Foam Abrasive Pore Opening for Stable Grain Anchoring

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Solution Overview

Problem

Existing foam abrasives suffer from premature wear and detachment of abrasive grains due to uncontrollable pore and bubble formation during the grinding process, leading to reduced durability and unwanted scratches on the workpiece.

Innovation Solution

A method involving the controlled opening of pores and bubbles near the surface of the foam using a directed fluid to create an open-cell structure, allowing the binder to penetrate deeply and anchor the abrasive grains more securely, enhancing the foam abrasive's stability and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pores and bubbles in the foam are left uncontrolled during foam abrasive production, then the manufacturing process is simpler, but the abrasive grains detach prematurely during grinding

Engineering Contradiction:

Improvedurability of foam abrasiveVSAvoidcomplexity of foam treatment process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by piercing and opening pores and bubbles in the foam base body before coating with binder and applying abrasive grains. This pre-treatment ensures that the binder can penetrate deeply into the foam structure, creating strong anchoring points for the abrasive grains before they are applied, thereby preventing premature detachment during grinding operations.

Inventive Principle:

Principle #10Preliminary action

2Strength

If the foam structure is modified to open pores and bubbles, then abrasive grain anchoring is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveanchoring strength of abrasive grainsVSAvoidcomplexity of pore opening process

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent employs pneumatics and hydraulics by using a fluid (liquid or gas) directed onto the foam surface to pierce and open the pores and bubbles. The fluid pressure creates channels and cavities in the foam structure, allowing subsequent binder penetration. This approach provides controlled modification of the foam structure without requiring complex mechanical or thermal processing equipment.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Reliability

If abrasive grains are applied to closed-pore foam, then the coating process is simpler, but the abrasive grains detach easily during use

Engineering Contradiction:

Improvestability of abrasive grainsVSAvoidease of binder penetration

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent transforms the closed-pore foam structure into an open-pore structure by piercing and opening the pores and bubbles before binder application. This creates a porous network that allows the binder to penetrate deeply into the foam base body, establishing strong mechanical interlocking with the abrasive grains and preventing their detachment during grinding operations.

Inventive Principle:

Principle #31Porous materials

4Strength

If the foam base body is treated to open pores near the surface, then binder penetration is enhanced, but the processing time increases

Engineering Contradiction:

Improvebond strength between binder and foamVSAvoidtime for foam treatment

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent applies partial action by directing the fluid treatment specifically at the surface and near-surface region of the foam base body, rather than attempting to open pores throughout the entire foam thickness. This localized treatment is sufficient to provide adequate binder penetration and abrasive grain anchoring while minimizing the time and energy required for the process.

Inventive Principle:

Principle #16Partial or excessive action

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 method ensures uniform and stable anchoring of abrasive grains, reducing grain detachment and minimizing surface imperfections, thereby extending the abrasive's lifespan and improving grinding performance.

Implementation Method 1

pores and bubbles located in the foam are pierced and opened by means of a directed fluid

Methodology Applied

Scientific EffectFluid pressure: Pressure Increase

Implementation Method 2

the binder penetrates into the opened pores and bubbles and anchors the abrasive grains to the foam surface

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 3

abrasive grains adhere to the foam surface by means of the binder

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentEP4188647B1Method for producing a foam abrasive

Publication Date: 2025.08.27 ROBERT BOSCH GMBH

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AI summary

The invention relates to a method for producing a foam abrasive (10) for grinding a workpiece, in which method abrasive particles (16) are scattered over a foam (12), the surface (14) of which foam is coated with binder (18). According to the invention, prior to the foam being coated with binder, pores and/or bubbles (20) in the foam (12) which are in a region (22) of the foam (12) that is close to the surface are opened using a fluid (28) directed at the surface (14) of the foam (12). The invention further relates to a foam abrasive (10) produced in accordance with the method according to the invention.