Shaped Abrasive Particles with Sloping Sidewalls
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Solution Overview
Problem
Existing abrasive particles and articles lack optimal performance and longevity, particularly in terms of cut rates and uniformity, due to their random shapes and orientations.
Innovation Solution
The development of shaped abrasive particles with sloping sidewalls, featuring draft angles between 95 degrees to 130 degrees, which allows for enhanced orientation and distribution in coated abrasive articles, resulting in improved cut rates and uniform cutting performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If triangular shaped abrasive particles are used, then cut rates are enhanced, but the particles lack uniform orientation and distribution in coated abrasive articles
Solution Approach 1:
The patent applies asymmetry by giving the triangular abrasive particles non-uniform sidewall angles (e.g., 95°, 100°, 105°) instead of equal angles. This asymmetric geometry causes particles to orient themselves at different angles when applied to the backing, creating a more uniform distribution of cutting orientations and improving overall cutting performance consistency.
Solution Approach 2:
The patent applies local quality by varying the sidewall angles at different locations of the triangular particle. Each sidewall has a specific angle optimized for its function, with steeper angles (95-100°) providing better orientation control and shallower angles (105-110°) providing structural stability, creating locally optimized properties throughout the particle structure.
2Manufacturing precision
If shaped abrasive particles with steep sidewalls are used, then particle orientation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by optimizing the sidewall angle within a specific range (95° to 110°) rather than using extreme values. This moderate angular range achieves sufficient orientation improvement while remaining compatible with conventional manufacturing processes, avoiding the need for complex specialized equipment or multi-step fabrication procedures.
Data Source
Figure 1A~1C
Figure 2~3
Figure 4A~4C
AI summary
Abrasive particles comprising shaped abrasive particles each having a sloping sidewall, each of the shaped abrasive particles comprising alpha alumina and having a first face and a second face separated by a thickness, t. The shaped abrasive particles further comprising either: a draft angle α between the second face and the sloping sidewall, and the draft angle α is between about 95 degrees to about 130 degrees, or the sloping sidewall having a radius, R, between the first face and the second face and the radius, R, is between about 0.5 to about 2 times the thickness, t.