Flexible abrasive member

Abstract: A flexible abrasive member comprises a porous sheet (1) carrying deposits (2) which consist of a metal (3) containing abrasive particles (4). The deposits (2) have been applied to the porous sheet (1) by electroplating and the sheet (1) has been impregnated with a coating (5) for stabilizing the deposits (2). The deposits (2) comprise at least one hollow space (6,9,10,11) through which the sheet (1) extends, which hollow space (6,9,10,11) is filled with coating material.

Description: The invention relates to a flexible abrasive member, as per the preamble of claim 1. An example of said flexible abrasive member is disclosed in JP-A-1164561. Said cloth material consists of yarns. Said cloth material carries a metal plating layer and superabrasive grains fixed in said metal plating layer. Furthermore, a synthetic resin coating is applied by impregnation onto the surface of the cloth material. In the process of manufacturing such members, first of all metal deposits are formed by e.g. electrodeposition, currentless sedimentation or vacuum deposition. These deposits contain the abrasive particles, which provide the member with its abrasive character. In a second step, a coating is applied onto the porous sheets and in the areas thereof between the deposits. Thereby, a stabilisation of the deposits should be obtained. In practice, the degree of stabilisation thus obtained is not fully satisfactory, because the backside of the deposits consist of metal deposits (the most used is nickel) which are flat and have a surface which appears to be "polished". First it is extremely difficult to glue anything to a nickel surface with at the same time maintaining the flexibility. Even if the nickel surface is primed or etched, the adhesion qualities are not improved substantially. The consequence is that all abrasives made by well known techniques have very low mechanical resistance and can therefore be easily damaged. In patent application PCT/NL 95/00265, already a considerable improvement of this problem has been achieved by creating cavities on the underside of the nickel deposit. This solution has improved the adhesion of the metal deposit to its back carrier sheet considerably. It is able to withstand high lateral forces and is therefore a very resistant product. The problem of damages caused to leverage forces has however not been solved yet and this is the subject of the present invention. The object of the invention is therefore to provide an abrasive member of the kind described before wherein a better stabilisation of the deposits is obtained. This object is achieved by the flexible abrasive member of claim 1. The hollow space(s) extend through the deposit and through the open, porous layer. Therefore on the inside of the deposit, the porous sheet is partially exposed and can be impregnated with glues such as silicon, polyester, polyurethane or epoxy glues. The glue is thus mechanically interlinked to the deposit and the adhesion from the deposit to the carrier back sheet is substantially increased as well as the resistance to leverage forces. Thus a highly resistant and strong abrasive is created which remains highly flexible with coating material. Because the coating in the member according to the invention has formed protrusions which extend into the correspondingly formed hollow spaces in the deposits, a much greater stabilisation is obtained. The protrusions form a unity with the rest of the coating, which makes them lock the deposits in their position. The hollow spaces and protrusions can be carried out in any desired shapes and numbers. Preferably, the hollow space is an essentially cylindrical hole. The correspondingly shaped protrusions are carried out cylindrically as well. Of course, several hollow spaces may be applied for stabilising a deposit. The invention will further be described with reference to some embodiments shown in the figures. Figure 1 shows a cross section through a flexible abrasive member according to the invention. Figures 2 up to 4 show views on several embodiments of the invention. Figure 5 shows a member, which is not part of the present invention. The flexible abrasive member according to figure 1 contains a porous sheet 1, carrying a deposit 2 which has been applied by electro-plating. The deposit 2 consists of a metal material 3, in which abrasive particles 4 have been imbedded. The metal material 4 has also impregnated the porous sheet 1. Furthermore, a coating material 5 has been applied which has also been impregnated in the porous sheet 1. The deposit carries at least one hole 6, which is also filled with the coating material. Moreover, a thin layer of coating material 8 may be present on the top surface of the deposit. The coating may comprise a silicon, polyester, polyurethane or epoxy glue. Due to the presence of a hole 6 in the deposit, filled with coating material 7 which forms a unity with the rest of the coating material 5, a very stable position of the deposit 2 with respect to shear forces is obtained. As shown in figures 2 up to 4, the hole in the deposit 2 may take several forms, such as a rectangular hole 9 (figure 2) or a circular hole 9 (figure 3); also, several circular holes 11 (figure 4) together are possible. Figure 5 shows a flexible abrasive member, which is not part of the present invention, wherein the metal material has a cavity 12, which at the top is closed by metal covering material 13.

Claims: A flexible abrasive member comprising a porous sheet (1) carrying deposits (2) which consists of metal (3) containing abrasive particles (4), which deposits (2) have been applied to the porous sheet (1) by electroplating and the porous sheet (1) being impregnated with a coating (5) for stabilising the deposits (2), characterized in that the deposits (2) comprise at least one hollow space (6) through which the porous sheet (1) extends, the hollow space (6) being filled with the coating material (7) which forms a unity with the rest of the coating (5). Member according to claim 1, wherein the hollow space of a deposit (2) is a through going hole (6, 9, 10, 11). Member according to claim 2, wherein the hollow space is an essentially cylindrical hole (6, 10, 11). Member according to claim 3, wherein the deposit (2) is cylindrically shaped, and the cylindrical hole (10) is situated essentially centrally within said deposit (2). Member according to claim 3, wherein a deposit (2) comprises at least two hollow spaces (11). Member according to any of the preceding claims, wherein the coating comprises silicon, polyester, polyurethane or epoxy glue.

Inventors: FERRONATO SANDRO GIOVANNI GIUS, FERRONATO, SANDRO GIOVANNI GIUSEPPE
Applicants: FERRONATO SANDRO GIOVANNI GIUS, FERRONATO, SANDRO GIOVANNI GIUSEPPE
Application year: 1996
Main classification: B24D3
IPC codes: B24D18, B24D3