Laterally-Stretched Netting Abrasive Particle Orientation

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Solution Overview

Problem

Conventional coated abrasive articles face challenges in achieving optimal positioning and orientation of abrasive particles, which affects their performance due to limitations in current coating methods such as drop coating and electrostatic coating.

Innovation Solution

A laterally-stretched netting with a patterned abrasive layer is created by bonding abrasive particles to a make coat layer on a polymer strand network, allowing for precise orientation and deposition of abrasive particles in a predetermined pattern, followed by lateral stretching to enhance the open area and retention of the abrasive particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional drop coating or electrostatic coating methods are used to coat abrasive particles onto a resin-coated backing, then the coating process is simple and fast, but the positioning and orientation of abrasive particles cannot be precisely controlled

Engineering Contradiction:

Improvepositioning and orientation of abrasive particlesVSAvoidcoating process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Abrasive particles are deposited onto the make coat layer before the lateral stretching step, establishing their positions and orientations in advance. The stretching process then preserves these pre-established configurations while expanding the overall structure, thereby achieving precise particle positioning without requiring complex coating equipment.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The coating process is segmented into distinct steps: first depositing a make coat layer, then depositing abrasive particles onto the make coat, and finally performing lateral stretching. This segmentation allows each step to be optimized independently, achieving precise particle positioning through the coordinated sequence of simpler operations.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If abrasive particles are coated densely onto the backing, then coverage is improved, but particle retention and singly-bonded configuration decrease

Engineering Contradiction:

Improvepatterned array distributionVSAvoidabrasive particle retention

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The make coat layer provides localized bonding sites that enable abrasive particles to be singly-bonded in a patterned array. This localized bonding approach ensures each particle is securely attached at its specific position while maintaining adequate spacing, thereby achieving both precise distribution and high retention simultaneously.

Inventive Principle:

Principle #3Local quality

3Area of stationary object

If the netting is stretched laterally to increase open area, then the abrasive article structure is enhanced, but abrasive particles may lose their orientation and distribution

Engineering Contradiction:

Improveopen area of nettingVSAvoidorientation and distribution of abrasive particles

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of attempting to maintain particle positions during stretching by applying complex constraints, the invention inverts the sequence: particles are positioned on the unstretched netting first, then the netting is stretched. The make coat layer's bonding action ensures particles move with the netting strands, preserving their relative orientations and distributions automatically through the stretching process.

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

This method results in a high yield of singly-bonded abrasive particles with improved retention and patterned array distribution, enhancing the abrasive performance by maintaining the desired orientation and distribution of particles post-stretching.

Implementation Method 1

a make coat layer on at least portions of the first major surface of at least some strands of the first set of strands, and on at least portions of the first major surface of at least some strands of the second set of strands; a plurality of abrasive particles at least a majority of which are singly-bonded, by way of the make coat layer, to a first surface of a strand

Methodology Applied

Scientific EffectAdhesion: Adhesive