WO2002007901A1

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Info

Publication number: WO2002007901A1
Application number: PCT/US2001/023294
Authority: WO
Inventors: Alan Bertram Kingsbury; Richard Alan Dickson
Original assignee: Alan Bertram Kingsbury; Richard Alan Dickson
Priority date: 2000-07-25
Filing date: 2001-07-25
Publication date: 2002-01-31
Also published as: AU2001278998A1

Abstract

A flexible file (10) and its associated method for manufacture are presented. The flexible file (10) provides a frictional or scraping surface for abrading metals, plastics, wood, or almost any other substance and is particularly well suited for precise filing work. The flexible file includes an elongated, generally rectangular body having broad, flat, opposing faces and is comprised of a metallic substrate (16) coated with a layer of abrasive particles (14). In the first step of the method a hard, flexible, metallic substrate is provided. In the second step of the method of the invention, the metal substrate is texturized to increase its surface area. By using chemical or mechanical processes to create a highly texturized surface, a sufficiently irregular surface topography is created, which, when selectively coated with an outer protective layer or finish in the third step of the method, provides a stable, durable, and abrasive surface.

Description

FLEXIBLE FILE AND METHOD FOR MAKING IT

TECHNICAL FIELD

The present invention relates generally to abrasive devices and more specifically to methods for making coated files.

BACKGROUND ART

Numerous devices have been introduced for attaching frictional coatings on metal bases. Over the years, some of the most significant advances in the art have centered around the deposition of abrasive particles on metal bases by electroplating. However, none of the references herein described presents a flexible file and the associated method for manufacturing it, wherein the exterior surface of a flexible metal substrate, which has been specially texturized, is electroplated with abrasive particles.

Most prior art metal files have a filing surface produced by making fine grooves or the like on the metal surface. For such a file to cut, the metal used must be hard, and the file as a whole must be hard and stiff. Such a file is by its nature inflexible and brittle, and has a tendency to break in use.

U.S. Patent No. 863,389, issued to Harkin, discloses a flexible file comprising a series of transversely slotted, substantially rectangular shaped sections, each having beveled edges, a flexible support extending through the slots, a handle at each end of the support, and a spring means for positively maintaining the abutment of the sections. U.S. Patent No. 3,774,355, issued to Dawson et al . , relates to file band stock and the production thereof, comprising a flexible base metal strip having an adherent abrasive armoring coating produced in situ from abrasive particles of hard, high melting material. The high melting material is selected from the group consisting of metals, borides, nitrides, suicides, and particles of a matrix metal . The matrix metal particles in the armoring coating are fusion bonded to each other, to the base metal strip, and to the abrasive particles. The matrix metal particles partially embed and anchor the abrasive particles, with the metal particles projecting therefrom in the form of a series of sharp cutting edges, the armoring coating being preferably applied to the base metal strip in spaced regularly recurring pattern areas longitudinally of the strip. U.S. Patents No. 3,956,858 and No. 3,874,126 issued to Catlin et al . disclose a flexible base metal strip having an adherent abrasive armoring coating produced thereon in situ from abrasive particles of hard, high melting material selected from the group consisting of metals, borides, nitrides, suicides and combinations thereof. Also included in the high melting materials are particles of a matrix metal, the matrix metal particles being in the armoring coating and fusion bonded to each other, to the base metal strip, and to the abrasive particles to anchor and partially embed the abrasive particles therein in the form of a series of sharp cutting edges. Attachment means are provided at each end of the coated strip for attachment of the strip to a suitable frame such as a standard hack saw frame . When properly secured and tensioned in such frame, a small flexible hand held abrading tool is formed which is suitable for hand working materials having a high hardness so as to be unsuitable to be worked by prior art abrading tools .

U.S. Patent No. 4,497,694, issued to Bankier et al . discloses a method of making files which comprises stamping sheet metal into a plurality of fingers depending from a header strip, covering the fingers with a slurry of epoxide resin and abrasive grits, heat curing the epoxide resin to form a sheath around each finger with the abrasive grits firmly anchored therein, suspending a plurality of the sheath covered fingers from their header strips in a vacuum chamber, evacuating the chamber to degasify the sheaths on the fingers, melting a strike metal in the chamber, increasing the vacuum in the chamber below the vapor pressure of the molten strike metal, depositing a thin layer of the strike metal around each plastic sheath, acid etching the deposited strike metal on each finger, electroplating a hard metal layer around each etched strike metal layer, separating the fingers from the header strips, and applying a plastic handle over the separated ends of the fingers .

U.S. Patent No. 4,102,085, issued to Church et al . , discloses an abrasive coated sharpening tool and method of making it consisting of abrasive grains embedded and held in place in a ceramic-metal matrix, chemically bonded to a substrate such as a steel ore and method of making the same .

U.S. Patent No. 4,397,325, issued to Van Roeyen, discusses an abrasive article comprising a structural base, a coating of abrasive particle containing resin material on the base, and a sheath of plated metal overlying the resin coating and having thin frangible portions covering the peaks of the particles which are broken off during abrasion to expose the particles.

U.S. Patent No. 4,621,465, issued to Pangburn, discusses a flexible file having flexible abrasive sheets mounted on flexible flanges comprising a resiliently flexible file sheet having an abrasive surface, the sheet retained to one of the flanges so that the abrasive surface is outwardly presented, whereby the sheet when pressed against a fingernail flexes along with one flange and assumes the contour of the fingernail, the sheet being elongated in the direction of the handle .

British Patent (BR 770,329), granted to Cucumo, relates to a filing tool comprising a flexible toothed member constituted by an elongated strip of metal which is wound tightly onto a core. The strip of metal is wound onto the core in a plurality of helical turns, each of which contacts its adjacent turn or turns. The flexible toothed member is mounted on a carrier with its teeth partially in contact with the face of the carrier.

British Patent (BR 1,445,520), granted to Yasushi et al . , illustrates a tubular abrasive member. British Patent (GB

2,175,827 A), granted to Northey, depicts an abrasive strip cartridge file. And finally, the British Patent (GB 2,179,248 A) granted to Mann, shows a nail file and lubricant for use therewith.

None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.

DISCLOSURE OF THE INVENTION

A method is disclosed for making a flexible file. The method includes a step of providing a flexible metal substrate. The metal substrate is texturized. Another step is applying abrasive particles to the metal substrate . In a preferred embodiment, the metal substrate is selected from the group consisting of steel, steel alloys, stainless steel, and titanium. The method includes a step of pre-treating the metal substrate to remove surface contaminants. The abrasive particles are electroplated to the metal substrate. The abrasive particles may be selected from the group consisting of metal carbides, carbides, borides, diamond, metals, nitrides, silicides, and particles of a matrix metal . The method may also be used for coating metal parts.

Also part of the invention is a flexible file. The file includes a texturized substrate having a layer of abrasive particles deposited thereon. The abrasive particles may be selected from the group consisting of corundum, diamond, metals, metal carbides, borides, nitrides, silicides, and particles of a matrix metal .

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is an environmental, perspective view of a flexible file according to the present invention.

Fig. 2 is a fragmented view of the flexible file.

Fig. 3 is a block diagram of the method for making the flexible file.

BEST MODES FOR CARRYING OUT THE INVENTION

The present invention is directed to a flexible file and method for making the flexible file. However, the method may be used for providing an abrasive surface on any metallic structure. The flexible file and its associated method for manufacture provide a frictional device or scraping means for abrading metals, plastics, wood, or almost any other substance, according to the invention. The flexible file is particularly well suited for meticulous or precise abrasive work, requiring great care and accuracy. In the preferred embodiment of the invention, the flexible file comprises an elongated, generally rectangular body having broad, flat, opposing faces and is comprised of a metallic substrate coated with a layer of abrasive particles. The file may be of any size, shape, and thickness, and its end portions are preferably free so that the area between them is unsupported, allowing the file to be deformable to easily accommodate the curvature of items of different shapes.

In the first step of the method a hard, flexible, metallic substrate is provided. The metal substrate may be any sufficiently hard and flexible metal such as steel, steel alloys, stainless steel, and titanium. The metal may be shim stock. The thickness of the metal substrate is preferably .003 or .006 through .045 inches (.008 or .015 through .11 cm).

In the second step of the method of the invention, the metal substrate is texturized to increase its surface area. By using chemical or mechanical processes to create a texturized surface, a sufficiently irregular surface topography is created, which, when selectively coated with an outer protective layer or finish, provides a stable, durable, and abrasive surface.

In one embodiment of the invention, chemical etchants will be employed to create the texturized surface. In an alternative embodiment of the invention, the metal substrate is mechanically stamped. In a preferred embodiment, the metal substrate is sandblasted with aluminum oxide. Nevertheless, it should be understood that any similarly hard material may be used, including silicon, quartz, and sand. After being texturized, the metal substrate is coated with a layer of abrasive particles so as to improve wear-resistance. The abrasive particles are relatively coarse and are sharp and jagged in shape to present a good abrading surface .

The coated abrasive article, according to the present invention, can be in the shape of conventional coated abrasive articles, for example, belts, discs, sheets, and strips. But the most preferred shape is a file. The preferred embodiment of the file is depicted in Figs. 1 - 3 and is generally referenced by the numeral 10.

As diagrammatically illustrated in Fig. 1, the flexible file 10 can be used for filing or cleaning both delicate and heavy-duty mechanical instruments M. Furthermore, since the file 10 is flexible, it can be easily bent around objects of various shapes and designs, reaching even the most hard to reach places. And though the file 10 is primarily for use as a slot file, it may be employed on a variety of materials such as plastics, wood, or almost any other substance, though it is particularly well suited for use on metals. Thus, the flexible file 10 is a truly multipurpose instrument, suitable for even complex scientific and mechanical devices . The file is particularly suited for use in the textile industry.

Referring now to Fig. 2, in the preferred embodiment of the invention, the flexible file 10 comprises an elongated, generally rectangular body having broad, flat, opposing faces, each generally 12. The file 10 comprises a metal substrate 16 over which a layer of abrasive particles 14 is deposited, as best appreciated by the area fragmented or broken away. The detail of Fig. 2 also shows that the exterior surface of the metal substrate 16 is texturized.

In Fig. 2, the file 10 is again shown as being bent at its lower end, further illustrating its flexibility and resiliency. As indicated, the metal substrate 16 and overlying layer of abrasive particles 14 are substantially uniform in cross-section along the entire length of the file 10. The metal substrate 16 may be of any size, shape, and thickness. Also, the metal substrate may be any sufficiently hard and flexible^■ metal such as steel, steel alloys, stainless steel, and titanium. Nevertheless, any sufficiently hard and flexible metal may be used. And so softer metals, such as copper, should preferably be avoided to ensure that the file 10 has a tough edge for cutting.

In the preferred manufacturing of the files, a strip of steel is unreeled from a roll, sandblasted, sheared to length, and successively stamped to form a plurality of individual metal blanks . The metal blanks are then suspended in a tank and washed using a commercial type washing solution. This specification embraces all conventional manufacturing practices and the techniques commonly appreciated as necessary to manufacture a file, limited only by the parameters and requirements of the invention.

In the second step of the method of the invention, the outer surface of the metal substrate 16 is texturized to increase its surface area. It has long been recognized that roughening materials increases surface area for adhesion. By using specific methods to create a texturized surface, an irregular topography is created, which, when selectively coated with an outer protective layer or finish, provides a stable, durable, and abrasive surface.

The surprisingly good results obtained by the present invention may be ascribed to the degree of roughening of the surface and the durable, protective, outer layer deposited thereon. The chemical and physical characteristics of the metal substrate 16 determine which texturizing process should be used. Nevertheless, it should be understood that this specification embraces any means for texturizing, whether by the removal, treatment, or deposition of material substances in relation to the outer layer of the metal substrate 16, including sputter etching.

In one embodiment of the invention chemical etchants will be employed to create the texturized surface. Again, the chemical and physical characteristics of the metal substrate 16 will determine the appropriate etchants. Examples of chemical etchants include ferric chloride, ammonium persulfate, and sulfuric, hydrochloric, and nitric acid. Pretreatment to remove surface contaminants is especially important prior to chemical etching because overlying substances will interfere with inter-atomic adhesion.

In an alternative embodiment of the invention, the metal substrate 16 is texturized by being mechanically stamped. With stamping, progressive dies can be used to mechanically remove unwanted metal from the exterior surface of the substrate 16. In a similar method, the substrate 16 may be laser machined, photolithographed, or scraped in any manner to increase surface area. The step of stamping includes any physical method to increase surface area such as re-shaping the substrate under pressure and heat to form a texturized surface using an appropriately pitted, nano-pitted, or crenulated die. One such surface could include a crenulated surface, which may be defined as having an irregular wavy or serrated outline.

In yet another embodiment of the invention, the metal substrate 16 is texturized by being sandblasted. In the preferred embodiment, the sandblasting composition may be applied at a predetermined angle to the surface of the metal substrate 16. While corundum (aluminum oxide) has been found to produce the required result and is the preferred sandblasting material, it should be understood that this specification does not exclude any similarly hard material . Corundum is the second hardest substance after diamond and creates microscopic valleys in the metal substrate 16 when used as a sandblasting material.

As appropriate, the sandblasting material may contain any additional chemical agents for insuring its consistent application to the metal substrate 16 so as to provide a surface free of unwanted or excessive cratering, pitting, or uneven texturizing. The standard abrasive blasting system comprises a compressed air or gas source, a pressurized media vessel having standard pressure gauges, pressure regulators, media valves, a media orifice plate, air lines, and media exit lines.

After being texturized, the metal substrate 16 is coated with a layer of abrasive particles so as to improve wear-resistance. The abrasive particles are harder than the metal itself. In the preferred embodiment, the deposition bath comprises at least one nickel salt, such as nickel sulphate (NiS0₄) or nickel chloride (NiCl₂) , and a suspension of particles of a carbide. The coating of nickel and particles of carbide are preferably electrolytically deposited, by the application of an electric current. Electroplating is advantageous in that the timing and therefore the thickness of the abrasive layer can be precisely controlled. In an alternative embodiment of the invention, electroless plating may be used.

The flexible file 10 may also have multiple layers of abrasive particles or electrodeposited metals. The abrasive granules on one side of the file 10 may be selectively applied so as to be coarser or more dense than the granules on the other side of the file 10. The thin end edges, generally 18, of the file 10 are also preferably coated with granules. The granules are relatively coarse, sharp, and jagged so as to present a good abrading surface. In alternative embodiments, the abrasive material impregnated or deposited on the texturized surface may be selected from the group consisting of metals, borides, diamond, nitrides, silicides, and particles of a matrix metal.

It should be understood that this specification covers any chemical agents conventionally in use for insuring the proper electrodeposition of granules onto the texturized surface of the metal substrate 16.

In the preferred embodiment of the invention, the end portions, generally 20, of the file 10 are free, and the area between the end portions 20 is unsupported, so as to maintain a high degree of flexibility, allowing the file band to be deformable to accommodate the curvature of items of different shapes. This flexibility, in addition to the inherent flexibility of the metal substrate 16, is advantageous when working with materials of many different types. Nevertheless, in an alternative embodiment, the flexible file 10 may be provided with holder-engaging means such as a conventional saw frame so as to facilitate the task of shaping materials such as ceramics and fiber glass. The file may also have a cap or other gripping structure frictionally embracing an end thereof; the cap may be comprised of any material, but is preferably made of plastic or a similar polymeric substance .

As should be now clearly apparent from the features of the apparatus, various embodiments of the invention may include an operational method (100) for making a flexible abrasive device comprising the steps of : a) providing a flexible metal substrate (110) ; b) texturizing the metal substrate (120) ; and c) electrodepositing abrasive particles onto the metal substrate (130) .

The texturizing step (120) may include any of the steps of 1) texturizing by chemical etching (140) , 2) texturizing by sandblasting (150) and 3) texturizing by stamping (160) , as indicated by the lines 135. The arrows 115 and 125 merely represent flow indicators in the method (100) from one step to the next step, as particularly shown in Fig. 3 and described in the specification.

The preferred embodiments of the invention provide a multipurpose flexible file and a method for making the file. The file is an abrasive device. The file is an abrasive article comprising frictional granules electrodeposited onto an underlying, flexible structural base. The same principle may be used in coating wet rocks for sharpening knives or scissor blades.

The improved wear-resistance provided by coating a metal substrate with a layer of abrasive particles may also be used in coating metal parts where the primary aim is to improve their wear- resistance . For example, the blades of scissors may be texturized and then coated with abrasive particles harder than the metal of the blades themselves. The coating method is similar to the method described above. The surface of the metal part is texturized, and abrasive particles are electroplated to the surface of the metal part. However, less texture is generally required for this use than when preparing a file. A finer particle size is also appropriate where the primary purpose is extending wear.

It is to be understood that the present invention is not limited to the sole embodiments described above, but encompasses any and all embodiments within the scope of the following claims.

Claims

CLAIMSWe claim:

1. A method for making a flexible file, comprising the steps of:

(a) providing a flexible metal substrate;

(b) texturizing said metal substrate; and,

(c) applying abrasive particles to said metal substrate.

2. The method for making a flexible file of claim 1, wherein said providing step (a) is followed by a step of pre-treating said metal substrate to remove surface contaminants .

3. The method for making a flexible file of claim 1, wherein said texturizing step (b) comprises texturizing said metal substrate by chemical etching.

4. The method for making a flexible file of claim 1, wherein said texturizing step (b) comprises texturizing said metal substrate by sandblasting.

5. The method for making a flexible file of claim 1, wherein said texturizing step (b) comprises the step of texturizing said metal substrate by stamping.

6. The method for making a flexible file of claim 1, wherein said metal substrate is selected from the group consisting of steel, steel alloys, stainless steel, and titanium.

7. The method for making a flexible file of claim 1, wherein said applying step (c) includes electroplating abrasive particles onto said substrate .

8. The method for making a flexible file of claim 1, wherein said texturizing step (b) comprises re-shaping said metal substrate .

9. The method for making a flexible file of claim 1, wherein said applying step (c) includes depositing abrasive particles onto said substrate.

10. The method for making a flexible file of claim 9, wherein said abrasive particles are selected from the group consisting of carbides, metal carbides, borides, nitrides, silicides, diamond, metals, and particles of a matrix metal.

11. The method for making a flexible file of claim 10, wherein said applying step (c) includes electroplating abrasive particles onto said substrate, said electroplating occurs in a deposition bath, and said deposition bath includes at least one nickel salt.

12. The method for making a flexible file of claim 11, wherein said nickel salt is selected from the group consisting of nickel sulphate and nickel chloride.

13. The method for making a flexible file of claim 12, wherein said abrasive particles are composed of a carbide, and said deposition bath includes a suspension of said abrasive particles.

14. A method for making a flexible file, comprising the steps of:

(a) providing a flexible metal substrate, said metal substrate being selected from the group consisting of steel, steel alloys, stainless steel, and titanium;

(b) pre-treating said metal substrate to remove surface contaminants ;

(c) texturizing said metal substrate; and,

(c) electroplating abrasive particles to said metal substrate.

15. The method for making a flexible file of claim 14, wherein said texturizing step (b) comprises the step of texturizing said metal substrate by treatment with chemical etchants, said etchants being selected from the group consisting of ferric chloride, ammonium persulfate, and sulfuric, hydrochloric, and nitric acid.

16. The method for making a flexible file of claim 14, wherein said texturizing step (b) comprises the step of texturizing said metal substrate by sandblasting.

17. The method for making a flexible file of claim 14, wherein said texturizing step (b) comprises the step of texturizing said metal substrate by stamping.

18. The method for making a flexible file of claim 14, wherein said abrasive particles are selected from the group consisting of metal carbides, carbides, borides, diamond, metals, nitrides, silicides, and particles of a matrix metal.

19. The method for making a flexible file of claim 14, wherein said stamping step includes the step of re-shaping said metal substrate using heat and pressure .

20. A flexible file comprising a substrate, said substrate being composed of metal, said substrate being texturized, said substrate having a layer of abrasive particles deposited thereon, said abrasive particles being selected from the group consisting of corundum, diamond, metals, metal carbides, borides, nitrides, silicides, and^' particles of a matrix metal.

21. The flexible file of claim 20 wherein said layer of abrasive particles is electroplated on said substrate.

22. The flexible file of claim 20, wherein said substrate is selected from the group consisting of steel, steel alloys, stainless steel, and titanium.

23. The flexible file of claim 20, wherein said substrate is substantially rectangular in shape.

24. The flexible file of claim 20, wherein said substrate is composed of a highly deformable material, and said substrate has a thickness of 0.003 inches to 0.045 inches (0.008 to 0.11 cm).

25. A method for coating metal parts, comprising the steps of:

(a) providing a metal part, said metal part being composed of a metal selected from the group consisting of steel, steel alloys, stainless steel, and titanium;

(b) pre-treating a surface of said metal part to remove surface contaminants;

(c) texturizing said surface of said metal part; and,

(c) electroplating abrasive particles to said surface of said metal part .