Coated Abrasive Disc Adhesive Bond Integrity
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Solution Overview
Problem
Coated abrasive laminate discs face challenges in maintaining bond integrity and resistance to delamination during heavy use, particularly due to issues with the melting onset temperature of thermoplastic laminating adhesives and the durability of the backing materials.
Innovation Solution
A coated abrasive laminate disc is created using a backing disc with a woven fabric and a glass fabric secured by a thermoplastic laminating adhesive with a melting onset temperature between 140° C. to 190° C., comprising polyamide or polyurethane with specific tensile strengths, along with an abrasive layer and optional supersize layer, to enhance durability and prevent delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thermoplastic laminating adhesive is used to secure the woven fabric to the glass fabric, then the backing structure is simplified and manufacturing is easier, but the bond integrity deteriorates at high temperatures during heavy use
Solution Approach 1:
The patent changes the critical parameter of the thermoplastic laminating adhesive by specifying a melting onset temperature range of 140°C to 190°C. This parameter optimization ensures the adhesive remains stable during heavy use while maintaining ease of manufacture through thermoplastic processing
Solution Approach 2:
The patent uses a composite approach by combining thermoplastic laminating adhesive with specific fabric treatments (saturants on glass fabric, backsize/presize on woven fabric) to achieve both manufacturing ease and bond integrity under demanding conditions
2Ease of manufacture
If the melting onset temperature of the thermoplastic laminating adhesive is lowered to facilitate processing, then the ease of manufacture improves, but the resistance to delamination deteriorates during heavy use
Solution Approach 1:
The patent optimizes the melting onset temperature parameter to a specific range (140°C to 190°C) that balances processing ease with delamination resistance, preventing the adhesive from melting at operating temperatures while remaining manufacturable
3Device complexity
If conventional backing materials are used without specific treatments, then the device complexity is reduced, but the durability and resistance to delamination deteriorate
Solution Approach 1:
The patent applies local quality improvements by treating specific regions of the backing materials: saturant treatment on the glass fabric side, and backsize/presize treatments on the woven fabric side. These localized treatments enhance durability without requiring complete restructuring of the entire backing system
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 provides resistance to delamination and maintains abrasive properties such as high cut, long life, and low shelling, while ensuring the adhesive bond remains intact under heavy use conditions.
Implementation Method 1
the thermoplastic laminating adhesive has a melting onset temperature in a range of from about 140° C. to 190° C., inclusive
Implementation Method 2
an abrasive layer secured to the backing proximate to the woven fabric, the abrasive layer comprising at least one binder and abrasive particles
Data Source
AI summary
A coated abrasive laminate disc (100) has a backing (120) with glass (125) and woven fabrics (124) laminated with a thermoplastic adhesive (122) having a melting onset temperature in a range of from about 140° C. to 190° C. and comprising polyamide and/or polyurethane. Methods of making are the coated abrasive laminate discs (100) are also disclosed.