Rotary Abrasive Disc Reinforcing Insert Placement

Solution Overview

Problem

Current rotary abrasive discs with side-mounted reinforcing rings experience increased vibration, reduced operational speeds, and lower precision due to side loading and torque transmission issues, leading to operator fatigue and reduced material removal rates.

Innovation Solution

A method of manufacturing rotary abrasive members with a reinforcing insert positioned centrally between a curable abrasive resin compound and a backing member, forming a substance-to-substance bond that enhances mechanical stability and structural integrity, allowing for higher rotational speeds and reduced thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If side-mounted reinforcing rings are used in rotary abrasive discs, then mechanical strength and structural stability are improved, but vibration increases and operational precision deteriorates

Engineering Contradiction:

Improvemechanical strengthVSAvoidoperational precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent inverts the conventional design by moving the reinforcing ring from the outer peripheral region to the central region of the abrasive disc. This inversion transforms the reinforcing ring from a side-mounted component causing imbalance to a centrally-mounted component that minimizes vibration and improves operational precision while maintaining mechanical strength.

Inventive Principle:

Principle #13The other way round (Inversion)

2Stability of the object's composition

If side-mounted reinforcing rings are used, then structural integrity is enhanced, but torque transmission and side loading characteristics deteriorate

Engineering Contradiction:

Improvestructural integrityVSAvoidtorque transmission

Core Design Contradiction:

Stability of the object's compositionVSPower

Solution Approach 1:

The patent inverts the conventional design by moving the reinforcing ring from the outer peripheral region to the central region of the abrasive disc. This inversion transforms the reinforcing ring from a side-mounted component causing imbalance to a centrally-mounted component that minimizes vibration and improves operational precision while maintaining mechanical strength.

Inventive Principle:

Principle #13The other way round (Inversion)

3Strength

If greater disc thickness is used to meet side loading requirements, then structural strength is improved, but vibration increases and material removal rate decreases

Engineering Contradiction:

Improvestructural strengthVSAvoidmaterial removal rate

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent inverts the conventional design by moving the reinforcing ring from the outer peripheral region to the central region of the abrasive disc. This inversion transforms the reinforcing ring from a side-mounted component causing imbalance to a centrally-mounted component that minimizes vibration and improves operational precision while maintaining mechanical strength.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the positional parameter of the reinforcing ring from side-mounted to centrally-mounted, and enables reduction of disc thickness parameter while maintaining structural strength. This parameter change allows thinner discs that remove material faster while producing less vibration.

Inventive Principle:

Principle #35Parameter changes

4Strength

If conventional side-mounted ring design is used, then mechanical reinforcement is achieved, but operational speed and precision are reduced

Engineering Contradiction:

Improvemechanical reinforcementVSAvoidoperational speed

Core Design Contradiction:

StrengthVSSpeed

Solution Approach 1:

The patent inverts the conventional design by moving the reinforcing ring from the outer peripheral region to the central region of the abrasive disc. This inversion transforms the reinforcing ring from a side-mounted component causing imbalance to a centrally-mounted component that minimizes vibration and improves operational precision while maintaining mechanical strength.

Inventive Principle:

Principle #13The other way round (Inversion)

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 central placement of the reinforcing insert minimizes imbalance and side forces, enabling higher precision and speed in abrasive material removal while reducing vibration and material waste, resulting in improved operational efficiency and extended disc life.

Implementation Method 1

bonding the reinforcing insert and the backing member by curing the curable abrasive resin compound, wherein the cured abrasive resin compound forms an abrasive layer of the abrasive member

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS11407086B2Method of manufacturing an abrasive member, in particular rotary abrasive disc, and abrasive member, in particular rotary abrasive disc

Publication Date: 2022.08.09 DRONCO GMBH

AI summary

A method of manufacturing an abrasive member, in particular having the general shape of a disc such as a cutting or grinding disc, comprisesarranging a reinforcing insert or reinforcing member into a mold between a layer of curable abrasive resin compound, in particular a layer of curable abrasive granulate, a backing member such that at least a section of the reinforcing insert or reinforcing member is in direct physical contact with the curable abrasive resin compound, the reinforcing insert or reinforcing member is at least partially covered by the backing member and at least a section of the backing member is in direct physical contact with the curable abrasive resin compound;bonding the reinforcing insert or reinforcing member and the backing member by curing the curable abrasive resin compound, wherein the cured abrasive resin compound forms an abrasive layer of the abrasive member.