Abrading – Flexible-member tool – per se
Reexamination Certificate
1998-12-15
2001-07-17
Rachuba, M. (Department: 3723)
Abrading
Flexible-member tool, per se
C451S533000, C451S534000, C407S029100
Reexamination Certificate
active
06261167
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to an abrasive tool, and in particular, a tool with two abrasive sides bonded to a core.
An abrasive tool may be used to sharpen, grind, hone, lap or debur a work piece or substrate of hard material, e.g., a knife. Such an abrasive tool may have a surface coated with abrasive grains such as diamond particles.
An abrasive tool having an abrasive surface with depressions, e.g., an interrupted cut pattern, is known to be effective for chip clearing when applied to various work pieces. Abrasive tools must be rigid and durable for many commercial and industrial applications.
SUMMARY OF THE INVENTION
In general, in one aspect, the invention features an abrasive tool, including a first perforated sheet having a front surface and a back surface, and a second perforated sheet having a front surface and a back surface. A first layer of abrasive grains is bonded to the front surface of the first perforated sheet and a second layer of abrasive grains bonded to the front surface of the second perforated sheet. A core is made of a first material, the core having a first surface and a second surface, the back surface of the first perforated sheet disposed adjacent to the first surface of the core and the back surface of the second perforated sheet disposed adjacent to the second surface of the core, the core being bonded to the first perforated sheet and the second perforated sheet by forming the core between the first perforated sheet and the second perforated sheet.
Implementations of the invention may include one or more of the following features. The core may be formed between the first perforated sheet and the second perforated sheet by injection molding, casting or laminating. The first material may include a plastic material, which may be a glass filled polycarbonate composite. The first material may include resin, epoxy or a cementitious material.
The first and second perforated sheets may have perforations that are counterbored or bevelled such that a portion of each of the perforations adjacent to the front surfaces of the sheets is wider than a portion of each of the perforations that is adjacent to the back surfaces of the sheets. The first material may be disposed within the counterbored or bevelled perforations to anchor the perforated sheets to the core.
The first and second perforated sheets may have perforations arranged to form an interrupted cut pattern. The first and second perforated sheets may have perforations in a portion less than the entirety of the sheets.
The first and second layers of abrasive grains may be bonded to the front surfaces of the first and second perforated sheets respectively by a plating material. The first and second layers of abrasive grains may have different degrees of abrasiveness.
The tool may be a file or a whetstone.
In general, in another aspect, the invention features a method of assembling an abrasive tool. A first perforated sheet having a front surface and a back surface and perforations therein, and a second perforated sheet having a front surface and a back surface and perforations therein, are provided. The back surfaces of the first and second perforated sheets are oriented to be spaced apart from and facing each other. A core is formed between the spaced apart back surfaces of the first and second perforated sheets. A first layer of abrasive grains is bonded to the front surface of the first perforated sheet, and a second layer of abrasive grains is bonded to the front surface of the second perforated sheet.
Implementations of the invention may include one or more of the following features. The core may be formed by injecting a first material between the spaced apart back surfaces of the first and second perforated sheets, and the first material is hardened. The first material injected between the spaced apart back surfaces of the first and second perforated sheets may flow into the perforations in the first and second perforated sheets. The core may also be formed by casting or laminating. The orienting step may include placing the first and second perforated sheets into a mold.
The method may also include grinding the front surfaces of the first and second perforated sheets. The bonding of the first and second layers of abrasive grains to the front surfaces of the first and second perforated sheets respectively may include electroplating, anodizing or brazing.
In general, in another aspect, the invention features an abrasive tool including a perforated sheet having a front surface and a back surface. A layer of abrasive grains is bonded to the front surface of the perforated sheet. A core is made of a first material and has a first surface, the back surface of the perforated sheet disposed adjacent to the first surface of the core, the core being bonded to the perforated sheet by forming the core adjacent to the perforated sheet.
In general, in another aspect, the invention features an abrasive tool, including a first sheet having a front surface, a back surface and a first anchoring member, and a second sheet having a front surface, a back surface and a second anchoring member. A first layer of abrasive grains is bonded to the front surface of the first sheet, and a second layer of abrasive grains is bonded to the front surface of the second sheet. A core is made of a first material, the core having a first surface and a second surface, the back surface of the first sheet disposed adjacent to the first surface of the core and the back surface of the second sheet disposed adjacent to the second surface of the core, the core being bonded to the first anchoring member of the first sheet and the second anchoring member of the second sheet by forming the core between the first sheet and the second sheet.
An advantage of the present invention is the ease and simplicity of using injection molding to form the core for the abrasive tool.
Another advantage of the present invention is the strength, durability, and dimensional stability of the abrasive tool, which allows for selection from a wide range of materials and yields desired properties.
Another advantage of the present invention is the high strength to weight ratios of the composite material used to form the core compared to any of the construction materials singularly.
Another advantage of the present invention is the economies of scale that can be achieved by fabricating a single tool with multiple abrasive surfaces.
A further advantage is the versatility of the abrasive tool, which may have varying shapes and different grades of abrasiveness for each of the surfaces.
Other features and advantages of the invention will become apparent from the following detailed description, and from the claims.
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Powell David G.
Watson Stanley A.
Diamond Machining Technology, Inc.
Kirkpatrick & Lockhart LLP
Rachuba M.
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