Coated Abrasive Structure With Controlled Make Coat Thickness
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Solution Overview
Problem
Existing abrasive articles face challenges in achieving optimal performance and manufacturing efficiency due to inconsistencies in make coat thickness and abrasive particle orientation, which affect material removal operations.
Innovation Solution
The development of coated abrasive articles with controlled make coat thickness ratios (Tg/Ta ≤ 1.5) and random abrasive particle orientations, utilizing materials like wollastonite and PF resin, enhances manufacturing and performance by ensuring uniform distribution and adherence of abrasive particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the make coat thickness is increased to ensure adequate abrasive particle embedding, then the abrasive particles are better retained, but the material removal efficiency decreases due to excessive thickness
Solution Approach 1:
The patent applies parameter changes by precisely controlling the make coat thickness ratio (Tg/Ta) within a specific range (0.5 to 1.5). This quantitative parameter optimization ensures that the make coat is thick enough to properly embed and retain abrasive particles while remaining thin enough to maintain material removal efficiency. The controlled thickness ratio balances particle retention with cutting performance.
2Manufacturing precision
If the make coat thickness is uniformly controlled, then the manufacturing precision improves, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent employs preliminary action by pre-establishing the target make coat thickness ratio (Tg/Ta) range before the coating process. The make coat is applied with controlled thickness parameters from the outset, rather than attempting to achieve uniformity through post-processing or complex real-time adjustments. This preliminary control of the thickness ratio simplifies the overall manufacturing process while ensuring consistent results.
Data Source
AI summary
An abrasive article includes a backing; a make coat overlying the backing; and a plurality of abrasive particles overlying the backing and at least partially contained in the make coat; and a make coat thickness ratio (Tg/Ta) of not greater than 1.5, wherein Tg is the average thickness of the make coat at the sides of the abrasive particles and the Ta is the average thickness of the make coat.