Coated Abrasive Articles With Open-Pattern Grinding Aid Particles
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Solution Overview
Problem
Coated abrasive articles inefficiently utilize abrasive particles, with many not contacting the workpiece before the article is worn out, leading to suboptimal performance and shortened lifespan.
Innovation Solution
The development of coated abrasive articles featuring agglomerate grinding aid particles retained in a binder, arranged in an open pattern, with abrasive particles disposed between them, enhancing their orientation and utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If abrasive particles are densely packed in traditional coated abrasive articles, then the article structure is simple and manufacturing is easy, but many abrasive particles do not contact the workpiece leading to poor utilization and shortened lifespan
Solution Approach 1:
The article is segmented into distinct functional zones: agglomerate grinding aid particles are arranged in a predetermined open pattern, while abrasive particles are positioned in the spaces between them. This segmentation allows each type of particle to perform its specific function optimally, with abrasive particles being properly oriented and utilized during grinding operations.
Solution Approach 2:
Different regions of the article have different particle distributions and functions. The agglomerate grinding aid particles provide localized grinding assistance in specific areas, while abrasive particles in the spaces between them perform cutting. This local quality differentiation improves overall abrasive particle utilization by ensuring proper orientation and contact with the workpiece.
2Reliability
If abrasive particles are arranged to maximize contact with workpiece, then abrading performance improves, but the manufacturing process becomes more complex requiring sequential deposition steps
Solution Approach 1:
The agglomerate grinding aid particles are deposited onto the backing in a predetermined open pattern before the abrasive particles are applied. This preliminary arrangement of grinding aid particles creates a template structure that guides the subsequent deposition of abrasive particles into the spaces between them, ensuring proper orientation and maximizing contact with the workpiece during use.
Solution Approach 2:
The agglomerate grinding aid particles serve as an intermediary structure that mediates between the backing and the abrasive particles. By arranging grinding aid particles in a predetermined pattern first, they act as a scaffold or template that facilitates the proper positioning and orientation of abrasive particles, thereby improving abrad ing performance while maintaining a systematic manufacturing approach.
Data Source
AI summary
A coated abrasive article comprises a backing having first and second opposed major surfaces. A make layer is bonded to the first major surface. Agglomerate grinding aid particles are directly bonded to the make layer. At least a portion of the agglomerate grinding aid particles comprise grinding aid particles retained in a binder, and are arranged according to an open predetermined pattern. Abrasive particles are directly bonded to the make layer in spaces between the agglomerate grinding aid particles. A size layer is directly bonded to the make layer, agglomerate grinding aid particles, and abrasive particles. A method of making a coated abrasive article, in which the agglomerate grinding aid particles are deposited onto a curable make layer precursor prior to depositing abrasive particles onto the curable make layer precursor in spaces between the agglomerate grinding aid particles is also disclosed.