Coated Abrasive Orientation via Cavity Tooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional coated abrasive articles suffer from random z-direction rotational orientation of abrasive particles, leading to suboptimal performance due to uncontrolled orientation and spacing, particularly with triangular and crushed abrasive particles, resulting in decreased cut efficiency and premature wear.
Innovation Solution
A method involving a production tool with cavities that align and orient platey crushed abrasive particles, ensuring their thickness axis is parallel to the intended use direction, which is then transferred to a make layer on a backing, controlling the orientation and spacing for improved grinding performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional electrostatic deposition or drop coating methods are used to apply abrasive particles, then the manufacturing process is simple and fast, but the abrasive particles have random z-direction rotational orientation leading to suboptimal cutting performance
Solution Approach 1:
The production tool with cavities pre-positions and orients the abrasive particles before they are transferred to the make layer. The cavities are designed to hold particles in specific orientations (with thickness axis parallel to intended use direction) beforehand, eliminating the need for complex real-time orientation control during deposition.
Solution Approach 2:
The production tool acts as an intermediary device between the abrasive particle source and the make layer. It temporarily holds and orients particles in cavities, then transfers them in the desired orientation to the make layer, simplifying the overall process while achieving precise orientation control.
2Reliability
If adhesive is used to transfer oriented abrasive particles from screens (as in WO 2012/112305 A2), then particle orientation can be controlled, but the adhesive may detackify over time and contaminate workpieces
Solution Approach 1:
The invention removes the adhesive layer from the particle transfer process. Instead of using adhesive to hold and transfer particles, the production tool uses mechanical cavities to hold particles and gravity/force to transfer them directly to the make layer, eliminating adhesive-related problems entirely.
Solution Approach 2:
The production tool with cavities serves as a temporary, disposable positioning structure that holds particles during transfer but does not require long-term adhesive bonding. The tool can be easily cleaned or replaced, and no permanent adhesive remains on the abrasive article.
3Productivity
If triangular shaped abrasive particles are used to enhance cut rates, then cutting performance is improved, but the particles have random orientation leading to premature wear
Solution Approach 1:
The production tool pre-orientes triangular abrasive particles with their thickness axis parallel to the intended use direction before application. This preliminary orientation ensures that the sharp edges of triangular particles are properly aligned for cutting while distributing wear more evenly, extending article life.
4Manufacturing precision
If abrasive particles are applied without controlled orientation, then the manufacturing process is simple, but cutting efficiency decreases and wear is premature
Solution Approach 1:
The production tool with cavities pre-positions and orients abrasive particles in specific orientations and spacings before transfer to the make layer. This preliminary arrangement ensures optimal cutting efficiency and extended article life without complicating the manufacturing process.
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 enhances the cut performance and extends the life of coated abrasive articles by ensuring optimal orientation and spacing of abrasive particles, improving cutting efficiency and reducing wear.
Implementation Method 1
a production tool with cavities that align and orient platey crushed abrasive particles, ensuring their thickness axis is parallel to the intended use direction
Data Source
AI summary
A coated abrasive article includes a backing, a make layer, crushed abrasive particles, and a size layer. The crushed abrasive particles include: 35 to 100 weight percent of initial crushed abrasive particles having a first composition and first size grade, wherein a majority of the initial crushed abrasive particles are platey crushed abrasive particles, and wherein each platey crushed abrasive particle has a respective length, width, and thickness; and 0 to 65 weight percent of crushed filler particles having a second composition and a second size grade. The first and second compositions and/or size grades are different. The coated abrasive article has a direction of intended use, a majority of the platey crushed abrasive particles of the coated abrasive article are positioned with their thickness oriented substantially parallel to the direction of intended use. A method of making the coated abrasive article is also disclosed.