Conformable abrasive articles and methods of making and using the same

• US 20070066185A1
• Filed: 09/22/2005
• Published: 03/22/2007
• Est. Priority Date: 09/22/2005
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Schutz, James, Annen, Michael, Everaerts, Albert, Koehnle, Gregory, Felipe, Peter
• Granted Patent: US 7,618,306 B2
• Time in Patent Office: Days
• US Class Current: 451/41
• CPC Class Codes: B24B 7/20 characterised by a special design with respect to properties of the material of non-metallic articles to be ground
• CPC Class Codes: B24D 11/02 Backings, e.g. foils, webs, mesh fabrics
• CPC Class Codes: B24D 13/14 acting by the front face

Abstract

Conformable abrasive article comprising: a backing having a first major surface; a deformable material contacting a central portion of the first major surface; an elastic member affixed to the first major surface of the backing and together with the backing enclosing the deformable material; and an abrasive member affixed to the elastic member, wherein the abrasive member comprises abrasive particles and a binder; and methods of making and using the same.

Claims

1. A conformable abrasive article comprising:

a backing having a first major surface;

a deformable material contacting a central portion of the first major surface, the deformable material having greatest thickness proximal to the center of the first major surface;

an elastic member affixed to the first major surface of the backing and together with the backing enclosing the deformable material; and

an abrasive member affixed to the elastic member, wherein the abrasive member comprises abrasive particles and a binder.

2. A conformable abrasive article according to claim 1, wherein the backing is compressible.

3. A conformable abrasive article according to claim 1, wherein the backing is compressible and resilient.

4. A conformable abrasive article according to claim 1, wherein the conformable abrasive article is selected from the group consisting of a circular abrasive pad, a rectangular abrasive pad, and an abrasive belt.

5. A conformable abrasive article according to claim 1, wherein the abrasive member comprises a coated abrasive member having an abrasive layer affixed to a flexible backing member, the abrasive layer comprising the abrasive particles and make and size layers, and wherein at least the make layer comprises the binder.

6. A conformable abrasive article according to claim 1, wherein the abrasive member comprises a coated abrasive member having an abrasive layer affixed to a flexible backing member, and wherein the abrasive layer comprises the abrasive particles uniformly dispersed in the binder.

7. A conformable abrasive article according to claim 6, wherein the backing member is elastic.

8. A conformable abrasive article according to claim 6, wherein the abrasive member comprises an abrasive layer that contacts the elastic member.

9. A conformable abrasive article according to claim 6, wherein the elastic member comprises an elastomeric film affixed to an elastomeric foam, and wherein the elastomeric film is further affixed to the first major surface of the backing.

10. A method of abrading a workpiece, the method comprising:

providing a conformable abrasive article according to claim 6;

frictionally contacting at least one abrasive particle with a workpiece; and

moving at least one of the abrasive particle and the workpiece relative to the other to abrade at least a portion of the surface of the workpiece.

11. A method according to claim 10, further comprising:

providing a liquid to the surface of the workpiece.

12. A conformable abrasive article according to claim 6, wherein the elastic member comprises a polyurethane elastomer.

13. A conformable abrasive article according to claim 1, wherein the abrasive member comprises a flexible backing member having an abrasive layer affixed thereto, wherein the abrasive layer comprises abrasive composite particles, the abrasive composite particles comprising the abrasive particles dispersed in the binder, and wherein the backing member is affixed to the elastic member.

14. A conformable abrasive article according to claim 13, wherein the abrasive composite particles comprise abrasive grits in a binder, and wherein the abrasive grits have a size within a range of from JIS grade 800 to JIS grade 6000, inclusive.

15. A conformable abrasive article according to claim 13, wherein the abrasive composite particles are precisely shaped.

16. A conformable abrasive article according to claim 1, wherein the backing comprises a flexible member having a compressible foam layer affixed thereto, wherein the flexible member has a surface that comprises a second major surface of the backing, and wherein the compressible foam layer has a surface that comprises the first major surface of the backing.

17. A conformable abrasive article according to claim 16, wherein the compressible foam layer is elastic.

18. A conformable abrasive article according to claim 16, wherein the flexible member comprises a polymeric film.

19. A method of abrading a workpiece, the method comprising:

providing a conformable abrasive article according to claim 16;

frictionally contacting at least one abrasive particle with a workpiece; and

moving at least one of the abrasive layer and the workpiece relative to the other to abrade at least a portion of the surface of the workpiece.

20. A conformable abrasive article according to claim 1, wherein the elastic member comprises compressible resilient foam.

21. A conformable abrasive article according to claim 1, wherein the elastic member comprises an elastomeric film affixed to an elastomeric foam, and wherein the conformable elastomeric film is further affixed to the first major surface of the backing.

22. A conformable abrasive article according to claim 21, wherein the elastomeric film comprises a polyurethane elastomer.

23. A method of abrading a workpiece, the method comprising:

providing a conformable abrasive article according to claim 20;

frictionally contacting at least one abrasive particle with a workpiece; and

moving at least one of the abrasive particles and the workpiece relative to the other to abrade at least a portion of the surface of the workpiece.

24. A conformable abrasive article according to claim 1, wherein the deformable material comprises an elastomer.

25. A conformable abrasive article according to claim 1, wherein the deformable material consists essentially of elastomeric gel.

26. A conformable abrasive article according to claim 1, wherein the deformable material comprises gas.

27. A conformable abrasive article according to claim 1, wherein the deformable material is domed or ridged.

28. A conformable abrasive article according to claim 1, wherein the abrasive member is outwardly convex.

29. A conformable abrasive article according to claim 1, wherein the deformable material has a central region of substantially uniform thickness and a peripheral region of decreasing thickness.

30. A conformable abrasive article according to claim 1, wherein the deformable material contacts at least one half of the first major surface.

31. A conformable abrasive article according to claim 1, further comprising an attachment system affixed to a second major surface of the backing, wherein the first and second major surfaces are opposed.

32. A conformable abrasive article according to claim 31, wherein the attachment system comprises hooks or loops.

33. A conformable abrasive article according to claim 1, wherein the abrasive member comprises an abrasive layer that contacts the elastic member.

34. A conformable abrasive article according to claim 33, wherein the binder comprises a reaction product of a polymerizable binder precursor comprising at least one of acrylic acid or methacrylic acid.

35. A method of abrading a workpiece, the method comprising:

providing a conformable abrasive article according to claim 1;

frictionally contacting the abrasive layer with a workpiece; and

moving at least one of the abrasive layer and the surface of the workpiece relative to the other to abrade at least a portion of the surface of the workpiece.

36. A method according to claim 35, wherein the workpiece comprises a painted substrate.

37. A method of making a conformable abrasive article comprising:

providing a backing having a first major surface;

contacting a deformable material with a central portion of the first major surface of the backing, the deformable material having greatest thickness proximal to the center of the first major surface;

affixing an elastic member to the first major surface of the backing, the elastic member and the compressible backing enclosing the deformable material; and

affixing an abrasive member to the elastic member, wherein the abrasive member comprises abrasive particles and a binder.

38. A method according to claim 37, wherein the backing is compressible.

39. A method according to claim 37, wherein the backing is compressible and resilient.

40. A method according to claim 37, wherein the backing comprises a flexible member having a compressible foam layer affixed thereto, wherein the flexible member has a surface that comprises a second major surface of the backing, and wherein the compressible foam layer has a surface that comprises the first major surface of the backing.

41. A method according to claim 37, wherein affixing an elastic member to the first major surface of the backing and enclosing the deformable material comprises:

affixing a conformable elastomeric film to the first major surface of the backing; and

affixing an elastomeric foam to the conformable elastomeric film.

42. A method according to claim 37, wherein the conformable elastomeric film comprises an elastomeric polyurethane.

43. A method according to claim 37, wherein affixing an abrasive member to the elastic member comprises:

providing a structured abrasive member comprising a backing and an abrasive layer; and

affixing the backing to the elastic member.

44. A method according to claim 37, wherein the abrasive member comprises a coated abrasive member having an abrasive layer affixed to a flexible backing member, the abrasive layer comprising the abrasive particles and make and size layers, and wherein at least the make layer comprises the binder.

45. A method according to claim 37, wherein the abrasive member comprises a coated abrasive member having an abrasive layer affixed to a flexible backing member, and wherein the abrasive layer comprises the abrasive particles uniformly dispersed in the binder.

46. A method according to claim 45, wherein the backing member is elastic.

47. A method according to claim 37, wherein the abrasive member comprises an abrasive layer that contacts the elastic member.

48. A method according to claim 37, wherein the abrasive member comprises a structured abrasive member.

49. A method of making a conformable abrasive article comprising:

providing a backing having a first major surface;

contacting a deformable material with a central portion of the first major surface of the backing, the deformable material having greatest thickness proximal to the center of the first major surface;

affixing an elastic member to the first major surface of the backing, the elastic member and the compressible backing enclosing the deformable material; and

applying a curable composition comprising a polymerizable binder precursor and abrasive particles to the extensible tie layer; and

at least partially curing the curable composition to provide an abrasive layer.

50. A method according to claim 49, further comprising:

imparting a textured surface to the curable composition with a production tool; and

separating the production tool from the at least partially cured curable composition to produce a plurality of shaped abrasive composites.

51. A method according to claim 49, wherein the polymerizable binder precursor comprises at least one of acrylic acid or methacrylic acid.