ATTACHMENT SYSTEMS AND METHODS FOR ABRASIVE DISCS

Abstract

A dual sided abrasive article is presented that includes a first side with a first abrading face and a second side, with a second abrading face. The second side is opposite the first side and separated by a thickness. The article also includes a center hole extending from the first side to the second side through the thickness. The article also includes a fastener for coupling the abrasive article to a powered tool, the fastener positioned within the center hole.

Description

BACKGROUND

Various articles and methods for attaching fasteners to articles are known in the art. For example, U.S. Pat. No. 4,551,189 to Peterson discloses a friction welding fastener system for fusing a thermoplastic material fastener to a substrate by heat of friction induced through the application of rotative and axial forces applied to the fastener. A cavity is formed inwardly of the bottom surface of the thermoplastic base member and a heat activated adhesive material having a bonding affinity for both the base material and the substrate material is inserted into the cavity to form a layer having a thickness equal or greater than the thickness of the base member. The base member is rotated with sufficient rotative and axial forces to cause the heat activated adhesive layer to adhere to the substrate.

U.S. Pat. No. 5,931,729 to Penttila et al. discloses a method of spin welding a fastener to an article and such an article. The fastener is melt-bonded to the back of the surface conditioning disc. The surface treating article comprises a working surface adapted to treat a workpiece surface, and a back surface, the back surface comprising an open woven scrim. In a preferred embodiment, the surface treating article has a nonwoven abrasive surface conditioning disc. The Penttila et al. reference states it is also possible for the surface treating article to be a coated abrasive disc, a polishing pad, a brush, or a similar surface treating element.

SUMMARY

A dual sided abrasive article is presented that includes a first side with a first abrading face and a second side, with a second abrading face. The second side is opposite the first side and separated by a thickness. The article also includes a center hole extending from the first side to the second side through the thickness. The article also includes a fastener for coupling the abrasive article to a powered tool, the fastener positioned within the center hole.

The above Summary is not intended to describe each illustrated embodiment or every implementation of the present disclosure. Further features and advantages are disclosed in the embodiments that follow. The Drawings and the Detailed Description that follow more particularly exemplify certain embodiments using the principles disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a sanding system in which embodiments of the present invention are useful.

FIGS. 2A-2C illustrate abrasive discs in accordance with embodiments herein.

FIGS. 3A and 3B illustrates a sanding system in accordance with embodiments herein.

FIGS. 4A and 4B illustrate methods for forming a dual sided abrasive disc for a sanding system in embodiments herein.

FIG. 5 illustrates a dual sided attachment system for attaching an abrasive disc to a backup pad.

FIG. 6 illustrates a sanding system in accordance with an embodiment of the present invention.

FIG. 7 illustrates a method of using a sanding system in accordance with embodiments herein.

DETAILED DESCRIPTION

Surface conditioning discs having a threaded button bonded to the back side of the disc by an adhesive are available commercially as Roloc™ surface conditioning discs from 3M Company of St. Paul, Minn., USA. These surface conditioning discs have an abrasive member and a fastener attached to the abrasive member by a layer of thermosetting adhesive. The fastener has a base and a threaded portion for attaching to a suitable back-up pad.

However, while abrasive material may be impregnated throughout an entire abrasive article, using a fixed fastener requires one side of an abrasive disc to be nonoperational. It is desired to have a fastening and attachment system for an abrasive disc that allows for the disc to have dual-sided use. Additionally, it is desired that the system be backwards compatible with existing systems, particularly with existing Roloc™ systems.

FIG. 1 illustrates a sanding system in which embodiments of the present invention are useful. Sanding system 100 includes a tool 110. Tool 110 is illustrated as a pneumatic sanding tool, in one embodiment, which receives air through air source 102. Tool 110 couples to a backup pad 120 (abbreviated as BUP) using a tool coupler 112. BUP 120 couples to an abrasive disc 130 using a fastener (not shown in FIG. 1) that connects to a receiver 132.

Abrasive discs 130 are manufactured such that resin and abrasive grit impregnates the entire disc. However, many current attachment systems that attach abrasive disc 130 to a backup pad 120 render one side of the disc unusable for abrading. If both sides were usable for abrading, and easily interchangeable, the disc would be usable for a customer for longer.

Additionally, often attachment systems currently in use require the use of tools to remove the abrasive disc from the backup pad - a nut for example. However, it takes time to retrieve a tool, remove the nut, replace the used abrasive disc with a new disc, and replace the nut with the tool. It is desired to have a system where the abrasive disc can be easily removed and replaced without tooling.

Systems and methods described herein allow for the use of dual sided discs with a toolless system of switching from a first disc side to a second disc side. This extends the useful life of an abrasive disc and removes the need for tools to replace abrasive discs. FIGS. 2A-2C illustrate abrasive discs in accordance with embodiments herein.

FIGS. 2A-2C illustrate three abrasive discs. FIG. 2A illustrates a coated abrasive disc 200. Coated abrasive disc 200 may include two different coated abrasive sides with a backing or scrim in between. FIGS. 2B and 2C illustrate nonwoven abrasive discs 230, 250 with FIG. 2C illustrating a more open nonwoven disc. Each of discs 200, 230 and 250 have a receiver 202, 232, 252 embedded in the center of the disc.

Fasteners 202, 232, and 252 are embedded within discs 200, 230 and 250 using spin welding, in one embodiment. Spin welding is a known technique, discussed for example in U.S. Pat. Nos. 5,931,729 and 6,001,202, which are incorporated herein by reference. Fasteners 202, 232, and 252, in one embodiment, are formed to be level with a first and second surface of discs 200, 230 and 250. In another embodiment, fasteners 202, 232 and 252 have a height that is smaller than a thickness of at least one of discs 200, 230 and 250 such that the fastener does not extend to at least one of the flat abrading faces of discs 200, 230 or 250.

FIG. 3 illustrates a sanding system in accordance with embodiments herein. As discussed above with respect to FIG. 1, a sanding system 300 includes a tool that couples to a backup pad 320, which couples to an abrasive disc 330. In one embodiment, abrasive disc 330 is a dual sided disc with a first abrasive side and a second abrasive side separated by a thickness. First and second sides are separated by a thickness.

An attachment mechanism 310 is illustrated in FIG. 3. Attachment mechanism 310 has a first side 312 and a second side 314. Extending from the first and second sides 312, 314 is male threading. In one embodiment, sides 312 and 314 are colored or textured differently such that a user can identify side 312 as BUP connecting side and side 314 as an abrasive disc connecting side. While FIG. 3 illustrates side 312 and side 314 as having similar sized threading, it is expressly contemplated that one side has larger threading than the other. For example BUP connecting side 312 may have Roloc™ compatible threading and disc connecting side 314 may have a disc-compatible threading.

BUP 320 receives attachment mechanism 310 using female threading that receives the threading of side 312. In one embodiment, attachment mechanism 310 has threading that is sized to interact with current Roloc™ BUPs 320.

An abrasive disc 330 has a fastener 340 embedded within a center hole of abrasive disc 330. Fastener 340, in one embodiment, includes corresponding female threading to receive threads on side 314 of attachment mechanism 310.

As illustrated in FIG. 3B, abrasive disc 330 couples to BUP 320 using the attachment mechanism 310, which couples to BUP threading on side 312 and disc fastener 340 on side 314.

In one embodiment, attachment mechanism 310 is designed to allow for easy, toolless removal of disc 330 from backup pad 320, and therefore from an attached tool system 300. In one embodiment, attachment mechanism 310 and fastener 340 are designed such that, when force is applied (e.g. by using a hand to twist disc 330 in an opposing direction from backup pad 320), disc 330 is removed while attachment mechanism 310 stays in place.

FIGS. 4A and 4B illustrate methods for forming a dual sided abrasive disc for a sanding system in embodiments herein. FIG. 4A illustrates a flow chart 400 for manufacturing a dual sided disc.

In block 410, an abrasive disc is provided. The abrasive disc may be a nonwoven disc 402, a bonded abrasive disc 404, or another disc 406, such as a coated disc with abrasives coated on either side of a backing. The abrasive disc may have the same abrasive grit on both sides, or different grits on either side. For example, one side may be for sanding and the other for polishing. In another embodiment, the abrasive disc is substantially evenly impregnated with abrasive grain on either exposed side and/or throughout its thickness.

In block 420, a fastener 420 is provided. In one embodiment, the abrasive disc has a center hole cut extending through its thickness into which the fastener fits. The fastener may have internal threading 422 that is sized to receive a coupling mechanism for attachment of the disc to a backup pad. The fastener may also have a thickness 424 that is sized to be similar to the thickness of an abrasive pad. In one embodiment, the fastener has a thickness smaller than the thickness of the abrasive pad into which it is inserted. In another embodiment, the fastener has a thickness that is similar to the thickness of the abrasive pad into which it is inserted.

The fastener may also have other features 426. For example, the fastener, in one embodiment, is configured to fit entirely within, and not couple to any portion of a surface of the abrasive disc. Instead, the fastener is substantially cylindrical in shape and the attachment is solely between the outer surface of the fastener and the inner surface of the center hole of the abrasive disc.

The fastener may be made of any of a variety of suitable materials. In one embodiment, the fastener is made of thermoplastic 412. In another embodiment, the fastener is made of metal 414. However, the fastener may also be made of another suitable material 416.

In block 430, spin welding is used to couple the fastener to the abrasive disc. It is important that the fastener be coupled to the fastener such that it does not come undone during use. Spin welding essentially involves contacting the outer surface of the fastener to the inner surface of the abrasive disc and spinning the fastener at a rate that causes friction, and a bond to form between the two articles. Spin welding is discussed in greater detail in U.S. Pat. No. 5,391,729 and 6,001,202, both of which are incorporated herein by reference.

In one embodiment, spin welding causes the abrasive disc to partially melt, as indicated in block 432. For example, for a nonwoven abrasive disc, spin welding can cause the fibers to partially melt, creating a bond to the fastener.

In one embodiment, spin welding causes the fastener to partially melt, as indicated in block 434. For example, in the embodiment where the fastener is a thermoplastic or a metal, spin welding can create enough friction to raise the surface temperature of the fastener, causing partial melting and fusing to the abrasive disc material.

In one embodiment, an adhesive is applied between the fastener and the interior area of the abrasive disc center hole. The adhesive may be a thermally activated adhesive, in one embodiment. Spin welding may cause the adhesive to activate and form a bond between the fastener and the abrasive article.

Other coupling agents are also contemplated, as indicated in block 438, such as a weld or an ultrasonic weld.

FIG. 4B illustrates a schematic 450 of the formation of a dual sided disc. Fastener 452 is placed within a center hole 454 of an abrasive disc 456. In one embodiment, fastener 452 has a thickness that is similar in size to the thickness of abrasive disc 456. For example, fastener 452 has a thickness, in one embodiment, between 50% and 150% of the thickness of the abrasive disc. In some embodiments, the thickness of fastener 452 is between about 75% and about 105% of the thickness of the abrasive disc. Additionally, in some embodiments, fastener 452 is significantly thinner than the abrasive disc, for example less than about 20% of the abrasive disc thickness, less than about 10% of the abrasive disc thickness, or less than about 5% of the abrasive disc thickness. In embodiments where fastener 452 has a thickness that is not substantially the same as the thickness of the abrasive disc, fastener 452 has a position on an axis defined by the thickness. Fastener 452 may be centered on the axis, such that it is centered within a thickness of the abrasive disc, in some embodiments. However, other suitable positions may be possible, or even preferable depending on manufacturing tolerances or considerations.

Once the fastener has been placed within center hole 454, a spin welding operation 460 is conducted. Spin welding may cause a portion of the abrasive disc to melt, for example the fibers of a nonwoven article and/or the resin or other binding agent. Spin welding may also cause a portion of fastener 452 to melt. However, internal threading of fastener 452 is substantially unaltered by the spin welding operation in some embodiments.

A dual sided disc 470 is produced. The fastener 452 does not extend substantially on to either abrading face of the dual sided disc. In some embodiments, fastener 452 is thinner than the thickness of abrasive disc 454, such that it does not extend to at least one of the abrasive surfaces. In another embodiment, fastener is substantially the same thickness as the abrasive disc. In another embodiment, the fastener is thicker than the abrasive disc, and extends beyond at least one of the first and second abrasive surfaces.

However, it is noted that the bond between the fastener and the abrasive disc is substantially only present within the inner area of the center hole 454 and the outer area of fastener 452. Unlike previous coupling mechanisms for abrasive discs and BUPs, the fastener does not extend over, or couple, to, an abrading face of the abrasive disc.

FIG. 5 illustrates a dual sided attachment system for attaching an abrasive disc to a backup pad. The dual sided attachment mechanism 500 has a first side 510, and a second side 520. First side 510 is configured to attach to a BUP, using threads 512 for example, while second side 520 is configured to attach an abrasive disc, such as disc 470 by coupling threads 522 to the internal threads of a fastener.

Both first side 510 and second side 520 are illustrated with a locking mechanism 514, 524, respectively. Locking mechanisms 514, 524 are designed to prevent an abrasive disc from spinning off of second side 520 when a sanding tool is turned off.

In one embodiment, locking mechanisms 514, 525 are designed to selectively release the coupling between side 520 and an abrasive disc, such that when a time comes to change the abrasive disc, mechanism 500 stays coupled to a sanding tool or sanding tool back-up pad. In one embodiment, mechanism 500 is configured to snap into place when locking mechanism 514 engages a receiver within threading of a BUP. Similarly, in one embodiment, mechanism 500 snaps an abrasive disc into place when locking mechanism 524 engages a receiver within threading of an abrasive disc fastener.

FIG. 6 illustrates a sanding system in accordance with an embodiment of the present invention. Tool system 600 includes a power tool 610, a backup pad 620, and an abrasive disc 630.

Tool 610, in one embodiment is a pneumatic power tool with a power source 612 and an air source 614. However, other power tools 610 are expressly contemplated. Power tool 610, in one embodiment, is configured to rotate such that abrasive disc 630 rotates as it contacts a work surface. Tool 610 has a BUP coupling mechanism 616 that is configured to couple to BUP and cause it to rotate. Tool 610 may also have other features 618.

BUP 620 has a tool coupling mechanism 622 that couples to BUP coupling mechanism 616. BUP 620 is also configured to couple to abrasive disc 630, using attachment mechanism 640. BUP 620 may also have other features 628.

Attachment mechanism 640, in one embodiment, is built into BUP 620. In another embodiment, attachment mechanism 640 is removable from BUP 620. For example, attachment mechanism 640 may couple to BUP 620, for example using a threading system where attachment mechanism 640 has male threading that couples to female threading of BUP 620. Attachment mechanism 640 may also have one or more tool locking mechanisms 624, configured to keep attachment mechanism 640 coupled to BUP 620 and/or abrasive disc 630. Attachment mechanism 640 also has a disc coupling mechanism 626 configured to couple to abrasive disc 630.

Abrasive disc 630 has a first abrasive side 634 and a second abrasive side 636 separated by a thickness of abrasive disc 630. Abrasive disc 630 may be a nonwoven disc, a bonded abrasive disc, cloth buffing disc, foam polishing pad, or a coated abrasive disc with any suitable backing. Abrasive disc 630 may comprise any suitable abrasive disc with a center aperture that would benefit from a fastening mechanism to a tool, such as a unitized, convolute or molded wheel or disc as well as wire brush wheels, etc. Abrasive disc 630 also has a receiving mechanism 632 that receives disc coupling mechanism 626. In one embodiment, receiving mechanism 632 includes female threading that receives corresponding threading of disc coupling mechanism 626.

FIG. 7 illustrates a method of using a sanding system in accordance with embodiments herein. Method 700 may be useful for an operator of a sanding system. The sanding system may be manually operated by a human operator, or automated, using a sanding robot.

In block 710, an abrasive disc is removed from a tool. The abrasive disc may be a nonwoven abrasive disc 702, a bonded abrasive disc 704, or another abrasive or buffing or polishing article 706. Removing the abrasive disc is a toolless operation in one embodiment, as indicated by block 712. Toolless involves the operator (or a robotic unit) removing the disc from a backup pad without the need for a tool such as a screwdriver or any other special tooling. In one embodiment, toolless removal includes an operator twisting the disc with respect to the BUP, as indicated in block 714. Toolless removal may also require unlocking the abrasive disc from the backup pad. Unlocking may require an additional application of force.

In block 720, a disc parameter is changed. For example, the abrasive disc may have been used only on a first side and may be changed to expose a second side for abrading, as indicated in block 722. The abrasive disc may be removed in order to replace the back up pad, as indicated in block 724. The abrasive disc may also have another parameter adjusted, for example a relative positioning of the abrasive disc with respect to the backup pad may be changed.

In block 730, the abrasive disc is reattached to the backup pad. Reattachment, in one embodiment, is also toolless, as indicated in block 732. Reattachment may include twisting abrasive disc with respect to a BUP, as indicated in block 734. Reattachment may also include locking abrasive disc into place with respect to the BUP, for example by twisting the abrasive disc until a locking mechanism is engaged.

A dual sided abrasive article is presented that includes a first side with a first abrading face and a second side, with a second abrading face. The second side is opposite the first side and separated by a thickness. The article also includes a center hole extending from the first side to the second side through the thickness. The article also includes a fastener for coupling the abrasive article to a powered tool, the fastener positioned within the center hole.

The dual sided abrasive article may be implemented such that the article is a disc.

The dual sided abrasive article may be implemented such that the disc is a nonwoven abrasive disc.

The dual sided abrasive article may be implemented such that the disc is a bonded abrasive disc.

The dual sided abrasive article may be implemented such that the first abrading face and the second abrading faces are, respectively, a first and second coated abrasive article.

The dual sided abrasive article may be implemented such that the first abrading face and the second abrading face include abrasive grains of the same grade.

The dual sided abrasive article may be implemented such that the first abrading face and the second abrading face include abrasive grains of different grades.

The dual sided abrasive article may be implemented such that the first abrading face and the second abrading face have different backing material, different fiber type, or different abrasive grain composition.

The dual sided abrasive article may be implemented such that the fastener is spun weld within the center hole. S portion of the abrasive article is melted.

The dual sided abrasive article may be implemented such that the fastener is spun weld within the center hole. A portion of the fastener is melted.

The dual sided abrasive article may be implemented such that the fastener includes a thermoplastic.

The dual sided abrasive article may be implemented such that the fastener includes metal.

The dual sided abrasive article may be implemented such that the fastener is coupled to the center hole using an adhesive.

The dual sided abrasive article may be implemented such that the adhesive is a thermally activated adhesive.

The dual sided abrasive article may be implemented such that the fastener is ultrasonically welded into the center hole.

The dual sided abrasive article may be implemented such that the fastener includes internal threading configured to receive an attachment mechanism for coupling to a powered tool.

The dual sided abrasive article may be implemented such that the fastener is coupled to the abrasive article only along an interior surface of center hole.

The dual sided abrasive article may be implemented such that the first and second abrading faces are free of a coupling to fastener.

The dual sided abrasive article may be implemented such that a fastener thickness is smaller than the thickness.

The dual sided abrasive article may be implemented such that a fastener thickness is substantially the same as the thickness.

The dual sided abrasive article may be implemented such that a fastener thickness is larger than the thickness.

A method of making a dual sided abrasive disc is presented. The method includes providing an abrasive disc with a first abrading face and a second abrading face separated by a thickness. The abrasive disc includes an aperture in a center of the abrasive disc extending from the first abrading face to the second abrading face. The method also includes providing a fastener with a diameter substantially similar to an aperture diameter. Providing includes placing the fastener within the aperture. The method also includes spin welding the fastener into place. The fastener is bonded to the abrasive disc only within the aperture such that no bond is present between the fastener and either of the first or second abrading faces.

The method may be implemented such that the fastener includes a thermoplastic or a metal.

The method may be implemented such that the abrasive disc is a nonwoven, bonded or coated abrasive disc.

The method may be implemented such that spin welding causes the fastener to at least partially melt.

The method may be implemented such that spin welding causes the abrasive article to at least partially melt.

The method may be implemented such that it also includes applying an adhesive between the fastener and the abrasive disc.

An attachment mechanism for coupling an abrasive article to a backup pad is presented that includes a first side configured to couple to the backup pad and a second side configured to couple to the abrasive article. The attachment mechanism is a toolless attachment system, such that the abrasive disc is removeable without additional tooling.

The attachment mechanism may be implemented such that the first side includes male threading. The first side is configured to couple to the backup pad using the male threading.

The attachment mechanism may be implemented such that the second side includes male threading. The second side is configured to couple to a fastener within an abrasive disc using the male threading.

The attachment mechanism may be implemented such that it also includes a first locking mechanism present on the first side. The first locking mechanism engages when the first side male threading is fully engaged to female threading within the backup pad.

The attachment mechanism may be implemented such that it also includes a second locking mechanism present on the second side. The second locking mechanism engages when the second side male threading is fully engaged to abrasive disc female threading.

The attachment mechanism may be implemented such that the second locking mechanism is configured to unlock before the first locking mechanism unlocks, such that the attachment mechanism remains coupled to the backup pad when the abrasive disc is removed.

The attachment mechanism may be implemented such that the first side has a first indication, the second side has a second indication. The first and second indications are different.

The attachment mechanism may be implemented such that the indicators are colors.

The attachment mechanism may be implemented such that the indicators include text.

A sanding system is presented that includes a backup pad configured to couple to a tool, an abrasive article configured to abrade a workspace, and an attachment mechanism configured to removably attach, on a first side, to the dual sided abrasive article and, on a second side, to the backup pad.

The sanding system may be implemented such that the abrasive article is toollessly removable from the attachment mechanism.

The sanding system may be implemented such that the abrasive article includes a fastener with female threading that receive the attachment mechanism.

The sanding system may be implemented such that the fastener is spun weld within the abrasive article.

The sanding system may be implemented such that the fastener is bonded only to an interior of the abrasive article, such that no bond is present between a surface of the abrasive article and the fastener.

The sanding system may be implemented such that the fastener includes thermoplastic or metal.

The sanding system may be implemented such that the abrasive article is a dual sided abrasive article.

The sanding system may be implemented such that the abrasive article is a nonwoven, a bonded, a coated abrasive article, a buffing article or a polishing article.

The sanding system may be implemented such that the attachment mechanism has a first male threading on the first side and a second male threading on the second side.

The sanding system may be implemented such that the attachment mechanism has a first locking mechanism on the first side and a second locking mechanism on the second side.

The sanding system may be implemented such that the first locking mechanism is configured to release before the second locking mechanism releases, such that the attachment mechanism remains coupled to the backup pad when the abrasive disc is removed.

The sanding system of may be implemented such that the backup pad also includes a coupling mechanism to couple to a tool.

The sanding system may be implemented such that the tool is a power tool.

The sanding system may be implemented such that the tool is a pneumatic tool.

A method of using a sanding system is presented that includes stopping rotation of an abrasive article having a first abrading face opposite a second abrading face. The first abrading face is exposed, the abrasive article is coupled to a backup pad, which is coupled to a sanding tool, and where stopping rotation of an abrasive article includes stopping a rotary mechanism of the sanding tool. The method also includes removing the abrasive article. The method also includes reattaching the abrasive article such that a second side is exposed. Removing and reattaching the abrasive article are toolless operations.

The method may be implemented such that the abrasive article is coupled to an attachment mechanism which is coupled to the backup pad.

The method may be implemented such that the attachment mechanism includes a first side, that couples to the abrasive article, and a second side that couples to the backup pad.

The method may be implemented such that the first side includes a first male threading, received by a fastener within the abrasive article. The second side includes a second male threading.

The method may be implemented such that the first side includes a first locking mechanism that is configured to maintain a coupling between the abrasive article and the backup pad during the stopping step.

The method may be implemented such that the second side includes a second locking mechanism that is configured to maintain a coupling between the attachment mechanism and the backup pad during removal and reattachment of the abrasive article.

The method may be implemented such that removing includes twisting the abrasive article in a first direction with respect to the backup pad.

The method may be implemented such that reattaching includes twisting the abrasive article in a second direction with respect to the backup pad.

The method may be implemented such that the fastener is spun welded within a center hole of abrasive article.

The method may be implemented such that the fastener is bonded to the abrasive article only along an interior area of the center hole.

The method may be implemented such that the fastener includes thermoplastic or metal.

The method may be implemented such that the fastener partially melted during spin welding.

The method may be implemented such that the abrasive article is a bonded abrasive disc, nonwoven abrasive disc or a coated abrasive disc.

As used herein:

The term “a”, “an”, and “the” are used interchangeably with “at least one” to mean one or more of the elements being described.

The term “and/or” means either or both. For example, “A and/or B” means only A, only B, or both A and B.

The terms “including,” “comprising,” or “having,” and variations thereof, are meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

The term “adjacent” refers to the relative position of two elements, such as, for example, two layers, that are close to each other and may or may not be necessarily in contact with each other or that may have one or more layers separating the two elements as understood by the context in which “adjacent” appears.

All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently in this application and are not meant to exclude a reasonable interpretation of those terms in the context of the present disclosure.

Unless otherwise indicated, all numbers in the description and the claims expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviations found in their respective testing measurements.

The term “substantially” means within 20 percent (in some cases within 15 percent, in yet other cases within 10 percent, and in yet other cases within 5 percent) of the attribute being referred to. Thus, a value A is “substantially similar” to a value B if the value A is within plus/minus one or more of 5%, 10%, 20% of the value A.

Features and advantages of the present disclosure will be further understood upon consideration of the detailed description as well as the appended claims.

The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g. a range from 1 to 5 includes, for instance, 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within that range.

EXAMPLES

Abrasive Product Samples

• 1) Clean and Strip XT Pro web was cut into 3″ diameter discs with a 0.75″ center hole. Disc thickness is ˜0.5″.
• 2) Deburr and Finish Pro 6C MED+was die cut to 3″ diameter discs with a 0.75″ center hole. Disc thickness is ˜ 5/16″.
• 3) Lab made Skinny Strip, dual-sided abrasive discs, were die cut to 3″ diameter discs with a 0.75″ center hole. Skinny Strip has a combination of PET(66%) and nylon 6.6(33%) staple fiber. Disc thickness is ˜0.25″.

Spin Welding

Spin welding was done on an Allen-Bradley Servo motor model number 1326AB-B41OJ-21 or model number 1326AS B330H-21, with a 1394-AMO4 axis module, all available from Allen-Bradley Company, Inc. located in Milwaukee, Wis. A spin weld machine, such as that described in U.S. Pat. No. 5,931,729, was set in manual mode with a torque setpoint of 100, a speed limit of 65, a spin time of 0.55 seconds and a hold time of 0.90 seconds.

The spin time is preferably between about 0.25 seconds and 0.75 Seconds. The Spin time is a measurement of how long the motor is maintained under power from the time the Solenoid valve is Signaled to apply air pressure for the cylinder to move the fixture and fastener towards the abrasive disc (a travel distance of from approximately ⅛ inch to 13/16 inch), and ends with the command to remove power from the motor after the fastener contacts the abrasive disc.

Samples 1 and 3 were spun weld using 30 PSI of down force on the spin welder and settings in FIG. 1. The nylon Roloc™ threaded center posts were flush with the top and bottom surface of the abrasive sample. The outside of the surface of the center post and the abrasive article were joined by friction melt bonding.

Sample 2 was spun weld at a lower PSI down force. To spin weld the center post inside sample 2 20 PSI and settings in FIG. 1. The nylon Roloc™ threaded center posts were flush with the top and bottom surface of the abrasive sample. The outside of the surface of the center post and the abrasive article were joined by friction melt bonding.

Although the present disclosure has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the present disclosure.

Claims

1. A dual sided abrasive article comprising:

a first side comprising a first abrading face;

a second side, comprising a second abrading face, wherein the second side is opposite the first side and separated by a thickness;

a center hole extending from the first side to the second side through the thickness; and

a fastener for coupling the abrasive article to a powered tool, the fastener positioned within the center hole.

2. (canceled)

3. The dual sided abrasive article of claim 1, wherein the first abrading face and the second abrading face comprise abrasive grains of different grades.

4. (canceled)

5. The dual sided abrasive article of claim 1, wherein the fastener is spun weld within the center hole, and wherein a portion of the abrasive article or a portion of the fastener is melted.

6. The dual sided abrasive article of claim 1, wherein the fastener comprises a thermoplastic or metal.

7. The dual sided abrasive article of claim 1, wherein the fastener is coupled to the center hole using an adhesive.

8. The dual sided abrasive article of claim 7, wherein the adhesive is a thermally activated adhesive.

9. The dual sided abrasive article of claim 1, wherein the fastener is ultrasonically welded into the center hole.

10. The dual sided abrasive article of claim 1, wherein the fastener comprises internal threading configured to receive an attachment mechanism for coupling to a powered tool.

11. The dual sided abrasive article of claim 1, wherein the fastener is coupled to the abrasive article only along an interior surface of center hole.

12. The dual sided abrasive article of claim 1, wherein a fastener thickness is smaller than the thickness.

13. The dual sided abrasive article of claim 1, wherein a fastener thickness is substantially the same as the thickness.

14. The dual sided abrasive article of claim 1, wherein a fastener thickness is larger than the thickness.

15. A method of making a dual sided abrasive disc, the method comprising:

providing an abrasive disc with a first abrading face and a second abrading face separated by a thickness, wherein the abrasive disc comprises an aperture in a center of the abrasive disc extending from the first abrading face to the second abrading face;

providing a fastener with a diameter substantially similar to an aperture diameter, wherein providing comprises placing the fastener within the aperture;

spin welding the fastener into place; and

wherein the fastener is bonded to the abrasive disc only within the aperture such that no bond is present between the fastener and either of the first or second abrading faces.

16. The method of claim 15, wherein spin welding causes the fastener or the abrasive article to at least partially melt.

17. The method of claim 15, and further comprising applying an adhesive between the fastener and the abrasive disc.

18. An attachment mechanism for coupling an abrasive article to a backup pad, the attachment mechanism comprising:

a first side configured to couple to the backup pad;

a second side configured to couple to the abrasive article;

wherein the attachment mechanism is a toolless attachment system, such that the abrasive disc is removeable without additional tooling.

19. The attachment mechanism of claim 18, wherein the first side comprises male threading, and wherein the first side is configured to couple to the backup pad using the male threading.

20. The attachment mechanism of claim 19, wherein the second side comprises male threading, and wherein the second side is configured to couple to a fastener within an abrasive disc using the male threading.

21. The attachment mechanism of claim 20, and further comprising a first locking mechanism present on the first side, wherein the first locking mechanism engages when the first side male threading is fully engaged to female threading within the backup pad.

22. The attachment mechanism of claim 18, wherein the first side has a first indication, the second side has a second indication, and wherein the first and second indications are different.

23-36. (canceled)