Rapid tooling system and method for manufacturing abrasive article

The present invention generally relates to a rapid working system and method for producing a polished product.

Abrasives such as coating abrasives and bond abrasives are used in various industries to process workpieces by lapping, grinding, polishing and the like. Machining using polished products covers a wide range from the optical industry, the automobile painting repair industry to the metal products industry. In each of these examples, the manufacturing equipment uses a significant amount of abrasives during each process.

In one typical process, the abrasive consumer orders a large amount of abrasive from the abrasive manufacturer. The abrasive manufacturer produces a batch of abrasives using the selected particle size and binding material. The abrasive manufacturer may subsequently produce another batch of abrasives with different particle sizes and binders.

Typically, it is difficult to completely clean the abrasive manufacturing equipment to prevent batches with a particular particle size from being contaminated with the grains used in the previous batch. If the grains of coarse-grained abrasive stain the fine-grained abrasive batch, the use of the soiled fine-grained abrasive batch will damage the surface to be polished or ground. Therefore, the abrasive product manufacturer pays great attention to suppress the stain between the abrasive product batches, which leads to an increase in cost.

Moreover, users order in batches. For large users, batch orders result in large labor costs, face storage and logistics issues with each batch received, and proactive use of abrasives. It will be. Underestimating the amount of abrasives used can lead to premature use of the abrasives ordered by the user, resulting in reduced productivity and loss of revenue.

In addition, traditional methods of producing abrasives produce excess debris, limiting the shape and form of abrasives that can be molded through such methods. For example, if a special contour of the coating abrasive is desired and the material plate of the coating abrasive is cut to fit the contour, a significant amount of unused material will remain as debris. When manufacturing combined abrasives, traditional methods are: (i) prepare one batch of slurry, (ii) inject the slurry into a mold, (iii) compress and cure the slurry, (iv) prepare the product. Use a molding process that includes the steps of removing from the mold and (v) finishing to the final dimensions. Excess factors are used throughout the manufacturing process to ensure that the final dimensions of the finished combined polish do not fall below the target dimensions. For example, inject excess slurry so that the mold is fully filled. In addition, a mold larger than the final size is used to trim the molded combined abrasive to the final size at the finishing stage. Thus, in both the coating and bonding abrasive manufacturing processes, material is wasted and time-consuming additional steps are taken to finish the polished product.

Therefore, in addition to improvements in the methods and systems for producing abrasives, the industry continues to demand new abrasives, including bond and coating abrasives. For example, existing manufacturing techniques have limitations in the design of abrasives, and in the context of reinforced abrasives and combined abrasives, typical abrasive structures are, for example, conical or pyramidal. The structure is limited to a shape that can be easily removed from the mold.

<p> As is clear from the above, the abrasive industry is embracing improved manufacturing techniques as well as new abrasive structures.</p>

<p> In one particular embodiment, the rapidly structured medium cartridge comprises a cartridge body, a first binder, and a first abrasive grain. The cartridge serves to precipitate a patterned continuous layer containing a first binder and a first abrasive grain to form a single abrasive structure.</p><p> In another embodiment, the solid freeform manufacturing system has a computational circuit, a cartridge with a first binder and a first abrasive grain, and a production surface. The computational circuit is configured to direct the cartridge in a direction that precipitates a patterned continuous layer of first binder and first abrasive grains onto the production surface to form a single abrasive structure.</p>

<figref num="1">It is a schematic diagram of the example immersion system which rapidly works a polished product.</figref><figref num="2">It is a schematic diagram of the example immersion system which rapidly works a polished product.</figref><figref num="3">It is an overview diagram of an exemplary print system for manufacturing a polished product.</figref><figref num="4">It is an overview diagram of an exemplary print system for manufacturing a polished product.</figref><figref num="5">It is an overview diagram of an exemplary print system for manufacturing a polished product.</figref><figref num="6">FIG. 6 is an overview view of an exemplary cartridge used in a system for rapid machining of polished products.</figref><figref num="7">FIG. 6 is an overview view of an exemplary cartridge used in a system for rapid machining of polished products.</figref><figref num="8">It is a schematic diagram of an exemplary polished product.</figref><figref num="9">It is a schematic diagram of an exemplary polished product.</figref><figref num="10">It is a schematic diagram of an exemplary polished product.</figref><figref num="11">It is a schematic diagram of an exemplary polished product.</figref><figref num="12">It is a schematic diagram of an exemplary polished product.</figref><figref num="13">It is a schematic diagram of an exemplary polished product.</figref><figref num="14">It is a schematic diagram of an exemplary polished product.</figref><figref num="15">It is a schematic diagram of an exemplary polished product.</figref><figref num="16">It is a schematic diagram of an exemplary polished product.</figref><figref num="17">It is a schematic diagram of an exemplary polished product.</figref><figref num="18">It is a schematic diagram of an exemplary polished product.</figref><figref num="19">It is a schematic diagram of an exemplary polished product.</figref><figref num="20">It is a flowchart which showed the example method of manufacturing a polished product.</figref><figref num="21">It is a flowchart which showed the example method of manufacturing a polished product.</figref>

The disclosure of the present invention will be better understood by reference to the accompanying drawings and a number of features and advantages thereof will be apparent to those skilled in the art.

Reference symbols attached in the figure refer to the same or similar symbols.

In one particular embodiment, the disclosure is directed to systems for manufacturing abrasives, such as solid freeform manufacturing systems and rapid machining systems. The system has computational circuits, cartridges and production surfaces. The cartridge is detachably coupled to the system and the abrasive and binder may be supplied from the cartridge when the cartridge is in mesh with the system. The calculation circuit is configured to control the precipitation or pattern of abrasive grains and binders placed on the substrate or production surface on which the abrasive is molded.

In another embodiment, the disclosure is directed to a cartridge containing a binder and abrasive grains. The cartridge is configured to be detachably coupled to the rapid machining system used in the manufacture of abrasives. The cartridge may further contain a second binder and a set of second abrasive grains.

Disclosures are also directed to methods of molding abrasives. This method comprises providing a polished product design data set to a rapid machining system and molding a polished product based on the polished product design data set. The method further comprises preparing a second abrasive design dataset and molding a second abrasive based on the second abrasive design dataset.

Disclosures are also directed to methods that facilitate the manufacture of abrasives. This method has a step of preparing a rapid working system having a structure for accepting a cartridge and a step of preparing a cartridge containing a binder and abrasive grains. The method may also include a step of collecting the used cartridge, a step of refilling the cartridge with a binder and abrasive grains, and a step of preparing the refilled cartridge.

The polished product may be a coated polished product or a combined polished product. Coated abrasives include products in which one or more layers of abrasive are bonded to a substrate. The substrate or backing material acts as a dimensionally stable component in which the layer carrying the abrasive has settled on the surface. Abrasive grains of the polishing layer adhere to the backing material through the use of the binder. Reinforced or structured abrasives have been developed to provide improved performance over traditional coated abrasives. The structured abrasive uses a backing material in which an abrasive layer is precipitated on the surface to match a pre-constructed pattern. Such structured abrasives generally exhibit superior grinding properties over conventional abrasive products, such as a consistently cheap, durable surface finish and extended life.

Bonding abrasives generally have a three-dimensional shape that does not rely on a substrate or backing material for structural perfection. For example, bond abrasives include grindstones and other three-dimensional abrasives. Traditionally, binder abrasives have been molded by injecting a mixture of abrasive grains and binder solution into a mold.

As disclosed herein, the coating and bonding abrasives may be molded through rapid working and solid freeform manufacturing. For example, the rapid machining method molds abrasives layer by layer to produce products with the desired grinding properties, such as consistently cheap and lasting surface finishes, effective life, porosity, cutting oil / debris grooves, etc. To do.

Rapid machining methods include dipping and printing methods. The dipping method generally uses a tank or container filled with a build material such as resin or powder. After each build layer is formed, the platform is lowered each time, and then the objects are built one layer at a time. A thin layer of uncured or unbonded build material is settled just above the last layer of abrasive and partially bonded in one pattern. In the embodiment, an energy source such as a laser light source or an ultraviolet light source is directed to a layer of unbound material in one pattern to harden or cure the binder in the material. In another embodiment, the binder is printed in one pattern on top of a layer of build material. The object is then lowered, a subsequent layer of unbound material settles on top of the previous layer, and the unbonded material is solidified again in one pattern to form an abrasive.

Illustrated dipping methods include a liquid method and a powder method. For example, the liquid method includes a three-dimensional lithograph method in which an object is constructed in a pool of liquid resin. The powder method includes a method of printing a binder and selectively burning it with a laser. For example, by printing a binder on a layer of ceramic material in one particular pattern, the layers may be bonded in that particular pattern. In another example, the powder material may be baked in that particular pattern by directing the laser beam over the layer of powder material in one particular pattern.

The solid freeform manufacturing method and the rapid working method also include the rapid printing method. The rapid printing method generally involves the step of precipitating the solution on a substrate in one pattern. In one embodiment, a polished product is formed by continuously precipitating a solution containing abrasive grains and a binder. Illustrated printing methods include a precipitation printing method and an extrusion method. The exemplary precipitation method includes a dry grain precipitation method such as a metal bonding system and a liquid precipitation method such as a liquid curable resin system. Extrusion methods include Fused Deposition Modeling (FDM), which melts filaments of a thermoplastic material and precipitates them in a desired pattern.

Figures 1 and 2 show an exemplary immersion system for molding a polished product. The system 100 depicted in FIG. 1 includes a tank 102 of an uncured solution 104 containing an uncured resin and abrasive grains. Abrasive 108 is molded on platform 106. An energy source 112, such as a laser or ultraviolet (UV) light source, cures or combines the solution 104 into one patterned layer, along the surface layer of the solution in one pattern. Let me go. For example, the laser may be scanned over the entire surface layer so that the pattern is formed on the surface of solution 104. In another example, the ultraviolet rays are directed in the direction of the mask passage so that the pattern is formed on the surface of the solution 104. The platform 106 is then lowered slightly and a bar or sweeper 110 is used to sweep a subsequent layer of uncured solution over the abrasive 108 being molded. This process continues by directing the energy of the subsequent pattern towards the surface layer, lowering the platform 106 and sweeping an additional layer overlying the previously cured layer. When the abrasive 108 is completed, the platform 106 is raised to clean the abrasive 108 and wash it with a solvent. In one embodiment, the object may be further post-cured using a thermal or ultraviolet method.

Solution 104 contains abrasive grains and a binder or curable resin. In one embodiment, the binder or curable resin is sensitive to at least one of heat, laser irradiation, UV energy irradiation, electron beam irradiation or patterned light. A layer of abrasive can be formed by directing energy or light rays in a single pattern. In one embodiment, the system depicted in FIG. 1 includes a three-dimensional lithograph scheme.

FIG. 2 shows an exemplary system 200 using a powder mixture. Container 202 contains a mixture 204 of abrasive grains and a powder binder. Mixture 204 may include binders such as ceramic powders, polyamides, polymeric materials such as polyesters, steel and foundry sand. The platform 206 is lowered to allow the abrasive 208 to be molded layer by layer. As soon as the platform descends a fraction of 2.54 cm (a fraction of an inch), a roller 210 deposits the build material on the material 204 and the abrasive 208 inside the vessel 202. Excess material may be wiped or rolled into container 214.

The energy source 212 directs the patterned energy to the surface of the material 204 to form a subsequent layer of abrasive 208. In one embodiment, the energy source 212 is a laser light source directed in one pattern over material 204 and abrasive 208. Alternatively, the material 204 is an abrasive grain. A binder or abrasive is printed in one pattern on the abrasive product 208 and material 204 being molded to form a layer of the abrasive product being molded.

The platform 206 is then lowered to form a subsequent patterned layer. Once the polish 208 is molded, the platform 206 is raised to clean the polish 208 and brush off the unbonded powder. Examples of the system depicted in FIG. 2 include a binder printing method and a selective laser quenching method (SLS).

Figures 3 and 4 show an exemplary printing system. Depicted in FIG. 3 is a system 300 that feeds filaments of thermoplastic material 308 through a heat-not-burn extrusion head 310. The platform 302 and / or the heated extrusion head 310 may move in a three-dimensional pattern to facilitate the molding of the three-dimensional abrasive 304. The spool 306 contains a filament 308, and the abrasive grains and the thermoplastic material contained therein are temporarily melted and precipitated when heated to form a layer of the abrasive 304. Illustrated thermoplastic materials include acrylonitrile butadiene styrene (ABS), polycarbonate and polyphenylsulfone. In one particular embodiment, the system 300 depicted in FIG. 3 is a Fused Deposition Modeling (FDM) system.

FIG. 4 shows an exemplary precipitation printing system 400 that melts powder at multiple locations on the surface of an abrasive 404. The platform 402 and / or the settling head 406 is moved in a three-dimensional pattern to facilitate layer-by-layer molding of the abrasive 404. In one embodiment, a laser light source, a high intensity light source, or a radiant heat source is directed in the direction through the precipitation head 406 and the powder is directed in the direction through the tube 408 so as to focus on the surface of the abrasive 404. The powder is hardened, melted or hardened in one pattern to form the abrasive 404. The powder may precipitate as a single stream of powder containing abrasive grains and binder, or may precipitate as two or more focused streams containing abrasive grains and the binder on the other. Illustrated binders include metals such as steel, copper, titanium and aluminum. In one example, the process involves precipitating a stream of powdered metal and abrasive, while simultaneously heating the precipitated region with a laser to fuse the powder to the abrasive 404.

FIG. 5 shows another precipitation printing system 500 that includes a continuous layer of printing that forms the abrasive 504. Platform 502 and / or printhead 506 are moved in a three-dimensional pattern to facilitate precipitation of the resin-based solution in the patterned layer forming the abrasive 504. The resin-based solution is subsequently cured to facilitate molding of the polished product 504. In one embodiment, the printing method comprises a resin-based precipitation method that prints a UV curable acrylic solution containing abrasive grains on a patterned build layer. The build layer is subsequently exposed to UV light from an energy source such as radiation source 508. In one embodiment, one printhead 506 is used to facilitate the molding of abrasives with the desired shape and micro features such as locally controlled porosity, reinforced dehiscence surfaces, debris grooves, etc. The above solutions are precipitated in different patterns.

The systems described above according to FIGS. 1-5, in particular the rapid work printing system, may be adapted to receive cartridges. The cartridge may be detachably attached to the system to contain the binder and abrasive grains. In one example, the cartridge comprises a container that holds a mixture or solution of abrasive grains and binder. For example, the solution may be a liquid binder and a slurry of abrasive grains. Alternatively, the solution may be a powdered mixture of abrasive grains and binder. In a further embodiment, the cartridge comprises a spool containing a filament composition containing a thermoplastic binder and abrasive grains.

FIG. 6 shows a special example 600 of a rapidly structured medium cartridge used in a print-based rapid machining system. In general, the cartridge serves to precipitate binders and / or abrasive grains into a continuous layer to form a polishing structure such as a coating polishing structure or a bonding polishing structure. For example, the cartridge 600 may be detachably coupled to a precipitation print fast working system. Cartridge 600 includes container 602 and supply nozzle 604. The cartridge 600 may also include a refill port 606 and may have a unique identification name 608.

The cartridge 600 is configured to contain a binder and abrasive grains. In one embodiment, the binder and abrasive grains may be integrally bonded in a common compartment such as container 602 in the cartridge body. The binder and abrasive grains are supplied from a common nozzle, such as nozzle 604. If the binder is a liquid, the abrasive grains and the binder form, for example, a slurry-like solution consisting of the liquid binder and the solid abrasive grains. If the binder is granular, the abrasive grains and the binder form a granular mixture.

In one embodiment, the binder is curable by synchrotron radiation. For example, the binder may be curable when exposed to an electron beam, laser, or diffused light such as ultraviolet light. In another embodiment, the binder and abrasive granule solution further comprises a second binder that can be cured by alternative methods such as thermosetting, chemical curing.

In one embodiment, the feed nozzle or orifice 604 is selectively controlled to feed the material. For example, the feed nozzle 604 may be part of a printhead. Thus, the supply nozzle 604 includes a mechanism for controlling the supply of the solution. Illustrated mechanisms include a heater driven bubble jet® mechanism, an electrostatic mechanism, and a piezoelectric mechanism. Alternatively, the orifice 604 provides the material for the printhead separated from the cartridge.

FIG. 7 shows an exemplary cartridge 700 containing two or more containers 702 and 704. The cartridge 700 also includes one or more supply nozzles (706 and 712) and one or more refill ports (708 and 710). In one embodiment, the binder and abrasive grains are separated from each other in dedicated compartments such as containers 702 and 704. The compartment may be of a structure in which the binder and abrasive grains are supplied through a common nozzle such as nozzle 706. For example, the cartridge 700 may include a supply structure having a structure that binds the first binder and the first abrasive grains before supplying the first binder and the first abrasive grains through one nozzle. In another example, the compartment may be of a structure in which the binder and abrasive grains are fed through separate nozzles such as nozzles 706 and 712.

In another embodiment, a container, such as container 702, may contain a solution containing a set of first abrasive grains and a first uncured binder. The second solution placed in container 704 contains a second uncured binder and optionally a set of second abrasive grains. In one particular embodiment, the second binder exhibits mechanical post-curing properties that differ from the mechanical post-curing properties of the first binder, such as mechanical post-curing strength. A set of second abrasive grains may have a different composition, different average particle size, different morphology, different performance and / or different hardness than a set of first abrasive grains. As a result, the polished product produced using the first solution exhibits different performance characteristics than the polished product produced using the second solution, such as wear resistance and material removal rate. In addition, the internal regions of the polished product produced by changing the ratio of the first solution to the second solution exhibit different performance characteristics.

In a further example, the polished product is a coated polished product. The cartridge may precipitate a first binder that forms a make coat and a second binder that forms a size coat. The cartridge may also contain a third binder in a third container. The third binder may be precipitated, for example, to form a supersize coat of the coated abrasive.

Alternatively, instead, the second solution placed in container 704 contains a curing agent. For example, the curing agent may induce polymerization, cross-linking or coagulation of the first binder. In another embodiment, the second solution may act as a diluent that reduces the density of abrasive grain distribution or alters the mechanical strength of the first binder.

In a further example, the second solution placed in the container 704 contains an adhesive that forms a pressure sensitive backing to the abrasive. For example, the second solution may be precipitated on a release film to form a pressure sensitive backing. The binder and abrasive grains may be precipitated on an adhesive backing to form the abrasive. The molded polished product may be removed from the release film and pressed against the surface of a grinding device, polishing device or fining device.

For refilling the cartridge 700, the consumer, service provider or manufacturer may use one or more refill ports (708 and 710). In one embodiment, the consumer may specify to the service provider or manufacturer the binder and abrasive grains to be injected into the cartridge. For example, the consumer may enter a unique Distinguished Name 714 on the website and specify the desired binder and abrasive grains to be injected into the cartridge 700 associated with that unique Distinguished Name 714. The consumer may then send the cartridge 700 to a service provider or manufacturer.

As depicted in FIGS. 6 and 7, the cartridge is configured for use in a three-dimensional precipitation printing device. In another embodiment, the cartridge is configured for use in a Fused Deposition Modeling (FDM) system, a selective laser precipitation system, or a metal precipitation system. In an alternative embodiment, the container is configured to contain a spool containing a thermoplastic filament or a powdered mixture.

In another embodiment, the cartridge is selectively coupled to a rapid machining system or a solid freeform manufacturing system. For example, in order to produce polished products with different properties, a cartridge containing a certain composition can be replaced with a cartridge containing a different composition.

In general, solutions, mixed powders and filaments may be formed using a binder and a set of abrasive grains. In the case of solutions, the binder may take the form of a curable resin, such as a resin that can be cured via an energy scheme using electron beams, microwaves, lasers, ultraviolet light, and the like. Alternatively, the binder may be curable via a catalyst-induced or moisture-induced chemical or thermal method.

Particularly useful UV curable binder compositions contain components selected from the group of acrylate oligomers, methacrylate oligomers and monomers. Useful oligomers include epoxy acrylates, aliphatic urethane acrylates, aromatic urethane acrylates, polyester acrylates, aromatic acid acrylates, epoxy methacrylates, and aromatic acid methacrylates. Monomers are monofunctional, bifunctional, trifunctional, tetrafunctional and pentafunctional acrylates and methacrylates such as trimethylolpropane triacrylate, trimethylolpropane triacrylate, triple (2-hydroxyethyl). Includes isocyanurate triacrylate, tripropylene glycol diacrylate, hexanediol diacrylate, octyl acrylate, and decyl acrylate. The binder preparation may contain a significant amount of acrylate monomers containing 3 or more acrylate groups per molecule. Representative commercial products include trimethylolpropane triacrylate (TMPTA) and pentaerythritol triacrylate (PETA). Relative amounts of bifunctional acrylates, trifunctional acrylates and high molecular weight acrylate oligomers are combined with other ingredients to give the cured final product the desired rheological treatment properties, desired tenacity and desired cutting properties. May be adjusted to.

The radiant flux of the photochemical source can be provided by any conventional UV source. For example, a coating or build layer is generated from a V-valve, D-valve, H-valve or H + valve, or a combination of them, with an energy output in the range of 100-600 watts per 2.54 cm (width inch) width. It may be exposed to the exposed ultraviolet rays.

In addition, a coupling agent may be used to improve the bond between the binder and the abrasive grains. Representative coupling agents include organosilanes such as A-174 and A-1100 available from Osi Specialties, Inc., and organotitanates, and zircoaluminates. A special group of coupling agents includes aminosilanes and methacryloxysilanes.

Fillers can be incorporated into the dispersion to improve the rheology and hardness and tenacity of the hardened binder dispersion. Useful fillers include, for example, metal carbonates such as calcium carbonate and sodium carbonate, silica such as quartz, glass beads and glass bubbles, talc, clay, silicates such as calcium metasilicate, metals such as barium sulfate and aluminum sulfate. Includes metal oxides such as sulfates, calcium oxide, aluminum oxide (eg, in the form of boehmite and / or pseudo-boehmite), and aluminum trihydrate.

The dispersion may be provided with a grinding aid that enhances grinding efficiency and cutting rate. Useful grinding aids may be inorganic, such as halogen salts, such as sodium cryolite, potassium tetrafluoroborate, or organic, such as chlorinated wax, such as polyvinyl chloride. Special examples include cryolite and potassium tetrafluoroborate having a particle size range of 1-80 microns, most preferably 5-30 microns. The weight percent of the grinding aid is in the range of 0-50%, most preferably 10-30% of the total preparation (including polishing components).

In addition to the above components, other components may be added, and typical examples thereof are benzo ether, benzyl ketel, α-alkoxy-acetophenone, α-hydroxy-alkylphenone, α-amino-alkylphenone, and acrylic phosphine. Photoinitiators such as oxides, benzophenone / amine, thioxanthone / amine, or other free radical generators, antistatic agents such as graphite and carbon black, suspending agents such as fumed silica, loads such as zinc stearate. Inhibitors, lubricants such as wax, wetting agents, dyes, fillers, viscosity modifiers, dispersants, and foam eliminators.

Various thermosetting polymers may be utilized in alternative rapid working systems or in combination with the binders described above. While thermoplastic and thermosetting polymers may be utilized, thermosetting polymers are often emphasized due to their stable properties, especially in the context of cutting or finishing operations that generate excess heat. According to a special embodiment, the binder compound comprises a powder, typically comprising a powder as a main component, or even an entirely powder. In some examples, liquid thermosetting polymers are used. In other embodiments, the liquid thermosetting polymer is eliminated in order to prioritize the powder. The powder curable binder is particularly advantageous in some embodiments, for example, where it is indeed easily incorporated into the process of molding the coating abrasive. In fact, the use of powdered thermosetting binders is particularly advantageous for the formation of abrasive dispersions used in the molding of structured abrasives. Moreover, the combined use of the powdered thermosetting component in combination with other liquid binders improves the polishing properties of the final product and, at least in part, favorably changes the viscosity of the dispersion, resulting in processability. Was also demonstrated to be improved. Thermosetting polymers include, for example, epoxy resins, urethane resins, phenolic resins, urea / formaldehyde, melamine / formaldehyde, acrylic resins, polyester resins, vinyls, and mixtures thereof. It is understood that such resins are available in either liquid or powder form and are used in some preferred embodiments in powdered or granular form.

In other examples, the binder may include powder build materials such as thermoplastics, metals, resin coated ceramics and the like. The resin-coated ceramics include resin-coated sand such as casting sand. Such binders can be useful in selective laser quenching techniques. Particularly useful powdered metals include steel, copper, titanium and aluminum. The powdered metal may be used, for example, in a metal precipitation scheme such as that performed in the apparatus depicted in FIG. Useful thermoplastic binders include polyamides, ABS, polycarbonates, polystyrenes, polyvinyl chlorides and polyphenylsulfones. Such thermoplastic binders may also be used in FDM systems as depicted in FIG.

The binder printing method may use a liquid adhesive that cures through drying or through contact with the underlying material. In alternative embodiments, the binder may be activated with water.

The abrasive grains are any one of the known abrasive grains including alumina (in the molten or hardened state), zirconia, zirconia / alumina oxide, silicon carbide, garnet, diamond, steric boron nitride, and combinations thereof. Or it may be in the form of a combination. Abrasive grains generally have an average particle size of 1 to 150 microns, more typically 1 to 80 microns. For fining and polishing applications, the average particle size may be about 1-16 microns, such as about 3-5 microns. However, in general, the amount of intervening abrasive may be from about 10 to about 90% of the weight of the preparation, such as about 30 to about 80%.

In the coated and reinforced abrasive examples, the backing material is a flexible but mechanically stable material, including various polymer films, papers and other cellulosic materials, and various polymers. It may be in the form of a cloth containing cotton and polyester with a saturant. The cloth may be a woven cloth or a non-woven fabric. A special type of backing material or substrate is polyethylene terephthalate film. Other polymeric films include polycarbonate films. The backing material may be primed or pretreated to facilitate adhesion between the polishing layer and the backing material. Alternatively, the backing material may be, for example, a release film such as that used in the manufacture of polished products with a pressure sensitive backing.

In one particular embodiment, a rapid working system and cartridge may be used to form the coated and reinforced abrasives. Such polished products can be molded as desired on demand without the expense associated with storage or batch ordering. For example, a rapid work system may be used to form a coating abrasive with a well-defined pattern. Figures 8 and 9 show exemplary rosette designs 800 and 904, including petal-like structures 802 and 906. By patterning and printing such designs 800 and 904, as a result, the entire surface of the sheet can be printed and the surface of the substrate can be specified without producing debris or contaminants associated with stamping or cutting of the desired shape or contour. The outline will be printed.

In a particular example, the optical industry may use such a rapid machining system to produce abrasives that are useful for polishing lenses and optical surfaces. In the optical industry, the single use of special coating sheets is common. Alternatively, a longer life is desired for applications such as paint removal and sanding. For longer life, rapid working of coated abrasives may include molding multiple layers or using stronger binders.

The performance characteristics of the abrasive can be controlled based on the distribution of abrasive grains throughout the coated abrasive. For example, the density of the abrasive grains can be adjusted according to the difference in relative velocity between the regions of the polished product. In the polished product depicted in FIG. 8, the abrasive grain distribution can be adjusted so that the desired removal rate is obtained over the entire curved surface of, for example, an spectacle lens. In the polished product depicted in FIG. 9, the distribution and density of the abrasive grains can be adjusted radially along the petal-like structure 906 of Rosette Design 904 so that it is adjusted according to the difference in rotational speed. .. The density of the abrasive grains can be adjusted by adding an auxiliary abrasive layer where a higher density is desired. Alternatively, the number of drops or pixels of the polishing solution per unit area may be adjusted to make a difference in performance characteristics. Different polishing solutions with different performance characteristics may be applied to different pattern regions, or may be applied in varying amounts throughout the polished product from place to place.

Another method of adjusting performance characteristics involves adjusting the solution distribution pattern. FIG. 10 shows an exemplary solution distribution pattern in which the local wear rate may be adjusted to compensate for rotational speed differences that extend along the radius. In pattern 1000, the distance between the lines near the center 1002 is greater than the distance between the lines near the outer edge 1004.

Turning to reinforced and structured abrasives, prior art methods for forming reinforced abrasives generally have outer surfaces with demoldable contours, such as pyramidal and conical sloping walls. Limited to. Unreinforced coating abrasives are generally considered two-dimensional because the thickness of a given structure is small for its cross-section. In contrast, reinforced abrasives, structured abrasives, and bond abrasives have fairly thick structures for their cross-section, which should be taken into account in the manufacture. In particular, if the rapid working method described here is used, it is generally possible to form a polished product having an outer surface having a contour that is difficult to remove, such as a negative inclined wall or a vertical wall. The contour of a negatively sloping wall is a contour that slopes inward toward the center of the structure as the height decreases, and the contour of a positively sloping wall is the center of the structure as the height decreases. It is a contour that slopes outward from. For example, a pyramid has a positively sloping wall, and an inverted pyramid has a negatively sloping wall. Vertical walls are also difficult to make using traditional methods of molding reinforced abrasives. Here, the term "generally negative slope" is used to include negative slope contours and vertical contours, where the polished structure is from -90 ° to 0 ° relative to the normal direction extending from the outer surface of the abrasive. Suppose it has at least one sloping wall extending along the angle α (alpha) of.

11 and 12 show a reinforced polished product 1100 containing a pattern or array of polishing structure 1102. Polished structure 1102 includes negative sloping wall 1106. As a result, the polished structure 1102 has a top that is wider than the portion that contacts the substrate 1108. Such a contour has a feature that is difficult to remove from the mold.

Walls or contours, generally including parts with a negative slope, exhibit features that are difficult to remove. FIG. 13 shows a polished product 1300 containing a pattern of a polished structure 1304 formed to cover the substrate 1302. Polished structure 1304 has a wall that includes a negatively sloping portion 1306.

With the rapid working method, it is also possible to form micro-features or integrated internal features inside the polished structure. For example, structured holes and grooves can be formed inside and on the surface of the polished structure by a rapid work method.

Returning to FIGS. 11 and 12, the pattern of the polishing structure 1102 forms a macro groove 1104 between the polishing structures 1102. Rapid machining allows the formation of micro-features such as structured grooves, holes and dehiscence surfaces. In general, a macro feature is a feature formed entirely by a pattern of structures or a pattern between structures, and a micro feature is a feature formed inside or on the surface of the polished structure itself. For example, in FIG. 11, micro-features such as internal structural holes 1110 are drawn inside the polished structure 1102, and macro-feature grooves 1104 are formed by the pattern of structure 1102 or the pattern between structures. .. The polished product may include a repeating pattern of the polished structure with a pattern of one or more internal structural holes. Similarly, in FIG. 13, an internal structural hole 1308 is drawn inside the polished structure 1304.

Internal structural holes (eg 1110 and 1308) can have precisely controlled dimensions and shapes. For example, this internal structural hole has a geometric cross section selected from the group consisting of polygons, circles and irregular shapes. Polygons include squares, triangles, rectangles, rhomboids, trapezoids, and pentagons. Irregular shapes include, for example, "D" shapes, semicircles, and stars. The internal structural holes may be dimensionally variable to about 50 microns or less, for example about 8 microns or less. Dimension changeable means that the hole size can be changed inside a set of polishing structures. In addition, the internal structure pores may be repositionable to about 50 microns or less, eg, about 8 microns or less (ie, the hole position can be changed within a set of polished structures). In these examples, the microfeatured holes are internal to the structure. Alternatively, microfeatures and grooves may be formed in the outer contours of the structure.

In another example, rapid machining can create a polished structure with micro features, such as a reinforced dehiscence surface. For example, as depicted in FIG. 14, the polished structure 1404 may include a reinforced dehiscence surface 1406. As depicted, the dehiscence surface 1406 is not horizontal or vertical and ends on the way through the structure. When the polishing product 1400 is in use, the polishing structure 1404 is designed to dehiscence or crack along the surface 1406 to provide a sharper angle, a higher polishing effect. Such a dehiscence surface 1406 may also be used to reduce the surface area of the abrasive when it comes into contact with one surface and increase the pressure exerted on the polished surface. In the example depicted in FIG. 14, the polishing structure 1404 is formed to cover the substrate 1402. Alternatively, the polishing structure 1404 may be formed as a combined polishing structure.

In another embodiment, the concentration of abrasive grains inside the abrasive structure may vary as a function of the distance perpendicular to the surface of the backing. For example, in a pyramidal structure, the concentration of abrasive grains may be higher as it is closer to the backing and lower as it is farther from the backing.

Rapid machining techniques may also be used in the molding of bonded abrasives. Again, rapid machining techniques can be used to form polished products with micro-features and hard-to-mold contours.

In the embodiment depicted in FIG. 15, the cutting oil groove 1502 is formed in a cylindrical or wheel-shaped combined abrasive 1500. In one embodiment, the cutting oil groove 1502 is a spiral structure designed to facilitate the flow of cutting oil through the cutting oil groove 1502 to the grinding surface 1504 during use. In the alternative embodiment depicted in FIG. 16, the combined abrasive includes a cutting oil groove 1602 and a scrap groove 1604. The cutting oil groove 1602 is designed to facilitate the flow of cutting oil to the surface 1600, and the waste groove 1604 is designed to remove the waste material from the surface 1600 when the abrasive is in use. Has been done. The waste groove 1604 has a curved cross section and is not straight, and as a result, the contour of the polished product 1600 is difficult to remove from the mold.

In one particular embodiment, the polished product comprises a characteristic structure, such as a debris groove 1604 extending from the outer surface of the combined polished product to the inside of the combined polished product. This characteristic structure has an aspect ratio of at least about 1.5. Here, the aspect ratio is the ratio of the depth of the opening extending inward from the outer surface of the bonded polished product to the minimum dimension of the opening on the outer surface thereof. The aspect ratio of this characteristic structure may be at least about 2.5, for example at least about 3.5.

In a special embodiment of a polished product that includes a cutting oil groove, coolant and lubricating oil can be delivered to the grinding interface. In a typical prior art system, the oil is directed to the grinding interface through an outer tube. However, the oil often does not sufficiently cool or lubricate the surface. Thus, the surface becomes too hot, producing excess debris, which can result in undergrinding and poor surface quality. In contrast, in the special embodiments described herein, the abrasive comprises a cutting fluid groove that delivers coolant and lubricating oil directly to the grinding interface. Moreover, such a cutting oil groove may have a structure that forcibly sends the cutting oil to the surface with the movement (for example, rotation) of the abrasive, and even if the abrasive is worn, the cutting oil is sent. It may be a structure that can be used.

As depicted in FIG. 17, the combined abrasive may include regions of different abrasive grains or regions of different concentrations of abrasive grains. For example, a cylindrical or wheel-shaped bonded abrasive 1700 may include regions with different abrasive properties such as abrasive grain density, porosity, bond strength, elastic modulus, compression modulus, such as regions 1702, 1704 and 1706. .. In this example, the region 1702 may have a certain concentration of abrasive grains and the region 1704 may have a different concentration. Different regions (1702, 1704 and 1706) may be formed using different polishing solutions or by adding polishing solutions in different proportions. Alternatively, the region may vary based on the distance from the center of the abrasive, as depicted in FIG. Different regions (eg 1802, 1804, 1806 and 1810) may be formed using different polishing solutions or by adding polishing solutions in different proportions and may exhibit different grinding and mechanical properties. .. In one particular embodiment, the concentration of abrasive grains may be locally controlled based on the distance from the center of the abrasive or the desired wear pattern inside the abrasive. Such a combined polished product consists of a patterned layer, a first region having a first composition inside one layer, and a second composition different from the first composition. It may have a patterned layer containing a second region.

A plurality of characteristic structures may be combined in order to improve the polishing performance in the polished product. FIG. 19 shows one example that includes some characteristic structures such as dehiscence surface and composition variation. For example, Polished 1900 comprises compositions 1902, 1910, 1912 and 1914. Abrasive 1900 also includes a dehiscence surface 1906. As the polished product wears, the dehiscence surface 1906 periodically dehisces, exposing the polished surface, for example, the polished surface 1908. In one embodiment, the polished surface 1908 has a surface area approximately equal to the initial polished surface 1904. In one particular embodiment, the polishing composition 1902 has a high bond strength. Other material compositions 1910, 1912 and 1914 serve to support the polished surface when a force is applied perpendicular to the polished surface. Other material compositions 1910, 1912 and 1914 may vary in bond strength, elasticity, polishing quality, and wear rate.

In general, rapid machining systems and rapid structured medium cartridges have a characteristic structure selected from the group consisting of micro-features, three-dimensional polishing features, cutting oil groove patterns, debris groove patterns, inner space patterns and oriented dehiscence surfaces. It can be used to form a three-dimensional polished structure that includes.

In one particular embodiment, a rapid machining system and a removable cartridge can be used to prepare the abrasive product for production at the request of the abrasive consumer. Such on-demand production allows consumers to reduce their inventory of abrasives and ensure that they supply as much abrasives as they need, when they need them.

In another embodiment, the rapid working method is used in the production of abrasives to reduce the debris and contaminants associated with traditional methods. For example, if it is a coated and polished product, it may be manufactured by covering a limited area of the underlying substrate. In this way, only the areas useful in the production of the coated abrasive are coated with the abrasive and the binder, and the other areas are left uncoated. In this way, the use of abrasives and binders is reduced.

In a further embodiment, the use of rapid working and removable cartridges in the manufacture of the abrasive reduces the likelihood that the abrasive will be contaminated with abrasive grains from another batch of abrasives. Consumers can be provided with cartridges containing only abrasive grains of the particle size desired by the consumer, including solutions, powders or filaments. By selecting a particular binder solution and the desired abrasive grains, the consumer can obtain the desired abrasive product, free of dirt and contaminants.

Rapid machining systems for the manufacture of abrasives are used, in particular, to form abrasives for finishing and polishing. For example, with such a system, it is possible to manufacture on-demand polishing products for finers for applications such as ophthalmic lens production and electronics production. Polished products for such applications may have an average particle size of about 3-5 microns and may have a build layer as thin as about 16 microns. Such systems are also useful in the production of abrasives for applications such as polishing jewelry, making polished samples, and removing paint.

Consumer-side abrasive manufacturing may be facilitated by providing consumers with a rapid working system and a cartridge filled with an abrasive composition. The consumer may be an internal consumer of the polished product, for example, a consumer who uses the polished product for the purpose of internal consumption and produces the polished product. Alternatively, the consumer may manufacture the polished product for sale and distribution purposes.

The exemplary method depicted in FIG. 20 provides the user with a rapid work system, as represented in 2002. For example, a rapid work system for the production of abrasives may be rented or sold to consumers of abrasive materials. Alternatively, instead, a rapid work system for the production of abrasives may be lent to future consumers for a fee or for free.

As shown in 2004, we provide consumers with cartridges containing abrasive grains and binders. For example, the consumer may select a particular binder and a particular particle size or type of abrasive grain. The manufacturer of the abrasive solution may directly or indirectly provide the consumer with a cartridge containing the solution containing the particular binder and the desired abrasive grains. In one embodiment, the consumer may purchase the cartridge. In another special embodiment, the consumer may purchase a solution, powder or filament in a cartridge.

When attempting to mold a coated and reinforced polished product, a substrate may be provided, as represented in 2005. For example, the substrate may be selected from the group consisting of paper, film, cloth, foil and foam. The rapid working system may have a structure in which a continuous layer of abrasive grains and a binder is precipitated on a substrate, and a cartridge is used to form a polished product.

In addition, as represented in 2006, it consumes software and computer-generated instruction manuals that can be used in rapid machining systems to control precipitation in patterned continuous layers of first binder and first abrasive grains. May be provided to the person. For example, structural software and data may be provided that direct the rapid machining system to create a particular polished structure design.

Consumers use cartridges and rapid machining systems to produce the desired abrasives. In doing so, the solution, powder or filament is consumed from the cartridge. In one embodiment, the manufacturer or service provider collects used cartridges directly or indirectly, as represented in 2007.

Alternatively, the consumer may send the used cartridge to a service provider or manufacturer. In a special example, the cartridge may be placed in a package with a structure suitable for sending the cartridge to a service provider or manufacturer. For example, the cartridge may be packaged and shipped to a postal service such as US Postal Service®, FedEx® or UPS®. The package may include a return address and a return address postal area. The consumer may prepare the package for return, insert the cartridge and consign it to the postman. In addition, the cartridge may include a unique identification name. Consumers may log on to the website, enter their unique identification name, and specify the desired binder and abrasive grain type. In one embodiment, the manufacturer sends a second cartridge with the desired binder and abrasive grains. In another embodiment, as represented in 2008, the manufacturer or service provider refills the cartridge with the desired binder and abrasive grains. However, if the cartridge is worn or unusable, the cartridge may be replaced.

The service provider or manufacturer then provides the refilled cartridge directly or indirectly to the consumer, eg, the consumer from which the cartridge was collected, or a different consumer, as represented in 2010. For example, the service provider or manufacturer may put the cartridge in a returnable package and consign it to a postman.

From the consumer's point of view, rapid work systems and removable cartridges may be used to produce polished products of one or more designs. For example, as depicted in FIG. 21, the abrasive consumer provides the rapid work system with design data for the first abrasive design. This is as represented by 2102. The consumer then molds the first abrasive based on the first abrasive design data, as represented by 2104, and optionally the first abrasive, as represented by 2106. Additional abrasives, such as a second abrasive, may be produced based on the design data. The consumer may provide another set of design data for the second abrasive design, as represented by 2108, followed by the second abrasive design, as represented by 2110. A third polished product may be molded based on the data.

As the abrasive is manufactured, the contents of the cartridge may be consumed. Consumers may replace cartridges and continue to manufacture polished products. In one particular embodiment, the consumer may swap cartridges containing different compositions inside and outside the rapid machining system to produce polished products with different performance characteristics. For example, the consumer may select the cartridge based on the mechanical strength of the binder, the particle size and wear resistance of the abrasive grains, or the wear resistance of the cured binder and abrasive grain solution. .. Consumers can put selected cartridges into a rapid machining system to produce polished products with the desired performance characteristics. An empty cartridge may be provided to the service provider or manufacturer for refilling.

The objects disclosed above should be considered as graphical examples and are not limiting, the claims are all of its improvements, developments and other embodiments that fall within the true scope of the invention. Is intended to cover. Therefore, to the maximum extent permitted by law, the scope of the present invention should be specified by the broadest permissible interpretation of the following claims and their equivalents, and is not limited or limited by the detailed description above. And.