Offset Segmented Diamond Blade for Fibrous Plastics
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Solution Overview
Problem
Existing diamond cutting discs are limited in cutting width and prone to overheating and clogging when processing fibrous plastics, making them unsuitable for cutting wider notches and requiring expensive milling tools.
Innovation Solution
The cutting segments are arranged with their cutting edges offset relative to the central cutting plane, allowing for increased cutting width and reduced clogging, achieved through bending the segments out of the central plane during production using an embossing mold with distributed bending supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the cutting width is increased by using conventional cutting discs, then the cutting capability is improved, but the segment gaps become clogged and overheating occurs
Solution Approach 1:
The cutting segments are arranged in multiple cutting planes (first, second, and third cutting planes) instead of a single plane, creating a three-dimensional staggered configuration. This dimensional change allows the cutting edges to be distributed vertically, preventing material from clogging the segment gaps while maintaining a wide cutting width capability
Solution Approach 2:
The cutting disc is divided into multiple cutting segments distributed across different cutting planes, with each segment having its own cutting edge. This segmentation allows the cutting width to be effectively multiplied while maintaining proper cooling and ejection channels between segments
2Length of moving object
If the cutting width is increased by using milling tools, then the cutting capability is improved, but the production cost increases
Solution Approach 1:
The cutting disc is designed to perform multiple functions: it can cut both narrow and wide notches, process various materials including fibrous plastics, and replace both conventional cutting discs and milling tools. The multi-plane segment arrangement provides universal cutting capability across different width requirements
Solution Approach 2:
The invention changes the geometric parameters of the cutting disc by introducing multiple cutting planes and staggering segment positions. This parameter change enables the disc to achieve cutting widths that previously required expensive milling tools, while maintaining the simpler and more cost-effective disc format
3Device complexity
If the cutting segments are arranged in a single cutting plane, then the structure is simple, but the cutting width is limited and overheating occurs
Solution Approach 1:
The cutting segments are arranged in multiple cutting planes (first, second, and third cutting planes) instead of a single plane, creating a three-dimensional staggered configuration. This dimensional change allows the cutting edges to be distributed vertically, preventing material from clogging the segment gaps while maintaining a wide cutting width capability
Solution Approach 2:
The cutting disc is divided into multiple cutting segments distributed across different cutting planes, with each segment having its own cutting edge. This segmentation allows the cutting width to be effectively multiplied while maintaining proper cooling and ejection channels between segments
4Device complexity
If conventional cutting discs are used for fibrous plastics, then the structure is simple, but the segment gaps become clogged
Solution Approach 1:
The cutting segments are arranged in multiple cutting planes (first, second, and third cutting planes) instead of a single plane, creating a three-dimensional staggered configuration. This dimensional change allows the cutting edges to be distributed vertically, preventing material from clogging the segment gaps while maintaining a wide cutting width capability
Solution Approach 2:
Each cutting segment is positioned at a different vertical level (different cutting planes), creating local variations in the cutting structure. This local quality differentiation ensures that material removed by one segment does not interfere with or clog the segment gaps of adjacent segments, particularly when processing fibrous plastics
Data Source
Figure 1~2b
Figure 3~4
AI summary
The segmented cutting disk, particularly diamond cutting disk, has a steel blade and cutting segments (12,13), which are arranged over an extent of the steel blade. The steel blade defines a central cutting plane. A segment gap is provided between two cutting segments in each case. The cuts of the cutting segments are arranged with respect to the central cutting plane in a shifted manner. An independent claim is included for a method for manufacturing a cutting disk.