Apparatus and method for forming a spiral wound abrasive article, and the resulting article

Abstract

An apparatus and method for forming an endless spiral wound abrasive article and the resulting article. The apparatus includes first and second spaced-apart hubs, configured so that a portion of first and second webs passing between the first hub and the second hub is oriented substantially in a plane which remains stationery even if a position of a hub is changed. The apparatus further includes winders and a web joiner. The method includes providing a second web which includes an adhesive disposed on a first surface and a liner releasably affixed to the adhesive. The method includes removing the liner from the second web before positioning the second web adjacent the first web. The first and second webs are wound about the first and second hubs to form a spiral wound article having a desired circumference.

1 . An apparatus for forming a spiral wound endless abrasive article comprising: 
 a first hub having a longitudinal axis and a convex outer surface;    a first winder adapted to introduce a first web to a web joiner;    a second winder adapted to introduce a second web onto the first hub and to the web joiner;    the web joiner adapted to join abutting edges of the first web by overlap of the second web as the first and second webs spirally wind about the first hub to form a spiral wound article, the first and second webs positioned in an offset and overlapping configuration; and    a second hub at a distance from the first hub, the first and second webs passing around the second hub while spirally winding about the first hub to produce a spiral wound article having a desired circumference;    wherein the first hub and the second hub are configured so that a portion of the first and second webs passing from the first hub to the second hub is oriented substantially in a stationary plane.    
   
   
       2 . The apparatus of  claim 1  wherein the first hub is supported in a cantilevered configuration.  
   
   
       3 . The apparatus of  claim 2  wherein the second hub is supported in a cantilevered configuration.  
   
   
       4 . The apparatus of  claim 1  wherein the second hub is adjustably supported.  
   
   
       5 . The apparatus of  claim 4  wherein adjustment of the second hub does not change the plane.  
   
   
       6 . The apparatus of  claim 1  further comprising: 
 a driving mechanism intermediate the first hub and the second hub.    
   
   
       7 . The apparatus of  claim 1 , wherein the plane is substantially vertical.  
   
   
       8 . The apparatus of  claim 1 , further comprising a heating element intermediate the first hub and driving mechanism.  
   
   
       9 . The apparatus of  claim 8 , wherein the spiral wound article comprises a first and second opposed major surfaces; and wherein the heating element heats both the first major surface and the second major surface of the spiral wound article.  
   
   
       10 . The apparatus of  claim 8 , wherein the heating element is an infrared heater.  
   
   
       11 . The apparatus of  claim 1 , wherein the first web and second web are adhered at the overlap of the first web and the second web.  
   
   
       12 . The apparatus of  claim 1 , wherein the first web is a coated abrasive.  
   
   
       13 . The apparatus of  claim 1 , wherein the second web is a prelaminated adhesive backing material comprising: 
 a backing layer having first and second opposed major surfaces; the first major surface comprising an adhesive; and    a liner layer releasably attached to the first major surface of the backing material by the adhesive.    
   
   
       14 . The apparatus of  claim 13  further comprising a slip layer applied to the second major surface of the backing layer.  
   
   
       15 . The apparatus of  claim 13  further comprising a third winder adapted to accept the liner layer from the second web as the second web is unwound from the second winder.  
   
   
       16 . The apparatus of  claim 1  further comprising a third winder adapted to introduce a third web onto the first hub, the third web positioned in an offset and overlapping configuration relative to the second web.  
   
   
       17 . The apparatus of  claim 16 , wherein the first web comprises a coated abrasive, the second web comprises an adhesive material, and the third web comprises a reinforcing material.