Nonwoven Abrasive With Flexible Binder Agglomerates
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing nonwoven abrasive articles often fail to achieve a desirable surface finish on workpieces while maintaining or increasing their cutting efficiency, with the type of binder previously thought to have a limited impact on the finish quality.
Innovation Solution
The use of a flexible polyurethane binder to agglomerate formed ceramic abrasive particles, which are then bound to a nonwoven web with a second binder, significantly improves the surface finish by creating a finer finish than non-agglomerated particles, even when used with the same abrasive particle sizes and amounts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If formed ceramic abrasive particles are agglomerated with a rigid binder, then the life of the abrasive article is increased, but the resulting surface finish becomes coarser
Solution Approach 1:
The patent changes the key parameter of binder flexibility by switching from rigid binders (phenolic, epoxy) to flexible binders (polyurethane, polyisoprene, polybutadiene). This parameter change allows the agglomerates to deform and conform to the workpiece surface, producing finer finishes while maintaining agglomerate integrity and abrasive article life through the flexible binder's ability to absorb stress without breaking.
2Manufacturing precision
If formed ceramic abrasive particles are used without agglomeration, then the surface finish is finer, but the abrasive article life is reduced
Solution Approach 1:
The patent creates composite agglomerates consisting of formed ceramic abrasive particles bound together by flexible binder material. This composite structure combines the sharp, defined geometry of formed abrasive particles (which produce fine finishes) with the durability and stress-absorbing properties of the flexible binder, enabling both fine surface finish and extended abrasive article life.
3Manufacturing precision
If the binder type is changed from phenolic to polyurethane, then the surface finish is significantly improved, but the binder strength may be reduced
Solution Approach 1:
The patent changes the chemical composition and physical properties of the binder from rigid phenolic resins to flexible polyurethane polymers. This parameter change fundamentally alters the binder's mechanical behavior, allowing it to flex and conform during abrasion, which produces finer finishes. The flexible binder maintains sufficient strength through its elastic properties and adhesion to both the abrasive particles and the substrate.
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
This approach results in a finer surface finish and maintains or increases the cutting efficiency of nonwoven abrasive articles, surpassing the performance of non-agglomerated particles and those agglomerated with rigid binders, while providing the expected performance improvements of agglomerated abrasive particles.
Implementation Method 1
agglomerates comprising formed ceramic abrasive particles bound together by a first flexible binder
Implementation Method 2
nonwoven abrasive article... exhibit significant improvements in the surface finish... when compared to alternative nonwoven abrasive articles
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
A nonwoven abrasive article formed from a nonwoven web and agglomerates comprising formed ceramic abrasive particles bound together by a first flexible binder, and a second binder binding the agglomerates to the nonwoven fiber web.