Abrasive Article and Method of Making such an Article

Abstract

A method for manufacturing an abrasive article (10), including:providing a sheet including a support layer (12) and members (20) of a quick release system, QRS (18, 19)applying a metal coating (36) onto the support layer and the QRS members;applying abrasive particles (38) onto at least part of the first surface of the support layer, so that the particles are thermally connected to the metal coating;The support layer defines a plurality of openings (26) that extend from a first surface (14) of the layer, through the layer, to an opposite surface (16) of the layer, and which allow abrasion dust to pass through. The QRS members are fixed on or in the support layer and protrude from this opposite surface, and are configured to fix the article to a surface including complementary QRS members (19). The metal coating covers both the support layer and the QRS members, and forms thermally conductive paths from the abrasive particles on the first surface, via the openings, to the QRS members on the opposite surface.

1 . A method for manufacturing an abrasive article, the method comprising:
 providing a base sheet that includes a support layer and fastening members of a quick release system, QRS; wherein the support layer defines a plurality of openings, the openings extending from a first surface of the support layer, through the support layer, to a second surface of the support layer opposite to the first surface, and being configured to allow abrasion dust to pass through the support layer; and wherein the fastening members are fixed on or in the support layer and protrude from the second surface thereof, and are configured to temporarily fix the abrasive article to a surface including complementary fastening members of the QRS;   applying an electrically and thermally conductive coating onto the support layer and the fastening members;   applying abrasive particles onto at least part of the first surface of the support layer, so that the abrasive particles are thermally connected to the coating;   wherein the coating covers both the support layer and the fastening members, and forms thermally conductive paths from the abrasive particles on the first surface, via the openings, to the fastening members on the second surface of the support layer.   
     
     
         2 . The method according to  claim 1 , wherein the fastening members are directly fixed onto or in the support layer before applying the coating, and wherein the method further comprises:
 applying the coating so as to cover and extend in a continuous manner across exposed outer surfaces of both the support layer and the fastening members.   
     
     
         3 . The method according to  claim 1 , wherein the coating forms a matrix layer, and wherein the method further comprises:
 applying the coating onto the support layer and the fastening members and embedding the abrasive particles in a portion of the coating present at the first surface of the support layer, using electrolytic co-deposition.   
     
     
         4 . The method according to  claim 1 , further comprising:
 before applying the coating, applying a metal primer coating directly onto the support layer and the fastening members, using electro-less plating, and;   applying the coating onto the metal primer coating, using electroplating or electrolytic co-deposition.   
     
     
         5 . The method according to  claim 1 , further comprising:
 providing the base sheet shaped as an elongated web that is stored on a roll or folded stack;   continuously or intermittently unrolling or unfolding consecutive web portions of the base sheet from the roll or the folded stack;   continuously or intermittently applying the coating onto both the support layer and the fastening members and applying abrasive particles onto the first surface of the support layer of respective consecutive web portions that have been unrolled or unfolded, thereby forming web portions of semi-finished abrasive sheet material;   cutting a predetermined shape form at least one of the web portions of semi-finished abrasive sheet material, to form the abrasive article.   
     
     
         6 . The method according to  claim 1 , forming the abrasive article as a pad, disc, sheet, or belt configured to carry out a grinding and/or polishing process. 
     
     
         7 . An abrasive article for processing a surface, comprising:
 a base sheet that includes a support layer and fastening members of a quick release system, QRS; wherein the support layer defines a plurality of openings, the openings extending from a first surface of the support layer, through the support layer, to a second surface of the support layer opposite to the first surface, and being configured to allow abrasion dust to pass through the support layer; and wherein the fastening members are fixed on or in the support layer and protrude from the second surface thereof, and are configured to temporarily fix the abrasive article to a surface including complementary fastening members of the QRS;   an electrically and thermally conductive coating covering both the support layer and the fastening members, and   a deposit with abrasive particles covering at least part of the first surface of the support layer, and being thermally connected to the coating;   wherein the coating forms thermally conductive paths from the abrasive particles on the first surface, via the openings, to the fastening members on the second surface of the support layer.   
     
     
         8 . The abrasive article according to  claim 7 , wherein the support layer is an open mesh formed of multiple strands that mutually cross or intersect, and which define the openings in between. 
     
     
         9 . The abrasive article according to  claim 8 , wherein the fastening members are integrated with the strands of the mesh so that the fastening members and strands engage along contact surfaces, and so that the coating covers and extends in a continuous manner across both the mesh and the fastening members, without extending directly in-between the fastening members and the strands along the contact surfaces. 
     
     
         10 . The abrasive article according to  claim 7 , wherein the fastening members are formed by filaments having base portions that are mechanically fixed to or incorporated into the support layer, for instance embedded in or intertwined with strands of the mesh support layer according to  claim 8  or  9 . 
     
     
         11 . The abrasive article according to  claim 8 , wherein the mesh is formed of woven, braided, or knitted strands. 
     
     
         12 . The abrasive article according to  claim 8 , wherein the mesh is an extruded mesh, a punched mesh, or a slit-and-expanded material mesh. 
     
     
         13 . The abrasive article according to  claim 8 , wherein the mesh is flexible. 
     
     
         14 . The abrasive article according to  claim 8 , wherein the mesh is made of polyester fibres. 
     
     
         15 . The abrasive article according to  claim 7 , wherein the openings in the support layer have an open area in a range of 20%-60% of the surface area of the abrasive article. 
     
     
         16 . The abrasive article according to  claim 7 , wherein the openings in the mesh are provided in a regular pattern, the pattern having one or more of:
 two-dimensional periodicity;   mirror symmetry;   discrete rotational symmetry.   
     
     
         17 . The abrasive article according to  claim 7 , being a rotationally symmetric pad, for instance a circular pad, and wherein the support layer and openings have discrete rotational symmetry. 
     
     
         18 . The abrasive article according to  claim 7 , wherein the coating is a metal coating consisting essentially of nickel or nickel-based alloy. 
     
     
         19 . The abrasive article according to  claim 7 , wherein the abrasive particles consist essentially of diamond or cubic boron nitride.