Double-Layer Abrasive Material for High-Load Durability
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Solution Overview
Problem
Existing abrasive materials lack durability when used for severe abrasive work with high loads, leading to reduced effectiveness and increased risk of separation from the substrate.
Innovation Solution
A coated abrasive material with a substrate and an abrasive part having a double-layer structure, where the upper layer contains abrasive particles dispersed in a resin and the lower layer is composed of a cured material with a radiation-curable monomer and/or oligomer and a thermosetting resin, providing enhanced adhesion and resistance to high loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-layer abrasive structure is used, then the manufacturing process is simple, but the durability under high load is insufficient
Solution Approach 1:
The abrasive layer is divided into two distinct layers: an upper abrasive layer containing abrasive particles for cutting function, and a lower binder layer providing adhesion to the substrate. This segmentation allows each layer to be optimized independently for its specific function, improving overall durability under high load while maintaining manufacturing feasibility.
Solution Approach 2:
The patent uses composite material structures where the upper layer combines abrasive particles with resin binder, and the lower layer uses radiation-curable monomer/oligomer with thermosetting resin. This composite approach provides both cutting effectiveness and enhanced adhesion resistance to high loads, resolving the contradiction between durability and structural complexity.
2Reliability
If the abrasive part is made with strong adhesion to resist high load, then the durability improves, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces conventional thermal curing processes with radiation-curable monomers and oligomers that cure upon exposure to radiation (UV, electron beam, etc.). This substitution enables faster curing, better adhesion to the substrate, and improved resistance to separation under high load, while the process remains manufacturable through established radiation curing techniques.
Solution Approach 2:
The use of radiation-curable materials changes the curing parameter from thermal to radiative energy input, enabling controlled adhesion strength and separation resistance. This parameter change allows the lower layer to achieve superior bonding to the substrate without significantly complicating the manufacturing process, as radiation curing is an established industrial process.
3Productivity
If shaped structures are formed to prevent loading, then the abrasive performance improves, but the adhesion under high load deteriorates
Solution Approach 1:
By separating the abrasive layer into two functional layers, the patent allows the upper layer to be optimized for abrasive performance with shaped structures that prevent loading, while the lower layer is optimized for adhesion under high load. This segmentation resolves the contradiction by assigning different optimization goals to different layers.
Solution Approach 2:
The composite structure of the two-layer abrasive system enables the upper layer to provide cutting effectiveness through shaped structures, while the lower layer with radiation-curable materials provides strong adhesion. This composite approach allows both contradictory requirements to be satisfied simultaneously in different layers.
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 material exhibits improved durability and resistance to separation, even under severe abrasive conditions, ensuring effective and long-lasting performance.
Implementation Method 1
a lower layer composed of a cured material of a binder agent containing a radiation-curable monomer and/or oligomer
Implementation Method 2
a thermosetting resin, providing enhanced adhesion and resistance to high loads
Implementation Method 3
an abrasive part having a plurality of shaped structures projecting from the substrate, in which the abrasive part comprises (1) an upper layer composed of a cured material of a mixture containing abrasive particles dispersed in a resin
Data Source
Figure 1~2
Figure 3~4
Figure 5~6b
AI summary
To provide an abrasive material with improved adhesion strength of an abrasive part to a substrate and durable to a severe abrasive work with applying high load and a long time abrading work. The abrasive material product comprises a substrate and an abrasive part having a plurality of shaped structures projecting from the substrate and is characterized in that the abrasive part comprises (1) an upper layer composed of a cured material of a mixture containing abrasive particles dispersed in a resin and (2) a lower layer composed of a cured material of a binder agent containing a radiation-curable monomer and/or oligomer and a thermosetting resin.