Abrasive Backing Material for Improved Adhesion and Flexibility
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Solution Overview
Problem
Conventional abrasive backings face challenges with high production costs, limited flexibility, and poor adhesion under mechanical and thermal loads, leading to issues such as tearing and embrittlement during grinding processes.
Innovation Solution
A backing material composed of at least 80% synthetic fibers, with a surface roughness of 100 μm to 500 μm and air permeability of at most 20 l/m², is developed using a compacted fleece structure and impregnated with a resin of high weight-average molecular weight, which enhances flexibility, strength, and adhesion without the need for chemical roughening or additional work steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fabric backings are used to manufacture abrasive articles, then tear resistance, dimensional stability, and flexibility are improved, but production costs increase significantly
Solution Approach 1:
The patent replaces expensive fabric backings with a cost-effective nonwoven carrier made from synthetic fibers (polyester, polyamide, acrylic) that can be produced more economically while achieving comparable mechanical properties through optimized fiber composition and structure
Solution Approach 2:
The invention creates a composite nonwoven carrier combining multiple synthetic fiber types (e.g., polyester for strength, polyamide for flexibility) to achieve the desired balance of tear resistance, dimensional stability, and cost-effectiveness without relying on natural fibers like cotton
2Ease of manufacture
If nonwovens made of synthetic fibers are used to replace fabric backings, then production costs are reduced, but flexibility and ability to conform to workpiece contours deteriorate
Solution Approach 1:
The patent optimizes parameters of the nonwoven carrier including fiber diameter (1-20 μm), fiber length (10-50 mm), basis weight (50-500 g/m²), and resin content (5-30 wt%) to achieve the desired flexibility and conformability while maintaining cost advantages over fabric backings
Solution Approach 2:
The invention applies different properties to different aspects of the nonwoven carrier: using fine synthetic fibers for flexibility and conformability, adding specific resin binders for structural integrity, and creating surface roughness in specific areas to enhance abrasive adhesion while maintaining overall flexibility
3Strength
If mechanical roughening is applied to improve adhesive adhesion, then adhesion strength is improved, but the backing material becomes embrittled and flexibility is reduced
Solution Approach 1:
The patent incorporates surface roughening features and adhesive promoter substances into the nonwoven carrier during the manufacturing process itself, before the abrasive is applied. This preliminary preparation ensures good adhesion without requiring subsequent mechanical roughening that would embrittle the material
Solution Approach 2:
The invention uses resin binders and adhesive promoters as intermediary substances within the nonwoven carrier structure that facilitate strong adhesive bonding without requiring mechanical damage to the backing. These intermediaries chemically or physically bridge the abrasive and the carrier, maintaining flexibility
4Strength
If chemicals are added to roughen fiber surface for improved binder adhesion, then adhesion is improved, but the chemicals degrade common coating and binder resins
Solution Approach 1:
The patent converts the potential harm of chemical treatment by selecting chemicals (e.g., plasma treatment, ozone treatment) that roughen the fiber surface and enhance adhesion without degrading the binder resins. The treatment is controlled to create beneficial surface morphology while preserving chemical compatibility with common resins like acrylic, vinyl, and epoxy binders
Solution Approach 2:
The invention carefully controls the parameters of surface treatment (energy level, treatment time, chemical concentration) to achieve sufficient surface roughness for good adhesion while staying below the threshold that would cause resin degradation. This parameter optimization ensures both adhesion and durability
Data Source
AI summary
The invention relates to an abrasive support, to an abrasive article comprising such a support, to the method for producing the same, and to the use of the abrasive article. According to at least one embodiment, the abrasive support comprises an impregnated support material based on synthetic fibers. The impregnated support material has at least on one side having a surface roughness Rz of 100 μm to 500 μm, and having an Rmax of 250 μm to 600 μm. The support has an air permeability of at most 20 l/m2s.