Patterned Coated Abrasive Articles for Swarf Removal
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Solution Overview
Problem
Existing coated abrasive articles often face inefficiencies in abrading performance due to uniform distribution of abrasive particles and lack of targeted application of grinding aids, leading to suboptimal material removal and increased friction during the abrading process.
Innovation Solution
The development of pattern-coated abrasive articles, where abrasive particles and grinding aids are applied in specific patterns on the backing, optimizing their distribution and alignment to enhance material removal efficiency and reduce friction, utilizing techniques such as patterned coating and alignment tools to create well-defined areas of material coating and open areas devoid of coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If uniform distribution of abrasive particles is used, then coverage area is maximized, but abrading efficiency deteriorates due to lack of targeted material removal
Solution Approach 1:
The patent applies local quality by creating non-uniform distribution of abrasive particles and grinding aids in specific patterns (e.g., concentrated zones, radial patterns, or alternating regions) rather than uniform distribution. This allows different areas of the abrasive article to have different functional characteristics, with high-concentration zones providing aggressive material removal and low-concentration zones providing finishing or cooling functions, thereby improving overall abrading efficiency.
Solution Approach 2:
The patent segments the abrasive particle distribution into distinct patterned zones rather than a continuous uniform distribution. The abrasive particles and grinding aids are applied in segmented patterns such as radial segments, concentric rings, or discrete clusters, which allows optimized material removal in specific areas while reducing friction and heat in other areas.
2Productivity
If uniform distribution of grinding aids is used, then friction reduction is generalized, but targeted friction reduction at high-stress areas is insufficient
Solution Approach 1:
The patent applies local quality by distributing grinding aids in non-uniform patterns that concentrate the lubricating effect in high-stress areas such as leading edges, radial zones, or regions corresponding to abrasive particle clusters. This targeted distribution reduces friction where it is most needed during the abrading process, improving material removal rate while preventing excessive heat generation.
3Productivity
If patterned coating is applied, then abrading efficiency is improved through optimized material removal, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-patterned substrates or pre-formed abrasive particle clusters that are subsequently coated with binding agents. The patterned structure is established before the coating process, simplifying the overall manufacturing. Alternatively, masking templates or patterned applicators are used to apply coatings in predetermined patterns without requiring complex real-time control systems.
Solution Approach 2:
The patent uses copying by employing patterned masters, templates, or transfer sheets that replicate the desired abrasive particle and grinding aid distribution pattern. A master pattern is created once and then used to reproduce the same pattern across multiple abrasive articles, ensuring consistency while simplifying the manufacturing process through repeated copying rather than direct complex patterning.
4Productivity
If abrasive particles are concentrated in specific areas, then material removal efficiency is improved, but coverage area deteriorates
Solution Approach 1:
The patent uses segmentation to divide the abrasive particle distribution into multiple discrete zones or clusters arranged in specific patterns (e.g., radial segments, concentric rings, or grid patterns). This segmentation allows concentrated abrasive zones for aggressive material removal to be distributed across the surface, maintaining both high material removal efficiency in each zone and broad overall coverage through the arrangement of multiple zones.
Solution Approach 2:
The patent applies another dimension by transitioning from two-dimensional uniform distribution to three-dimensional patterned distribution with varying densities. Abrasive particles are concentrated in specific zones with higher density while maintaining overall coverage through strategic placement, effectively utilizing vertical density variation to achieve both concentrated action and broad coverage simultaneously.
Data Source
AI summary
A coated abrasive article is presented. The coated abrasive article includes a backing having first and second opposed major surfaces. The coated abrasive article also includes a make layer bonded to the first major surface. The coated abrasive article also includes abrasive particles directly bonded to the make layer. The abrasive particles are at least partially embedded in the make layer. The coated abrasive article also includes a size layer directly bonded to the make layer, and abrasive particles. One of the make layer and size layer comprise a patterned coating.