Phenolic Abrasive Binder Rheology for Particle Orientation Control
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Solution Overview
Problem
Existing abrasive articles face issues with abrasive particles tipping over due to fluid or hard phenolic resin binders, particularly resole phenolic resin, during the curing process, leading to loss of orientation and adhesion.
Innovation Solution
A curable composition comprising a resole phenolic resin and an organic polymeric rheology modifier, such as alkali-soluble acrylic polymers, which includes an organic polymeric rheology modifier, such as an alkali-soluble polymer, such as an alkali-swellable polymer, and hydrophobic polymers, which are used in aqueous compositions for latex paints, personal care products, and drilling muds. The composition comprises a resole phenolic resin and an organic polymer rheology modifier, such as an alkali-swellable polymer, and hydrophobic polymers, which are used in aqueous compositions for latex paints, personal care products, and drilling muds. In a first aspect, the composition comprises a resole phenolic resin and an organic polymeric rheology modifier, such as an alkali-swellable/soluble polymer, to maintain abrasive particle orientation during curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fluid binder precursor material is used, then the abrasive particles can be deposited easily, but the particles tip over due to gravity because the binder is too fluid
Solution Approach 1:
The patent changes the rheological parameters of the binder precursor material by adding thixotropic agents. This allows the binder to be fluid during deposition (easy particle placement) then become more viscous upon standing (prevents particle tipping), resolving the contradiction between ease of manufacture and manufacturing precision
Solution Approach 2:
The patent introduces thixotropic agents as intermediary substances that mediate between the binder and abrasive particles. These agents modify the binder's flow characteristics to provide temporary support for particles during deposition, preventing gravity-induced tipping while maintaining ease of application
2Reliability
If a hard binder precursor material is used, then the abrasive particles are retained well, but the particles do not adhere properly and tip over due to gravity
Solution Approach 1:
The patent applies thixotropic modification to create a dynamically changing binder viscosity. The binder transitions from a softer, more adhesive state during application to a harder, more retentive state after deposition, enabling both good adhesion and reliable particle retention without particle tipping
3Reliability
If resole phenolic resin binder material precursor is used, then the abrasive article achieves good curing properties, but the abrasive particles tip over during the curing process
Solution Approach 1:
The patent introduces thixotropic agents as intermediary substances between the resole phenolic resin and abrasive particles. These agents modify the resin's rheological behavior to provide temporary structural support during curing, preventing particle tipping while preserving the resin's good curing properties
4Productivity
If precision shaped grain loadings are reduced, then the abrasive performance is maintained or improved, but the control of abrasive tip density becomes more difficult
Solution Approach 1:
The patent changes the rheological parameters of the binder precursor using thixotropic agents, which provides better flow control and particle positioning. This enables precise control of abrasive tip density even at lower precision shaped grain loadings, maintaining or improving abrasive performance while achieving better density control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The use of alkali-swellable/soluble polymers, such as alkali-swellable/soluble acrylic emulsion (ASE), Hydrophobically-modified Alkali-Swellable/soluble Emulsion (HASE), and Hydrophobically-modified Ethoxylated URethane (HEUR) polymers, provides better control of abrasive tip density and maintains particle orientation, resulting in abrasives with equal or better performance at lower precision shaped grain loadings.
Implementation Method 1
the curable composition comprises a resole phenolic resin and an organic polymeric rheology modifier, wherein the organic polymeric rheology modifier comprises an alkali-swellable/soluble polymer
Implementation Method 2
The present disclosure overcomes this problem by using a resole phenolic-based curable composition (typically thixotropic) suitable for use in manufacture of an abrasive article
Implementation Method 3
the organic polymeric rheology modifier comprises an alkali-swellable/soluble polymer
Data Source
Figure 1~2B
AI summary
An abrasive article comprises abrasive particles adhered to a substrate by a binder material. The binder material comprises an at least partially cured resole phenolic resin and an organic polymeric rheology modifier. The amount of the at least partially cured resole phenolic resin comprises from 75 to 99.99 weight percent of the combined weight of the at least partially cured resole phenolic resin and the organic polymeric rheology modifier. Methods of making the abrasive article are also disclosed.