3D Photocured Polymer Bond Abrasives for Complex Surface Polishing

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Solution Overview

Problem

Existing abrasive articles lack the ability to form complex geometries necessary for effective polishing of glass, ceramic, or polymer substrates, and traditional methods require labor-intensive wrapping of abrasive sheets around shafts.

Innovation Solution

The development of polymer bond abrasive articles with a continuous photocured polymer matrix incorporating abrasive particles, optical brighteners, and light absorbers, manufactured through additive manufacturing processes like stereolithography, allowing for three-dimensional shapes and improved design flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If traditional wrapping methods are used to manufacture abrasive articles, then the manufacturing process is simple, but the ability to form complex geometries is limited

Engineering Contradiction:

Improvecomplex geometriesVSAvoidlabor-intensive wrapping

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical wrapping process with a photocuring-based additive manufacturing system. A liquid photocurable composition containing abrasive particles is selectively cured using light (UV or visible) to build complex three-dimensional geometries layer by layer, eliminating the need for manual wrapping while enabling intricate shapes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the state of the bonding matrix from a pre-formed solid (in traditional wrapping) to a photocurable liquid composition that can be selectively solidified. This parameter change enables the formation of complex geometries through controlled photocuring while reducing manufacturing complexity.

Inventive Principle:

Principle #35Parameter changes

2Shape

If photocurable composition is used to form continuous polymer matrix, then three-dimensional shapes are achieved, but the manufacturing process complexity increases

Engineering Contradiction:

Improvethree-dimensional shapeVSAvoidadditive manufacturing process

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent uses optical energy (photocuring) instead of complex mechanical assembly processes. The continuous polymer matrix is formed by selective photocuring of a liquid composition, replacing multi-step mechanical manufacturing with a streamlined light-based process that achieves three-dimensional shapes more efficiently.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If optical brightener is added to photocured polymer matrix, then polishing performance is improved, but the composition complexity increases

Engineering Contradiction:

Improvepolishing performanceVSAvoidcomposition formulation

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent creates a composite photocurable composition that integrates multiple functional components: abrasive particles for material removal, optical brightener for enhanced polishing performance, photoinitiator for curing, and polymer matrix for structural integrity. This composite formulation achieves superior polishing performance while managing composition complexity through functional integration.

Inventive Principle:

Principle #40Composite materials

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 polymer bond abrasive articles can efficiently polish glass, ceramic, or polymer substrates with complex geometries, reducing labor requirements and providing seamless, three-dimensional structures that enhance polishing performance.

Implementation Method 1

The composition includes a photoinitiator and a photocurable component and is lacking a polymer. The composition has been cured to form a polymer and includes the polymer.

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

The polymer bond abrasive article includes an optical brightener.

Methodology Applied

Scientific EffectFluorescence: Fluorescence

Data Source

PatentEP4072782B1Polymer bond abrasive articles including continuous polymer matrix, and methods of making same

Publication Date: 2026.01.28 3M INNOVATIVE PROPERTIES CO

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AI summary

The present disclosure provides a polymer bond abrasive article formed of a continuous photocured polymer matrix having abrasive particles retained therein. The photocured polymer matrix includes at least one of an optical brightener or a light absorber, and the polymer bond abrasive article has a three-dimensional shape. An abrasive tool is also provided, including the abrasive article affixed to a shaft or a pad. Further, a method of making the polymer bond abrasive article is provided, including a) obtaining a photocurable composition liquid dispersion; b) selectively curing a portion of the photocurable composition; and repeating steps a) and b) to form the polymer bond abrasive article. The dispersion contains at least one photocurable component; abrasive particles; a photoinitiator; and at least one of an optical brightener or a light absorber.