Polishing system and method of use

Abstract

A polishing system is presented. The system includes a first vibrating structure having a first plurality of protrusions. The system also includes a second vibrating structure having a second plurality of protrusions. The system also includes an abrasive article in contact with the first film. The system also includes a stroke plate coupled to the second film. When the stroke plate is actuated, the first plurality of protrusions and the second plurality of protrusions are interconnected in a first direction and configured to slide relative to each other.

Description

[Background technology]

[0001] For many years, a class of abrasive articles generally known as "structured abrasive articles" has been commercially available for use in surface finishing. Structured abrasive articles have a structured abrasive layer fixed to a backing material, and are typically used with a liquid such as water, optionally containing a surfactant. The structured abrasive layer has a plurality of shaped abrasive composites (typically having a microscopic size), each of which has abrasive particles dispersed in a binder. In many cases, the shaped abrasive composites are precisely shaped, for example, according to various geometric shapes (e.g., pyramidal). Examples of such structured abrasive articles include those sold under the trade name "TRIZACT" by 3M Company (St. Paul, Minnesota).

[0002] Structured abrasive articles are often used in combination with a back-up pad attached to a tool (e.g., a disc sander or random orbital sander). In such applications, the structured abrasive articles typically have an attachment interface layer (e.g., a hook film, a loop fabric, or an adhesive) that secures them to the back-up pad during use. Summary of the Invention

[0003] A polishing system is presented. The system includes a first vibrating structure having a first plurality of protrusions. The system also includes a second vibrating structure having a second plurality of protrusions. The system also includes an abrasive article in contact with the first film. The system also includes a stroke plate coupled to the second film. When the stroke plate is actuated, the first plurality of protrusions and the second plurality of protrusions are interconnected in a first direction and configured to slide relative to each other.

[0004] The systems provided herein provide vibration to the abrasive article during the abrading operation, which improves abrading efficiency and allows for greater surface area to be used during the sanding operation than was available with previous systems. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 is a schematic diagram showing the configuration of a superfinishing device. [Figure 2A] FIG. 1 is a schematic diagram of a linear vibratory finishing apparatus according to embodiments herein. [Figure 2B] FIG. 1 is a schematic diagram of a linear vibratory finishing apparatus according to embodiments herein. [Figure 2C] FIG. 1 is a schematic diagram of a linear vibratory finishing apparatus according to embodiments herein. [Figure 3A] 1 is a schematic diagram of a microreplicated film structure according to an embodiment herein. [Figure 3B] 1 is a schematic diagram of a microreplicated film structure according to an embodiment herein. [Figure 3C] 1 is a schematic diagram of a microreplicated film structure according to an embodiment herein. [Figure 3D] 1 is a schematic diagram of a microreplicated film structure according to an embodiment herein. [Figure 4] 1 illustrates a method of polishing a workpiece according to an embodiment herein. [Figure 5A] 1 shows an image of a linear vibratory finishing system according to embodiments herein. [Figure 5B] 1 shows an image of a linear vibratory finishing system according to embodiments herein. [Figure 5C] 1 shows an image of a linear vibratory finishing system according to embodiments herein. [Figure 6A] 1 illustrates a vibratory finishing system according to an embodiment herein. [Figure 6B] 1 illustrates a vibratory finishing system according to an embodiment herein. [Figure 7A] 1 shows the results of experiments described in the Examples herein. [Figure 7B] 1 shows the results of experiments described in the Examples herein. [Figure 7C]1 shows the results of experiments described in the Examples herein. DETAILED DESCRIPTION OF THE INVENTION

[0006] Figure 1 is a schematic diagram showing the configuration of a superfinishing device. An abrasive product 11 is fed from a feed roll 12 and taken up by a rolling roll 14 via a contact roll 13. The contact roll is pressed against the outer circumferential surface of a cylindrical workpiece 16 by an air cylinder 15. While the cylindrical workpiece 16 is rotated in the direction of the arrow, the abrasive product is fed in the opposite direction to the movement of the object surface, thereby performing polishing.

[0007] Currently, robot sanders utilize abrasive discs for sanding operations. However, it is difficult to determine when the abrasive disc needs to be replaced, and the actual replacement method is complicated. Customers desire a sanding system that provides consistent cutting performance over the life of the abrasive article and a long abrasive article life to reduce the frequency and associated difficulties of replacing the abrasive article for robotic repair.

[0008] Contact wheel-based sanding systems are an alternative to sanding disk systems because they can be used in roll-to-roll systems and allow for long abrasive life. Contact wheel-based systems have a small contact area, which can result in an applied unit pressure that is too high for a given operation. As more and more sanding and finishing operations are transitioning to robotic solutions, systems must be able to conform to surfaces with curvature. Additionally, to enable vibration-assisted grinding, systems must have a holding method that allows slip in the feed direction but not slip in the cross-feed direction. While feed sanding units using contact wheels in the sanding section, such as the example in Figure 1, exist, feed sanding units with large, flat sanding sections using soft materials do not exist.

[0009] Conventional contact wheels are not soft or flexible, a necessary feature for finishing curved or curved surfaces. Soft contact wheels are not ideal because deformation of the wheel causes the soft sheet to wrinkle, preventing satisfactory polishing performance. In contrast, contact wheels cannot deform, making it difficult to finish curved surfaces such as automobile hoods.

[0010] A system utilizing a soft, flexible, deformable abrasive article to accommodate surface curvature is desirable. Additionally, flat pads provide a larger, more expansive surface area. Deformation has less effect on the area of ​​the flat pad that contacts the surface due to the softness of the article.

[0011] As used herein, the term "softness" with respect to polishing pads is defined by JIS K 7312. C hardness refers to the hardness measured immediately after the pressure surface is pressed against the pad, as determined by the test method specified in Appendix 2 of JIS K 7312:1996, "Spring Hardness Test Type C Test Method." A spring hardness tester is used, which measures the distance a spring pressure pushes back a pin projecting from a hole in the center of the pressure surface of a test piece when the test piece is pressed against the surface of the test piece. The test piece's measurement surface is at least as large as or larger than the pressure surface of the tester. In some embodiments, the C hardness of the pads described herein is as low as about 5, as low as about 10, as low as about 15, as low as about 20, as low as about 25, or as low as about 30.

[0012] The pads described herein can be used in either continuous feed or intermittent feed methods. Continuous feed setups create dynamic friction. Therefore, the system may have lower abrasive performance and / or require equipment with higher feed power.

[0013] In an indexing setup, there is dynamic friction, but static friction also occurs in the transverse direction. The friction is more stable in the transverse direction, but the feed direction remains smooth.

[0014] The systems and methods herein can use a roll-to-roll feed system in either a continuous feed or intermediate feed operation, which offers an improvement over the disk-changing systems previously used in many finishing operations. This reduces the downtime required to change disks and increases efficiency. Furthermore, disk-changing systems typically experience a decrease in cutting performance over time. The ability to use a roll of abrasive material can result in a more consistent cut rate and a longer service life based on the length of the roll. Additionally, with respect to existing roll-to-roll systems, the systems and methods described herein can make a larger surface available for the abrasive operation thanks to a softer material that allows curved surfaces to be abraded.

[0015] 2A-2C are schematic diagrams of a linear vibratory finishing apparatus according to embodiments herein. FIG. 2A is a perspective view of a linear vibratory finishing apparatus 100 including a stroke plate 110 that activates a vibratory polishing system 150 that polishes the surface of a workpiece 130. As shown in a side view 102 of FIG. 2B, in some embodiments, a cushion 120 or pad may be present between the stroke plate 110 and the vibratory polishing system 150. The cushion 120 may function to increase and even out the pressure applied across the rectangular surface area of ​​the workpiece 130. The surface area may be substantially the width of an abrasive article such as abrasive belt 156, and in some embodiments, may have a length comparable to that of the stroke plate 110. The cushion 120 is a soft material that allows the applied pressure to be spread across a curved surface.

[0016] FIG. 2C is an enlarged cross-sectional view 104 more clearly illustrating the components of the vibration system 150 in one embodiment of the present disclosure. In one embodiment, the first structure 152 is coupled to the stroke plate, either directly or via the cushion 120. The first structure 152 is shaped to interconnect with corresponding features of the second structure 154 that contact the abrasive article 156. For example, the abrasive article 156 may be a seamless abrasive belt fed under tension by the system 100, or a long abrasive article fed from a roll-to-roll source. The abrasive article 156 may be a coated abrasive article, a nonwoven abrasive article, or a bonded abrasive article. The abrasive article 156 may include ground abrasive particles, formed abrasive particles, shaped abrasive particles, and / or agglomerates, composites, or mixtures thereof. The abrasive article 156 contacts and abrades the surface of the workpiece 130, as shown in FIG. 2C.

[0017] In some embodiments, first structure 152 and second structure 154 each include a repeating pattern of interconnecting substructures, as shown in Figure 2C. The repeating pattern of substructures can include evenly spaced protrusions, alternating peaks and valleys, or more complex structures such as varying heights of teeth on a key.

[0018] In some embodiments, the first structures 152 and the second structures 154 are uniformly striped fine structures. Such a configuration may provide better mechanical transmission of vibrations during feeding because the first structures 152 and the second structures 154 mesh and interconnect like teeth on a gear. A non-uniformly striped fine structure may result in dynamic friction that does not transmit vibrations well.

[0019] In some embodiments, the first structure 152 and the second structure 154 are formed from a high-definition film. In some embodiments, the high-definition film is preferably made from a resin that is flexible and lubricious, as long as strength can be ensured. For example, a polyolefin film can be used.

[0020] The use of high definition film structures 152, 154 facilitates sanding of larger surface areas not previously possible using a system such as that shown in FIG. 1, which provides abrasion only along the points of contact between roll 13 and surface 16.

[0021] Returning to FIG. 1 , for example, if the diameter of the contact wheel is approximately 50 mm, a contact angle of approximately 60 degrees is required to ensure friction. For contact to conform to a curved surface with a diameter and contact angle, the abrasive article 11 must be elastic. However, handling a stretched web is difficult. In contrast, using a pad with film structures 152, 154 over a large surface area results in only slight expansion and contraction when conforming to a curved surface. The system shown in FIGS. 2A-2C can polish flat surfaces but offers improved ability to conform to curved surfaces over prior art systems. The cushion 120 compensates and improves the ability to manage curved surfaces. FIGS. 3A-3C are schematic diagrams of high-definition film structures according to embodiments herein. As described with respect to FIG. 2 , in some embodiments, the vibration system includes a first structure 210 and a second structure 220 that allow movement or sliding along a first direction 234 but without substantial sliding in a second direction 232. Sliding can be facilitated by an interlocking 230 between the first structure 210 and the second structure 220. In some embodiments, the engagement 230 may include a gap to allow freedom of movement.

[0022] Structure 210, in some embodiments, includes a plurality of protrusions 212 extending from a backing 214. In some embodiments, protrusions 212 are substantially identical in height and width, as well as the spacing between adjacent protrusions. In some embodiments, protrusions 212 are the same material as backing 214. Protrusions 212 may be co-extruded with backing 214 or may conform to backing 214.

[0023] Structure 220, in some embodiments, includes a plurality of protrusions 222 extending from a backing 224. In some embodiments, protrusions 222 are substantially identical in height and width, as well as the spacing between adjacent protrusions. In some embodiments, protrusions 222 are the same material as backing 224. Protrusions 222 may be co-extruded with backing 224 or may conform to backing 224.

[0024] In some embodiments, interdigitation 230 does not include a gap, and structures 210 are substantially identical in that the dimensions of protrusions 212 are identical to the dimensions of protrusions 222. As shown in Figure 3A, each of structures 210, 220 is defined by a width 238 and a length 236. Slippage between structures 210, 220 occurs substantially only in a direction 234 along the width.

[0025] Although Figures 3A and 3B show substantially rectangular protrusions 212, 222 with rounded edges, it is expressly contemplated that other fine structures are possible, as shown by comparing Figures 3C and 3D.

[0026] FIG. 3C shows a diagram 250 of a pair of protrusions 260 extending from a support structure. Each of the protrusions 260 is identical and has a height 256 and width 252 extending from a base, with the width being substantially perpendicular to the height 256 in the embodiment shown in FIG. 3C. The protrusions 260 are substantially rectangular in shape and have rounded edges. However, other shapes, including greater degrees of rounding or sharp corners, are expressly contemplated. As shown in FIG. 3C, the height 256 of the protrusions 260 is the height of the protrusions only and does not include the thickness 258 of the base of the structure 250.

[0027] In some embodiments, thickness 258 is sufficient to allow stability for structure 250, but thin enough to allow some flexibility for structure 250 as protrusions 260 vibrate.

[0028] Protrusions 260 are spaced apart from one another by spaces 254. As shown in FIG. 2C , in some embodiments, spaces 254 are greater than widths 252, allowing room for protrusions 260 to vibrate when in the interconnected position. In some embodiments, widths 252 are less than or equal to spacings 254. Furthermore, in some embodiments, the combination of spacings 254 and widths 252 is less than two times height 256, as shown in Equation 1 below: (Width 252 + Spacing 254) < (2 x Height 256) Equation 1

[0029] In addition to providing slippage prevention, referring to FIG. 3D, when the pitch is large relative to the height, the force per pitch increases. Because the force is gentle, skidding is more likely to occur. The value that ensures an angle of approximately 45 degrees is limited to approximately 2:1. FIG. 3D shows another configuration of protrusions 280 extending from a structure 270 having a base thickness 278. Protrusions 280 have a height 276 and a combined repeat width of first width 272 and second width 274. In some embodiments, triangular protrusions 280 are isosceles triangles, such that widths 272 and 274 are the same. In other embodiments, protrusions 280 are scalene triangles, such that widths 272 and 274 are different from each other and from the overall width of protrusion 280. Additionally, widths 272 and 274 are presented such that there is no gap (comparable to gap 254) between adjacent protrusions, although such embodiments are expressly contemplated.

[0030] 3D shows an embodiment in which the protrusions 280 have sharp corners both at their tips and where adjacent protrusions meet. However, in other embodiments, the protrusions may be rounded. In extreme embodiments, the protrusions 280 are rounded to the point that they resemble a sine or cosine wave.

[0031] Furthermore, in some embodiments, the combination of width 254 and width 252 is less than two times height 256, as shown in Equation 2 below. (Width 272 + Width 274) < (2 × Height 276) Equation 2

[0032] FIG. 4 illustrates a method of polishing a workpiece according to an embodiment herein.

[0033] At block 310, the abrasive article is coupled to a vibration system. The vibration system, in some embodiments, includes a vibration source, an abrasive feed source, and a vibration assembly. The vibration assembly may include opposing structures that may be positioned relative to each other at interconnection locations 316, as described above with respect to Figures 2A-2C, and the abrasive article may interact with only one of the structures on the opposite side of the plurality of protrusions.

[0034] The abrasive article may be movably coupled to the oscillatory system, as shown in block 312. For example, the abrasive article may be a seamless belt that is fed through the oscillatory system so that the surface area of ​​the abrasive article that contacts the workpiece changes constantly or frequently during the abrading operation. This may include the abrasive article being in a non-fixed position relative to the oscillatory system, as shown in block 314. However, other configurations 318 are possible. For example, the abrasive article may be a coated abrasive article that is secured to the oscillatory system using, for example, a hook and loop bond or an adhesive-based bond.

[0035] In block 320, the workpiece is polished. The workpiece is polished 332 using the surface area of ​​the abrasive article that contacts the workpiece. In contrast to the conventional system shown in Figure 1, a square or rectangular surface area of ​​the abrasive article is available during the polishing operation, resulting in a larger area being polished at any given time and a faster polishing operation. For example, the length and width of the polishing region may be similar, in contrast to previous systems such as the system of Figure 1, where the length and width of the polishing operation may differ by five or ten times or more.

[0036] Either the abrasive article or the workpiece can be fed by the vibratory system as a linear feed 334. For example, the abrasive article can be a seamless belt fed by the system, as shown in the examples of Figures 5 and 6 presented below. Alternatively, the abrasive article can be a coated abrasive article and the workpiece can be fed by the vibratory system. However, in other embodiments 336, the vibratory system is moved relative to the workpiece, as described with respect to the robotic repair unit embodiment of Figure 6 described below.

[0037] The vibration system, in some embodiments, vibrates during the polishing operation. The vibration can be caused by stroke plate movement 332, coupler movement 324, or via another movement mechanism 326.

[0038] 5A-5C show images of a linear vibratory finishing system according to embodiments herein. FIG. 5A is a diagram of the system 500 showing stroke directionality 510 and feed direction 520. In some embodiments, the stroke plate can facilitate vibration at a rate on the order of at least 30 strokes / minute, or at least 100 strokes / minute, or at least 500 strokes / minute, or at least 1000 strokes / minute, or at least 5000 strokes / minute, or at least 8000 strokes / minute, or at least 10,000 strokes / minute, or at least 12,000 strokes / minute, or at least 15,000 strokes / minute. Longer strokes result in fewer strokes, and shorter strokes result in more strokes.

[0039] The system 500 is designed to accept an abrasive belt moving in a feed direction 520 at a feed rate of at least 1 mm / min, at least 10 mm / min, at least 20 mm / min, at least 50 mm / min, at least 100 mm / min, at least 150 mm / min, or 200 mm / min, where a higher number of strokes results in a faster feed rate and a lower number of strokes results in a slower feed rate.

[0040] Figure 5B is a diagram of system 500 with abrasive article 530 in place. As shown in Figure 5B, in one embodiment, the abrasive article is fed linearly through system 500. In some embodiments, the entire width 532, or substantially the entire width, is available for use within system 500, allowing a larger surface area 534 to be used at one time during a polishing operation. Figure 5C is an enlarged view of the feed region of system 500, including workpiece 540.

[0041] 6A and 6B illustrate a vibratory finishing system according to embodiments herein. Figure 6A illustrates a robot repair-mounted finishing system 600 that includes a vibratory finishing system 620 mounted on a robot repair unit 610. The robot repair unit 610 can automatically move the finishing system 620 into position above a workpiece requiring a finishing operation.

[0042] The vibratory finishing system 620 includes a vibration system 622, which can include a compressible cushion that allows the system 620 to provide a finish to curved surfaces such as automobile hoods and doors. The system 622 also includes an interconnecting structure, as described with reference to FIGS. 2-3, disposed between the abrasive article 630 and the stroke plate 626, which allows slippage to occur in a direction perpendicular to the movement of the abrasive article 630, e.g., in and out of the plane of FIG. 6A. In the embodiment of FIG. 6A, the abrasive article 630 is a belt that moves from one side of the roll 624 to the other during the sanding operation. The abrasive article 630 is stabilized by guides 628, which ensure that the abrasive article 630 is held securely against the vibration system 622. This can be useful to ensure that the interconnecting structure can move in and out of the plane of FIG. 6A but does not move so freely that it becomes misaligned. The abrasive article 630 is maintained under tension during operation.

[0043] As described with reference to Figures 2-3, the vibration system 622 includes upper and lower structures with interlocking features that behave like gear teeth, allowing movement in a single direction, for example, in and out of the plane of Figure 6A, rather than in the direction of movement of the abrasive article 630.

[0044] An alternative system 650 is shown in Figure 6B. System 650 may also be mountable to a robotic repair unit or may operate independently. As shown in Figure 6B, abrasive article 660 is fed from a first roll 652 to a second roll 654 under tension provided by a guide 656.

[0045] The vibration system 680 is provided as described above to include first and second interconnection structures that allow sliding in a direction 682, for example, into and out of the plane of Figure 6B. The vibration system 680 may also include a cushion that ensures that a surface area 684 of the workpiece surface 670 contacts the abrasive article 660 throughout the polishing operation.

[0046] The abrasive articles described herein can be formed from any suitable material and can contain any suitable abrasive particles. Suitable backings include, for example, polymer films (including primed polymer films), cloth, paper, perforated and non-perforated polymer foams, vulcanized fibers, fiber-reinforced thermoplastic backings, melt-spun or melt-blown nonwoven fabrics, treated versions thereof (e.g., with waterproofing treatments), and combinations thereof. Suitable thermoplastic polymers used in the polymer film include, for example, polyolefins (e.g., polyethylene and polypropylene), polyesters (e.g., polyethylene terephthalate), polyamides (e.g., nylon-6 and nylon-6,6), polyimides, polycarbonates, blends thereof, and combinations thereof.

[0047] Typically, at least one major surface of the backing is smooth (eg, serves as the first major surface).

[0048] The backing may contain various additive(s). Examples of suitable additives include colorants, processing aids, reinforcing fibers, heat stabilizers, UV stabilizers, and antioxidants. Examples of useful fillers include clay, calcium carbonate, glass beads, talc, clay, mica, wood flour, and carbon black. In some embodiments, the backing may be a composite film, such as a coextruded film having two or more distinct layers.

[0049] The abrasive particles may comprise particles of any suitable shape and composition, including crushed abrasive particles, formed abrasive particles, precision-molded abrasive particles, and / or agglomerates, mixtures, or composites thereof.

[0050] Examples of suitable abrasive particles for the first and / or second sets of abrasive particles include fused aluminum oxide, heat-treated aluminum oxide, white fused aluminum oxide, ceramic aluminum oxide materials such as those commercially available from 3M Company, St. Paul, Minnesota under the trademark 3M CERAMIC ABRASIVE GRAIN, brown aluminum oxide, blue aluminum oxide, silicon carbide (including green silicon carbide), titanium diboride, boron carbide, tungsten carbide, garnet, titanium carbide, diamond, cubic boron nitride, garnet, fused alumina-zirconia, iron oxide, chromia, zirconia, titania, tin oxide, quartz, feldspar, flint, emery, sol-gel derived abrasive particles, and combinations thereof. Of these, shaped sol-gel derived alpha alumina abrasive particles are preferred in many embodiments. Abrasive materials that cannot be processed by the sol-gel route can be shaped using temporary or permanent binders to form shaped precursor particles that are then sintered to form shaped abrasive particles, for example, as described in U.S. Patent Application Publication No. 2016 / 0068729 A1 (Erickson et al.).

[0051] Examples of sol-gel-derived abrasive particles 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 contemplated that the abrasive particles may include abrasive agglomerates, such as those described in U.S. Patent Nos. 4,652,275 (Bloecher et al.) or 4,799,939 (Bloecher et al.). In some embodiments, the primary and / or abrasive particles may be surface treated with a coupling agent (e.g., an organosilane coupling agent) or other physical treatment (e.g., iron oxide or titanium oxide) to enhance adhesion of the abrasive particles to the binder (e.g., make layer and / or size layer). The abrasive particles can be treated prior to combining them with the corresponding binder precursor, or the abrasive particles can be surface treated in situ by including a coupling agent in the binder.

[0052] Preferably, the first and / or second abrasive particles comprise ceramic abrasive particles, such as sol-gel derived polycrystalline alpha alumina particles. Abrasive particles composed of alpha alumina, magnesium alumina spinel, and rare earth hexagonal aluminate crystallites can be prepared using sol-gel precursor alpha alumina particles, for example, by methods described in U.S. Pat. No. 5,213,591 (Celikkaya et al.) and U.S. Patent Application Publication Nos. 2009 / 0165394(A1) (Culler et al.) and 2009 / 0169816(A1) (Erickson et al.).

[0053] Alpha-alumina-based triangular abrasive particles can be manufactured according to a well-known multi-step process. Briefly, the method includes the steps of preparing a sol-gel alpha-alumina precursor dispersion, either seeded or unseeded, that can be converted to alpha-alumina, filling the sol-gel into one or more mold cavities having the desired outer shape of the abrasive particles, drying the sol-gel to form precursor triangular abrasive particles, removing the precursor abrasive particles from the mold cavities, calcining the precursor abrasive particles to form calcined precursor abrasive particles, and then sintering the calcined precursor abrasive particles to form the first and / or second sets of abrasive particles. The process is described in more detail below.

[0054] Further details regarding methods for making sol-gel derived abrasive particles can be found, for example, in U.S. Pat. Nos. 4,314,827 (Leitheiser), 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.), and U.S. Patent Application Publication No. 2009 / 0165394(A1) (Culler et al.).

[0055] In some preferred embodiments, the abrasive particles will have a shape in which the individual abrasive particles, prior to optional calcination and sintering, are essentially the shape of the portion of the cavity of the forming or production tool in which the particle precursor was dried.

[0056] Abrasive particles used in the present disclosure can typically be manufactured using tools (i.e., dies) cut using precision machining processes that provide higher feature definition than other manufacturing alternatives, such as stamping or punching. Examples of sol-gel derived alpha alumina (i.e., ceramic) abrasive particles can be found in U.S. Patent Nos. 5,201,916 (Berg), 5,366,523 (Rowenhorst (Re 35,570)), and 5,984,988 (Berg). Details regarding such abrasive particles and methods for preparing them can be found, for example, in U.S. Pat. Nos. 8,142,531 (Adefris et al.), 8,142,891 (Culler et al.), and 8,142,532 (Erickson et al.), and U.S. Patent Application Publication Nos. 2012 / 0227333 (Adefris et al.), 2013 / 0040537 (Schwabel et al.), and 2013 / 0125477 (Adefris).

[0057] Examples of slurry-derived alpha alumina abrasive particles can be found in WO 2014 / 070468, published May 8, 2014. Slurry-derived particles may be formed from a powder precursor, such as an alumina oxide powder. Slurry processes can be advantageous for larger particles that may be difficult to make using sol-gel techniques.

[0058] The abrasive particles may be subjected to a sintering process, such as the process described in U.S. Patent No. 10,400,146, issued September 3, 2019. However, other processing techniques are expressly contemplated.

[0059] Ultrafine PSG may also be used in the abrasive articles described herein. Ultrafine PSG can be formed using techniques described in U.S. Patent Application Publication No. 2019 / 0233693, published August 1, 2019, or International Publication No. 2018023177, published December 20, 2018, or International Publication No. 2018 / 207145, published November 15, 2018.

[0060] Softer PSG particles having a Mohs hardness of 2.0 to 5.0 that can be used in the abrasive particles herein, particularly when non-scratch applications are anticipated, can be made according to the methods described in WO 2019 / 215539, published November 14, 2019.

[0061] The shaped abrasive particle can have at least one sidewall, which may be a sloping sidewall. In some embodiments, there can be two or more (e.g., two or three) sloping sidewalls, and the slope or angle of each sloping sidewall can be the same or different. In other embodiments, the sidewalls can be minimized in particles where the first and second faces, instead of having sidewalls, taper to a thin edge or point where they meet. The sloping sidewalls can also be defined by a radius R (as shown in Figure 5B of U.S. Patent Application Publication No. 2010 / 0151196). The radius R can vary for each of the sidewalls.

[0062] Specific examples of shaped particles having ridges include roof-shaped particles, such as those shown in Figures 4A-4C of WO 2011 / 068714. Preferred roof-shaped particles include particles having the shape of a hip roof or hipped roof (a type of roof in which any sidewall facets slope downward from the ridge to a first side). Hip roofs typically do not include vertical sidewall(s) or facet(s).

[0063] Methods for making shaped abrasive particles having at least one sloping sidewall are described, for example, in US Patent Application Publication No. 2009 / 0165394.

[0064] The shaped abrasive particles can also include ridges on their surfaces. The ridges can be formed by ridges (or grooves) in the bottom surface of the mold cavity, which has been found to make it easier to remove the precursor shaped abrasive particles from the mold.

[0065] Methods for making shaped abrasive particles having grooves on at least one side are described, for example, in US Patent Application Publication No. 2010 / 0146867.

[0066] The shaped abrasive particles may also have one or more notches on one of the faces of the abrasive particle, as described in PCT Application No. IB2019 / 060861, filed December 16, 2019.

[0067] The shaped abrasive particles can have apertures, preferably apertures that extend through or pass through the first and second sides. Methods for making apertured shaped abrasive particles are described, for example, in U.S. Patent Application Publication Nos. 2010 / 0151201 and 2009 / 0165394.

[0068] The shaped abrasive particles can also have at least one concave (or recessed) surface or facet and at least one convex (or recessed) surface or facet. Methods for making dished abrasive particles are described, for example, in U.S. Patent Application Publication Nos. 2010 / 0151195 and 2009 / 0165394. Additionally, the shaped abrasive particles can also have multi-faceted surfaces, as described in U.S. Patent Application Publication No. 10,150,900, issued December 11, 2018.

[0069] The shaped abrasive particles can also have at least one fracture surface. Methods of making shaped abrasive particles having at least one fracture surface are described, for example, in U.S. Patent Application Publication Nos. 2009 / 0169816 and 2009 / 0165394.

[0070] The shaped abrasive particles can also have cavities. The shaped abrasive particles may also include apertures as described in U.S. Patent No. 8,142,532, issued March 27, 2012, which is incorporated herein by reference.

[0071] The shaped abrasive particles can also have a low roundness factor. Methods of making shaped abrasive particles with a low roundness factor are described, for example, in U.S. Patent Application Publication No. 2010 / 0319269.

[0072] The shaped abrasive particles may have a second apex on the second side, as described in U.S. Patent No. 9,447,311, issued September 16, 2016. Methods of making abrasive particles whose second side is an apex (e.g., a double-tapered abrasive particle) or a ridge (e.g., a roof-shaped particle) are described, for example, in U.S. Patent Application Publication No. 2012 / 022733, published September 13, 2012.

[0073] The shaped abrasive particles may be formed with sharp points as described in U.S. Patent Application Publication No. 2019 / 0233693, published August 1, 2019, or U.S. Provisional Patent Application No. 62 / 877443, filed July 23, 2019.

[0074] The shaped abrasive particles may also be formed to include a rake angle as described in WO 2019 / 207423 published on October 31, 2019, or WO 2019 / 207417 published on October 31, 2019, or PCT Application No. IB2019 / 059112 filed on October 24, 2019.

[0075] Shaped abrasive particles may also be formed to have a precision-shaped portion and a non-shaped portion, such as a ground portion, as described in U.S. Provisional Patent Application No. 62 / 833,865, filed April 15, 2019.

[0076] The shaped abrasive particles can also have a combination of one or more of the shape features discussed herein, including sloping sidewalls, grooves, recesses, facets, fractured surfaces, cavities, two or more vertices, sharp edges, non-shaped portions, notches, rake angles, and / or low roundness factors.

[0077] Additionally, the shaped abrasive particles may be agglomerates of shaped abrasive particles and / or crushed abrasive particles.

[0078] As used herein in reference to triangular abrasive particles, the term "length" refers to the largest dimension of the triangular abrasive particle. "Width" refers to the largest dimension of the triangular abrasive particle that is perpendicular to the length. The terms "thickness" or "height" refer to the dimensions of the triangular abrasive particle that are perpendicular to the length and width. For abrasive particles having a shape other than triangular, length refers to the longest dimension, width refers to the largest dimension perpendicular to the length, and thickness refers to the dimension perpendicular to both the length and width.

[0079] The shaped abrasive particles may have an elongated shape as described in U.S. Patent Application Publication No. 2019 / 0106362, published April 11, 2019, or WO 2019 / 069157, published April 11, 2019. The elongated shape may be a triangular prism, a rod, or otherwise a shape that includes one or more vertices along its perimeter.

[0080] The shaped abrasive particles may have a variable cross-sectional area along the length of the particle, as described in U.S. Patent Application Publication No. 2019 / 0249051. For example, the shaped abrasive particles may be dog-bone shaped or otherwise have a cross-sectional area that varies from a first end to a second end.

[0081] The shaped abrasive particles may have a tetrahedral shape as described in WO 2018 / 207145 published November 15, 2018, or U.S. Pat. No. 9,573,250 issued February 21, 2017.

[0082] Shaped abrasive particles may also have concave or convex portions, or may be defined as having one or more acute interior angles as described in U.S. Pat. No. 10,301,518, issued May 28, 2019.

[0083] Shaped abrasive particles may also include shape-on-shape particles, such as plate-on-plate shaped particles as described in US Pat. No. 8,728,185, issued May 20, 2014.

[0084] The shaped abrasive particles may also include shaped abrasive particles having irregular polygonal shapes such as those described in U.S. Provisional Patent Application No. 62 / 924,956, filed October 23, 2019.

[0085] The shaped abrasive particles may also be shaped to be free-standing abrasive particles so that the cutting portions are more likely to be embedded in the make coat in an orientation away from the backing, as described, for example, in PCT Application No. IB2019 / 060457, filed December 4, 2019.

[0086] The shaped abrasive particles may be agglomerated particles. The agglomerated particles may comprise shaped abrasive particles in a vitreous bond matrix, as described, for example, in U.S. Patent Application Publication No. 2018 / 081246, published May 3, 2018. The agglomerated particles may also comprise shaped abrasive particles in a silicate binder, as described, for example, in WO 2019 / 167022, published September 6, 2019. The agglomerated particles may also comprise truncated pyramidal shaped particles in a vitreous bond matrix, as described, for example, in U.S. Patent Application Publication No. 2019 / 0283216, published September 19, 2019. The agglomerates may also comprise a mixture of ground and shaped particles, as described, for example, in PCT Publication No. IB / 2019 / 058349, filed October 1, 2019.

[0087] The abrasive grain may have a surface treatment thereon. In some instances, the surface treatment may improve adhesion to the binder, change the abrasive properties of the abrasive particle, etc. Examples of surface treatments include coupling agents, halide salts, metal oxides including silica, refractory metal nitrides, and refractory metal carbides.

[0088] The abrasive layer may also contain diluent particles, typically in the same proportion as the abrasive particles, examples of which include gypsum, marble, limestone, flint, silica, glass bubbles, glass beads, and aluminum silicate.

[0089] The abrasive article and vibratory finishing system described herein can be suitable for various workpieces having various materials and can have any shape.Examples of materials include metals, metal alloys, exotic metal alloys, ceramics, painted surfaces, plastics, polymer coatings, stone, polycrystalline silicon, wood, marble, and combinations thereof.Examples of workpieces include molded and / or shaped articles (e.g., optical lenses, automobile body panels, boat hulls, countertops, and sinks), wafers, sheets, and blocks.

[0090] Depending on the application, the force at the polishing interface can range from about 0.1 kg to over 1000 kg. Typically, this range is 1 kg to 500 kg of force at the polishing interface. Also, depending on the application, a liquid may be present during polishing. This liquid may be water and / or organic compounds. Typical examples of organic compounds include lubricants, oils, emulsified organic compounds, cutting fluids, surfactants (e.g., soaps, organic sulfates, sulfonates, organic phosphonates, organic phosphates), and combinations thereof. These liquids may contain other additives, such as antifoaming agents, degreasers, corrosion inhibitors, and combinations thereof.

[0091] The objects and advantages of this invention are further illustrated by the following non-limiting examples, but the specific materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this invention.

[0092] A polishing system is presented that includes a first vibrating structure having a first plurality of protrusions, a second vibrating structure having a second plurality of protrusions, an abrasive article contacting the first film, and a stroke plate coupled to the second film, wherein the first and second plurality of protrusions are interconnected in a first direction and configured to slide relative to each other when the stroke plate is actuated.

[0093] The polishing system may be implemented such that the abrasive article is a rolled sheet of abrasive material that is fed through the polishing system in a feed direction, the feed direction being perpendicular to the first direction.

[0094] The abrasive system may be implemented so that the abrasive article is a coated abrasive article, a bonded abrasive article, or a nonwoven abrasive article.

[0095] The abrasive system may be implemented such that the abrasive article comprises abrasive particles, including ground abrasive particles, formed abrasive particles, or shaped abrasive particles.

[0096] The polishing system may be implemented such that the first plurality of protrusions includes shaped protrusions that repeat along a surface of the first vibrating structure.

[0097] The polishing system may be implemented such that the shaped protrusions repeat at regular intervals along the surface of the first vibrating structure.

[0098] The polishing system may be implemented such that the constant spacing has a space length between adjacent protrusions that is greater than the protrusion width.

[0099] The polishing system may be implemented such that the sum of the fixed spacing and the protrusion width is no more than twice the height of the shaped protrusions.

[0100] The polishing system may be implemented such that the shaped protrusion is a rectangular shaped protrusion.

[0101] The polishing system may be implemented such that the shaped protrusions include triangular shaped protrusions.

[0102] The polishing system may be implemented such that the shaped protrusions have rounded corners.

[0103] The polishing system may be implemented such that the first and second vibrating structures include high definition films.

[0104] The polishing system may be implemented such that the high definition film includes a resin.

[0105] The polishing system may be implemented such that the high definition film comprises a polyolefin.

[0106] The polishing system may be implemented to include a compressible pad between the stroke plate and the second vibrating structure.

[0107] A robotic repair system is presented, including a polishing system having a vibration source, a first structure coupled to the vibration source and having a first interconnecting feature, and a second structure having a second interconnecting feature interconnected to the first interconnecting feature. The first and second structures are configured to slide in a first direction when coupled. The abrasive article contacts the second structure on a second side opposite the first side that contacts the first structure. The polishing system also includes a robotic repair unit configured to move the polishing system to a fixed position over the workpiece, and a mount that couples the polishing system to the robotic repair unit.

[0108] The robotic repair system may be implemented such that the abrasive article is an abrasive belt. The abrasive system also includes a belt feeder that feeds the belt between the second structure and the workpiece in a feed direction, the feed direction being different from the first direction.

[0109] The robotic repair system may be implemented such that the feed direction is perpendicular to the first direction.

[0110] The robotic repair system may be implemented such that a surface area of ​​the abrasive belt contacts the workpiece during the abrading operation. The surface area of ​​the abrasive article includes the dimensions of the second structure and the width of the abrasive belt.

[0111] The robotic repair system may be implemented such that the abrasive belt is fed from a first belt roll to a second belt roll.

[0112] The robotic repair system may also be implemented to include a cushion between the vibration source and the first structure.

[0113] The robotic repair system may be implemented such that the vibration source is the stroke plate.

[0114] The robotic repair system may be implemented such that the abrasive article is a polishing pad coupled to a second structure.

[0115] The robotic repair system may be implemented such that the abrasive article comprises abrasive particles, including ground abrasive particles, formed abrasive particles, or shaped abrasive particles.

[0116] The robotic repair system may be implemented so that the abrasive article is a coated abrasive article, a bonded abrasive article, or a nonwoven abrasive article.

[0117] The robotic repair system may be implemented such that the first and second interconnecting features are high-definition features.

[0118] The robotic repair system can be implemented such that the first and second interconnecting features each include a plurality of protrusions extending from a base surface.

[0119] The robotic repair system may be implemented such that when in the interconnected position, there are multiple spaces between the first interconnecting feature and the second interconnecting feature.

[0120] The robotic repair system may be implemented such that the plurality of protrusions comprises a repeating shape.

[0121] The robotic repair system may be implemented such that the repeating shape is a rectangle or a triangle.

[0122] The robotic repair system may be implemented such that the repeating shape is a spatially adjacent polygon.

[0123] The robotic repair system may be implemented such that the length of the repeating feature is no more than twice the height of the repeating feature.

[0124] A method of polishing a surface includes coupling an abrasive article to a polishing system. The polishing system includes a vibration source and a first structure coupled to the vibration source. The first structure includes a first plurality of protrusions extending from a first base. The polishing system also includes a second structure including a second plurality of protrusions extending from a second base. The second plurality of protrusions interconnect with the first plurality of protrusions. The abrasive article is coupled to the second structure. The method also includes operating the polishing system. When the polishing system is operated, the first and second plurality of protrusions slide relative to each other in a first direction.

[0125] The method may also be implemented to include moving the abrasive article relative to the workpiece in a feed direction.

[0126] The method may be implemented such that the workpiece remains stationary, the abrasive article is physically attached to the second structure, and moving the abrasive article includes moving the abrasive system using a robotic repair unit.

[0127] The method may be implemented such that the workpiece remains stationary and the abrasive article is an abrasive belt. Moving the abrasive article includes feeding the abrasive belt under tension from a feed roll to a mill roll.

[0128] The method may be implemented such that the feed direction is opposite to the first direction, the first and second pluralities of protrusions substantially preventing slippage in the feed direction.

[0129] The method may be implemented such that the first plurality of protrusions are highly precise.

[0130] The method may be implemented such that a first plurality of protrusions are machined into the first structure.

[0131] The method may be implemented such that the first plurality of protrusions are formed from the same material as the first base.

[0132] The method may be implemented such that the first plurality of protrusions are integral with the first base.

[0133] The method may be implemented such that the first plurality of protrusions has a first protrusion height and the second plurality of protrusions has a second protrusion height, the first protrusion height and the second protrusion height being the same.

[0134] The method may be implemented such that the first and second pluralities of protrusions are interconnected such that gaps exist between adjacent protrusions.

[0135] The method may be implemented such that the first plurality of protrusions are polygonal in shape.

[0136] The method may be implemented such that the polygonal shapes are substantially rectangular or substantially triangular.

[0137] The method may be implemented such that the vibration source is a stroke plate.

[0138] The method may be implemented such that there is a cushion between the vibration source and the first structure.

[0139] An abrasive article is provided that includes a substrate that is longer in a first direction than in a second direction. The abrasive article also includes a plurality of protrusions on the substrate. The protrusions extend in the second direction. The protrusions are in a repeating pattern on the substrate.

[0140] The abrasive article may be implemented such that the substrate has a first side including the protrusions and a second side including a plurality of abrasive particles configured to contact the work surface.

[0141] The abrasive article may be mounted such that the substrate has a first side that includes the protrusions and a second side, the second side contacting the cushion.

[0142] The abrasive article may be implemented such that the abrasive article is a coated abrasive article, a nonwoven abrasive article, or a bonded abrasive article.

[0143] The abrasive article may be implemented such that the abrasive particles include ground abrasive particles, formed abrasive particles, or shaped abrasive particles.

[0144] The abrasive article may be implemented such that the repeating pattern includes a space length between adjacent protrusions that is greater than the protrusion width.

[0145] The abrasive article may be implemented such that the length of the first edge of the first protrusion and the corresponding first edge of the second protrusion is no more than twice the height of the shaped protrusion.

[0146] The abrasive article may be packaged such that the abrasive article is wrapped around a core.

[0147] The abrasive article may be mounted so that the abrasive article is on the side of the core.

[0148] The abrasive article may be mounted so that the protrusions are on the sides of the core. [Example]

[0149] Figures 7A-7C show experimental results described in the Examples herein. The abrasive was obtained from 3M Company, Model 373L, 30 microns. The abrasive was attached to a high-definition film described herein with dimensions of a+a'==230 μm and b=150 μm. The workpiece was SUS304. The machine shown in Figures 5A-5C was used, and the abrasive article was manually fed into the machine. The pad size was 25 mm x 50 mm x 10 mm high. A sponge was used as the pad to provide cushioning. A load of 15.7 N was applied.

[0150] Figure 7A shows the cut rate of the pad described above, labeled "Example A," compared to a conventional pad. Figure 7B shows the pad of Example A after a grinding operation with vibration scratches, and Figure 7C shows the pad of Example A with only feed scratches. When vibration is observed, more wear is indicated.

[0151] It should be understood that various modifications and variations of the present invention may be practiced by those skilled in the art without departing from the scope and spirit of the present invention, and that this invention should not be unduly limited to the illustrative embodiments set forth herein.

Claims

1. 1. A polishing system comprising: a first structure having a first plurality of protrusions on one surface; a second structure having a second plurality of protrusions on one surface; a stroke plate contacting another surface of the first structure; an abrasive article bonded to the other surface of the second structure; Equipped with the first plurality of protrusions and the second plurality of protrusions are arranged in uniform stripes such that the first plurality of protrusions and the second plurality of protrusions are interconnected; The first and second plurality of protrusions are configured to interconnect in a second direction, which is a stroke direction of the stroke plate, and to slide relative to each other along a first direction, which is a feed direction perpendicular to the second direction, when the stroke plate is actuated. Polishing system.

2. 10. The abrading system of claim 1, wherein the abrasive article is a rolled sheet of abrasive material advanced in a feed direction by the abrading system.

3. The polishing system of claim 1 , wherein the first plurality of protrusions comprises shaped protrusions that repeat along a surface of the first structure.

4. 1. A method of polishing a surface, comprising: coupling an abrasive article to a polishing system, said polishing system comprising: a first structure having a first plurality of protrusions on one surface; a second structure having a second plurality of protrusions on one surface; a vibration source in contact with another surface of the first structure; an abrasive article bonded to the other surface of the second structure; Equipped with the first plurality of protrusions and the second plurality of protrusions are arranged in uniform stripes such that the first plurality of protrusions and the second plurality of protrusions are interconnected; the coupling, wherein the first plurality of protrusions and the second plurality of protrusions are configured to interconnect in a second direction, which is a vibration direction of the vibration source, while sliding relative to one another along a first direction, which is a feed direction perpendicular to the second direction, when the vibration source is activated; operating the sharpening system to advance the second plurality of protrusions along the first direction; A method comprising:

5. The method of claim 4 , wherein the first plurality of protrusions and the second plurality of protrusions interconnect such that gaps exist between adjacent protrusions.

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