Partially Sized Abrasive Base Paper for Balanced Flexibility and Strength
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Solution Overview
Problem
Existing abrasive papers face challenges in achieving the right balance of flexibility and strength, with wet sandpapers being too porous and energy-intensive to produce, and dry sandpapers being too stiff and prone to edge damage during use.
Innovation Solution
A partially sized abrasive base paper with a synthetic sizing agent, which reduces absorbency and allows for even impregnation, enhancing flexibility and strength, and can be used as a replacement for both wet and dry sandpapers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wet sandpaper is made highly porous to improve flexibility and absorbency, then flexibility and splitting strength are improved, but energy consumption in the drying process increases significantly
Solution Approach 1:
The invention changes the porosity parameter of the base paper from high (wet sandpaper) to medium range (30-70%), and adjusts the impregnation agent content to 5-30% by weight. This parameter optimization reduces water absorption while maintaining flexibility and splitting strength, thereby reducing drying energy consumption without sacrificing mechanical properties
Solution Approach 2:
Instead of making the paper highly porous (excessive porosity), the invention uses partially porous base paper with controlled porosity of 30-70%. This partial porosity is sufficient to provide flexibility and adequate absorbency for impregnation, but not so high as to cause excessive water absorption and high energy consumption during drying
2Loss of energy
If dry sandpaper is made dense to reduce porosity, then flexibility is improved, but the paper becomes stiffer and less flexible
Solution Approach 1:
The invention optimizes the porosity parameter to a medium range of 30-70%, avoiding both high porosity (wet sandpaper) and low porosity (dry sandpaper). This intermediate porosity level provides the right balance between flexibility and stiffness, enabling the sandpaper to be flexible enough for easy operation while not being too soft
Solution Approach 2:
The invention uses a composite structure combining a porous base paper with an impregnation agent (5-30% by weight). The base paper provides the porous structure for flexibility, while the impregnation agent adds strength and controls the mechanical properties, creating a composite material with optimized flexibility and energy consumption characteristics
3Strength
If high porosity is used to improve absorbency of impregnation agent, then splitting strength is improved, but too much water is absorbed requiring high energy for drying
Solution Approach 1:
The invention changes the porosity parameter from high to medium range (30-70%) and optimizes the impregnation agent content to 5-30% by weight. This parameter combination provides sufficient absorbency for the impregnation agent to achieve high splitting strength, while limiting water absorption to reduce drying energy requirements
Solution Approach 2:
The invention uses partial porosity (30-70%) rather than high porosity, which provides just enough absorbency for adequate impregnation agent absorption to achieve high splitting strength, but not so much that excessive water is absorbed requiring high energy for drying
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 abrasive paper exhibits significantly longer service life due to improved load distribution and reduced abrasive grain tearing, maintaining high flexibility and strength while reducing energy consumption in production.
Implementation Method 1
The base paper has a suction height of 2 mm to 70 mm in the longitudinal direction and is impregnated with an impregnating agent
Implementation Method 2
the base paper has a suction height of 2 mm to 70 mm in the longitudinal direction and is impregnated with an impregnating agent
Implementation Method 3
Due to the significantly higher flexibility and elasticity of the abrasive base paper according to the invention, the abrasives produced from it absorb the point loads and edge loads arising during use better
Data Source
AI summary
The invention relates to an impregnated abrasive base paper produced from fibres and having a weight per unit area of 110 - 360 g/m2, which abrasive base paper is partially sized by means of a synthetic sizing agent. The added quantity of sizing agent amounts to 0.5 % - 3.0 %, relative to the dry fibres, such that the abrasive base paper has a suction height in the longitudinal direction of 2 mm to 70 mm. The abrasive base paper has a tensile stiffness index in the longitudinal direction of 2.0 MNm/kg to 7.0 MNm/kg and a modulus of elasticity in the longitudinal direction of 2000 to 5500 MPa.