Abrasive Article Binder Rheology Modifier Orientation
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Solution Overview
Problem
Abrasive particles in abrasive articles often tip over due to the properties of resole phenolic resin binder material precursors, either being too fluid or too hard, which disrupts their original orientation during the curing process.
Innovation Solution
A resole phenolic-based curable composition is used, incorporating an organic polymeric rheology modifier such as an alkali-swellable/soluble polymer, which provides thixotropic properties to maintain the orientation of abrasive particles until sufficient curing occurs, comprising a liquid phenolic resin and an organic polymeric rheology modifier with a specific weight percentage ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resole phenolic resin binder material precursor is used, then abrasive particles can be adhered to the substrate, but the particles tip over due to the binder being too fluid or too hard
Solution Approach 1:
The invention changes the rheological parameters of the binder material precursor by adding a rheology modifier, transforming it from a thixotropic fluid to a pseudoplastic fluid. This parameter change allows the binder to provide adequate adhesion strength while preventing abrasive particle tipping during the coating and curing process
Solution Approach 2:
The rheology modifier acts as an intermediary substance between the resole phenolic resin and the abrasive particles. It mediates the flow characteristics of the binder, enabling the particles to be properly oriented and adhered without tipping over during manufacturing
2Ease of manufacture
If the binder precursor material is too fluid, then particles can be deposited, but they tip over by gravity
Solution Approach 1:
The invention modifies the viscosity parameter of the binder precursor through the addition of a rheology modifier. The binder transitions from a thixotropic fluid (too fluid) to a pseudoplastic fluid with controlled viscosity, maintaining ease of coating application while preventing particle tipping due to gravity
3Stability of the object's composition
If the binder precursor material is too hard, then particles are retained, but they do not adhere properly and tip over due to gravity
Solution Approach 1:
The invention adjusts the rheological parameters of the binder precursor by incorporating a rheology modifier. This creates a pseudoplastic fluid that remains soft enough to allow proper particle adhesion while maintaining sufficient structure to prevent tipping, resolving the contradiction between binder stability and particle orientation
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 solution effectively preserves the initial placement and orientation of abrasive particles, enhancing the performance and precision of abrasive articles by maintaining consistent tip density across various mineral coating technologies.
Implementation Method 1
These curable compositions typically exhibit thixotropic flow characteristics and are useful for preserving the initial placement and orientation of applied abrasives until sufficient curing has occurred.
Implementation Method 2
the organic polymeric rheology modifier comprises an alkali-swellable/soluble polymer
Data Source
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 99.01 to 99.98 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.