Coated Abrasive Article with Macro-Channels for Surface Quality
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Solution Overview
Problem
Abrasive articles that offer high material removal rates often compromise on surface quality, while those that excel in surface characteristics have low material removal rates, leading to inefficient and costly multi-step processes in industries like automotive paint repair.
Innovation Solution
A coated abrasive article design featuring a backing with abrasive regions and macro-channels that are free of adhesive and abrasive grains, allowing for optimized material removal and surface finish through controlled channel widths and grain sizes, enhancing both material removal rates and surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If abrasive articles use coarse grain sizes to achieve high material removal rates, then productivity increases, but surface quality deteriorates with fine scratches and surface flaws
Solution Approach 1:
The abrasive article is segmented into multiple abrasive regions with different grain sizes arranged in a specific pattern. Coarse grain regions perform initial material removal while fine grain regions subsequently refine the surface, all in a single article. This segmentation allows simultaneous achievement of high material removal rates and good surface quality without requiring multiple separate abrasives.
Solution Approach 2:
The invention merges multiple abrasive functions (coarse grinding and fine polishing) into a single abrasive article by incorporating different grain size regions. This combines the high productivity of coarse abrasives with the surface quality benefits of fine abrasives, eliminating the need for multi-step processes using separate abrasive products.
2Manufacturing precision
If abrasive articles use fine grain sizes to achieve desirable surface characteristics, then surface quality improves, but material removal rate decreases
Solution Approach 1:
The abrasive article is segmented into multiple abrasive regions with different grain sizes arranged in a specific pattern. Coarse grain regions perform initial material removal while fine grain regions subsequently refine the surface, all in a single article. This segmentation allows simultaneous achievement of high material removal rates and good surface quality without requiring multiple separate abrasives.
Solution Approach 2:
The invention merges multiple abrasive functions (coarse grinding and fine polishing) into a single abrasive article by incorporating different grain size regions. This combines the high productivity of coarse abrasives with the surface quality benefits of fine abrasives, eliminating the need for multi-step processes using separate abrasive products.
3Manufacturing precision
If multi-step abrasive processes are used to achieve both material removal and surface quality, then surface characteristics improve, but process complexity and costs increase
Solution Approach 1:
The invention merges multiple abrasive functions (coarse grinding and fine polishing) into a single abrasive article by incorporating different grain size regions. This combines the high productivity of coarse abrasives with the surface quality benefits of fine abrasives, eliminating the need for multi-step processes using separate abrasive products.
Solution Approach 2:
The abrasive article is designed to perform multiple functions (roughing and finishing) simultaneously through its multi-region structure. This universal design allows one abrasive product to replace multiple specialized abrasives, reducing process complexity and costs while maintaining both material removal efficiency and surface quality.
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 achieves a balance between high material removal rates and improved surface characteristics, reducing the need for multiple abrasive steps and associated costs by optimizing the design of abrasive articles with specific grain sizes and channel configurations.
Implementation Method 1
abrasive articles, such as coated abrasive articles, are used in various industries to machine work pieces, such as by lapping, grinding, or polishing
Data Source
AI summary
A coated abrasive article includes a backing having a surface, a plurality of abrasive regions overlying the surface in each of the first and second portions, and at least one macro-channel. The surface of the backing has a shape defined by an outer contour. A bisecting axis divides the shape into first and second portions. Each abrasive region includes a binder and a plurality of abrasive grains in contact with the binder. The abrasive grains have an average grain size of not greater than about 200 microns. The at least one macro-channel defines a passageway extending between a pair of adjacent abrasive regions and terminating at openings at the outer contour within each of the first and second portions. The macro-channel has an average channel width of between about 0.1 millimeters to about 5 millimeters and is substantially free of the binder and the abrasive grains.