Patterned Coated Abrasive Articles for Curl Resistance
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Solution Overview
Problem
Conventional coated abrasive sheets tend to curl in humid environments, both during manufacturing and when used, leading to operational issues such as curling and delamination, which are not effectively addressed by pre-flexing methods.
Innovation Solution
The development of coated abrasive articles with a patterned coating configuration where the make layer, abrasive particle layer, and size layer are in registration, creating uncoated areas on the backing, which enhances curl resistance, flexibility, and durability, reducing the need for pre-flexing and minimizing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coated abrasive sheets are used in humid environments, then the abrasive function is provided, but the sheets tend to curl and delaminate
Solution Approach 1:
The coating is divided into discrete patterned areas rather than continuous coverage. The make layer, abrasive particle layer, and size layer are applied in registration to form segmented coated regions with uncoated areas between them, reducing overall coating weight and improving curl resistance while maintaining abrasive functionality.
Solution Approach 2:
Different regions of the backing are treated differently - coated areas provide abrasive functionality while uncoated areas maintain flexibility and reduce curling. The patterned configuration creates local variations in coating density and composition optimized for specific functional requirements.
2Reliability
If pre-flexing is applied to mitigate curling, then some curl resistance is achieved, but the method is generally ineffective in preventing curling during use
Solution Approach 1:
The patterned coating configuration is established during manufacturing to preemptively address curling issues. By designing the coating pattern to inherently reduce curling tendencies rather than applying post-manufacturing corrections like pre-flexing, the solution is integrated into the product structure itself.
3Reliability
If patterned coating configuration is used, then curl resistance and flexibility are enhanced, but coating coverage is reduced
Solution Approach 1:
Instead of applying coating to the entire backing surface, the patterned configuration applies coating only to necessary areas where abrasive particles are located. This partial coverage approach reduces overall coating material usage while maintaining sufficient abrasive functionality.
4Strength
If continuous coating is applied to ensure durability, then strength is improved, but flexibility and curl resistance decrease
Solution Approach 1:
The continuous coating is segmented into discrete patterned areas. Each segmented region maintains sufficient coating strength to secure abrasive particles, while the spaces between segments preserve backing flexibility and reduce overall coating weight that contributes to curling.
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 patterned coating configuration significantly reduces curling, improves flexibility and durability, and maintains performance with reduced raw material usage, as demonstrated by increased curl radius and resistance to tearing and delamination in wet and dry conditions.
Implementation Method 1
The abrasive particles may be adhered using one or more tough and resilient binders to secure the particles to the backing during an abrading operation
Implementation Method 2
In a manufacturing process, these binders are often processed in a flowable state to coat the backing and the particles, and then subsequently hardened to lock in a desired structure
Implementation Method 3
The make layer is then hardened (e.g., crosslinked) to secure the particles
Implementation Method 4
Coated abrasive articles are commonly used for abrading, grinding and polishing operations
Data Source
AI summary
Provided are abrasive articles in which the make layer, abrasive particle layer, and size layer are coated onto a backing according to a pre-determined coating pattern. All three components are generally in registration with each other, thereby providing a pervasive uncoated area extending across the backing. Advantageously, this configuration provides a coated abrasive that displays superior curl-resistance compared with previously disclosed abrasive articles. Moreover, this configuration resists loading, resists de-lamination, has enhanced flexibility, and decreases the quantity of raw materials required to achieve the same level of performance as conventional abrasive articles.