Fixed Abrasive Articles With Shaped Particles for Consistent Removal

Solution Overview

Problem

Existing abrasive articles lack improved materials and methods for shaping abrasive particles, leading to inconsistent performance in material removal operations.

Innovation Solution

The development of fixed abrasive articles with shaped and elongated abrasive particles, positioned and oriented in a predetermined manner within a three-dimensional volume, utilizing a bond material and reinforcing members to enhance material removal efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional fusion, sintering, or chemical ceramic processes are used to produce abrasive particles, then abrasive articles can be manufactured, but the abrasive particles lack consistent geometry and predetermined orientation

Engineering Contradiction:

Improvegeometry consistency of abrasive particlesVSAvoidcomplexity of shaping process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming abrasive particles with specific geometries (triangular, rectangular, cylindrical, or irregular shapes) before incorporating them into the abrasive article. This allows the particles to be positioned and oriented in predetermined patterns within the article body, ensuring consistent geometry and controlled orientation during material removal operations, thereby improving manufacturing precision without requiring complex in-situ shaping processes

Inventive Principle:

Principle #10Preliminary action

2Productivity

If abrasive particles are randomly distributed in abrasive articles, then manufacturing is simpler, but material removal performance is inconsistent

Engineering Contradiction:

Improvematerial removal efficiencyVSAvoidpositioning and orientation control of abrasive particles

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating regions within the abrasive article body where abrasive particles are positioned and oriented in specific patterns. Different zones can have different particle distributions, orientations, or types, allowing optimization of material removal performance in different areas of the article while maintaining overall structural integrity and achieving consistent productivity

Inventive Principle:

Principle #3Local quality

3Productivity

If shaped abrasive particles are used to improve cutting performance, then material removal efficiency increases, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvegrinding and cutting capabilityVSAvoidease of forming shaped abrasive particles

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-forming abrasive particles with specific geometries (triangular, rectangular, cylindrical, or irregular shapes) before incorporating them into the abrasive article. This allows the particles to be positioned and oriented in predetermined patterns within the article body, ensuring consistent geometry and controlled orientation during material removal operations, thereby improving manufacturing precision without requiring complex in-situ shaping processes

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250223478A1Fixed abrasive articles and methods of forming same

Publication Date: 2025.07.10 SAINT GOBAIN ABRASIVES INC

AI summary

A fixed abrasive article having a body including abrasive particles contained within a bond material, the abrasive particles including shaped abrasive particles or elongated abrasive particles having an aspect ratio of length:width of at least 1.1:1, each of the shaped abrasive particles or elongated abrasive particles having a predetermined position or a predetermined three-axis orientation.