Extensible Abrasive Article With Resin Layer For Irregular Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing structured abrasive articles face challenges in achieving good contact with objects to be abraded, particularly those with irregular or curved surfaces, due to limitations in extensibility and durability of the abrasive surface during bending and extension.
Innovation Solution
A structured abrasive article comprising an extensible base member, a three-dimensional element with abrasive particles and binder, and a resin layer that binds the base member and the three-dimensional element, allowing for flexible contact with objects. The resin layer is formed without a core material to prevent damage and maintain uniform abrasion performance, and is tacky to ensure strong bonding and conformability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a structured abrasive article uses a rigid structure to maintain abrasive surface integrity, then durability is improved, but contact with irregular or curved surfaces deteriorates
Solution Approach 1:
The abrasive article is divided into multiple independent three-dimensional elements (protrusions) rather than a single rigid structure. Each element can independently deform and conform to the surface being abraded, enabling excellent contact with irregular or curved surfaces while maintaining structural integrity through the modular design
Solution Approach 2:
The abrasive article employs a flexible structure where the three-dimensional elements can elastically deform. This flexibility allows the elements to conform to irregular surfaces for excellent contact, while the overall structure maintains durability through the resilient nature of the flexible material that can recover its shape
2Strength
If the resin layer includes a core material to provide structural support, then strength is improved, but the abrasive surface may become damaged during bending and extension
Solution Approach 1:
The core material is completely removed from the resin layer, eliminating the source of damage during deformation. The resin layer is formed only by bonding the abrasive coating to the flexible base member, allowing the structure to bend and extend without the core material causing surface damage while maintaining sufficient strength through the bonding interface
Solution Approach 2:
The abrasive coating itself forms a composite structure with the resin layer, combining the abrasive particles with the bonding resin to create a strong, flexible surface layer that provides both strength and resistance to damage during deformation without requiring a separate core material
3Reliability
If the abrasive coating is applied thickly to ensure coverage, then abrasive performance is improved, but conformability to surfaces deteriorates
Solution Approach 1:
The abrasive coating is applied in a dynamic process where the flexible base member can deform during application and use. The coating thickness is controlled to provide adequate abrasive performance while the flexible nature of the base member allows the coating to conform to irregular surfaces through elastic deformation, achieving both good coverage and conformability
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 structured abrasive article achieves excellent contact with objects having irregular or curved surfaces, maintaining stable abrasion performance even with repeated bending and extension, and prevents damage to the abrasion surface, ensuring effective and durable use.
Implementation Method 1
a resin layer (13) that binds the extensible base member (11) and the three-dimensional element (12)
Implementation Method 2
an extensible base member (11), and a three-dimensional element (12) including abrasive particles and binder therefore
Data Source
Figure 1~2
Figure 3a~3d
Figure 4~5
AI summary
A structured abrasive article having an extensible base member; a three-dimensional element including abrasive particles and binder therefore; and a resin layer that binds the extensible base member and the three-dimensional element.