Wearable Backing for Abrasive Flap Disk
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Solution Overview
Problem
Existing wearable backing plates for rotary abrasive disks face challenges in balancing wear rate and strength, as fiberglass strengthens but does not wear cleanly, while resin-abrasive mix wears cleanly but lacks sufficient strength for some applications.
Innovation Solution
A backing plate structure composed of multiple layers with reinforcing glass material positioned to absorb stresses and a fiber-reinforced resin mix that wears at the same rate as the abrasive flaps, ensuring both strength and clean wear, with glass layers concentrated at areas of high tensile stress and resin mix at the wearing flange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiberglass is used to strengthen the backing plate, then the structural strength is improved, but the wear cleanliness deteriorates
Solution Approach 1:
The backing plate incorporates different materials at different locations: fiberglass is concentrated in the inner radial region (within 6 inches from the center) where tensile stresses are highest, while the outer radial region uses resin-abrasive mix for clean wearing. This local differentiation allows each material to perform its optimal function - fiberglass provides strength where needed most, and resin-abrasive mix ensures clean wear at the working surface.
Solution Approach 2:
The backing plate is constructed as a composite structure combining two distinct materials - fiberglass and resin-abrasive mix - each with complementary properties. The fiberglass layers provide tensile strength to prevent plate failure under load, while the resin-abrasive mix provides clean wearing characteristics. This composite approach allows the backing plate to simultaneously achieve both high strength and clean wear performance that neither material could provide alone.
2Object-generated harmful factors
If resin-abrasive mix is used for the backing plate, then the wear cleanliness is improved, but the structural strength deteriorates
Solution Approach 1:
The backing plate incorporates different materials at different locations: fiberglass is concentrated in the inner radial region (within 6 inches from the center) where tensile stresses are highest, while the outer radial region uses resin-abrasive mix for clean wearing. This local differentiation allows each material to perform its optimal function - fiberglass provides strength where needed most, and resin-abrasive mix ensures clean wear at the working surface.
Solution Approach 2:
The backing plate is constructed as a composite structure combining two distinct materials - fiberglass and resin-abrasive mix - each with complementary properties. The fiberglass layers provide tensile strength to prevent plate failure under load, while the resin-abrasive mix provides clean wearing characteristics. This composite approach allows the backing plate to simultaneously achieve both high strength and clean wear performance that neither material could provide alone.
3Productivity
If the backing plate wears at the same rate as the abrasive flaps, then the grinding performance consistency is improved, but the material selection becomes more complex
Solution Approach 1:
The backing plate incorporates different materials at different locations: fiberglass is concentrated in the inner radial region (within 6 inches from the center) where tensile stresses are highest, while the outer radial region uses resin-abrasive mix for clean wearing. This local differentiation allows each material to perform its optimal function - fiberglass provides strength where needed most, and resin-abrasive mix ensures clean wear at the working surface.
Solution Approach 2:
The backing plate is constructed as a composite structure combining two distinct materials - fiberglass and resin-abrasive mix - each with complementary properties. The fiberglass layers provide tensile strength to prevent plate failure under load, while the resin-abrasive mix provides clean wearing characteristics. This composite approach allows the backing plate to simultaneously achieve both high strength and clean wear performance that neither material could provide alone.
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 solution provides a strong, efficiently wearing backing plate that maintains structural integrity under operational loads and wears cleanly, allowing consistent grinding performance without damaging the workpiece, even when flaps are worn down.
Implementation Method 1
fiberglass (e.g., woven or nonwoven) can be positioned to absorb tensile loads experienced in a backing plate
Implementation Method 2
The rotating disk has an abrasive surface which contacts and prepares the surface as desired by the user
Data Source
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AI summary
A structure for a backing plate of an abrasive disk is disclosed. The structure includes layers of abrasive resin interspersed with layers of reinforcing fiberglass. The layers are generally disk shaped and cover certain radial intervals of the entire backing plate between the inner diameter and the outer diameter. For example, a radial stress profile plotting the stress along a radial line from inner to outer diameter can be determined. The amount and radial positioning of reinforcing layers (e.g., reinforcing fiberglass) may then be determined. An appropriate amount of reinforcing layers may then be placed within the radial intervals that experience the highest stress.