Grinding Disc Rigid Cover with Radial Struts
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Solution Overview
Problem
Existing sanding discs face challenges in achieving a balance between rigidity and lightness, with conventional designs often compromising on either strength or ease of handling, particularly in eccentric grinding systems where weight and mass balancing are critical.
Innovation Solution
A sanding disc design featuring a load-bearing cover firmly connected to the support plate with radial struts, creating a rigid structure that allows for deformation in the elastically deformable cushion while maintaining mechanical integrity and ease of handling, utilizing materials like fiber-reinforced plastics and a foamed filling for added strength and lightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sanding disc is designed with high rigidity to withstand mechanical loads, then strength is improved, but weight increases making handling difficult
Solution Approach 1:
The support plate is made from fiber-reinforced plastic composite material, combining the strength of fibers (glass or carbon) with the lightweight properties of plastic matrix. This allows achieving high rigidity and load-bearing capacity while maintaining low weight for easy handling in eccentric grinding systems
Solution Approach 2:
The support plate is divided into a rigid outer ring structure and a more flexible central area with radial struts. The outer ring provides structural integrity and load bearing, while the radial struts provide stiffness without requiring a solid disc construction, reducing overall weight while maintaining necessary rigidity
2Strength
If the cover is firmly connected to the support plate with radial struts to increase rigidity, then structural strength is improved, but manufacturing complexity increases
Solution Approach 1:
The cover and support plate are integrated into a single injection-molded composite component. The radial struts are formed as integral parts of the injection molding process, eliminating the need for separate assembly steps. Fiber reinforcement is incorporated during molding, combining multiple functions (structural support, rigidity, weight reduction) into one manufacturing operation
Solution Approach 2:
The injection molding process parameters are optimized to create the complex radial strut structure and fiber reinforcement distribution. By controlling fiber orientation, density, and distribution during molding, the desired rigidity and strength properties are achieved while maintaining manufacturing efficiency
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 results in a sanding disc that is both robust and lightweight, capable of withstanding mechanical loads, easy to handle, and suitable for eccentric systems, with the cover and support plate forming a strong, rigid unit that maintains connection to the drive even under overload.
Implementation Method 1
an elastically deformable cushion (5), which is attached under the support plate (3)
Implementation Method 2
the cavities formed between the cover and the support plate at the height of the webs can be filled with a light but strong material, which is inserted and glued in a prefabricated manner, for example in the form of a plastic rigid foam, but is preferably introduced and foamed in a foaming process in a pressure mold
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The plate (1) has a drive connection (2) supported at a supporting plate (3). The supporting plate sits on an elastically deformable cushion (5). The supporting plate has a cover (4) that is designed as a mechanically-loadable structure part. An outer edge of the cover is fixedly connected with the supporting plate. Radially-running rods are arranged between the supporting plate and the cover and fixedly connected with the supporting plate and with the cover. Hollow spaces filled with foam material i.e. polyurethane foam, are formed between the cover and the grinding plate. The drive connection has a connection element that is made from metal.