Compressed Polymer Impregnated Backing Material Abrasive Articles
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Solution Overview
Problem
Abrasive articles using vulcanized fiber substrates suffer from dimensional instability due to moisture changes, leading to shape distortion and premature product failure, despite various attempts to address this issue.
Innovation Solution
A compressed composite backing material is developed by impregnating a backing substrate, such as nonwoven or woven fabric, with a polymeric composition like epoxy or phenolic resin, and then compressing and curing it to enhance mechanical properties and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If vulcanized fiber substrate is used in abrasive articles, then the substrate provides leather-like or horn-like material properties, but the substrate suffers from dimensional instability and shape distortion due to moisture absorption
Solution Approach 1:
The patent uses a composite substrate made of woven or nonwoven fabric impregnated with polymeric composition (such as phenolic resin, epoxy resin, or polyester resin). This composite structure combines the mechanical strength of the fabric with the dimensional stability of the polymer, creating a substrate that resists moisture absorption and shape distortion while maintaining the required mechanical properties for abrasive article support.
2Strength
If vulcanized fiber substrate is used, then the substrate provides structural support, but the substrate absorbs moisture leading to curling and cupping
Solution Approach 1:
The patent changes the chemical composition parameters of the substrate by replacing traditional vulcanized fiber with polymer-impregnated fabric. The polymeric composition (phenolic, epoxy, or polyester resin) has different hygroscopic properties compared to vulcanized fiber, resulting in reduced moisture absorption while maintaining structural support capability.
3Ease of manufacture
If conventional vulcanized fiber is used, then the substrate is readily available and easy to manufacture, but the abrasive article experiences premature end of life due to warping and delamination
Solution Approach 1:
The patent employs a composite substrate structure of fabric impregnated with polymeric composition that can be manufactured using conventional processes. The fabric provides a stable base that when impregnated with resin and cured, creates a dimensionally stable substrate that prevents warping and delamination, thereby extending abrasive article life while remaining compatible with existing manufacturing capabilities.
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 solution provides superior abrasive performance with improved tensile strength, flexural modulus, and dimensional stability, reducing weight gain and dimensional distortion under humid conditions, extending the life of abrasive discs.
Implementation Method 1
a compressed polymer impregnated backing substrate comprised of a backing substrate that has been impregnated with a polymeric composition
Implementation Method 2
compressed and cured to enhance mechanical properties and stability
Data Source
AI summary
This invention relates to compressed composite backing materials (e.g., compressed polymer impregnated backing substrates) and coated abrasive articles that include such compressed composite backing materials. This invention also relates to methods of making and using said compressed composite backing materials and coated abrasive articles. The claimed processes and systems related to the use and manufacturing of coated abrasive articles are improved and cost effective.