Abrasive Article Coating for Controlled Particle Tilt Orientation
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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 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
Engineering Contradiction Analysis
1Manufacturing precision
If traditional abrasive articles are manufactured with random particle distribution, then manufacturing process is simple, but material removal performance is suboptimal
Solution Approach 1:
The patent changes the orientation parameter of abrasive particles from random to controlled tilt angles (at least 65% with tilt angle of 10-85 degrees relative to the normal of the backing layer). This is achieved through modified manufacturing processes including controlled particle application and make coat formulation, transforming the particle orientation state to improve cutting performance while maintaining manufacturability.
Solution Approach 2:
The patent applies preliminary action by pre-orienting abrasive particles during the manufacturing process before final product completion. The particles are positioned with specific tilt orientations in the front fill layer and make coat layer during application, ensuring optimal orientation is established before the abrasive article enters service, thereby eliminating the need for post-manufacturing reorientation.
2Productivity
If abrasive particles are densely packed for high material removal rate, then productivity increases, but particle orientation control becomes more difficult
Solution Approach 1:
The patent applies local quality by creating different density and orientation characteristics in different layers. The front fill layer contains particles at controlled tilt angles with specific spacing, while the make coat layer provides additional support. This layered approach with varying local properties allows high particle density for productivity while maintaining orientation control through the structured front fill layer.
Solution Approach 2:
The patent uses composite material structure with multiple layers (front fill layer, make coat layer, backing layer) each serving specific functions. The front fill layer is formulated with specific viscosity and particle concentration to achieve both dense packing and orientation control, while the make coat layer provides additional bonding and orientation stabilization, creating a composite structure that simultaneously achieves high productivity and precision.
3Stability of the object's composition
If make coat viscosity is increased to improve particle bonding, then particle distribution stability improves, but particle orientation control during application deteriorates
Solution Approach 1:
The patent applies dynamics by using a make coat with intermediate viscosity that allows particle reorientation during the application process. The viscosity is formulated to be fluid enough to permit particle rotation and orientation adjustment under shear stress during coating application, yet viscous enough to maintain bonding and prevent particle displacement after application. This dynamic viscosity characteristic enables both orientation control and distribution stability.
Data Source
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.