WO1994027833B1 - Patterned abrasive material and method - Google Patents

Patterned abrasive material and method

Info

Publication number
WO1994027833B1
WO1994027833B1 PCT/US1994/005780 US9405780W WO9427833B1 WO 1994027833 B1 WO1994027833 B1 WO 1994027833B1 US 9405780 W US9405780 W US 9405780W WO 9427833 B1 WO9427833 B1 WO 9427833B1
Authority
WO
WIPO (PCT)
Prior art keywords
particles
matrix material
sensitive adhesive
pressure sensitive
adhesive tape
Prior art date
Application number
PCT/US1994/005780
Other languages
French (fr)
Other versions
WO1994027833A1 (en
Filing date
Publication date
Priority claimed from US08066475 external-priority patent/US5380390B1/en
Application filed filed Critical
Priority to AT94918093T priority Critical patent/ATE259278T1/en
Priority to AU69561/94A priority patent/AU690560C/en
Priority to CA002163030A priority patent/CA2163030C/en
Priority to EP94918093A priority patent/EP0713452B1/en
Priority to JP7500870A priority patent/JPH08510694A/en
Priority to BR9406663A priority patent/BR9406663A/en
Priority to RU95122657A priority patent/RU2143332C1/en
Priority to DE69433547T priority patent/DE69433547T2/en
Publication of WO1994027833A1 publication Critical patent/WO1994027833A1/en
Publication of WO1994027833B1 publication Critical patent/WO1994027833B1/en

Links

Abstract

An abrasive material is formed by coating a substrate (10) with an adhesive (11) contacting the substrate with a quantity of hard, abrasive particles (12) then removing all particles not held by the adhesive. The remaining particles are surrounded with a sinterable or fusible material while the particles are temporarily held. The substrate can have the adhesive applied in a pattern, or covering uniformly and masked (14) to cause particles to adhere in certain areas to achieve a desired pattern. While the particles are held on the substrate, physical force can be applied to orient the particles uniformly; then, a powder can be applied, or the substrate can be applied to a preform. Subsequent treatment with heat and/or pressure will complete the abrasive material.

Claims

AMENDED CLAIMS[received by the International Bureau on 21 November 1994 (21.11.94); original claims 1-23 replaced by new claims 1-41 (8 pages)]
1. A method for making an abrasive material comprising the steps of coating a substrate with an adhesive, contacting said substrate with a first plurality of hard particles and then removing a second plurality of hard particles consisting of particles that are not adhered to said substrate by said adhesive so that a third plurality of hard particles remains on said substrate adhered to said substrate by said adhesive, and at least partially surrounding most of the particles of said third plurality of hard particles with a sinterable matrix material, and heating said material to cause said sinterable matrix material to permanently.hold said third plurality of hard particles, wherein the said step of at least partially surrounding most of the hard particles with a sinterable matrix material includes the steps of sealing one side of a porous preform with a pressure sensitive adhesive tape, depositing a quantity of fusible powder into said porous preform, and placing together said porous preform and said substrate having said hard particles adhered to it prior to the said step of heating the material.
2. A method for making an abrasive material, said abrasive material comprising a plurality of hard particles for providing the abrasive quality, and a sinterable matrix material having the hard particles distributed therein for holding said hard particles, said method comprising the steps of placing a pressure sensitive adhesive tape against one side of a mask so that said pressure sensitive adhesive tape is adhered to said mask, said mask defining a plurality of openings distributed in a predetermined pattern, said openings extending completely through said mask so that said pressure sensitive adhesive tape closes said openings, then placing a quantity of hard particles against the opposite side of said mask so that some of said hard particles are received within said openings and at least some of said hard particles that are received within said openings are adhered to said pressure sensitive adhesive tape, removing hard particles that are not adhered to said pressure sensitive adhesive tape and subsequently at least partially surrounding said particles that are adhered to said pressure sensitive adhesive tape with a sinterable matrix material and heating said material to cause said material to hold said particles that adhere to said tape.
3. A method as claimed in claim 2, and further including the step of removing said mask from said pressure sensitive adhesive tape prior to the said step of at least partially surrounding said particles that are adhered to said substrate with a sinterable matrix material.
4. A method as claimed in claim 3, and further including the step of applying a supplementary force to said hard particles that are adhered to said pressure sensitive adhesive substrate before the said step of partially surrounding said particles with a sinterable matrix material.
5. A method as claimed in claim 4, wherein said supplementary force is selected from the group consisting of mechanical force and magnetic force.
6. A method as claimed in claim 2, and further including the step of applying a supplementary force to said hard particles that are adhered to said pressure sensitive adhesive tape for orienting said particles before the said step of partially surrounding said particles with a matrix material, and wherein said particles are of a size as to protrude from said openings in said mask.
7. A method as claimed in claim 6, wherein said supplementary force is selected from the group consisting of mechanical force and magnetic force.
8. A method as claimed in claim 3, including the step of applying a meltable material to said pressure sensitive adhesive tape after the said step of removing said mask from said pressure sensitive adhesive tape, and before the said step of at least partially surrounding said particles that are adhered to said tape with a sinterable matrix material. 1 9
9. A method as claimed in claim 8, wherein said meltable material is selected from the group consisting of fusible and brazable materials.
10. A method as claimed in claim 2, wherein said mask is formed of a polymeric material, and further including the step of heating said material sufficiently that said mask effectively disappears from said material.
11. A method as claimed in claim 2, including the step of applying a meltable material to said pressure sensitive adhesive tape before the said step at least partially surrounding said particles that are adhered to said pressure sensitive tape with a sensitive matrix material.
12. A method as claimed in claim 2, wherein said hard particles are selected from the group consisting of diamonds, carbides, borides, nitrides, pieces of hard metals, and pieces of ceramic.
13. A method as claimed in claim 2, wherein said step of at least partially surrounding said particles that are adhered to said pressure sensitive adhesive tape with a sinterable matrix material includes the step of placing a sinterable preform against at least one side of said tape and urging said preform and said tape together.
14. A method as claimed in claim 2, wherein said step of at least partially surrounding said particles that are adhered to said pressure sensitive adhesive tape with a sinterable matrix material includes the step of placing a sinterable preform having hard particles randomly distributed therein against at least one side of said tape and urging said preform and said tape together.
15. A method as claimed in claim 3, wherein said step of at least partially surrounding said particles that are adhered to said pressure sensitive adhesive tape with a sinterable matrix material includes the step of placing a sinterable preform against at least one side of said tape and urging said preform and said tape together. 2 0
16. A method as claimed in claim 13, wherein said step of placing a preform against at least one side of said tape includes the steps of making said preform by coating a pressure sensitive adhesive tape with a sinterable matrix material to provide a first layer of a sinterable matrix material, and coating the surface of said sinterable matrix material with an adhesive, applying a second sinterable matrix material layer, and repeating said steps until said preform of the desired thickness is formed.
17. A method as claimed in claim 2, wherein said mask and said pressure sensitive adhesive tape are in the form of continuous strips, and wherein the said step of placing the pressure sensitive adhesive tape against one side of the mask is accomplished by feeding said continuous strips of said mask and pressure sensitive adhesive tape between opposed compressing means.
18. A method as claimed in claim 2, wherein the said step of at least partially surrounding said hard particles that are adhered to said pressure sensitive adhesive tape with a sinterable matrix material comprises feeding a sinterable preform between compressing means along with said mask and pressure sensitive adhesive tape after having said hard particles applied to said openings in said mask.
19. A method for preparing an abrasive material comprising the steps of applying to a pressure sensitive adhesive tape a mesh material having a plurality of openings, placing a quantity of hard particles into at least some of the opening in said mesh material wherein at least some of said particles in said openings adhere to said adhesive, at least partially surrounding the particles in said openings with a sinterable matrix material, and sintering said matrix material under pressure to cause said sinterable matrix material to hold said particles in said openings of said mesh material.
20. A method as claimed in claim 19 further including the step of removing said mesh material from said pressure
' sensitive adhesive tape prior to the said step of at least 2 1
partially surrounding said particles in said openings with a sinterable matrix material.
21. A method as claimed in claim 19 further including the step of applying a supplementary force to orient said hard particles that adhere to said pressure sensitive adhesive tape before the said step of partially surrounding said particles with a sinterable matrix material.
22. A method as claimed in claim 21, wherein said supplementary force is selected from the group consisting of mechanical force or magnetic force.
23. A method as claimed in claim 20, including the step of applying a meltable material to said pressure sensitive adhesive tape after the said step of removing said mesh material from said pressure sensitive adhesive tape, and before the said step of at least partially surrounding said particles that are adhered to said substrate with a sinterable matrix material.
24. A method as claimed in claim 23, wherein said meltable material is selected from the group consisting of fusible and brazable material.
25. A method as claimed in claim 19, wherein said step of at least partially surrounding said particles in said openings of the mesh material that adhere to said pressure sensitive adhesive tape with' a sinterable matrix material includes placing a sinterable preform against at least one side of said particles and urging said preform and said particles together.
26. A method as claimed in claim 19, wherein said step of at least partially surrounding said particles in said openings of the mesh material that adhere to said pressure sensitive adhesive tape with a sinterable matrix material includes placing a sinterable preform having hard particles randomly distributed therein against at least one side of said particles and urging said preform and said particles together. 2 2
27. A method as claimed in claim 25, wherein said step of placing a sinterable preform against at least one side of said particles includes the steps of making said preform by coating a pressure sensitive adhesive tape with a sinterable matrix material for providing a first layer of a sinterable matrix material, and coating the surface of said sinterable matrix material with adhesive and applying a second sinterable matrix material layer, and repeating said steps until said preform of the desired thickness is formed.
28. A method as claimed in claim 19, wherein said mesh material is formed of a polymeric or low melting point metallic material.
29. A method as claimed in claim 28, wherein said mesh material effectively disappears in the sinterable matrix material during sintering.
30. A method of claim 19, wherein the mesh material is a wire mesh.
31. A method as claimed in claim 19, including the steps of applying a coating of an adhesive to said particles which adhere to said pressure sensitive adhesive tape before the said step of at least partially surrounding said particles in said openings with a sinterable matrix material.
32. A method as claimed in claim 19, wherein said mesh material and said pressure sensitive adhesive tape are in the form of continuous strips, and wherein the said step of applying to a pressure sensitive adhesive tape a mesh material is accomplished by feeding continuous strips of pressure sensitive adhesive tape and said mesh material between opposed compressing means.
33. A method as claimed in claim 19, wherein the said "step of at least partially surrounding said hard particles in said openings of the mesh material with a sinterable matrix material comprises the step of feeding a sinterable preform between said compressing means along with said mesh material and pressure sensitive adhesive tape. 2 3 <■'
34. A method as claimed in claim 19, wherein said hard particles are selected from the group consisting of diamonds, carbides, borides, nitrides, pieces of hard metals, pieces of ceramic, and mixtures thereof.
35. A method as claimed in claim 19 wherein said step of at least partially surrounding the hard particles with a sinterable matrix material includes the steps of sealing one side of a porous sinterable preform with an adhesive material, depositing a quantity of fusible powder into said porous preform, and placing said porous preform against said hard particles prior to the said step of sintering the material.
36. A method for preparing an abrasive material comprising the steps of applying adhesive to at least one side of a mesh material defining a plurality of openings, applying a quantity of hard particles into at least some of the openings in said mesh material wherein at least some of said particles in said openings adhere to said adhesive, at least partially surrounding the particles in said openings with a sinterable matrix material, and sintering said matrix material under pressure to cause said sinterable matrix material to hold said particles in said openings of said mesh.
37. A composite abrasive material comprising a plurality of hard abrasive particles, wherein said plurality of particles are evenly distributed by means of positioning said abrasive particles in openings of a mesh material, said composite abrasive material prepared by the steps of applying adhesive to at least one side of said mesh material defining a plurality of openings, applying a quantity of hard particles into at least some of the openings in said mesh material wherein at least some of said particles in said openings adhere to said abrasive, at least partially surrounding the particles in said openings with a sinterable matrix material, and sintering said matrix material under pressure to compact said matrix material and fix said hard particles in said sintered matrix material in positions determined by said openings of said mesh material.
38. The composite material of claim 37, wherein said hard abrasive particles protrude from at least one side of the sintered matrix material.
39. The composite material of claim 37, wherein said hard abrasive particles are positioned within said openings of said mesh material.
40. The composite material of claim 37, wherein said mesh material is formed of a polymeric or low melting point metallic material which effectively disappears in the sinterable matrix material during sintering.
41. The composite material of claim 37 wherein the mesh material is a wire mesh.
PCT/US1994/005780 1993-05-25 1994-05-24 Patterned abrasive material and method WO1994027833A1 (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
AT94918093T ATE259278T1 (en) 1993-05-25 1994-05-24 PATTERNED ABRASIVE AND METHOD
AU69561/94A AU690560C (en) 1993-05-25 1994-05-24 Patterned abrasive material and method
CA002163030A CA2163030C (en) 1993-05-25 1994-05-24 Patterned abrasive material and method
EP94918093A EP0713452B1 (en) 1993-05-25 1994-05-24 Patterned abrasive material and method
JP7500870A JPH08510694A (en) 1993-05-25 1994-05-24 Patterned abrasive material and method
BR9406663A BR9406663A (en) 1993-05-25 1994-05-24 Standardized abrasive material and method
RU95122657A RU2143332C1 (en) 1993-05-25 1994-05-24 Shaped abrasive material and process for making it
DE69433547T DE69433547T2 (en) 1993-05-25 1994-05-24 PATTERNED ABRASIVE AND METHOD

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US08066475 US5380390B1 (en) 1991-06-10 1993-05-25 Patterned abrasive material and method
US08/066,475 1993-05-25

Publications (2)

Publication Number Publication Date
WO1994027833A1 WO1994027833A1 (en) 1994-12-08
WO1994027833B1 true WO1994027833B1 (en) 1995-01-19

Family

ID=22069735

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1994/005780 WO1994027833A1 (en) 1993-05-25 1994-05-24 Patterned abrasive material and method

Country Status (15)

Country Link
US (1) US5380390B1 (en)
EP (2) EP1430999B1 (en)
JP (2) JPH08510694A (en)
KR (1) KR100340851B1 (en)
CN (1) CN1111575C (en)
AT (2) ATE259278T1 (en)
BR (1) BR9406663A (en)
CA (1) CA2163030C (en)
DE (2) DE69435041T2 (en)
ES (2) ES2295712T3 (en)
HK (1) HK1069795A1 (en)
RU (1) RU2143332C1 (en)
TW (1) TW254878B (en)
WO (1) WO1994027833A1 (en)
ZA (1) ZA943643B (en)

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