Shaped Abrasive Particles with Controlled Orientation

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Solution Overview

Problem

There is a need in the industry for improving the performance, life, and efficacy of abrasive particles and the abrasive articles that employ them.

Innovation Solution

The development of shaped abrasive particles formed using techniques such as extrusion, molding, screen printing, and sintering, with specific geometries and compositions to enhance their performance and integration into abrasive articles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional abrasive particles are used, then manufacturing simplicity is maintained, but performance and durability are insufficient

Engineering Contradiction:

Improveperformance and life of abrasive particlesVSAvoidcomplexity of forming processes

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by modifying the geometric parameters of abrasive particles through controlled forming processes. Specific shapes (triangular, pyramidal, conical) are achieved by adjusting forming parameters such as mold geometry, sintering conditions, and extrusion parameters, thereby improving cutting efficiency and particle durability without fundamentally changing the manufacturing approach

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite materials by combining abrasive grains with binder materials in structured configurations. The shaped abrasive particles are formed from composite compositions including abrasive materials (such as aluminum oxide, silicon carbide) mixed with binders, creating particles that maintain structural integrity while achieving superior cutting performance and extended service life

Inventive Principle:

Principle #40Composite materials

2Productivity

If shaped abrasive particles are formed using extrusion, molding, screen printing, and sintering, then material removal capability and durability are enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improvematerial removal capabilityVSAvoidease of forming abrasive particles

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-forming abrasive particles into specific shapes (triangular, pyramidal, conical) before they are incorporated into abrasive articles. This pre-shaping is achieved through extrusion, molding, or screen printing of green bodies, followed by sintering to consolidate the shape. The preliminary formation of geometric features enhances cutting efficiency and edge retention from the outset, rather than relying on random fracture patterns

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces traditional mechanical fragmentation methods with controlled forming processes. Instead of relying on mechanical breaking and sorting to achieve desired shapes, the invention uses extrusion, molding, and screen printing to directly form particles with predetermined geometries. This substitution of mechanical systems with controlled material deposition and consolidation processes enables more precise shape control and better reproducibility

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The shaped abrasive particles demonstrate improved performance and life in abrasive articles, with enhanced material removal capabilities and increased durability.

Implementation Method 1

In the sintering process, abrasive particles can be formed from refractory powders having a particle size of 45 micrometers or less in diameter. Binders can be added to the powders along with a lubricant and a suitable solvent, e.g., water. The resulting mixtures or slurries can be shaped into platelets or rods of various lengths and diameters.

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

sintering the agglomerations of particles at a temperature below the fusion temperature of the bauxite to induce limited recrystallization of the particles, whereby abrasive grains are produced directly to size

Methodology Applied

Scientific EffectRecrystallization: Crystallisation

Implementation Method 3

In the fusion process, abrasive particles can be shaped by a chill roll, the face of which may or may not be engraved, a mold into which molten material is poured, or a heat sink material immersed in an aluminum oxide melt.

Methodology Applied

Scientific EffectRapid solidification: Freezing

Data Source

PatentUS20250025988A1Abrasive particles having particular shapes and methods of forming such particles

Publication Date: 2025.01.23 SAINT GOBAIN ABRASIVES INC

AI summary

A coated abrasive article comprising a backing, an adhesive layer disposed in a discontinuous distribution on at least a portion of the backing, wherein the discontinuous distribution comprises a plurality of adhesive contact regions and at least one shaped abrasive particle is disposed on a majority of each of the discrete adhesive contact regions, wherein at least 50% of the shaped abrasive particles comprise a predetermined side orientation and have a tilt angle of at least 45 degrees, wherein the shaped abrasive particles comprise a polycrystalline material and are free of binder, wherein the first plurality of discrete adhesive contact regions comprise a predetermined two-dimensional shape as viewed from above, and wherein each of the discrete contact regions comprises a length, a width, or a combination thereof that substantially corresponds to a dimension of the at least one abrasive particle.