Flap Disc Backing Plate Contour for Secure Bonding With Less Adhesive
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Solution Overview
Problem
Conventional grinding wheels face issues with abrasive elements detaching due to high centrifugal forces, leading to partial unusability or safety hazards, and excessive adhesive use for secure attachment.
Innovation Solution
A flap disc design with a boundary contour on the backing plate that restricts adhesive application to areas contributing to the bond strength, ensuring a reliable and efficient material-bonded connection between abrasive flaps and the backing plate, reducing adhesive usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a considerable amount of adhesive is used to ensure strong connection of abrasive elements to backing plate, then the reliability of the bond is improved, but the adhesive consumption increases excessively
Solution Approach 1:
The invention applies adhesive only in specific local areas where it is most effective - namely at the peripheral region and overlap zones of adjacent abrasive elements. The boundary contour defines precise application zones, concentrating adhesive where it provides maximum bonding benefit while avoiding waste in areas where adhesive cannot contribute to bond strength.
Solution Approach 2:
The backing plate surface is segmented into distinct zones by the boundary contour: areas where adhesive should be applied (peripheral and overlap regions) and areas where adhesive should not be applied (central regions and areas beyond the boundary). This segmentation enables controlled, localized adhesive application that optimizes both bond strength and material efficiency.
2Ease of manufacture
If adhesive is applied without restriction during bond formation, then the bonding process is simple, but the adhesive distributes uncontrollably and reaches areas where it cannot contribute to bond strength
Solution Approach 1:
The boundary contour is pre-formed on the backing plate before adhesive application. This preliminary structural feature guides adhesive placement automatically during the bonding process, ensuring adhesive is deposited only in effective zones without requiring complex real-time control systems or manual precision.
Solution Approach 2:
The boundary contour acts as an intermediary element between the adhesive and the backing plate surface. It mediates adhesive distribution by providing a physical or visual guide that channels adhesive to appropriate locations, simplifying the bonding process while maintaining precise control over adhesive placement.
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 design provides a secure, reliable bond between abrasive flaps and the backing plate, enhancing safety and reducing adhesive consumption while maintaining bond strength.
Implementation Method 1
the abrasive flaps being connected to the backing plate on the front surface by means of a material-bonded connection, in particular an adhesive bond
Implementation Method 2
the boundary contour prevents an adhesive for the bond from extending into an area of the carrier plate during the bond formation where the adhesive cannot be used to form the bond
Implementation Method 3
the abrasive elements can detach from the backing plate during operation of the grinding tool due to high centrifugal forces
Data Source
Figure 1~2
Figure 3a~3b
Figure 3c
AI summary
A flap disc (1) which is rotatably driven about an axis of rotation (6a), wherein the flap disc (1) comprises a carrier plate (2) and abrasive flaps (3), wherein the carrier plate (2) comprises a front (8a) and a back (8b), and wherein the abrasive flaps (3) are connected to the carrier plate (2) on the front (8a) by means of a material-bonded connection (5), in particular an adhesive bond, wherein the carrier plate (2) has a boundary contour (4) on the front which is arranged between the axis of rotation (6a) and the material-bonded connection (5), wherein the boundary contour (4) extends at least as far in a positive direction as the material-bonded connection (5), and wherein the positive direction (7) corresponds to a direction from the back (8b) to the front (8a) along the axis of rotation (6a).