Coated Abrasive Backing Layers for Controlled Particle Tilt

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Solution Overview

Problem

Existing abrasive articles face challenges in achieving optimal particle orientation and distribution, which affects their performance and manufacturing efficiency.

Innovation Solution

The development of coated abrasive articles with a backing layer, make coat, and abrasive particles, where at least 65% of the abrasive particles have a well-oriented tilt orientation, and the use of specific materials and viscosities for the front fill and make coat to enhance manufacturing and performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional abrasive articles are manufactured with random particle orientation, then manufacturing process is simpler, but material removal capability and performance are reduced

Engineering Contradiction:

Improvematerial removal capabilityVSAvoidparticle orientation control

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by controlling the tilt angle of abrasive particles during the manufacturing process. Specifically, the method involves adjusting process parameters to achieve a predetermined distribution of particle tilt angles, where at least 65% of particles have a tilt angle within a specified range. This controlled parameter adjustment enables optimized material removal capability while maintaining manufacturing feasibility.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If abrasive particles are oriented with specific tilt angle, then material removal capability improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improvematerial removal rateVSAvoidparticle tilt orientation precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements partial action by establishing a minimum threshold for well-oriented particles (at least 65% of total particles). This approach does not require every single particle to meet the orientation specification, but rather achieves the performance benefit through a majority proportion. This reduces the overall manufacturing precision burden while still delivering significant material removal capability improvement.

Inventive Principle:

Principle #16Partial or excessive action

3Manufacturing precision

If front fill and make coat materials are optimized for particle orientation, then particle distribution improves, but manufacturing process complexity increases

Engineering Contradiction:

Improveparticle distribution uniformityVSAvoidcoating process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent utilizes parameter changes in the coating materials by specifying particular viscosity ranges for the front fill and make coat materials. These viscosity parameters are controlled to facilitate proper particle distribution and orientation during the coating process. By adjusting these material parameters, the patent achieves improved particle distribution without requiring complex manufacturing equipment or processes.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12564916B2Abrasive articles and methods of forming same

Publication Date: 2026.03.03 SAINT GOBAIN ABRASIVES INC

AI summary

An abrasive article including: a backing layer including a front fill overlying a backing, wherein the backing layer including the front fill comprises (1) a surface roughness of not greater than 100 microns or (2) an average thickness/roughness ratio of greater than 0.80; a make coat overlying the backing layer; and a plurality of abrasive particles overlying the backing layer, wherein at least 65% of the abrasive particles have a well-oriented tilt orientation.