Coated Abrasive Triangular Platelets Animal Glue Make Layer
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Solution Overview
Problem
Existing coated abrasive articles face challenges in improving abrasive particle pick-up and retention, particularly for precisely-shaped particles during electrostatic deposition, which affects their orientation and adhesion to the make layer precursor.
Innovation Solution
A method involving a backing with a make layer precursor composed of water-based animal glue, where shaped triangular platelet abrasive particles are partially embedded and cured, followed by a size layer comprising a thermoset polymer, enhancing particle retention and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electrostatic deposition is used to embed abrasive particles into make layer precursor, then particle pick-up is improved, but particle retention and orientation are insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the make layer precursor by incorporating specific binders (polyvinyl alcohol, carboxymethyl cellulose, or starch) and controlling water content (5-20%) to optimize both particle pick-up and retention. This chemical parameter modification enables the precursor to maintain shaped particles in an upright position while allowing effective electrostatic deposition.
Solution Approach 2:
The patent creates a composite make layer precursor system combining multiple components: binder polymers, water, and abrasive particles. This composite structure provides both the adhesive properties needed for particle retention and the electrostatic characteristics required for effective deposition, resolving the contradiction between quantity and precision.
2Manufacturing precision
If shaped abrasive particles are embedded into make layer precursor, then particle orientation is improved, but adhesion to backing is insufficient
Solution Approach 1:
The patent applies a sizing layer precursor to the backing before embedding the shaped abrasive particles. This preliminary action creates a preparatory layer that enhances the adhesion between the abrasive particles and the backing, ensuring that particles remain oriented correctly while maintaining strong bonding.
Solution Approach 2:
The sizing layer acts as an intermediary between the abrasive particles and the backing. This intermediate layer improves the interface adhesion, allowing shaped particles to maintain their orientation while ensuring strong attachment to the backing structure.
3Reliability
If make layer precursor is cured to secure abrasive particles, then particle retention is improved, but manufacturing complexity increases
Solution Approach 1:
The patent modifies the curing parameters by using water-based binders that cure through water evaporation and natural drying rather than requiring complex thermal or chemical curing processes. This parameter change simplifies the manufacturing process while maintaining reliable particle retention through the formation of a solid make layer.
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 approach significantly improves the pick-up and retention of precisely-shaped abrasive particles, ensuring better adhesion and performance in abrading processes, as demonstrated by increased peak count and mass loss in abrading tests.
Implementation Method 1
a make layer disposed on the first major surface of the backing, wherein the make layer comprise at least partially cured animal glue
Implementation Method 2
abrasive particles are then at least partially embedded into the curable make resin (for example, via electrostatic coating)
Data Source
AI summary
A coated abrasive article comprises: a backing having first and second opposed major surfaces; a make layer disposed on the first major surface of the backing; shaped abrasive particles partially embedded in the make layer wherein the shaped abrasive particles are triangular platelets; and a size layer disposed over the make layer and shaped abrasive particles, wherein the size layer comprises a thermoset polymer. The make layer comprise at least partially cured animal glue. A method of making the coated abrasive article is also disclosed.