Magnetically assisted transfer of magnetizable abrasive particles and methods, apparatuses and systems related thereto

Abstract

According to one embodiment, a method of making an abrasive layer on a backing is disclosed. The method can comprise: providing dispensable magnetizable abrasive particles and a distribution tool, wherein the distribution tool is configured to receive the magnetizable abrasive particles therein, and wherein the distribution tool is configured to impart at least one of a predetermined orientation and alignment of the magnetizable abrasive particles, positioning a backing adjacent to the distribution tool and spaced therefrom by a gap, applying a magnetic field to at least the backing and a portion of the gap between the backing and the distribution tool, and transferring the magnetizable abrasive particles from the distribution tool to a first major surface of the backing, wherein the magnetic field is applied during the transfer of the magnetizable abrasive particles.

1 . A method of making a coated abrasive article, the method comprising:
 providing dispensable magnetizable abrasive particles and a distribution tool, wherein the distribution tool is configured to receive the magnetizable abrasive particles therein, and wherein the distribution tool is configured to impart at least one of a predetermined orientation and alignment of the magnetizable abrasive particles;   positioning a backing adjacent to the distribution tool and spaced therefrom by a gap;   applying a magnetic field to at least the backing and a portion of the gap between the backing and the distribution tool; and   transferring the magnetizable abrasive particles from the distribution tool to a first major surface of the backing, wherein the magnetic field is applied during the transfer of the magnetizable abrasive particles.   
     
     
         2 . The method of  claim 1 , wherein the distribution tool is configured to provide a predetermined pattern to the magnetizable abrasive particles. 
     
     
         3 . The method of  claim 1 , wherein one of the backing and distribution tool is moved relative to the other of the backing and distribution tool, and the method is part of a continuous process. 
     
     
         4 . The method of  claim 1 , wherein the distribution tool includes a plurality of walls defining slots allowing for the passage of one or more of the magnetizable abrasive particles therethrough, each one of the slots being open to an exterior side of the distribution tool. 
     
     
         5 . The method of  claim 1 , wherein the distribution tool has an exterior dispensing surface with cavities therein, and wherein each of the cavities is shaped to receive at least part of one of the magnetizable abrasive particles therein. 
     
     
         6 . The method of  claim 5 , further comprising inverting the distribution tool such that a gravitational field acts to attempt to remove the magnetizable abrasive particles from the cavities, and wherein at least some of the magnetizable abrasive particles are retained in the cavities by a vacuum. 
     
     
         7 . The method of  claim 1 , further comprising:
 at least partially curing a make layer precursor disposed on the backing;   disposing a size layer precursor on at least a portion of the at least partially cured make layer precursor; and   at least partially curing the size layer precursor.   
     
     
         8 . The method of  claim 1 , wherein the magnetic field acts on the magnetizable abrasive particles in substantially a same direction as a gravitational field and together the magnetic field and the gravitational field urge the magnetizable abrasive particles from the distribution tool and influence a passage of the magnetizable abrasive particles through the gap to the first major surface of the backing. 
     
     
         9 . The method of  claim 1 , wherein the magnetic field acts on the magnetizable abrasive particles in a substantially opposing direction as a gravitational field and the magnetic field acts to overcome the gravitational field to urge the magnetizable abrasive particles from the distribution tool and influence a passage of the magnetizable abrasive particles through the gap to the first major surface of the backing. 
     
     
         10 . The method of  claim 1 , wherein the gap is at least as large as a maximum dimension of the magnetizable abrasive particles. 
     
     
         11 . The method of  claim 1 , wherein the gap is at least twice a maximum dimension of the magnetizable abrasive particles. 
     
     
         12 . The method of  claim 1 , wherein the gap is between 0.010 inches and 1.0 inches in extent as measured from a closest most point of the distribution tool to the first major surface of the backing. 
     
     
         13 . The method of  claim 1 , wherein the magnetic field is applied by a magnet disposed relatively nearer to the first major surface of the backing than the distribution tool. 
     
     
         14 . The method of  claim 1 , wherein a majority of the magnetizable abrasive particles have a major planar surface disposed at an angle of at least 70 degrees relative to the first major surface of the backing upon transfer to the backing. 
     
     
         15 . The method of  claim 1 , wherein lines of force of the magnetic field are substantially perpendicular to the backing in a region comprising the gap between the backing and the distribution tool. 
     
     
         16 . An abrasive particle positioning system comprising:
 a distribution tool configured to impart at least one of a predetermined orientation and alignment of the magnetizable abrasive particles, the distribution tool comprising:
 a carrier member having a dispensing surface and a back surface opposite the dispensing surface, wherein the carrier member has cavities formed therein, wherein the cavities extend into the carrier member from the dispensing surface toward the back surface; 
   magnetizable abrasive particles removably disposed within at least some of the cavities;   a backing disposed adjacent to the distribution tool and spaced therefrom by a gap, the backing having a first major surface facing the distribution tool and a second major surface opposing the first major surface; and   a magnet disposed facing the second major surface of the backing, the magnet applying a magnetic field during a transfer of the magnetizable abrasive particles from the distribution tool to the backing to aid in achieving at least one of a predetermined orientation and alignment of the magnetizable abrasive particles on a first major surface of the backing.   
     
     
         17 . The abrasive particle positioning system of  claim 16 , wherein the carrier member comprises a polymer and is flexible. 
     
     
         18 . The abrasive particle positioning system of  claim 16 , wherein the distribution tool comprises an endless belt. 
     
     
         19 . The abrasive particle positioning system of  claim 16 , wherein on a respective basis, each of the magnetizable abrasive particles comprises a shaped ceramic body having a surface with a magnetizable layer disposed on at least a portion thereof, and wherein the one or more magnetic layers each substantially covers the entire surface of the shaped ceramic body. 
     
     
         20 . The abrasive particle positioning system of  claim 16 , wherein the magnetizable abrasive particles comprise triangular platelets. 
     
     
         21 . The abrasive particle positioning system of  claim 16 , wherein the distribution tool is inverted such that a gravitational field acts to attempt to remove the magnetizable abrasive particles from the cavities, and wherein at least some of the magnetizable abrasive particles are retained in the cavities by a vacuum. 
     
     
         22 . The abrasive particle positioning system of  claim 16 , wherein a pattern of the cavities on the carrier member is configured to impart at least one of the predetermined orientation and alignment of the magnetizable abrasive particles prior to the transfer. 
     
     
         23 . An abrasive particle positioning system comprising:
 a distribution tool configured to impart at least one of a predetermined orientation and alignment of the magnetizable abrasive particles, the distribution tool comprising:
 a member includes a plurality of walls defining slots configured to allow for the passage of one or more of the magnetizable abrasive particles therethrough, each one of the slots being open at a first end to a dispensing surface of the distribution tool and open at a second end to feed surface of the distribution tool; 
   a backing disposed adjacent to the distribution tool and spaced therefrom by a gap, the backing having a first major surface facing the dispensing surface and a second major surface opposing the first major surface; and   a magnet disposed facing the second major surface of the backing, the magnet applying a magnetic field during a transfer of the magnetizable abrasive particles from the distribution tool to the backing to aid in achieving at least one of a predetermined orientation and alignment of the magnetizable abrasive particles on a first major surface of the backing.   
     
     
         24 . The abrasive particle positioning system of  claim 23 , wherein the distribution tool comprises an endless belt. 
     
     
         25 . The abrasive particle positioning system of  claim 23 , wherein the magnetizable abrasive particles comprise triangular platelets. 
     
     
         26 . The abrasive particle positioning system of  claim 23 , wherein the slots generally align with a gravitational field and the magnetic field acts on the magnetizable abrasive particles in a same direction as the gravitational field and together the magnetic field and the gravitational field urge the magnetizable abrasive particles from the distribution tool through the slots and influence a passage of the magnetizable abrasive particles through the gap to the first major surface of the backing. 
     
     
         27 . The abrasive particle positioning system of  claim 23 , wherein the slots generally align with a gravitational field and the magnetic field acts on the magnetizable abrasive particles in substantially an opposing direction to the gravitational field and overcomes the gravitational field to urge the magnetizable abrasive particles from the distribution tool through the slots and influences a passage of the magnetizable abrasive particles through the gap to the first major surface of the backing. 
     
     
         28 . The abrasive particle positioning system of  claim 23 , wherein a pattern of the slots on the member is configured to impart at least one of the predetermined orientation and alignment of the magnetizable abrasive particles prior to the transfer. 
     
     
         29 . A method of making a coated abrasive article, the method comprising:
 providing dispensable magnetizable abrasive particles and a distribution tool, wherein the distribution tool is configured to receive the magnetizable abrasive particles therein, and wherein the distribution tool is configured to impart at least one of a predetermined orientation and alignment of the magnetizable abrasive particles;   positioning a backing adjacent to the distribution tool and spaced therefrom by a gap;   applying a magnetic field to at least the backing and a portion of the gap between the backing and the distribution tool; and   transferring the magnetizable abrasive particles from the distribution tool to the backing, wherein the magnetic field influences transfer of the magnetizable abrasive particles from the distribution tool to the backing to achieve at least one of the predetermined orientation and alignment of the magnetizable abrasive particles on a first major surface of the backing.