Magnetizable Abrasive Particle Bonding via Waterglass

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Solution Overview

Problem

Existing methods for bonding magnetizable particles to abrasive particles face challenges in precision, reproducibility, productivity, and cost, particularly in depositing magnetizable material on specific portions of abrasive particles.

Innovation Solution

A method involving the use of waterglass to moisten ceramic particles, followed by contacting them with magnetizable particles and heating to bond the magnetizable particles to the ceramic particles, allowing for selective bonding and precise placement of magnetizable layers on abrasive particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If bulk coating techniques (solution coating, powder coating, or vapor coating) are used to deposit magnetizable material onto abrasive particles, then the coating process is relatively straightforward, but it is difficult to achieve precise placement of magnetizable material on specific portions of the abrasive particle surface

Engineering Contradiction:

Improveease of coating processVSAvoidprecision of magnetizable material placement

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention applies local quality by treating only specific portions of the abrasive particle surface with waterglass, creating localized bonding sites. The waterglass solution is applied in a controlled manner to deposit magnetizable material only on selected areas of the particle surface, enabling precise placement while maintaining ease of manufacture through a simplified two-step process.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If magnetic flux is used to orient abrasive grain in bonded abrasive articles, then radial orientation can be achieved, but the method requires abrasive grain having a thin coating of iron dust or steel dust

Engineering Contradiction:

Improveorientation of abrasive particlesVSAvoidapplicability to different abrasive particle types

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The invention changes the bonding mechanism from direct magnetic attraction of iron/steel coatings to chemical bonding via waterglass. This parameter change allows magnetizable material to be firmly bonded to abrasive particles of various types (alumina, silicon carbide, boron carbide, etc.) without requiring pre-coating with iron or steel dust, thereby increasing versatility while maintaining orientability.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If precise placement and orientation of abrasive particles is achieved using electrostatic coating or mechanical methods, then alignment can be obtained, but the processes are complex and time-consuming

Engineering Contradiction:

Improvealignment of abrasive particlesVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The invention applies preliminary action by depositing the magnetizable material coating before bonding the abrasive particles to the backing. This preliminary coating creates magnetic particles that can be easily oriented using simple magnetic fields during the bonding process, achieving precise alignment without complex electrostatic coating or mechanical alignment equipment, thereby improving productivity.

Inventive Principle:

Principle #10Preliminary 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

This method enables the effective and efficient bonding of magnetizable particles to ceramic abrasive particles, overcoming previous challenges in precision and cost while allowing for controlled orientation and manipulation using magnetic fields, enhancing the performance of abrasive articles.

Implementation Method 1

heating the powder-coated ceramic particles to at least a temperature sufficient to bond the magnetizable particles of the powder-coated ceramic particles to the respective ceramic particles

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

allowing for controlled orientation and manipulation using magnetic fields

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Data Source

PatentEP3532562B1Magnetizable abrasive particle and method of making the same

Publication Date: 2021.05.19 3M INNOVATIVE PROPERTIES CO

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AI summary

A method of making magnetizable abrasive particles includes: moistening the outer surfaces of ceramic particles with waterglass to provide moistened ceramic particles. Magnetizable particles are contacted with the moistened ceramic particles to provide powder-coated ceramic particles. The powder-coated ceramic particles are heated to at least a temperature sufficient to bond the magnetizable particles of the powder-coated ceramic particles to the respective ceramic particles thereby providing the magnetizable abrasive particles. On a respective basis, each magnetizable abrasive particle comprises a respective ceramic particle having a magnetizable particles bonded thereto.