Magnetizable Abrasive Particles via Polyionic Coating

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

There is a continuing need for new materials and methods to bond magnetic materials to abrasive particles effectively, particularly for precise placement and orientation in abrasive articles, as existing techniques are limited in achieving uniform distribution and alignment.

Innovation Solution

A method involving ceramic particles coated with a polyionic solution and magnetic particles, where the ceramic particles are coated with an aqueous solution comprising a polyionic material, and then combined with magnetic particles, allowing for the formation of magnetizable abrasive particles that can be oriented using a magnetic field within a binder material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If magnetic particles are bonded to abrasive particles using existing techniques, then magnetic orientation is achieved, but uniform distribution and alignment are limited

Engineering Contradiction:

Improveuniform distribution and alignment of magnetic particlesVSAvoideffectiveness of bonding method

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent introduces a binder material as an intermediary substance that chemically or physically bonds magnetic particles to abrasive particles. This mediator enables reliable attachment while allowing uniform distribution, resolving the contradiction between bonding effectiveness and distribution uniformity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent modifies parameters such as magnetic particle size, magnetic field strength, and binder composition to optimize both bonding reliability and uniform distribution. By adjusting these parameters, the system achieves effective bonding while maintaining precise orientation and alignment.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If magnetic particles are used for orientation, then alignment control is improved, but agglomeration occurs

Engineering Contradiction:

Improveorientation control of abrasive particlesVSAvoidagglomeration of particles

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent applies local quality by creating controlled magnetic zones or gradient fields that provide sufficient orientation control in specific areas without causing widespread agglomeration. The magnetic field strength or distribution is varied locally to achieve alignment while preventing clumping.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent creates a composite structure consisting of abrasive particles, magnetic particles, and binder material. This composite approach allows the system to benefit from magnetic orientation while the binder prevents agglomeration, combining the advantages of different materials to resolve the contradiction.

Inventive Principle:

Principle #40Composite materials

3Reliability

If new bonding materials and methods are developed, then bonding effectiveness is improved, but process complexity increases

Engineering Contradiction:

Improvebonding effectiveness of magnetic particlesVSAvoidcomplexity of coating process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-coating abrasive particles with binder material before adding magnetic particles. This preparatory step simplifies the overall process by establishing bonding capacity in advance, reducing the need for complex multi-step bonding procedures while maintaining effective attachment.

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 produces magnetizable abrasive particles with minimal agglomeration, enabling controlled orientation and improved performance in abrasive articles by ensuring even distribution and alignment of magnetic particles, enhancing the abrasive properties of the particles.

Implementation Method 1

coating the outer surfaces of ceramic particles with an aqueous solution comprising a polyion thereby forming polyion-coated ceramic particles; combining the polyion-coated ceramic particles with magnetic particles

Methodology Applied

Scientific EffectElectrostatic interaction: Electrostatics

Implementation Method 2

enabling controlled orientation and improved performance in abrasive articles by ensuring even distribution and alignment of magnetic particles

Methodology Applied

Scientific EffectMagnetic field orientation: Magnetic Field

Data Source

PatentUS11597860B2Magnetizable abrasive particle and method of making the same

Publication Date: 2023.03.07 3M INNOVATIVE PROPERTIES CO

AI summary

Magnetizable abrasive particles are described comprising ceramic particles having outer surfaces comprising a coating of unsintered polyion and magnetic particles bonded to the polyion. In favored embodiments, the magnetic particles have a magnetic saturation of at least 10, 15, 20, 25, 30, 35, 40, 45 or 50 emu/gram. In another embodiment, an abrasive article is described comprising a plurality of magnetizable abrasive particles as described herein retained in a binder material. Also described are method of making magnetizable abrasive particles and methods of making an abrasive article comprising magnetizable abrasive particles.