Coated Abrasive Articles with Oriented Platelets
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Solution Overview
Problem
Existing coated abrasive articles often fail to maintain the initial orientation of shaped abrasive particles, leading to suboptimal performance due to particle misalignment during the curing process of the make layer precursor.
Innovation Solution
The use of production tools with precisely-shaped cavities that orient and secure abrasive particles in specific orientations, such as vertical or inclined positions, ensures that the abrasive particles maintain their alignment during the transfer to the make layer precursor and subsequent curing, resulting in a coated abrasive article with improved abrading performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shaped abrasive particles are disposed at various desired orientations relative to the backing, then the abrading performance is improved, but the particles tip substantially from their original orientation before curing of the make layer precursor
Solution Approach 1:
The production tool with precisely-shaped cavities is used to position and orient the shaped abrasive particles in their desired orientations before the make layer precursor is applied. This preliminary positioning action ensures that when the particles are transferred to the backing, they maintain their intended orientation, preventing the tipping problem that occurs with conventional methods.
Solution Approach 2:
The production tool with precisely-shaped cavities serves as an intermediary device between the abrasive particle supply and the make layer precursor application system. The cavities act as temporary holders that constrain and orient the particles, allowing for precise control during the transfer process without direct contact with the final backing.
2Ease of manufacture
If conventional methods are used to apply abrasive particles to the make layer precursor, then the manufacturing process is simple, but the abrasive particles fail to maintain their initial orientation
Solution Approach 1:
The manufacturing process is segmented into distinct functional stages: (1) positioning particles in precisely-shaped cavities of the production tool, (2) transferring oriented particles to the make layer precursor, and (3) curing the precursor. This segmentation allows each stage to be optimized independently, maintaining particle orientation while keeping the overall process manufacturable.
Solution Approach 2:
The production tool features locally varied cavity geometries that are specifically designed to accommodate different particle shapes and desired orientations. Each cavity is shaped to provide the appropriate constraints and guidance for the abrasive particles, ensuring correct orientation at each local position without requiring complex global process changes.
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 method effectively retains the initial orientation of abrasive particles, enhancing the abrading performance and efficiency of coated abrasive articles by maintaining optimal particle alignment and packing density.
Implementation Method 1
contacting the precisely-shaped abrasive platelets with a curable make layer precursor disposed on a major surface of a backing; and at least partially curing the curable make layer precursor to provide and at least partially cured make layer precursor
Data Source
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AI summary
A method of making a coated abrasive article includes: depositing precisely-shaped abrasive platelets into precisely-shaped cavities in a production tool; depositing diluent abrasive particles onto the production tool; contacting the precisely-shaped abrasive platelets and the diluent abrasive particles with a curable make layer precursor disposed on a major surface of a backing; separating the tool from the precisely-shaped abrasive platelets and the diluent abrasive particles; and at least partially curing the curable make layer precursor to provide an at least partially cured make layer precursor. Coated abrasive articles preparable by the method are also disclosed.