Abrasive and method for producing such an abrasive
By embedding filler agglomerates and/or granules within the abrasive and/or topcoat layers, the abrasive maintains consistent performance over its service life, addressing the issue of rapid filler wear in existing abrasives.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- KLINGSPOR
- Filing Date
- 2025-12-09
- Publication Date
- 2026-06-18
AI Technical Summary
Existing abrasives lose functionality quickly due to the rapid wear of fillers applied on the topcoat layer, requiring additional manufacturing steps and providing short-term support.
Incorporating filler agglomerates and/or granules into the abrasive layer and/or topcoat layer, which are embedded to be continuously released over the abrasive's service life, ensuring consistent performance.
The embedded fillers provide sustained support to the abrasive process, maintaining functionality over an extended period without additional manufacturing steps.
Smart Images
Figure EP2025086096_18062026_PF_FP_ABST
Abstract
Description
[0001] December 9, 2025
[0002] KLINGSPOR AG M / KLI-121-WO
[0003] Abrasives and methods for producing such abrasives
[0004] The present invention relates to an abrasive comprising an abrasive layer with abrasive particles. The present invention further relates to a method for producing such an abrasive.
[0005] Abrasives, comprising an abrasive layer with abrasive particles, are known in various forms from the prior art. Furthermore, it is known from the prior art to sprinkle fillers onto a topcoat layer adjacent to the abrasive layer to improve the functionality of the abrasive. Due to the arrangement of the fillers on the topcoat layer, the fillers are at least largely worn away after a short time when the abrasive is used. The fillers therefore only support the abrasive process for a short period. Moreover, applying the fillers to the topcoat layer requires an additional manufacturing step.
[0006] The invention is based on the objective of providing an abrasive that exhibits approximately the same functionality for at least a large part of its service life. Furthermore, it is an objective of the present invention to provide a method for producing such an abrasive.
[0007] This problem is solved according to the invention by the abrasive having the features of claim 1 and the method having the features of claim 15.
[0008] According to the invention, an abrasive is provided that comprises an abrasive layer with abrasive particles as well as filler agglomerates and / or filler granules. The filler agglomerates and / or the filler granules are / are at least partially arranged in the abrasive layer and / or in a topcoat layer adjacent to the abrasive layer. If the filler agglomerates and / or the filler granules are / are at least partially arranged in the abrasive layer, the topcoat layer is therefore optional.
[0009] The core idea of the invention is therefore to provide the filler agglomerates and / or filler granules within the abrasive layer and / or within the topcoat layer, in particular to embed them in one or both of these layers. Thus, the filler agglomerates and / or filler granules are / will be continuously released over the service life of the abrasive.
[0010] A filler agglomerate is, for example, a combination of several particles of the same and / or different sizes, wherein the particles are joined together, in particular with the help of a binder, to form a particle accumulation with a solid bond.
[0011] A granulate can comprise a large number of particle aggregates with a solid bond, so-called grains, wherein the particle aggregates with a solid bond are produced by joining several particles of the same and / or different sizes, in particular by a mechanical, thermal or chemical process.
[0012] The particle clusters with a solid bond can be at least approximately the same size.
[0013] The abrasive is, for example, a grinding wheel, a roughing wheel, or a cutting wheel. The term "abrasive" is therefore to be understood in the broadest sense within the scope of the present invention.
[0014] In an exemplary embodiment of the abrasive according to the invention, the filler agglomerates and / or grains of the filler granules are largely, and in particular completely, encapsulated by the abrasive layer and / or the topcoat layer. The filler agglomerates and / or the grains of the filler granules are thus embedded in the abrasive layer and / or the topcoat layer. This allows the filler agglomerates and / or the grains of the filler granules to continuously exert their respective effects over a long period of time.
[0015] The composition of the filler agglomerates and / or the grains of the filler granulate may differ from the composition of the adjacent areas of the abrasive.
[0016] In a preferred embodiment of the abrasive according to the invention, the average size of the filler agglomerates and / or the grains of the filler granules is in a range of 1 pm to 4000 pm.
[0017] For example, the ratio of the average size of the filler agglomerates and / or the average size of the grains of the filler granules to the thickness of the abrasive layer, in particular the thickness of a binder of the abrasive layer, is at least 1:1 and at most 10:1.
[0018] The ratio of the average size of the filler agglomerates and / or the average size of the filler granules to the thickness of the topcoat layer can be at least 1:1 and at most 15:1.
[0019] In a preferred embodiment of the abrasive according to the invention, the individual particles of the filler agglomerates and / or the filler granules have an average size of a maximum of 3000 pm.
[0020] The filler agglomerates and / or filler granules may contain micro-abrasive particles. Therefore, the particles within the filler agglomerates or filler granules may, at least in part, consist of micro-abrasive particles. The removal of these micro-abrasive particles during use of the abrasive exposes the abrasive particles within the abrasive layer, thus ensuring consistent grinding performance over an extended period.
[0021] In an exemplary embodiment of the abrasive according to the invention, the average size of the abrasive particles of the abrasive layer is at least four times larger than the average size of the micro-abrasive particles of the filler agglomerates and / or the average size of the micro-abrasive particles of the filler granules.
[0022] The average size of the abrasive particles in the abrasive layer is, for example, less than or equal to 6000 pm. In a preferred embodiment of the abrasive according to the invention, the filler agglomerates and / or the filler granules comprise at least one type of the following particles: directly or indirectly abrasive-active filler particles, strength-increasing and / or elasticity-increasing filler particles, wear-reducing filler particles, filler particles that increase electrical and / or thermal conductivity, a manufacturing process of the abrasive, in particular curing and / or pressing, supporting filler particles, filler particles that support the flow of melted and / or worn material of the abrasive, and / or filler particles that act as a fire retardant.
[0023] In an exemplary embodiment, the filler agglomerates and / or the filler granules contain at least one of the following substances: nutshell, wax, graphite, coke, hollow corundum spheres, glass beads, glass fibers, whiskers, silicate, frits, mica, tungsten carbide, silicon nitride, copper, silver, silicon carbide, cryolite, bomitride, sulfide, chloride, phosphate, calcium oxide, magnesium oxide, a fatty acid salt, in particular stearate and / or a fatty acid salt other than stearate, elastomer, in particular rubber, calcium carbonate, calcium metasilicate, talc, kaolin, clay, feldspar, borax, wollastonite, lithium nitrate, sodium salt, potassium salt, sodium potassium salt, lithium carbonate, quartz, fluoride, phosphorus-based flame retardant, in particular aluminum diethylphosphinate, fruit kernel granules, diamond, starch, other filler agglomerates of organic or inorganic composition, one further Filler granules of organic or inorganic composition.
[0024] The filler agglomerates and / or filler granules may be formed from a homogeneous mixture of substances.
[0025] In an exemplary embodiment of the abrasive according to the invention, the filler agglomerates and / or the grains of the filler granules have pores.
[0026] The filler agglomerates and / or filler granules can be absorbent. This allows them, for example, when a topcoat is applied to the topcoat during the manufacturing of the abrasive, to absorb the topcoat material in such a way that the abrasive particles remain exposed on the surface. The absorbency of the filler agglomerates and / or filler granules thus ensures that the abrasive exhibits good grinding properties from the outset.
[0027] In an exemplary embodiment of the abrasive according to the invention, the filler agglomerates and / or the grains of the filler granules are each enclosed by a coating, in particular completely.
[0028] The coating can have stabilizing, in particular strength-enhancing, and / or adhesion-promoting properties.
[0029] The coating comprises, for example, resin and / or at least one fatty acid salt, in particular stearate and / or a fatty acid salt other than stearate.
[0030] In a preferred embodiment of the abrasive according to the invention, the filler agglomerates and / or the grains of the filler granules are statistically distributed, and in particular at least approximately homogeneously, in at least one relevant layer of the abrasive, in particular in the abrasive layer and / or the topcoat layer.
[0031] For example, the filler agglomerates and / or the grains of the filler granules are arranged between abrasive particles.
[0032] The filler agglomerates and / or the grains of the filler granules can be arranged in such a way that they directly border the abrasive particles. Thus, the filler agglomerates and / or the grains of the filler granules can provide a supporting effect for the abrasive particles.
[0033] For example, the abrasive includes a top layer.
[0034] The topcoat can completely cover the topcoat layer on one side facing away from the sanding layer.
[0035] The top layer, for example, forms the uppermost layer of the abrasive.
[0036] In an exemplary embodiment of the abrasive according to the invention, the filler agglomerates and / or grains of the filler granules are each completely enclosed by the abrasive layer, the topcoat layer, and / or the topcoat. At least an upper region of the topcoat, i.e., a region of the topcoat facing away from the topcoat layer, can be free of the filler agglomerates and / or the filler granules. The filler agglomerates and / or the grains of the filler granules thus project from the topcoat layer at most into a lower region of the topcoat, which faces the topcoat layer.
[0037] All filler agglomerates and / or grains of the filler granules are therefore, for example, at least partially embedded in the topcoat layer and / or the sanding layer.
[0038] For example, the entire top layer is free of filler agglomerates and / or filler granules.
[0039] For example, the abrasive comprises a carrier layer on which the abrasive layer is arranged, which is, in particular, completely covered by the abrasive layer, especially the binder of the abrasive layer.
[0040] The abrasive grains can be fixed to the carrier layer by means of the binder.
[0041] Furthermore, the present invention relates to a method for producing the abrasive described above. The method according to the invention comprises mixing the filler agglomerates and / or the filler granules into a binder of the abrasive layer and / or into a topcoat forming the topcoat layer and / or sprinkling the filler agglomerates and / or the filler granules onto the abrasive layer and / or onto the topcoat layer.
[0042] The filler agglomerates and / or filler granules are sprinkled onto the abrasive layer before the binder hardens, so that the filler agglomerates and / or the grains of the filler granules sink into the abrasive layer.
[0043] The filler agglomerates and / or filler granules can be sprinkled onto the topcoat layer before the topcoat cures, so that the filler agglomerates and / or the filler granules sink into the topcoat layer. For example, the abrasive grains are sprinkled onto the binder after the filler agglomerates and / or filler granules have been sprinkled onto the binder.
[0044] The filler agglomerates and / or filler granules can also be mixed into the binder before the abrasive grains are sprinkled onto the binder.
[0045] In a preferred embodiment, the method according to the invention comprises applying a top layer to the topcoat layer.
[0046] For example, the topcoat is applied to the topcoat layer after the filler agglomerates and / or filler granules have been sprinkled onto the topcoat layer.
[0047] Further advantages and advantageous embodiments of the present invention are explained in more detail below with reference to the drawing.
[0048] An embodiment of an abrasive according to the invention is shown schematically simplified in the drawing and is explained in more detail in the following description. It shows:
[0049] Figure 1 shows a sectional view through an abrasive according to the invention in an unused state; and
[0050] Figure 2 shows a corresponding view of Figure 1 after use.
[0051] Figures 1 and 2 show a simplified schematic representation of an abrasive 10 according to the invention. Figure 1 shows the abrasive 10 in an unused state, i.e., before its first use. Figure 2 shows the abrasive 10 in a used state.
[0052] The abrasive 10 comprises a carrier layer 12. An abrasive layer is arranged on the carrier layer 12. The abrasive layer comprises a binder 14 and abrasive particles 16. The binder 14 covers the carrier layer 12, in particular completely, across its entire surface. Before the binder 14 is cured, the abrasive particles 16 are sprinkled onto the binder 14. The abrasive particles 16 thus sink at least partially into the binder and are thereby fixed to the carrier layer 12 by means of the binder 14 after the binder 14 has cured. The abrasive particles 16 protrude from the binder 14 on the upper surface of the binder 14 facing away from the carrier layer.
[0053] A topcoat layer 18 is provided on the abrasive layer. The topcoat layer 18 covers the entire surface of the binder 14, which faces away from the carrier layer 12. As can be seen in Figure 1, the abrasive particles 16 protrude from the topcoat layer 18 and are at least partially embedded laterally in the topcoat layer 18.
[0054] The topcoat layer 18 contains filler agglomerates 20 and / or filler granules. The filler agglomerates 20 and / or filler granules 20 are, for example, mixed into a topcoat forming the topcoat layer 18 before it is applied to the sanding layer, or sprinkled onto the topcoat after it has been applied to the sanding layer, where they then sink into the topcoat.
[0055] In contrast to the abrasive 10 shown, it is also conceivable that the filler agglomerates and / or the filler granules are embedded in the binder 14 in addition to the topcoat layer 18, or even only in the binder 14. The filler agglomerates 20 and / or the filler granules can therefore be sprinkled onto the binder 14, for example, before, after, and / or together with the abrasive particles 16.
[0056] The abrasive particles 16 are partially in contact laterally with the filler agglomerates 20 and / or the particles 20 of the filler granules. This stabilizes the abrasive particles 16.
[0057] As can be seen from Figure 2, by providing the filler agglomerates 20 and / or the filler granules in the topcoat layer 18, it can be ensured that the grinding process is supported by the filler agglomerates and / or the filler granules over a long service life of the abrasive 10, since the filler agglomerates and / or the filler granules are thus worn away slowly like the abrasive particles 16.
[0058] A top layer (not shown) may be provided on the topcoat layer, which forms the uppermost layer of the abrasive 12.
[0059] Reference symbol list
[0060] 10 abrasives
[0061] 12 Carrier layer
[0062] 14 binders 16 abrasive particles
[0063] 18 Topcoat layer
[0064] 20 Filler agglomerate / grains of filler granules
Claims
December 9, 2025 KLINGSPOR AG M / KLI-121-WO Patent claims 1. Abrasive comprising an abrasive layer with abrasive particles (16), characterized by filler agglomerates (20) and / or a filler granulate, characterized in that - that the filler agglomerates (20) and / or the filler granules are at least partially arranged in the abrasive layer; or - that the abrasive (10) comprises a topcoat layer (18) adjacent to the abrasive layer, wherein the filler agglomerates (20) and / or the filler granules are / are at least partially arranged in the abrasive layer and / or the topcoat layer (18).
2. Abrasive according to claim 1, characterized in that the filler agglomerates (20) and / or grains (20) of the filler granules are each completely enclosed by the abrasive layer and / or the topcoat layer (18).
3. Abrasive according to claim 1 or 2, characterized in that the filler agglomerates (20) and / or the grains (20) of the filler granules each have an average size in a range of 1 pm to 4000 pm.
4. Abrasive according to one of claims 1 to 3, characterized in that the ratio of an average size of the filler agglomerates (20) and / or the grains (20) of the filler granules to a thickness of the abrasive layer is at least 1:1 and at most 10:1 and / or that the ratio of the average size of the filler agglomerates (20) and / or the grains (20) of the filler granules to a thickness of the top layer is at least 1:1 and at most 15:
1.
5. Abrasive according to one of claims 1 to 4, characterized in that particles of the filler agglomerates (20) and / or particles of the grains (20) of the filler granules have an average size of a maximum of 3000 pm.
6. Abrasive according to one of claims 1 to 5, characterized in that the filler agglomerates (20) and / or the filler granules comprise / comprise micro-abrasive particles.
7. Abrasive according to claim 6, characterized in that an average size of the abrasive particles (16) of the abrasive layer is at least four times larger than an average size of the micro-abrasive particles of the filler agglomerates (20) and / or an average size of the micro-abrasive particles of the filler granules, wherein the average size of the abrasive particles (16) of the abrasive layer is in particular less than or equal to 6000 pm.
8. Abrasive according to any one of claims 1 to 7, characterized in that the filler agglomerates (20) and / or the filler granules comprise / comprise at least one of the following substances: directly or indirectly abrasive-active filler particles, filler particles increasing strength and / or elasticity, filler particles reducing wear of the abrasive (10), filler particles increasing electrical and / or thermal conductivity, filler particles supporting a manufacturing process of the abrasive (10), in particular curing and / or pressing, supporting the flow of melted and / or worn material of the abrasive (10), filler particles forming fire retardant.
9. Abrasive according to any one of claims 1 to 8, characterized in that the filler agglomerates (20) and / or the filler granules comprise at least one of the following substances: nutshell, wax, graphite, coke, hollow corundum, glass beads, glass fibers, whiskers, silicate, frits, mica, tungsten carbide, silicon nitride, copper, silver, silicon carbide, cryolite, bomitride, sulfide, chloride, phosphate, calcium oxide, magnesium oxide, stearate, a fatty acid salt other than stearate, elastomer, in particular rubber, calcium carbonate, Cal- Calcium metasilicate, talc, kaolin, clay, feldspar, borax, wollastonite, lithium nitrate, sodium salt, potassium salt, sodium potassium salt, lithium carbonate, quartz, fluoride, phosphorus-based flame retardant, in particular aluminum diethyl phosphinate, fruit kernel peel granules, diamond, starch, other filler agglomerates of organic or inorganic composition, one further filler granule of organic or inorganic composition.
10. Abrasive according to any one of claims 1 to 9, characterized in that the filler agglomerates (20) and / or the filler granules have pores and / or are absorbent.
11. Abrasive according to one of claims 1 to 10, characterized in that the filler agglomerates (20) and / or the grains (20) of the filler granules are each enclosed by a coating, wherein the coating comprises in particular resin and / or at least one fatty acid salt, in particular stearate and / or a fatty acid salt other than stearate.
12. Abrasive according to one of claims 1 to 11, characterized in that the filler agglomerates (20) and / or the grains (20) of the filler granules are statistically, in particular at least approximately homogeneously, distributed in at least one relevant layer of the abrasive (10).
13. Abrasive according to one of claims 1 to 12, characterized in that the filler agglomerates (20) and / or the grains (20) of the filler granules are arranged between abrasive particles (16), in particular directly adjacent to them.
14. Abrasive according to one of claims 1 to 13, characterized by a top layer which covers the topcoat layer (18) on a side facing away from the abrasive layer.
15. Method for producing an abrasive according to any one of claims 1 to 14, characterized in that the filler agglomerates (20) and / or the filler granules are incorporated into a binder (14) of the abrasive layer and / or into a topcoat- layer (18) forming topcoat are / will be mixed in and / or the filler agglomerates (20) and / or the filler granules are / will be sprinkled onto the binder (14) of the sanding layer.