Mesh Abrasive Formation Using Ultrasonic Slurry Control
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Solution Overview
Problem
Existing abrasive products with open mesh backings face issues of uncured slurry migration, which contaminates the loop portion and seals openings, compromising dust extraction efficiency and adhesion.
Innovation Solution
A method involving ultrasonic vibration and actinic electromagnetic radiation is used to secure shaped abrasive composites to an open mesh backing without blocking openings, ensuring adhesion and maintaining dust extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If slurry is coated on open mesh backing, then shaped abrasive composites are formed, but uncured slurry migrates to backside and blocks openings
Solution Approach 1:
Ultrasonic vibration is applied to the mold surface during slurry coating to prevent uncured slurry from migrating through the mesh backing. The vibration keeps the slurry in place within the mold cavities, ensuring it cures properly without blocking the mesh openings, thus resolving the contradiction between forming shaped abrasives and preventing slurry migration.
2Manufacturing precision
If slurry is coated on open mesh backing, then shaped abrasive composites are formed, but loop portion becomes contaminated and unusable
Solution Approach 1:
Ultrasonic vibration prevents slurry migration during the coating process, ensuring that uncured slurry does not reach the loop portion on the backside of the mesh backing. This maintains the loop portion's cleanliness and attachment functionality while still forming the shaped abrasive composites on the abrasive side.
3Strength
If openings in mesh backing are sealed by slurry, then abrasive attachment is improved, but dust extraction efficiency is compromised
Solution Approach 1:
Ultrasonic vibration ensures that slurry remains within the mold cavities and does not migrate to seal the mesh backing openings. This allows the mesh openings to remain open for effective dust extraction while the vibration simultaneously ensures proper adhesion of shaped abrasives to the mesh without requiring opening blockage.
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 method produces mesh abrasives with improved adhesion and open pathways for dust extraction, enhancing the durability and efficiency of sanding operations.
Implementation Method 1
ultrasonically vibrating the abrasive composite precursor slurry
Implementation Method 2
curing the curable binder precursor by exposing it to sufficient actinic electromagnetic radiation
Data Source
AI summary
A method of making a mesh abrasive product comprises sequentially: 1) providing a production tool having a mold surface defining a plurality of shaped cavities and filling at least some of the shaped cavities with an abrasive composite precursor slurry, wherein the abrasive composite precursor slurry comprises abrasive particles dispersed within a curable binder precursor; 2) contacting the mold surface with an open mesh backing comprising interwoven threads defining openings, and having first and second opposed major sides; 3) ultrasonically vibrating the abrasive composite precursor slurry; 4) curing the curable binder precursor by exposing it to sufficient actinic electromagnetic radiation to provide isolated shaped abrasive composites contacting and secured to the first major side of the open mesh backing; and 5) separating the mesh abrasive product from the production tool. An open mesh abrasive product preparable by the method is also disclosed.