Abrasive Articles With Deep UV Cure Photoinitiator
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Solution Overview
Problem
Commercially available abrasive articles often leave random surface defects, such as deep scratches, which reduce optical clarity and increase the risk of bacterial attachment, and require frequent replacement due to grain loss, leading to high costs for manufacturers.
Innovation Solution
Incorporating a photoinitiator, such as an oxime ester, into the make layer of abrasive articles to increase the depth of ultraviolet cure, enhancing grain retention and surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional photoinitiators are used in the make layer, then the curing process is simple and fast, but the depth of ultraviolet cure is insufficient, leading to poor grain retention and frequent abrasive article replacement
Solution Approach 1:
The patent employs a composite photoinitiator system combining multiple photoinitiators with different absorption characteristics and curing mechanisms. This composite approach enables deeper and more uniform ultraviolet penetration through the make layer, achieving cure depths exceeding 15 mils while maintaining grain retention and reducing abrasive article replacement frequency
Solution Approach 2:
The patent modifies the photoinitiator system by selecting specific photoinitiators with optimized absorption coefficients and quantum yields for deep UV curing. By adjusting photoinitiator concentration, molecular structure, and curing wavelength parameters, the system achieves enhanced penetration depth and cure quality without excessive complexity
2Reliability
If the make layer is cured to sufficient depth to retain grains, then grain retention improves, but the curing process requires more energy and time
Solution Approach 1:
The patent optimizes the balance between cure depth and energy consumption by selecting photoinitiators with peak absorption in the UV range and adjusting their concentration to achieve maximum curing efficiency. This parameter optimization ensures sufficient grain retention while minimizing unnecessary energy input and curing time
Solution Approach 2:
The patent replaces conventional single-wavelength UV curing with a multi-wavelength or optimized wavelength UV curing system that matches the photoinitiator absorption spectrum. This substitution improves energy utilization efficiency by directing UV energy precisely where it is most effective, reducing total energy consumption while achieving the required cure depth for grain retention
3Reliability
If abrasive grains are tightly bound to prevent loss, then grain retention improves, but surface quality and uniformity may deteriorate
Solution Approach 1:
The patent creates local quality variations in the make layer by optimizing the gradient of photoinitiator concentration, abrasive grain distribution, and binder composition from the backing interface to the exposed surface. This local optimization ensures strong grain binding at the interface while maintaining surface uniformity and quality for optimal machining performance
Solution Approach 2:
The patent uses a composite make layer comprising multiple components including photoinitiators, binders, abrasive grains, and optional additives in optimized proportions. This composite structure achieves simultaneous grain retention and surface uniformity by distributing functions across different components: photoinitiators ensure deep curing for grain binding, while binder composition and grain distribution control surface quality
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 increased depth of cure improves the retention of abrasive grains, reducing surface defects and extending the life of abrasive articles, thereby lowering replacement costs and enhancing surface characteristics.
Implementation Method 1
The make layer has abrasive grains and a photoinitiator that increases the depth of ultraviolet cure of the make layer
Data Source
AI summary
The disclosure is directed to an abrasive article. The abrasive article includes a backing having a major surface and a make layer. The make layer is disposed over the major surface of the backing. The make layer includes abrasive grains and a photoinitiator that increases the depth of ultraviolet cure of the make layer by at least about 50% compared to bis(2,4,6-trimethyl benzoyl) phenyl phosphine oxide. The disclosure is also directed to a method for forming the abrasive article.