Abrasive rotary tool

Abstract

The disclosure provides abrasive rotary tools with enhanced adhesion of an abrasive layer. Exemplary abrasive rotary tools include a securing element configured to secure an abrasive layer to an abrasive rotary tool. The securing element may be positioned over a portion of the abrasive layer, such as a tab or end, such that repeated forces on the abrasive layer do not decouple the abrasive layer from the rotary tool. In this way, an abrasive rotary tool may maintain a contact surface integrity through repeated use for extended life of the rotary tool.

1 . An abrasive rotary tool, comprising:
 an abrasive assembly holder including:
 a shank defining an axis of rotation for the rotary tool; and 
 a three-dimensional core, having an exterior surface, wherein the three-dimensional core is adjacent to the shank; 
   an abrasive layer adjacent to the exterior surface, wherein the abrasive layer includes a contact surface; and   at least one securing element positioned over a portion of the abrasive layer, securing the abrasive layer to the abrasive assembly holder.   
     
     
         2 . The abrasive rotary tool of  claim 1 , wherein the three-dimensional core includes at least one side-wall adjacent to the exterior surface and the securing element secures the abrasive layer to the at least one side wall of the three-dimensional core. 
     
     
         3 . The abrasive rotary tool of  claim 1 , wherein at least a portion of the abrasive layer includes tabs. 
     
     
         4 . The abrasive rotary tool of  claim 3 , wherein the securing element is positioned over at least a portion of the tabs. 
     
     
         5 . The abrasive rotary tool of  claim 4 , wherein the securing element is only positioned over at least a portion of the tabs. 
     
     
         6 . The abrasive rotary tool of  claim 1 , wherein the abrasive layer is secured to the three-dimensional core without overlap of the abrasive layer. 
     
     
         7 . (canceled) 
     
     
         8 . The abrasive rotary tool of  claim 1 , wherein the contact surface of the abrasive layer comprises a plurality of precisely shaped abrasive composites. 
     
     
         9 . The abrasive rotary tool of  claim 1 , wherein at least a portion of the three-dimensional core and shank are a unitary body. 
     
     
         10 . The abrasive rotary tool of  claim 1 , wherein the securing element is at least one of an elastomer, a plastic, a tape, and a metal. 
     
     
         11 . The abrasive rotary tool of  claim 10 , wherein the elastomer is at least one of an O-ring, a band, a wrap, a thermally shrinkable sleeve, a screw, and a flange. 
     
     
         12 . The abrasive rotary tool of  claim 10 , wherein the plastic is at least one of an O-ring, a band, a wrap, a thermally shrinkable sleeve, a screw, and a flange. 
     
     
         13 . The abrasive rotary tool of  claim 10 , wherein the metal is at least one of an O-ring, a band, a wrap, and a flange. 
     
     
         14 . The abrasive rotary tool of  claim 1 , wherein the three-dimensional core includes at least one of a metal, elastomer, and a plastic. 
     
     
         15 . (canceled) 
     
     
         16 . The abrasive rotary tool of  claim 1 , wherein the three-dimensional core includes an elastic layer which includes the exterior surface. 
     
     
         17 . (canceled) 
     
     
         18 . The abrasive rotary tool of  claim 16 , wherein the elastic layer has a Shore A hardness of less than 80. 
     
     
         19 - 25 . (canceled) 
     
     
         26 . The abrasive rotary tool of  claim 1 , wherein the core includes a retaining channel. 
     
     
         27 . The abrasive rotary tool of  claim 26 , wherein the securing element is contained in at least a portion of the retaining channel. 
     
     
         28 . An assembly, comprising:
 a computer-controlled machining system comprising a computer controlled rotary tool holder and a substrate platform;   a substrate secured to the substrate platform; and   an abrasive rotary tool comprising:
 an abrasive assembly holder including:
 a shank defining an axis of rotation for the rotary tool; and 
 a three-dimensional core, having an exterior surface, wherein the three-dimensional core is adjacent to the shank; 
 
 an abrasive layer adjacent to the exterior surface, wherein the abrasive layer includes a contact surface; and 
 at least one securing element positioned over a portion of the abrasive layer, securing the abrasive layer to the abrasive assembly holder. 
   
     
     
         29 - 30 . (canceled) 
     
     
         31 . A method for polishing a substrate, comprising:
 providing a computer-controlled machining system including a computer controlled rotary tool holder and a substrate platform;   securing an abrasive rotary tool to the rotary tool holder of the computer-controlled machining system, wherein the abrasive rotary tool comprises:
 an abrasive assembly holder including:
 a shank defining an axis of rotation for the rotary tool; and 
 a three-dimensional core, having an exterior surface, wherein the three-dimensional core is adjacent to the shank; 
 
 an abrasive layer adjacent to the exterior surface, wherein the abrasive layer includes a contact surface; and 
 at least one securing element positioned over a portion of the abrasive layer, securing the abrasive layer to the abrasive assembly holder; 
   operating the computer-controlled machining system to abrade a contact surface of the substrate using the abrasive layer of the abrasive rotary tool.   
     
     
         32 . A method for manufacturing an abrasive rotary tool, comprising:
 positioning an abrasive layer adjacent to an exterior surface of a three-dimensional core of an abrasive assembly holder, wherein the three-dimensional core is adjacent to a shank of the abrasive assembly holder, wherein the abrasive layer includes a contact surface, wherein the shank defines an axis of rotation of the rotary tool; and   positioning at least one securing element over a portion of the abrasive layer, securing the abrasive layer to the abrasive assembly holder.   
     
     
         33 . (canceled)