Sheet-Like Abrasive Article With Closed Cells for Self-Dressing
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Solution Overview
Problem
Existing abrasive materials, such as Trizact, struggle to maintain abrasive performance due to uneven wear and clogging, making it difficult to achieve a mirror-finished state on coating films without frequent rework.
Innovation Solution
A sheet-like abrasive article with closed-cell bodies and abrasive grains, where the closed-cell bodies provide air voids and space for chip discharge, and as they break, new abrasive grains expose, enabling self-dressing and extended life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a molded abrasive material with pyramid-like structures is used, then stable finish and stable abrasive ratio are achieved, but the abrasive material wears away quickly and cannot be used for a long time
Solution Approach 1:
The patent uses a foam body with numerous closed cells as the base material for the abrasive article. This porous structure provides air voids for chip discharge and creates space between the abrasive surface and workpiece, preventing clogging and extending abrasive material life while maintaining manufacturing precision
Solution Approach 2:
The patent combines foam material with abrasive grains and binder to create a composite abrasive structure. The foam provides structural support and chip discharge pathways, while the abrasive grains perform the cutting function, achieving both long life and high precision finishing
2Manufacturing precision
If traditional lapping film is used, then the surface can be finished to mirror state, but sufficient abrasive ability cannot be obtained for coating films
Solution Approach 1:
The foam body structure with closed cells provides air voids that facilitate chip discharge and create space between the abrasive surface and workpiece, enabling the abrasive article to maintain high abrasive ability while achieving mirror-like surface finish on coating films
3Productivity
If abrasive grains are densely packed, then abrasive ability is high, but chips cannot be discharged efficiently causing clogging
Solution Approach 1:
The foam body with closed cells provides air voids and discharge pathways for chips, allowing dense abrasive grain packing for high abrasive ability while preventing chip clogging through the three-dimensional cellular structure that facilitates chip ejection
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 efficient chip discharge and maintains effective abrading performance over a larger area, with self-dressing ability and reduced scratch depth, extending the life of the abrasive layer.
Implementation Method 1
the closed-cell bodies not only provide air voids for discharging chips
Implementation Method 2
a sheet-like abrasive article capable of being suitably used for abrading (polishing) to finish a coating film to a mirror surface state
Implementation Method 3
as the closed-cell bodies in a surface part of the abrasive material layer break up due to friction caused by an abrading work
Data Source
AI summary
[Problem]Provided is a long-life sheet-like abrasive article which comprises an abrasive material layer comprising closed-cell bodies and abrasive grains, wherein the closed-cell bodies not only provide air voids for discharging chips, but also ensure a space between the surface of the abrasive material layer and a workpiece material, thereby facilitating discharge of chips of the workpiece material, and, as the closed-cell bodies in a surface part of the abrasive material layer break up due to friction caused by an abrading work, new abrasive grains act on a workpiece material, thereby allowing the abrasive material layer to have self-dressing ability.[Solution]The sheet-like abrasive article comprises a substrate, and an abrasive material layer provided on one surface of the substrate, wherein the abrasive material layer comprises closed-cell bodies, first abrasive grains, and a first adhesive binder, wherein: each of the closed-cell bodies has an inner diameter of 30 μm to 200 μm; the first abrasive grains have an average grain size which is equal to or less than of one third of the inner diameter of each of the closed-cell bodies; and the first adhesive binder adhesively bonds the abrasive material layer to the substrate, and wherein the closed-cell bodies, the first abrasive grains and the first adhesive binder account for 70% by volume to 85% by volume, 5% by volume to 13% by volume, and a remainder, respectively, based on a volume of an entirety of the abrasive material layer.