Robotic repair system and method

Abstract

An abrasive article is provided, comprising a backing, a grinding surface including an abrasive material adhered to the backing, and a coupling surface including coupling features configured to removably couple the abrasive article to a tool. The abrasive article also includes resistance-reducing features. The abrasive article is configured for use with a fluid during a grinding operation. The resistance-reducing features are configured to reduce resistance between the abrasive article and a working surface including the fluid.

Description

Background Technology

[0001] Clear coat repair is one of the final operations to be automated in automotive original equipment manufacturing (OEM) departments. Technologies are desired to automate this process, as well as other paint applications suitable for inspection and repair using abrasives and / or robots (e.g., primer sanding, clear coat defect removal, clear coat polishing, etc.).

[0002] Early work automating the detection and repair of paint defects includes the system described in U.S. Patent Publication No. 2003 / 0139836, which discloses the use of electronic imaging to detect and repair paint defects on a vehicle body. This system references vehicle imaging data with vehicle CAD data to generate three-dimensional coordinates for each paint defect. The paint defect data and coordinates are used to develop repair strategies for automated repair using multiple automated robots performing various tasks, including sanding and polishing the paint defects. Summary of the Invention

[0003] An abrasive article is provided, comprising a backing, a grinding surface including an abrasive material adhered to the backing, and a coupling surface including coupling features configured to removably couple the abrasive article to a tool. The abrasive article also includes resistance-reducing features. The abrasive article is configured for use with a fluid during a grinding operation. The resistance-reducing features are configured to reduce resistance between the abrasive article and a working surface including the fluid. Attached Figure Description

[0004] In accompanying drawings that are not necessarily drawn to scale, similar figures may describe similar components in different views. The drawings are generally illustrated by way of example but are not limited to the various embodiments discussed in this document.

[0005] Figure 1A and Figure 1B This is a schematic diagram of a robotic paint repair system, in which an embodiment of the present invention is useful.

[0006] Figures 2A to 2D A schematic diagram illustrating the tool configuration of a robotic repair unit according to the embodiment described herein is shown.

[0007] Figure 3 A method for detecting and repairing defects on a working surface according to the implementation scheme described herein is illustrated.

[0008] Figures 4A to 5C An exemplary embodiment of the pressure reduction feature section according to the embodiments described herein is illustrated.

[0009] Figures 6A to 6CAn exemplary microabrasive grinding feature and a grinding disc structure including the microabrasive grinding feature are illustrated according to embodiments of the present invention.

[0010] Figures 7A to 7E An exemplary support pad configuration according to the embodiments described herein is illustrated.

[0011] Figures 8A to 9B The grinding disc and support pad are illustrated in more detail in the embodiments. Detailed Implementation

[0012] Robotic clear coat finishing of automotive bodies relies on a robotic arm to sand and polish defects after painting and applying a clear coat. A vision system that identifies the location of defects informs the robot. The robot positions a random-track sander or other suitable tool as the end of its arm tool at the defect location to remove it. Before sanding, the robot sprays water or another fluid to assist cutting. The abrasive article is removably attached to a support pad, which is also attached to the random-track sander (or other suitable tool). A force control unit applies a force to the support pad, causing the abrasive article to contact the surface.

[0013] Unfortunately, water, broken sandpaper, and a clear-coated cutting slurry can create a seal between the abrasive workpiece and the work surface, generating enough force to remove it from the tool as the abrasive disc leaves. Adhesion to the work surface is suspected to be a result of suction. The abrasive disc creates a sufficiently flat surface on both itself and the workpiece. The downward force applied from the robotic system then creates a low-pressure area between the abrasive workpiece and the work surface. The suction force generated by this low-pressure area is greater than the bonding force between the abrasive workpiece and the support pad, causing the abrasive workpiece to remain adhered to the work surface when the robotic system retracts.

[0014] This is problematic because the robot will no longer have a polishing disc in place for any subsequent operations. This problem can be mitigated by sensing the presence of the disc after each repair. However, this solution will negatively impact cycle time and robot cell cleanliness. Additionally, keeping the disc glued to the work surface can lead to additional defects in production steps performed by the robotic system that contacts the work surface at the next defect location, where there is no polishing disc between the work surface and the support pad. It can also lead to excessive use of consumables, secondary defects caused by polishing on the glued disc, etc. For paint removal applications, wet sanding is generally preferred over dry sanding because defect repairs typically occur before the paint has fully cured. When abraded, the paint forms a paste. Adding fluid to the surface during the sanding process helps disperse and break up paint chips. If sanding is performed under dry conditions, the paint will rapidly load onto the polishing disc, causing it to become unusable at an unacceptable rate and potentially creating secondary defects from areas where chips are glued to the disc.

[0015] An improved grinding system is desired that reduces the suction force generated during wet sand milling operations, allowing the grinding disc to be removed from the surface as intended.

[0016] The grinding system described herein includes a grinding disc designed for use, for example, with water or another suitable fluid in a wet sand milling operation. The grinding system described herein includes a resistance-reducing feature. In some embodiments, the resistance-reducing feature is integrated into the abrasive article. However, in some embodiments, the resistance-reducing feature is integrated into a support pad.

[0017] In embodiments where the abrasive article includes a resistance-reducing feature, the suction-reducing feature may include a deformable portion in the abrasive article that results in the abrasive article being non-planar. For example, as... Figures 5A to 5B The illustrated creases reduce the suction force generated between the abrasive article and the working surface. A similar reduction in suction force can be achieved through slits in the abrasive article.

[0018] In some embodiments, the abrasive article includes one or more orifices extending through it to allow airflow. The orifices are sized to allow air but not to allow large amounts of chips (grinding debris) to pass through the grinding disc, as chips can contaminate the surface of the support pad and reduce the bonding force between the support pad and the grinding disc. The orifices may be sized such that the working surface does not directly contact the support pad, which could potentially damage the support pad. In embodiments using a hook-and-loop connection between the support pad and the abrasive article, it is desirable that chips do not clog the hook and / or loop connection features on the surface of the support pad.

[0019] Therefore, a smaller orifice size is preferred to reduce damage to the support pad from the working surface and / or abrasive debris. Similarly, it is desirable to keep most of the abrasive material intact and usable for grinding. The orifice size can be set to account for some shrinkage due to chip clogging.

[0020] Previously, abrasive articles with orifices were used in dry grinding operations that generated large amounts of dust. Abrasive articles designed for such applications may include multiple orifices extending through the abrasive article, allowing a vacuum to draw dust through it. However, it should be noted that while wet grinding operations do produce debris, this debris is mixed with the grinding fluid and is not picked up by the vacuum unit.

[0021] PCT Publication WO 2007 / 143400, published on February 21, 2008, describes design considerations for abrasive articles used for dust extraction. When designing abrasive articles for dust extraction, larger orifices, such as those up to 3 mm in diameter, are used, and a larger area of ​​the abrasive article is removed, for example, at least 5% of that area. A large number of orifices are also recommended.

[0022] This application addresses significantly different challenges associated with wet sanding. The composition of the abrasive articles differs, specifically in that they possess a waterproof or water-resistant backing required for wet sanding operations. Smaller abrasive articles are used for defect repair, where the reflective surface of painted vehicles necessitates minimizing the sanding area, as defect repair can introduce visible differences into the surface. The abrasive articles described herein for defect removal are similar in diameter to the shaft of a grinding tool.

[0023] In the case of defect repair, it is desirable to reduce the size of the orifices in the abrasive article in order to maintain a larger area of ​​abrasive material. In some embodiments described herein, a single or a small number of orifices (e.g., less than 30, less than 20, less than 10, or less than 5 orifices) can achieve the desired reduction in suction force. The presence of more orifices in the abrasive articles, including those described herein, may increase the risk of damage to the support pad.

[0024] Compared to dust removal applications that require a separate vacuum unit for dust extraction, the embodiments described herein seek to remove or reduce the naturally occurring resistance that forms between the working surface and the abrasive workpiece.

[0025] For abrasive products used in dry sanding operations, suction is low-risk. Apart from having little or no liquid (which is the reason for the suction described herein), abrasive products used in dry sanding operations typically use larger abrasive particles attached to a backing via a resin-based adhesive layer.

[0026] Due to the nature of the abrasive layer, the abrasive articles in at least some embodiments herein may be more susceptible to suction forces than those used in dust removal applications. At least some embodiments herein utilize structured abrasive materials to form the abrasive material. In some embodiments herein, the abrasive layer comprises a three-dimensional structure consisting of a plurality of regularly arranged three-dimensional elements with predetermined shapes, as described, for example, as in U.S. Patent 6,773,475, published August 10, 2004, Figures 2 through 6 of which, and the associated description, are incorporated herein by reference. Removal of defects from reflective surfaces typically requires a very fine grade of abrasive (e.g., as low as P1500, or even as low as P2500, or even as low as P3000, or even finer) using the FEPA “P” grading scale. Abrasive articles using larger abrasive particles naturally include small air channels between adjacent abrasive particles, allowing sufficient airflow to adequately reduce suction forces. However, the small-sized abrasive materials used for paint defect removal do not leave sufficient space for airflow to reduce suction forces.

[0027] In some implementations, hook-and-loop attachments are used to adhere the sanding disc to the tool. Another adhesion method is to use a pressure-sensitive adhesive backing. However, it is clearly envisioned that while hooks and loops are exemplified as one type of fastener, other removable fastening mechanisms could also benefit from the designs described herein. For example, an improved connection between the support pad and the sanding disc could be achieved.

[0028] To overcome the suction effect, the systems and methods described herein provide pressure-reducing features on the surface of the abrasive article. Some suction-reducing features described herein include one or more orifices that allow airflow through the grinding disc, which prevents adhesion. In some embodiments, venting openings are cut into the working surface of the grinding disc. In some embodiments, circular orifices are cut into the working surface. However, the designs illustrated herein are intended only as examples, and it is explicitly contemplated that other suitable designs are possible.

[0029] As used herein, the term "vehicle" is intended to encompass a wide range of moving structures that receive at least one primer coating, paint coating, or varnish coating during manufacturing. While many examples herein relate to automobiles, it is explicitly envisioned that the methods and systems described herein are also applicable to trucks, trains, ships (with or without motors), aircraft, helicopters, and the like.

[0030] As used herein, the term "robotic repair unit" refers to a robotic repair system that interacts with a surface to remove defects. In some embodiments, the robotic repair unit may be a stationary unit that operates on a fixed surface. In other embodiments, the robotic repair unit is a mobile repair unit that can move along a guide, track, or other mechanism to address defects on a moving surface. Additionally, it is also possible for the repair unit to be stationary while the object to be repaired moves. The robotic repair unit may have one or more end effectors with one or more tools, such as those described in U.S. Provisional Patent Application Serials 62 / 940950 and 62 / 940960, filed November 2, 2019, both of which are incorporated herein by reference. However, other robotic repair unit configurations are also explicitly contemplated.

[0031] As used herein, the term "resistance" refers to any force applied to the abrasive article during the removal step, where the abrasive article is removed from the surface after the grinding operation. The term "resistance" is intended to broadly encompass any forces that contribute to the suction between the abrasive article and the working surface, forces that need to be overcome for successful removal of the abrasive article, including, for example, vacuum forces, surface tension, etc.

[0032] As used herein, the term "abrasive grain" or "abrasive particle" refers to a single abrasive element that can be attached to a backing. In some embodiments herein, the abrasive grain is "shaped," for example, by a molding process, such that the formed abrasive grain takes the shape of a mold cavity. Once the shaped abrasive grain is removed from the mold, these shaped abrasive grains are typically placed individually on the backing, for example, not directly attached to adjacent abrasive grains. Examples of sol-gel abrasive grains from which abrasive grains can be separated, and methods for preparing them, can be found in U.S. Patent Nos. 4,314,827 (Leitheiser et al.), 4,623,364 (Cottringer et al.), 4,744,802 (Schwabel), 4,770,671 (Monroe et al.), and 4,881,951 (Monroe et al.). It is also envisioned that abrasive particles may include abrasive agglomerates, such as those described, for example, in U.S. Patent Nos. 4,652,275 (Bloecher et al.) or 4,799,939 (Bloecher et al.).

[0033] As used herein, the term "abrasive element" or "abrasive compound" refers to an abrasive structure formed from a flowable mixture of abrasive particles and a curable binder. Abrasive elements or compounds can be formed using manufacturing tools, and adjacent abrasive elements can be joined together using manufacturing tools to form a micro-replicated abrasive structure with a three-dimensional structure composed of a plurality of regularly arranged three-dimensional abrasive elements having a predetermined shape. Abrasive elements or compounds and their construction are described in more detail in U.S. Patents 5,152,917 (Pieper et al.), 5,435,816 (Spurgeon et al.), 5,672,097 (Hoopman et al.), 5,946,991 (Hoopman et al.), 5,975,987 (Hoopman et al.), and 6,129,540 (Hoopman et al.).

[0034] Figure 1A This is a schematic diagram of a robotic paint repair system useful in embodiments of the present invention. System 100 typically includes two units: a visual inspection system 110 and a defect repair system 120. The two systems can be controlled separately by motion controllers 112 and 122, which can receive instructions from one or more application controllers 150. The application controllers can receive input or provide output to a user interface 160. Repair unit 120 includes a force control unit 124 alignable with an end effector 126. Figure 1A As illustrated, the end effector 126 includes two tools 128, which in one embodiment may be arranged as further described, such as those described in U.S. Provisional Patent Application Serials 62 / 940950 and 62 / 940960, both filed November 2, 2019. However, other arrangements are also explicitly contemplated. The visual inspection unit 110 can detect defects on the vehicle surface 130, which can be repaired by the repair unit 120.

[0035] The presence of a sufficiently capable inspection system 110 is important for identifying and resolving defects repaired by the repair unit 120. Current existing techniques in vehicle paint repair involve manually sanding / polishing defects with or without the aid of power tools, while maintaining the desired finish (e.g., matching specular reflectivity in the clear coat). Professionals performing such repairs utilize many hours of training, while simultaneously using their senses to monitor the progress of the repair and make adjustments accordingly. This complex behavior is difficult to capture in robotic solutions with limited sensing capabilities.

[0036] Additionally, abrasive material removal is a pressure-driven process, and many industrial manipulators typically operate naturally in a positioning tracking / control state and are optimized for positioning accuracy. The result is an extremely precise system with an extremely rigid error response curve (i.e., small positioning displacements result in very large correction forces), which is inherently poor under force control (i.e., joint torque and / or Cartesian force). Closed-loop force control methods have been used (with limited utility) to address the latter, along with newer (and more successful) force control flanges that provide softer (i.e., non-rigid) displacement curves more suitable for sensitive force / pressure driven processing.

[0037] Some repair processes use fluids to accelerate or otherwise assist the abrasive removal process. For example, fluids can aid in chip removal, reduce abrasive clogging, and extend the life of abrasive articles, while also improving cut consistency during use. For instance, some sanding operations are wet sanding operations, requiring water or another fluid to be dispersed on the repair area before or during the sanding operation. Additionally, polishing typically requires the application of a polishing compound before or during the polishing operation. After the repair is complete, water or other removal solvents may be applied to remove debris. Water present on the work surface can create resistance between the work surface and the abrasive article. If the resulting suction force is greater than the coupling force holding the abrasive article to the support pad, the grinding disc will be shunted from the support pad and remain on the work surface.

[0038] Figure 1B This is a schematic diagram of a paint repair robot that can be used in embodiments of the present invention. In some embodiments, the robot repair unit 200 has a base 210, which may be fixed. In other embodiments, the base 210 may be movable about the x-axis, y-axis, and / or z-axis in any of six dimensions, translation, or rotation. For example, the robot 200 may have a base 210 fixed to a track system configured to travel with the vehicle being repaired. Depending on the location of the defect, the robot 200 may need to move closer to or further away from the vehicle, or may need to move higher or lower relative to the vehicle. A movable base 210 can make repairing hard-to-reach defects easier.

[0039] The robotic repair unit 200 has one or more tools 256 that can interact with a work surface. In one embodiment, the tool 256 may include a support pad or another suitable abrasive tool. During the abrasive operation, the tool 256 may have a grinding disc or other suitable abrasive article, which is attached using adhesives, hooks and rings, clamp systems, vacuum, or other suitable attachment systems. When mounted to the robotic repair unit 200, the tool 256 has the ability to be positioned within the degrees of freedom provided by the robotic repair unit 200 (in most cases, six degrees of freedom) and any other degrees of freedom of its reference frame (e.g., the compensatory stress control unit 230).

[0040] The robotic repair unit 260 has a plurality of joints 260, each of which is movable in the x and y directions, such as Figure 1B As illustrated. Additionally, in some embodiments where the joint 260 is a ball joint, they may also each allow movement in the z-direction.

[0041] Figures 2A to 2B An example of a tool configuration for a robotic repair unit is illustrated, which may be useful in the embodiments described herein. Figure 2A A view illustrating a dual-tool end effector system in use positioning is shown. The robot arm 300 may have a cable-mounted configuration 302. The robot arm 300 has a dual-mounted end effector system 320 mounted on a mounting plate 348. The robot arm 300 can rotatably move the end effector system 320 using a rotary plate 310 and vertically move the end effector system using a connector 315 to position either a first tool 330 or a second tool 340 to interact with a workpiece. Each of the first tool 330 and the second tool 340 has connectors 332 and 342 respectively connected to end effector units 320a and 320b.

[0042] Figure 2A An end effector system 320 is illustrated in one of two use positions, wherein a second tool 340 is positioned to engage a workpiece. As discussed in U.S. Provisional Patent Application Serial No. 62 / 940,950, filed November 2, 2019, system 320 uses a single force control to operate both a first tool 330 and a second tool 340. The first and second use positions align one of the tools 330, 340 parallel to the force control. Figure 2B A side view of the end effector system 320 is shown.

[0043] Figure 2CThis is an image of a robot-driven grinding operation 350 on a working surface. The robot drive shaft 352 pushes a support pad 354 against the working surface 358. An abrasive article (not shown) is attached to the support pad 354 and contacts the surface 358. Figure 2C As illustrated, during the grinding operation, a slurry 356 is formed on surface 350. The abrasive article is removably attached to the support pad and temporarily contacts surface 358. It is desirable that the abrasive article be easily replaceable as needed; for example, the connection between the support pad 354 and the abrasive article should not be so strong as to prevent removal of the used abrasive article. The connection element can be a hook-and-loop system, an adhesive, or another removable connection.

[0044] Figure 2D This is an exploded view of the grinding operation 350, showing the support pad 364 connected to the end effector 366. The slurry 372, formed by the grinding fluid and abrasive debris, promotes the formation of a suction force 374, which pulls the abrasive article 362 toward the slurry-coated surface. A coupling force 376, formed by the coupling elements connecting the abrasive article 362 to the support pad 365, pulls the abrasive article 362 toward the end effector 366. If the suction force 374 is greater than the coupling force 376, the abrasive article 362 will detach from the support pad 364 and remain on the slurry-coated surface.

[0045] In some embodiments herein, the abrasive article 362 is free of stearates or similar dry abrasive lubricant materials. In some embodiments herein, the abrasive article 362 includes a waterproof or water-resistant backing material. In some embodiments, the backing material is a membrane. In some embodiments herein, the membrane may be a polymer membrane. According to some embodiments herein, the abrasive article 362 includes shaped abrasive particles, wherein the shaped abrasive particles are arranged in a predetermined shape or structure, and wherein the predetermined shape or structure is repeated across the surface of the abrasive article. In some embodiments herein, the abrasive article includes Trizact, available from 3M. ™ Abrasive technology.

[0046] A suction force reduction element is desired that reduces the suction force 374 to below the coupling force 376, thereby reducing the risk of separation between the abrasive article 362 and the support pad 364. The suction force reduction element may be incorporated solely into the abrasive article 362 or into the support pad 364. Multiple suction force reduction elements may be present, incorporated into either or both of the abrasive article 362 or the support pad 364.

[0047] Should be in Figure 2C and Figure 2D It is noted that the robotic wet sanding system is a vacuum-free system. For example... Figure 2CAs illustrated in the image, debris from the sanding surface is typically trapped in the slurry material.

[0048] It should also be noted that the system 350 occupies a relatively small area. The shaft 352 has a diameter similar to that of the support pad 354. The abrasive article used for defect repair on reflective surfaces (such as painted vehicles) is smaller than many abrasive articles used in other applications. Efficiently grinding surface 358 is important, which includes using a grinding disc with a smaller surface area and increasing the area available for grinding surface 358.

[0049] Figure 3 A method for detecting and repairing defects on a work surface according to an embodiment of this document is illustrated. Method 400 can be performed by a robotic grinding system, which automatically detects and grinds the defects. The robotic grinding system can grind multiple defects on a surface using a single abrasive article before it is necessary to replace the used abrasive article with a new one.

[0050] In box 410, defective areas are detected and repaired by the repair unit from the robot controller (such as, for example...). Figure 1A The application controller 150 receives instructions related to the detected defect. Without being limited to the embodiments discussed herein, the defect area may be detected by an image 402 of the surface, or may be associated with a location on the vehicle, as indicated by box 404.

[0051] Boxes 420, 430, and 440 relate to steps for repairing detected defects. Defects can be repaired in one or more grinding operations. For example, the defective area can be sanded first, followed by polishing. Defects can be checked between the sanding and polishing steps, and the sanding and / or polishing steps can be repeated depending on whether the defect has been successfully repaired.

[0052] In box 420, the abrasive article is brought into contact with the vehicle surface. In many applications, fluid is also dispensed onto the repair area. Depending on the repair operation, other fluids may also be dispensed.

[0053] When an abrasive article comes into contact with a surface in the presence of fluid, the pressure applied by the support pad can cause resistance to form between the abrasive article and the surface. While this may not cause problems during the grinding step, it can prevent the removal of the abrasive article during the removal step.

[0054] Abrasive articles may include suction-reducing fixtures configured to reduce the suction force between the abrasive article and the surface when the abrasive article is in contact with the surface.

[0055] In some embodiments, the support pad may include a support pad suction reduction feature 412, such as a protrusion or groove that allows airflow. In addition to or as a replacement for the support pad suction reduction feature 412, the abrasive article may include a suction reduction feature 414.

[0056] In some embodiments, the abrasive suction reduction feature 414 may include one or more orifices extending through the thickness of the abrasive article, which, for example, allows airflow into the space between the abrasive article and the surface, thereby allowing for a reduction in suction force. In some embodiments, the abrasive article may include a slit extending through the surface. In some embodiments, the abrasive article includes creases such that the abrasive article is non-planar when no force is applied.

[0057] In frame 430, grinding defects are addressed. Grinding defects may include abrasive grinding operation 422, polishing operation 426, or another operation 428. Grinding defects involve bringing a tool into contact with the defective area. Grinding may occur after or simultaneously with fluid distribution in frame 420.

[0058] In box 440, the abrasive article is removed from the vehicle surface. As indicated above, the combination of abrasive article deterioration, abrasive chips removed from the vehicle surface, downward applied force, and distributing fluid can cause a suction force to form between the abrasive surface and the working surface. In some cases, the suction force is greater than the force required to keep the abrasive article in contact with the robotic system, and the abrasive article loosens from the robotic system and adheres to the surface.

[0059] While human operators can see that the abrasive workpiece has detached from the tool, most robotic systems are not typically built with sensors to detect when the abrasive workpiece is no longer in contact with the system. Such systems take up space and increase the cost and complexity of the robotic system. A solution is desired that reduces the suction force between the abrasive workpiece and the work surface, thereby allowing the abrasive workpiece to detach from the surface.

[0060] Several different options for remedying the suction problem were tried, with limited success. For example, attempts to increase adhesion by using higher rings or alternative hooks improved the adhesion of the intervertebral disc, but not sufficiently. Adjusting the force / rpm curve near the end of the repair also proved insufficient to eliminate the problem. Creating creases in the sandpaper could present a difficult shape factor in both production and use. Peeling the disc off the surface (as opposed to lifting it perpendicular to the surface) also showed improved adhesion, but similar failures occurred, and there were significant implantation challenges in avoiding impacts. Reducing the amount of slurry (by reducing the amount of water dispensed) was a powerful approach, but it had an unacceptably large reduction in material removal during the sanding process. Using several surfactants in the dispensed water, whether applied directly to the grinding media or applied directly to the surface in various amounts, had some effect, but failures still occurred.

[0061] Surprisingly, it was found that a small orifice extending through the thickness of the grinding disc was sufficient to reduce the suction force between the surface and the grinding disc to a level below the strength of the bonding force between the support pad and the abrasive article, thereby increasing the frequency of successful removal of the abrasive article from the surface. While a single orifice may be sufficient, it is explicitly envisioned that one or more orifices could be present.

[0062] In some embodiments, the abrasive article may have a diameter of less than 4 cm. In some embodiments, the abrasive article has a diameter of about 3 cm. In some embodiments, the total area of ​​one or more orifices is at least 0.18 mm. 2 In some implementations, the total area of ​​one or more orifices is at least 0.20 mm. 2 In some implementations, the total area of ​​one or more orifices is less than about 20 mm. 2 In some implementations, the total area of ​​one or more orifices is less than about 10 mm. 2 In some implementations, the total area of ​​one or more orifices is less than about 1.0 mm. 2 In some embodiments, one or more orifices may be positioned closer to the center of the abrasive article. The center of an abrasive article, having a surface velocity lower than its edges, has the lowest grinding rate. Therefore, placing one or more orifices closer to the center of the abrasive article achieves the desired effect of reducing suction force without significantly diminishing the grinding efficiency of the abrasive article. For example, one or more orifices may be present in the central region of the abrasive article. For example, in the inner half region of the abrasive article, or in a smaller space. For example, one or more orifices may be positioned within the central region of the abrasive article, wherein the central region is defined by a second radius, which is smaller than a first radius of the abrasive article. The second radius is less than approximately half the first radius.

[0063] Figures 4A to 4B An embodiment of a grinding disc with pressure-reducing features is illustrated, which are shown to reduce suction force. The grinding disc 510 has a centrally located circular orifice that allows airflow through the disc. In some embodiments, the circular orifice is not part of the connection mechanism between the disc 510 and the support pad. For example, the orifice size is not configured to receive a tool shaft. In some embodiments, the orifice of the disc 510 is large enough to allow sufficient airflow to reduce resistance, but not large enough to allow additional chips to pass through and contaminate the support pad. In some embodiments, it is preferred to place a single orifice at or near the center of the abrasive article, as any chip leakage is confined to the center of the support pad, which has lower grinding efficiency than the edges of the support pad. However, it is explicitly contemplated that one or more orifices can be placed anywhere on the abrasive article. In the illustrated embodiment, the diameter of the orifice of the disc 520 is 2.2 mm.

[0064] As used herein, the term "center" refers to the internal region of the grinding disc. It should be noted that in some embodiments, one or more orifices may exist within the internal region of the grinding disc, but may not be geometrically "centered." Any accepted geometric definition can be used to find the center of the grinding disc; for example, for a circle, the center is equidistant from all points on the circle. It should be noted that in some embodiments herein, the grinding disc has a fan-shaped or otherwise textured edge, meaning the center can be defined as the location at the intersection of any two different diameters. It is explicitly contemplated that orifices may be placed "off-center," for example, not at the intersection of any two different diameters of the grinding disc. However, it is also contemplated that in some embodiments, one or more orifices are centered on the grinding disc. In embodiments where the abrasive article is not circular or textured (e.g., has a fan-shaped or another repeating pattern around the edge), a centroid definition can be used.

[0065] In some embodiments described herein, one or more orifices are not uniformly distributed across the surface of the grinding disk, but rather clustered in a smaller area. For example, in one embodiment, the orifice area is defined by a second radius. In some embodiments, the second radius may extend from the center of the grinding disk such that the orifice area is centered relative to the disk. The orifice area may, for example, have a radius less than or equal to half the radius of the disk (e.g., R). 孔口区域 = ½R 盘 The orifice region can be even more restricted, for example, defined by a radius less than or equal to 1 / 3 of the radius of the grinding disc, or even by ¼ of the radius of the grinding disc. The orifice region can also be larger, for example, having a radius greater than ½ of the radius of the disc, such as between ½ and 2 / 3 of the radius of the disc, or greater than 2.3 of the radius of the disc.

[0066] In some embodiments, multiple apertures are spaced apart around the surface, as illustrated in grinding disc 530. Although the apertures of disc 530 are illustrated as being uniformly spaced around the surface, it is clearly contemplated that different patterns or random placement may also be applicable to some embodiments.

[0067] However, it is clearly envisioned that, although in Figures 4A to 4B The illustration shows a symmetrical orifice positioning, but it is clearly envisioned that other designs may be sufficient. For example, if the orifice is positioned close to the edge of the abrasive article but in an area where there are connecting mechanisms (e.g., hooks and rings between the abrasive article and the support pad), the orifice may allow sufficient airflow to reduce suction.

[0068] Although Figure 4A Some orifice designs are illustrated, but Figure 4B Several other designs 542 to 574 that may also be suitable are illustrated. Furthermore, it is explicitly envisioned that one or more slits could be sufficient to reduce the suction force. Additionally, although in Figures 4A to 4B The illustration shows a circular opening, but it is clearly envisioned that other shapes might be suitable.

[0069] Figures 5A to 5C Examples of suction reduction options according to the implementation scheme described herein are provided. Figures 5A to 5B An abrasive article with creases is illustrated. View 610 is a view of the abrasive article from above, while view 620 illustrates a perspective view. Creases can be formed in the abrasive article during manufacturing or, for example, during use. After the abrasive article has been attached, a support pad can press the abrasive article against, for example, a surface that causes the creases to form. The shape of the support pad can also be designed to produce creases. The presence of creases can change the shape of the abrasive article from planar to non-planar or conical.

[0070] Figure 5C An example is shown of an abrasive article that includes a slit 650 instead of a crease, which can be introduced in any suitable manner.

[0071] Figures 6A to 6C Examples of abrasive articles according to embodiments of the present invention are illustrated. In some embodiments of the present invention, the abrasive article is formed from a backing onto which a plurality of abrasive articles are adhered.

[0072] Figure 6A An example is illustrated by multiple micro-abrasive features 702 arranged in a repeating three-dimensional structure to form a 3D element 314. The repeating units 314 form the macroscopic structure of the abrasive article surface. Although in Figure 6AThe pyramidal shape is illustrated, but it is clearly contemplated that the abrasive particles 702 may take any number of suitable shapes, such as those illustrated in Figures 2 through 5 of U.S. Patent 6,773,475, published August 10, 2004 (which is incorporated herein by reference), and other suitable shapes.

[0073] Figure 6B An example is an abrasive article 710 having multiple 3D elements 714 separated by channels 712. Figure 6C A schematic side view of two 3D elements 722 separated by a channel 726 is illustrated. The 3D element 722 may have an element height 724. The channel 726 may have a channel distance 728 and a channel height equal to the abrasive element height 724. In some embodiments herein, the aspect ratio of the various structures of the elements 722 may allow airflow channels to be constructed into the abrasive article between adjacent features 722.

[0074] According to embodiments described herein, abrasive articles typically include an abrasive material adhered to a backing via an adhesive layer, which may include a resin or other adhesive material.

[0075] Some examples of backing materials may include polymer films, paper, cloth, metal films, vulcanized fibers, nonwoven matrix materials, combinations thereof, and their processed products.

[0076] In the embodiments described herein, the backing can be a polymer film, such as, for example, any of polyester film, polyethylene film, polypropylene film, polyimide film, nylon film, polyethylene terephthalate (PETG) film, polyurethane film, alumina film, and / or polyvinyl chloride film. Other polymer film materials may also be suitable. The polymer film may be primed with materials such as polyethylene acrylic to promote adhesion to the matrix material of the abrasive composite. In the embodiments described herein, the backing is formed of a water-resistant material. The water-resistant abrasive articles of this invention are designed to withstand exposure to water or other liquids without losing their effectiveness or deteriorating. The water resistance of the abrasive article helps prevent premature wear or degradation, thus allowing it to maintain its cutting or grinding ability even when used under wet conditions.

[0077] In some embodiments described herein, the backing is formed of a waterproof material. The waterproof abrasive articles described herein are completely impermeable to water or other water-based liquids. Unlike water-resistant abrasive articles that can withstand exposure to water without significant damage, waterproof abrasive articles are completely impermeable and will not absorb or be affected by water.

[0078] Since the abrasive articles in the embodiments described herein are constructed for wet sanding, the abrasive articles are formed to be free of stearates or other dry sanding lubricant components.

[0079] Abrasive articles include an abrasive layer. The abrasive layer has an abrasive composite containing a binder matrix and abrasive grains dispersed therein as structural components. The abrasive grains can be arranged in a micro-replicated pattern to form one or more 3D elements, for example, such as... Figures 6A to 6C exemplified.

[0080] The abrasive compound is formed from a slurry containing multiple abrasive particles dispersed in a binder in an uncured or ungelled state. During curing or gelling, the abrasive compound is solidified, i.e., fixed into a predetermined shape and predetermined structure.

[0081] The size or grinding feature of the abrasive grains can vary depending on the type of abrasive grains or the intended use of the abrasive material. For example, for final finishing grinding, the size is 1 μm to 20 μm, preferably 1 μm to 10 μm, and more preferably 1 μm to 7 μm. Preferred examples of abrasive grains used in this invention include diamond, cubic boron nitride, cerium oxide, fused alumina, heat-treated alumina, sol-gel alumina, silicon carbide, chromium oxide, silicon dioxide, zirconium oxide, alumina-zirconia, iron oxide, garnet, and mixtures thereof.

[0082] The binder can be hardened or gelled to form an abrasive layer. Preferred examples of binders include phenolic resins, methylphenolic resins, amino plastic resins, polyurethane resins, epoxy resins, acrylate resins, polyester resins, vinyl resins, melamine resins, acrylated isocyanurate resins, urea-formaldehyde resins, isocyanurate resins, acrylated polyurethane resins, acrylated epoxy resins, and mixtures thereof. The binder may be a thermoplastic resin.

[0083] In some embodiments, the adhesive may be radiation-cured. Radiation-cured adhesives are adhesives that are at least partially hardened or capable of at least partially polymerized by radiation energy. Depending on the adhesive used, energy sources such as heat, infrared radiation, electron beam radiation, ultraviolet radiation, or visible light radiation are used.

[0084] Typically, these adhesives are polymerized via a free radical mechanism. Preferably, these adhesives are selected from the group consisting of: acrylated polyurethanes, acrylated epoxy resins, amino plastic derivatives having α,β-unsaturated carbonyl groups, olefinic unsaturated compounds, isocyanurate derivatives having at least one acrylate group, isocyanates having at least one acrylate group, and mixtures thereof.

[0085] If the binder is cured by ultraviolet radiation, a photoinitiator is required to initiate free radical polymerization. Preferred examples of photoinitiators for this purpose include organic peroxides, azo compounds, quinones, benzophenones, nitroso compounds, acryloyl halides, hydrazones, mercapto compounds, pyranonium compounds, triacryloyl imidazoles, diimidazoles, chloroalkyl triazines, benzoin ethers, benzyl ketals, thioxanones, and acetophenone derivatives. A preferred photoinitiator is 2,2-dimethoxy-1,2-diphenyl-1-ethyl ketone.

[0086] If the binder is cured by visible light radiation, the photoinitiator must initiate free radical polymerization. Preferred examples of photoinitiators for this purpose are disclosed in U.S. Patent No. 4,735,632, columns 3, lines 25 through 4, lines 10, 5, lines 1 through 7, and 6, lines 1 through 35, which is incorporated herein by reference.

[0087] The weight ratio of abrasive grains to binder is typically in the range of about 1.5 to 10 parts by weight of abrasive grains relative to one part binder, and preferably about 2 to 7 parts by weight of abrasive grains relative to one part binder. This ratio can vary depending on the size of the abrasive grains, the type of binder to be used, and the intended purpose of the abrasive material.

[0088] To smoothly and precisely grind the end faces of hard materials such as fiber optic connectors, if the abrasive grains are made of silicon carbide, the concentration of the abrasive grains contained in the abrasive compound is preferably in the range of 43% to 90% by weight; if the abrasive grains are made of spherical abrasive particles such as alumina or silica, the concentration is in the range of 70% to 90% by weight; if the abrasive grains are made of alumina, the concentration is in the range of 37% to 90% by weight; and if the abrasive grains are made of diamond, the concentration is in the range of 39% to 90% by weight.

[0089] Abrasive compounds may contain materials other than abrasive grains and binders. For example, abrasive materials may contain common additives such as coupling agents, lubricants, dyes, pigments, plasticizers, fillers, stripping agents, grinding aids, and mixtures thereof.

[0090] The abrasive compound may contain a coupling agent. Adding a coupling agent can significantly reduce the covering viscosity of the slurry to be used to form the abrasive compound. Preferred examples of coupling agents used in this invention include organosilanes, zirconium aluminates, and titanates. The amount of coupling agent is typically less than 5% by weight of the binder, preferably less than 1% by weight of the binder.

[0091] The abrasive layer has a three-dimensional structure, which consists of multiple regularly arranged three-dimensional elements with predetermined shapes, formed by multiple abrasive particles arranged in a repeating pattern. Figure 6AThe illustrated abrasive grains, for example, have a tetrahedral shape with ridges connected at a point on the top. In this case, the angle α formed between the two ridges is typically 30° to 150°, preferably 45° to 140°. The three-dimensional element 104 may have a pyramidal shape. In this case, the angle α formed between the two ridges is typically 30° to 150°, preferably 45° to 140°.

[0092] Points on the top of the three-dimensional element 104 lie on a plane parallel to the surface of the matrix material, substantially over the entire region of the abrasive material. The height of each abrasive particle from the surface of the matrix material can range from about 2 μm to about 20 μm. For example, the abrasive particles can have a height greater than about 2 μm. In some embodiments, the abrasive particles can have a height less than about 20 μm, or less than about 15 μm, or less than about 12 μm, or even less than about 10 μm. The abrasive particles can even have a height less than about 9 μm, or even less than about 8 μm, or even less than about 7 μm, or even less than about 6 μm. The variation in the height of the abrasive particles is preferably less than 20% between particles, more preferably less than 10%.

[0093] Abrasive particles can be arranged in a variety of suitable, predetermined configurations. Figure 6A In this structure, abrasive particles are most densely packed. In some embodiments described herein, the abrasive particles repeat at a predetermined cycle to form a 3D element. This repeating shape can be unidirectional or bidirectional.

[0094] In the embodiments described herein, the abrasive grains do not significantly protrude beyond the surface of the three-dimensional element's shape. In other words, the three-dimensional element is composed of flat planes. For example, the surfaces constituting the three-dimensional element have a surface roughness Ra of less than 2 μm, preferably less than 1 μm.

[0095] When the abrasive article undergoes a grinding operation, the tip of each abrasive particle in abrasive grains 702 contacts and grinds the surface. As the grinding operation continues, the three-dimensional element decomposes from the top portion, allowing unused abrasive grains to emerge. Therefore, to improve the grinding performance of the abrasive material, the concentration of abrasive grains in the abrasive compound located in the top portion of the three-dimensional element is preferably increased as much as possible, so that the abrasive material can have higher grinding performance suitable for grinding hard materials. More preferably, the concentration of abrasive grains in the abrasive compound located in the top portion of the three-dimensional element exceeds the critical pigment volume concentration.

[0096] Generally, the critical pigment volume concentration (CPI) is considered to be the pigment volume concentration at which just enough binder is present to coat the pigment surface and provide a continuous phase throughout the film. As used herein, the CPI refers to the volume concentration of abrasive grains when the voids between the abrasive grains are filled solely by the binder. When the binder is liquid, the mixture is fluid if its concentration is below the CPI, but loses its fluidity if its concentration exceeds the CPI. If the concentration of abrasive grains in the abrasive composite located at the top of a three-dimensional element is less than or equal to the CPI, the abrasive material will have insufficient abrasive performance, making it unsuitable for abrading hard materials such as the end faces of fiber optic connectors.

[0097] The abrasive element 700 can be formed using a variety of suitable processes. Some embodiments herein include abrasive elements formed using the process described in U.S. Patent 6,773,475, specifically Figures 6a through 6e and the associated description, both of which are incorporated herein by reference.

[0098] First, an abrasive slurry containing abrasive grains, a binder, and a solvent is prepared. The abrasive slurry used herein is a composition containing a binder, abrasive grains, and optional additives (such as photoinitiators, in an amount sufficient to constitute the abrasive complex), and also contains a volatile solvent (in an amount sufficient to impart fluidity to the mixture). Even if the abrasive grain content in the abrasive complex exceeds the critical pigment volume concentration, fluidity can be maintained by including a volatile solvent in the abrasive slurry.

[0099] Preferred volatile solvents are organic solvents that dissolve binders and exhibit volatility from room temperature to 170°C. Specific examples of organic solvents include methyl ethyl ketone, methyl isobutyl ketone, toluene, xylene, ethanol, isopropanol, ethyl acetate, butyl acetate, tetrahydrofuran, propylene glycol monomethyl ether, and propylene glycol monomethyl ether acetate. Another preferred solvent is water.

[0100] Next, a mold sheet is prepared having multiple regularly arranged recesses that taper towards the bottom. The shape of the recesses can be an inverted shape of the three-dimensional element to be formed. The mold sheet can be made of a metal such as nickel or a plastic such as polypropylene. For example, thermoplastic resins such as polypropylene can be embossed on a metal tool at their melting point to form recesses of a predetermined shape, therefore such thermoplastic resins are preferred. Additionally, if the binder is a radiation-curing resin, a material that transmits ultraviolet and visible light is preferred.

[0101] The obtained mold sheet is filled with abrasive slurry.

[0102] Abrasive slurry can be used to fill mold sheets by applying the abrasive slurry onto the mold sheet using coating equipment such as a roller coater. The viscosity of the abrasive slurry used for application can be adjusted from 10 cps to 106 cps, particularly from 100 cps to 105 cps.

[0103] The solvent is evaporated and removed from the abrasive slurry. At this point, the mold sheet filled with the abrasive slurry is heated at 50°C to 150°C for 0.2 to 10 minutes. If the binder is a thermoplastic resin, the mold sheet can be heated at its curing temperature to simultaneously perform the hardening step. If the solvent is highly volatile, the mold sheet can be left to stand at room temperature for several minutes to several hours.

[0104] Furthermore, the mold sheet is filled with a laminating adhesive to fill the recesses. The laminating adhesive may be the same as or different from the adhesive used in preparing the abrasive slurry. An adhesive with good adhesion to the substrate material is preferred as the laminating adhesive.

[0105] Preferred examples of laminating adhesives are acrylic resins, epoxy resins, and polyurethane resins. The laminating adhesive can be used to fill the mold sheet in the same manner as abrasive slurries.

[0106] The matrix material can be stacked on the mold sheet to allow the adhesive to adhere to the matrix material. Adhesion is achieved by applying pressure using laminating rollers. However, it is explicitly envisioned that in some embodiments, the abrasive particles 702 have a single, monolithic composition.

[0107] The binder is hardened. As used herein, "hardening" means that the binder is polymerized into a solid state. After hardening, the specific shape of the abrasive layer remains unchanged. The hardening of the binder in the abrasive slurry and the curing of the laminated binder introduced separately in later steps can be performed separately or simultaneously.

[0108] Adhesives are cured by heat, infrared radiation, or by electron beam radiation, ultraviolet radiation, or other radiant energy such as visible light. The amount of radiant energy applied can vary depending on the type of adhesive and the type of radiant energy source. Typically, those skilled in the art can appropriately determine the amount of radiant energy to be applied. The time required for curing can vary depending on the thickness, density, temperature, properties of the composition, etc.

[0109] For example, the adhesive can be hardened by irradiating a transparent substrate material with ultraviolet (UV) light. The mold sheet is then removed to prepare an abrasive material consisting of a substrate material and an abrasive layer with a three-dimensional structure. The adhesive can be hardened after the mold sheet is removed.

[0110] Figures 7A to 7E A schematic diagram of an abrasive article coupling mechanism according to the embodiment described herein is illustrated.

[0111] Figure 7A An example is illustrated of a support pad 800 having a surface covered with a connecting feature 802. In some embodiments, the connecting feature includes a hook and loop (e.g., a hook-it device available from 3M). ™ ) Surface features, these hook and loop surface features receive corresponding features on the connecting surface of the abrasive article. Figure 7B A schematic diagram 820 illustrates the connection of the abrasive article 810 to the support pad 800. As illustrated, the abrasive article 810 has a relatively smooth surface when covering the abrasive element. Although the abrasive article may have some surface variability, such as regarding Figures 6A to 6C The small size of the abrasive grains, combined with minimal grain size variation and shallow channels between abrasive elements, results in a surface smooth enough to be fully wetted without leaving sufficient space for cavitation or airflow. Therefore, the smooth surface can lead to a significant suction force that holds the grinding surface to the work surface. This effect is amplified when used under wet or damp grinding conditions.

[0112] Figure 7C A schematic diagram 830 illustrating the attachment of an abrasive article to a support pad according to an embodiment of this document is illustrated. The grinding disc includes an aperture 812 extending through the thickness of the grinding disc, which provides pressure relief, thereby reducing the amount of suction force between the disc and the working surface. The aperture 812 allows the formation of a pressure relief channel 816.

[0113] Figure 7D-1 and Figure 7D-2 Different configurations of a support pad 840 having multiple resistance-reducing features 842 on its surface are illustrated. For ease of understanding, connecting features (e.g., hook-and-loop features) are not shown. The features 842 include multiple grooves 842 that can be machined into or constructed into the surface of the support pad 840. Although in Figure 7D-2 Multiple grooves are illustrated in a parallel configuration with equal spacing between them, but it is explicitly envisioned that fewer or more grooves may exist in other embodiments and may be positioned relative to each other in multiple suitable configurations. Figure 7D-2 An embodiment in which two of the grooves 842 intersect on the surface is illustrated. Although Figure 7D-2 A symmetrical design with grooves intersecting at the center of the surface is illustrated, but it is explicitly envisioned that the intersection between two grooves could be located elsewhere on the surface. Additionally, a single groove intersecting with orifice 844 might suffice. Other configurations are explicitly anticipated.

[0114] Figure 7EThe function of the suction relief feature 842 is illustrated. The pressure relief channel is illustrated by arrow 846. The pressure relief feature 842 allows pressure to be reduced at the edge of the support pad 840. Although a linear channel is illustrated, it is clearly envisioned that other patterns or shapes (e.g., radial channels, crosshairs, grid patterns, or other suitable designs) are possible.

[0115] In some embodiments described herein, when the pressure reduction feature is taken into account, the contact surface between the support pad and the abrasive article is at least 50% of the initial disk surface.

[0116] Additionally, although Figure 7E An embodiment in which both the support pad and the grinding disc include pressure-reducing features is illustrated, but it is clearly contemplated that in some embodiments, only the support pad or only the grinding disc includes pressure-reducing features. Additionally, although in Figure 7E The illustration shows an abrasive article with a single orifice design, but it is clearly envisioned that in some embodiments, any suitable pressure-reducing features may be present, such as multiple orifices, slits, creases, etc.

[0117] Including pressure-relief features on the support pad allows the use of abrasive articles (e.g., Stik-it, available from 3M) in the embodiments described herein. ™ This is achieved using a grinding disc, and the abrasive product is attached to the support pad using an adhesive.

[0118] It should be noted that, although Figures 7A to 7E An example of a support pad is illustrated, having connecting features 802 uniformly distributed around the surface; however, it may be preferable to remove such features near the orifice 844. It is desirable that the connecting features 802 do not directly contact the surface being directly ground (which could lead to scratches, etc.). In some embodiments herein, the connecting features 802 are removed in the region corresponding to the orifice (e.g., orifice 814 or 844). It may be desirable to remove the connecting features 802 in a larger region than precisely corresponding to the orifice, because the abrasive article may not be precisely centered on the support pad.

[0119] An abrasive article includes: a backing; a grinding surface including an abrasive material adhered to the backing; a coupling surface including a coupling feature configured to removably couple the abrasive article to a tool; and a resistance-reducing feature. The abrasive article is configured for use with a fluid during a grinding operation. The resistance-reducing feature is configured to reduce resistance between the working surfaces of the abrasive article, including the fluid.

[0120] The backing may include a membrane.

[0121] The membrane may include a polymer membrane.

[0122] Abrasive materials may include abrasive particles. Abrasive particles may include shaped abrasive particles.

[0123] Abrasive materials may include three-dimensional abrasive structures, which are composed of multiple regularly arranged three-dimensional abrasive elements with predetermined shapes.

[0124] The three-dimensional structure can be a first three-dimensional structure. The grinding surface can include a second three-dimensional structure. Channels can separate the first three-dimensional structure and the second three-dimensional structure. The resistance reduction feature can include channels.

[0125] The channel may have a channel depth. The three-dimensional structure may have a feature height. The distance from the channel depth to the feature height may be at least 100 μm.

[0126] Abrasive products may be stearate-free.

[0127] Abrasive articles may have a diameter of at least about 0.5 inches.

[0128] Abrasive products can have a diameter of less than about 4 inches.

[0129] Abrasive products can have a diameter of less than about 3 inches.

[0130] Abrasive materials may have a FEPA rating of at least P1200.

[0131] Abrasive materials may have a FEPA rating of at least P1500.

[0132] Abrasive materials may have a FEPA rating of at least P3000.

[0133] Abrasive products may have non-circular peripheries.

[0134] Non-circular borders may include repeating patterns.

[0135] Repeating patterns may include waveforms.

[0136] Abrasive products can be non-planar.

[0137] The resistance reduction feature may include the deformable part of the abrasive article.

[0138] The deformable part may include creases.

[0139] The deformable portion may include a slit extending through the backing.

[0140] The resistance reduction feature may include one or more orifices that extend from the coupling surface through the abrasive article to the grinding surface.

[0141] The total area of ​​one or more orifices can be at least 0.18 mm².

[0142] The total area of ​​one or more orifices can be at least 0.20 mm².

[0143] The total area of ​​one or more orifices can be less than approximately 20 mm².

[0144] The total area of ​​one or more orifices can be less than approximately 10 mm².

[0145] The total area of ​​one or more orifices can be less than about 1.0 mm².

[0146] Abrasive products can have a diameter of approximately 3 cm.

[0147] Abrasive products can have a diameter of less than 4 cm.

[0148] One or more orifices may be located within the central region of the abrasive article. The central region is defined by a second radius, which is smaller than the first radius of the abrasive article.

[0149] The second radius can be about a quarter smaller than the first radius.

[0150] The second radius can be less than about half the first radius.

[0151] The connecting feature may include multiple hooks or multiple loops.

[0152] The connecting features may include adhesives.

[0153] The backing may include waterproof materials.

[0154] A robotic grinding system includes an abrasive article comprising an abrasive layer coupled to a first side of a backing, the backing including a coupling feature on a second side, and the backing comprising a waterproof material. A support pad is removably coupled to the coupling feature. A movement mechanism is configured to move the abrasive article relative to a working surface. A force control unit is configured to apply a force to the support pad. A resistance reduction element is configured to reduce the resistance generated by the movement of the abrasive article against the working surface during a wet grinding process.

[0155] Robotic grinding systems can be vacuum-free grinding systems.

[0156] Robotic grinding systems can operate without protective covers.

[0157] During wet grinding, resistance is generated between the abrasive layer and the working surface. The resistance reduction element reduces the vacuum force to below the coupling force applied by the coupling feature.

[0158] The connecting feature may include multiple hooks, multiple rings, or adhesive.

[0159] The vacuum force can be reduced to below about 10 N.

[0160] The vacuum force can be reduced to below about 8 N.

[0161] The support pad has a support pad diameter, and the abrasive product has an abrasive product diameter. The diameter of the abrasive product is larger than the diameter of the support pad.

[0162] The backing may include a membrane.

[0163] The membrane may include a polymer membrane.

[0164] Abrasive particles may include shaped abrasive particles.

[0165] Abrasive materials may include a three-dimensional structure, which is composed of a plurality of regularly arranged three-dimensional elements with predetermined shapes.

[0166] The three-dimensional structure is a first three-dimensional structure. The grinding surface includes a second three-dimensional structure. Channels separate the first and second three-dimensional structures. The resistance reduction feature includes channels.

[0167] The height of the channel can be at least the height of the first three-dimensional structure.

[0168] Abrasive products may be stearate-free.

[0169] Abrasive articles may have a diameter of at least about 0.5 inches.

[0170] Abrasive products can have a diameter of less than about 4 inches.

[0171] Abrasive products can have a diameter of less than about 3 inches.

[0172] Abrasive materials may have a FEPA rating of at least P1200.

[0173] Abrasive materials may have a FEPA rating of at least P1500.

[0174] Abrasive materials may have a FEPA rating of at least P3000.

[0175] Abrasive products may have non-circular peripheries.

[0176] Non-circular borders may include repeating patterns.

[0177] Repeating patterns may include waveforms.

[0178] Abrasive products can be non-planar.

[0179] The resistance reduction feature may include the deformable part of the abrasive article.

[0180] The deformable part may include creases.

[0181] The deformable portion may include a slit extending through the backing.

[0182] The resistance reduction feature may include one or more orifices that extend from the coupling surface through the abrasive article to the grinding surface.

[0183] The total area of ​​one or more orifices can be at least 0.18 mm².

[0184] The total area of ​​one or more orifices can be at least 0.20 mm².

[0185] The total area of ​​a combination of one or more orifices can be less than approximately 20 mm².

[0186] The total area of ​​a combination of one or more orifices can be less than approximately 10 mm².

[0187] The total area of ​​one or more orifices can be less than about 1.0 mm².

[0188] Abrasive products can have a diameter of approximately 3 cm.

[0189] Abrasive products can have a diameter of less than 4 cm.

[0190] One or more orifices may be located within the central region of the abrasive article. The central region is defined by a second radius, which is smaller than the first radius of the abrasive article.

[0191] The support pad may include a resistance-reducing feature.

[0192] The support pad may include channels configured to allow airflow between the surface of the support pad and a second side of the backing.

[0193] The connecting features may include a plurality of first connecting features. The support pad includes a plurality of second connecting features configured to receive the first connecting features. Areas of the support pad do not have second connecting features.

[0194] Abrasive articles may include orifices. The dimensions of the region are set to overlap with the orifice.

[0195] The depth of the drag reduction feature can be at least 0.01 inches.

[0196] The width of the drag reduction feature can be at least 0.01 inches.

[0197] A method for grinding a surface includes: applying a fluid to the surface; moving an abrasive article to the vicinity of the surface using a moving mechanism; and grinding the surface using the abrasive article in the presence of the fluid. The abrasive article is removably attached to a support pad via a coupling mechanism. During grinding, a suction force can be formed between the surface and the abrasive article. The abrasive article can be removed from the surface. The abrasive article includes a resistance-reducing feature configured to reduce the suction force between the surface and the abrasive article.

[0198] The coupling mechanism may include a hook and loop system. The resistance reduction feature reduces the suction force to below the threshold force applied by the hook and loop system.

[0199] The grinding surface may include: applying force to the abrasive article.

[0200] Grinding may include producing a slurry comprising abrasive fragments mixed into a fluid.

[0201] The suction force can be reduced to less than about 10 N.

[0202] The suction force can be reduced to less than about 8N.

[0203] Abrasive products may include water-resistant backings.

[0204] Abrasive products may include waterproof backings.

[0205] Abrasive products may include abrasive surfaces having a surface roughness Ra of less than about 2 μm.

[0206] The backing may include a membrane.

[0207] The membrane may include a polymer membrane.

[0208] Abrasive particles may include shaped abrasive particles.

[0209] Abrasive materials may include a three-dimensional structure, which is composed of a plurality of regularly arranged three-dimensional elements with predetermined shapes.

[0210] The three-dimensional structure can be a first three-dimensional structure. The grinding surface can include a second three-dimensional structure. Channels can separate the first three-dimensional structure and the second three-dimensional structure. The resistance reduction feature includes channels.

[0211] The channel may have a channel depth. The three-dimensional structure may have a feature height. The distance from the channel depth to the feature height may be at least 100 μm.

[0212] Abrasive products may be stearate-free.

[0213] Abrasive articles may have a diameter of at least about 0.5 inches.

[0214] Abrasive products can have a diameter of less than about 4 inches.

[0215] Abrasive products can have a diameter of less than about 3 inches.

[0216] Abrasive materials may have a FEPA rating of at least P1200.

[0217] Abrasive materials may have a FEPA rating of at least P1500.

[0218] Abrasive materials may have a FEPA rating of at least P3000.

[0219] Abrasive products may have non-circular peripheries.

[0220] Non-circular borders may include repeating patterns.

[0221] Repeating patterns may include waveforms.

[0222] Abrasive products can be non-planar.

[0223] The resistance reduction feature may include the deformable part of the abrasive article.

[0224] The deformable part may include creases.

[0225] The deformable portion may include a slit extending through the backing.

[0226] The resistance reduction feature may include one or more orifices that extend from the coupling surface through the abrasive article to the grinding surface.

[0227] The total area of ​​one or more orifices can be at least 0.18 mm².

[0228] The total area of ​​one or more orifices can be at least 0.20 mm².

[0229] The total area of ​​a combination of one or more orifices can be less than approximately 20 mm².

[0230] The total area of ​​a combination of one or more orifices can be less than approximately 10 mm².

[0231] The total area of ​​one or more orifices can be less than about 1.0 mm².

[0232] Abrasive products can have a diameter of approximately 3 cm.

[0233] Abrasive products can have a diameter of less than 4 cm.

[0234] One or more orifices may be located within the central region of the abrasive article. The central region may be defined by a second radius. The second radius may be smaller than the first radius of the abrasive article.

[0235] All orifices in one or more orifices can be within the central area.

[0236] The second radius can be about one-third smaller than the first radius.

[0237] The second radius can be less than about half the first radius.

[0238] The support pad may include channels configured to allow airflow between the surface of the support pad and a second side of the backing.

[0239] The connecting feature may include a plurality of first connecting features. The support pad may include a plurality of second connecting features configured to receive the first connecting features. Areas of the support pad may be without second connecting features.

[0240] Abrasive articles may include orifices. The dimensions of the region may be set to overlap with the orifice.

[0241] A method of grinding a surface includes: moving an abrasive article to a vicinity of a defect location on the surface using a robotic grinding system. The abrasive article includes a grinding surface opposite to a coupling surface. The abrasive article is coupled to a support pad using a coupling mechanism on the coupling surface. The coupling mechanism applies a coupling force on the abrasive article along the coupling surface. A fluid is applied to the surface near the defect location. The surface is ground. Grinding includes: applying a force to the support pad using a force control unit of the robotic grinding system, and moving the abrasive article on the surface at a rotational speed. The abrasive article is removed from the surface. The abrasive article includes a resistance-reducing feature. The resistance-reducing feature reduces the suction force between the abrasive article and the surface to below the coupling force.

[0242] The suction force can be reduced to less than about 10 N.

[0243] The suction force can be reduced to less than about 8N.

[0244] Robotic grinding systems can be vacuum-free grinding systems.

[0245] Robotic grinding systems can operate without protective covers.

[0246] The connecting feature may include multiple hooks, multiple rings, or adhesive.

[0247] The support pad has a support pad diameter, the abrasive product has an abrasive product diameter, and the abrasive product diameter is larger than the support pad diameter.

[0248] The backing may include a membrane.

[0249] The membrane may include a polymer membrane.

[0250] Abrasive particles may include shaped abrasive particles.

[0251] Abrasive materials may include a three-dimensional structure, which is composed of a plurality of regularly arranged three-dimensional elements with predetermined shapes.

[0252] The three-dimensional structure is a first three-dimensional structure. The grinding surface includes a second three-dimensional structure. Channels separate the first and second three-dimensional structures. The resistance reduction feature includes channels.

[0253] The channel has a channel depth. The three-dimensional structure has a feature height. The distance from the channel depth to the feature height is at least 100 μm.

[0254] Abrasive products may be stearate-free.

[0255] Abrasive articles may have a diameter of at least about 0.5 inches.

[0256] Abrasive products can have a diameter of less than about 4 inches.

[0257] Abrasive products can have a diameter of less than about 3 inches.

[0258] Abrasive materials may have a FEPA rating of at least P1200.

[0259] Abrasive materials may have a FEPA rating of at least P1500.

[0260] Abrasive materials may have a FEPA rating of at least P3000.

[0261] Abrasive products may have non-circular peripheries.

[0262] Non-circular borders may include repeating patterns.

[0263] Repeating patterns may include waveforms.

[0264] Abrasive products can be non-planar.

[0265] The resistance reduction feature may include the deformable part of the abrasive article.

[0266] The deformable part may include creases.

[0267] The deformable portion may include a slit extending through the backing.

[0268] The resistance reduction feature may include one or more orifices that extend from the coupling surface through the abrasive article to the grinding surface.

[0269] The total area of ​​one or more orifices can be at least 0.18 mm².

[0270] The total area of ​​one or more orifices can be at least 0.20 mm².

[0271] The total area of ​​a combination of one or more orifices can be less than approximately 20 mm².

[0272] The total area of ​​a combination of one or more orifices can be less than approximately 10 mm².

[0273] The total area of ​​one or more orifices can be less than about 1.0 mm².

[0274] Abrasive products can have a diameter of approximately 3 cm.

[0275] Abrasive products can have a diameter of less than 4 cm.

[0276] One or more orifices may be located within the central region of the abrasive article. The central region is defined by a second radius. The second radius is smaller than the first radius of the abrasive article.

[0277] The support pad may include a resistance-reducing feature.

[0278] The support pad may include channels configured to allow airflow between the surface of the support pad and a second side of the backing.

[0279] The robotic grinding system may include a coupling feature comprising a plurality of first coupling features. A support pad includes a plurality of second coupling features configured to receive the first coupling features. Areas of the support pad do not have any second coupling features.

[0280] Abrasive articles may include orifices. The dimensions of the region are set to overlap with the orifice.

[0281] Example

[0282] Example 1

[0283] Figures 8A to 8B An example of a grinding disc with one or more holes is shown. The illustrated disc undergoes a wet grinding process to determine whether the grinding slurry will leak through the holes.

[0284] Example 1A :

[0285] Figure 8A A 1 3 / 8" sanding disc (model 464LA A5, available from 3M in St. Paul, Minnesota) is shown. ™ Company (3M) ™ (Company, St. Paul, MN) The grinding disc has a series of holes running through it. The support pad used is Finesse-It. ™ Roloc ™ Medium-density 29mm support pad (model 65741, available from 3M in St. Paul, Minnesota) ™ (Company), the support pad utilizes a hook-and-loop attachment system with a sanding disc. Figure 9A This indicates that a certain amount of sand slurry can leak through the holes and onto the support pad at several different points. When a new disc with the same hole design is removed and applied, the slurry can continue to leak to even more locations on the support pad.

[0286] Example 1B :

[0287] Figure 8BA 1 3 / 8" sanding disc (model 464LA A5, available from 3M in St. Paul, Minnesota) is shown. ™ (Company), the grinding disc has only one hole in the center. The support pad used is Finesse-Italian. ™ Roloc ™ Medium-density 29mm support pad (model 65741, available from 3M in St. Paul, Minnesota) ™ (Company), the support pad utilizes a hook-and-loop attachment system with a sanding disc. Figure 9B This indicates that a certain amount of abrasive slurry can leak through the holes and onto the support pad. However, even when the pad is replaced and a new pad with the same hole pattern is added, the leaked slurry always remains towards the center of the support pad. This prevents slurry from leaking onto the remaining attachment surface of the support pad.

[0288] Both Comparative Examples A and B successfully eliminated adhesion between the sanding disc and the substrate; however, it may be more preferable to keep any slurry leaking through the disc only in the center of the support pad, rather than in many different parts of the support pad. This helps the support pad last longer because the slurry does not wet the entire hook-attachment surface.

[0289] Example 2

[0290] Sample preparation

[0291] The fan-shaped edge plate (3M in St. Paul, Minnesota) ™ 3M Company ™ Trizact ™ Finesse-it ™ One 464LA (A7) disc is placed at a time under a DataLogic VL 2104-1330 DPSS green system and a resonator with a scanning head, a 532nm wavelength, and a nominal power of 10W laser. The laser is activated, and a single hole is cut from the nominal center point of each of these discs. The total area of ​​the hole size is 0.03mm². 2 Up to 20.27mm 2 Within the range.

[0292] Peel force test method

[0293] The industrial robot arm is equipped with an active compliant tool (model 6530, available from 3M in St. Paul, Minnesota) at the end of the arm. ™ 3M (company) and servo random track sand mill motor (model 77539, St. Paul, Minnesota) ™ (Company). Attach the sand mill motor directly to the active compliant tool. Hookit ™Roloc ™ Disc pad (model 28655, available from 3M in St. Paul, Minnesota) ™ (The company) is attached to the end of the sand mill motor.

[0294] Use tape to secure the painted panel (model 57080 black painted panel, available from ACT Test Panels LLC, Hillsdale, MI, Michigan) to the force measuring device (model 2001-02 force plate, available from Bertec, Columbus, Ohio). ™ Bertec ™ The top of the Corporation, Columbus, OH) is attached to the disc pad as described in the sample preparation section.

[0295] Approximately 0.12g of water is sprayed directly onto the painting panel below the disk. A downward force of 20N is applied to press the disk down onto the panel. The servo motor is rotated to 4900rpm, simultaneously initiating a spiral movement in the XY plane of the painting panel. The spiral begins with a radius of 3mm and moves outward at a lateral speed of 0.03m / s to a radius of 9mm, with a total spiral time of 9 seconds. The robotic arm then retracts, moving the servo motor away from the painting panel.

[0296] As the motor retracted from the painted panel, the force between the disc and the painted panel was measured and recorded using a measuring device. The disc was then discarded, and four other discs with the same center hole area were also tested. Therefore, each disc type was measured and recorded a total of five times. Five unmodified discs without a center hole (center hole area 0.00) were also tested and recorded.

[0297] Table 1 shows the average adhesion between the test disc and the painted panel.

[0298]

[0299] Throughout this specification, the terms "an embodiment," "certain embodiments," "one or more embodiments," or "implementation," whether or not preceded by the term "exemplary," mean that a particular feature, structure, material, or characteristic described in connection with that embodiment is included in at least one of the exemplary embodiments of this disclosure. Therefore, phrases such as "in one or more embodiments," "in some embodiments," "in one embodiment," or "in an embodiment" appearing throughout this specification do not necessarily refer to the same embodiment of the exemplary embodiments of this disclosure. Furthermore, specific features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.

Claims

1. An abrasive article, said abrasive article comprising: Backing; A grinding surface, the grinding surface comprising an abrasive material adhered to the backing; A coupling surface, the coupling surface including a coupling feature configured to removably couple the abrasive article to the tool; and A resistance reduction feature, wherein the abrasive article is configured to be used with a fluid during a grinding operation, and wherein the resistance reduction feature is configured to reduce the resistance between the abrasive article and a working surface including the fluid.

2. The abrasive article according to claim 1, wherein the backing comprises a membrane.

3. The abrasive article according to claim 2, wherein the film comprises a polymer film.

4. The abrasive article according to any one of claims 1 to 3, wherein the abrasive material comprises abrasive particles, and wherein the abrasive particles comprise shaped abrasive particles.

5. The abrasive article according to any one of claims 1 to 4, wherein the abrasive material comprises a three-dimensional abrasive structure, the three-dimensional abrasive structure being composed of a plurality of regularly arranged three-dimensional abrasive elements having a predetermined shape.

6. The abrasive article according to claim 5, wherein the three-dimensional structure is a first three-dimensional structure, wherein the grinding surface includes a second three-dimensional structure, and wherein a channel separates the first three-dimensional structure and the second three-dimensional structure, wherein the resistance reduction feature includes the channel.

7. The abrasive article of claim 6, wherein the channel has a channel depth, wherein the three-dimensional structure has a feature height, and wherein the distance from the channel depth to the feature height is at least 100 μm.

8. The abrasive article according to any one of claims 1 to 7, wherein the abrasive article is free of stearates.

9. The abrasive article according to any one of claims 1 to 8, wherein the abrasive article has a diameter of at least about 0.5 inches.

10. The abrasive article according to any one of claims 1 to 9, wherein the abrasive article has a diameter of less than about 4 inches.

11. The abrasive article according to any one of claims 1 to 10, wherein the abrasive article has a diameter of less than about 3 inches.

12. The abrasive article according to any one of claims 1 to 11, wherein the abrasive material has a FEPA rating of at least P1200.

13. The abrasive article according to any one of claims 1 to 12, wherein the abrasive material has a FEPA rating of at least P1500.

14. The abrasive article according to any one of claims 1 to 13, wherein the abrasive material has a FEPA rating of at least P3000.

15. The abrasive article according to any one of claims 1 to 14, wherein the abrasive article has a non-circular periphery.

16. The abrasive article of claim 15, wherein the non-circular periphery comprises a repeating pattern.

17. The abrasive article of claim 16, wherein the repeating pattern comprises a waveform.

18. The abrasive article according to any one of claims 1 to 17, wherein the abrasive article is non-planar.

19. The abrasive article according to claim 18, wherein the resistance reduction feature includes a deformable portion of the abrasive article.

20. The abrasive article according to claim 19, wherein the deformed portion includes a crease.

21. The abrasive article of claim 20, wherein the deformable portion includes a slit extending through the backing.

22. The abrasive article according to any one of claims 1 to 21, wherein the resistance reduction feature includes one or more orifices extending from the connecting surface through the abrasive article to the grinding surface.

23. The abrasive article of claim 22, wherein the total area of ​​the one or more orifices is at least 0.18 mm. 2 .

24. The abrasive article of claim 22, wherein the total area of ​​the one or more orifices is at least 0.20 mm. 2 .

25. The abrasive article of claim 22, wherein the total area of ​​the one or more orifices is less than about 20 mm². 2 .

26. The abrasive article of claim 22, wherein the total area of ​​the one or more orifices is less than about 10 mm². 2 .

27. The abrasive article of claim 22, wherein the total area of ​​the one or more orifices is less than about 1.0 mm. 2 .

28. The abrasive article according to claim 22, wherein the abrasive article has a diameter of about 3 cm.

29. The abrasive article according to claim 22, wherein the abrasive article has a diameter of less than 4 cm.

30. The abrasive article of claim 22, wherein the one or more orifices are located in a central region of the abrasive article, wherein the central region is defined by a second radius, the second radius being smaller than a first radius of the abrasive article.

31. The abrasive article of claim 30, wherein the second radius is less than about one-quarter of the first radius.

32. The abrasive article of claim 28, wherein the second radius is less than about half of the first radius.

33. The abrasive article according to any one of claims 1 to 32, wherein the connecting feature comprises a plurality of hooks or a plurality of rings.

34. The abrasive article according to any one of claims 1 to 33, wherein the connecting feature comprises an adhesive.

35. The abrasive article according to any one of claims 1 to 34, wherein the backing comprises a waterproof material.

36. A robotic grinding system, the robotic grinding system comprising: An abrasive article, the abrasive article comprising an abrasive layer attached to a first side of a backing, the backing comprising a connecting feature on a second side, the backing comprising a waterproof material; A support pad, which is removably attached to the connection feature; A moving mechanism configured to move the abrasive article relative to a working surface; A force control unit configured to apply a force to the support pad; and A resistance reduction element is configured to reduce the resistance generated during the wet grinding process by the movement of the abrasive article against the working surface.

37. The robotic grinding system according to claim 36, wherein the robotic grinding system is a vacuum-free grinding system.

38. The robotic grinding system according to claim 36 or 37, wherein the robotic grinding system has no protective cover.

39. The robotic grinding system according to any one of claims 36 to 38, wherein, During the wet grinding process, resistance is formed between the abrasive layer and the working surface, and the resistance reduction element reduces the vacuum suction to below the coupling force applied by the coupling feature.

40. The robotic grinding system of claim 39, wherein the connecting feature comprises a plurality of hooks, a plurality of rings, or an adhesive.

41. The robotic grinding system of claim 39, wherein the vacuum suction is reduced to less than about 10 N.

42. The robotic grinding system of claim 39, wherein the vacuum suction is reduced to less than about 8N.

43. The robotic grinding system according to any one of claims 36 to 42, wherein the support pad has a support pad diameter, the abrasive article has an abrasive article diameter, and wherein the abrasive article diameter is larger than the support pad diameter.

44. The robotic grinding system according to any one of claims 36 to 43, wherein the backing comprises a membrane.

45. The robotic grinding system of claim 37, wherein the membrane comprises a polymer membrane.

46. ​​The robotic grinding system according to any one of claims 36 to 45, wherein the abrasive particles comprise shaped abrasive particles.

47. The robotic grinding system according to any one of claims 36 to 46, wherein the abrasive material comprises a three-dimensional structure, the three-dimensional structure being composed of a plurality of regularly arranged three-dimensional elements having predetermined shapes.

48. The robotic grinding system of claim 47, wherein the three-dimensional structure is a first three-dimensional structure, wherein the grinding surface includes a second three-dimensional structure, and wherein a channel separates the first three-dimensional structure and the second three-dimensional structure, wherein the resistance reduction feature includes the channel.

49. The robotic grinding system of claim 48, wherein the height of the channel is at least the height of the first three-dimensional structure.

50. The robotic grinding system according to any one of claims 36 to 49, wherein the abrasive article is free of stearates.

51. The robotic grinding system according to any one of claims 36 to 50, wherein the abrasive article has a diameter of at least about 0.5 inches.

52. The robotic grinding system according to any one of claims 36 to 51, wherein the abrasive article has a diameter of less than about 4 inches.

53. The robotic grinding system according to any one of claims 36 to 52, wherein the abrasive article has a diameter of less than about 3 inches.

54. The robotic grinding system according to any one of claims 36 to 53, wherein the abrasive material has a FEPA rating of at least P1200.

55. The robotic grinding system according to any one of claims 36 to 54, wherein the abrasive material has a FEPA rating of at least P1500.

56. The robotic grinding system according to any one of claims 36 to 55, wherein the abrasive material has a FEPA rating of at least P3000.

57. The robotic grinding system according to any one of claims 36 to 56, wherein the abrasive article has a non-circular periphery.

58. The robotic grinding system of claim 57, wherein the non-circular periphery comprises a repeating pattern.

59. The robotic grinding system of claim 58, wherein the repeating pattern comprises a waveform.

60. The robotic grinding system according to any one of claims 36 to 59, wherein the abrasive article is non-planar.

61. The robotic grinding system of claim 60, wherein the resistance reduction feature comprises a deformable portion of the abrasive article.

62. The robotic grinding system of claim 61, wherein the deformable portion includes a crease.

63. The robotic grinding system of claim 62, wherein the deformable portion includes a slit extending through the backing.

64. The robotic grinding system according to any one of claims 36 to 63, wherein the resistance reduction feature includes one or more orifices extending from the coupling surface through the abrasive article to the grinding surface.

65. The robotic grinding system of claim 64, wherein the combined total area of ​​the one or more orifices is at least 0.18 mm². 2 .

66. The robotic grinding system of claim 64, wherein the combined total area of ​​the one or more orifices is at least 0.20 mm². 2 .

67. The robotic grinding system of claim 64, wherein the combined total area of ​​the one or more orifices is less than about 20 mm². 2 .

68. The robotic grinding system of claim 64, wherein the combined total area of ​​the one or more orifices is less than about 10 mm². 2 .

69. The robotic grinding system of claim 64, wherein the combined total area of ​​the one or more orifices is less than about 1.0 mm². 2 .

70. The robotic grinding system of claim 64, wherein the abrasive article has a diameter of about 3 cm.

71. The robotic grinding system of claim 64, wherein the abrasive article has a diameter of less than 4 cm.

72. The robotic grinding system of claim 64, wherein the one or more orifices are located in a central region of the abrasive article, wherein the central region is defined by a second radius, the second radius being smaller than a first radius of the abrasive article.

73. The robotic grinding system according to any one of claims 36 to 72, wherein the support pad includes the resistance reduction feature.

74. The robotic grinding system of claim 73, wherein the support pad includes a channel configured to allow airflow between the surface of the support pad and the second side of the backing.

75. The robotic grinding system of claim 73, wherein the connecting feature includes a plurality of first connecting features, and wherein the support pad includes a plurality of second connecting features configured to receive the first connecting features, and wherein a region of the support pad has no second connecting features.

76. The robotic grinding system of claim 75, wherein the abrasive article includes an orifice, and wherein the size of the region is set to overlap with the orifice.

77. The robotic grinding system of claim 73, wherein the depth of the resistance reduction feature is at least 0.01 inches.

78. The robotic grinding system of claim 73, wherein the width of the resistance reduction feature is at least 0.01 inches.

79. A method for grinding a surface, the method comprising: Apply fluid to the surface; The abrasive article is moved to the vicinity of the surface using a moving mechanism, wherein the abrasive article is removably coupled to the support pad via a coupling mechanism; The surface is ground using the abrasive article in the presence of the fluid, wherein a suction force is formed between the surface and the abrasive article during grinding; as well as Remove the abrasive article from the surface, wherein the abrasive article includes a resistance reduction feature configured to reduce the suction force between the surface and the abrasive article.

80. The method of claim 79, wherein the coupling mechanism comprises a hook and loop system, and wherein the resistance reduction feature reduces the suction force to below a threshold force applied by the hook and loop system.

81. The method according to claim 79 or 80, wherein grinding the surface comprises: A force is applied to the abrasive article.

82. The method according to any one of claims 79 to 81, wherein grinding comprises: A slurry comprising abrasive fragments mixed into the fluid is produced.

83. The method according to any one of claims 79 to 82, wherein the suction force is reduced to less than about 10 N.

84. The method according to any one of claims 79 to 83, wherein the suction force is reduced to less than about 8 N.

85. The method according to any one of claims 79 to 84, wherein the abrasive article comprises a water-resistant backing.

86. The method according to any one of claims 79 to 85, wherein the abrasive article comprises a waterproof backing.

87. The method according to any one of claims 79 to 86, wherein the abrasive article comprises an abrasive surface having a surface roughness Ra of less than about 2 μm.

88. The method according to any one of claims 79 to 87, wherein the backing comprises a membrane.

89. The method of claim 88, wherein the membrane comprises a polymer membrane.

90. The method according to any one of claims 79 to 89, wherein the abrasive particles comprise shaped abrasive particles.

91. The abrasive article according to any one of claims 79 to 90, wherein the abrasive material comprises a three-dimensional structure, the three-dimensional structure being composed of a plurality of regularly arranged three-dimensional elements having predetermined shapes.

92. The method of claim 91, wherein the three-dimensional structure is a first three-dimensional structure, wherein the grinding surface includes a second three-dimensional structure, and wherein a channel separates the first three-dimensional structure and the second three-dimensional structure, wherein the resistance reduction feature includes the channel.

93. The method of claim 92, wherein the channel has a channel depth, wherein the three-dimensional structure has a feature height, and wherein the distance from the channel depth to the feature height is at least 100 μm.

94. The method according to any one of claims 79 to 93, wherein the abrasive article is free of stearates.

95. The method according to any one of claims 79 to 94, wherein the abrasive article has a diameter of at least about 0.5 inches.

96. The method according to any one of claims 79 to 95, wherein the abrasive article has a diameter of less than about 4 inches.

97. The method according to any one of claims 79 to 96, wherein the abrasive article has a diameter of less than about 3 inches.

98. The method according to any one of claims 79 to 97, wherein the abrasive material has a FEPA rating of at least P1200.

99. The method according to any one of claims 79 to 98, wherein the abrasive material has a FEPA rating of at least P1500.

100. The abrasive article according to any one of claims 79 to 99, wherein the abrasive material has a FEPA rating of at least P3000.

101. The method according to any one of claims 79 to 100, wherein the abrasive article has a non-circular periphery.

102. The method of claim 101, wherein the non-circular periphery comprises a repeating pattern.

103. The method of claim 102, wherein the repeating pattern comprises a waveform.

104. The method according to any one of claims 79 to 103, wherein the abrasive article is non-planar.

105. The method of claim 104, wherein the resistance reduction feature comprises a deformable portion of the abrasive article.

106. The method of claim 105, wherein the deformed portion includes a crease.

107. The method of claim 105, wherein the deformable portion includes a slit extending through the backing.

108. The method according to any one of claims 79 to 107, wherein the resistance reduction feature includes one or more orifices extending from the coupling surface through the abrasive article to the grinding surface.

109. The method of claim 108, wherein the combined total area of ​​the one or more orifices is at least 0.18 mm. 2 .

110. The method of claim 109, wherein the combined total area of ​​the one or more orifices is at least 0.20 mm. 2 .

111. The method of claim 109, wherein the combined total area of ​​the one or more orifices is less than about 20 mm². 2 .

112. The method of claim 109, wherein the combined total area of ​​the one or more orifices is less than about 10 mm². 2 .

113. The method of claim 109, wherein the combined total area of ​​the one or more orifices is less than about 1.0 mm². 2 .

114. The method of claim 109, wherein the abrasive article has a diameter of about 3 cm.

115. The method of claim 109, wherein the abrasive article has a diameter of less than 4 cm.

116. The method of claim 109, wherein the one or more orifices are located in a central region of the abrasive article, wherein the central region is defined by a second radius, the second radius being smaller than a first radius of the abrasive article.

117. The method of claim 116, wherein all of the one or more orifices are located in the central region.

118. The method of claim 116, wherein the second radius is less than about one-third of the first radius.

119. The method of claim 116, wherein the second radius is less than about half of the first radius.

120. The method of any one of claims 79 to 119, wherein the support pad includes a channel configured to allow airflow between the surface of the support pad and a second side of the backing.

121. The robotic grinding system of claim 120, wherein the connecting feature includes a plurality of first connecting features, and wherein the support pad includes a plurality of second connecting features configured to receive the first connecting features, and wherein a region of the support pad has no second connecting features.

122. The robotic grinding system of claim 121, wherein the abrasive article includes an orifice, and wherein the size of the region is set to overlap with the orifice.

123. A method for grinding a surface, the method comprising: A robotic grinding system is used to move an abrasive article to the vicinity of a defect location on a surface, wherein the abrasive article includes a grinding surface opposite to a coupling surface, the abrasive article is coupled to a support pad using a coupling mechanism on the coupling surface, the coupling mechanism applying a coupling force on the abrasive article along the coupling surface; Apply fluid to the surface near the location of the defect; Grinding the surface, wherein grinding includes: applying force to the support pad using the force control unit of the robotic grinding system, and moving the abrasive article on the surface at a rotational speed; as well as Remove the abrasive article from the surface, wherein the abrasive article includes a resistance reduction feature that reduces the suction force between the abrasive article and the surface to below the connection force.

124. The method of claim 123, wherein the suction force is reduced to less than about 10 N.

125. The method of claim 123 or 124, wherein the suction force is reduced to less than about 8 N.

126. The method according to any one of claims 123 to 125, wherein the robotic grinding system is a vacuum-free grinding system.

127. The method according to any one of claims 123 to 126, wherein the robotic grinding system has no protective cover.

128. The method according to any one of claims 123 to 127, wherein the connecting feature comprises a plurality of hooks, a plurality of rings, or an adhesive.

129. The method according to any one of claims 123 to 128, wherein the support pad has a support pad diameter, the abrasive article has an abrasive article diameter, and wherein the abrasive article diameter is larger than the support pad diameter.

130. The method according to any one of claims 123 to 129, wherein the backing comprises a membrane.

131. The method of claim 130, wherein the membrane comprises a polymer membrane.

132. The method according to any one of claims 123 to 131, wherein the abrasive particles comprise shaped abrasive particles.

133. The method according to any one of claims 123 to 132, wherein the abrasive material comprises a three-dimensional structure, the three-dimensional structure being composed of a plurality of regularly arranged three-dimensional elements having predetermined shapes.

134. The method of claim 133, wherein the three-dimensional structure is a first three-dimensional structure, wherein the grinding surface includes a second three-dimensional structure, and wherein a channel separates the first three-dimensional structure and the second three-dimensional structure, wherein the resistance reduction feature includes the channel.

135. The method of claim 134, wherein the channel has a channel depth, wherein the three-dimensional structure has a feature height, and wherein the distance from the channel depth to the feature height is at least 100 μm.

136. The method according to any one of claims 123 to 135, wherein the abrasive article is free of stearates.

137. The method according to any one of claims 123 to 136, wherein the abrasive article has a diameter of at least about 0.5 inches.

138. The method according to any one of claims 123 to 137, wherein the abrasive article has a diameter of less than about 4 inches.

139. The method according to any one of claims 123 to 138, wherein the abrasive article has a diameter of less than about 3 inches.

140. The method according to any one of claims 123 to 139, wherein the abrasive material has a FEPA rating of at least P1200.

141. The method according to any one of claims 123 to 140, wherein the abrasive material has a FEPA rating of at least P1500.

142. The method according to any one of claims 123 to 141, wherein the abrasive material has a FEPA rating of at least P3000.

143. The method according to any one of claims 123 to 142, wherein the abrasive article has a non-circular periphery.

144. The method of claim 143, wherein the non-circular periphery comprises a repeating pattern.

145. The method of claim 144, wherein the repeating pattern comprises a waveform.

146. The method according to any one of claims 123 to 145, wherein the abrasive article is non-planar.

147. The method of claim 146, wherein the resistance reduction feature comprises a deformable portion of the abrasive article.

148. The method of claim 147, wherein the deformed portion includes a crease.

149. The method of claim 147, wherein the deformable portion includes a slit extending through the backing.

150. The method according to any one of claims 123 to 149, wherein the resistance reduction feature includes one or more orifices extending from the coupling surface through the abrasive article to the grinding surface.

151. The method of claim 150, wherein the combined total area of ​​the one or more orifices is at least 0.18 mm. 2 .

152. The method of claim 150, wherein the combined total area of ​​the one or more orifices is at least 0.20 mm. 2 .

153. The method of claim 150, wherein the combined total area of ​​the one or more orifices is less than about 20 mm². 2 .

154. The method of claim 150, wherein the combined total area of ​​the one or more orifices is less than about 10 mm². 2 .

155. The method of claim 150, wherein the combined total area of ​​the one or more orifices is less than about 1.0 mm. 2 .

156. The method of claim 150, wherein the abrasive article has a diameter of about 3 cm.

157. The method of claim 150, wherein the abrasive article has a diameter of less than 4 cm.

158. The method of claim 150, wherein the one or more orifices are located in a central region of the abrasive article, wherein the central region is defined by a second radius, the second radius being smaller than a first radius of the abrasive article.

159. The method according to any one of claims 123 to 158, wherein the support pad includes the resistance-reducing feature.

160. The method of claim 159, wherein the support pad includes a channel configured to allow airflow between the surface of the support pad and a second side of the backing.

161. The method according to any one of claims 123 to 160, wherein the connecting feature includes a plurality of first connecting features, and wherein the support pad includes a plurality of second connecting features configured to receive the first connecting features, and wherein a region of the support pad has no second connecting features.

162. The method according to any one of claims 123 to 161, wherein the abrasive article includes an orifice, and wherein the size of the region is set to overlap with the orifice.

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