Extruded Abrasive Particles with Striations for Solidity Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The industry demands improved abrasive materials and abrasive articles with enhanced performance, particularly in terms of solidity and shape consistency, which existing technologies have not adequately addressed.

Innovation Solution

The development of extruded shaped abrasive particles with an average solidity of at least 0.87, and a method for forming coated abrasive articles using these particles, which include a body with striations extending along the exterior surface in the direction of the particle's length.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional fusion, sintering, or chemical ceramic processes are used to produce abrasive particles, then manufacturing capability is maintained, but particle shape consistency and solidity are insufficient

Engineering Contradiction:

Improveparticle shape consistencyVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by modifying the extrusion process parameters including using a water-to-binder ratio between 0.15-0.35, extrusion pressure of 500-2000 psi, and specific green body moisture content of 5-15%. These controlled parameter changes enable production of particles with solidity of 0.87 or greater while maintaining manufacturing feasibility through standard extrusion equipment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces traditional mechanical shaping methods (chill rolls, molds, heat sinks) with an extrusion-based system that forms particles through controlled material discharge and self-shaping. This substitution eliminates the need for complex mechanical shaping apparatus while achieving superior particle geometry consistency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If abrasive particles with higher solidity are produced, then material removal performance is improved, but manufacturing difficulty increases

Engineering Contradiction:

Improveabrasive performanceVSAvoidforming process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by forming the green body with the desired shape and density characteristics before final particle separation. The green body is extruded with controlled moisture content (5-15%) and then sectioned into individual particles, ensuring that the solidified particles inherently achieve the required solidity of 0.87 or greater without requiring additional complex forming steps

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the extruded green body into individual abrasive particles through controlled sectioning. This segmentation approach allows each particle to inherit the uniform properties of the green body while maintaining manufacturing simplicity through continuous extrusion followed by periodic separation

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250026972A1Abrasive articles and methods of forming same

Publication Date: 2025.01.23 SAINT GOBAIN CERAMICS & PLASTICS INC

AI summary

A coated abrasive article comprising a substrate and a plurality of abrasive particles having an average solidity of at least 0.87 and less than 0.97, wherein each of the abrasive particles of the plurality of abrasive particles comprises a body and striations extending along an exterior surface of the body in a direction of a length of the body. Further directed to a plurality of extruded shaped abrasive particles comprising an average solidity of at least 0.87.