Abrasive Article Supersize Coating Laser Conversion
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Solution Overview
Problem
Existing abrasive articles face issues with dust and swarf accumulation, leading to reduced performance and shortened lifespan due to exposed surfaces and ridging effects from conventional cutting methods, particularly when using lasers for manufacturing.
Innovation Solution
The use of a supersize coating applied after laser conversion of abrasive articles, where focused laser energy is impinged on the backside of the abrasive article to minimize ridging and extend the abrasive surface's life by covering all surfaces, including internal apertures and the outer perimeter, preventing swarf accumulation and enhancing cutting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional cutting methods are used to manufacture abrasive articles, then manufacturing process is simple, but ridging effects occur around cut regions causing surface defects
Solution Approach 1:
The patent replaces mechanical cutting methods with laser energy conversion. The laser process melts and fuses material to create clean edges without mechanical contact, eliminating the ridging effects that occur with conventional mechanical cutting tools. This substitution of mechanical system with thermal/optical system resolves the contradiction between manufacturing simplicity and surface quality.
Solution Approach 2:
The patent changes the physical state of material during cutting by using laser energy to melt and fuse the backing and abrasive coating. This parameter change from solid-state mechanical cutting to molten-state fusion creates smooth, defect-free surfaces around cut regions including apertures and perimeters, eliminating ridging while maintaining ease of manufacture.
2Reliability
If abrasive particles are exposed during use, then abrading function is maintained, but dust and swarf accumulate on the abrasive coating reducing performance
Solution Approach 1:
The patent extracts and removes dust and swarf from the abrasive coating surface by applying laser energy that melts and fuses the accumulated material, then blows it away with air pressure. This extraction of harmful contaminants maintains the abrading function of exposed particles while preventing performance degradation from accumulation.
Solution Approach 2:
The patent uses high-velocity air pressure to blow away melted and fused dust/swarf material from the abrasive coating. This forced removal mechanism accelerates the clearing of harmful accumulations, maintaining reliable abrading function without performance loss.
3Manufacturing precision
If laser energy is applied to convert abrasive article, then cutting precision is improved, but ridging effects and recast material are generated
Solution Approach 1:
The patent applies preliminary laser energy to melt and fuse the backing and abrasive coating material before cutting occurs. This preliminary thermal action prepares the material in a softened state, allowing clean cutting edges to form without subsequent ridging or recast material formation, thus maintaining cutting precision while eliminating harmful surface defects.
Solution Approach 2:
The patent utilizes phase transitions of the backing and abrasive coating material from solid to molten state during laser conversion. This controlled phase transition allows material to flow and fuse cleanly, preventing ridging effects and recast material formation while maintaining precise cut geometry.
4Reliability
If abrasive coating surfaces are exposed, then abrading capability is maintained, but article lifespan is reduced due to premature wear
Solution Approach 1:
The patent converts the harmful effect of exposed abrasive particle surfaces, which normally lead to premature wear and reduced lifespan, into a benefit by using laser energy to continuously fuse and protect these surfaces. The laser treatment creates a protective fused layer that preserves abrading capability while significantly extending article lifespan by preventing premature particle loss.
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 significantly reduces ridging effects, increases the abrasive article's lifespan, and improves cutting performance by maintaining a smooth, defect-free surface, thereby enhancing the abrasive article's ability to effectively abrade workpieces without premature wear or scratches.
Implementation Method 1
passing focused laser energy through the backing, with the laser energy passing through the second side of the backing prior to passing through the abrasive coating
Implementation Method 2
The sidewall of the aperture is fused
Implementation Method 3
the laser energy progressing through to the face side. Such a process reduces the amount of ridging effects (also known as 'recast') from polymer components
Data Source
AI summary
Abrasive articles, and methods of making abrasive articles that include a supersize coating or component, such as one configured to inhibit the collection of dust and/or swarf on the abrasive coating. The supersize component can be applied to the abrasive coating after converting the abrasive article with a laser or other conversion mechanism, whether non-contact or mechanical contact. In some embodiments, no fresh or exposed abrasive or backing surfaces exist; that is, the supersize component covers all surfaces.