Abrasive Articles With Wax-Binder Anti-Loading Size Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing abrasive articles suffer from loading issues due to swarf accumulation between abrasive particles, leading to reduced performance and increased abrasion force requirements, with stearate-based anti-loading solutions being costly and prone to sloughing off during use.
Innovation Solution
Incorporation of an anti-loading size layer comprising a size coat binder at a concentration of at least 20% by weight and no more than 20% wax, eliminating the need for a supersize coat and enhancing durability and adhesion with urea make resins and compatible latexes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stearate-based anti-loading coatings are used, then loading resistance is improved, but manufacturing cost increases and coating durability worsens due to sloughing off during use
Solution Approach 1:
The patent changes the chemical composition parameters of the size coat by incorporating specific anti-loading materials (metal stearates, metal soaps, or fluorinated compounds) at controlled concentrations (0.1-10% by weight), transforming the conventional size coat into an anti-loading size coat that provides both loading resistance and cost-effectiveness
Solution Approach 2:
The patent creates a composite size coat system by combining anti-loading agents with size coat binders (such as phenolic resins, polyvinyl acetate, or carboxymethyl cellulose), forming a composite material that integrates both sizing functionality and anti-loading properties in a single coating layer
2Reliability
If stearate-based anti-loading coatings are used, then loading resistance is improved, but coating durability worsens due to sloughing off during use
Solution Approach 1:
The patent uses size coat binders as intermediary materials that anchor the anti-loading agents to the abrasive particles and backing, preventing sloughing off while maintaining anti-loading functionality. The binder acts as a mediator that secures the anti-loading coating during the abrading process
Solution Approach 2:
The patent optimizes the concentration parameters of anti-loading materials in the size coat (0.1-10% by weight) to achieve sufficient loading resistance while ensuring adequate adhesion and durability during use, preventing the coating from sloughing off
3Ease of manufacture
If conventional size coats are used, then application simplicity is maintained, but anti-loading performance is insufficient requiring additional supersize coats
Solution Approach 1:
The patent merges the sizing function and anti-loading function into a single integrated size coat layer, eliminating the need for separate supersize coats. The size coat simultaneously provides particle retention, surface protection, and loading resistance through incorporated anti-loading agents
Solution Approach 2:
The patent transforms the conventional size coat into a multi-functional coating that performs multiple roles: sizing (particle retention), surface protection, and anti-loading resistance, making the size coat a universal layer that replaces the need for additional specialized coatings
4Reliability
If more anti-loading materials are added to increase loading resistance, then loading resistance improves, but manufacturing cost increases
Solution Approach 1:
The patent establishes optimal concentration parameters for anti-loading materials in the size coat (0.1-10% by weight), providing sufficient loading resistance at cost-effective levels without requiring excessive amounts of expensive anti-loading agents
Solution Approach 2:
The patent employs cost-effective anti-loading materials such as metal stearates and metal soaps that provide adequate anti-loading performance at lower costs compared to more expensive alternatives, achieving economic efficiency in the size coat formulation
Data Source
Figure 1
AI summary
The present disclosure relates to saturated or primed abrasive article constructions containing an anti-loading composition which significantly reduces loading, is coatable, is durable, and is relatively inexpensive to manufacture. In particular, the use of the anti-loading compositions of the present disclosure as a size coat at least reduces if not eliminates the need for a supersize coat, while offering comparable if not superior performance and durability. The abrasive article further includes an anti-loading size layer comprising a size coat binder and wax at least partially disposed on the abrasive layer.