Placement of abrasive particles for achieving orientation independent scratches and minimizing observable manufacturing defects

Abstract

The present invention includes an abrasive tool comprising a substrate and plurality of abrasive grains arranged in a pseudo-random pattern on the substrate. The abrasive grains cover in the range of 10% to 30% of the substrate surface, and in some instances, the arrangement of abrasive grains demonstrate improved orientation independence and homogeneity in distribution of abrasive grains.

1 . An abrasive tool comprising a substrate and plurality of abrasive grains arranged in a pseudo-random pattern on the substrate, wherein the abrasive grains cover in the range of 10% to 30% of the substrate surface and wherein the arrangement of abrasive grains has a score of 20% or less on the Orientation Independence Test and has a score in the range of 0.7 to 0.9 in the Local Homogeneity Index Test. 
     
     
         2 . The abrasive tool of  claim 1 , wherein the arrangement of abrasive grains has a score of 10% or less on the Orientation Independence Test. 
     
     
         3 . The abrasive tool of  claim 1 , wherein the abrasive grains cover 10% to 15% of the surface substrate. 
     
     
         4 . The abrasive tool of  claim 1 , wherein the substrate comprises a lofty non-woven material. 
     
     
         5 . The abrasive tool of  claim 4 , wherein the lofty non-woven material comprises a densified surface. 
     
     
         6 . The abrasive tool of  claim 1 , wherein the abrasive grains are at least one of: single abrasive grits, cutting points, and composites comprising a plurality of abrasive grits, and combinations thereof. 
     
     
         7 . The abrasive tool of  claim 6  wherein the composites comprise a plurality of abrasive grits in a resin. 
     
     
         8 . The abrasive tool of  claim 1 , wherein the abrasive grains are printed onto the substrate. 
     
     
         9 . The abrasive tool of  claim 1 , wherein the average abrasive grain height from the surface of the substrate is in the range of 0.25 mm to 1.5 mm. 
     
     
         10 . The abrasive tool of  claim 1 , wherein the pseudo-random pattern comprises clusters of abrasive grains. 
     
     
         11 . The abrasive tool of  claim 1 , wherein the substrate is selected from the group consisting of paper, woven fabrics, nonwoven fabrics, calendared nonwoven fabrics, polymeric films, stitchbonded fabrics, open cell foams, closed cell foams, and combinations thereof. 
     
     
         12 . The abrasive tool of  claim 1 , wherein the substrate comprises an open cell foam or a closed cell foam laminated to a substrate selected from the group consisting of paper, woven fabrics, nonwoven fabrics, calendared nonwoven fabrics, polymeric films, stitchbonded fabrics, open cell foams, closed cell foams, and combinations thereof. 
     
     
         13 . The abrasive tool of  claim 1 , wherein the pseudo-random pattern is a pseudo-poisson pattern. 
     
     
         14 - 24 . (canceled)