Ceramic Grinding Tools Using Polymer Pore Former Mixtures
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Solution Overview
Problem
Existing ceramic-bonded grinding tools face issues with toxic and odor-causing naphthalene as pore formers, which lead to environmental pollution and health risks, and alternative pore formers fail to meet requirements for low rebound, mixing behavior, and controlled burning without residue.
Innovation Solution
A method using a mixture of polymers with distinct firing curves, specifically thermoplastics like polylactide, polyacrylate, polyethylene, and polyvinyl butyral, that extend the release of pore formers over a wide temperature interval, ensuring complete combustion to CO2 and H2O, and optimizing the firing curve for improved homogeneity and grinding performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If naphthalene is used as pore former, then low temperature removal and good pore formation are achieved, but toxicity and intense odor are generated causing environmental pollution and health risks
Solution Approach 1:
The patent changes the chemical composition parameters by replacing naphthalene with a specific mixture of polymers (polyacrylate, polyvinyl acetate, polyvinyl butyral, polyethylene) that have different thermal decomposition characteristics. This parameter change maintains the pore formation function while eliminating toxicity and odor issues associated with naphthalene.
Solution Approach 2:
The patent uses a composite pore former system consisting of multiple polymers with different firing curves rather than a single substance. This composite approach allows the mixture to provide both low-temperature removal capability and environmentally friendly decomposition, resolving the contradiction between temperature efficiency and environmental harm.
2Object-affected harmful factors
If alternative pore formers are used to replace naphthalene, then environmental harm is reduced, but they fail to meet requirements for low rebound, mixing behavior, and controlled burning
Solution Approach 1:
The patent employs a composite pore former mixture of four specific polymers that work synergistically. Each polymer contributes different properties: polyacrylate provides low-temperature decomposition, polyvinyl acetate and polyvinyl butyral ensure controlled burning, and polyethylene provides structural stability. This composite formulation meets all performance requirements while being environmentally friendly.
Solution Approach 2:
The patent applies local quality by assigning specific functional roles to different polymers within the mixture. Each polymer is selected and proportioned to provide specific local functions: some components handle low-temperature removal, others ensure controlled combustion, and others maintain mixing behavior and low rebound characteristics.
3Object-affected harmful factors
If dicarboxylic acids are used as pore formers, then alternative to naphthalene is achieved, but considerable gas volumes are released causing mechanical damage and requiring complex temperature regimes
Solution Approach 1:
The patent changes the decomposition behavior parameters by selecting polymers with gradual, controlled decomposition over a wide temperature range rather than rapid decomposition at low temperature. This parameter change prevents sudden gas volume expansion while still achieving effective pore formation, eliminating mechanical damage risks.
Solution Approach 2:
The patent implements periodic action through the sequential decomposition of different polymers at different temperature stages. The firing process occurs in distinct phases: initial low-temperature decomposition of polyacrylate, followed by controlled burning of polyvinyl acetate and polyvinyl butyral, and finally polyethylene decomposition. This staged approach prevents simultaneous gas expansion and mechanical damage.
4Stability of the object's composition
If acrylate glasses are used as pore formers, then non-deformable and non-swelling properties are achieved, but severe short-term load on incineration units and incomplete combustion occur
Solution Approach 1:
The patent changes the thermal decomposition parameters by replacing acrylate glasses with a polymer mixture that decomposes gradually over a wide temperature interval. This parameter change distributes the combustion load over time rather than concentrating it in a short period, preventing severe emissions loads while maintaining structural stability during the green compact stage.
Solution Approach 2:
The patent ensures continuity of useful action through the progressive decomposition of the polymer mixture. Different polymers decompose at different temperatures, creating a continuous and controlled release of gases over an extended period rather than a sudden burst. This continuous action prevents incineration unit overload and ensures complete combustion.
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 polymer mixture provides a safer, more environmentally friendly grinding tool with enhanced homogeneity, reduced rebound, and improved grinding performance, overcoming the limitations of previous pore formers by extending the firing process and minimizing environmental impact.
Implementation Method 1
ensuring complete combustion to CO2 and H2O
Implementation Method 2
The maxima of at least two firing curves of the different polymers differ by at least 20° C., the maxima of the firing curves of all the polymers in the mixture being in each case below 750° C.
Implementation Method 3
these being substances which can be removed from the green compact at low temperatures by evaporation, sublimation or burning
Data Source
AI summary
In a method for producing open-pore, ceramic-bonded grinding tools, a pore former mixture consisting of at least two polymers having different firing curves, the maxima of which differ by at least 20° C., is used. The polymers are preferably thermoplastics that can be decomposed exclusively into CO2 and water during combustion. The resulting grinding tool has a multimodal pore size distribution.