Machining Segment Particle Layout for Dry Concrete Cutting

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Solution Overview

Problem

Existing processing tools for concrete materials are not suitable for dry processing, as they rely on abrasive concrete sludge for self-sharpening, leading to reduced machining rate and lifespan when processing dry materials.

Innovation Solution

A procedure for producing processing segments using a powder-shaped support material with a higher melting temperature than the first matrix material, allowing for the arrangement of hard particles according to a defined pattern and subsequent melting of the matrix material using Powder Bed Fusion, enabling the creation of segments suitable for dry processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If machining segments are designed for wet machining with similar wear rates of matrix material and hard particles, then self-sharpening occurs during machining, but the machining rate drops and service life decreases during dry machining

Engineering Contradiction:

Improveself-sharpening capabilityVSAvoidmachining rate during dry machining

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies local quality by creating different wear rates in different zones of the machining segment. The machining zone has a matrix material with wear rate higher than hard particles to enable self-sharpening, while the neutral zone has matrix material with wear rate lower than hard particles to maintain structural integrity during dry machining. This spatial differentiation of material properties resolves the contradiction between self-sharpening and sustained machining rate.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining matrix material with hard particles in a structured arrangement. The composite structure consists of a machining zone with specific material composition for self-sharpening and a neutral zone with different composition for structural support. This composite approach allows the segment to exhibit both self-sharpening behavior and sustained performance during dry machining operations.

Inventive Principle:

Principle #40Composite materials

2Productivity

If hard material particles are quickly exposed during dry machining, then machining rate increases, but matrix material wears too slowly and service life decreases

Engineering Contradiction:

Improvemachining rate during dry machiningVSAvoidservice life of machining segment

Core Design Contradiction:

ProductivityVSDuration of action of moving object

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent applies dynamics by creating a layered structure where the machining zone is designed to wear faster and expose hard particles dynamically during operation, while the neutral zone wears slower to maintain structural integrity. This dynamic wear behavior allows the segment to adapt its performance characteristics during dry machining, optimizing both machining rate and service life.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If a green compact is built up layer by layer with hard particles arranged in defined pattern, then particle arrangement precision improves, but manufacturing complexity increases

Engineering Contradiction:

Improveparticle pattern arrangementVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-arranging hard particles in the desired pattern within the support material before applying and melting the matrix material. This preliminary arrangement of particles in the correct spatial configuration simplifies the overall manufacturing process while achieving high precision particle patterns, as the complex arrangement task is performed in advance during the layer building process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces traditional mechanical layer-by-layer compacting methods with a powder bed fusion process. Instead of mechanically building up green compacts, the invention uses selective melting of powder layers to create the final structure, maintaining particle pattern precision while reducing manufacturing process complexity and eliminating the need for separate compacting and sintering operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 produced processing segments maintain a high machining rate and extended lifespan during dry processing of concrete materials, as the support material's higher melting point ensures secure attachment of hard particles and prevents unnecessary wear.

Implementation Method 1

the melting temperature of the support material being greater than the melting temperature of the first matrix material

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

melting the first layer using a powder bed fusion process

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

melting the first layer using a powder bed fusion process and carrying out a sequence of several steps which is carried out N times, N ≥ 1, wherein in a first step of the sequence a layer of the first matrix material is applied to the layer structure and in a second step of the sequence the layer of the first matrix material is melted and connected to the layer structure using the powder bed fusion process

Methodology Applied

Scientific EffectPowder bed fusion: Selective Laser Sintering

Data Source

PatentEP4263093B1Method for producing a machining segment

Publication Date: 2025.04.30 HILTI AG

Figure 1A~1B
Figure 2A~2B
Figure 3~4

AI summary

The invention relates to a method for producing a machining segment (51) from a first powder matrix material (54) and first hard material particles (55) which are arranged according to a defined first particle pattern, having the steps of:  depositing a powder support material (61) in the form of a support layer (62), the melting temperature of the support material (61) being higher than the melting temperature of the first matrix material (54),  arranging the first hard material particles (55) according to the defined first particle pattern in the support material (61), the first hard material particles (55) being arranged in the support material (61) at an insertion depth (din),  applying a first layer (63) of the first matrix material (54) on the first hard material particles (55) and the support material (61) and melting the first layer (63) using a powder bed fusion method, and  carrying out a sequence of multiple steps which are carried out N times, N ≥ 1, wherein in a first step of the sequence, a layer (64) of the first matrix material (54) is applied onto the layer structure, and in a second step of the sequence, the layer (64) of the first matrix material (54) is melted using the powder bed fusion method and connected to the layer structure.