Abrasive article with shaped abrasive particles with predetermined rake angles

Solution Overview

Problem

Existing abrasive particles and articles lack consistent performance and efficiency in abrading and finishing materials due to random orientation and shape, leading to suboptimal cost and lifespan.

Innovation Solution

The development of abrasive articles with shaped abrasive particles having predetermined rake angles and geometric features, positioned to achieve specific performance characteristics, such as rake, relief, and draft angles, enhancing consistency and effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional abrasive particles with random orientation are used, then manufacturing simplicity is maintained, but abrasive performance consistency deteriorates

Engineering Contradiction:

Improveabrasive performance consistencyVSAvoidparticle orientation control

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The abrasive particles are pre-formed with specific geometric shapes (triangular, tetrahedral, or pyramidal configurations) and predetermined rake angles before being applied to the workpiece. This preliminary shaping ensures that when the particles fracture and roll during abrasion, they consistently expose sharp edges at optimal angles, resolving the contradiction by establishing performance consistency through pre-configured geometry rather than random orientation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the physical and geometric parameters of the abrasive particles by controlling their shape (using ratios such as 0.6-1.4:1:0.3-1.0 for edge length:base length:height), hardness (Mohs scale 7-9), and rake angle (45-60 degrees). These parameter specifications ensure consistent abrasive performance while maintaining manufacturing feasibility through controlled formation processes

Inventive Principle:

Principle #35Parameter changes

2Productivity

If shaped abrasive particles with predetermined rake angles are used, then abrasive performance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvematerial removal rateVSAvoidparticle formation process

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The abrasive particles are pre-formed with specific geometric shapes (triangular, tetrahedral, or pyramidal configurations) and predetermined rake angles before being applied to the workpiece. This preliminary shaping ensures that when the particles fracture and roll during abrasion, they consistently expose sharp edges at optimal angles, resolving the contradiction by establishing performance consistency through pre-configured geometry rather than random orientation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the physical and geometric parameters of the abrasive particles by controlling their shape (using ratios such as 0.6-1.4:1:0.3-1.0 for edge length:base length:height), hardness (Mohs scale 7-9), and rake angle (45-60 degrees). These parameter specifications ensure consistent abrasive performance while maintaining manufacturing feasibility through controlled formation processes

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If abrasive particles with consistent geometry are used, then surface finishing quality is improved, but manufacturing cost increases

Engineering Contradiction:

Improvesurface finishing qualityVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention changes the physical and geometric parameters of the abrasive particles by controlling their shape (using ratios such as 0.6-1.4:1:0.3-1.0 for edge length:base length:height), hardness (Mohs scale 7-9), and rake angle (45-60 degrees). These parameter specifications ensure consistent abrasive performance while maintaining manufacturing feasibility through controlled formation processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention applies local quality by ensuring that specific critical features of the abrasive particles (the cutting edges and rake angles) have precise geometric control, while other less critical dimensions can have broader tolerances. This selective precision focuses manufacturing resources on the features that most directly impact surface finishing quality, thereby controlling costs

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP3784437B1Abrasive article with shaped abrasive particles with predetermined rake angles

Publication Date: 2025.12.24 3M INNOVATIVE PROPERTIES CO

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Figure 1B
Figure 1C

AI summary

The present disclosure provides an abrasive article (10). The abrasive article (10) has a direction of use, a y-axis and a z-axis orthogonal to the y-axis and the direction of use. The abrasive article (10) further includes a backing (12) and shaped abrasive particles attached to the backing. About 5% to about 100% of the shaped abrasive particles (14) independently include a first side surface (16), a second side surface (18) opposed to the first side surface (16), a leading surface (20) connected to the first side surface (16) at a first edge (24) and connected to the second side surface (18) at a second edge (26), a rake angle (30) between the backing (12) and the leading surface (20) in a range of from about 10 degrees to about 110 degrees, and a z-direction rotational angle (50) between a line (52) intersecting the first edge (16) and second edge (18) and the direction of use (22) of the abrasive article (10) in a range of from about 10 degrees to about 170 degrees.