Segmented Abrasive Product With Multi-Level Channels

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Solution Overview

Problem

Conventional abrasive products often fail to provide uniform abrasion due to rigidity, leading to uneven wear and reduced effectiveness, especially when used on non-planar surfaces with height deviations, as they lack the necessary flexibility and durability for both machine and hand abrasion applications.

Innovation Solution

The development of an abrasive product with multiple abrasive zones supported by a backing layer, featuring interconnected channel portions with varying dimensions and patterns to enhance flexibility and efficient material conveyance, reducing clogging and improving durability through a combination of surface height deviations and functional layers for improved attachment and functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the abrasive product is made rigid to maintain structural integrity, then durability is improved, but flexibility and conformability to complex surfaces deteriorate

Engineering Contradiction:

ImprovedurabilityVSAvoidflexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The abrasive product is divided into multiple abrasive zones separated by channel portions, creating a segmented structure that allows each zone to independently conform to surface variations while maintaining overall structural integrity through the backing layer

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The backing layer is designed with controlled flexibility to allow the abrasive product to conform to complex surfaces, while the abrasive zones and channel portions are configured to maintain structural integrity during use

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If the abrasive product is made flexible to conform to surfaces, then adaptability is improved, but structural integrity and durability deteriorate

Engineering Contradiction:

ImproveconformabilityVSAvoidstructural integrity

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The abrasive zones are segmented and supported by the backing layer, allowing each zone to flex independently while the backing layer maintains overall structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The abrasive product combines the backing layer with abrasive zones and channel portions to create a composite structure that exhibits both flexibility for conformability and sufficient strength for durability

Inventive Principle:

Principle #40Composite materials

3Device complexity

If conventional abrasive products are used on non-planar surfaces, then simplicity of design is maintained, but uniformity of abrasion deteriorates

Engineering Contradiction:

Improvedesign simplicityVSAvoiduniformity of abrasion

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The abrasive zones are configured with specific patterns and densities to provide uniform abrasion across different areas of the product, ensuring consistent performance when used on non-planar surfaces

Inventive Principle:

Principle #3Local quality

4Productivity

If channel portions with increasing volumes are provided, then efficiency of material conveyance is improved, but device complexity increases

Engineering Contradiction:

Improveefficiency of material conveyanceVSAvoidchannel structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The channel portions are designed with varying volumes that adapt to the flow of abraded material, with larger volumes in areas where material accumulation is more likely, optimizing conveyance efficiency without requiring complex external mechanisms

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP3552762B1A method to provide an abrasive product surface and abrasive products thereof

Publication Date: 2023.07.05 KWH MIRKA LTD

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Figure 4a~4b

AI summary

The invention relates to an abrasive product which comprises multiple abrasive zones supported by a backing layer, where each abrasive zone is surrounded by interconnected channel portions with at least two levels of transverse dimensions and second channel portion with a second transverse dimension larger than the first transverse dimension. An abrasive product may thus be provided with a structure that provides both flexibility and efficient abrasion, which is unidirectional.