Abrasive Article Supersize Coating Without Surfactants
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Solution Overview
Problem
Existing abrasive articles face challenges in achieving improved translucency and performance without using surfactants like DOWANOL DPnP, which are volatile organic compounds, and in optimizing the ratio of formed abrasive particles to diluent abrasive particles for enhanced cut rates and cut life.
Innovation Solution
The development of abrasive articles with a particulate mixture comprising 0 wt. % to less than 10 wt. % formed abrasive particles and greater than 90 wt. % diluent abrasive particles, along with a supersize coat that is substantially transparent without surfactants, utilizing a metal salt of a long-chain fatty acid and a styrene-acrylic polymer binder for improved translucency and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If surfactants like DOWANOL DPnP are used to prepare the supersize coating composition, then the coating transparency is improved, but volatile organic compounds (VOCs) are introduced which are harmful to the environment
Solution Approach 1:
The invention extracts and removes the surfactant component from the supersize coating composition. By formulating the coating without surfactants like DOWANOL DPnP, the patent eliminates VOC emissions while maintaining coating transparency through alternative composition formulations including metal salts of long-chain fatty acids and styrene-acrylic polymer binders.
2Productivity
If the abrasive layer comprises high amounts of formed abrasive particles (10 wt. % or more), then the cut rate and cut life are improved, but the translucency of the abrasive article deteriorates
Solution Approach 1:
The invention changes the concentration parameter of formed abrasive particles in the abrasive layer to less than 10 wt. %, creating an optimized balance between productivity and translucency. This parameter adjustment, combined with the transparent supersize coating formulation, achieves both improved cut rate and cut life while maintaining high translucency that allows the backing color and printed information to show through.
3Productivity
If diluent abrasive particles are used to increase the formed abrasive particle concentration, then the cut rate improves, but the translucency and environmental safety deteriorate due to VOC usage
Solution Approach 1:
The invention removes surfactants from the supersize coating formulation, eliminating VOC emissions while maintaining the optimized concentration of diluent abrasive particles (greater than 90 wt. %) that supports high cut rates through efficient particle distribution and exposure.
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 achieves improved translucency and extended cut rates and cut life while avoiding the use of surfactants, ensuring environmental safety and enhanced abrasive article performance.
Implementation Method 1
a supersize coat that is substantially transparent without surfactants, utilizing a metal salt of a long-chain fatty acid and a styrene-acrylic polymer binder for improved translucency
Implementation Method 2
The provided abrasive articles can be useful in, for example, abrading soft materials such as painted automotive surfaces
Data Source
AI summary
Abrasive articles, along with related compositions and methods, are provided. A first aspect relates to an abrasive article comprising a backing and an abrasive layer disposed on a major surface of the backing. The abrasive layer comprises a particulate mixture comprising formed abrasive particles and diluent abrasive particles. Based on the overall weight of the particulate mixture, about 0 wt. % to less than 10 wt. % formed abrasive particles having a substantially monodisperse particle size of from about 80 micrometers to about 120 micrometers; and about greater than 90 wt. % to about 99 wt. % diluent abrasive particles having a median particle size of from about 50 micrometers to about 250 micrometers.