Aqueous Polyurethane Binder for Nonwoven Abrasive Pads

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Solution Overview

Problem

There is a need for improving the cost, performance, and manufacture of abrasive articles while making them more environmentally friendly, particularly in the use of organic solvents in abrasive applications.

Innovation Solution

The development of an abrasive article comprising a backing material, a binder with an anionic water solubilizing material such as dimethylolpropionic acid (DMPA), and abrasive particles, where the binder is an aqueous polyurethane dispersion that allows for the production of nonwoven abrasive pads without organic solvents, maintaining desirable properties like thickness, flexibility, and bulk density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If organic solvents are used in abrasive articles, then performance and manufacturing are maintained, but environmental friendliness deteriorates

Engineering Contradiction:

Improveenvironmental friendlinessVSAvoidperformance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent changes the chemical composition parameter of the binder from organic solvent-based to aqueous-based, specifically using anionic water solubilizing material. This parameter change eliminates harmful organic solvents while maintaining the binder's functional properties for holding abrasive particles and providing flexibility to the abrasive article.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the organic solvent-based binding system with an aqueous polyurethane dispersion system containing anionic water solubilizing material. This substitution maintains the mechanical and functional performance requirements while eliminating environmental harm from organic solvents.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional coating techniques are used for nonwoven abrasive pads, then manufacturing simplicity is maintained, but thickness and flexibility are compromised

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidthickness and flexibility

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent modifies the binder parameters by using an aqueous polyurethane dispersion with specific anionic water solubilizing materials, which allows the binder to maintain flexibility and thickness even when applied through conventional coating techniques to nonwoven fabrics.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite binder system combining aqueous polyurethane dispersion with anionic water solubilizing materials, which provides both the flexibility needed for nonwoven abrasive pads and the structural integrity to maintain thickness, while being compatible with conventional coating methods.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If anionic water solubilizing material is used in the binder, then environmental friendliness is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveenvironmental friendlinessVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent changes the binder composition to aqueous-based with anionic water solubilizing material, which simplifies the manufacturing process by eliminating organic solvent handling while maintaining environmental friendliness. The parameter change actually reduces manufacturing complexity despite the specialized material used.

Inventive Principle:

Principle #35Parameter changes

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 solution enables the production of environmentally friendly abrasive articles with improved performance and cost-effectiveness, using conventional coating techniques, and allows lofty nonwoven abrasive articles to rebound and maintain their thickness and flexibility, addressing the limitations of existing abrasive technologies.

Implementation Method 1

a binder with an anionic water solubilizing material such as dimethylolpropionic acid (DMPA), where the binder is an aqueous polyurethane dispersion

Methodology Applied

Scientific EffectAnionic water solubilizing material binding: Adhesive

Implementation Method 2

anionic water solubilizing material comprises dimethylolpropionic acid (DMPA)... aqueous polyurethane dispersion containing an anionic water solubilizing material

Methodology Applied

Scientific EffectWater solubilizing: Solvation

Implementation Method 3

open lofty fibrous nonwoven web comprising at least 55% synthetic fibers, a polyurethane binder containing DMPA distributed generally uniformly throughout the nonwoven web, thereby serving to bond the fibers of the nonwoven web together

Methodology Applied

Scientific EffectFiber bonding: Adhesive

Data Source

PatentUS11642756B2Abrasive article with anionic water solubilizing material and method of making

Publication Date: 2023.05.09 3M INNOVATIVE PROPERTIES CO

AI summary

An abrasive article includes backing material, binder comprising an anionic water solubilizing material provided on at least a portion of the backing material and abrasive particles provided on at least a portion of the backing material. A method of making such an abrasive article comprises the steps of providing a backing material, applying a first binder containing an anionic water solubilizing material to the backing material, and applying abrasive particles to the backing material.