Triangular Platelet Grid Orientation for Abrasive Disc Durability

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Solution Overview

Problem

Coated abrasive discs used for abrading and finishing materials, particularly mild steel welds, face challenges in cost, performance, and longevity, with existing technologies not effectively optimizing the arrangement and orientation of triangular abrasive platelets for enhanced grinding efficiency.

Innovation Solution

The development of a coated abrasive disc with a specific arrangement of triangular abrasive platelets at contiguous intersections of a rectangular grid pattern, where at least 70% of intersections have abrasive elements, and precise orientation of these elements to ensure optimal contact with the disc backing, enhancing the abrasive layer's effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If triangular abrasive platelets are arranged in a rectangular grid pattern with specific orientation, then cutting ability and grinding efficiency are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecutting abilityVSAvoidarrangement complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The abrasive layer is segmented into discrete abrasive elements, each comprising two triangular abrasive platelets positioned at specific orientations. This segmentation allows independent optimization of each element's geometry and orientation to maximize cutting efficiency while maintaining a systematic grid arrangement for manufacturability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each abrasive element exhibits local quality through its specific dual-platelet configuration and orientation within the grid pattern. The two triangular platelets are positioned with their long dimensions aligned at different angles (e.g., 0° and 45°), creating locally optimized cutting edges that enhance grinding efficiency while the overall grid pattern maintains manufacturing simplicity.

Inventive Principle:

Principle #3Local quality

2Productivity

If at least 70% of grid intersections have abrasive elements, then abrasive layer effectiveness is enhanced, but material usage and cost increase

Engineering Contradiction:

Improveabrasive layer effectivenessVSAvoidabrasive material quantity

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

Instead of placing abrasive elements at every single grid intersection, the design uses partial action by requiring only at least 70% of intersections to have abrasive elements. This provides sufficient abrasive coverage for effective grinding while reducing the total quantity of abrasive material needed compared to 100% coverage, optimizing the balance between performance and material cost.

Inventive Principle:

Principle #16Partial or excessive action

3Duration of action of stationary object

If one sidewall of at least 90% of triangular abrasive platelets faces the disc backing, then durability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvedisc durabilityVSAvoidplatelet orientation precision

Core Design Contradiction:

Duration of action of stationary objectVSManufacturing precision

Solution Approach 1:

The design specifies a parameter threshold (at least 90% of platelets) rather than requiring 100% precision in orientation. By setting the criterion that one sidewall of at least 90% of triangular abrasive platelets faces the disc backing, the invention allows for reasonable manufacturing tolerances while still achieving improved durability through optimized platelet orientation for better mechanical interlocking and reduced platelet dislodgement.

Inventive Principle:

Principle #35Parameter changes

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 configuration results in superior performance for off-hand abrading of mild steel welds, improving the disc's durability and efficiency compared to previous designs, as demonstrated by increased cutting ability and reduced wear.

Implementation Method 1

frictionally contacting a portion of the abrasive layer of a coated abrasive disc according to the present disclosure with the workpiece

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

moving at least one of the workpiece and the abrasive article relative to the other to abrade the workpiece

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS11597059B2Coated abrasive disc and methods of making and using the same

Publication Date: 2023.03.07 3M INNOVATIVE PROPERTIES CO

AI summary

A coated abrasive disc includes a disc backing and an abrasive layer disposed thereon. The abrasive layer comprises abrasive elements secured to a major surface of the disc backing by at least one binder material. The abrasive elements are disposed at contiguous intersections of horizontal and vertical lines of a rectangular grid pattern. Each abrasive element has two triangular abrasive platelets, each having respective top and bottom surfaces connected to each other, and separated by, three sidewalls. On a respective basis, one sidewall of the triangular abrasive platelets is disposed facing and proximate to the disc backing. A first portion of the abrasive elements is arranged in alternating first rows wherein the triangular abrasive platelets are disposed lengthwise aligned with the vertical lines. A second portion of the abrasive elements is arranged in alternating second rows wherein the triangular abrasive platelets are disposed lengthwise aligned with the horizontal lines. The first and second rows repeatedly alternate along the vertical lines. Methods of making and using the coated abrasive disc are also disclosed.