Multilayer Abrasive Particle Deposition via Lattice Structure
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Solution Overview
Problem
Existing methods for producing multi-layer abrasive particles result in inconsistent grinding performance due to varying sizes and geometries, limiting the complexity and precision of achievable structures, and fail to integrate grinding-active substances effectively close to the abrasive surface.
Innovation Solution
A method utilizing a lattice structure with alternating coverage and pressure areas to deposit and dry layers of abrasive particle precursors, allowing for precise control of layer thickness and geometry, and integration of grinding-active substances, enabling the production of complex geometries and maintaining consistent grinding performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If comminution of large-area shaped pieces is used to produce abrasive particles, then production is possible, but the resulting particles have broad size distribution and inconsistent geometry leading to variable grinding performance
Solution Approach 1:
The invention applies preliminary action by forming abrasive particles layer by layer through sequential deposition of precursor materials before final sintering. Each layer is precisely controlled during deposition, ensuring consistent geometry and size from the formation stage rather than attempting to achieve consistency through post-formation comminution.
Solution Approach 2:
The invention segments the abrasive particle structure into multiple functional layers (support layer, abrasive layer, bonding layer, etc.), with each layer deposited and controlled independently. This segmentation allows precise control of each layer's thickness and composition, resulting in consistent particle geometry and predictable grinding performance.
2Shape
If conventional methods are used to produce multi-layer abrasive particles, then layer structures can be formed, but only very simple geometries with large feature sizes (millimeter range) can be achieved
Solution Approach 1:
The invention replaces conventional mechanical layer formation methods with a deposition-based approach where precursor materials are deposited in liquid or aerosol form and then sintered. This substitution enables precise control of layer thickness at the micrometer scale and allows formation of complex three-dimensional geometries that cannot be achieved with traditional mechanical layering methods.
3Manufacturing precision
If abrasive particles are produced with complex geometries and small features, then grinding performance consistency improves, but conventional production methods cannot achieve the required structural precision
Solution Approach 1:
The invention changes the physical parameters of the deposition process, including precursor material viscosity, deposition rate, and sintering temperature, to achieve precise control of layer thickness in the micrometer range. By optimizing these parameters, the process can form complex geometries with high precision using relatively simple equipment compared to what would be required for direct mechanical fabrication of such precise structures.
4Duration of action of moving object
If grinding particles wear during the grinding process, then material is removed, but the contact surface changes leading to inconsistent grinding performance over time
Solution Approach 1:
The invention uses composite multi-layer structures where a support layer material is combined with abrasive layer materials having different wear characteristics. The support layer is designed to wear at a different rate than the abrasive layer, creating a self-regenerating effect where the contact surface geometry is maintained over time. This composite structure ensures consistent grinding performance throughout the particle's service life.
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 produces abrasive particles with consistent grinding performance and complex geometries, effectively utilizing grinding-active substances, resulting in high-quality grinding performance with minimal wear and change in surface contact during the grinding process.
Implementation Method 1
a dispersion layer is deposited in the print areas of the lattice structure on the substrate support or on the layers already arranged thereon
Implementation Method 2
the respectively deposited dispersion layer is then dried to form a layer
Implementation Method 3
drying within the meaning of the present invention should not only be understood as meaning a loss of liquid or solvent from the dispersion layer
Data Source
Figure 1~1g
Figure 2~5d
Figure 6
AI summary
A method for producing multilayer abrasive particles (12) is proposed, comprising the method steps of: providing a substrate support (01) and at least one dispersion of an abrasive particle precursor (05); repeated positioning of at least one grid structure (02) above the substrate support (01), wherein covering regions (03) are defined by at least partially covered grid meshes (11) and printing regions (04) are defined by open grid meshes (11); applying the at least one dispersion of an abrasive particle precursor (05) to the grid structure (02), wherein contact is created between the grid structure (02) and the substrate support (01) or layers (08) arranged on the substrate support (01), and wherein, when the contact is broken, a layer of dispersion (07) is deposited in the printing regions (04) on the substrate support (01) or on the layers (08) already arranged on it, and subsequent drying of the respectively deposited layer of dispersion (07) to form a layer (08).