Apparatus and method for forming a spiral wound abrasive article, and the resulting article

An endless spiral wound abrasive article comprising:

• at least one first elongate web including first and second opposed major surfaces and having elongated side edges, wherein the first elongate web comprises a coated abrasive including at least one layer of abrasive particles on the first major surface;
• and
• at least one second elongate web including first and second opposed major surfaces and having elongated side edges, the first major surface of the second elongate web positioned adjacent the second major surface of the first elongate web but offset from at least one of the side edges of the first elongate web, the second elongate web configured to adhere at least in part to the second major surface of the first elongate web along one of the side edges of the first elongate web, the second elongate web further comprising a slip layer applied to the second major surface of the second elongate web,
• the first and second elongate webs wound at an angle of wrap of less than about 60° in a spiral configuration to form an endless spiral wound article, wherein the side edges of the first elongate web abut and are joined by the second elongate web overlapping the abutted side edges of the first elongate web.

An endless spiral wound abrasive article comprising:

• at least one first elongate web including first and second opposed major surfaces and having elongated side edges, wherein the first elongate web comprises a coated abrasive including at least one layer of abrasive particles on the first major surfacer;
• at least one second elongated web including first and second opposed major surfaces and having elongated side edges, the first major surface of the second elongate web positioned adjacent to the second major surface of the first elongate web but offset from at least one of the side edges of the first elongate web;
• the second elongate web comprising an adhesive layer comprising an adhesive material chosen from the group consisting of thermoplastics, urethanes, epoxies, ethyleneacrylic acids, radiation curable resins, pressure sensitive adhesives, latex, polyvinylacetate, polyvinylacrylic acids and combinations thereof;
• the second elongate web configured to adhere at least in part to the second major surface of the first elongate web along one of the side edges of the first elongate web;
• the first and second elongate webs wound at an angle of wrap of less than about 6 in a spiral configuration to form an endless spiral wound article, wherein the side edges of the first elongate web abut and are joined by the second elongate web overlapping the abutted side edges of the first elongate web;
• and
• a third elongate web including first and second major surfaces and having elongated side edges;
• the third elongate web comprising a reinforcing layer comprising a reinforcing material chosen from the group consisting of woven, nonwoven and film materials;
• the third elongate web positioned adjacent to the second elongate web but offset from at least one of the side edges of the second elongate web, with the second elongate web further configured to adhere at least in part to one of the major surfaces of the third elongate web, the third elongate web further comprising a slip layer applied to a major surface of the third elongate web;
• the third elongate web wound at an angle in a spiral configuration along with the first and second elongate webs to form the endless spiral wound article, wherein the side edges of the third elongate web also abut and are joined by the second elongate web overlapping the abutted side edges of the third elongate web.

A method for forming a spiral wound endless abrasive article comprising:

• providing a first elongate web having first and second opposed major surfaces and elongated side edges;
• providing a second elongate web having first and second opposed major surfaces and elongated side edges;
• the second elongate web having an adhesive disposed on the first major surface;
• the second elongate web further having a liner layer releasably affixed to the adhesive;
• removing the liner layer from the second elongate web;
• positioning the second elongate web adjacent the first elongate web in a configuration offset from at least one of the side edges of the first elongate web;
• and
• adhering the first web to the second web while winding the first and second elongate webs in a spiral manner while abutting the side edges of the first elongate web and joining the abutted side edges of the first elongate web by overlap of the second elongate web to form an endless spiral wound article.