Flexible Abrasive Article with Self-Supporting Epoxy-Acrylate Resin
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Solution Overview
Problem
Existing flexible coated abrasive products face challenges such as brittleness, poor adhesion with untreated backings, and time-consuming cleanup, particularly when used with water, necessitating the development of a more effective and efficient flexible abrasive solution.
Innovation Solution
A curable composition comprising a polymerizable epoxy-acrylate resin with specific viscosity and tack properties, combined with abrasive particles, which forms a self-supporting abrasive layer that can serve as both make and backing, eliminating the need for expensive backing materials and improving adhesion and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing flexible coated abrasive products use paper or polymer backing, then flexibility is achieved, but adhesion to untreated backings deteriorates and cleanup becomes time-consuming
Solution Approach 1:
The patent uses a composite resin composition combining epoxy and acrylate polymers with specific molecular weights and functional groups. This composite material provides both flexibility (through polyether glycol chains) and strong adhesion (through epoxy groups and carboxylic acid functionalities) to untreated substrates, eliminating the need for separate backing materials while maintaining both properties simultaneously.
Solution Approach 2:
The patent specifies precise parameter ranges for the resin composition including epoxy equivalent weight (50-200), acrylate functional group content (0.5-5 mmol/g), and molecular weight (1000-10000). By optimizing these parameters, the composition achieves optimal balance between flexibility and adhesion without requiring traditional backing materials.
2Adaptability or versatility
If existing flexible abrasives use paper backing soaked in water, then flexibility is improved, but cleanup time increases
Solution Approach 1:
The resin composition forms a self-supporting abrasive layer that does not require separate backing materials. The cured resin structure inherently provides both flexibility and structural integrity, eliminating the need for post-use cleanup of paper or polymer backings while maintaining flexibility during use.
3Strength
If traditional coated abrasives use separate backing materials, then structural support is achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges the backing material function and abrasive layer into a single integrated structure. The cured resin composition itself provides the structural support traditionally requiring separate backing materials, while also serving as the adhesive matrix for abrasive particles. This consolidation eliminates additional manufacturing steps and material costs.
Solution Approach 2:
The resin composition performs multiple functions simultaneously: it provides structural support, adhesion to substrate, flexibility, and serves as the binding matrix for abrasive particles. This multi-functionality eliminates the need for separate backing materials and reduces manufacturing complexity.
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 a flexible abrasive article with enhanced adhesion, reduced brittleness, and improved performance on contoured surfaces, while also simplifying cleanup and reducing manufacturing costs by eliminating the need for additional backing materials.
Implementation Method 1
a polymerizable epoxy-acrylate resin composition having a complex viscosity at 25° C. and 1 Hz frequency of at least about 4500 Pa-s and a probe tack peak force of at least about 400 g
Data Source
AI summary
The disclosure relates to a curable composition comprising: a polymerizable epoxy-acrylate resin composition having a complex viscosity at 25° C. and 1 Hz frequency of at least about 4500 Pa-s and a probe tack peak force of at least about 300 kPa; and abrasive particles partially or fully embedded in the polymerizable epoxy-acrylate resin composition. The disclosure also relates to cured compositions formed from such curable compositions, wherein the abrasive particles are partially or fully embedded in the cured composition. In addition, the disclosure relates to abrasive articles made from such cured compositions as well as methods for making abrasive articles.