Segmented Abrasive Article With Hinge Channels

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Solution Overview

Problem

Conventional abrasive articles are stiff and fail to conform to curved workpiece surfaces, leading to uneven material removal and increased time in finishing processes, while also generating dust and debris that can hinder abrading efficiency.

Innovation Solution

The development of abrasive articles with elongated channels on the working surface and a flexible attachment layer, which enhances flexibility and segregates debris, allowing for improved access to recessed areas and efficient particle extraction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional coated abrasive layers are used, then abrasive performance is maintained, but the article is stiff and does not conform to curved contours of the workpiece surface

Engineering Contradiction:

Improveconformability to curved surfacesVSAvoidstructural rigidity

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The abrasive layer is divided into multiple segments by creating channels that extend across its thickness. These channels divide the abrasive layer into a plurality of segments, allowing each segment to independently conform to curved surfaces while maintaining overall structural integrity through the attachment layer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The attachment layer is formed with a flexible material that allows the abrasive article to be acutely bent along the channels. This flexible backing enables the article to adapt to curved workpiece contours without compromising the abrasive performance of the coated layer.

Inventive Principle:

Principle #30Flexible shells and thin films

2Productivity

If conventional abrasive articles are used, then material removal occurs, but dust and debris build up between the abrasive surface and workpiece, reducing efficiency

Engineering Contradiction:

Improveabrading efficiencyVSAvoiddebris buildup

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

Channels are created that extend across the abrasive layer from the working surface to the attachment layer, providing pathways for dust and debris to be extracted from between the abrasive surface and the workpiece. This prevents contaminant accumulation and maintains consistent abrading efficiency throughout the process.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If thinner, more flexible sheets are used, then conformability to curved surfaces improves, but abrasive performance and robustness of the abrasive layer deteriorate

Engineering Contradiction:

ImproveflexibilityVSAvoidabrasive performance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Rather than reducing the overall thickness of the abrasive layer, the invention segments it using channels. This maintains the robustness and abrasive performance of the full-thickness coated layer while the segmented structure provides the necessary flexibility to conform to curved surfaces.

Inventive Principle:

Principle #1Segmentation

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 solution provides even material removal across curved surfaces, reduces the risk of surface unevenness, and enhances abrading efficiency by preventing debris buildup, thus improving the overall finishing process.

Implementation Method 1

an abrasive article having a series of elongated and optionally intersecting channels which extend across the working surface of an abrasive layer and act as hinge points that enhance the flexibility of the article

Methodology Applied

Scientific EffectFlexibility enhancement through hinge points: Hinge

Implementation Method 2

The channels preferably extend across the working surface of the abrasive layer in two or more coplanar directions, and provide sufficient flexibility for the abrasive to access recessed areas of the workpiece and evenly abrade convex and concave workpiece surfaces. As a further advantage, the channels act to segregate debris and dust particles generated by the abrading operation.

Methodology Applied

Scientific EffectDebris segregation:

Implementation Method 3

The apertures, if present, advantageously provide conduits for particle extraction. Particle extraction may be achieved, for example, by connecting the back surface of the article to a vacuum source.

Methodology Applied

Scientific EffectParticle extraction through apertures:

Implementation Method 4

The present disclosure describes abrasive articles for removing defects from workpiece surfaces, including painted surfaces

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS9168636B2Flexible abrasive article and methods of making

Publication Date: 2015.10.27 3M INNOVATIVE PROPERTIES CO

AI summary

Provided are abrasive articles having a plurality of elongated channels extending across its working surface and intersecting with each other. These channels provide hinge points that enhance flexibility of the article along two or more directions. Optionally, the abrasive article includes a flexible attachment layer, along with apertures that penetrate through the attachment layer located at the intersection points of the channels. The enhanced flexibility allows the abrasive article to easily access recessed areas of the workpiece and facilitates applying even pressure across convex and concave surfaces. The channels assist in segregating dust particles from the abrading operation, and the optional apertures can be advantageously connected to a vacuum source for evacuation of the dust particles from the channels.