Elastic Abrasive Core with Masonry Grain Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing elastic abrasives used in blasting for surface polishing face issues such as detachment of abrasive grains due to moisture loss or adhesiveness degradation, leading to reduced cutting ability and increased consumption rates, making it difficult to achieve a glossy or mirror-like finish without frequent replacement or process adjustments.
Innovation Solution
A method involving a crosslinked polyrotaxane compound core with a rubber hardness of 30 or less and an abrasive-grain layer formed by sprinkling and pressing abrasive grains onto the core, creating a masonry structure that maintains adhesiveness and impact absorption, preventing mutual clumping and extending the abrasive's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional elastic abrasives are used for blasting, then impact absorption and surface polishing are achieved, but abrasive grains detach due to moisture loss or adhesiveness degradation, reducing cutting ability and increasing consumption
Solution Approach 1:
The invention uses a composite structure combining crosslinked polyrotaxane compound (elastic body) with abrasive grains. The crosslinked polyrotaxane provides both elasticity for impact absorption and chemical adhesion to bind abrasive grains, creating a composite material that maintains structural integrity and cutting ability throughout service life.
Solution Approach 2:
The invention changes the chemical and physical parameters of the elastic body by using crosslinked polyrotaxane compound with specific properties (rubber hardness of 30 or less, compression set of 5% or less, tan δ of 0.3 or more). These parameter changes enable the elastic body to maintain adhesion and elasticity under blasting conditions, preventing abrasive grain detachment.
2Manufacturing precision
If fine abrasive grains are used to achieve glossy finish, then surface polishing quality improves, but abrasive grains float in air and interfere with vision, hindering monitoring of treated region
Solution Approach 1:
The crosslinked polyrotaxane compound acts as an intermediary carrier that binds fine abrasive grains, preventing them from floating in air. This intermediary structure allows fine grains to be effectively used for high-quality surface finishing while maintaining visibility and monitoring capability in the blasting zone.
3Manufacturing precision
If fine abrasive grains are used for blasting, then surface polishing precision improves, but abrasive grains become charged with static electricity and contact with cabinet and workpiece, requiring ionized air or wet cleaning
Solution Approach 1:
The invention changes the surface properties of the elastic abrasive by using crosslinked polyrotaxane compound with specific adhesion characteristics. This parameter change reduces static electricity generation during blasting, preventing abrasive grain adhesion to surfaces and eliminating the need for additional static control devices.
4Strength
If elastic bodies and abrasive grains are integrally formed, then impact absorption improves, but abrasive grains become exposed at surface, leading to detachment and reduced service life
Solution Approach 1:
The invention creates a composite material where crosslinked polyrotaxane compound serves dual functions: providing elasticity for impact absorption and providing chemical adhesion to retain abrasive grains. This composite structure eliminates the problem of grain exposure and detachment while maintaining impact absorption capabilities.
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 solution effectively prevents abrasive grain detachment and maintains cutting ability over a long period, allowing for consistent mirror-surface polishing without significant performance degradation, with the abrasive-grain layer being easily replenished to restore the abrasive's effectiveness.
Implementation Method 1
a core (2) prepared by granulating a crosslinked polyrotaxane compound having a rubber hardness of 30 or less and having autohesion properties
Implementation Method 2
the core (2) has a compression set of 5% or less and vibration absorbing properties (tan δ) of 0.3 or more at 1 Hz to 100 kHz
Implementation Method 3
an abrasive-grain layer (3) having a masonry structure formed by integrally forming multiple abrasive grains (31) in the thickness direction on the surface of the core (2)
Data Source
AI summary
A long-lasting elastic grinding material capable of subjecting surfaces of objects to mirror-finishing, glossifying and the like via blasting thereof. A nucleus (2) is obtained by granulating a crosslinked polyrotaxane compound having self-tackiness and a rubber hardness of 30 or less into particles of a prescribed diameter. The nucleus (2), which is soft and exhibits significant deformability, is sealed on the inside of an abrasive-particle layer (3) by: adhering abrasive particles (31) to the surface of the nucleus (2): then affixing the abrasive particles (31) to the surface of the nucleus (2) by applying pressure to the surface of the nucleus (2) to which the abrasive particles (31) are adhered; and forming the abrasive-particle layer (3), which has a masonry-like structure formed by attaching a plurality of the abrasive particles (31) in the thickness direction to the surface of the nucleus (2), by further subjecting the surface of the nucleus (2) to which the abrasive particles (31) are affixed to repeated adhesion of identical abrasive particles (31) and affixing by application of pressure.