Non-woven Abrasive Fleece Uniform Coating via Preliminary Fiber Treatment
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Solution Overview
Problem
The existing methods for producing abrasive fleece face challenges in achieving homogeneous and reproducible properties due to difficulties in consistently coating abrasive particles onto the fleece during the manufacturing process.
Innovation Solution
Applying abrasive grains to the fleece fibers before the fleece formation or consolidation process, allowing for even distribution and using a light-curing synthetic resin for adhesion, along with processes like carding, aerodynamic processing, and water jet swirling for bonding, which enhances the uniformity and durability of the abrasive fleece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If abrasive particles are applied during the fleece formation or consolidation process, then the coating can be applied to the fleece, but the distribution of abrasive particles becomes non-uniform and reproduction of properties becomes difficult
Solution Approach 1:
The patent applies abrasive particles to the fleece fibers before the fleece formation process, rather than during or after. This preliminary application ensures that abrasive particles are uniformly distributed throughout the fleece structure from the beginning, solving the problem of non-uniform coating that occurs when particles are applied later in the process
Solution Approach 2:
The patent segments the coating process by applying abrasive particles to individual fibers before they are assembled into the fleece structure. This segmentation allows each fiber to be uniformly coated independently, ensuring consistent distribution throughout the final product and improving both homogeneity and reproducibility
2Ease of manufacture
If traditional adhesive coating methods are used, then abrasive particles can be bound to the fleece, but the coating process becomes complex and difficult to control consistently
Solution Approach 1:
By applying abrasive particles to fibers before fleece formation, the patent eliminates the need for complex adhesive coating equipment and processes. The particles are incorporated into the fiber structure itself, simplifying manufacturing while ensuring uniform distribution throughout the fleece
Solution Approach 2:
The patent merges the abrasive particle application with the fiber preparation process itself, rather than treating them as separate operations. This integration simplifies the overall manufacturing process while ensuring that abrasive particles are uniformly distributed throughout the fleece structure
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 method ensures a more even and reproducible application of abrasive grains, improving the homogeneity and mechanical properties of the abrasive fleece, reducing tool wear and allowing for controlled distribution of abrasive particles, resulting in a higher-quality product.
Implementation Method 1
using a light-curing synthetic resin for adhesion
Implementation Method 2
the fleece bonding takes place using a swirling process, for example with water jet swirling
Data Source
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AI summary
The invention relates to a method for manufacturing a non-woven abrasive article, wherein non-woven fibers made of a certain starting material are subjected to the method steps of forming a non-woven web and then consolidating the non-woven web. In order to improve the homogeneity and the reproducibility of the obtained non-woven abrasive article, prior to the method step of forming the non-woven web and/or prior to the method step of consolidating the non-woven web, the non-woven fibers are coated with abrasive grains in such a way that the abrasive grains adhere to the starting material.