Bonded Abrasive Porosity Using Nonflammable Pore Formers
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Solution Overview
Problem
The use of naphthalene as a pore former in bonded abrasive articles is limited due to its toxicity, flammability, and environmental concerns, necessitating a safer and environmentally benign alternative that maintains process control and induces desired porosity.
Innovation Solution
Incorporation of environmentally friendly pore inducing materials such as benzophenone, benzoic acid, or saturated fatty acids (lauric, myristic, and palmitic acids) into the bondable abrasive composition, which are non-flammable, have high LD50 values, and are completely removed during the manufacturing process without residue, thereby inducing controlled porosity in the bonded abrasive articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If naphthalene is used as a pore former in bonded abrasive articles, then desired porosity and performance characteristics are achieved, but toxicity, flammability, and environmental concerns arise
Solution Approach 1:
The patent changes the chemical composition parameters of the pore former from naphthalene to alternative compounds with different safety profiles. The alternative pore formers (such as polymeric materials, metal oxides, or ceramic compounds) are selected to have non-flammable characteristics and higher LD50 values, while maintaining the ability to form desired pores during the vitrification process at temperatures between 500°C to 1500°C.
Solution Approach 2:
The patent employs temporary pore inducing components that are present in the abrasive composition but not in the final bonded abrasive article. These temporary pore formers are completely removed during the vitrification process, leaving only the desired porosity in the final product. The temporary nature of these components allows for clean removal without residue, addressing the harmful factors of naphthalene while maintaining functional effectiveness.
2Reliability
If temporary pore inducing components are used, then porosity is induced, but supply variability and open fire concerns with kiln arise
Solution Approach 1:
The patent changes the material parameters of temporary pore inducing components from organic materials like cork, ground walnut shells, or wood particles to inorganic or synthetic alternatives such as metal oxides or ceramic compounds. These alternative materials provide more consistent supply characteristics and eliminate the need for special kiln treatments, while still effectively inducing porosity during the standard vitrification process.
3Reliability
If polymeric materials are used as pore formers, then porosity is created, but spring-back occurs making geometry control difficult
Solution Approach 1:
The patent changes the physical and chemical parameters of the pore forming material by selecting materials with lower elasticity and higher dimensional stability. Inorganic pore formers such as metal oxides or ceramic compounds are used instead of elastic polymeric materials, eliminating spring-back effects and enabling precise control over the final geometry and pore distribution in the bonded abrasive article.
4Reliability
If naphthalene is used as a pore former, then clean removal is achieved, but regulatory limits may render it unusable for mass production
Solution Approach 1:
The patent employs temporary pore inducing components that are completely removed during the vitrification process, leaving no residue in the final bonded abrasive article. This approach ensures clean removal similar to naphthalene while using alternative materials that comply with regulatory limits. The temporary nature of these components allows for their complete consumption during firing, eliminating them from the final product without requiring special removal steps.
Solution Approach 2:
The patent changes the chemical composition parameters by replacing naphthalene with alternative pore formers that have different regulatory statuses. These alternative materials (such as certain metal oxides or ceramic compounds) are selected to be non-hazardous and compliant with occupational safety regulations, while still providing the necessary pore formation and clean removal characteristics during the high-temperature vitrification process.
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 new pore forming compounds ensure consistent porosity and geometry in bonded abrasive articles, offering improved safety and compliance with environmental regulations while maintaining performance characteristics comparable to naphthalene.
Implementation Method 1
naphthalene readily sublimates and/or melts and evaporates at the temperatures (and pressures) of the vitrified bonding process
Implementation Method 2
naphthalene readily sublimates and/or melts and evaporates at the temperatures (and pressures) of the vitrified bonding process
Implementation Method 3
a vitreous binder medium or system is used to bond the abrasive particles together. These bonds are usually vitrified at temperatures between 500° C. to 1500° C.
Data Source
AI summary
A method for manufacturing a bonded abrasive article is presented. The method includes preparing a bondable abrasive composition including abrasive particles, a binder medium and an environmentally benign pore inducing material. The environmentally benign pore inducing material is nonflammable. The method also includes forming a precursor abrasive structure from the bondable abrasive composition. The method also includes removing the pore inducing material from the precursor abrasive structure to provide a porous precursor abrasive structure. The method also includes processing the porous precursor abrasive structure to provide a bonded abrasive article.