Abrasive articles, rotationally reciprocating tools, and methods

Abstract

Methods of abrading surfaces by rotationally reciprocating abrasive surfaces in contact with the surfaces, abrasive articles for use in rotationally reciprocating tools, and methods of removing defects in a surface, where the methods include sanding using a rotationally reciprocating abrasive surface followed by one or more polishing operations are disclosed.

1 . A method of abrading a surface of a workpiece, the method comprising:
 providing an abrasive article mounted on a shaft of a driven tool, wherein the abrasive article comprises an abrasive surface that comprises abrasive particles attached thereto, wherein the abrasive article comprises:
 a base plate comprising a mounting surface, wherein the base plate is attached to the shaft; 
 a resiliently compressible member attached to the mounting surface of the base plate, wherein the compressible member comprises a first major surface facing the mounting surface of the base plate and a second major surface facing away from the mounting surface, and wherein the first major surface and the second major surface of the compressible member are each as large or larger than the mounting surface of the base plate; and 
 an abrasive member attached to the compressible member, the abrasive member comprising a first major surface and the abrasive surface, wherein the abrasive surface faces away from the compressible member, and wherein the first major surface of the abrasive member and the abrasive surface are each larger than the second major surface of the compressible member such that a portion of the first major surface of the abrasive member is not attached to the compressible member; 
   contacting the surface of the workpiece with the abrasive surface of the abrasive article; and   rotationally reciprocating the abrasive surface of the abrasive article about an axis of rotation by rotationally reciprocating the shaft of the driven tool, wherein the surface of the workpiece is abraded by the abrasive particles attached to the abrasive surface of the abrasive article while the abrasive surface of the abrasive article is rotationally reciprocating about the axis of rotation.   
   
   
       2 . A method according to  claim 1 , wherein rotationally reciprocating the abrasive surface comprises reciprocating the abrasive surface at a frequency of 1 Hz or higher. 
   
   
       3 . A method according to  claim 1 , wherein the abrasive article comprises an abrasive surface with an area of about 500 square millimeters (mm 2 ) or less. 
   
   
       4 . A method according to  claim 1 , wherein rotationally reciprocating the abrasive surface comprises reciprocating the abrasive surface over an arc of less than about 360 degrees. 
   
   
       5 . A method according to  claim 1 , wherein rotationally reciprocating the abrasive surface comprises reciprocating the abrasive surface over an arc of about 90 degrees or less. 
   
   
       6 . A method according to  claim 1 , wherein the abrasive surface of the abrasive article comprises a flat abrasive surface. 
   
   
       7 . A method according to  claim 1 , wherein the abrasive surface of the abrasive article comprises a flat abrasive surface, and wherein the flat abrasive surface is oriented perpendicular to the axis of rotation. 
   
   
       8 . A method according to  claim 1 , wherein the abrasive particles of the abrasive surface are dispersed in a binder. 
   
   
       9 . A method according to  claim 1 , wherein the abrasive surface comprises a plurality of structured abrasive composites containing the abrasive particles. 
   
   
       10 . (canceled) 
   
   
       11 . A method according to  claim 1 , wherein the base plate comprises a rigid base plate. 
   
   
       12 . A method according to  claim 11 , wherein the abrasive article comprises a sleeve coupling attached to the distal end of the shaft, wherein the sleeve coupling attaches the rigid base plate to the shaft. 
   
   
       13 . A method according to  claim 1 , wherein the abrasive article comprises
 a flexible support layer attached to the compressible member, wherein the support layer is located between the compressible member and the abrasive member, and further wherein the support layer comprises a first major surface facing the compressible member and a second major surface facing the abrasive member, and wherein the first major surface and the second major surface of the support layer are each larger than the second major surface of the compressible member.   
   
   
       14 . A method according to  claim 13 , wherein the abrasive member comprises an abrasive layer forming the abrasive surface, wherein the abrasive layer is attached to the second major surface of the support layer. 
   
   
       15 . A conformable abrasive article, comprising:
 a base plate comprising a mounting surface;   a resiliently compressible member attached to the, mounting surface of the base plate, wherein the compressible member comprises a first major surface facing the mounting surface and a second major surface facing away from the mounting surface, and wherein the first major surface and the second major surface of the compressible member are each as large or larger than the mounting surface of the base plate; and   an abrasive member attached to the compressible member, the abrasive member comprising a first major surface and the abrasive surface, wherein the abrasive surface faces away from the compressible member, and wherein the first major surface of the abrasive member and the abrasive surface are each larger than the second major surface of the compressible member such that a portion of the first major surface of the abrasive member is not attached to the compressible member.   
   
   
       16 . An article according to  claim 25 , wherein the abrasive member comprises an abrasive layer forming the abrasive surface, wherein the abrasive layer is attached to the second major surface of the support layer 
   
   
       17 . An article according to  claim 16 , wherein the abrasive member and the support layer are coextensive with each other over the second major surface of the support layer. 
   
   
       18 . An article according to  claim 15 , wherein the abrasive member comprises an abrasive layer attached to a polymeric film backing. 
   
   
       19 . An article according to  claim 16 , wherein the support layer is adhesively attached to the backing. 
   
   
       20 . An article according to  claim 16 , wherein the support layer comprises a compressible support layer. 
   
   
       21 . An article according to  claim 15 , wherein the mounting surface of the base plate is flat and wherein the compressible member and the abrasive member comprise disc-shaped articles with flat major surfaces. 
   
   
       22 . An article according to  claim 21 , wherein the compressible member is attached to the abrasive member proximate a center of the major surface of the abrasive member. 
   
   
       23 . An article according to  claim 15 , wherein the abrasive surface comprises an area of about 500 square millimeters or less. 
   
   
       24 . An article according to  claim 15 , wherein the abrasive surface comprises an area of about 300 square millimeters or less. 
   
   
       25 . An article according to  claim 15 , wherein the abrasive surface comprises an area of about 150 square millimeters or less. 
   
   
       26 . An article according to  claim 15 , wherein the abrasive surface has an abrasive grade of about JIS 1000 to about JIS 2000. 
   
   
       27 . An article according to  claim 15 , wherein the abrasive surface comprises abrasive particles dispersed in a binder. 
   
   
       28 . An article according to  claim 15 , wherein the abrasive surface comprises a plurality of structured abrasive composites. 
   
   
       29 . An article according to  claim 15 , wherein the base plate comprises a sleeve coupling extending in a direction away from the abrasive surface, wherein the sleeve coupling is adapted to attach the abrasive article to a shaft oriented normal to a plane defined by the mounting surface of the base plate. 
   
   
       30 . An abrasive tool comprising:
 a powered device comprising an output shaft adapted to rotationally reciprocate about an axis of rotation;   an abrasive article comprising an abrasive surface that comprises abrasive particles, wherein the abrasive article is attached the output shaft, wherein rotational reciprocation of the output shaft rotationally reciprocates the abrasive article about the axis of rotation, wherein the abrasive article comprises:
 a base plate comprising a mounting surface, wherein the base plate is attached to the shaft; 
 a resiliently compressible member attached to the mounting surface of the base plate, wherein the compressible member comprises a first major surface facing the mounting surface of the base plate and a second major surface facing away from the mounting surface, and wherein the first major surface and the second major surface of the compressible member are each as large or larger than the mounting surface of the base plate; and 
 an abrasive member attached to the compressible member, the abrasive member comprising a first major surface and the abrasive surface, wherein the abrasive surface faces away from the compressible member, and wherein the first major surface of the abrasive member and the abrasive surface are each larger than the second major surface of the compressible member such that a portion of the first major surface of the abrasive member is not attached to the compressible member. 
   
   
   
       31 . A tool according to  claim 30 , wherein the output shaft rotationally reciprocates at a frequency of 1 Hz or higher. 
   
   
       32 . A tool according to  claim 30 , wherein the abrasive article is attached to the output shaft with a sleeve coupling. 
   
   
       33 . A tool according to  claim 30 , wherein output shaft rotationally reciprocates about the axis of rotation over an arc of less than 360 degrees. 
   
   
       34 . A tool according to  claim 30 , wherein output shaft rotationally reciprocates about the axis of rotation over an arc of 90 degrees or less. 
   
   
       35 . An article according to  claim 15 , wherein the abrasive article comprises a flexible support layer attached to the compressible member, wherein the support layer is located between the compressible member and the abrasive member, and further wherein the support layer comprises a first major surface facing the compressible member and a second major surface facing the abrasive member, and wherein the first major surface and the second major surface of the support layer are each larger than the second major surface of the compressible member.