Abrasive Article Make-Coat Ratios for Particle Distribution

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Solution Overview

Problem

Existing abrasive articles face challenges in achieving optimal distribution and orientation of abrasive particles, which affect their performance and manufacturing efficiency.

Innovation Solution

The abrasive articles are designed with a make coat thickness ratio (Tg/Ta) of not greater than 1.5, where Tg is the average thickness of the make coat at the sides of the abrasive particles and Ta is the average thickness of the make coat, along with controlled rotational and tilt angles of the abrasive particles, to enhance particle distribution and orientation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional abrasive articles are manufactured without controlled make coat thickness ratio, then manufacturing process is simpler, but particle distribution and orientation are suboptimal affecting performance

Engineering Contradiction:

Improveparticle distribution and orientationVSAvoidmake coat thickness control

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by controlling the make coat thickness ratio (Tg/Ta) to not greater than 1.5, where Tg is the average thickness of the make coat at the sides of the abrasive particles and Ta is the average thickness of the make coat. This specific parameter control optimizes particle distribution and orientation, resolving the contradiction between manufacturing precision and device complexity by establishing a quantitative threshold for make coat thickness.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If make coat thickness is increased to ensure particle containment, then particle distribution improves, but material removal efficiency decreases

Engineering Contradiction:

Improveparticle containmentVSAvoidmaterial removal efficiency

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent optimizes the make coat thickness ratio (Tg/Ta) to not greater than 1.5, finding the optimal balance point where sufficient particle containment is achieved while maintaining material removal efficiency. This parameter optimization resolves the contradiction by identifying the threshold value that simultaneously satisfies both particle stability and productivity requirements.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies partial action by controlling the make coat thickness at the sides of particles (Tg) to be no more than 1.5 times the average thickness (Ta), rather than uniformly increasing thickness throughout. This selective thickness control provides sufficient containment where needed while minimizing overall material removal resistance, resolving the contradiction between particle containment and productivity.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS12384004B2Abrasive articles and methods of forming same

Publication Date: 2025.08.12 SAINT GOBAIN ABRASIVES INC

AI summary

An abrasive article includes a backing; a make coat overlying the backing; and a plurality of abrasive particles overlying the backing and at least partially contained in the make coat; and a make coat thickness ratio (Tg/Ta) of not greater than 1.5, wherein Tg is the average thickness of the make coat at the sides of the abrasive particles and the Ta is the average thickness of the make coat.