Molded Abrasive Rotary Tool

Abstract

The disclosure is generally directed to a method of manufacturing an abrasive rotary tool using a molded elastic layer. A mold includes a cavity with a peripheral surface. An abrasive sheet is positioned so that a working surface of the abrasive sheet is positioned along at least a portion of the peripheral surface. A spindle is positioned within the mold to create a region between the spindle and the abrasive sheet. An elastomeric precursor material is injected into the region and solidified to form an elastic layer. As a result, the elastic layer is in direct contact with at least a portion of the opposed surface of the abrasive sheet and at least a portion of the exterior surface of the spindle. In this way, an abrasive rotary tool may be manufactured without using adhesive layers and/or fastening means.

1 . A method of making an abrasive rotary tool comprising:
 providing a mold having a cavity with a peripheral surface;   providing an abrasive sheet having a working surface and an opposed surface, wherein the working surface is adjacent to and along at least a portion of the peripheral surface of the cavity;   providing a spindle having an exterior surface within the mold and creating a region between the exterior surface of the spindle and opposed surface of the abrasive sheet;   injecting an elastomeric precursor material into the region; and   solidifying the elastomeric precursor material to form an elastic layer, wherein the elastic layer is in contact with at least a portion of the opposed surface of the abrasive sheet and at least a portion of the exterior surface of the spindle.   
     
     
         2 . The method of  claim 1 , wherein the elastic layer fills at least 50% by volume of the region. 
     
     
         3 . The method of  claim 1 , wherein the spindle is centered within the cavity. 
     
     
         4 . The method of  claim 1 , wherein the cavity is at least one of a cylindrical shaped cavity, a conical shaped cavity, or a hemispherical shaped cavity. 
     
     
         5 . The method of  claim 4 , wherein a circumference of the cylindrical shaped cavity is Cm and the abrasive sheet has a length Ca, wherein Ca is at least within ±5% of Cm. 
     
     
         6 . The method of  claim 1 , wherein the elastic layer is an elastomeric foam. 
     
     
         7 . The method of  claim 1 , wherein the elastic layer is a thermoplastic elastomer. 
     
     
         8 . The method of  claim 1 , wherein the elastic layer is a thermosetting elastomer. 
     
     
         9 . The method of  claim 1 , wherein the working surface of the abrasive sheet includes plurality of three-dimensional features. 
     
     
         10 . (canceled) 
     
     
         11 . An abrasive rotary tool comprising:
 an abrasive sheet having a working surface and an opposed surface;   a spindle having an exterior surface; and   an elastic layer, wherein the elastic layer is in contact with at least a portion of the opposed surface of the abrasive sheet and at least a portion of the exterior surface of the spindle, wherein the elastic layer is a unitary body and wherein the abrasive sheet is coupled to the elastic layer by only adhesive forces at the contact between the at least a portion of the opposed surface of the abrasive sheet and the elastic layer.   
     
     
         12 . The abrasive rotary tool of  claim 11 , wherein the elastic layer has a substantially uniform radial density. 
     
     
         13 . The abrasive rotary tool of  claim 11 , wherein the abrasive rotary tool has at least one of a cylindrical shape, a conical shape, or a hemispherical shape. 
     
     
         14 . The abrasive rotary tool of  claim 11 , wherein the elastic layer is an elastomeric foam. 
     
     
         15 . The abrasive rotary tool of  claim 11 , wherein the elastic layer is a thermoplastic elastomer. 
     
     
         16 . The abrasive rotary tool of  claim 11 , wherein the elastic layer is a thermosetting elastomer. 
     
     
         17 . The abrasive rotary tool of  claim 11 , wherein the elastic layer has at least one of a Young's Modulus of less than about 6.0 MPa (870 psi) or a Poisson's ratio less than about 0.5. 
     
     
         18 . The abrasive rotary tool of  claim 11 , wherein the elastic layer has rubber hardness less than about 70 Shore A and greater than about 10 Shore A. 
     
     
         19 . The abrasive rotary tool of  claim 11 , wherein the elastic layer has a compression set of less than about 25%. 
     
     
         20 . The abrasive rotary tool of  claim 11 , wherein the working surface of the abrasive sheet includes plurality of three-dimensional features. 
     
     
         21 . (canceled) 
     
     
         22 . A system for forming an abrasive rotary tool, comprising:
 a mold having a cavity with a peripheral surface, wherein the peripheral surface is configured to receive a working surface of an abrasive sheet adjacent to and along at least a portion of the peripheral surface of the mold, and wherein the mold is configured to center a spindle within the cavity to create a region between an exterior surface of the spindle and the opposed surface of the abrasive sheet; and   an injection device configured to inject an elastomeric precursor material into the region.   
     
     
         23 . (canceled)