Glass Fiber-Free Back Pad for Abrasive Disks
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Solution Overview
Problem
Conventional glass fiber textile back pads for abrasive disks are heavy, expensive, stiff, and generate dust during dressing operations, leading to skin and respiratory irritation, poor productivity, and increased manufacturing costs due to unsatisfactory wear resistance and uneven abrasion efficiency.
Innovation Solution
A glass fiber-free back pad comprising a nonwoven fabric with stacked carbon and polyester fiber textile layers, treated with an adhesive resin and subjected to heat and pressure for fusion, providing improved dimensional stability, flexibility, and extended lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If glass fiber textile is used for the back pad, then dimensional stability is achieved, but weight increases and flexibility deteriorates
Solution Approach 1:
The patent employs a composite material structure consisting of a nonwoven fabric base layer combined with a woven fabric layer. This composite construction achieves dimensional stability through the woven fabric's structural integrity while the nonwoven base provides lightweight properties and flexibility, thereby resolving the contradiction between dimensional stability and weight reduction.
2Stability of the object's composition
If glass fiber textile is used for the back pad, then dimensional stability is achieved, but flexibility deteriorates
Solution Approach 1:
The composite structure of nonwoven fabric base layer and woven fabric layer provides dimensional stability through the woven layer while maintaining flexibility via the nonwoven base layer's inherent properties, thus resolving the contradiction between dimensional stability and flexibility.
3Strength
If glass fiber textile is used for the back pad, then structural integrity is maintained, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive glass fiber textile with a cost-effective combination of nonwoven and woven fabrics that can be mass-produced through conventional textile manufacturing processes, thereby reducing manufacturing costs while maintaining sufficient structural integrity for abrasive disk applications.
4Strength
If glass fiber textile is used for the back pad, then initial strength is achieved, but wear resistance deteriorates
Solution Approach 1:
The composite structure combines a durable woven fabric layer that provides initial strength and structural integrity with a nonwoven base layer that contributes to overall durability and wear resistance, achieving both high initial strength and extended service life under abrasive conditions.
5Stability of the object's composition
If glass fiber textile is used for the back pad, then dimensional stability is achieved, but harmful dust generation occurs during dressing
Solution Approach 1:
The patent extracts and eliminates glass fiber material from the back pad construction, replacing it with organic or synthetic fiber alternatives that do not generate irritating dust during dressing operations, while maintaining dimensional stability through the woven fabric layer's structural properties.
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 results in a back pad with enhanced tensile strength, rotation breakage resistance, flexibility, and reduced skin irritation, allowing for prolonged use and increased productivity while lowering manufacturing costs, as evidenced by comparative testing.
Implementation Method 1
applying heat and pressure to the stack of the nonwoven fabric and textiles
Data Source
AI summary
A back pad comprising a nonwoven fabric, and at least one carbon and polyester fiber textile layers stacked thereon has an improved flexibility and provides an improved working environment, and thus, it can be advantageously used in the manufacturing of an abrasive disk.