Abstract
The Present Invention introduces novel methods and tools for improving the surfaces of metals and other flowable materials with smooth-surfaced tools, such as fibers and spheroids bonded to a ground. The new tools deform and compress rather than remove material, thereby increasing surface hardness, density, reflectivity, electrical conductivity, impermeability and corrosion resistance. Benefits include economies in production and maintenance, an improved work environment, and reduced costs for energy, stock materials and precious metal reclamation.
Claims
1. A method of reducing asperities on the surface of a workpiece comprising the steps of: providing a tool comprising a plurality of smooth-surfaced members of a material harder than the material of the surface of the intended workpiece, and a substantially rigid backing member, said smooth-surfaced members being affixed to said backing member; urging said tool against the asperities in said surface such that said smooth-surfaced members exert high local pressure on said asperities, while simultaneously moving said tool with respect to said surface; whereby said asperities are reduced by plastic deformation of the material of the workpiece, and without removal of the material of the workpiece.
2. (canceled)
3. The method of claim 1, wherein said smooth-surfaced members are spheroids.
4. The method of claim 3, wherein the material of said spheroids is selected from the group comprising metals, glass, carbides, and ceramics.
5. The method of claim 1, wherein said smooth-surfaced members are fibers.
6. The method of claim 5, wherein the materials of said fibers are selected from the group comprising metal, glass and carbon fibers.
7. The method of claim 5, wherein said fibers are provided in the form of woven cloth, nonwoven batts, wire, or screen.
8. (canceled)
9. The method of claim 1, wherein said backing member comprises a layer of a material selected from the group comprising paper, mesh, woven and non-woven fabric, resin impregnated fabric, felt, polymer film and foam, polishing cloth and metal.
10. The method of claim 1, wherein said backing member comprises a layer of a material selected from the group comprising films, belts, discs, cylinders, wheels, and flap wheels; non-woven pads; foam-backed cloth; and metal wools.
11. The method of claim 1, wherein the pressure at which the smooth-surfaced members urged against the surface to be treated is increased to the point that material of the surface is removed by adhesion to the smooth-surfaced members.
12. The method of claim 1, wherein said backing member is provided in the form of a contoured wheel.
13. The method of claim 1, wherein said backing member is provided in the form of a contoured disk.
14. The method of claim 1, wherein said backing member is provided in the form of a burr.
15. The method of claim 1, wherein said backing member is provided in the form of a pipe conditioning tool.
16. (canceled)
17. The method of claim 1, wherein said backing member comprises a layer of acrylic foam.
18. The method of claim 1, wherein the relative motion of the tool with respect to the workpiece is provided by affixing said backing member to a reciprocating tool.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0082] FIG. 1 Prior Art: Three traditional burnishing tools.
[0083] FIG. 2 Prior Art: A drawing from ROTARY BURNISHING TOOL U.S. Pat. No. 1,010,127.
[0084] FIG. 3 Prior Art: From a photomicrograph of one steel brush fiber of FIG. 14 showing the sharp, cutting end.
[0085] FIG. 4 Prior Art: A drawing from Fiberglass Scratch Brush, taught by U.S. Pat. No. 5,730,644, Blemish Repair Kit, which uses sharp ends of glass fibers for abrading a surface.
[0086] FIG. 5 Prior Art: A fiberglass disk embedded with resin as described in FIBRE-GLASS BURNISHING WHEEL at the Franklin Institute (image made by me). The cut ends at the disk's outer margin 501 abrade a surface.
[0087] FIG. 6 Prior Art: A drawing from Pangburn U.S. Pat. No. 5,361,786, 1994.
[0088] FIG. 7: A conceptual cross section of the smoothing process according to the invention.
[0089] FIG. 8 Prior Art: Manniglas® 1900 Non-woven Glass-fiber.
[0090] FIG. 9 Prior Art: From a Photomicrograph of non-woven glass fibers showing that the fibers are smooth.
[0091] FIG. 10 Prior Art: From a Photomicrograph of carbon fibers showing that the fibers are smooth.
[0092] FIG. 11 Prior Art: Non-woven fiberglass batting.
[0093] FIG. 12: Examples of perforated metal sheet.
[0094] FIG. 13: Cross section of woven fibers.
[0095] FIG. 14: Closeup view of stainless steel mesh.
[0096] FIG. 15: From a photomicrograph of flap peened parcel.
[0097] FIG. 16: From a photomicrograph of a parcel to be processed with a compound containing glass spheroids, before work showing intersection of scribed lines 1601.
[0098] FIG. 17: From a photomicrographic closeup of FIG. 16 showing intersection of scribed lines.
[0099] FIG. 18: Deforming the parcel of FIG. 47 with the compound containing glass spheroids.
[0100] FIG. 19: The parcel of FIG. 16 showing intersection of scribed lines processed with the compound containing glass spheroids, after work.
[0101] FIG. 20: From a photomicrograph of FIG. 20.
[0102] FIG. 21: From a photomicrograph of a parcel to be processed with standard polishing compound containing abrasive grains before work.
[0103] FIG. 22: From a photomicrograph of the parcel of FIG. 22 processed with polishing compound containing standard abrasive grains after work.
[0104] FIG. 23: Closeup of FIG. 23 showing intersection of scribed lines.
[0105] FIG. 24: View of brass 5 cm ø tube section with bead-blasted raw stock.
[0106] FIG. 25: Finish achieved on the tube section of FIG. 24 with an EVA disk with fiberglass cloth media.
[0107] FIG. 26: Finishes on a stainless steel parcel produced by a wheel comprised of smooth glass microbeads compared with the stainless steel surface of a Kenmore ELITE refrigerator produced by standard abrasives.
[0108] FIG. 27: Expandable drum spring coil tool with coiled steel media on a flexible core.
[0109] FIG. 28: An Almen strip type parcel being deformed perpendicular to the strip's length.
[0110] FIG. 29: An Almen strip type parcel being deformed parallel to the strip's length.
[0111] FIG. 30: An Almen strip type parcel held in a steel support being flap peened on a lathe.
[0112] FIG. 31: Comparison of parcels 2801, 2901 and 3001.
[0113] FIG. 32: From a photomicrograph of the pre-treated surface of parcel 2901.
[0114] FIG. 33: From a photomicrograph of the treated surface of parcel 2901.
[0115] FIG. 34: The Expandable Drum Spring Coil treating a pipe interior.
[0116] FIG. 35: Interior of a pipe with a failure near a joint.
[0117] FIG. 36: side view of the same failed pipe with failure.
[0118] FIG. 37: Cross section of a pipe interior with fissures.
[0119] FIG. 38: A computer simulation based on the image of FIG. 37 approximating the condition of the fissures treated with a tool of the present invention.
[0120] FIG. 39: A prototype tool comprised of a wheel with a coiled spring as the medium.
[0121] FIG. 40: Bead blasted brass casting with oxidized surface.
[0122] FIG. 41: Smooth media of various profiles.
[0123] FIG. 42: An element from a decorative brass candelabra part.
[0124] FIG. 43: The element from a decorative brass candelabra part being treated with a burr with fiberglass media.
[0125] FIG. 44: The assembled decorative brass candelabra part after treatment.
[0126] FIG. 45: Tooling of the present invention being used to treat the rust on a sanding machine platen.
[0127] FIG. 46: From a photomicrograph of the FIG. 46 tool surface after use.
[0128] FIG. 47: A tool formed by adhering a sheet of fiberglass fabric to a foam ground.
[0129] FIG. 48: A parcel treated with the tool of FIG. 47.
[0130] FIG. 49: A prototype comprised of woven carbon fiber fabric on a sheet of EVA foam.
[0131] FIG. 50: A tool formed by adhering a sheet of metal screen mesh to a ground.
[0132] FIG. 51: Edge view of a tool with woven fiberglass fabric as both medium and ground.
[0133] FIG. 52: Wire mesh tool with wrapped edges.
[0134] FIG. 53: A tool made of fiberglass building insulation impregnated with resin.
[0135] FIG. 54: Rotary tools comprised of spirals.
[0136] FIG. 55: Three tools comprised of woven carbon fiber mounted on EVA foam sheet at different angles.
[0137] FIG. 56: A brass tube divided into swatch segments.
[0138] FIG. 57: The brass tube of FIG. 56 being rotated on a lathe being treated with woven carbon fiber tools.
[0139] FIG. 58: The effects of the three tools of FIG. 55 on the brass tube of FIG. 56.
[0140] FIG. 59: Results of the three tools of FIG. 56.
[0141] FIG. 60: 1 mm glass beads embedded in acrylic binder on a ground.
[0142] FIG. 61: From a photomicrograph of FIG. 60.
[0143] FIG. 62: From a photomicrographic edge view of a tool comprised of multiple layers of glass beads on a fabric ground.
[0144] FIG. 63: A frying pan before using tool 6201 to remove burnt food.
[0145] FIG. 64: The pan of FIG. 63 after treatment with the multi-layer smooth tool.
[0146] FIG. 65: A chamois cloth with spheroidal media.
[0147] FIG. 66: From a photomicrograph of the glass microbeads bound to the chamois cloth of FIG. 65.
[0148] FIG. 67: A wheel type tool prototype comprised of EVA foam surfaced with glass microbead media.
[0149] FIG. 68: Closeup surface view of the wheel tool of EVA foam surfaced with glass microbead media.
[0150] FIG. 69: A prototype sponge with spheroids.
[0151] FIG. 70: From a photomicrograph of the sponge of FIG. 69's surface.
[0152] FIG. 71: An oscillating tool with a tool of the present invention.
[0153] FIG. 72: A fibrous tool of stainless steel mesh.
[0154] FIG. 73: A fibrous stainless steel mesh tool permanently integrated into to a standard oscillating tool backup pad.
[0155] FIG. 74: The oscillating tool pad of FIG. 73 being used to remove aged resinous finish.
[0156] FIG. 75: The wood surface of FIG. 74 with the aged varnish removed.
[0157] FIG. 76: A prototype spindle mounted wheel comprised of a wheel-form ground and woven fiberglass media.
[0158] FIG. 77: shows a cross section of a flexible edged disk.
[0159] FIG. 78: shows a prototype of the face of a PSA disk made of glass bead media.
[0160] FIG. 79: From a photomicrograph side section view of PSA disk of FIG. 78.
[0161] FIG. 80: A disk comprised of a semi-rigid, fiber reinforced disk with fiberglass media.
[0162] FIG. 81: A replaceable shell of the new invention with a backup wheel.
[0163] FIG. 82: A burr of the new invention.
[0164] FIG. 83: Another burr of the new invention.
[0165] FIG. 84: A burr of the new invention being used to burnish the inner bowl of a silver spoon.
[0166] FIG. 85: The spoon of FIG. 85 after processing with a new burr.
[0167] FIG. 86: A contoured wheel of the new invention mounted in a lathe chuck.
[0168] FIG. 87: A reversible contoured wheel with woven fiberglass media.
[0169] FIG. 88: The reversible contoured wheel of FIG. 87 from the lathe chuck side.
[0170] FIG. 89: The reversible contoured wheel of FIG. 87 with the wheel reversed on the arbor.
[0171] FIG. 90: A felt lapping wheel comprised of smooth media of the new invention on a lathe.
[0172] FIG. 91: A mill finish brass parcel finished with the lapping wheel of FIG. 90 showing the finished surface section.
[0173] FIG. 92: A wheel or buff comprised of flexible smooth media.
[0174] FIG. 93: A wheel comprised of EVA foam with metal mesh medium.
[0175] FIG. 94: A cross section of an Expandable Smooth Tool Drive Mechanism.
[0176] FIG. 95: A prototype composite wheel made of epoxy and spheroids, with a test parcel.
[0177] FIG. 96: A side view of the prototype composite wheel of FIG. 95.
[0178] FIG. 97: From a photomicrograph of the surface of the prototype composite wheel of FIG. 95.
[0179] FIG. 98: From a photomicrograph of a parcel before treatment with the composite wheel of FIG. 95.
[0180] FIG. 99A: From a photomicrograph of the parcel of FIG. 98 after treatment with the composite wheel of FIG. 95.
[0181] FIG. 99B: From a photomicrograph of waste water lubricant containing the material removed by Controlled Adhesion from the parcel of FIG. 99A.
[0182] FIG. 100: A section of a belt comprised of a flexible, or non-flexible, fabric or film ground with parcels comprised of a matrix with multiple embedded smooth media.
[0183] FIG. 101: An acrylic foam block with glass bead media.
[0184] FIG. 102: A magnified view of the acrylic foam block with glass bead media.
[0185] FIG. 103: From a photomicrograph of the acrylic foam block with glass bead media showing the individual glass media and acrylic binder.
[0186] FIG. 104: A scrub brush of the prior art with bristle tips of smooth media.
[0187] FIG. 105: A detail of the scrub brush of the prior art with bristle tips of smooth media.
[0188] FIG. 106: From a photomicrograph of the scrub brush of the prior art with bristle tips of smooth media.
[0189] FIG. 107: Grouped smooth ended bristles of a metal work brush.
[0190] FIG. 108: From a photomicrograph of a smooth ended bristle of a metal work brush.
[0191] FIG. 109: A brush back with embedded glass fibers with spheroidal ends.
[0192] FIG. 110: shows a brush configuration common in the prior art comprised of a handle and ferrule, but with fibers comprised of spheroidal ends.
[0193] FIG. 111: A spheroid attached to a rod, fiber or bristle with a matrix, or tool holder.
[0194] FIG. 112: A prototype smooth media compound.
[0195] FIG. 113: From a photomicrograph of the prototype smooth media compound.
[0196] FIG. 114: A test object before treatment with slurry comprised of smooth media on a glove.
[0197] FIG. 115: Burnishing with slurry comprised of smooth media on a glove.
[0198] FIG. 116: A glove after being used with standard metal polish, with characteristic black residue comprised of silver metal abraded, and eroded from, the test object's surface.
[0199] FIG. 117: A tool made with a felt covered stick wrapped with beaded chain smooth media.
[0200] FIG. 118: A composite wheel made of assembled lamina, a single lamina and a side view of one possible form at a lamina's outer margin.
DETAILED DESCRIPTION OF THE INVENTION
Surfaces Produced by the New Tools
[0201] The basic principle of my novel method of finishing surfaces is the use of tools comprised of smooth elements bonded to a ground urged against and moved along a workpiece surface to smooth asperities in the surface by plastic deformation. The structure of the tools and mechanisms employed to move the tool with respect to the surface of the workpiece are generally similar to abrasive papers, belts, discs and wheels of the prior art. However, the new tools produce surfaces that are not achievable with those tools of the prior art.
[0202] The functions of the invention's three elements—smooth media, binder and ground—can be performed by separate materials, or materials that are able to serve two or all three of the functions. One example of material serving multiple functions is fiberglass cloth, which can act as both a smooth medium and ground.
[0203] A variety of finishes are achieved by varying the tools' speed and pressure. The new finishes can replace current finishes achieved in the prior art by abrasives, and also contribute a series of new, previously unachievable, finishes. While the tool forms which follow are comprised with one type of smooth media, the forms are manufacturable with a variety of smooth media made of any material harder than the intended workpiece, and attached to the ground in any useful manner.
[0204] To recall, the present invention's basic principle is graphically described in FIG. 7, which is a conceptual cross section illustrating the process of altering a surface by plastic deformation. Prior to treatment, a workpiece 701 exhibits asperities 702 on the surface, for example, with tool marks remaining after a machining operation. A smooth-surfaced tool 703 is urged against the workpiece with significant force as indicated at 704, while being moved along the surface as indicated at 705.
[0205] As smooth tool 703 is urged against and moved along the surface, the force exerted by the tool 703 on the asperities 702, as indicated by arrows 707, causes the asperities 702 to be pressed into the work surface by plastic deformation. Forces indicated by arrows 708 are transferred into the workpiece as indicated at 709, resulting in the smoothed area after work as shown at 710. It is important to understand that materials which flow, such as ductile metals, allow the material of the asperities to flow into the workpiece mass, so that the material of the asperities or high spots flows into the adjoining low spots, effectively smoothing the surface.
[0206] Significantly, the friction between the workpiece and the tool 703 at the interface 706 is intentionally minimized compared to abrasives, for which friction at the interface is intentionally maximized. According to design, lubricants may or may not be used to control friction at the interface 706.
[0207] Thus, the invention comprises a method of smoothing a surface of a given object exhibiting asperities by plastic deformation, the method first comprising the step of making a tool by affixing a plurality of smooth-surfaced members of a material harder than the material of the surface of the intended work object to a substrate, and then urging the smooth-surfaced members against the asperities on that surface with substantial local pressure, and simultaneously moving the tool with respect to the surface, so that the asperities are reduced, and the surface is smoothed, by plastic deformation. At the same time, the surface may be compressed to a degree by force exerted on the atoms of the surface by the smooth-surfaced members.
[0208] FIGS. 16 through 23 demonstrate of the new tools' ability to create reflective surfaces without removing design details.
[0209] FIG. 16 shows a parcel, before processing as shown in FIG. 19, of mill finished copper with intersecting lines scored with a pointed tool at 1701.
[0210] FIG. 17 is from a photomicrograph of the pre-processed lines' intersection 1701.
[0211] FIG. 18 shows the parcel of FIGS. 17 and 18 being burnished on a lathe with compound containing smooth media.
[0212] FIG. 19 shows the results of the burnishing process; a smoothed surface with no loss of detailing at the lines' intersection 1701.
[0213] FIG. 20 is from a photomicrograph of the burnished parcel at the lines' intersection 1701. Note that my current invention has burnished the metal surface of the parcel and improved the definition of the scratches at the intersection by removing loosely adherent burrs while not eroding the edges of the lines.
[0214] FIG. 21 shows, for comparison, a parcel before processing with standard abrasive compounds, of mill finished copper with intersecting lines 2201 scored with a pointed tool.
[0215] FIG. 22 is the parcel of FIG. 22 after polishing at 3450 RPM with White Diamond and then Black Rouge abrasive compounds. The effects of erosion on the definition of the scratches compared to my present invention in FIGS. 20-21 is clear. Note the intersections at 2201.
[0216] FIG. 23 is from a photomicrograph of the polished parcel of FIG. 22 at the intersecting lines 2201 in which the vertical line is largely obliterated compared to the similar line in FIGS. 20 and 21 which is finished with the new compound of the invention. It is apparent that use of the method of the invention provides advantages with respect to conventional finishing techniques; the compound of the new invention has improved the surface while preserving the scored lines, which in practice would be logos and texts inserted into the metal before finishing.
[0217] FIGS. 24 and 25 demonstrate the ability of smooth sided flexible burnishing tools to create new types of finishes which approximate surface finishes heavily used in industry in the prior art, but without stock removal.
[0218] FIG. 24 shows the raw finish produced on a brass 5 cm ø tube section by bead-blasting @ 80 psi with #6 glass beads.
[0219] FIG. 25 shows the finish achieved on the section of FIG. 52 with an EVA disk with fiberglass cloth media according to the invention @ 490 M/min.
[0220] FIG. 26 shows a comparison of finishes produced by a wheel according to the invention comprised of glass microbeads on a stainless steel parcel, and the finish on a Kenmore ELITE stainless steel refrigerator case. View A shows the stainless steel parcel being worked with the wheel. B shows the face of the parcel after work with the new wheel. C is a closeup of the surface produced by the new wheel in A and B. D shows the existing surface of the Kenmore ELITE refrigerator revealing that a similar finish has been produced by the new tool, but with little or no waste byproduct and a more compact work surface.
Burnishing to Improve Metal Structure
[0221] Surfaces worked with tools of my present invention are improved similarly to surfaces created by peening in the prior art, e.g., the replacement of tensile stress in metal with compressive forces. However, since my new tools operate by moving along a surface under high local pressure rather the textured surface generated by roto-peening shown in FIG. 16, my new tools create a burnished worked surface with superior qualities.
[0222] In FIGS. 27 to 32, parcels 2901, 3001, and 3101 were made of 0.013″ brass cut to the same size as standard Almen strips as used to evaluate the amount of peening provided in a standard peeing operation; see Winter et al U.S. Pat. No. 3,778,241. Each strip was worked for one minute by hand. The resultant structural qualities and surface appearance depends upon the pattern of the media comprising the burnishing tool.
[0223] FIG. 27 shows an expandable drum spring coil tool according to the invention. This design takes advantages of the expandability of coils 2801 to operate in pipes and holes, and the flexibility of the tool core 2802 in adapting to workpiece contours. The core in this prototype is of a polymer foam which is part of a holder for abrasive cylinders of the prior art. However, the expandable drum may be comprised of other materials and methods.
[0224] FIG. 28 shows an Almen strip type parcel held in a steel support being burnished perpendicular to the strip's length 2901 with the tool of FIG. 28 on a lathe turning at 2450 RPM.
[0225] FIG. 29 shows an Almen strip type parcel held in a steel support being burnished parallel to the strip's length 3001 with the tool of FIG. 28 on a lathe turning at 2450 RPM.
[0226] FIG. 30 shows an Almen strip type parcel 3101 held in a steel support, being flap peened on a lathe at 3450 RPM. The flap peeing device is a 3M Roto Peen Flap Assembly.
[0227] FIG. 31 compares parcels 2901, 3001, and 3101. Parcel 2901 shows that burnishing perpendicular to the strip's length results in a convex arch, indicating selective stress modification predominantly along the axis of the strip perpendicular to the strip's length. Parcel 3001 shows that a concave arch results from burnishing parallel to the length of the strip, indicating selective stress modification predominantly parallel to the length of the strip. Parcel 3101 shows that flap peening with the 3M Roto Peen Flap Assembly results in a pillow form indicating stress modification of the strip in all directions relative to the length of the strip. Burnishing provides the option of applying stress relief selectively to a workpiece by controlling for the direction of the burnishing process.
[0228] Regarding fluid flow, the surface texture created by flap peening creates resistance, while burnishing produces a surface with improved fluid flow, contributing to the maintenance of oil and gas wells, high pressure steam and gas turbines, nuclear reactors and other systems where optimal fluid flow is critical. As an example, the following article in the EJournal of Advanced Maintenance site; jsm.or.jp/ejam/Vol.2.No.2/GA/13/article, which is concerned with the most advanced reactor maintenance processes, now addresses PWSCC (Primary Water Stress Corrosion Cracking) with existing peening technologies. My Present Invention is a substantial contribution to their processing options.
[0229] The effectiveness of my new invention in improving fluid flow is shown in the following two images:
[0230] FIG. 32 is from a photomicrograph of the pre-treated surface of parcel 3001.
[0231] FIG. 33 is from a photomicrograph of the treated surface of parcel 3001 on which burnishing has been done parallel to the direction of work, resulting in a smooth surface—an improvement in fluid flow quality over the textured flap peened surface of parcel 3101.
Improved Cleanliness in the Medical and Food Industries
[0232] Tools of my present invention close fissures in surfaces, making them more impervious to organic foreign matter ripe for contamination by microorganisms in, for example, food and hospital machinery.
[0233] Currently, the recommended procedure for finishing in the medical and food industries is the #4 Dairy or Sanitary Finish:
[0234] From ofrmetals.com: [0235] ‘Great care should be taken in removing the surface defects in the metal, like pits, that could allow bacteria to grow. #4 Dairy or Sanitary Finish, which is commonly used for the medical and food industry and almost exclusively used on stainless steel. This finish demands great care in removing surface defects like pits, that could allow bacterial growth.’ and, ‘a #4 Dairy or Sanitary Finish is produced by polishing with a 180-240 grit belt or wheel finish softened with 120-240 grit greaseless compound or a fine non-woven abrasive belt or pad.’
[0236] Despite the above recommendation, it is my opinion that the traditional abrasives described above do not seal pits that harbor microorganisms. While cutting away the surface material may remove shallow pits, the material removal also may expose fissures that lurk deeper in the metal body, exacerbating the opportunity for infestation.
Burnishing for Pipes and Tubes
[0237] My Present Invention improves the production of pipes by burnishing and compressing their inner surfaces rather than, as happens during abrasive polishing, removing the surface material and therefore exposing subsurface pores. Burnishing also improves the quality of the welds used to join pipe sections by reducing stress in the weld zone. During maintenance, burnishing cleans and smooths a pipe in the same action while simultaneously reducing porosity, thereby retarding corrosion and microbial infestation, thereby extending the effective maintenance interval. Peening, which also reduces surface pores, creates a rough, flow-resistant surface, while burnishing reduces surface pores while creating a smooth surface with improved flow qualities.
[0238] FIG. 34 shows the Peenburnishing tool of FIG. 28 being used to maintain a pipe interior. Area 3501 has been processed with the tool,
[0239] FIG. 35 shows the interior of a failed pipe near a joint. 6701 is the crack.
[0240] FIG. 36 shows a side view of the same failed pipe. 6701 is the crack.
[0241] FIG. 37 shows a cross section with fissures 3801 from METALLURGICAL TECHNOLOGIES, INC., P.A. at: met-tech.com/preheater-tube-failure, of a pipe interior: [0242] ‘The 316Ti stainless steel tube cracked by transgranular stress corrosion cracking due to the presence of sulfur and chlorine in a moist environment at elevated temperatures.’
[0243] It is my opinion that manufacturing and maintaining the pipes in FIGS. 35, 36 and 37 with tools of the new invention reduces the fissures and the consequent corrosion and structural col lapse.
[0244] FIG. 38 is a computer simulation by me, based on FIG. 37, of what this cross section might have looked like at the same point in its life, had the part been treated with the new tooling. The fissures 3901 would have been eliminated during manufacture or reduced with maintenance.
Burnishing for Cast Metal Finishing
[0245] Porosity in metal castings is an inherent vice. Standard abrasive grinding and polishing creates a finish that erroneously implies that pores have been reduced or eliminated. To the contrary, sub-surface voids are actually opened, exposing the cast's interior to invasion by chemical or organic elements. In contrast, treatment withs the new tooling according to the invention creates an improved surface while reducing or closing the pores, isolating the casting's interior voids from the outside environment.
[0246] FIG. 39 shows a prototype tool comprised of a wheel 3901 with a coiled spring 3902 operating as the medium—useful for general surface smoothing by burnishing. While this prototype is made with the media at the wheel circumference, media may optionally be arrayed on any face of the wheel, and the wheel may be of any profile, as I discuss in the section on contoured tooling, below.
[0247] FIG. 40 shows a 15 cm long bead blasted brass casting with oxidized surface. The right side 4101 is the raw casting with naturally occurring oxides. The left side 4102 is finished with the coiled spring burnisher of FIG. 27. Some of the brittle surface oxides were removed, a lustrous surface was created with little loss of surface detail, and pores were closed. The oval on the viewer's right is the sprue cutoff unrelated to the invention.
[0248] FIG. 41 shows burnishing media of various profiles 4201 bonded to a wheel edge. The tool is an improvement upon the prior art of FIG. 2 ROTARY BURNISHING-TOOL U.S. Pat. No. 1,010,127, in that the burnishing elements are of a variety of forms beyond steel spheres, and are affixed to the wheel with adhesives and mechanical methods beyond being locked in races. The elements may be of any useful profile, and arrayed across a tool in any useful arrangement.
Electroplating
[0249] I first created the new tools to treat plated objects. As compared to abrasive polishing, the new tools remove either no, or dramatically less, material, leading to substantial reduction in the needed thickness of deposited metal plate, substantially less processing time and more efficient use of equipment, while the produced plated parts benefit from improved surface density and reduced porosity. The following Figures explain this more fully.
[0250] FIG. 42 shows an element from a decorative brass candelabra part.
[0251] FIG. 43 shows the same part being treated with a burr with fiberglass media according to the invention after having been immersion plated—an extremely thin, weak type of plating. With standard abrasive polishing techniques this plate layer would have instantaneously disappeared due to abrasive erosion.
[0252] FIG. 44 shows the finished, assembled candelabra part. The plate, although extremely thin and weakly adherent, is satisfactorily burnished.
Enhancing Surfaces by Burnishing, Instead of Removing, Oxides
[0253] While hard, brittle oxides are removed with the new tools by adhesion, non-adherent, softer oxides such as rust are also removed. However, the oxide molecules adhering to the iron substrate remain, resulting in a more passive surface on the treated workpiece with reduced tendency toward further oxidation.
[0254] FIG. 45 shows a sheet of the new tooling wrapped onto a sanding block being used to clean the rusty surface of a sanding machine platen. Treating oxidized surfaces with the new tooling removes the loose oxide and compresses the adherent, passive, protective oxides surface oxides, leaving the surface resistant to further oxidation compared to the raw metal surface produced by abrasive or chemical cleaning.
[0255] FIG. 46 From a photomicrograph of the FIG. 45 tool surface shown after work. While some residual oxide of the work remains, in contrast to abrasive media which would be eroded, the glass bead burnisher media remains entirely serviceable.
Fibers as a Burnishing Medium
[0256] Filaments of glass, carbon fiber and other smooth materials operate as media for the new tools. Fibers assembled as woven, non-woven and knitted fabrics, or made individually into spirals such as springs, present multiple burnishers to a surface in the form of many smooth high points. Such fibers modify the work surface according to the radius of each fiber at the point of intersection with the work and the resultant pressure at the point of contact. In contrast to these smooth fibers are steel wool fibers, which are scrapers.
[0257] FIG. 47 shows a tool formed by adhering a sheet of fabric to a ground, in this case, fiberglass cloth 4701, bonded with low viscosity epoxy resin to 1 mm thick EVA foam 4702.
[0258] FIG. 48 shows a parcel treated with the tool of FIG. 48. Note the burnished quality of the treated area 4801.
[0259] FIG. 49 shows a prototype comprised of woven carbon fiber fabric 4901 consolidated with resin on a 10 mm sheet of EVA foam 4902.
[0260] FIG. 50 shows the prototype of a tool comprised of stainless steel screen mesh bonded to an EVA foam pad with low viscosity epoxy resin. The screen mesh may be of any weave and gauge. The ground may be of any useful material.
Smooth Media made of Perforated and Expanded Sheets
[0261] FIG. 13 shows perforated and expanded sheets with the smooth faces between the openings functioning as the media. Different shape openings and edges effect the burnishing process in various useful ways.
Unbacked Media
[0262] FIG. 51: In this tool, the medium, in this case woven fiberglass fabric, serves also as the ground. The binder is low viscosity epoxy resin.
[0263] FIG. 52: While many smooth media according to the invention are supple at tool edges, metal screen meshes may be sufficiently rigid at the edges to damage the work. As an example of an embodiment which addresses this issue, the edges and the corners in this prototype are wrapped to avoid damage to the work surface.
[0264] FIG. 53 shows a batt of fiberglass building insulation impregnated with low viscosity epoxy resin to produce a tool of the new invention. The medium, in this case woven fiberglass fabric, also serves as the ground.
[0265] FIG. 54 shows rotary tools comprised of spirals of any usable material, an example being metal spring stock. 5401 shows circumferential spirals, 5402 shows radial spirals.
[0266] FIG. 28 shows a non-woven sheet of Manniglas 1900 used for insulation in the prior art. Now, impregnated with low viscosity epoxy, the fiberglass material becomes a new tool with itself as the ground.
Fabric Bias and Smooth Media Tools
[0267] The attack angle of smooth sided fiber tooling according to the invention relative to a workpiece creates a continuum of useful qualities, from moderate burnishing with the fibers moving parallel to the work, to maximum burnishing with the fibers moving at 90° to the work. The effect of smooth sided fiber tooling depends on the pressure of the tool on the work, the weave, knit, or non-woven configuration of the fabric, the fabric's fiber density and the quantity and type of lubrication, if any, between the fiber tool and the work.
[0268] FIG. 55 shows three tools comprised of a heavier carbon fiber warp bound with a weft of thinner material present in the cloth only to bind the carbon fibers together. The fabric is mounted on EVA foam sheet, with the carbon fibers parallel to the length of the tool 5501, at 45° to the length of the tool 5502, and perpendicular to the length of the tool 5503.
[0269] FIG. 56 shows a 5 cm ø brass tube divided into swatch segments and oxidized to emphasize, in the experiments below, the effect of the tools on the swatches.
[0270] FIG. 57 shows the tube of FIG. 57 being rotated on a lathe with the tools of FIG. 56 operating on the rotating tube at ˜60 M/m, which is very slow for finishing speeds in the prior art. As explained below, tap water was employed as a lubricant for some of these tests.
[0271] FIG. 58 shows the cylinder of FIG. 57. after work.
[0272] FIG. 59 shows the effects of the alignment of the weave and employment of water as a lubricant. Specifically in swatches 5901 the fibers of the tool are parallel to the direction of motion, and lubricant is applied with swatch 5901w (for “wet”) and is not applied with swatch 5901d (“dry”). In swatches 5902 the weave is at 45° to the direction of work, and in swatches 5903 the direction of work is perpendicular to the fibers. Thus, FIG. 59 illustrates that that a particular tool can be customized to a particular work according to the weave and the option of lubricated and un-lubricated work, to produce varying degrees of lustre and smoothing, and different surface patterns, according to the design and operation of the fabric burnisher. The surface oxides have been progressively removed because the oxides are brittle and do not flow, i.e., deform, and therefore are separated from the surface by adhesion.
Spheroids and Other Smooth Faced Particles as Media
[0273] In addition to the use of smooth fibers as burnishing media, surface improvement is achieved by the use of smooth surfaced particles of any material harder than the intended workpiece, examples being spheroids of glass, zirconium, ceramic, steel, plated steel and polymers such as polypropylene, and attached by any adhesive means such as used in the prior art to affix adhesive particles to a ground such as paper, woven or non-woven fibers, polymer films and foams.
[0274] FIG. 60 shows 1 mm glass beads embedded in acrylic binder on a ground. My finger, left, gives a sense of scale.
[0275] FIG. 61 is from a photomicrograph of the 1 mm glass beads embedded in acrylic binder of FIG. 61.
[0276] FIG. 62 is from a photomicrographic edge view of an embodiment 6201 comprised of multiple layers of glass beads 6202 on a fabric ground 6203 with an acrylic binder. The resultant tool is a tough, bendable sheet. According to the binder used, the internal strength of the bead layers may also serve as the ground, making the fabric ground optional.
[0277] FIG. 63 shows a frying pan 6301 before using tool 6201 to remove burnt food from area 6303. While the new tools improve the surface of a cooking implement, waste material adhered to the surface of the implement is dragged away from the pan surface by adhesion.
[0278] FIG. 64 shows a small section of the pan 6301 after treatment with the multi-layer burnishing tool 6201, the area 6202 having been cleaned of the burnt food.
[0279] FIG. 65 is a chamois cloth with spheroidal media 6501 applied to the cloth's surface.
[0280] FIG. 66 is from a photomicrograph of the glass microbeads bound to the chamois cloth of FIG. 66 with spray adhesive.
OTHER EMBODIMENTS
[0281] In addition to the embodiments described above, the following describe tools and prototypes which, although made with a particular medium of the present invention, may be used with any applicable medium of the present invention.
[0282] FIG. 67 is a wheel type tool prototype comprised of EVA foam surfaced with media in the form of glass microbeads.
[0283] FIG. 68 shows the surface of the tool of FIG. 67, the binder of which has, through work, fractured into islands having cross dimensions of approximately ˜1-5 mm. These islands, which remain attached to the EVA disk ground, operate as reinforcements for retaining the spheroids on the surface thereby extending the tool's life while allowing flexibility at the tool's surface. The islands may also be created during manufacture by segmentation of the binder and media.
[0284] Burnishing media may also be secured to a metallic ground by brazing, similarly to the process described in HIGH-INTENSITY ROTARY PEENING PARTICLE SUPPORT AND METHOD OF MAKING SAME U.S. Pat. No. 5,179,852 A.
[0285] FIG. 69 shows a prototype sponge with spheroids bonded to the sponge surface with acrylic emulsion, after approximately six hours of kitchen use. It is my opinion that this embodiment improves on 3M abrasive pads with sponge backing by my present invention's aggressive ability to remove soil from a surface without removing material from the substrate.
[0286] FIG. 70 is from a photomicrograph of the sponge of FIG. 70 showing the rinsed sponge surface after a week used in a kitchen sink. Note the cleanliness and durability of the surface relative to sponges of the prior art.
[0287] Yet another tool of the prior art, the Blitz Silver Polishing Cloth—93118WEB, is comprised of a cloth embedded with abrasives. By replacing the abrasives with smooth media, burnishing is achieved without erosion of the workpieces' surfaces as occurs with the abrasive-embedded cloths. As a result, precious metals are not removed, engraving details are not degraded, and plated films are not eroded by repeated polishings to the point of complete removal of the plated layer and subsequent exposure of the metal substrate. Such cloths may be made of fiberglass of other smooth fabric. Cloths of my present invention may also be infused with thiourea or other chemical tarnish removers.
[0288] FIG. 71 shows an embodiment for an oscillating tool with a tool of the new invention comprised of fiberglass 7201 with a hook-and-loop back attachment commonly used in the prior art, and which is interchangeable with pressure sensitive adhesives and other backup pad connectors.
[0289] FIG. 72 shows a fibrous tool of stainless steel mesh 7201 with a hook-and-loop back attachment (in the rear—not visible in this view) which is interchangeable with pressure sensitive adhesives and other tool-to-backup pad connectors.
[0290] FIG. 73 shows a prototype embodiment of a fibrous stainless steel mesh permanently integrated into to a standard oscillating tool backup pad. Any smooth media can similarly be integrated into backup pads. 7301 is the medium, 7302 is a tube section which binds the medium at the tool center, creating the mounting lug space, 7303 is an optional tape which absorbs vibratory movement of the medium thereby preventing deterioration of the backup pad foam 7304.
[0291] FIG. 74 shows the oscillating tool 7101 being used to remove aged, brittle resinous finish 7401 on a substrate by adhesion. On the left, an original wood surface is covered with aged, brittle varnish. On the right, the smooth tool is removing the varnish. In contrast to the use of abrasives for this process, the substrate is unaffected or improved by the new tool. More particularly, the brittle, aged varnish fractures into dust due to the varnish's adhesion to the new tool, while the fibers making up the wood of the substrate are long grained and flexible, allowing them to flex and be smoothed, but not dragged away by adhesion.
[0292] FIG. 75 shows the wood surface substrate with the aged varnish removed 7501 and the underlying wood unaffected. This experiment illustrates the beneficial use of smooth media tools as a low-cost, cleaner, safer replacement for abrasives and chemical paint removers.
[0293] FIG. 76 shows a prototype spindle mounted wheel comprised of a wheel-form ground made of EVA polymer 7601 supplying surface flexibility. The media is, in this case, woven fiberglass 7602. The binder is low viscosity epoxy which bonds the fiberglass to the wheel yet leaves the consolidated glass fiber surface exposed for work.
[0294] FIG. 77 shows a flexible edged disc 7701 with a periphery 7702 on an arbor 7704. The disk is held onto the arbor by two nut-and-washer sets 7705 Due to the non-erosive nature of smooth media 7703, this tool will maintain its original form. The core 7702 may be of any useful material and hardness, one example being EVA foams.
Vehicle in the Form of a PSA Disk
[0295] FIG. 78 shows a prototype of the face of a PSA disk 7801 made of glass bead media 7802 with an area with beads lost due to work 7803.
[0296] FIG. 79 is from a photomicrograph side section view of PSA disk 7801 showing the 1 mm glass beads 7802 adhered to a cotton ground 7903 with acrylic emulsion, then adhered to a 1 mm foam ground 7904 with spray adhesive.
[0297] Vehicle in the Form of a Fiber Reinforced Disk
[0298] FIG. 80 shows a disk 8001 comprised of a semi-rigid, fiber reinforced disk of the type manufactured by Norton Abrasives, and by the 3M corporation, but with fiberglass media 8002 replacing the abrasives of the prior art.
Replaceable Shell on a Backup Pad
[0299] Replaceable shells with surfaces comprised of smooth media are pressed or otherwise formed into compound curves to conform to standard supports.
[0300] FIG. 81 shows an example of a tool in the form of a replaceable shell 8102. 8101 is the backup wheel. The grounds of the replaceable shells are vacuformed, pressed, or otherwise formed of polymer, metal, paper or any other applicable material. Due to the non-eroding quality of the new tools, these replaceable compound curved shells are particularly advantageous for this current invention. However, these replaceable compound curved shells are also suitable for the application of abrasive grains to their surfaces. The shells are mounted to the backup wheel by any useful means including Velcro, mechanical connectors and adhesives.
Burrs with Smooth Media
[0301] FIG. 82 shows a prototype burr with a head 8201. The head is of EVA polymer. The media 8202 is woven fiberglass bonded to the head with low viscosity epoxy. The shaft 8203 is solid nylon rod. The fiberglass ends at the shaft are, in this prototype, bound with vinyl tape 8204. This burr's parts are replaceable by any applicable materials.
[0302] U.S. Pat. No. 6,685,547 B2 PNEUMATIC SANDING ROLL FOR FLEXIBLE ABRASIVE CLOTH SLEEVE refers to an abrasive configured to be attached to a pneumatic burr. Tool forms which are developments of replaceable media can also be comprised of smooth media rather than abrasive grains, thereby providing further tool flexibility. Generally, although tools of the new invention media are non-eroding, attachment systems used in the prior art to replace exhausted abrasives are useable with the new tools, such systems being PSA adhesives, mechanical center connectors and other common attachment systems.
[0303] FIG. 83 is a view of a prototype burr 8301 comprised of EVA foam, a shaft of aluminum tubing 8302, and woven fiberglass Bonded Burnishing medium 8303. The shaft and the fiberglass are both bonded with low viscosity epoxy. This view, during the model making process, shows the head wrapped with Saran Wrap while the binder solidifies.
[0304] Because the new tools often work at low RPM's, these and other burr shapes can be fabricated as desired of a wide range of materials such as plastic foams, tubing, and other material not required to operate under the stresses of high speed tools.
[0305] FIG. 84 shows the completed prototype burr being used to burnish the inner bowl of a silver spoon.
[0306] FIG. 85 shows the spoon treated with a new tool whereby little or no metal is removed in the process. The new tool was run at 350 RPM, dramatically slower, safer and cleaner than abrasive bearing polishing lathes of the prior art which run at 3450 RPM—ten times the speed needed for my new invention in this trial.
Contoured Disks and Wheels with the New Tools
[0307] Consequent to the non-erosive nature of the new tools, tools utilizing my new invention maintain their original forms which remain intact for the life of the tool.
[0308] FIG. 86 is a prototype of contoured wheel constructed of EVA foam and surfaced with fibrous Bonded Burnishing media, in this example woven fiberglass. The wheel is mounted in a lathe chuck, viewer's left.
[0309] Contoured disks of the present art are improvements based on prior art produced by Alpha Professional Tools of Oakland, N.J.: alpha-tools.com, wherein media of the new tools replace attachable abrasive disks, and a wide variety of profiles and hardnesses not previously produced are possible due in part to the slower speeds required.
Reversible Contoured EVA Disk with Recessed Center
[0310] FIG. 87 shows a reversible wheel mounted in a lathe chuck with multiple profile contours and a recessed center, permitting work to be done across the wheel faces without damage to the work due to collision with the arbor mount.
[0311] FIG. 88 shows the wheel of FIG. 88 from its opposite side relative to the arbor.
[0312] FIG. 89 shows the wheel reversed on the arbor, allowing even greater exploitation of the wheel's contours for work.
Lapping Wheel
[0313] FIG. 90 shows a felt lapping wheel with smooth media on a lathe. The felt wheel supplies a firm but resilient surface—midway between a buff and a hard wheel. The tool is made by impregnating the wheel surface with glass microspheres in a resin binder. My hand is holding the parcel of FIG. 92.
[0314] FIG. 91 shows a parcel of mill finish brass 9101 processed with the lapping wheel of FIG. 91. The result is the refined surface 9102.
Sewn Buff with Applied Spheroidal Media
[0315] A sewn muslin or other fibrous buff of the prior art is impregnated at the working surface with binder, for example acrylic emulsion or epoxy, to which is applied spheroidal media, the tool operating flexibly in the manner of a muslin buff of the prior art to which polishing compound has been applied. In an improvement to the standard compound impregnated muslin buff which are typically used at 3450 RPM, the new tools are effective at roughly 100 RPM and upward, according to application.
Sewn Buff Comprised of Lamina Impregnated with Spheroidal Media
[0316] A sewn buff is comprised of laminated sheets of spheroidal media. As in the prior art, the buffs's hardness at the working margin is dependent upon the flexibility of the individual lamina and the stitch frequency.
Spirally Wound Buff
[0317] FIG. 92 shows a wheel or buff comprised of a flexible smooth medium 9201 spirally wrapped around a tubular core 9203, the assembly bound optionally by stitching or adhesives or other means, and sized to fit an arbor 9204. As the wheel rotates in direction 9205, the end of the sheet is at a trailing edge 9202 shown here as optionally separated from the roll body, causing the sharp cut fiber ends to not cut the workpiece surface. Prior art related to this embodiment are cylindrical abrasive rolls.
Wheel with a Metal Mesh Face
[0318] FIG. 93 shows a prototype for a wheel comprised of EVA foam 9401 with a metal mesh 9402. The sheet is butt-joined to the cylinder by resin or other means so to prevent sharp cut ends of the sheet from contacting the work. The metal mesh edges 9403 are rendered non-cutting by either preconditioning of the edge by burnishing with a harder material tool, or by folding of the edge away from the work surface (not shown).
Planarization Device
[0319] Embodiments of planarization devices are made by replacing the abrasives in appropriate stages of the planarization process of the prior art withs tools of the new invention resulting in reduced machine speeds, reduced material waste, improved electrical connectivity and prolonged tool life. An example of such a system in the prior art is POLISH METHOD FOR SEMICONDUCTOR DEVICE PLANARIZATION U.S. Pat No. 7,172,970 B2, which teaches “that the HSP-CMP process with the fix abrasive polishing pad can be performed to provide a planarized surface with accurate dimension control.”
Pipe Conditioners
[0320] FIG. 94 is a cross section of an Expandable burnisher Drive Mechanism for extending a pipe's or tube's useful service life. A head 9401 with smooth media 9402, forced against the inner surface 9403 of a pipe by a flexible pressurizable bladder 9404 fed by pressurized fluid entering as shown by the arrows 9413 though a channel 9412, rotates and/or reciprocates as shown by the arrows 9413, the head mechanism moving back and forth within the pipe as shown by the arrows 9414 to clean and burnish the inside surface of the pipe. During each cycle of the process, the head mechanism is held in place within the pipe by a non-rotating stabilizer head 9405 comprised of a flexible bladder 9406 with an optional durable anchoring band 9407, which progressively locks the mechanism to the inner pipe walls as each section by pressurized fluid flowing as shown by the arrows 9408 within the stabilizer head. At the end of each cycle, the entire mechanism is moved along the pipe. The head mechanism is driven by a flexible shaft 9409 while fluid flowing as shown by arrows 9410 entering though channels 9416 flushes detritus (not shown) away from the media into the pipe beyond the head 9415, leaving the newly serviced area 14711 clean and freshly burnished, the burnishing process smoothing and compacting the pipe walls thereby extending the pipe's useful service life.
[0321] The pressure forcing both the burnishing and stabilizer heads against the pipe walls is optionally operated mechanically, pneumatically, hydraulically or any combination thereof.
[0322] After the process is complete, the mechanism is removed by deflating the head bladders, and drawing the head and the flexible shaft through the pipe from either end of the pipe.
Composite Tools
[0323] Smooth media held in a solid matrix can be of any useful configuration now made with abrasives in the prior art, one example being sharpening stones, and composed of any useful media of the present invention held in matrices of resins or other suitable grounds.
[0324] FIG. 95 shows a prototype composite wheel made of epoxy and spheroids, using water as a lubricant with a test parcel 9502 held in my hand, left. According to wheel hardness and speed, lubrication, and the pressure between the work and the tool, the surface is improved by a combination of smoothing, surface compression, and material removal by controlled adhesion, along with the controlled removal of material free of abrasive waste—advantageous in the processing of precious materials such as gold. In my experiments the removed material can be collected and recycled directly without costly reclamation. Furthermore, since the tool's shape remains relatively unchanged during work, down-time for tool dressing or replacement is dramatically reduced.
[0325] FIG. 96 is a side view of the prototype composite wheel made of epoxy and spheroids (the various bubbles are prototype imperfections).
[0326] FIG. 97 is from a photomicrograph of the surface of the prototype composite wheel made of epoxy and spheroids, showing the glass beads embedded in the epoxy. The combination of the glass bead media and the epoxy also serve as the ground.
[0327] FIG. 98 is from a photomicrograph of intersecting incised lines in a parcel before treatment with a composite burnishing wheel.
[0328] FIG. 99A is from a photomicrograph of the parcel in FIG. 98 after treatment with the composite wheel with water lubricant at under 150 M/m. Note the complete preservation of the incised line details while the surface coarseness of the four quadrants of outer surface have been significantly reduced. The resultant surface is due to a combination of Controlled Adhesion and burnishing, making the surface lustrous while maintaining the sharpness and definition of the incised lines, which is useful for improving surfaces incised with logos and other designs.
[0329] FIG. 99B is from a photomicrograph of slurry containing the material removed by Controlled Adhesion from the parcel of FIG. 99A. With the exception of a few glass spheroids that have broken away from the prototype wheel, the material is pure, uncontaminated with abrasive waste as would be present with material removed by abrasives. With industrially produced tools of this type, the spheroids in the slurry would be dramatically reduced or eliminated, leaving pure, recyclable material
[0330] FIG. 100 illustrates the section of a belt comprised of a flexible or non-flexible fabric or film ground 10001, with parcels 10002 comprised of a matrix 10003 with multiple embedded fibrous or spheroidal media 10004, arrayed along the face of the belt so that the belt can be mounted on any belt-type device such as a belt sander and/or the face of an expandable wheel.
Cutting Tool Tips
[0331] Yet other embodiments adapted as grounds for the present art are tools having forms such as milling cutters, rotary files, drill bits and flexible linked tools such as chain saw blades. With burnishers at the multiple working tips, bound using similar technologies now used for attachment of carbide cutter tips, and generally operating at considerably slower speeds, these tools are, in my opinion, usable with smooth media instead of as cutters as the forms now are used in the prior art.
Composite Hand Held Tools
[0332] The heads of hand held burnishing tools such as those in FIG. 1 may be produced more economically and with greater variability in their forms by replacing their single-burnisher ends with, for example, smooth spheroids in resin bonding material.
Composite Machine Mounted Tools
[0333] The heads of machine mounted burnishing tools such as those produced by Lambda Technologies Group are produced more economically and with greater variability in their forms by replacing the burnisher ends with composites comprised of smooth media. Similarly, ROTARY BURNISHERS U.S. Pat. No. 872,594 shows the prior art of multi-headed dental burnishers made of solid materials such as tool steel. My present invention replaces these and similar tool heads with composites made of media with, for example, smooth spheroids in resin bonding material.
Tool for Honing of Razor and Other Blades
[0334] See prior art; RAZOR SHARPENING SYSTEM U.S. Pat. No. 8,801,501. Honing of razor blades both manually and mechanically, is done either with or without abrasives. The operation, machine production and cost of such tooling is improved by the honing elements being replaced by smooth media of the present invention.
FOAMS
A New Foaming Process
[0335] A simplified and less costly method for producing foams for the present invention is a direct consequence of the addition of smooth burnishing media to the foam mix. During production of a foam member impregnated with smooth media, the media, being smooth, is continually and uniformly distributed in the mix by the turbulence of the aqueous solvent boiling away in production of the foam. In an experiment, where heat was provided by microwave oven, a homogenous solidified foam product was produced in contrast to the clumping which occurs when manufacturing foams containing abrasives, due to the jagged abrasive grains locking to one another. In the prior art, this problem required the addition of blowing agents and metal fragments to the mix to break up the clumps of abrasive grains and disperse them uniformly in the foam product: From COMPOSITE RETICULATED FOAM-TEXTILE CLEANING PAD U.S. Pat. No. 4,581,287: [0336] . . . it contains, ‘(B) at least one blowing agent which releases gas on heating, and (C) at least one metal powder or metal compound, for example a metal oxide, individually, or a mixture thereof, which has microwave activity.
[0337] FIG. 101 shows an acrylic foam block impregnated with glass spheroids which, during work, assumes the shape of a workpiece. Within several hours after work on a particular shaped workpiece is done, the foam tool reassumes its original form, ready to be used on another, unrelated shape. This memory quality allows the use of the foam tool for a variety of specific shapes without having to use a new foam tool for another workpiece.
[0338] FIG. 102 shows a magnified view of the foam of FIG. 102.
[0339] FIG. 103 is from a photomicrograph of the foam of FIG. 102, showing the glass spheroids, and acrylic binder which also functions as a ground.
Brushes
[0340] In contrast to brushes in the prior art which operate on the principle that sharp bristles scratch with their sharp ends, my present invention operates as burnishers and at a wide range of velocities, the lowest speeds being just above zero M/m.
[0341] FIG. 104 shows a ground comprised of a scrub brush of the prior art to which media are bonded to the bristle ends 10401 with any viable binder, in this prototype, epoxy resin.
[0342] FIG. 105 shows a detail of the bristles 10401 of the brush of FIG. 104.
[0343] FIG. 106 is from a photomicrograph of the scrub brush of the prior art with bristle tips of smooth media with the bristles 10601 with the bonded glass beads 10602.
[0344] The forms of brushes which may incorporate smooth media include among others; engine cylinder hones, and industrial hand and machine mounted rotary, spiral and straight brushes.
Solid Brush Bristles
[0345] Yet another method for making the new tools is with brush bristles. While brushes of the prior art use the sharpened ends of bristles to abrade materials, such as the common steel bristle brush, or sharp bristles that create fine striations in a surface, bristle ends which are rounded and smooth create tools of the present invention, which smooth a surface by plastic displacement rather than by abrasion or scratching as done with the prior art.
[0346] The prior art shown in FIG. 3 clarifies this difference by showing the sharp, cutting bristle end of a common steel bristled work brush. See also under Definitions: ‘Scratch.’
[0347] In contrast to the prior art are the following tools comprised of smooth media:
[0348] FIG. 107 shows bristles of a common steel work brush altered by abrasive treatment of the bristles' sharp tips with a 3M Scotch-Brite Deburring Wheel to create radii at those tips. The resulting new tool, rather than creating fine gouges at a surface, smooths the surface by plastic deformation.
[0349] FIG. 108 is from a photomicrograph of a smooth ended bristle of a metal work brush as in FIG. 107.
[0350] FIG. 109 shows a cross section of a brush comprised of a brush back 10901 as a binder, with embedded glass or plastic fibers, with the fibers' tips 10902 formed so to create a spheroidal tip.
[0351] FIG. 110 shows a brush configuration common in the prior art comprised of a handle 11001, a ferrule 11002, but with fibers comprised of glass with spheroidal melted ends 11003 operating as tools of the present invention.
[0352] FIG. 111 shows a spheroid 11101 attached to a rod, fiber or bristle 11102 by any means and at any scale, further attached to any matrix or tool holder 11103 singularly or in groups, the tools being hand or power driven in a rotary, reciprocating or other motion. In the prior art, a similar construction is used for hair brushes to avoid abrading the scalp—a distinctly separate tool used for a distinctly different purpose. See HAIR BRUSH EP 0141532 B1, HAIR BRUSH US 2004/0200021 A1, METHOD FOR BOUNDING THE TIPS OF BRISTLES U.S. Pat. No. 2,587,792.
Compounds
[0353] FIG. 112 shows a prototype compound 10 cm across 11201 comprised of tallow and glass spheroidal media, on a common poly food container lid 11202, for scale. During manufacture, the smooth media are mixed into standard burnishing compound mixtures of the prior art up to now used with abrasive media. One example of such a compound of the prior art is POLISHING COMPOUND U.S. Pat. No. 2,129,377. Such compounds are generally poured into ingot-like shapes which are pressed against rotating fabric buffs, thereby impregnating the buff with the compound which is consumed during use and must frequently be reapplied.
[0354] Bonded Burnishing burnishing compounds are cast into similar forms and similarly consumed during use.
[0355] FIG. 113 is from a photomicrograph of the prototype Bonded Burnishing compound of FIG. 112. In this example, the spheroids are ˜ø090-140 μm. The surface modifications achieved vary with spheroids of various dimensions.
Spheroidal Vehicle in Cream Media
[0356] This vehicle uses flexible burnishing media in place of fine abrasives in metal polishing creams of the prior art such as Wright's, MAAS, Brasso, Blue Magic Goddard's Simichrome and the like. Additives such as thiourea and other tarnish removers and inhibitors remove surface oxides, allowing the media to operate on the unoxidized metal surface. An early patent for an abrasive cream is METAL-POLISHING COMPOUND U.S. Pat. No. 5,48,310 A which uses the abrasive qualities of coal ash and Cream of Tartar.
Spheroidal Vehicle in the Form of a Slurry
[0357] This embodiment combines smooth media with aqueous, resinous, or other liquid and cream carriers and dispersed onto platens, faceplates, brushes, polishing cloths, polishing pads, gloves and other tools for treatment of work surfaces such as microchip wafers and floors as well as for treatments by manual techniques. A major advantage being the reduced erosion and waste produced. Slurries in combination with applicable tools of my present invention differ by application from slurries used in tumbling barrels of the prior art, wherein burnishing is already a standard practice. The slurries are often combined with tarnish removal agents:
[0358] FIG. 115 shows a test object before treatment with smooth media slurry on a glove.
[0359] FIG. 116 shows the slurry on a glove during treatment. Note the absence of black residue on the glove of FIG. 118.
[0360] FIG. 117 For contrast, this shows a glove soiled with the black metal residual waste produced by standard metal polish.
Burnishing Stick
[0361] FIG. 118 shows a tool made of a felt covered stick 11801 wrapped with beaded chain 11802. Such media made of interconnected individual smooth elements can be described as both fibers and spheroids. The chain may be attached to the stick by mechanical or adhesive means.
Solid Tools
[0362] The new tools are also made of solid homogeneous material, for instance glass, disks, bars and other shapes are laminated into groups. The work surface of the lamina may be without a pattern or comprised of any useful pattern in any useful frequency, the individual elements of the pattern presenting themselves consecutively to the work through spinning, as with a wheel, or by hand work, as done in the prior art by files or sharpening stones.
[0363] FIG. 119
[0364] shows a wheel lamina 11901 of a solid medium with a castellated surface laminated into a group 11902. 11903 shows a cross section of one type of castellation. Any suitable geometric and non-geometric configurations of multiple smooth faces are usable.
Limitations
[0365] While several preferred embodiments of the invention have been described, the invention is not to be limited thereby, but only by the following claims.
