Abrasive Disc Laminated Construction Reduces Production Costs
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Solution Overview
Problem
Existing methods for manufacturing abrasive discs are costly due to the need for complex supporting constructions to withstand mechanical stress, resulting in high operating costs and inefficient production processes.
Innovation Solution
A method involving a laminated construction of a vulcanized fiber support layer coupled with a fiberglass net layer, impregnated with synthetic resins, and coated with abrasive material, which is then molded and cured at controlled temperatures to create a lightweight, mechanically resistant abrasive disc.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex supporting constructions are used to withstand mechanical stress, then mechanical strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses a composite construction combining fiberglass net layers with resin impregnation to create a supporting structure that provides high mechanical strength while maintaining simplicity. The fiberglass-resin composite achieves the required stress resistance without needing complex metal frameworks or multiple structural components.
Solution Approach 2:
The patent changes the material parameters by using synthetic resins with specific mechanical properties and fiberglass configurations that provide high strength-to-weight ratios. This allows the supporting construction to withstand mechanical efforts with simpler, lighter materials rather than complex heavy-duty structures.
2Strength
If complex supporting constructions are used to withstand mechanical stress, then mechanical strength is improved, but operating cost increases
Solution Approach 1:
The fiberglass-resin composite material provides durable mechanical strength that reduces maintenance frequency and replacement costs. The composite structure's resistance to wear and mechanical degradation lowers long-term operating costs compared to more complex conventional constructions.
3Device complexity
If simple supporting constructions are used, then manufacturing cost is reduced, but mechanical strength decreases
Solution Approach 1:
The patent demonstrates that simple fiberglass net layers impregnated with resin can achieve the required mechanical strength without complex constructions. The composite material's inherent strength properties allow simple geometries to perform adequately under operational stresses.
Solution Approach 2:
By optimizing the resin formulation and fiberglass configuration parameters, the patent achieves high mechanical strength from simple constructions. The material parameter optimization compensates for the lack of structural complexity, maintaining strength while simplifying the overall design.
4Stability of the object's composition
If traditional single-material supporting elements are used, then structural integrity is maintained, but weight increases
Solution Approach 1:
The fiberglass-resin composite provides high specific strength (strength-to-weight ratio), allowing the supporting construction to maintain structural integrity while being significantly lighter than traditional single-material elements like metal plates or dense plastics.
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
This approach simplifies the construction process, reduces production costs by 30%, and results in a reliable, safe, and efficient abrasive disc with improved mechanical resistance and maintenance capabilities.
Implementation Method 1
a laminated construction of a vulcanized fiber support layer (1) coupled with a fiberglass net layer (2), impregnated with synthetic resins
Implementation Method 2
which is then molded and cured at controlled temperatures to create a lightweight, mechanically resistant abrasive disc
Data Source
Figure 1~2
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AI summary
The present invention relates to a method for making abrasive discs, comprising the steps of coupling a vulcanized fiber or fiber paperboard or paperboard supporting layer (1) to a further layer (2) having at least a glass fiber net, hot pressing, in a pressing mold, the two coupled layers, thereby forming a central bulged portion (4), fixing a central ring nut (5), spreading on the concave face a binding resin, applying fabric blade elements (11) coated by an abrading material and pressing the assembly in a heated oven.