 1%, such as at least about 10%, at least about 20%, at least about 30%, at least the open area of the top surface (ie, the first surface) of the abrasive article. About 40%, at least about 50%, or even at least about 60%. In one embodiment, one or more of the holes may occupy an open area of the top surface (ie, the first surface) of the abrasive article Not more than 70%, such as not more than about 60%, not more than about 50%, not more than about 40%, not more than about 30%, not more than about 20%, not more than about 10%, or even not more than about 1% . It should be understood that the percentage of the open area of the top surface (i.e., the first surface) of the abrasive article that the one or more holes occupy may include any of the aforementioned upper and lower limits.

Each opening of the aperture can include a particular size. For example, the opening of the one or more apertures can be at least about 1 mm, such as at least about 5 mm, at least about 10 mm, at least about 20 mm, or even at least about 30 mm. In one embodiment, the opening of the one or more apertures may be no more than about 30 millimeters, such as no greater than about 20 millimeters, no greater than about 10 millimeters, no greater than about 5 millimeters, or even no greater than about 1 millimeter. It should be understood that the size of the opening of one or more of the apertures may be within the range of any of the foregoing upper and lower limits.

In some embodiments, the apertures can be arranged in a predetermined distribution. It should be understood that the predetermined distribution of the first discrete regions may be defined by a combination of predetermined locations on the selected substrate. The predetermined distribution may include a pattern such that the predetermined location may define a two-dimensional array. The array may have a short range order defined by a unit of first discrete regions. The array may also be a pattern having a long range order comprising regular and repeating units joined together, such an arrangement may be symmetrical and/or predictable. The array can have an order that can be predicted using mathematical formulas. It should be understood that the two-dimensional array can be formed into a polygonal shape, omitting marks, decorative indicia, product indicia, or other designs. The predetermined distribution may also include a controlled uneven distribution, a controlled uniform distribution, and combinations thereof. In certain cases, the predetermined distribution may include radiation Pattern, spiral pattern, leaf pattern, asymmetric pattern, self-avoiding random distribution, and combinations thereof. The predetermined distribution may be partially, substantially, or completely asymmetrical. As used herein, "leaf pattern" refers to a pattern associated with a leaf order. Leaf order is the arrangement of lateral organs such as leaves, flowers, scales, florets, seeds, etc. of many plants. Many leaf-sequence patterns are naturally occurring phenomena with distinct patterns of arcs, spirals, and turbines. Seeds on the head of a sunflower are an example of this phenomenon. In a particular embodiment, the plurality of first discrete regions can be arranged in rows, columns, circles, squares, rectangles, or any combination thereof.

According to one embodiment, the scum ridges 103 may be formed on the first surface 101. The scum ridges 103 may extend from at least a portion of the rim 102, and thus it is understood that the scum ridges 103 may extend from at least a portion of the perimeter 107 and/or the edge 102 of the aperture 106. In particular, the scum ridges 103 may extend from at least a portion of the rim 102 to have an average width 104. The average width 104 of the scum ridge 103 can be defined as the average distance between the edge 102 and the instantaneous scum ridge outer boundary 113, which is measured along the vertical edge 102 of the scum ridge 103 to be measured. direction. In some examples, the average width 104 of the scum ridges 103 can be at least about 101 microns, such as at least about 110 microns, at least about 120 microns, at least about 130 microns, at least about 140 microns, at least about 150 microns, at least about 200 microns, at least about 250 microns, at least about 300 microns, at least about 350 microns, at least about 400 microns, or even at least about 450 microns. Nonetheless, in one embodiment, the scum ridges 103 can include an average width 104 of no greater than about 500 microns, such as no greater than about 450 microns, no greater than about 400 microns, no greater than about 350 microns, and no greater than about 300 microns. Do not Greater than about 250 microns, no greater than about 200 microns, no greater than about 150 microns, no greater than about 140 microns, no greater than about 130 microns, no greater than about 120 microns, or even no greater than about 110 microns. It should be understood that the average width may be within a range including any of the aforementioned upper and lower limits.

According to one embodiment, the scum ridge 103 may comprise a particular height defined as the distance of the average highest point of the scum ridges 103 on the first surface 101, the distance being along the section of the scum ridge, along The direction of the vertical edge 102 of the scum ridge 103 to be measured is measured. In some examples, the scum ridge 103 can comprise a particular height that is no greater than about 50 microns, such as no greater than about 40 microns, no greater than about 30 microns, no greater than about 20 microns, no greater than about 10 microns, or Not even greater than about 5 microns. In one embodiment, the scum ridges 103 can comprise a particular height that is at least about 1 micron, such as at least about 5 microns, at least about 10 microns, at least about 20 microns, at least about 30 microns, or even at least about 40 microns. . It should be understood that the height of the scum ridge may be within the range including any of the aforementioned upper and lower limits.

According to one embodiment, the scum ridge 103 may comprise a ratio of height (h _dr ) to ridge width (w _dr ), calculated according to the formula h _dr /w _dr , having a value of no greater than about 0.495, such as no greater than about 0.45, no greater than About 0.40, no greater than about 0.35, no greater than about 0.30, no greater than about 0.25, no greater than about 0.20, no greater than about 0.15, no greater than about 0.10, or even no greater than about 0.05. In one embodiment, the scum ridge 103 can include a ratio of height (h _dr ) to ridge width (w _dr ) of at least about 0.01, such as at least about 0.05, at least about 0.10, at least about 0.15, at least about 0.20, at least about 0.25. At least about 0.30, at least about 0.35, at least about 0.40, at least about 0.45. It should be understood that the scum ridge 103 may include a ratio of the height (h _dr ) to the ridge width (w _dr ) that is within the range including any of the aforementioned upper and lower limits.

According to one embodiment, the intensity of the laser light used to form the abrasive article can affect the width of the scum ridge. In some embodiments, the intensity of the laser light can be at least about 300 watts (W), such as at least about 500 W, at least about 750 W, at least about 1000 W, at least about 1250 W, at least about 1500 W, at least about 1750 W, or even at least about 2000 W. , or even at least about 2250W. In other non-limiting embodiments, the intensity of the laser light can be no greater than about 2500 watts (W), such as no greater than about 2250 W, no greater than about 2000 W, no greater than about 1750 W, no greater than about 1500 W, greater than about 1250 W. , no more than about 1000 W, no more than about 750 W, or even no more than about 500 W. It should be understood that the intensity of the laser light may be within a range including any of the aforementioned upper and lower limits.

According to one embodiment, the laser head speed (inches per second) of the laser light can affect the width of the scum ridge. In some embodiments, the speed (in inches per second) of the laser head can be at least about 1, such as at least about 2, at least about 3, at least about 5, at least about 8, at least about 10, 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, at least about 80, at least About 85%, at least about 90, at least about 100, at least about 150, at least about 200, at least about 250, at least about 300, at least about 350, at least about 400, at least about 450, or even at least about 500, in other non-limiting In an embodiment, the speed (in inches per second) of the laser head may be no greater than about 500, such as no greater than about 450, no greater than about 400, no greater than about 350, no greater than about 300, no greater than about 250, and no greater than about 250. About 200, no more than about 150, no more than about 110, no more than about 100, no more than about 95, no more than about 90, no more than about 85, not greater than about 80, not less than about 75, not greater than about 70, not greater than about 65, not greater than about 60, not greater than about 55, not greater than about 50, not greater than about 45, not greater than about 40, not greater than About 35, no greater than about 30, no greater than about 25, no greater than about 20, no greater than about 15, no greater than about 10, no greater than about 8, no greater than about 5, no greater than about 3, no greater than about 2, or even Not more than about 1, it should be understood that the speed of the laser head may be within the range including any of the aforementioned upper and lower limits.

According to one embodiment, the perimeter defining the perimeter of the abrasive article or the one or more apertures may partially define a third surface that intersects the first surface and the second surface. 2 is a cross-sectional side view of an abrasive article 200 in accordance with one embodiment. As shown, the third surfaces 209 and 210 intersect the first surface 201 and the second surface 208, and in some cases, the third surfaces 209 and 210 can intersect the first surface substantially at a normal (vertical) angle. 201 and/or second surface 208, as shown in FIG. 2, in other cases, third surfaces 209 and 210 may intersect at first surface 201 and/or second substantially at an abnormal (non-perpendicular) angle Surface 208. In certain instances, the third surface 210 can partially define the opening 206 defining a tapered bore 206. In a more specific embodiment, the tapered bore 206 can include a first edge 211 disposed on the first surface 201 and a second edge 212 disposed on the second surface 208, wherein the diameter of the second edge 212 is greater than the first edge 211 diameter of.

Abrasive articles in accordance with embodiments described herein can include specifically arranged layers. FIG. 3 is a cross-sectional side view of an abrasive article 300 in accordance with one embodiment. As shown, the abrasive article 300 can include an abrasive layer 314 that is secured to the first major surface 315 of the backing pad 310. Back pad 310 can include a second major surface 325 that is spaced apart from first major surface 315. In some cases, you can use more Layer back pad. For example, the backing pads of the plurality of layers can be a laminate of one or more known backing materials, typically with an adhesive to hold the layers together. In other embodiments, the backing pad may include one or more treatments to seal the backing pad and/or modify the physical properties of the backing pad.

According to one embodiment, the first major surface 315 of the backing pad 310 can be the surface on which the abrasive layer 314 is disposed. Moreover, it should be understood that the first major surface 315 of the backing pad 310 can be a surface on which the make coating 316, the size coating 317, the oversize coating 319, or a combination thereof, etc. are disposed.

According to one embodiment, the second major surface 325 of the backing pad 310 can include a attachment system to secure the resulting abrasive article 300 to a tool or device to facilitate use of the abrasive article. In a particular embodiment, the second major surface 325 of the backing pad 310 can include a support pad, a support pad, a hook and loop attachment system, an engagement connection system, a threaded projection, or a combination thereof. It should be understood that the fixed attachment system can include, for example, pressure sensitive adhesive 360, release liner 370, non-slip or friction coating, or a combination thereof.

According to one embodiment, the back pad 310 can be flexible or rigid. Back pad 310 can be formed from any number of materials, including those used in the manufacture of generally applied abrasive materials. Exemplary flexible backings include polymeric films (eg, primer films) such as polyolefin films (eg, polypropylene, including biaxially oriented polypropylene), polyester films (eg, polyethylene terephthalate) Alcohol ester), polyamide film, or cellulose ester film; metal foil; mesh; foam (for example, natural sponge material or polyurethane foam); cloth (for example, fiber or yarn including polyester, nylon, silk, Cotton, cotton, or rayon); paper; vulcanized paper; vulcanized rubber; vulcanized fiber; non-woven Materials; combinations thereof; or their treated variants. The cloth back pad can be formed by weaving or stitching. In a specific example, 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, organic material, Synthetic materials, nylon, para-aramid materials, and combinations thereof. In other embodiments, the backing pad comprises a polypropylene film or a polyethylene terephthalate (PET) film.

In some cases, the back pad 310 can include multiple layers. For example, the backing pads of the plurality of layers can be a laminate of one or more known backing materials, typically held together by an adhesive. In other embodiments, the backing pad may include one or more processes for sealing the backing pad and/or modifying the physical characteristics of the backing pad 310. Back pad 310 can optionally have at least one of a saturant, a front size coating or a back size coating. The purpose of these layers is usually to seal the backing or to protect the yarn or fiber of the backing pad. If the backing pad is a cloth material, at least one of these layers is typically used. The addition of a front or back size coating can create a "smoother" surface on the front or back side of the backing pad. Other optional layers known in the art can also be used (e.g., 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 can reduce the tendency to accumulate static electricity when the coated abrasive article is sanded wood or wood based materials. Further details regarding the treatment of the antistatic backing 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.); 5328716 (Buchanan); and 5,560,753 Case (Buchanan et al.) The disclosure is incorporated herein by reference.

The backing pad may be a fiber reinforced thermoplastic, for example, as described in U.S. Patent No. 5,417,726 (Stout et al.), or a ring-shaped endless belt, for example, as described in U.S. Patent No. 5,573,619 (Benedict et al.). The disclosure of which is incorporated herein by reference. Likewise, the backing pad can be a polymeric substrate having a raised 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. Patent No. 5,556,011, the disclosure of which is incorporated herein by reference.

According to one embodiment, the make coat 316 can include abrasive particles 318 embedded therein, and can further include a size coating 317 that can cover the make coat 316 and the abrasive particles 318. In a specific example, the oversized coating 319 can cover the size coating 317. In some examples, the scum ridges 330a can be disposed adjacent to at least a portion of the edge 332 that defines the perimeter of the abrasive article 300. In other examples, the scum ridges 330b can be disposed adjacent to at least a portion of the edge 134 that defines the aperture 134.

According to one embodiment, the make coat 316 or size coating 317 can include one or more binders. The binder from which the coating 316 or size coating 317 is made is formed from a single polymer or blend of polymers. For example, the binder may be formed of an epoxy resin, an acrylic polymer, or a combination 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 formulation that is cured to form the adhesive is a package A colloidal suspension of particulate fillers is included. Alternatively, or in addition, the binder may be a binder of a nanocomposite, including submicron particulate fillers.

The binder typically comprises a polymeric substrate that bonds the abrasive particles to a backing or compliant coating, if any. Generally, 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. Chemical agent.

The polymer component can form a thermoplastic or a thermoset plastic. By way of example, the polymer component may comprise a monomer and a resin which may form a polyurethane, a polyurea, a polymerized epoxy resin, a polyester, a polyimide, a polyoxyalkylene (organoindole), a polymeric alkyd. Resin, styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene, or a reactive resin which is generally used to produce thermosetting polymers. Another example includes an acrylate or methacrylate polymer composition. The precursor polymer component is typically a curable organic material (ie, can be polymerized or exposed to heat or other energy sources such as electron beams, ultraviolet light, visible light, etc., or chemical catalysts, water vapor or other agents added over time or a monomer or material of a crosslinked polymer). Examples of precursor polymer components include reactive components which are used to form amino polymer or aminoplast polymers, such as alkylated urea-formaldehyde polymers, melamine-formaldehyde polymers, And alkylated benzoguanamine-formaldehyde polymers; acrylate polymers including acrylate and methacrylate polymers, alkyl acrylates, acrylated epoxies, acrylated urethanes , an acrylated polyester, an acrylated polyether, a vinyl ether, an acrylated oil, or an acrylated polyoxyalkylene; an alkyd polymer such as a polyurethane alkyd polymer; a polyester polymer; Reactive polyurethane polymer; phenolic polymer such as phenolic resin A and novolak polymer; phenolic/latex polymer such as bisphenol epoxy polymer; epoxy polymer obtained from isocyanate; isocyanurate; a polyoxyalkylene polymer of an alkoxydecane polymer; or a reactive vinyl polymer. The binder formulation can include monomers, oligomers, polymers, or combinations thereof. In a particular embodiment, the adhesive formulation includes 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 form an epoxy/acrylic polymer upon curing.

The coated abrasive article can include an oversized coating 319 overlying the size coating 317. The oversized coating 319 can be the same or different from the polymeric binder composition or size coating composition. The oversized coating 319 can comprise any of the conventional compositions known in the art for forming oversized coatings. In one embodiment, the oversized coating 319 includes known conventional compositions overlying the size coating composition. In another embodiment, the oversized coating 319 comprises at least one of the same composition as the polymeric coating composition of the size coating composition or the abrasive layer. In a particular embodiment, the oversized coating comprises a composition that is the same as the polymeric binder composition or size coating composition of the abrasive layer plus one or more grinding aids.

Suitable grinding aids can be based on inorganic materials such as halide salts, For example, sodium cryolite, and potassium tetrafluoroborate; or based on organic matter such as sodium lauryl sulfate, or a chlorinated wax such as polyvinyl chloride, or a metal salt of a fatty acid such as zinc stearate or calcium stearate. In one embodiment, the grinding aid can be an environmentally friendly material.

A particular embodiment includes cryolite and potassium tetrafluoroborate having a particle size ranging from 1 micron to 80 microns, most typically from 5 microns to 30 microns. The oversized coating can be a plastic material applied to the abrasive particles that provides properties that are resistant to vitrification and load. In one embodiment, the scum ridge 330a and the scum ridge 330b may comprise a material from which the coating 316 is made, a material of the size coating 317, a recast material, stearic acid, zinc stearate, and combinations thereof. It will be appreciated that because of the laser ablation process used to form the edges of the perimeter defining one or more apertures of the coated abrasive article 300, the scum ridges 330a and scum ridges 330b may comprise from the coated abrasive article 300. Any material that is recast (such as molten and resolidified).

In one embodiment, the abrasive particles 318 can be dispersed in a binder that is secured to the backing pad 310. Such coated abrasive articles can have a desired surface shape. For example, the abrasive layer 314 can include a shaped abrasive composite that, in at least some embodiments, has a precise shape and is secured to the backing pad 310. Structured abrasive articles fall into this category.

According to one embodiment, the coated abrasive article 300 can have a particular abrasive particle size. In some embodiments, the abrasive article 300 can have a specific abrasive particle size of at least about P100, such as at least about P200, at least about P300, at least about P400, at least about P500, at least about P600, at least about P700, at least about P800, At least about P900, at least about P1000, at least about P1100, at least about P1200, at least about P1300, at least about P1400, or even at least about P1500. In other non-limiting embodiments, the abrasive article 300 can have a specific abrasive particle size of no greater than about P1500, such as no greater than about P1400, no greater than about P1300, no greater than about P1200, no greater than about P1100, and no greater than about P1000. No more than about P900, no more than about P800, no more than about P700, no more than about P600, no more than about P500, no more than about P400, or even no more than about P300. It should be understood that the specific abrasive particle size of the abrasive article 300 can include any of the foregoing upper and lower limits.

Reference is now made to Fig. 4, which is a cross-sectional side elevational view of an abrasive article in accordance with one embodiment. The coated abrasive article 400 (structured abrasive article) has an abrasive layer 414 that includes a shaped abrasive composite 420 that is secured to the first major surface 415 of the backing pad 410. The shaped abrasive composite 420 includes abrasive particles 418 dispersed in a binder 450. A selective oversize coating 419 can be overlaid on the abrasive layer 414. The scum ridges 430a may be disposed adjacent to the peripheral edge 432, while the scum ridges 430b may be disposed adjacent to the holes (perforations) 434. A selective pressure sensitive adhesive layer 460 can be disposed on the second major surface 425 of the backing pad 410 relative to the first major surface 415. A selective release liner 470 can be disposed over the selective pressure sensitive adhesive layer 460.

Figure 5 is a top plan view of a portion of an abrasive article having a scum ridge 502 formed using laser light and having a width ( _wdr ), in accordance with one embodiment. 6 is a top plan view of a portion of an abrasive article having a scum ridge 602 formed using laser light and having a width (w _dr ), in accordance with one embodiment.

example

Samples of the three abrasive articles were treated with laser light to create a scum ridge in the sample of the abrasive article. Laser light having a intensity of 1000 watts was directed to samples of the three abrasive articles, each having an abrasive grain size of P600. Laser light was incident on samples 1, 2 and 3 of the abrasive article at a speed of 100 inches per second, 500 inches per second, and 15 inches per second, respectively. The width of the scum ridge formed by the laser treatment is shown in Table 1 below. In particular, laser light having a strength of 1000 watts and a laser head speed of 15 inches/second provides scum having an average width of 21 microns. ridge.

As used herein, the terms "comprises," "comprising," "includes," "includes", "including", "has" ("has," "),"have" ("having,"), or any other variation thereof, is intended to cover non-exclusive inclusions. For example, a process, method, article, or device that includes the features of the list is not necessarily limited to those features, but may include features not specifically listed, or other processes inherent in such processes, methods, articles, or devices. Characteristics. As used herein, the phrase "consisting essentially of" or "consisting essentially of" is used to mean "consists essentially of" or "consisting essentially of" The body of the description does not include any other components that substantially affect the attributes of the subject.

In addition, unless expressly stated to the contrary, "or" ("or") is meant to be inclusive or rather than 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 Be true (or exist).

The use of "a" or "an" is used to describe the elements and components described herein. This is for convenience only and is intended to give a general sense of the scope of the invention. This description is to be understood as inclusive of the claims

In addition, references to values expressed in ranges include each value in the range. The term "about" or "approximately" before a numerical value, for example, when describing a numerical range, the precise numerical value is also included. For example, a numerical range "about 25" is intended to start at exactly 25 but also includes a range.

As used herein, the term "average particle size" ("average Particle diameter") can represent an average, average, or median particle size, and is also commonly referred to in the art as D50.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as understood by one of ordinary skill in the art. The materials, methods, and examples are illustrative only and are not intended to be limiting. To the extent not recited herein, many details of particular materials and processing methods are conventional and can be found in textbooks and other sources of scintillation and radiation detection techniques.

In the above, reference to specific embodiments and connections of certain components are exemplary. It should be understood that the reference to the components to be coupled or connected is intended to disclose a direct connection of the components or an indirect connection via the intermediate components to implement the methods discussed herein, which should be understood. Therefore, the above-disclosed subject matter is considered to be illustrative and not restrictive, and the appended claims are intended to cover all such modifications, Inside. Moreover, not all of the above general descriptions or embodiments are required, a portion of the specific function may not be required, and one or more other effects may be additionally added. Furthermore, the order in which these effects are listed is not necessarily the order in which they are performed.

It is to be understood that the invention is not to be construed as limited or limited. In addition, some of the features described herein in the context of separate embodiments may also be combined in a single embodiment for clarity. Conversely, various features that are described in the context of a single embodiment can also be provided separately or in any Sub-combinations are provided. Nonetheless, the subject matter of the present invention may be directed to less than all features of any disclosed embodiments.

Benefits, other advantages, and solutions to problems have been described above in terms of specific embodiments. However, benefits, advantages, resolution of problems, and any features that may be more apparent to cause any benefit, advantage, or resolution of the problem, should not be construed as critical or necessary for any or all of the scope of the patent application, or Essential feature.

The scope of the invention is to be construed as being limited by the

Item 1. An abrasive article comprising: a first surface having an edge; and a scum ridge formed on the first surface, the scum ridge extending from at least a portion of the edge and having an average width of at least about 101 microns and no greater than About 500 microns.

Item 2. The abrasive article of item 1, wherein the edge defines a hole, wherein the edge defines a perimeter of the abrasive article.

Item 3. An abrasive article comprising: an edge having a first surface, wherein the edge defines a hole; and a scum ridge formed on the first surface, the scum ridge extending from at least a portion of the edge and having an average width at least About 101 microns and no more than about 500 microns.

Item 4. The abrasive article of any of the preceding items, wherein the shape of the edge is a circle, a rectangle, an ellipse, a curve, a polygonal two-dimensional shape, or a combination thereof.

Item 5: The abrasive article of any of the above items, wherein the average of the scum ridges The width is defined as the average distance between the edge and the outer boundary of the scum ridge, which is measured along the direction in which the scum ridge extends vertically from the edge.

Item 6. The abrasive article of any of the preceding items, wherein the material of the scum ridge comprises a material for coating, a material for size coating, a material for oversize coating, a material for recasting, stearic acid, hard Zinc citrate, calcium stearate, or a combination thereof.

Item 7. The abrasive article of any of the preceding items, wherein the scum ridge is formed using an infrared laser, wherein the scum ridge is formed using a CO ₂ laser.

Item 8. The abrasive article of any of the preceding items, wherein the scum ridge further comprises a height defined as a distance of the scum ridge from an average highest point of the first surface, the distance being at the scum ridge The cross-sectional view is measured along the direction in which the scum ridge extends vertically from the edge.

The abrasive article of any of the preceding items, wherein the height of the scum ridge is no greater than about 50 microns and at least about 1 micron.

Item 10. The abrasive article of item 8, wherein the scum ridge comprises a ratio of ridge height (h _dr ) to ridge width (w _dr ) according to the formula h _dr /w _dr , the value of which is no greater than about 0.495.

The abrasive article of any of the preceding items, further comprising a back pad, wherein the back pad material comprises at least one of the following materials: woven material, nonwoven material, fiber material, organic material, synthetic material, nylon, Carbon fiber, para-aramid material, or a combination thereof.

Item 12. The abrasive article of item 11, further comprising an abrasive layer affixed to the backing pad, wherein the abrasive layer comprises abrasive particles.

Item 13. The abrasive article of item 12, wherein the abrasive particles comprise a D50 of no greater than about 30 microns.

Item 14. The abrasive article of any of the preceding items, wherein the abrasive article is a coated abrasive article.

The abrasive article of any of the preceding items, wherein the abrasive article comprises a make coat, a size coat, an oversize coat, or a combination thereof.

The abrasive article of any of the preceding items, wherein the first surface is at least one of an abrasive layer, a make coat, a size coat, an oversize coat, or a combination thereof.

Item 17. A method of forming an abrasive article, comprising: providing an abrasive article having a first surface and a second surface spaced from the first surface; forming an edge on the first surface; and forming on the first surface A scum ridge extending from at least a portion of the rim and having an average width of at least about 101 microns and no greater than about 500 microns.

Item 18. The abrasive article of item 17, wherein the edge defines a hole, wherein the edge defines a perimeter of the abrasive article.

The method of item 17, wherein the forming the ridge comprises using a laser to form the ridge.

The method of item 19, wherein the infrared laser has a maximum average power of at least about 1000 watts.

The method of any of item 21, wherein the forming a spine pack The laser light is directed to the abrasive article and the second surface is illuminated prior to illuminating the first surface.

The method of any of clauses 19 or 20, wherein forming a scum ridge on the first surface of the abrasive article comprises forming a hole extending from the second surface of the abrasive article to the first surface of the abrasive article .

Item 23. A coated abrasive article comprising: a backing pad material having a first major surface spaced apart from a first major surface; an abrasive layer disposed on the first major surface; disposed in the abrasive layer a size coating on the size; an oversize coating disposed on the size coating; at least one hole extending through the backing material, the abrasive layer, the size coating, and the oversize coating; and being disposed in at least a portion A scum ridge on the coated abrasive article, the scum ridge directly adjacent at least a portion of the edge of the aperture, wherein the scum ridge has an average width ranging from 101 microns to 500 microns.

The coated abrasive article of clause 23, wherein the scum ridge has a maximum average height on the first surface on which the scum ridge is located, the value of which is less than 40 microns.

Item 25. The coated abrasive article of item 23, wherein the ratio of the average width (w _dr ) of the scum ridge to the maximum average height (h _dr ) of the scum ridge is no greater than 0.495.

Item 26. An abrasive article comprising: a first surface having an edge; and a scum ridge formed on the first surface, the scum ridge extending from at least a portion of the rim having an average width of at least about 101 microns and no greater than About 500 microns.

Item 27. The abrasive article of item 26, wherein the edge defines a hole.

Item 28. The abrasive article of item 26, wherein the average width of the scum ridge is defined as the average distance between the edge and the outer boundary of the scum ridge, the distance extending perpendicularly from the edge along the scum ridge Measured.

Item 29. The abrasive article of item 26, wherein the scum ridge comprises a recast material.

The abrasive article of item 26, wherein the scum ridge further comprises a height defined as a distance of the scum ridge from an average highest point of the first surface, the distance being on a cross-sectional view of the scum ridge Measured along the direction in which the scum ridge extends vertically from the edge.

The abrasive article of item 31, wherein the scum ridge has a height of no greater than about 50 microns and at least about 1 micron.

Item 32. The abrasive article of item 30, wherein the scum ridge comprises a ratio of height (h _dr ) to scum ridge width (w _dr ), the value of which is no greater than about 0.495 according to the formula h _dr /w _dr .

The abrasive article of item 26, wherein the first surface comprises an abrasive layer affixed to the backing pad, and wherein the abrasive layer comprises abrasive particles.

Item 34. The abrasive article of item 33, wherein the abrasive particles have a D50 of no greater than about 30 microns.

Item 35. The abrasive article of item 33, wherein the abrasive layer comprises a make coat, a size coat, an oversize coat, or a combination thereof.

Item 36. A method of forming an abrasive article, comprising: providing a first surface and a second surface spaced from the first surface; on the first surface Forming an edge; and forming a scum ridge on the first surface, the scum ridge extending from at least a portion of the edge having an average width of at least about 101 microns and no greater than about 500 microns.

Item 37. The method of item 36, wherein forming a scum ridge comprises using a laser to form a scum ridge.

Item 38. The method of item 37, wherein the laser light has a maximum average power of at least about 1000 watts.

The method of item 37, wherein forming the scum ridge comprises directing the laser light to illuminate the second surface prior to illuminating the first surface.

The method of item 36, wherein forming the scum ridge on the first surface of the abrasive article comprises forming a hole extending from the second surface of the abrasive article to the first surface of the abrasive article.

100‧‧‧Abrased products

101‧‧‧ first surface

102‧‧‧ edge

103‧‧‧ scum ridge

104‧‧‧ average width

105‧‧‧ Height of scum ridge

106‧‧‧ holes

107‧‧‧around

108‧‧‧second surface

150‧‧‧Laser light

Claims (13)

An abrasive article comprising: a first surface having an edge; and a scum ridge formed on the first surface, the scum ridge extending from at least a portion of the rim having an average width of at least about 101 microns and Not greater than about 500 microns, wherein the dross ridge comprises a recast material. The abrasive article of claim 1, wherein the edge defines a hole. The abrasive article of claim 1, wherein the average width of the scum ridge is defined as an average distance between the edge and an outer boundary of the scum ridge, the distance being along the scum ridge The direction in which the edge extends vertically is measured. The abrasive article of claim 1, wherein the scum ridge further comprises a height defined as a distance of the scum ridge from an average highest point of the first surface, the distance being at the float The cross section of the slag ridge is measured along the direction in which the scum ridge extends vertically from the edge. The abrasive article of claim 4, wherein the scum ridge has a height of no greater than about 50 microns and at least about 1 micron. The abrasive article of claim 4, wherein the scum ridge comprises a ratio of a height (h _dr ) to a width (w _dr ) of the scum ridge, according to the formula h _dr /w _dr , the value is not greater than about 0.495. The abrasive article of claim 1, wherein the first surface comprises an abrasive layer affixed to a backing pad, and wherein the abrasive layer comprises abrasive particles. The abrasive article of claim 7, wherein the abrasive particles have a D50 of no greater than about 30 microns. The abrasive article of claim 7, wherein the abrasive layer comprises a make coat, a size coat, an oversize coat, or a combination thereof. A method of forming an abrasive article, comprising: providing an abrasive article having a first surface and a second surface spaced from the first surface; forming an edge on the first surface; and on the first surface Forming a scum ridge extending from at least a portion of the rim having an average width of at least about 101 microns and no greater than about 500 microns, wherein forming the scum ridge on the first surface of the abrasive article comprises forming A hole extends from the second surface of the abrasive article to one of the first surfaces of the abrasive article. The method of claim 10, wherein forming the scum ridge comprises using a laser to form a scum ridge. The method of claim 11, wherein the laser light has a maximum average power of at least about 1000 watts. The method of claim 11, wherein forming the scum ridge comprises directing the laser light to illuminate the second surface prior to illuminating the first surface.