Dry Grinding Aid Application on Coated Abrasives
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Solution Overview
Problem
Conventional methods for producing coated abrasives with grinding aids are costly and inefficient, as the liquid application of grinding aids leads to accumulation in valleys between abrasive grains, reducing their effectiveness and service life.
Innovation Solution
A method involving the dry application of grinding aids to an uncured size coat on an intermediate abrasive product, ensuring homogeneous distribution and increased contact with the work surface, reducing the amount of grinding aid required and extending the abrasive's service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If liquid mixture is applied to intermediate abrasive product, then additional coating can be applied, but grinding aid accumulates in valleys between abrasive grains reducing effectiveness
Solution Approach 1:
The patent changes the physical state of the grinding aid from liquid to dry form. By applying grinding aid in dry form instead of liquid mixture, the grinding aid particles are distributed more uniformly on the abrasive surface without accumulating in valleys between grains. This parameter change resolves the contradiction by improving both distribution quality and service life.
Solution Approach 2:
The patent extracts the solvent and binding agents from the conventional liquid coating mixture, using only the pure grinding aid substance. This extraction eliminates the problems caused by liquid carriers that cause uneven distribution and accumulation in valleys, while maintaining the functional coating effect.
2Productivity
If liquid additional coating is applied by roll process, then coating can be applied efficiently, but grinding aid accumulates in valleys between individual abrasive grains
Solution Approach 1:
The patent changes the application method from liquid roll coating to dry powder application. This parameter change allows the grinding aid to be applied in a manner that achieves both high productivity and uniform distribution, eliminating the valley accumulation problem inherent in liquid roll application.
Solution Approach 2:
The patent replaces the liquid-based mechanical roll coating system with a dry powder application system. This substitution fundamentally changes how the grinding aid is deposited, allowing for more precise control over distribution uniformity while maintaining efficient application rates.
3Reliability
If conventional liquid coating method is used, then additional coating can be formed, but large amount of grinding aid is required to achieve effective coverage
Solution Approach 1:
The patent extracts and eliminates the need for large quantities of grinding aid by removing solvent and binding agent carriers. The pure dry grinding aid applies directly to the abrasive surface, requiring significantly less material to achieve the same or better performance compared to conventional liquid coatings.
Solution Approach 2:
The patent changes the concentration and purity parameters of the grinding aid application. By using 100% pure grinding aid in dry form rather than diluted liquid mixtures, the effective concentration of active substance is dramatically increased, reducing the total quantity needed while improving performance.
4Ease of manufacture
If liquid suspension is prepared and cured again, then additional coating can be applied, but production process becomes costly and inconvenient
Solution Approach 1:
The patent extracts and removes the unnecessary steps of preparing liquid suspension and performing secondary curing. By using dry grinding aid that applies directly to the uncured size coat, the process eliminates complex liquid handling and additional curing operations, greatly simplifying manufacturing.
Solution Approach 2:
The patent inverts the conventional sequence by applying dry grinding aid to the uncured size coat rather than incorporating it into a liquid mixture that requires curing. This inversion eliminates the need for suspension preparation and re-curing, simplifying the overall process.
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 dry application method enhances the distribution and bonding of grinding aids, leading to improved abrasive performance, reduced material accumulation between grains, and increased service life, while minimizing the amount of grinding aid needed, thus making the process more economical.
Implementation Method 1
applying at least one grinding aid to the uppermost, uncured size coat
Implementation Method 2
curing the uppermost size coat
Data Source
AI summary
A method for producing a coated abrasive includes producing or providing an intermediate abrasive product that comprises a substrate, a plurality of abrasive grains that are bonded to the substrate, and at least one layer of an uncured size coat that at least partially covers the abrasive grains with the uppermost size coat being uncured. The method further includes applying at least one grinding additive to the uppermost, uncured size coat with the grinding additive applied to the size coat in dry form. The method also includes curing the uppermost size coat. A coated abrasive is produced by the method and the coated abrasive is used to process a surface.