Agglomerate Particle Production via UVA Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing large abrasive agglomerate particles are energy-intensive and require expensive molding or replication tools, limiting efficiency and cost-effectiveness in producing particles larger than 80 microns for applications like concrete and stone grinding.
Innovation Solution
A method involving forming a slurry of agglomerate components in a polymerizable liquid resin carrier, mixing with a non-miscible fluid to create discrete droplets, solidifying with UVA radiation, and isolating and firing the particles to produce large, solid agglomerate particles up to 500 microns without the need for molding tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If molding or replication tools are used to produce large abrasive agglomerate particles, then particle size can be increased beyond 80 microns, but production cost and device complexity increase significantly
Solution Approach 1:
The patent replaces the mechanical molding tool system with a chemical/physical process using liquid resin carriers and UVA radiation curing. Instead of using complex molding tools to shape particles, the invention uses a liquid slurry that is dispensed and then cured in place to form the desired particle shapes, eliminating the need for mechanical contact with molds
Solution Approach 2:
The patent employs liquid resin carriers and slurry delivery systems to transport and deposit abrasive materials. The liquid medium allows for easy dispensing and shaping of particles without mechanical contact, and the fluid dynamics enable controlled droplet formation and placement
2Volume of moving object
If molding or replication tools are used to produce large abrasive agglomerate particles, then particle size can be increased beyond 80 microns, but energy consumption increases
Solution Approach 1:
The patent replaces energy-intensive mechanical molding processes with a photopolymerization process that uses UVA radiation to cure liquid resin carriers. This chemical curing process requires significantly less energy than the high-pressure, high-temperature mechanical molding or replication processes traditionally used for large particles
Solution Approach 2:
The patent utilizes the phase transition of the liquid resin carrier from liquid to solid state through photopolymerization. The UVA radiation triggers crosslinking reactions that transform the liquid slurry into solid particles, providing an energy-efficient alternative to thermal or mechanical solidification methods
3Reliability
If conventional abrasive particles are used for hard material grinding, then abrasion performance is achieved, but production cost increases significantly due to superabrasive requirements
Solution Approach 1:
The patent creates composite abrasive particles by combining conventional abrasive materials (alumina, silicon carbide) with liquid resin carriers that contain reinforcing fibers or other abrasive particles. This composite structure allows smaller, less expensive conventional abrasives to work together synergistically to achieve performance comparable to expensive superabrasives like diamond or cubic boron nitride
Solution Approach 2:
The patent divides the abrasive function across multiple smaller particles rather than relying on a single large superabrasive particle. The liquid resin carrier binds multiple smaller conventional abrasive particles into a composite structure that collectively provides the necessary cutting and abrasion performance, reducing the need for expensive single-particle superabrasives
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 enables the cost-effective production of large agglomerate particles with varied shapes and sizes, enhancing abrasion resistance and longevity in abrasive articles used for grinding and polishing hard materials.
Implementation Method 1
solidifying with UVA radiation
Data Source
AI summary
The invention provides a method for making agglomerate particles, said method comprising: (a) forming by mixing at high speed a slurry of mineral agglomerate components in a polymerizable liquid resin carrier; (b) mixing said slurry with a non-miscible fluid to form discrete dispersed droplets; (c) exposing the discrete dispersed droplets to UVA radiation; (c) solidifying said droplets to form a multitude of solid particles; (d) isolating said solid particles and then firing said particles. The resulting size of the fired particles of the invention are estimated to be in the range from approximately 20 μm to approximately 500 μm.