Composite Shaped Abrasive Particles via Screen Printing
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Solution Overview
Problem
The industry demands improved abrasive materials and articles with enhanced performance, as existing methods for producing shaped abrasive particles, such as fusion, sintering, and chemical ceramic technologies, have limitations in terms of geometry, durability, and efficiency.
Innovation Solution
A method of forming composite shaped abrasive particles by creating a mixture of ceramic powder and liquid with specific rheological characteristics, which is then extruded and shaped using a screen printing process, allowing for the attachment of additional abrasive particles to the surface of a precursor particle, resulting in a composite particle with improved surface area and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If traditional fusion, sintering, or chemical ceramic processes are used to produce shaped abrasive particles, then the particles can be formed with specific geometries, but the surface area and material removal capability are limited
Solution Approach 1:
The abrasive particle is divided into multiple segments: a shaped body (such as triangular or rectangular platelet) and multiple smaller abrasive particles attached to its surface. This segmentation increases the total surface area and provides multiple cutting edges, thereby improving material removal capability while maintaining manufacturability through a systematic attachment process.
Solution Approach 2:
The invention creates a composite abrasive particle by combining a shaped body with multiple smaller abrasive particles attached to its surface. This composite structure integrates the geometric advantages of shaped particles with the high surface area of aggregated particles, achieving both improved performance and manufacturability through controlled composition and attachment.
2Productivity
If abrasive particles are attached to the surface of a shaped body, then material removal capability and surface area are improved, but the bonding process complexity increases
Solution Approach 1:
The invention utilizes changes in physical or chemical parameters during the attachment process, such as temperature, pressure, or chemical reactivity, to bond abrasive particles to the shaped body. By controlling these parameters, the bonding process achieves high productivity without excessive complexity, allowing for efficient attachment while maintaining particle integrity and bond strength.
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 method enables the creation of composite abrasive particles with enhanced surface area and performance, offering improved material removal capabilities and durability, addressing the limitations of existing technologies.
Implementation Method 1
which is then extruded and shaped using a screen printing process
Implementation Method 2
attaching a plurality of abrasive particles to at least one surface of the body
Data Source
AI summary
An abrasive particle including a shaped abrasive particle having a body and a plurality of abrasive particles bonded to at least one surface of the body of the shaped abrasive particle.