Composite abradable bodies and methods of manufacturing thereof

Abstract

There is provided a composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder. The binder is derived from a pre-cursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius. The viscosity, of the pre-cursor composition, at 120 degrees Celsius, has a value, and the value is within a range, and the range is from 20,000 mPa*s (millipascal second) to 100,000 mPa*s (millipascal second). The hardness, of the pre-cursor composition, has a value, as measured in accordance with the Shore A Hardness Scale, and the value is within a range, and the range is from 70 to 105.

Description

COMPOSITE ABRADABLE BODIES AND METHODS OF MANUFACTURING THEREOFCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority from US provisional patent application no. 63 / 560,348 filed March 1, 2024, the contents of which are incorporated herein by reference.FIELD

[0002] The present disclosure relates to composite abrasive bodies for use in abrading materials, and methods for making thereof.BACKGROUND

[0003] Abrasive bodies, such as abrasive flap discs, are used for abrading work surfaces. Such abrasive bodies are typically comprised of an abrasive material configuration (such as a plurality of abrasive flaps) that is coupled to a carrier (such as a carrier disc) with a binder. Relatively strong bonding is achieved with binders that are curable at relatively high temperatures. Unfortunately, in high temperature environments, there is a risk of damage to the abrasive material configurations. Binders are also available which are curable at relatively low temperatures. However, bonding between low temperature-curing binders and the carrier, as well as low temperature-curing binders and the abrasive material configuration, is generally weaker than with high temperature-curing binders, which reduces service life of the abrasive bodies.SUMMARY

[0004] According to one aspect of the present invention, there is provided a composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive materialcarrier with a binder derived from a pre-cursor composition that is curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius, wherein the binder is characterized such that, for a test abrasive flap disc comprising a respective test abrasive material configuration bonded to a respective test carrier disc by a respective test binder material, wherein the composition of the test binder material, that is respective to the test abrasive flap disc, is identical to the composition of the binder, wherein the total mass of the test binder material, that is respective to the test abrasive flap disc, is within a range and the range is from 11.5 grams to 12.5 grams, and wherein the test abrasive material configuration, that is respective to the test abrasive flap disc, consists of a total number of 52 rectangular flaps, and each one of the 52 rectangular flaps: (i) has a length of 25 millimetres and a width of 25 millimetres, and (ii) includes a polycotton cloth backing whose surface is bonded to a ceramic grain blend, and the total mass of the 52 rectangular flaps is 60 grams, and wherein the test carrier disc, that is respective to the test abrasive flap disc, is of a nylon PA6 material, has a diameter of 115 millimetres, and has a total mass that is within a range and the range is from 53.4 grams to 61.7 grams, such that the test abrasive flap disc has a total mass that is within a range and the range is from 120 grams to 135 grams, and the test binder material, that is respective to the test abrasive flap disc, is effective in binding the test abrasive material configuration, that is respective to the test abrasive flap disc, to the test carrier disc, that is respective to the test abrasive flap disc, such that the test abrasive flap disc is characterized by a minimum bursting speed, measured in accordance with European Standard, EN 13743, "Safety requirements for coated abrasive products", approved on October 13th, 2016 by the European Committee for Standardization (CEN), and the minimum bursting speed is at least 22,750 revolutions per minute (R.PM).

[0005] According to another aspect of the present invention, there is provided a composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder, wherein : the binder is derived from a pre-cursorcomposition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; the viscosity, of the precursor composition, at 120 degrees Celsius, has a value, and the value is within a range, and the range is from 20,000 mPa*s (millipascal second) to 100,000 mPa*s (millipascal second).

[0006] According to still another aspect of the present invention, there is provided a composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder, wherein: the binder is derived from a precursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; and the hardness, of the pre-cursor composition, has a value, as measured in accordance with the Shore A Hardness Scale, and the value is within a range, and the range is from 70 to 105.

[0007] According to yet another aspect of the present invention, there is provided a composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder, wherein: the binder is derived from a precursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; the co-efficient efficient of thermal expansion, of the pre-cursor composition, has a value of less than 350 pm / m°C (micrometers / meter * degrees Celsius).

[0008] According to a further aspect of the present invention, there is provided a composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder, wherein : the binder is derived from a pre-cursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; and the pre-cursor composition is curable at a relative humidity of at least 60%.

[0009] According to yet a further aspect of the present invention, there is provided a method of producing a composite abrasive body, for use in abrading materials, wherein the composite abrasive body comprises anabrasive material configuration that is bonded to an abrasive material carrier with a binder; wherein the binder is derived from a pre-cursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; and wherein the method includes: applying the pre-cursor composition to the abrasive material carrier such that an intermediate product is obtained;heating the intermediate product over at least a time interval that is with effect that the open time of the pre-cursor composition is modified such that the modified open time of the pre-cursor composition has a value that is greater than five (5) minutes; and after the time interval, embedding the abrasive material configuration within the precursor composition.

[0010] According to still a further aspect of the present invention, there is provided a method of producing a composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder, wherein : the binder is derived from a pre-cursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; and the method includes: applying the pre-cursor composition to the abrasive material carrier such that an intermediate product is obtained;heating the intermediate product such that a heated intermediate product is obtained; and embedding the abrasive material configuration within the pre-cursor composition of the heated intermediate product.

[0011] According to another aspect of the present invention, there is provided a method of producing a composite abrasive body for use in abrading materials, wherein the composite abrasive body includes an abrasive material configuration that is bonded to an abrasive material carrier with a binder that is derived from a pre-cursor composition that is curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius, wherein the method includes curing of the pre-cursor composition, and the curing is such that there is an absence of any gaseous material, produced by the curing, within the binder that is obtained in response to the curing of the pre-cursor composition.BRIEF DESCRIPTION OF DRAWINGS

[0012] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of the present application, and in which:

[0013] Fig. 1 is a schematic illustration of a plan view of a first side of an abrasive flap disc;

[0014] Fig. 2 is a schematic illustration of a plan view of a second, opposite side of the abrasive flap disc illustrated in Fig.l; and

[0015] Fig. 3 is a schematic illustration of a partially completed abrasive flap disc, during its manufacture, as the abrasive flaps are being embedded within the binder.DETAILED DESCRIPTION

[0016] Referring to Figs. 1, 2, and 3, there is provided a composite abrasive body 10 for use in abrading materials. The composite abrasive body 10 includes an abrasive material configuration 12 that is bonded to an abrasive material carrier 14 with a binder 16.

[0017] In some embodiments, for example, the binder 16 is derived from a curable pre-cursor composition, and is obtained in response to curing of the pre-cursor composition. In some embodiments, for example, there is an absence of any gaseous material, produced by the curing, within the binder 16 that is obtained in response to the curing of the pre-cursor composition. In some embodiments, for example, there is an absence of production of gaseous material by the curing.

[0018] In some embodiments, for example, the pre-cursor composition is curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius. In some of these embodiments, for example, the pre-cursor composition is curable at atmospheric pressure.

[0019] In some embodiments, for example, the viscosity, of the precursor composition, at 120 degrees Celsius, has a value, and the value is within a range, and the range is from 20,000 mPa*s (millipascal second) to 100,000 mPa*s (millipascal second), such as, for example, 20,000 mPa*s(millipascal second) to 80,000 mPa*s (millipascal second), such as, for example, 20,000 mPa*s (millipascal second) to 60,000 mPa*s (millipascal second). In some embodiments, for example, by selecting the pre-cursor composition with the above-specified viscosity, enhanced bonding, of the abrasive material configuration 12 to the abrasive material carrier 14 by the binder 16, resulting from the curing of the pre-cursor composition, is obtained, as is explained below.

[0020] In some embodiments, for example, the hardness, of the precursor composition, has a value, as measured in accordance with the Shore A Hardness Scale, and the value is within a range, and the range is from 70 to 105. In some embodiments, for example, the range is from 75 to 100, such as, for example, 80 to 95. In some embodiments, for example, by selecting the pre-cursor composition with the above-specified hardness, enhanced bonding, of the abrasive material configuration 12 to the abrasive material carrier 14 by the binder 16, obtained from the curing of the pre-cursor composition, is established, as is explained below. Also in some embodiments, for example, by selecting the pre-cursor composition with the above-specified hardness, the binder 16, obtained from the curing of the precursor composition, is imparted with enhanced vibrational resistance characteristics, which improves the integrity of the bonding of the abrasive material configuration 12 to the abrasive material carrier 14.

[0021] In some embodiments, for example, the co-efficient of thermal expansion, of the pre-cursor composition, has a value of less than 350 pm / m°C (micrometers / meter * degrees Celsius), such as, for example, less than 300 pm / m°C (micrometers / meter * degrees Celsius), such as, for example, less than 250 pm / m°C (micrometers / meter * degrees Celsius). In some embodiments, for example, the co-efficient of thermal expansion of the pre-cursor composition is negligible. In some embodiments, for example, by selecting the pre-cursor composition with the above-specified co-efficient of thermal expansion, the expansion of the pre-cursor composition, if any, in response to receiving of heat energy, mitigates the need to re-work the article obtained upon curing.

[0022] In some embodiments, for example, the binder 16 is characterized such that, for a test abrasive flap disc comprising a respective test abrasive material configuration bonded to a respective test carrier disc by a respective test binder material, wherein the composition of the test binder material, that is respective to the test abrasive flap disc, is identical to the composition of the binder 16, wherein the total mass of the test binder material, that is respective to the test abrasive flap disc, is within a range and the range is from 11.5 grams to 12.5 grams, and wherein the test abrasive material configuration, that is respective to the test abrasive flap disc, consists of a total number of 52 rectangular flaps, and each one of the 52 rectangular flaps: (i) has a length of 25 millimetres and a width of 25 millimetres, and (ii) includes a polycotton cloth backing whose surface is bonded to a ceramic grain blend, and the total mass of the 52 rectangular flaps is 60 grams, and wherein the test carrier disc, that is respective to the test abrasive flap disc, is of a nylon PA6 material, has a diameter of 115 millimetres, and has a total mass that is within a range and the range is from 53.4 grams to 61.7 grams, such that the test abrasive flap disc has a total mass that is within a range and the range is from 120 grams to 135 grams, and the test binder material, that is respective to the test abrasive flap disc, is effective in binding the test abrasive material configuration, that is respective to the test abrasive flap disc, to the test carrier disc, that is respective to the test abrasive flap disc, such that the test abrasive flap disc is characterized by a minimum bursting speed, measured in accordance with European Standard, EN 13743, "Safety requirements for coated abrasive products", approved on October 13th, 2016 by the European Committee for Standardization (CEN), and the minimum bursting speed is at least 22,750 revolutions per minute (RPM), such as, for example, at least 23,000 RPM, such as, for example, at least 23,250 RPM, such as, for example, at least 23,500 RPM, such as, for example, at least 23,750, such as, for example, 24,000 RPM.

[0023] In some embodiments, for example, the binder 16 is a polyurethane-based binder. In some embodiments, for example, the binder16 is a single component polyurethane-based binder. In some embodiments, for example, the pre-cursor composition is a reactive, polyurethane-based hot melt adhesive, such as, for example, Jowatherm-Reaktant™ 605.44 PUR hot melt adhesive, produced by Jowat SE of Detmold, Germany.

[0024] In some embodiments, for example, the abrasive material configuration 12 is in the form of a plurality of abrasive flaps 121. In some embodiments, for example, each one of the abrasive flaps 121, independently, includes a thin, flexible backing material (such as cloth or paper) which defines a planar surface, to which abrasive particles are bonded (e.g. by a polymeric binder), such that a generally planar abrasive surface is defined for abrading a work surface. Suitable abrasive particles include one or more of alumina, silicon carbide, silica, seria, cubic boron nitride, and diamond. In some embodiments, for example, the abrasive particles are a blend of ceramic materials. In some embodiments, for example, each one of the abrasive flaps 121, independently, has a rectangular shape, and, in some embodiments, for example, the abrasive flaps 121 are dimensionally identical.

[0025] In some embodiments, for example, the abrasive material carrier 14 is constructed of plastic, such as, for example, fiberglass, Nylon PA6, Nylon-PA3, polypropylene, and acrylonitrile butadiene styrene (ABS).

[0026] In some embodiments, for example, the abrasive body 10 is configured for connecting to a grinding machine, with effect that the abrasive material carrier 14 transfers force, applied by the grinding machine, to the abrasive material configuration 12. In those embodiments where the abrasive material configuration 12 is in contact engagement with a work surface, in such embodiments, such force transfer effects abrading of the work surface by the abrasive material configuration 12.

[0027] In some embodiments, for example, the abrasive body 10 is in the form of an abrasive flap disc 100. The abrasive material carrier 14, of the abrasive flap disc 100, is an abrasive material carrier disc 140.

[0028] The abrasive material carrier disc 140 defines a generally planar surface 144 (see Fig. 3) to which the abrasive material configuration 12 isbonded by the binder 16. The abrasive material configuration 12 is defined by a plurality of overlapping ones of the abrasive flaps 121. For each one of the abrasive flaps 121, independently, the lower edge of the flap 121 is bonded, by the binder 16, to the generally planar surface 144 of the carrier disc 140, and extends radially outwardly from the centre of the disc 140. Each one of the abrasive flaps 121, independently, is bent such that, for each one of the abrasive flaps 121, the abrasive surface is facing outwardly, relative to the generally planar surface 144, of the support disc 140, to which the flap 121 is bonded by the binder 16 (and, in this respect, the abrasive surface is disposed on a side of the flap 121 that is opposite to the side of the flap 121 whose surface is facing the generally planar surface 144 of the support disc 140). In this condition, each one of the flaps 121, independently, overlaps adjacent ones of the flaps 121, with effect that the plurality of overlapping abrasive flaps 121 are emplaced in a circular arrangement above the generally planar surface 144 of the support disc 140.

[0029] The abrasive material carrier disc 140 has a central aperture 142 through which a spindle, of a grinding machine, is insertable, for connecting the abrasive flap disc 100 to the grinding machine. In some embodiments, for example, the central aperture 142 is internally threaded, and the spindle is externally threaded for engaging the internal threads of the aperture 142 such that the grinding machine becomes connected to the abrasive flap disc 100 for transmitting rotational motion, imparted to the spindle by the grinding machine, to the disc 100. The rotation of the disc 100, when in contact with a work surface, causes the abrasive surface, of the abrasive flaps 121, to abrasively wear the work surface.

[0030] A method of producing an embodiment of an abrasive flap disc 100 will now be described. Initially, the abrasive material carrier disc 140 is subjected to a surface treatment (such as, for example, plasma treatment, flame treatment, and chemical treatment). For example, plasma treatment would condition the carrier disc, via excitation, for bonding with the curable pre-cursor composition. Referring to Fig. 3, a circular bead configuration, of the curable pre-cursor composition, is deposited on the generally planarsurface 142 of the conditioned abrasive material carrier disc 140, such that the circular bead configuration becomes emplaced on the generally planar surface 142. In this respect, the emplacement of the pre-cursor composition onto the abrasive material carrier disc (such as, for example, the generally planar surface 142) is with effect that a first intermediate product is established. In some embodiments, for example, the circular bead configuration is defined by two circular beads 150, 152 in concentric circular arrangements. It is understood that, in some embodiments, for example, one bead is sufficient, and that, in some embodiments, for example, more than two (2) circular beads may be deposited. In some embodiments, for example, the depositing of the beads 150, 152 is effected by injection of the curable pre-cursor composition via a heated nozzle such that the curable precursor composition being discharged from the nozzle is disposed at a temperature that is within a range, and the range is from 100 degrees Celsius to 120 degrees Celsius. In some embodiments, for example, the abrasive material carrier disc 140, upon which the beads 150, 152 are deposited, is disposed in ambient temperature and pressure conditions.After the depositing of the circular beads 150, 152 of the curable pre-cursor composition, for each one of the abrasive flaps 121, independently, the lower edge of the abrasive flap 121 is lowered into the circular beads 150, 152, with effect that the lower edge penetrates the circular beads 150, 152. For each one of the abrasive flaps 121, independently, the penetration of the lower edge of the abrasive flap 121 is with effect that the abrasive flap 121 becomes embedded into the circular beads 150, 152, such that a second intermediate product is established. In some embodiments, for example, the embedding, of the abrasive flaps 121, is effected during the curing of the pre-cursor composition. In some embodiments, for example, the embedding, of the abrasive flaps 121, is with effect that a flap-intermediate pre-cursor material configuration, defined by the pre-cursor composition, becomes disposed between the abrasive flaps 121, and an interfacial contact area configuration, defined by contact between the flap-intermediate precursor material configuration and the abrasive flaps 121, is established. Insome embodiments, for example, the embedding, of the abrasive flaps 121, is with additional effect that a penetrating pre-cursor material configuration, defined by the pre-cursor composition, penetrates into the abrasive flaps 121, and becomes emplaced within the abrasive flaps 121. In some embodiments, for example, for each one of the abrasive flaps 121, independently, the embedding of the abrasive flap 121 is such that the abrasive flap 121 is emplaced in a radial orientation relative to the centre of the carrier disc 142, and with effect that a plurality of overlapping, radially- oriented abrasive flaps become embedded within the curable pre-cursor composition in a circular arrangement above the generally planar surface 144 of the carrier disc 140.

[0031] After the second intermediate product has been established, and sufficient time has elapsed such that the curable pre-cursor composition has cured and been converted to the binder 16, an abrasive flap disc is obtained, and includes an abrasive material configuration 12, defined by the plurality of overlapping, radially-oriented abrasive flaps 121, that is bonded to the abrasive material carrier disc 140 by the binder 16. In some embodiments, for example, the curing of the curable pre-cursor composition is effected at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius. In some embodiments, for example, the curing of the curable pre-cursor composition is effected within a humid environment, such as, for example, an environment that is characterized by a relative humidity of 60%, such as, for example, at least 65%.

[0032] In some embodiments, for example, after the first intermediate product is established, and prior to the embedding of the abrasive flaps 121, the first intermediate product is heated.

[0033] In some embodiments, for example, the heating of the first intermediate product, is over at least a time interval that is effective for modifying the open time of the pre-cursor composition, with effect that the modified open time of the pre-cursor composition has a value that is greater than five (5) minutes, such as, for example, greater than seven (7) minutes and 30 seconds, such as, for example, greater than ten (10) minutes, suchas, for example, greater than 12 minutes and 30 seconds, such as, for example, greater than 15 minutes. In such embodiments, for example, the embedding of the abrasive material configuration (e.g. the abrasive flaps 121), within the pre-cursor composition, is effected after the time interval (and, in some embodiments, is effected while the heating is continuing to be effected). In some of these embodiments, for example, the heating is with effect that a heated pre-cursor composition is obtained, and the embedding, of the abrasive material configuration (e.g. the abrasive flaps 121), is an embedding within the heated pre-cursor composition.

[0034] In some embodiments, for example, the heating is with effect that a heated first intermediate product is established, and, in this respect, a heated pre-cursor composition is also established. In this respect, in some embodiments, for example, adhesion of the pre-cursor composition to the carrier disc 140, and the adhesion of the pre-cursor composition to the abrasive flaps 141, is enhanced by the heating.

[0035] In some embodiments, for example, while the curable precursor composition is curing, the second intermediate flap disc is subjected to a first pressing operation.

[0036] In some embodiments, for example, during the first pressing operation, the abrasive flaps 121 are compressed by a force applied (e.g. by a press) in a direction that is normal to the generally planar surface 144 of the carrier disc 140. This compressing of the abrasive flaps 121 is with effect that the abrasive flaps 121 become flattened, such that, for each one of the abrasive flaps 121, independently, the abrasive surface becomes disposed at a desired angle relative to the planar surface 144 of the carrier disc 140, and the abrasive flap 121 becomes disposed in an overlapping relationship with adjacent ones of the abrasive flaps 121. In this respect, the compressing of the abrasive flaps 121, by the first pressing operation, is with effect that a third intermediate product is established. In some embodiments, for example, this compressing of the abrasive flaps 121 is effected while the curable pre-cursor composition is disposed in a gel-like state, and, in some of these embodiments, for example, while the second intermediate product isestablished, the abrasive flaps 121 and the flap-intermediate pre-cursor material configuration (defined by the pre-cursor composition that is emplaced between the abrasive flaps 121) are co-operatively configured such that, in response to the compression of the abrasive flaps 121, the interfacial contact area (between the flap-intermediate pre-cursor material configuration and the abrasive flaps 121) increases. In some of these embodiments, for example, the abrasive flaps 121 and the flap-intermediate pre-cursor material configuration are further co-operatively configured such that, in response to the compression of the abrasive flaps 121, a compression-responsive penetrating pre-cursor material configuration, of the flap-intermediate pre-cursor material configuration (defined by the precursor composition), is encouraged to penetrate into the abrasive flaps 121, with effect that a compression-responsive penetrating pre-cursor material configuration, of the flap-intermediate pre-cursor material configuration, penetrates the abrasive flaps 121 and becomes emplaced within the abrasive flaps 121. In some embodiments, for example, the increase in the interfacial contact area, combined with the penetration of the compression-responsive penetrating pre-cursor material configuration, is with effect that the abrasive flaps 121 and the pre-cursor composition become co-operatively configured such that, upon establishment of the binder 16, in response to curing of the pre-cursor composition, bonding of the binder 16, to the abrasive flaps 121, is enhanced.

[0037] In some embodiments, for example, the increase in the interfacial contact area, and the penetration of the compression-responsive penetrating pre-cursor material configuration, is attributable to the viscosity of the pre-cursor composition. In some embodiments, for example, the increase in the interfacial contact area, and the penetration of the compression-responsive penetrating pre-cursor material configuration, is attributable to the hardness of the pre-cursor composition. In some embodiments, for example, the increase in the interfacial contact area, and the penetration of the compression-responsive penetrating pre-cursor material configuration, is attributable to at least the combination of theviscosity of the pre-cursor composition and the hardness of the pre-cursor composition.

[0038] In some embodiments, during the first pressing operation, and simultaneously with the flattening of the abrasive flaps 121, the second intermediate product is compressed by a force applied (e.g. by a press) in a direction that is perpendicular to an axis that is normal to the generally planar surface 144 of the carrier disc 140. In some embodiments, for example, the applied force, in a direction that is perpendicular to an axis that is normal to the generally planar surface 144 of the carrier disc 140 urges emplacement of the abrasive flaps 121 within the perimeter of the carrier disc 140, such that, upon completion of the first pressing operation, the abrasive flaps 121 are emplaced within the perimeter of the carrier disc 140 and the flaps 121 are circumferentially aligned relative to centre of the disc 140.

[0039] In some embodiments, for example, a plurality of third intermediate products are established, and, in some of these embodiments, for example, the third intermediate products are stacked to establish a vertical stack of intermediate products. In some embodiments, for example, the vertical stacking is established by mounting the plurality of third intermediate products onto a vertical shaft via, for each one of the third intermediate products, independently, the aperture 142 respective to the third intermediate product. The vertical stack of intermediate products is subjected to a second pressing operation. In this respect, the vertical stack is compressed by a force applied (e.g. by a press) in a direction that is normal to the generally planar surface 144 of the carrier disc 140 (such as, for example, along a vertical axis) for maintaining dimensional stability while the curing process is completed (e.g. for a time interval of at least one hour, such as, for example, at least four hours, such as, for example, at least six (6) hours, such as, for example, at least 12 hours) and the bonding of the abrasive flaps 121, by the binder 18, to the carrier disc 140 is established.

[0040] The preceding discussion provides many example embodiments. Although each embodiment represents a single combination of inventiveelements, other examples may include all suitable combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, other remaining combinations of A, B, C, or D, may also be used.

[0041] Although the embodiments have been described in detail, it should be understood that various changes, substitutions and alterations could be made herein.

[0042] Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

[0043] As can be understood, the examples described above and illustrated are intended to be examples only. The invention is defined by the appended claims

Claims

CLAIMS1. A composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder derived from a pre-cursor composition that is curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; wherein the binder is characterized such that, for a test abrasive flap disc comprising a respective test abrasive material configuration bonded to a respective test carrier disc by a respective test binder material, wherein the composition of the test binder material, that is respective to the test abrasive flap disc, is identical to the composition of the binder, wherein the total mass of the test binder material, that is respective to the test abrasive flap disc, is within a range and the range is from 11.5 grams to 12.5 grams, and wherein the test abrasive material configuration, that is respective to the test abrasive flap disc, consists of a total number of 52 rectangular flaps, and each one of the 52 rectangular flaps: (i) has a length of 25 millimetres and a width of 25 millimetres, and (ii) includes a polycotton cloth backing whose surface is bonded to a ceramic grain blend, and the total mass of the 52 rectangular flaps is 60 grams, and wherein the test carrier disc, that is respective to the test abrasive flap disc, is of a nylon PA6 material, has a diameter of 115 millimetres, and has a total mass that is within a range and the range is from 53.4 grams to 61.7 grams, such that the test abrasive flap disc has a total mass that is within a range and the range is from 120 grams to 135 grams, and the test binder material, that is respective to the test abrasive flap disc, is effective in binding the test abrasive material configuration, that is respective to the test abrasive flap disc, to the test carrier disc, that is respective to the test abrasive flap disc, such that the test abrasive flap disc is characterized by a minimum bursting speed, measured in accordance with European Standard, EN 13743, "Safety requirements for coated abrasive products", approved on October 13th, 2016 by the EuropeanCommittee for Standardization (CEN), and the minimum bursting speed is at least 22,750 revolutions per minute (RPM).

2. The composite abrasive body as claimed in claim 1; wherein: the viscosity, of the pre-cursor composition, at 120 degrees Celsius, has a value, and the value is within a range, and the range is from 20,000 mPa*s (millipascal second) to 100,000 mPa*s (millipascal second).

3. The composite abradable body as claimed in claim 1 or 2; wherein: the hardness, of the pre-cursor composition, has a value, as measured in accordance with the Shore A Hardness Scale, and the value is within a range, and the range is from 70 to 105.

4. A composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder, wherein: the binder is derived from a pre-cursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; the viscosity, of the pre-cursor composition, at 120 degrees Celsius, has a value, and the value is within a range, and the range is from 20,000 mPa*s (millipascal second) to 100,000 mPa*s (millipascal second).

5. The composite abradable body as claimed in claim 4; wherein: the hardness, of the pre-cursor composition, has a value, as measured in accordance with the Shore A Hardness Scale, and the value is within a range, and the range is from 70 to 105.

6. A composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder, wherein: the binder is derived from a pre-cursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; and the hardness, of the pre-cursor composition, has a value, as measured in accordance with the Shore A Hardness Scale, and the value is within a range, and the range is from 70 to 105.

7. A composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder, wherein: the binder is derived from a pre-cursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; the co-efficient of thermal expansion, of the pre-cursor composition, has a value of less than 350 pm / m°C (micrometers / meter * degrees Celsius).

8. A composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder, wherein: the binder is derived from a pre-cursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; and the pre-cursor composition is curable at a relative humidity of at least 60%.

9. The composite abrasive body as claimed in claim 8;wherein: the binder is a polyurethane-based binder.

10. The composite abrasive body as claimed in claim 9; wherein: the polyurethane-based binder is a single component polyurethane-based binder.

11. The composite abrasive body as claimed in any one of claims 1 to 10; wherein: the composite abrasive body is an abrasive flap disc; and the abrasive material configuration is defined by a plurality of abrasive flaps.

12. A method of producing a composite abrasive body, for use in abrading materials, wherein the composite abrasive body comprises an abrasive material configuration that is bonded to an abrasive material carrier with a binder; wherein the binder is derived from a pre-cursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; and wherein the method includes: applying the pre-cursor composition to the abrasive material carrier such that an intermediate product is obtained; heating the intermediate product over at least a time interval that is with effect that the open time of the pre-cursor composition is modified such that the modified open time of the pre-cursor composition has a value that is greater than five (5) minutes; andafter the time interval, embedding the abrasive material configuration within the pre-cursor composition.

13. A method of producing a composite abrasive body for use in abrading materials, comprising an abrasive material configuration that is bonded to an abrasive material carrier with a binder, wherein: the binder is derived from a pre-cursor composition, curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius; and the method includes: applying the pre-cursor composition to the abrasive material carrier such that an intermediate product is obtained; heating the intermediate product such that a heated intermediate product is obtained; and embedding the abrasive material configuration within the precursor composition of the heated intermediate product.

14. A method of producing a composite abrasive body for use in abrading materials, wherein the composite abrasive body includes an abrasive material configuration that is bonded to an abrasive material carrier with a binder that is derived from a pre-cursor composition that is curable at a temperature that is within a range, and the range is from 18 degrees Celsius to 100 degrees Celsius, wherein the method includes curing of the pre-cursor composition, and the curing is such that there is an absence of any gaseous material, produced by the curing, within the binder that is obtained in response to the curing of the pre-cursor composition.

15. The method as claimed in claim 14; wherein: there is an absence of production of gaseous material by the curing.

16. The method as claimed in any one of claims 12 to 15; wherein: the binder is a polyurethane-based binder.

17. The method as claimed in claim 16; wherein: the polyurethane-based binder is a single component polyurethane-based binder.

18. The method as claimed in any one of claims 12 to 17; wherein: the composite abrasive body is an abrasive flap disc; and the abrasive material configuration is defined by a plurality of abrasive flaps.