Pattern-Coated Abrasive Article for Dust-Extracting Dry Sanding

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Solution Overview

Problem

Existing coated abrasive products face challenges in achieving enhanced cut and/or life performance while effectively minimizing airborne dust during dry sanding operations.

Innovation Solution

A pattern-coated abrasive article is designed with a porous substrate having openings, featuring a functional layer that partially occludes these openings to allow swarf passage, combined with an abrasive layer dispersed in a make layer, and optionally a supersize layer, to enhance dust extraction and abrasive performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the abrasive layer is coated onto a porous knit fabric with loops integrally formed for hook-and-loop attachment, then attachment to power tool is enabled, but dust extraction performance is insufficient

Engineering Contradiction:

Improveattachment to power toolVSAvoidairborne dust

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The abrasive layer is segmented into distinct functional zones: a first portion with higher abrasive particle density for cutting performance, and a second portion with lower density and larger openings for dust extraction. This segmentation allows simultaneous optimization of both attachment functionality and dust removal capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the abrasive layer are given different properties: the first portion has higher abrasiveness for effective cutting, while the second portion has larger openings and lower density to facilitate dust extraction. This local differentiation resolves the contradiction between cutting performance and dust removal.

Inventive Principle:

Principle #3Local quality

2Productivity

If the functional layer fully occludes the openings in the porous substrate, then abrasive performance is enhanced, but dust extraction is blocked

Engineering Contradiction:

Improveabrasive performanceVSAvoidairborne dust

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The functional layer is segmented into two distinct portions: a first portion that fully occludes openings to enhance abrasive performance, and a second portion that does not fully occlude openings to maintain dust extraction capability. This segmentation allows both functions to coexist.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The functional layer exhibits different occlusion characteristics in different regions: dense occlusion in the first portion for optimal abrasion, and partial occlusion in the second portion for optimal dust removal. This local quality differentiation resolves the technical contradiction.

Inventive Principle:

Principle #3Local quality

3Productivity

If a patterned abrasive layer is designed independent of the porous substrate pattern, then balance between abrasive performance and dust extraction is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improveabrasive performanceVSAvoidpattern coating process

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The abrasive layer is divided into multiple portions with different functional characteristics. The first portion is positioned over a first region of the porous substrate, and the second portion is positioned over a second region, creating distinct functional zones that can be manufactured using multi-step coating processes.

Inventive Principle:

Principle #1Segmentation

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 solution provides superior dust extraction and maintains or improves abrasive performance by allowing swarf to be drawn through the substrate, while maintaining effective abrasive action.

Implementation Method 1

the functional layer fully occludes a first portion of the openings and does not fully occlude a second portion of the openings

Methodology Applied

Scientific EffectPhysical occlusion:

Implementation Method 2

the functional layer comprises a first chemically crosslinked binder, wherein the functional layer fully occludes a first portion of the openings

Methodology Applied

Scientific EffectChemical crosslinking: Chemical Bonding

Implementation Method 3

a porous substrate having openings extending through the porous substrate between first and second opposed major surfaces

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 4

abrasive particles dispersed in or partially embedded in the make layer

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS12528158B2Abrasive article and method of making the same

Publication Date: 2026.01.20 3M INNOVATIVE PROPERTIES CO

AI summary

An abrasive article comprises a porous substrate having openings extending through the porous substrate between first and second opposed major surfaces. An abrasive coating is disposed on only a portion of a first major surface of the porous substrate. The abrasive coating comprises a functional layer disposed on only a portion of a first major surface of the porous substrate, a make layer disposed on at least a portion of the functional layer opposite the porous substrate, and abrasive particles. The functional layer and the make layer independently comprise chemically crosslinked binders. The functional layer fully occludes a first portion the openings and does not fully occlude a second portion of the openings, which permits passage of abraded swarf through the abrasive article. Methods of making the abrasive article are also disclosed.