Composite Abrasive Article with Open Mesh Backing for Dust Removal
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Solution Overview
Problem
Existing abrasive articles either suffer from dust accumulation, reducing abrading performance, or fail to effectively remove dust, compromising efficiency in applications like vehicle body repair and drywall sanding.
Innovation Solution
A composite abrasive article featuring an open mesh backing with coated abrasive members secured by a binder material, allowing for dust removal while maintaining aggressive abrading performance, utilizing a combination of a make layer, size layer, and optional supersize layer to prevent swarf accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If screen abrasives with porous backing are used, then dust removal is improved, but abrading performance is reduced
Solution Approach 1:
The abrasive article is divided into multiple discrete coated abrasive members (discs, strips, or squares) that are separately secured to the porous backing. Each member functions as an independent abrasive unit, allowing dust to pass through the porous backing while maintaining effective abrading surfaces.
Solution Approach 2:
Different regions of the abrasive article have different properties: the coated abrasive members provide aggressive abrading performance at the contact surface, while the porous backing provides dust removal capabilities. This spatial differentiation of functions resolves the contradiction between dust removal and abrading performance.
2Productivity
If coated abrasive articles with dense backing are used, then abrading performance is improved, but dust removal is reduced
Solution Approach 1:
The dense coated abrasive members are segmented and mounted on a porous backing rather than using a single dense backing. This allows the abrasive function to remain aggressive while the backing provides dust egress pathways.
Solution Approach 2:
The backing structure is differentiated from the abrasive members: the backing is porous to enable dust removal, while the abrasive members maintain their dense, aggressive structure for effective material removal. This local differentiation resolves the contradiction.
3Object-generated harmful factors
If screen abrasives are used, then dust removal is improved, but aggressiveness is reduced
Solution Approach 1:
Multiple coated abrasive members are distributed across the porous backing, creating numerous aggressive abrading points that collectively provide forceful material removal while maintaining dust removal capabilities through the porous structure.
Solution Approach 2:
The abrasive article combines coated abrasive materials (for aggressiveness) with porous backing materials (for dust removal), creating a composite structure that exhibits both aggressive abrading properties and effective dust removal properties simultaneously.
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 composite abrasive article effectively removes dust and maintains high abrading performance by combining the benefits of screen abrasives with the aggressiveness of coated abrasives, enhancing efficiency in applications like vehicle body repair and drywall sanding.
Implementation Method 1
an abrasive layer comprising abrasive particles secured to a coated abrasive backing by at least one binder material
Implementation Method 2
the porous nature of these products allows dust to pass through the screen abrasive and not load the abrasive layer
Implementation Method 3
frictionally contacting the abrasive layer of at least one of the coated abrasive members of a coated abrasive article according to the present disclosure with a surface of a workpiece; and moving at least one of the coated abrasive article or the workpiece relative to the other to abrade the surface of the workpiece
Data Source
AI summary
A composite abrasive article comprises an open mesh backing member having first and second major surfaces and coated abrasive members secured to the first major surface. Independently, each coated abrasive member respectively comprises an abrasive layer comprising abrasive particles secured to a coated abrasive backing by at least one binder material. A method of making a composite abrasive article is also disclosed.