Porous Abrasive Article With Segmented Layers for Dust Extraction
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Solution Overview
Problem
Conventional abrasive articles with net-type knit backing provide superior dust extraction but lack adequate abrasive performance in terms of cut and life, while abrasive discs with dust-extraction holes suffer from reduced performance due to low abrasive area coverage.
Innovation Solution
A pattern-coated abrasive article with a porous backing layer and abrasive layer, featuring well-defined abrasive coating areas and open voids, optimized for both dust extraction and abrasive performance, using a hook-and-loop attachment mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If abrasive is coated onto fibers of net-type knit backing, then dust extraction is improved, but abrasive area coverage is reduced
Solution Approach 1:
The abrasive backing is segmented into distinct functional zones: a net-type knit backing structure that provides dust extraction pathways, and an abrasive coating layer that provides cutting functionality. This segmentation allows each zone to optimize its specific function without compromising the other.
Solution Approach 2:
Different regions of the abrasive article have different properties: the backing layer has high porosity for dust extraction, while the abrasive coating layer has high abrasive particle density for cutting performance. This local differentiation resolves the contradiction by assigning specific functions to specific locations.
2Productivity
If conventional abrasive discs with dust-extraction holes are used, then abrasive performance is improved, but dust extraction capability is reduced
Solution Approach 1:
The dust extraction function is extracted from the abrasive coating layer and transferred to the backing layer structure. The net-type knit backing with its open loop structure provides dedicated dust extraction pathways, separating the abrasive function from the dust extraction function.
Solution Approach 2:
The dust extraction mechanism is moved from a two-dimensional hole pattern in the abrasive layer to a three-dimensional open loop structure in the backing layer. This dimensional change allows for superior dust extraction while maintaining abrasive performance.
3Object-affected harmful factors
If net-type knit backing with loops is used, then dust extraction and anti-loading properties are improved, but cut and life performance are reduced
Solution Approach 1:
The abrasive article uses a composite structure combining net-type knit backing material with abrasive coating material. This composite approach allows the backing to provide dust extraction and anti-loading properties while the abrasive coating provides cut and life performance.
Solution Approach 2:
The invention merges the dust extraction function and abrasive cutting function into a single integrated article. The net-type backing with its open loop structure is combined with an abrasive coating layer, creating a multi-functional product that achieves both dust extraction and superior abrasive performance.
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 abrasive article achieves enhanced cut and life performance while maintaining superior dust extraction capabilities, with air flow rates of at least 1.0 L/s, effectively removing dust from abraded surfaces.
Implementation Method 1
with air flow rates of at least 1.0 L/s, effectively removing dust from abraded surfaces
Data Source
AI summary
An abrasive article comprising an attachment layer and an abrasive layer. The attachment layer comprises a porous backing having a first major surface, an opposed second major surface, and a first plurality of voids extending from the first major surface to the second major surface. The abrasive layer has a third major surface and an opposed fourth major surface and comprises a cured composition, abrasive particles at least partially embedded in the cured composition, and a second plurality of voids extending from the third major surface to the fourth major surface. The first major surface of the attachment layer is adjacent the third major surface of the abrasive layer, and the pattern of the second plurality of voids is independent of the pattern of the first plurality of voids.