Nonwoven Abrasive Article With Edge-Wise Platelet Bonding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional nonwoven abrasive articles lack superior abrading performance due to inefficient bonding of abrasive particles with the fiber web, resulting in suboptimal cutting efficiency and durability.

Innovation Solution

A nonwoven abrasive article comprising a lofty open fiber web with abrasive platelets secured by a binder material, where a majority of the abrasive platelets are bonded edge-wise to the fibers using an electrostatic deposition method, ensuring orthogonal orientation and close packing for enhanced performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional coating techniques (spray, drop coating, gravity settling) are used to apply abrasive particles to nonwoven fiber web, then the manufacturing process is simple and easy to implement, but the abrasive particles are not efficiently bonded to the fibers, resulting in suboptimal cutting efficiency and durability

Engineering Contradiction:

Improvebonding efficiencyVSAvoidcoating process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces conventional mechanical coating methods (spray, drop coating, gravity settling) with electrostatic deposition. In this method, abrasive platelets are charged and deposited onto the fiber web under an electrostatic field, enabling precise control of particle orientation and bonding. The platelets are oriented with their flat surfaces perpendicular to the fiber axis and bonded edge-wise, maximizing cutting efficiency while ensuring durable attachment to the fiber web.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If abrasive particles are randomly distributed on the fiber web, then the coating process is simple, but the cutting efficiency is suboptimal due to lack of proper orientation

Engineering Contradiction:

Improvecutting efficiencyVSAvoidparticle orientation control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by ensuring that each abrasive platelet is oriented in a specific local configuration: the flat surface is perpendicular to the fiber axis and the platelet is bonded edge-wise to the fiber. This localized precise orientation maximizes the cutting efficiency of each individual platelet while maintaining the overall structure of the nonwoven abrasive article.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The electrostatic deposition process replaces random mechanical distribution with controlled electrical field-based positioning. The charged platelets are attracted to and oriented on the fiber web under the electrostatic field, achieving precise orientation control that maximizes cutting efficiency while enabling continuous manufacturing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a single layer of closely-packed abrasive platelets is formed, then the abrading performance is superior, but the coating process becomes more complex compared to conventional methods

Engineering Contradiction:

Improveabrading performanceVSAvoidcoating process ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces complex multi-step conventional coating processes with a single electrostatic deposition step. The electrostatic field simultaneously achieves particle charging, transport, orientation, and deposition in one continuous process, forming a single layer of closely-packed platelets with superior abrading performance while simplifying the overall manufacturing procedure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 described solution achieves superior abrading performance by ensuring effective bonding and orientation of abrasive platelets, leading to improved cutting efficiency and durability compared to conventional methods.

Implementation Method 1

electrostatically depositing a plurality of abrasive platelets on at least a portion of the first curable binder precursor

Methodology Applied

Scientific EffectElectrostatic deposition: Electrostatic Deposition

Data Source

PatentUS10556323B2Nonwoven abrasive article and method of making the same

Publication Date: 2020.02.11 3M INNOVATIVE PROPERTIES CO

AI summary

A nonwoven abrasive article includes a lofty open nonwoven fiber web comprising entangled fibers; and abrasive platelets secured to the entangled fibers by at least one binder material. A majority of the abrasive platelets are respectively bonded in an edge-wise manner to at least one of the entangled fibers. Methods of making the nonwoven abrasive article and converted forms, including a convolute abrasive wheel, are also disclosed.