Coated Abrasive Ridge Formation Using Modulated Magnetic Fields

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Solution Overview

Problem

The manufacturing of coated abrasive articles with structured surface topography requires expensive machined production tools and is difficult to practice, leading to high costs and significant scrap.

Innovation Solution

The use of magnetizable particles and non-magnetizable abrasive particles dispersed in a binder, with ridges formed by modulation of a magnetic field, eliminates the need for molding processes, allowing for cost-effective production of abrasive articles with structured topography.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If expensive machined production tools with precisely-shaped microcavities are used to manufacture coated abrasive articles with structured surface topography, then manufacturing precision and structured topography are improved, but manufacturing cost and device complexity increase significantly

Engineering Contradiction:

Improvestructured surface topographyVSAvoidmachined production tool

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical molding system (machined production tools with microcavities) with a magnetic field system. Magnetizable particles are used to form the structured topography through magnetic field modulation during the coating process, eliminating the need for expensive mechanical molds while achieving the same structured surface effect.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and properties of the binder system by introducing magnetizable particles that respond to magnetic field parameters. By modulating the magnetic field during coating, the particles self-organize into ridge structures, transforming a mechanical forming process into a field-based parameter control process.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If traditional molding processes are used to create structured abrasive articles, then consistent topography is achieved, but manufacturing cost and production difficulty increase

Engineering Contradiction:

Improvestructured topographyVSAvoidmanufacturing process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The magnetizable particles in the binder system self-organize into ridge structures when exposed to a modulated magnetic field during the coating process. This self-organization eliminates the need for external molding tools, allowing the material itself to create its own structured topography automatically during application.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The magnetic field acts as an intermediary between the binder precursor and the final structured topography. Instead of direct mechanical contact with molds, the magnetic field mediates the formation of ridge structures by aligning magnetizable particles during the coating process.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If molded shaped abrasive composites are used, then fine finishing performance is achieved, but scrap generation and manufacturing cost increase

Engineering Contradiction:

Improveabrading performanceVSAvoidscrap

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent replaces mechanical molding with magnetic field-based particle arrangement, eliminating the need for expensive molds that generate scrap. The magnetic field method allows for direct formation of structured topography during coating, reducing material waste and production costs while maintaining performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method reduces manufacturing costs and scrap while maintaining effective abrading performance by creating irregularly shaped ridges oriented parallel to each other, enhancing the abrasive layer's efficiency.

Implementation Method 1

forming ridges on the outer major surface of the curable binder precursor layer by modulation of at least one magnetic field relative to the backing

Methodology Applied

Scientific EffectMagnetic field modulation: Magnetic Field

Implementation Method 2

the curable binder precursor layer comprises magnetizable particles and abrasive particles dispersed in a curable binder precursor; forming ridges on the outer major surface of the curable binder precursor layer by modulation of at least one magnetic field

Methodology Applied

Scientific EffectMagnetism: Magnetism

Data Source

PatentUS12589467B2Coated abrasive articles and methods of making and using the same

Publication Date: 2026.03.31 3M INNOVATIVE PROPERTIES CO

AI summary

Coated abrasive articles comprises a backing having a major surface with an abrasive layer disposed thereon. The abrasive layer has an outer major surface comprising ridges separated by valleys, wherein the abrasive layer comprises magnetizable particles and abrasive particles in a binder. Each of the ridges is irregularly shaped and is oriented along at least a portion of its length substantially parallel to adjacent ridges. Methods of making the same involving a modulated magnetic field are also disclosed.