Abrading tools and methods of making same

Abstract

An abrading tool includes a base member having a support portion defining a first level, and a plurality of integral raised islands extending upwardly above the first level. The base member may be formed of metal or a non-conductive material. The islands are spaced apart from one another. Each island includes a respective tip portion. The distance between adjacent islands may be greater than the width of a single island. An abrasive composite material, including a carrier material and particles of an abrasive material, is affixed to the tip portions of at least some of the islands. The abrasive material may be applied by electroplating, electroless plating, brazing or another method. The abrasive material is applied only to the tip portion of the islands, such that the first level of the support portion is substantially free of the abrasive material. Methods of making the abrading tool are also described.

What is claimed is: 
     
         1 . A method of manufacturing an abrading tool, said method comprising the steps of:
 a) applying a masking material to substantially cover a metal base member having a plurality of raised islands thereon, the islands being spaced apart from one another and each having a respective tip portion;   b) removing the masking material from the tip portions of the islands;   c) applying a composite material to the exposed tip portions of the base member, said composite material comprising a metal carrier and particles of an abrasive material selected from the group consisting of diamond, cubic boron nitride, tungsten carbide, titanium carbide, and mixtures thereof; and   d) removing the remaining masking material from the base member.   
     
     
         2 . An abrading tool which is a product of the method of  claim 1 . 
     
     
         3 . An attachment for a reciprocating sander, which is a product of the method of  claim 1 . 
     
     
         4 . The method of  claim 1 , wherein the masking material is an electrical insulator, and wherein the composite abrasive material is applied either by electrodeposition or by electroless deposition. 
     
     
         5 . The method of  claim 1 , wherein the raised islands are formed on the metal base member by a metal stamping process. 
     
     
         6 . An abrading tool comprising:
 a metal base member comprising a plate portion defining a first level and a plurality of raised islands integrally formed with and extending outwardly from the first level, the islands being spaced apart from one another and each including a respective tip portion;   an abrasive composite affixed to at least the tip portion of at least some of the islands, the abrasive composite comprising a carrier material and particles of an abrasive material selected from the group consisting of diamond, tungsten carbide, titanium carbide, and mixtures thereof,   wherein the first level of the plate portion is substantially free of said abrasive material.   
     
     
         7 . The abrading tool according to  claim 6 , wherein:
 the islands are substantially round and have a width W;   a distance between the nearest point of two adjacent islands has a length D; and   
       W is less than D. 
     
     
         8 . The abrading tool according to  claim 6 , wherein at least some of the tip portions are located in an abrasion plane, said abrasion plane being co-planar to and raised above the first level. 
     
     
         9 . The abrading tool according to  claim 6 , wherein the base member is cylindrical in shape, and the abrading tool is provided with a shaft for inserting into a rotary driving tool. 
     
     
         10 . The abrading tool according to  claim 6 , wherein the base member is spherical in shape, and the abrading tool is provided with a shaft for inserting into a rotary driving tool. 
     
     
         11 . The abrading tool according to  claim 6 , wherein the base member has a rounded conical shape, and the abrading tool is provided with a shaft for inserting into a rotary driving tool. 
     
     
         12 . The abrading tool according to  claim 6 , wherein the base member has cylindrical shape with a conical tip, and the abrading tool is provided with a shaft for inserting into a rotary driving tool. 
     
     
         13 . An abrading tool comprising:
 a non-conductive base member comprising a plate portion defining a first level and a plurality of raised islands formed thereon and extending outwardly from the first level, the islands being spaced apart from one another and each including a respective tip portion;   an abrasive composite affixed to at least the tip portion of at least some of the islands, the abrasive composite comprising a carrier material and particles of an abrasive material selected from the group consisting of diamond, cubic boron nitride, tungsten carbide, titanium carbide, and mixtures thereof,   wherein the first level of the plate portion is substantially free of said abrasive material.   
     
     
         14 . An abrading tool comprising:
 a cylindrical shaft and a grinding head having a longitudinal axis and formed in a shape having a substantially circular cross-sectional outline in a section taken along a plane transverse to the longitudinal axis, said grinding head having an external working surface defining a first level, and a plurality of raised islands integrally formed with and extending outwardly from the first level, the islands being spaced apart from one another and each including a respective tip portion;   an abrasive composite affixed to at least the tip portion of at least some of the islands, the abrasive composite comprising a carrier material and particles of an abrasive material selected from the group consisting of diamond, tungsten carbide, titanium carbide, and mixtures thereof,   wherein the first level of the plate portion is substantially free of said abrasive material.