Segmented Abrasive Assembly with Transfer Film Adhesion
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Solution Overview
Problem
Existing abrasive articles with backing layers face challenges in securely mounting and adhering to support pads, especially when dealing with high-pressure applications or contoured surfaces, due to limitations in adhesive strength and flexibility.
Innovation Solution
A method of creating a segmented adhesive-backed abrasive article with a release liner, where each abrasive segment has a segment abrasive layer and a segment adhesive layer, and a transfer film assembly is applied to enhance adhesion between the abrasive segments and the support surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a pressure-sensitive adhesive layer is used to mount the abrasive article onto the support pad, then the abrasive article can be easily applied to various surfaces, but the adhesion strength is insufficient for high-pressure applications or contoured surfaces
Solution Approach 1:
The abrasive article is divided into multiple discrete abrasive segments that are separately mounted onto the support pad. Each segment can be independently positioned and pressed onto the surface, allowing for better distribution of mounting pressure and improved adhesion on contoured surfaces while maintaining ease of application.
Solution Approach 2:
Different regions of the abrasive article are converted into separate segments that can be locally optimized for specific mounting conditions. The segmentation allows each portion to conform to local surface variations, providing both ease of application and enhanced adhesion strength where needed.
2Stability of the object's composition
If the abrasive article is made as a single continuous piece with backing layer, then it provides structural integrity, but it cannot conform well to contoured surfaces
Solution Approach 1:
The continuous abrasive article is segmented into multiple discrete portions that can independently conform to contoured surfaces. Each segment maintains its structural integrity while the collection of segments provides overall adaptability to complex geometries, resolving the contradiction between structural stability and surface conformability.
Solution Approach 2:
The segmented structure allows each abrasive segment to dynamically adjust and conform to the contours of the support pad surface during application. This dynamic adaptability enables the abrasive article to maintain structural integrity while conforming to various surface geometries.
3Adaptability or versatility
If the abrasive segments are discrete and separated, then they can conform to contoured surfaces, but the adhesion to the support pad is weakened
Solution Approach 1:
Each discrete abrasive segment is optimized for local adhesion to the support pad surface. The segmentation allows each portion to make intimate contact with the contoured surface, maximizing local adhesion strength while maintaining the ability to conform to complex geometries.
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 method achieves improved adhesion between the abrasive segments and the support surface, with the second adhesive layer providing at least 20% greater adhesion than the segment adhesive layer to the release liner, ensuring secure attachment and effective abrasion on contoured surfaces.
Implementation Method 1
A first adhesion between the second adhesive layer and the segment abrasive layer is at least 20 percent, or at least 50 percent greater than a second adhesion between the segment adhesive layer and the release liner
Data Source
AI summary
Aspects of the present disclosure relate to an abrasive assembly and a method of making an abrasive assembly. The method can include receiving a segmented adhesive-backed abrasive article that includes a release liner and a plurality of abrasive segments disposed on the release liner. Each abrasive segment comprises a segment abrasive layer and a segment adhesive layer that each have a smaller planar surface area than a planar surface area of an adhesive-backed abrasive sheet. The release liner of the segmented adhesive-backed abrasive article is continuous and connects the plurality of abrasive segments which are discrete from each other. The method can include applying transfer film assembly to the segmented adhesive-backed abrasive article. A second adhesive layer of the transfer film assembly adheres to the segment abrasive layer and the segment abrasive layer is sandwiched between the segment adhesive layer of a first adhesive layer and the second adhesive layer.