Shaped Abrasive Particles via Extrusion
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Solution Overview
Problem
The industry demands improved abrasive materials and methods for forming shaped abrasive particles that can efficiently produce particles with specific geometries and high productivity, as existing methods are limited in speed and precision.
Innovation Solution
A method involving a mixture with specific rheological characteristics, such as high viscosity and storage modulus, is applied to a shaping assembly where the mixture is extruded and ejected to form precursor shaped abrasive particles, which are then processed to achieve desired shapes and high batch productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional fusion, sintering, or chemical ceramic processes are used to produce shaped abrasive particles, then particles with specific geometries can be obtained, but the production speed is slow and productivity is limited
Solution Approach 1:
The patent changes the physical state parameters of the abrasive material from solid powder (in conventional sintering) to liquid slurry (in extrusion process). This parameter change enables continuous shaping at high speed while maintaining geometric precision through the viscosity and flow characteristics of the liquid mixture, resolving the contradiction between production speed and geometry precision
Solution Approach 2:
The patent replaces the high-temperature thermal field (sintering) and chemical field (chemical ceramic) with a mechanical extrusion field. The mixture is forced through shaped orifices under pressure to form particles with precise geometries, achieving both high productivity and manufacturing precision through mechanical shaping
2Ease of manufacture
If rudimentary molding processes are used to form shaped abrasive particles, then limited shapes can be produced, but the process complexity and difficulty of achieving specific geometries increase
Solution Approach 1:
Instead of trying to form complex shapes from solid particles through molding (which increases device complexity), the patent inverts the approach by extruding liquid mixture through pre-shaped orifices. The shape is defined by the orifice geometry rather than by complex molding tools, greatly simplifying the manufacturing process and equipment
Solution Approach 2:
The patent performs preliminary shaping by designing the orifices in the screen with the desired particle geometries before the extrusion process. This preliminary action eliminates the need for complex post-forming operations and reduces process complexity while maintaining ease of manufacture
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 enables the rapid formation of shaped abrasive particles with unique features like tortuous contours and arrowhead shapes, achieving high productivity and precision, comparable to conventional abrasive products.
Implementation Method 1
extruding a mixture having a viscosity of at least about 4×10³ Pa s into an opening in a shaping assembly
Implementation Method 2
directing an ejection material at the mixture in the shaping assembly under a predetermined force, removing the mixture from the shaping assembly
Data Source
AI summary
A method of forming a shaped abrasive particle includes applying a mixture into a shaping assembly within an application zone and directing an ejection material at the mixture in the shaping assembly under a predetermined force, removing the mixture from the shaping assembly and forming a precursor shaped abrasive particle.