Shaped Abrasive Particles with Bonded Surface Layer
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Solution Overview
Problem
The industry demands improved abrasive materials and articles with enhanced performance in material removal operations, as existing technologies face limitations in producing abrasive particles with specific shapes and bonding methods that optimize grinding and polishing efficiency.
Innovation Solution
The method involves forming a mixture of ceramic powder and liquid with specific rheological characteristics, which is then extruded through a screen printing process to create shaped abrasive particles with a body and bonded abrasive particles, allowing for improved bonding and attachment of additional abrasive particles to the surface, enhancing the abrasive properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fusion, sintering, or chemical ceramic processes are used to produce abrasive particles, then abrasive particles can be formed with basic shapes, but the ability to produce particles with optimized specific shapes and enhanced bonding performance is limited
Solution Approach 1:
The patent applies preliminary action by forming a shaped core particle first, then subsequently attaching additional abrasive particles to its surface. This two-stage approach allows the core to be prepared in advance with a specific geometry, and then the surface is customized with additional particles to achieve the desired final shape and bonding characteristics, resolving the contradiction between shape precision and manufacturing ease
Solution Approach 2:
The patent implements the nested doll principle by creating a composite structure where smaller abrasive particles are attached to the surface of a larger shaped core particle. This nested arrangement allows the inner core to provide structural integrity while the outer layer of attached particles provides the final shape and bonding performance, achieving both high shape precision and manufacturing feasibility
2Productivity
If abrasive particles are formed with complex shapes to improve grinding and polishing efficiency, then material removal performance is enhanced, but the bonding and attachment of additional abrasive particles to the surface becomes more difficult
Solution Approach 1:
The patent applies segmentation by dividing the abrasive particle into two functional segments: a shaped core that provides the primary geometry for material removal efficiency, and an outer layer of attached abrasive particles that can be selectively bonded to enhance performance. This segmentation allows each part to be optimized independently, resolving the contradiction between productivity and structural complexity
Solution Approach 2:
The patent uses composite materials by combining a shaped core particle with additional abrasive particles attached to its surface. This composite structure integrates the advantages of both components: the core provides the necessary shape for efficient material removal, while the attached particles form a composite surface that enhances bonding characteristics and overall abrasive performance, thereby achieving high productivity without excessive device complexity
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 approach results in abrasive particles with improved bonding and performance, offering better grinding and polishing efficiency due to the specific shape and surface attachment of additional abrasive particles, addressing the industry's need for enhanced material removal capabilities.
Implementation Method 1
The method involves forming a mixture of ceramic powder and liquid with specific rheological characteristics, which is then extruded through a screen printing process to create shaped abrasive particles
Data Source
Figure 1A~1B
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AI summary
An abrasive particle including a shaped abrasive particle including a body having a plurality of abrasive particles bonded to at least one surface of the body of the shaped abrasive particle.