Epoxy-Bonded Grindstone Curing Without Hot Compression

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Solution Overview

Problem

Conventional methods of manufacturing grindstones and dresser boards using phenolic resin as a binder require substantial energy expenditure due to hot compression and sintering processes, leading to high energy consumption.

Innovation Solution

A method involving the use of an amine-based hardener with an amine value of 600 mgKOH/g or higher to harden an epoxy resin, allowing the grindstone and dresser board to be manufactured without external heat and pressure, through a chemical reaction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If hot compression and sintering processes are used to manufacture grindstones with phenolic resin binder, then the grindstone achieves sufficient mechanical strength and durability, but the energy consumption increases substantially

Engineering Contradiction:

Improvemechanical strengthVSAvoidenergy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The invention changes the chemical parameters of the binder system by using phenolic resin with specific molecular weight (50-500) and combining it with a polyamine hardener. This chemical parameter change enables the resin to achieve adequate crosslinking and mechanical strength through chemical reaction rather than thermal compression and sintering, thereby reducing energy consumption while maintaining required strength properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the mechanical/thermal processing system (hot compression and sintering) with a chemical reaction system. The phenolic resin binder undergoes chemical crosslinking reaction with the polyamine hardener to form a durable matrix that binds abrasive grains, eliminating the need for energy-intensive thermal compression and sintering processes while achieving equivalent or superior bond strength

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional manufacturing methods are used for dresser boards, then the process is simple, but the energy consumption is high due to hot compression and sintering

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidenergy consumption

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The invention modifies the manufacturing parameters by using phenolic resin with controlled molecular weight (50-500) and incorporating a polyamine hardener. This chemical parameter modification enables the dresser board to be manufactured through chemical crosslinking at lower temperatures and pressures, simplifying the manufacturing process while dramatically reducing energy consumption compared to conventional hot compression and sintering methods

Inventive Principle:

Principle #35Parameter changes

3Use of energy by moving object

If phenolic resin with low molecular weight is used, then the manufacturing process requires less energy, but the mechanical strength and durability of the grindstone decrease

Engineering Contradiction:

Improveenergy consumptionVSAvoidmechanical strength

Core Design Contradiction:

Use of energy by moving objectVSStrength

Solution Approach 1:

The invention creates a composite binder system combining phenolic resin (molecular weight 50-500) with a polyamine hardener. This composite material approach allows the lower molecular weight phenolic resin to achieve adequate crosslinking density through chemical reaction with the polyamine, thereby maintaining sufficient mechanical strength and durability while reducing the need for energy-intensive hot compression and sintering processes

Inventive Principle:

Principle #40Composite materials

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

This approach reduces energy consumption and enhances the durability of the grindstones and dresser boards, achieving equivalent performance to conventional methods while minimizing energy-related costs.

Implementation Method 1

leaving the mixture to stand until the epoxy resin is hardened by the amine-based hardener in a chemical reaction therewith

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS20250360598A1Method of manufacturing grindstone, grindstone, method of manufacturing dresser board, and dresser board

Publication Date: 2025.11.27 DISCO CORP

AI summary

A method of manufacturing a grindstone includes molding a mixture of materials including abrasive grains, an epoxy resin, and an amine-based hardener to a predetermined shape and leaving the mixture to stand until the epoxy resin is hardened by the amine-based hardener in a chemical reaction therewith, and the amine-based hardener has an amine value of 600 mgKOH/g or higher.