Core-Shell Impact Modifiers for Flexible Abrasive Articles
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Solution Overview
Problem
Existing abrasive articles lack improved flexibility, impact strength, and optimal modulus ratio, which affects their performance in material removal operations.
Innovation Solution
Incorporating an impact modifier with a core-shell structure, where the core has a higher flexibility and the shell has higher rigidity, into the abrasive article composition, along with specific particle size distributions and content percentages, to enhance the abrasive article's modulus and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional bond materials are used in abrasive articles, then manufacturing simplicity is maintained, but flexibility and impact strength are insufficient
Solution Approach 1:
The patent employs composite materials by combining bond material with impact modifier particles having core-shell structures. The core contains a first polymer matrix with rubber-like elasticity, while the shell contains a second polymer matrix with plasticity. This composite structure resolves the contradiction by providing both the flexibility from the rubber-like core and the strength from the plastic shell, achieving improved impact strength without excessive complexity in the manufacturing process.
Solution Approach 2:
The impact modifier particles exhibit local quality through their core-shell structure, where different regions have distinct mechanical properties. The core provides rubber-like elasticity for flexibility and shock absorption, while the shell provides plasticity for structural integrity. This local differentiation of material properties within the particle structure enables the abrasive article to simultaneously achieve flexibility and impact strength.
2Stability of the object's composition
If rigid bond materials are used, then structural stability is improved, but flexibility and surface finishing quality deteriorate
Solution Approach 1:
The composite structure of impact modifier particles with rubber-like elastic cores and plastic shells provides both structural stability and surface finishing quality. The rubber-like core maintains structural integrity under stress while the plastic shell allows for controlled deformation, enabling the abrasive article to achieve both stability and high-quality surface finishing.
Solution Approach 2:
The patent changes the mechanical parameters of the bond material system by incorporating impact modifiers with specific rubber-like elasticity and plasticity characteristics. This parameter change allows the bond material to exhibit both structural stability during operation and flexibility for high-quality surface finishing, resolving the contradiction between stability and finishing quality.
3Strength
If high flexibility is achieved through soft materials, then impact absorption improves, but structural rigidity and modulus deteriorate
Solution Approach 1:
The impact modifier particles use a composite core-shell structure where the rubber-like elastic core provides impact absorption capability, while the plastic shell maintains structural rigidity. This composite approach resolves the contradiction by allowing the soft core to absorb impact energy while the harder shell preserves the necessary modulus and structural integrity of the abrasive article.
Solution Approach 2:
The local quality principle is applied through the core-shell structure where the core region provides rubber-like elasticity for impact absorption, while the shell region provides plasticity and structural support. This spatial differentiation of material properties enables the particle to simultaneously achieve high impact absorption and maintain adequate modulus ratio.
Data Source
AI summary
An abrasive article can include a body including a bond material, abrasive particles contained in the bond material, and an impact modifier. In an embodiment, the impact modifier can be in a content of at least 1 vol % of and at most 10 vol % for a total volume of the body. In another embodiment, the impact modifier can include particles having an average particle size (D50) of at least 10 microns, a particle size D10 of at least 2 microns, a particles size D90 of at most 2 mm or any combination thereof.