Abrasive Article Wax Size Coating to Reduce Swarf Loading
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing abrasive articles suffer from loading issues due to swarf accumulation between abrasive particles, leading to reduced performance and increased abrasion force requirements, with stearate-based anti-loading solutions being costly and prone to sloughing off during use.
Innovation Solution
An anti-loading composition is developed, incorporating wax into the size coat precursor, eliminating the need for a supersize coat and enhancing durability and anti-loading properties, particularly effective with finer abrasive particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stearate-based anti-loading coatings are used, then anti-loading performance is improved, but manufacturing cost increases and durability deteriorates due to sloughing off during use
Solution Approach 1:
The patent changes the chemical composition parameters of the size coat by incorporating specific additives (waxes, metal stearates, fluorochemicals) in optimized concentrations. This modifies the physical and chemical properties of the size coat to achieve durable anti-loading performance without requiring expensive supersize coatings or frequent reapplication.
Solution Approach 2:
The patent creates a composite size coat formulation by combining multiple components (binder, wax, metal stearate, fluorochemical additives) into a unified coating system. This composite approach leverages the synergistic effects of each component to achieve both cost-effectiveness and durable anti-loading performance, eliminating the need for separate supersize coating applications.
2Reliability
If multiple coatings (make coat, size coat, supersize coat) are applied, then anti-loading performance is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of the size coat and supersize coat into a single enhanced size coat formulation. By incorporating anti-loading additives directly into the size coat, the patent eliminates the need for a separate supersize coating layer, thereby simplifying the overall coating structure while maintaining or improving anti-loading performance.
Solution Approach 2:
The enhanced size coat formulation serves multiple functions simultaneously: it provides the primary size coating function, delivers durable anti-loading performance, and eliminates the need for separate supersize coating. This multi-functional approach reduces coating complexity while achieving comprehensive performance.
3Reliability
If stearate coatings are applied to prevent loading, then anti-loading performance is improved, but durability worsens as the coating sloughs off during abrading
Solution Approach 1:
The patent modifies the physical and chemical parameters of the size coat by incorporating waxes and fluorochemical additives alongside metal stearates. These parameter changes enhance the coating's adhesion properties and thermal stability, preventing the coating from sloughing off during the abrading process while maintaining effective anti-loading performance throughout the abrasive article's service life.
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 composition significantly reduces loading, maintains cut durability, and is cost-effective, offering superior performance without the need for additional coatings, suitable for various workpieces including wood, plastic, and fiberglass.
Implementation Method 1
The abrasive industry has sought loading-resistant or anti-loading materials to use in abrasive articles. Preferred materials have been zinc stearate and calcium stearate. One theory for the success of metal stearates as an anti-loading agent is that the metal stearate coating powders off the coated abrasive surface during the abrading process, which in turn causes the swarf to also powder off of the surface, thus reducing the amount of loading.
Implementation Method 2
an anti-loading size layer at least partially disposed on the abrasive layer and comprising a cured size precursor
Data Source
Figure 1
AI summary
The present disclosure relates to an abrasive article construction containing an anti-loading composition which significantly reduces loading, is coatable, is durable, and is relatively inexpensive to manufacture. In particular, the use of the anti-loading compositions of the present disclosure as a size coat at least reduces if not eliminates the need for a supersize coat, while offering comparable if not superior performance and durability. In one aspect, the present disclosure provides an abrasive article including a backing with a first major surface and an opposing second major surface, an abrasive layer bonded to at least a portion of the first major surface, with the abrasive layer comprising abrasive particles retained in a make coat. The abrasive article further includes an anti-loading size layer comprising a size coat binder and wax at least partially disposed on the abrasive layer.