Photocured Polymer-Bond Abrasives for Complex 3D Tool Shapes
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Solution Overview
Problem
Existing abrasive technologies struggle to create complex geometries and efficiently polish materials like glass, ceramic, or polymer substrates, lacking the design flexibility to form three-dimensional abrasive tools effectively.
Innovation Solution
The development of polymer bond abrasive articles with a continuous photocured polymer matrix, incorporating abrasive particles and optional optical brighteners or light absorbers, formed through additive manufacturing processes, allowing for the creation of three-dimensional shapes and tools affixed to shafts or pads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional abrasive technologies are used, then manufacturing simplicity is maintained, but the ability to create complex geometries and three-dimensional shapes is limited
Solution Approach 1:
The patent transitions from conventional two-dimensional abrasive sheets to three-dimensional abrasive tools with complex geometries. The additive manufacturing process enables creation of multi-layered structures, internal channels, and varied surface profiles that cannot be achieved with traditional abrasive technologies, directly addressing the shape complexity limitation.
Solution Approach 2:
The invention changes the manufacturing parameters from conventional methods to additive manufacturing with photocurable compositions. By adjusting parameters such as layer thickness, curing conditions, and material composition, the process achieves complex geometries while maintaining manufacturing feasibility through digital control and automated processes.
2Adaptability or versatility
If additive manufacturing with photocurable composition is used, then design flexibility and three-dimensional shape creation are improved, but manufacturing process complexity increases
Solution Approach 1:
The additive manufacturing process serves multiple functions: it creates the abrasive tool structure, embeds abrasive particles, forms internal channels for coolant flow, and enables custom geometry all in a single manufacturing process. This multi-functionality compensates for the increased process complexity by eliminating the need for separate manufacturing steps.
Solution Approach 2:
The invention replaces traditional mechanical manufacturing methods with photocurable additive manufacturing. The photocurable composition is selectively cured using light or other energy sources, substituting mechanical machining and assembly processes with a digital fabrication approach that offers greater design flexibility while managing complexity through automation.
3Productivity
If optical brighteners or light absorbers are added to the photocured polymer matrix, then curing control and polymerization efficiency are improved, but material composition complexity increases
Solution Approach 1:
Optical brighteners and light absorbers act as intermediaries in the photocuring process. They mediate the interaction between the curing light and the photocurable composition, controlling the depth and rate of polymerization. These additives enable precise curing control by absorbing or emitting light at specific wavelengths, ensuring complete and uniform polymerization throughout the abrasive tool structure.
Solution Approach 2:
The invention changes the optical parameters of the photocurable composition by adding optical brighteners or light absorbers. These additives modify the light absorption characteristics, allowing control over curing depth, rate, and uniformity. By adjusting the type and concentration of these additives, the polymerization process can be optimized for different geometries and material requirements.
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
Enables the fabrication of complex abrasive tools with enhanced polishing capabilities for glass, ceramic, and polymer substrates, offering improved efficiency and flexibility in abrasive applications.
Implementation Method 1
The composition comprises at least one photocurable component; abrasive particles; a photoinitiator
Implementation Method 2
The photocured polymer matrix comprises at least one of an optical brightener or a light absorber
Data Source
AI summary
A polymer bond abrasive article is formed of a continuous photocured polymer matrix having abrasive particles retained therein. The photocured polymer matrix includes at least one of an optical brightener or a light absorber, and the polymer bond abrasive article has a three-dimensional shape. An abrasive tool includes the abrasive article affixed to a shaft or a pad. Further, a method of making the polymer bond abrasive article includes a) obtaining a photocurable composition liquid dispersion; b) selectively curing a portion of the photocurable composition; and repeating steps a) and b) to form the polymer bond abrasive article. The dispersion contains at least one photocurable component; abrasive particles; a photoinitiator; and at least one of an optical brightener or a light absorber.