Screen Printed Shaped Abrasive Particles via Differential Pressure Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing abrasive particles and articles face limitations in cost, performance, and lifespan, particularly in manufacturing processes where triangular-shaped particles are used, as they often result in suboptimal cut rates and surface finish due to their random crushing methods.
Innovation Solution
The production of shaped abrasive particles using a screen printing technique with an alpha alumina precursor, employing differential pressure to assist in transferring the dispersion from the printing screen, allowing for thicker particles and improved grinding performance by creating particles with a tapered shape due to sol gel viscosity and drying processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If random crushing method is used to produce abrasive particles, then production cost is reduced, but cutting performance and surface finish deteriorate
Solution Approach 1:
The patent changes the shape parameter of abrasive particles from random (crushed) to controlled geometric shapes (triangular, rectangular, circular) through screen printing. This allows optimization of cutting performance while maintaining cost-effectiveness by using a scalable manufacturing process.
Solution Approach 2:
The patent applies different shapes to different abrasive particles in the mixture, creating local quality variations. Triangular particles provide cutting action, while rounded particles provide finishing action, optimizing overall performance without requiring all particles to be uniformly complex shapes.
2Manufacturing precision
If screen printing technique is used to produce shaped abrasive particles, then cutting performance is improved, but productivity decreases
Solution Approach 1:
The patent uses screen printing to pre-form the abrasive particles into desired shapes before they are applied to the workpiece. This preliminary shaping action ensures optimal cutting performance from the start, eliminating the need for subsequent reshaping or selection processes.
Solution Approach 2:
The patent employs a continuous screen printing process where the screen is repeatedly dipped into the abrasive slurry and pressed against the substrate, allowing continuous production of shaped abrasive particles without interruption or batch processing delays.
3Duration of action of stationary object
If thick shaped abrasive particles are produced, then lifespan is extended, but removal from screen openings becomes difficult
Solution Approach 1:
The patent employs vibration or ultrasonic assistance during the screen printing process to facilitate the removal of thick abrasive particle formations from the screen openings. The vibration energy helps break the adhesion between the thick particle layer and the screen, enabling easy removal while maintaining particle integrity.
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 enhances grinding performance by producing particles with thinner edges and acute angles, leading to improved cutting efficiency and surface finish, as demonstrated by the comparison of high and low viscosity sol gels in grinding tests.
Implementation Method 1
a sol gel dispersion having a lower viscosity that creeps or flows under its own weight after the formation process
Implementation Method 2
applying a differential pressure between a first side of the screen printed shape and a second side of the screen printed shape that is in contact with a receiving surface
Implementation Method 3
a pressurized transfer roll can apply a positive pressure to the first side to release the screen printed shapes from the printing screen
Implementation Method 4
a vacuum box or a vacuum roll can be located to provide a pressure less than atmospheric pressure to the second side of the screen printed shapes
Implementation Method 5
at least partially drying the dispersion to form precursor shaped abrasive particles
Implementation Method 6
firing the precursor shaped abrasive particles to final sintered hardness forming shaped abrasive particles comprising alpha alumina
Data Source
Figure 1
Figure 2~3A
Figure 3B~3C
AI summary
The present invention relates to a shaped abrasive particles comprising a first side 38, a second side 40, and a sidewall 54 connecting the first side 38 to the second side 40, the particles comprising a generally triangular shape; the sidewall 54 comprising a first portion 56 intersecting the first side 38 and a second portion 58 intersecting the second side 40, wherein the slope of the first portion 56 is greater than the slope of the second portion 58.