Self-Supporting Abrasive Layer with Epoxy-Acrylate Resin
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Solution Overview
Problem
Existing coated abrasives face challenges such as brittle make resin coatings, poor adhesion with untreated backings, and increased manufacturing complexity and cost due to the need for processing to enhance adhesion, particularly with epoxy-acrylate hybrid chemistry-based products.
Innovation Solution
Development of abrasive articles using a polymerizable epoxy-acrylate resin composition that forms a self-supporting abrasive layer, eliminating the need for expensive backings and allowing for cost-advantaged constructs, with a curable composition that includes abrasive particles and void spaces, and optional additional layers for attachment or backing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy-acrylate hybrid chemistry is used to prepare the make coat, then adhesion to backing is improved, but the make resin coating becomes brittle and manufacturing complexity increases
Solution Approach 1:
The patent modifies the chemical composition parameters of the make resin by incorporating flexible polymer components (such as polybutadiene or polyester) into the epoxy-acrylate hybrid system. This changes the molecular structure to include flexible segments that prevent brittleness while maintaining the adhesive properties of the epoxy-acrylate chemistry.
2Strength
If epoxy-acrylate hybrid chemistry is used to prepare the make coat, then adhesion to backing is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple functions into the make resin coating itself. The make resin simultaneously provides adhesion to the backing, flexibility to prevent brittleness, and serves as the structural matrix for embedding abrasive particles. This merging of functions eliminates the need for separate processing steps to enhance adhesion, thereby reducing manufacturing complexity while maintaining strong adhesion.
3Adaptability or versatility
If paper or polymer backing is used to support flexible abrasives, then flexibility for contoured areas is enabled, but cleanup time increases and disadvantages of existing products occur
Solution Approach 1:
The patent extracts and removes the traditional paper or polymer backing from the abrasive article structure. Instead of using a separate backing layer, the make resin coating itself is formulated to provide both the structural support and the flexibility needed for contoured surfaces. This elimination of the backing layer removes the source of cleanup problems associated with paper or polymer residues while maintaining the desired flexibility for sanding contoured areas.
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 a flexible and cost-effective abrasive article with improved adhesion and reduced manufacturing complexity, enabling efficient sanding of various substrates without the brittleness issues of traditional coated abrasives.
Implementation Method 1
Abrasive products can, in some instances, comprise a make coat, mineral, a size coat, and a super-size coat. Some abrasives currently in production employ epoxy-acrylate hybrid chemistry to prepare the make coat to manufacture coated abrasives.
Data Source
AI summary
The disclosure relates to layers comprising a body having a thickness, T, comprising a curable composition comprising a polymerizable epoxy-acrylate resin composition and abrasive particles at least partially embedded in the polymerizable epoxy-acrylate resin composition, wherein the body includes a plurality of void spaces free of the curable composition extending into the body from the first major surface and the depth of the plurality of void spaces is at least 10 percent of thickness T. The disclosure also relates to cured compositions formed from such curable compositions and, in turn, abrasive articles made from such cured compositions as well as methods for making abrasive articles.