Coated Abrasive Particle Deposition via Magnetic Field Segregation
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Solution Overview
Problem
Conventional methods for making coated abrasive articles require two particle coating apparatuses when sequentially coating two types of abrasive particles, which is inefficient and costly.
Innovation Solution
A method that uses a single particle coating apparatus to simultaneously coat two types/sizes of abrasive particles by employing a magnetic field to differentiate and deposit magnetizable and non-magnetizable particles in a predetermined order onto a make layer precursor, allowing for efficient sequential coating without additional apparatuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two particle coating apparatuses are used to sequentially coat two types of abrasive particles, then sequential coating can be achieved, but device complexity and cost increase
Solution Approach 1:
The particle coating process is segmented into two distinct zones within a single apparatus: a first drop zone for coating larger abrasive particles and a second drop zone for coating smaller abrasive particles. This segmentation allows sequential coating functionality to be achieved without requiring two separate apparatuses, thereby reducing device complexity while maintaining the adaptability to coat different particle types in a predetermined order
Solution Approach 2:
A single particle coating apparatus is designed to perform multiple functions by incorporating both a first particle coating zone and a second particle coating zone. The apparatus can sequentially coat different types of abrasive particles (larger and smaller) onto the make layer precursor within the same device, making it universal and eliminating the need for multiple specialized apparatuses
2Adaptability or versatility
If two particle coating apparatuses are used to sequentially coat two types of abrasive particles, then sequential coating can be achieved, but manufacturing cost increases
Solution Approach 1:
Two separate particle coating apparatuses are merged into a single integrated apparatus that contains both a first particle coating zone and a second particle coating zone. By combining the functionality of two devices into one, the manufacturing cost is reduced while maintaining the capability to sequentially coat two types of abrasive particles in a predetermined order
3Productivity
If abrasive particles are coated simultaneously as a mixture, then coating process is simplified, but particle distribution control is reduced
Solution Approach 1:
Different local zones within the particle coating apparatus are assigned different functions: the first drop zone is optimized for coating larger abrasive particles while the second drop zone is optimized for coating smaller abrasive particles. This local differentiation allows the coating process to maintain high efficiency similar to simultaneous coating, while achieving precise control over particle distribution and size placement, thereby resolving the trade-off between productivity and manufacturing precision
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
Enables efficient and cost-effective sequential coating of two types of abrasive particles using a single apparatus, improving the production process and reducing equipment needs while maintaining effective particle distribution and adhesion.
Implementation Method 1
employing a magnetic field to differentiate and deposit magnetizable and non-magnetizable particles in a predetermined order onto a make layer precursor
Implementation Method 2
Magnetizable particles and the non-magnetizable particles are predominantly deposited onto the web within a drop zone at different locations
Data Source
AI summary
A method of making a coated abrasive article includes at least four steps. In step a), a web is provided comprising a backing having a make layer precursor disposed thereon. The web moves along a web path in a downweb direction, and the web has a crossweb direction that is perpendicular to the downweb direction. The make layer precursor comprises a first curable binder precursor; In step b) an applied magnetic field is provided. In step c), a mixture of magnetizable non-magnetizable particles is passed through the applied magnetic field and onto the make layer precursor such that the magnetizable and non-magnetizable particles are predominantly deposited onto the web in a drop zone according to a predetermined order. At least one of the magnetizable particles or the non-magnetizable particles comprises abrasive particles. In step d), the make layer precursor is at least partially cured to provide a make layer.