Coated abrasive disc and methods of making and using the same

Patent metadata

Field	Value
Publication number	US-11607775-B2
Application number	US-201816763104-A
Country	US
Kind code	B2
Filing date	Nov 16, 2018
Priority date	Nov 21, 2017
Publication date	Mar 21, 2023
Grant date	Mar 21, 2023

Abstract

A coated abrasive disc includes a disc backing having an outer circumference. An abrasive layer is disposed on the disc backing. The abrasive layer comprises triangular abrasive platelets secured to a major surface of the disc backing by at least one binder material. The triangular abrasive platelets are outwardly disposed at regularly-spaced points along a spiral pattern extending outwardly toward the outer circumference. Each triangular abrasive platelet has respective top and bottom surfaces connected to each other, and separated by, three sidewalls. On a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing, and at least 70 percent of the triangular abrasive platelets are disposed in a recurring sequential orientation having an oscillating Z-axis rotational orientation of the first respective sidewall relative to the tangents to the spiral pattern at regularly-spaced points. Methods of making and using the coated abrasive disc are also disclosed.

First claim

What is claimed is:

1. A coated abrasive disc comprising:
a disc backing having an outer circumference;
an abrasive layer disposed on the disc backing, wherein the abrasive layer comprises triangular abrasive platelets secured to a major surface of the disc backing by at least one binder material, wherein the triangular abrasive platelets are outwardly disposed at regularly-spaced points along a spiral pattern extending outwardly toward the outer circumference,
wherein each one of the triangular abrasive platelets has respective top and bottom surfaces connected to each other, and separated by, three sidewalls,
wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing, and
wherein at least 70 percent of the triangular abrasive platelets are disposed in a recurring sequential orientation having:
i) a first triangular abrasive platelet with a first respective sidewall facing the disc backing, wherein the Z-axis rotational orientation of the first respective sidewall is longitudinally outwardly oriented at an angle of −10 to −40 degrees relative to the tangent to the spiral pattern at a first one of the regularly-spaced points;
ii) a second triangular abrasive platelet with a second respective sidewall facing the disc backing, wherein the Z-axis rotational orientation of the second respective sidewall is longitudinally outwardly oriented at an angle of −15 to +15 degrees relative to the tangent to the spiral pattern at a second one of the regularly-spaced points;
iii) a third triangular abrasive platelet with a third respective sidewall facing the disc backing, wherein the Z-axis rotational orientation of the third respective sidewall is longitudinally outwardly oriented at an angle of +10 to +40 degrees relative to the tangent to the spiral pattern at a third one of the regularly-spaced points; and
iv) a fourth triangular abrasive platelet with a fourth respective sidewall facing the disc backing, wherein the Z-axis rotational orientation of the fourth respective sidewall is longitudinally outwardly oriented at an angle of −15 to +15 degrees relative to the tangent to the spiral pattern at a fourth one of the regularly-spaced points.

2. The abrasive disc of claim 1 , wherein the triangular abrasive platelets have an average thickness, wherein the spiral pattern comprises an arithmetic spiral pattern, and wherein the arithmetic spiral pattern has a pitch that is 1 to 3 times the average thickness of the triangular abrasive platelets.

3. The abrasive disc of claim 1 , wherein the abrasive layer further comprises crushed abrasive or non-abrasive particles.

4. The abrasive disc of claim 1 , wherein the disc backing comprises vulcanized fiber.

5. The abrasive disc of claim 1 , wherein the abrasive layer comprises a make layer and a size layer disposed over the make layer and the triangular abrasive platelets.

6. The abrasive disc of claim 1 , wherein the triangular abrasive platelets comprise alpha alumina.

7. A method of abrading, the method comprising frictionally contacting a portion of the abrasive layer of a coated abrasive disc according to claim 1 with a substrate, and moving at least one of the substrate and the abrasive disc relative to the other to abrade the substrate.

8. The method of claim 7 , wherein the substrate comprises carbon steel, and wherein the abrasive layer contacts the carbon steel.

9. A method of making a coated abrasive disc, the method comprising:
disposing a curable make layer precursor on a major surface of a disc backing;
embedding triangular abrasive platelets into the curable make layer precursor, wherein the triangular abrasive platelets are outwardly disposed at regularly-spaced points along a spiral pattern extending outwardly toward the outer circumference,
wherein each one of the triangular abrasive platelets has respective top and bottom surfaces connected to each other, and separated by, three sidewalls,
wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing, and
wherein at least 70 percent of the triangular abrasive platelets are disposed in a recurring sequential orientation having:
i) a first triangular abrasive platelet with a first respective sidewall facing the disc backing, wherein the Z-axis rotational orientation of the first respective sidewall is longitudinally outwardly oriented at an angle of −10 to −40 degrees relative to the tangent to the spiral pattern at a first one of the regularly-spaced points;
ii) a second triangular abrasive platelet with a second respective sidewall facing the disc backing, wherein the Z-axis rotational orientation of the second respective sidewall is longitudinally outwardly oriented at an angle of −15 to +15 degrees relative to the tangent to the spiral pattern at a second one of the regularly-spaced points;
iii) a third triangular abrasive platelet with a third respective sidewall facing the disc backing, wherein the Z-axis rotational orientation of the third respective sidewall is longitudinally outwardly oriented at an angle of +10 to +40 degrees relative to the tangent to the spiral pattern at a third one of the regularly-spaced points; and
iv) a fourth triangular abrasive platelet with a fourth respective sidewall facing the disc backing, wherein the Z-axis rotational orientation of the fourth respective sidewall is longitudinally outwardly oriented at an angle of −15 to +15 degrees relative to the tangent to the spiral pattern at a fourth one of the regularly-spaced points;

at least partially curing the curable make layer precursor to provide a make layer;
disposing a curable size layer precursor over the make layer and triangular abrasive platelets; and
at least partially curing the curable size layer precursor to provide a size layer.

10. The method of claim 9 , wherein the triangular abrasive platelets have an average thickness, wherein the spiral pattern comprises an arithmetic spiral pattern, and wherein the arithmetic spiral pattern has a pitch that is 1 to 3 times the average thickness of the triangular abrasive platelets.

11. The method of claim 9 , wherein the abrasive layer further comprises crushed abrasive or non-abrasive particles.

12. The method of claim 9 , wherein the disc backing comprises vulcanized fiber.

13. The method of claim 9 , wherein the triangular abrasive platelets comprise alpha alumina.

Assignees

• 3M Innovative Properties Company

Inventors

• Hanschen Thomas P
• Keipert Steven J
• Eckel Joseph B
• Nienaber Aaron K
• Spring Erin D
• Moegenburg Brant A
• Moore Eric M
• Nelson Thomas J

Classifications

• B24D2203/00

  Tool surfaces formed with a pattern · CPC title

• B24D3/28 Primary

  Resins {or natural or synthetic macromolecular compounds (B24D3/22 takes precedence)} · CPC title

• B24D11/02

  Backings, e.g. foils, webs, mesh fabrics · CPC title

• C09K3/1409 Primary

  Abrasive particles per se (preparation of diamond C01B32/25) · CPC title