System for making abrasive article

Abstract

In some examples, an abrasive particle transfer system including a production tool comprising a dispensing surface and a back surface opposite the dispensing surface, wherein the production tool has cavities formed therein, wherein, on a respective basis, each of the cavities extends from a first opening at the dispensing surface through the production tool to a second opening at the back surface, and wherein the second opening is smaller than the first opening; abrasive particles removably disposed within at least some of the cavities such that a portion of each particle protrudes from the back surface through the second opening; and a transfer roll having an outer surface, wherein the production tool is guided along a web path such that the portion of the abrasive particles protruding from the back surface of the production tool contacts the outer surface of the abrasive particle transfer roll to displace the abrasive particles.

1 . An abrasive particle transfer system comprising:
 a production tool comprising a dispensing surface and a back surface opposite the dispensing surface, wherein the production tool has cavities formed therein, wherein, on a respective basis, each of the cavities extends from a first opening at the dispensing surface through the production tool to a second opening at the back surface, and wherein the second opening is smaller than the first opening;   abrasive particles removably disposed within at least some of the cavities such that a portion of each particle of the abrasive particles protrudes from the back surface through the second opening; and   an abrasive particle transfer roll having an outer surface, wherein the production tool is guided along a web path such that the portion of the abrasive particles protruding from the back surface of the production tool contacts the outer surface of the abrasive particle transfer roll to displace the abrasive particles.   
     
     
         2 . The abrasive particle transfer system of  claim 1 , wherein the outer surface of the abrasive particle transfer roll contacts the portion of the abrasive particles protruding from the back surface of the production tool such that an opposite portion of each particle of the abrasive particles protrudes from the dispensing surface of the production tool. 
     
     
         3 . The abrasive particle transfer system of  claim 2 , wherein the abrasive particle transfer roll contacts the portion of the abrasive particles protruding from the back surface of the production tool such that an opposite portion of each particle of the abrasive particles protrudes from the dispensing surface of the production tool at least approximately 1 mil. 
     
     
         4 . The abrasive particle transfer system of  claim 2 , wherein the abrasive particle transfer roll contacts the portion of the abrasive particles protruding from the back surface of the production tool such that an opposite portion of each particle of the abrasive particles protrudes from the dispensing surface of the production tool approximately 1 mil and approximately 25 mils. 
     
     
         5 . The abrasive particle transfer system of  claim 1 , wherein the web path of the production tool comprises a first web path, the system further comprising a resin coated backing guided along a second web path such that a resin layer of the resin coated backing is positioned facing the dispensing surface of the production tool and the production tool is positioned between the resin coated backing and the abrasive particle transfer roll. 
     
     
         6 . The abrasive particle transfer system of  claim 5 , wherein the portion of the abrasive particles protruding from the back surface of the production tool contacts the abrasive particle transfer roll to urge the abrasive particles from the respective cavities onto the resin coating backing. 
     
     
         7 . The abrasive particle transfer system of  claim 6 , wherein the abrasive particle transfer roll contacts the portion of the abrasive particles protruding from the back surface of the production tool such that an opposite portion of each particle of the abrasive particles protrudes from the dispensing surface of the production tool to bring the abrasive particles into contact with the resin layer of the resin coated backing. 
     
     
         8 . The abrasive particle transfer system of  claim 6 , wherein the resin coated backing and the dispensing surface of the production tool are separated by a gap where the abrasive particles are transferred from the plurality of cavities to the resin coated backing. 
     
     
         9 . The abrasive particle transfer system of any of  claims 1 - 8 , wherein the portion of each particle of the abrasive particles protrudes from the back surface through the second opening at least approximately 1 mil. 
     
     
         10 . The abrasive particle transfer system of  claim 1 , wherein the portion of each particle of the abrasive particles protrudes from the back surface through the second opening between approximately 1 mil and approximately 25 mils. 
     
     
         11 . The abrasive particle transfer system of  claim 1 , wherein the abrasive particles are removably disposed within at least some of the cavities such that they do not extend beyond the dispensing surface prior to the portion of the abrasive particles protruding from the back surface of the production tool contacting the abrasive particle transfer roll. 
     
     
         12 . The abrasive particle transfer system of  claim 1 , wherein the abrasive particles are removably disposed within at least some of the cavities such that they extend beyond the dispensing surface prior to the portion of the abrasive particles protruding from the back surface of the production tool contacting the abrasive particle transfer roll. 
     
     
         13 . A method comprising:
 providing a production tool comprising a dispensing surface and a back surface opposite the dispensing surface, wherein the production tool has cavities formed therein, wherein, on a respective basis, each of the cavities extends from a first opening at the dispensing surface through the production tool to a second opening at the back surface, and wherein the second opening is smaller than the first opening, wherein abrasive particles removably disposed within at least some of the cavities such that a portion of each particle of the abrasive particles protrudes from the back surface through the second opening; and   guiding the production tool along a web path such that the portion of the abrasive particles protruding from the back surface of the production tool contacts an outer surface of an abrasive particle transfer roll to displace the abrasive particles.   
     
     
         14 . The method of  claim 13 , wherein the outer surface of the abrasive particle transfer roll contacts the portion of the abrasive particles protruding from the back surface of the production tool such that an opposite portion of each particle of the abrasive particles protrudes from the dispensing surface of the production tool. 
     
     
         15 . The method of  claim 14 , wherein the abrasive particle transfer roll contacts the portion of the abrasive particles protruding from the back surface of the production tool such that an opposite portion of each particle of the abrasive particles protrudes from the dispensing surface of the production tool approximately 1 mil and approximately 25 mils.