Coated Abrasive Article Discontinuous Pattern Curl Resistance
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Solution Overview
Problem
Conventional coated abrasive sheets tend to curl in humid environments, leading to operational issues, and existing solutions like pre-flexing do not effectively address curling during use.
Innovation Solution
The development of coated abrasive articles with a make resin, abrasive particles, and size resin applied in a discontinuous pattern on a flexible backing, creating uncoated areas that enhance curl resistance and improve cut and finish performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coated abrasive sheets are used in humid environments, then they provide standard abrasive performance, but they tend to curl which causes operational issues
Solution Approach 1:
The coating is divided into discrete pattern features (islands) rather than continuous coverage. Each feature is separated by uncoated areas, creating a segmented structure that allows the backing to flex uniformly without curling while maintaining abrasive functionality in the coated regions.
Solution Approach 2:
The coating is applied selectively in specific pattern features rather than uniformly across the entire backing. This creates local coated regions with abrasive particles and binders while leaving other areas uncoated, allowing different zones to serve different functions (abrasion vs. flexibility).
2Reliability
If pre-flexing is applied to mitigate curling, then some curl resistance is achieved, but it is generally ineffective in preventing curling during use
Solution Approach 1:
The discontinuous coating pattern is designed in advance to inherently prevent curling during use, eliminating the need for post-manufacturing pre-flexing operations. The pattern itself provides the curl-resistance function that pre-flexing attempts to achieve.
3Area of stationary object
If continuous coating is applied to provide complete coverage, then maximum abrasive surface area is achieved, but curling tendency increases
Solution Approach 1:
Instead of applying coating to 100% of the backing surface, the invention uses partial coverage with discrete pattern features. This partial action provides sufficient abrasive surface area for effective operation while avoiding the excessive coating that causes curling.
Data Source
AI summary
Provided are abrasive articles in which the make layer, abrasive particle layer, and size layer are coated onto a backing according to a coating pattern characterized by a pattern of discrete islands, or features, having an areal density ranging from about 30 features to about 300 features per square centimeter and an average feature diameter ranging from about 0.1 millimeters to about 1.5 millimeters. Optionally, the provided abrasive particles have an average abrasive particle size ranging from about 20 micrometers to about 250 micrometers and the average make layer thickness ranging from 33 percent to 100 percent of the average abrasive particle size. This coating pattern provides that all three components are generally in registration with each other, while also providing a pervasive uncoated area extending across the backing, thereby providing improved cut and finish performance while displaying a resistance to curl in wet environments.