Formed Ceramic Abrasive Particles with Controlled Tip Radius
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current abrasive particles and articles face challenges in maintaining the radius of curvature of tips during abrasion, porosity, and size control, leading to reduced performance and increased fragility.
Innovation Solution
The development of formed ceramic abrasive particles comprising a mixture of ceramic oxides such as yttrium, praseodymium, and iron oxides, with edges ranging from 0.1 µm to 5000 µm and tips with a radius of curvature between 0.5 µm to 80 µm, which are produced through a method involving molding, drying, calcining, and sintering, and impregnation with specific metal oxides to enhance durability and control over ceramic oxide size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional abrasive particles are used, then manufacturing cost is reduced, but the radius of curvature of tips deteriorates during abrasion
Solution Approach 1:
The patent uses composite ceramic materials containing aluminum oxide combined with other ceramic oxides (such as silicon oxide, zirconium oxide, titanium oxide, or boron oxide) to create abrasive particles that maintain structural integrity and tip radius of curvature during abrasion while remaining cost-effective to manufacture
2Reliability
If conventional abrasive particles are used, then production speed is maintained, but porosity increases leading to reduced performance
Solution Approach 1:
The patent modifies the chemical composition parameters of the abrasive particles by incorporating specific ceramic oxide combinations and controlling the ratio of aluminum oxide to other oxides, which changes the physical properties including porosity and enhances abrasive performance
3Manufacturing precision
If conventional abrasive particles are used, then size control is simplified, but edge length and tip radius of curvature cannot be precisely controlled
Solution Approach 1:
The patent employs preliminary molding of the abrasive particles into specific geometric shapes (such as triangular prisms, pyramids, or other polyhedra) before final sintering, which pre-establishes the desired edge lengths and tip geometries that are then maintained through controlled ceramic firing processes
4Duration of action of stationary object
If conventional abrasive particles are used, then durability is maintained, but fragility increases reducing lifespan
Solution Approach 1:
The patent creates composite ceramic structures with multiple oxide phases that work together to enhance both durability and mechanical strength, reducing fragility while maintaining long service life through the synergistic properties of the combined 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
The formed ceramic abrasive particles exhibit improved durability, reduced porosity, and controlled size distribution, resulting in enhanced performance and longer lifespan with better electrostatic coating and orientation on backings.
Implementation Method 1
The formed ceramic abrasive particle is produced through a method involving molding, drying, calcining, and sintering
Implementation Method 2
The method also includes calcining the ceramic abrasive particle precursor
Data Source
AI summary
A method of making a formed ceramic abrasive particle is presented that includes molding a dispersion of a ceramic abrasive particle precursor mixture. The method also includes drying the molded dispersion to form a ceramic abrasive particle particle precursor. The method also includes calcining the ceramic abrasive particle precursor. The method also includes sintering the ceramic abrasive particle precursor to form the formed ceramic abrasive particle. The method also includes impregnating the ceramic abrasive particle precusor with a mixture. The mixture includes one or more of a first group consisting of: an oxide of yttrium, praseodymium, samarium, ytterbium, neodymium, lanthanum, gadolinium, dysprosium, and erbium or one or more of a second group consisting of: oxide of iron, magnesium, zinc, silicon, cobalt, nickel, zirconium, hafnium, chromium, cerium, titanium. Impregnating the ceramic abrasive particle precursor occurs after drying, calcining or sintering.