Polymer impregnated backing material, abrasive articles incorporating same, and processes of making and using

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Solution Overview

Problem

Abrasive articles using vulcanized fiber substrates suffer from dimensional instability due to moisture changes, leading to shape distortion and premature product failure, despite various attempts to address these issues.

Innovation Solution

A composite backing material is developed by impregnating a nonwoven fabric with a polymer composition, featuring a front fill layer and a back fill layer, which provides improved tensile strength, flexural modulus, and dimensional stability, enhancing the performance and longevity of abrasive articles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If vulcanized fiber substrate is used in abrasive articles, then the substrate provides flexibility and ease of manufacture, but it suffers from dimensional instability and shape distortion due to moisture absorption

Engineering Contradiction:

Improveease of manufactureVSAvoiddimensional stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent applies composite materials by combining vulcanized fiber with polymer coatings and fill layers to create a multi-layer composite structure. This composite approach allows the substrate to retain the flexibility and ease of manufacture of vulcanized fiber while gaining dimensional stability from the polymer and fill components that resist moisture-induced deformation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs parameter changes by modifying the physical and chemical properties of the vulcanized fiber substrate through polymer impregnation and coating. The polymer content, coating thickness, and cross-linking density are adjusted to optimize the balance between flexibility and dimensional stability, transforming the substrate's moisture response characteristics.

Inventive Principle:

Principle #35Parameter changes

2Shape

If vulcanized fiber substrate is used in abrasive articles, then the substrate provides flexibility, but it causes shape distortion such as curling and cupping due to moisture changes

Engineering Contradiction:

Improveshape stabilityVSAvoidmoisture sensitivity

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful moisture absorption特性 of vulcanized fiber into a benefit by using the moisture uptake to trigger polymer cross-linking and dimensional stabilization. The moisture that previously caused distortion is now utilized to activate the polymer network formation that prevents future distortion, turning the harmful hygroscopic nature into a stabilizing mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the physical and chemical parameters of the substrate by introducing polymer coatings and fill layers that modify the moisture interaction. The polymer content, coating structure, and cross-linking degree are optimized to control how the substrate responds to moisture, preventing curling and cupping while maintaining appropriate flexibility.

Inventive Principle:

Principle #35Parameter changes

3Duration of action of stationary object

If conventional vulcanized fiber substrates are used, then the abrasive articles can be manufactured easily, but they experience premature end of life due to excessive warping and delamination

Engineering Contradiction:

Improveservice lifeVSAvoiddimensional reliability

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

The patent uses composite materials comprising vulcanized fiber reinforced with polymer networks and fill layers to create a structurally stable substrate. This composite structure prevents excessive warping and delamination by distributing stresses uniformly and providing a rigid framework that maintains dimensional reliability throughout the service life of the abrasive article.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies preliminary action by pre-treating the vulcanized fiber substrate with polymer impregnation and coating before the abrasive layers are applied. This preliminary stabilization ensures that the substrate achieves its final dimensional configuration and polymer network structure before serving as the base for the abrasive article, preventing subsequent warping and delamination during use.

Inventive Principle:

Principle #10Preliminary action

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 composite backing material significantly reduces dimensional changes and weight gain under varying humidity conditions, maintaining performance and extending the life of abrasive articles compared to conventional vulcanized fiber substrates.

Implementation Method 1

impregnating a nonwoven fabric with a polymer composition

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS9751192B2Polymer impregnated backing material, abrasive articles incorporating same, and processes of making and using

Publication Date: 2017.09.05 SAINT GOBAIN ABRASIVES INC

AI summary

This invention relates to composite backing materials (e.g., polymer impregnated nonwoven fabrics) and coated abrasive articles that include such composite backing materials. This invention also relates to methods of making and using said composite backing materials and coated abrasive articles. The claimed processes and systems related to the use and manufacturing of coated abrasive articles are improved and cost effective.