Grinding Tools that Contain Uniform Distribution of Abrasive Grits and Method of Manufacture Thereof

Abstract

The present invention relates to a method of uniformly distributing abrasive grits on grinding tools. It can be applied in the cutting, grinding segments of diamond tools, which are typically used in cutting and drilling various hard and fragile materials, such as granite, marble, concrete, asphalt, etc. The present invention provides a template, the template designed based on the arranging requirement of abrasive particles such as diamond grits. The template can adsorb only a single layer of abrasive particles and is then placed onto a sheet, where the diamond grits are pressed into the sheet, with the diamond grits distributed uniformly on the sheet.

1 . A method of uniformly distributing abrasive grits on grinding or cutting tools, comprising the steps of:
 providing a template designed on the single-layer arranging requirement of diamonds or other abrasive particles, said template having a layer of adsorbent material capable of adsorbing a single layer of diamond grits;   placing said template on a sheet,   pressing said layer of diamond grits into said sheet, said diamond grits being embedded uniformly on said sheet in a layer.   
   
   
       2 . The method of  claim 1 , wherein said adsorbent layer has a lower viscosity, a higher percent of condensate and a lower percent of solvent. 
   
   
       3 . The method of  claim 1 , wherein said sheet is a paste, wherein said pasted is solidified, after said diamond grits are pressed into said paste, by means of heating or cooling to form a single layer of uniformly-distributed diamond grits. 
   
   
       4 . The method of  claim 1 , wherein said sheet is made by mixing metal powder and bond to form a mixture, and wherein when said mixture is about to solidify, said abrasive particles are pressed into either one surface or both surfaces of said sheet. 
   
   
       5 . The method of  claim 1 , further comprising the steps of:
 pressing a plurality of said sheets to form a composite with a thickness as required by said grinding or cutting tools;   placing said composite into a mold to be sintered.   
   
   
       6 . The method of  claim 1 , wherein said grinding or cutting tools comprises multiple sheets and wherein the distribution pattern of abrasive particles on each layer are the same as or different. 
   
   
       7 . The method of  claim 1 , wherein the outer layer of said grinding or cutting tool has a higher density of diamond grits and the inner layer has a lower density and bigger-size diamond grits. 
   
   
       8 . The method of either  claims 1  or  5 , further comprising the following steps:
 cutting said sheets into diamond saw segments in a predetermined shape,   assembling a plurality of such segments and placing said segments into a graphite mold for forming conventional diamond saw segments;   sintering and consolidating said segments; and   laser welding said segments onto a circular saw.   
   
   
       9 . A method of uniformly distributing abrasive grits on grinding tools comprising the steps of:
 providing a sheet;   providing an electric/electromagnetic template, designed based on the arrangement requirement of diamonds or other abrasive particles;   adsorbing said diamonds or other abrasive particles on a template in a layer;   pressing said template with the adsorbed diamonds or other abrasive particles onto said sheet;   separating said template from said sheet, wherein said diamonds or other abravise particles will be uniformly distributed on the sheet.   
   
   
       10 . The method of  claim 9 , wherein said template is a plane template formed by electromagnetic radiating and covering the positions where it is not needed to adsorb abrasive particles. 
   
   
       11 . The method of  claim 9 , wherein said template is a plasma-template. 
   
   
       12 . The method of  claim 9 , wherein said template is an electric template with a positive or negative charge. 
   
   
       13 . The method of  claim 9 , wherein said sheet is made by mixing metal powder and bond compressed in a mold. 
   
   
       14 . The method of  claim 9 , wherein said sheets of selected layers on the requirement of cutting were compressed to be a one by static press or stamping press, then placed into a mold to be sintered. 
   
   
       15 . The method of either  claims 9  or  14 , wherein the cutting tool is formed by multiple sheets, the distribution pattern of abrasive particles on each layer are the same as or different. 
   
   
       16 . The method of  claim 15 , wherein the outer layer has a higher density of diamond while the inner layer has a lower density and bigger-size diamond. 
   
   
       17 . The method of  claim 9 , further comprising the steps of
 cutting the sheets impregnated with uniform-distributed diamond grits into diamond saw segments;   assembling a plurality of segments;   placing said segments into a graphite mold for making conventional diamond saw segments;   sintering and consolidating said segments, the segments were consolidated; and.   laser welding said segments onto a circular saw.