Coated Abrasive Belt With Alternating Triangular Platelet Rows
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Solution Overview
Problem
There is a need to improve the cost, performance, and life of coated abrasive belts, particularly those with triangular abrasive platelets, which are used for shaping, finishing, or grinding various materials like wood and non-ferrous metals, as existing technologies do not effectively address these aspects.
Innovation Solution
The development of a coated abrasive belt with triangular abrasive platelets precisely secured at specific locations and Z-axis rotational orientations on a flexible backing, utilizing a multilayer construction including a make layer and size layer, with the triangular abrasive platelets oriented at angles to avoid scoring and enhance abrasion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If triangular abrasive platelets are randomly oriented on the belt backing, then the manufacturing process is simpler and cost is reduced, but the abrasion performance deteriorates due to scoring and reduced efficiency
Solution Approach 1:
The abrasive platelets are pre-oriented and pre-positioned in a controlled manner during the manufacturing process. The platelets are applied to the belt backing with predetermined rotational orientations (e.g., within ±10 degrees of vertical or horizontal alignments) and specific spacing patterns before the belt is put into service, ensuring optimal abrasion performance from the start
Solution Approach 2:
The patent applies different orientation patterns to different regions of the abrasive layer. Alternate rows of abrasive platelets are oriented at different angles (e.g., first row within ±10 degrees of vertical, second row within ±10 degrees of horizontal), creating local variations in abrasion characteristics that prevent scoring while maintaining overall effectiveness
2Reliability
If triangular abrasive platelets are precisely placed and oriented at specific angles, then abrasion performance and belt life are improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent specifies precise parameter ranges for abrasive platelet orientation (e.g., within ±10 degrees of vertical or horizontal alignments) and spacing (e.g., 1-3 times the platelet length apart). These controlled parameter variations ensure consistent reliability and performance while providing clear manufacturing targets that can be achieved through standardized processes
Solution Approach 2:
The abrasive layer is segmented into alternate rows with different orientation patterns. This segmentation into discrete, repeatable units (rows with specific orientations) simplifies the manufacturing process by breaking down the complex orientation requirement into manageable, periodic patterns that can be applied systematically
3Productivity
If abrasive platelets are closely spaced to increase material removal rate, then productivity is improved, but the belt clogs more quickly reducing its life
Solution Approach 1:
The patent creates local variations in abrasive platelet spacing and orientation across different rows. Alternate rows are oriented at different angles with controlled spacing (1-3 times the platelet length), creating a non-uniform distribution that maintains high material removal rates while preventing localized clogging that would otherwise limit belt 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 solution results in improved abrasion performance and extended belt life by ensuring precise placement and orientation of triangular abrasive platelets, enhancing the belt's ability to effectively grind materials without scoring, thereby improving overall cost-effectiveness and performance.
Implementation Method 1
frictionally contacting a portion of the abrasive layer of a coated abrasive belt according to the present disclosure with the workpiece, and moving at least one of the workpiece and the abrasive article relative to the other to abrade the workpiece
Data Source
Figure 1
Figure 1A
Figure 1B~3B
AI summary
A coated abrasive belt (100) includes a belt backing (110) and an abrasive layer disposed thereon. The abrasive layer comprises abrasive elements (160) secured to at least a portion of a major surface of the belt backing (110) by at least one binder material. The abrasive elements are disposed at contiguous intersections of horizontal (192) and vertical lines (194) of a rectangular grid pattern. Each abrasive element has at least two triangular abrasive platelets (130), each having respective top and bottom surfaces connected to each other, and separated by, three sidewalls. On a respective basis, one sidewall of the triangular abrasive platelets is disposed facing and proximate to the belt backing. A first portion of the abrasive elements is arranged in alternating first rows (16) wherein the triangular abrasive platelets are disposed lengthwise aligned with the vertical lines (194). A second portion of the abrasive elements is arranged in alternating second rows (168) wherein the triangular abrasive platelets (130) are disposed lengthwise aligned with the horizontal lines (194). The first and second rows repeatedly alternate along the vertical lines. Methods of making and using the coated abrasive belt are also disclosed.