Patterned Abrasive Article Without Scrims
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Solution Overview
Problem
Existing bonded abrasive articles lack efficient methods for forming patterned layers of abrasive particles without the need for additional reinforcing structures like scrims, which limits their cut rate and longevity.
Innovation Solution
The development of an abrasive article with layers of abrasive particles arranged in predetermined patterns, retained by a continuous binder material, where the particles are directly placed into a mold and formed without a scrim, allowing for optimized patterns that enhance cut rate and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If abrasive particles are arranged in predetermined patterns without scrims, then cut rate and longevity are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming molds with predetermined patterns of cavities or channels before abrasive particle placement. These pre-formed molds guide the abrasive particles into specific patterns during the molding process, eliminating the need for complex post-manufacturing arrangements while achieving optimized cut rates and longevity.
Solution Approach 2:
The patent uses the mold as an intermediary element that transfers the predetermined pattern to the abrasive article. The mold's internal structure with pre-designed cavities or channels acts as a mediator, automatically forming the abrasive particles into optimized patterns during the molding process without requiring additional reinforcing structures like scrims.
2Duration of action of moving object
If abrasive particles are arranged in predetermined patterns, then abrasive article life is extended, but material distribution uniformity becomes more difficult to achieve
Solution Approach 1:
The patent applies local quality by designing different regions of the mold with specific cavity patterns optimized for different functional requirements. The mold can have varying cavity densities, sizes, or arrangements in different zones, allowing abrasive particles to be distributed non-uniformly in a controlled manner that extends article life while maintaining overall structural integrity.
Solution Approach 2:
The patent transitions from two-dimensional surface patterns to three-dimensional internal patterns by incorporating cavities and channels within the bulk structure of the abrasive article. This dimensional change allows particles to be arranged in optimized patterns throughout the volume, extending article life while the mold ensures uniform distribution through its pre-formed geometry.
3Ease of manufacture
If scrims are removed from the abrasive article structure, then production costs are reduced, but structural support between layers becomes insufficient
Solution Approach 1:
The patent merges the structural support function previously performed by separate scrim layers with the binder material itself. The binder is formulated to provide both adhesive bonding between abrasive particle layers and structural reinforcement, eliminating the need for additional scrim materials and reducing production costs while maintaining adequate strength.
Solution Approach 2:
The binder material is designed to perform multiple functions simultaneously: it acts as an adhesive to bond abrasive particles, provides structural support between layers, and can even contribute to the cutting action. This multi-functionality eliminates the need for separate scrim components, reducing production costs while maintaining structural integrity.
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 approach results in increased cut rate and longer abrasive article life, while reducing material usage and production costs, as the patterned arrangement of abrasive particles improves performance and allows for uniform distribution in both 2D and 3D planes.
Implementation Method 1
A binder material retains the first and second layers of abrasive particles in the abrasive article
Implementation Method 2
The mold is heated to produce the abrasive article
Data Source
AI summary
Various embodiments disclosed relate to an abrasive article. The abrasive article includes a first major surface and an opposed second major surface. Each major surface contacts a peripheral side surface. A central axis extends through the first and second major surfaces. A first layer of abrasive particles is dispersed within the abrasive article according to a first predetermined pattern. Further a second layer of abrasive particles spaced apart from the first layer of abrasive particles and is dispersed within the abrasive article along a according to a second predetermined pattern. A binder material retains the first and second layers of abrasive particles in the abrasive article. A portion of the binder material is located between the first and second layers of abrasive particles. That portion of the binder material is substantially continuous.