Structured Abrasive Article with Embedded Surfactant
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Solution Overview
Problem
Current abrasive articles for glossy surface finishing and repair require surfactant solutions during abrading, which can be costly and inefficient, and their performance in extending the useful life and cut rate is limited.
Innovation Solution
A structured abrasive article with a backing and a structured abrasive layer comprising precisely-shaped abrasive composites, nonionic polyether surfactant dispersed in a crosslinked polymeric binder, and an attachment interface layer, allowing for effective abrading with tap water instead of surfactant solutions, enhancing cut rate and product life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If surfactant solutions are used during abrading, then the useful life of the abrasive article is extended, but the cost increases and efficiency is reduced
Solution Approach 1:
The patent extracts the surfactant from the external application requirement and incorporates it directly into the abrasive article structure itself. The surfactant is embedded within the binder matrix of the abrasive layer, allowing it to be released during the abrading process without requiring separate surfactant solution application. This eliminates the need for costly external surfactant solutions while maintaining the useful life extension benefit.
Solution Approach 2:
The abrasive article becomes self-sufficient by containing its own surfactant supply within the binder. The surfactant is released during abrasion to perform its functions (reducing friction, preventing clogging, extending article life) without requiring external intervention or additional substances. The article serves itself by integrating the surfactant function directly into its structure.
2Reliability
If surfactant solutions are used during abrading, then the abrasive article can function properly, but the process becomes less efficient
Solution Approach 1:
The surfactant function is extracted from the external process step and integrated into the abrasive article itself. This eliminates the need for separate surfactant solution application steps, streamlining the abrading process and improving productivity while maintaining reliable functionality through the embedded surfactant release mechanism.
Solution Approach 2:
The patent changes the delivery mechanism parameter of the surfactant from external application to internal release. By controlling the surfactant release rate and concentration through the binder matrix design, the process achieves both reliable functionality and improved efficiency by eliminating unnecessary process steps and reducing friction more effectively.
3Productivity
If conventional abrasive articles are used, then the abrading process can proceed, but the cut rate and product life are limited
Solution Approach 1:
The patent creates a composite abrasive layer combining abrasive particles, binder, and surfactant in a unified structure. This composite formulation allows the surfactant to be released during abrasion, reducing friction and heat buildup, which prevents premature wear of the abrasive particles and extends product life while maintaining high cut rate through improved cutting efficiency.
Solution Approach 2:
By changing the chemical composition parameters of the abrasive layer to include surfactant at specific concentrations within the binder matrix, the patent achieves both enhanced cut rate (through reduced friction) and extended product life (through prevented clogging and reduced wear). The parameter change in surfactant concentration and distribution directly impacts both productivity and duration of action.
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 structured abrasive article achieves improved abrading performance and extended useful life by using tap water, reducing costs and enhancing efficiency compared to industry standards.
Implementation Method 1
a structured abrasive layer comprising shaped abrasive composites, wherein the shaped abrasive composites comprise abrasive particles and nonionic polyether surfactant dispersed in a crosslinked polymeric binder
Implementation Method 2
nonionic polyether surfactant dispersed in a crosslinked polymeric binder
Implementation Method 3
frictionally contacting at least a portion of the structured abrasive layer of the structured abrasive article with a surface of a workpiece while in the presence of an aqueous fluid; and moving at least one of the workpiece or the structured abrasive layer relative to the other to abrade at least a portion of the surface of the workpiece
Data Source
Figure 1
AI summary
A structured abrasive article includes a backing having a structured abrasive layer disposed on and secured thereto. The structured abrasive layer includes shaped abrasive composites that comprise abrasive particles and nonionic polyether surfactant dispersed in a crosslinked polymeric binder. The abrasive particles have a mean particle size of less than 10 micrometers. The nonionic polyether surfactant is not covalently bound to the crosslinked polymeric binder and is present in an amount of from 2.5 to 3.2 percent by weight based on a total weight of the shaped abrasive composites. The structured abrasive articles are useful for abrading a workpiece.