Shaped Particle Transfer Scrim for Orientation Control
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Solution Overview
Problem
Maintaining the preferred orientation of shaped abrasive particles during the manufacturing of abrasive articles is challenging due to issues with binder precursor fluidity or hardness, leading to particles tipping over and inadequate adhesion.
Innovation Solution
A net-like transfer tool with elongate strands and flexible bond regions that expand to securely receive and retain shaped particles in a predetermined orientation, allowing them to be deposited onto a substrate in the desired position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the binder precursor material is made fluid to facilitate particle embedding, then particle adhesion is improved, but particles tip over due to gravity
Solution Approach 1:
A transfer tool with apertures serves as an intermediary device between the particle source and the substrate. The apertures are sized to receive and hold particles in the desired orientation, preventing them from tipping over while transferring them to the substrate. This intermediary mechanism resolves the contradiction by providing a stable holding structure that doesn't require the binder to be either too fluid or too hard.
Solution Approach 2:
Particles are pre-positioned in the transfer tool apertures before transfer to the substrate. The apertures are designed with specific dimensions that preliminarily orient the particles in the correct orientation, ensuring they maintain their orientation during the transfer process. This preliminary action prevents orientation loss without requiring specific binder properties.
2Stability of the object's composition
If the binder precursor material is made hard to maintain particle orientation, then particle orientation is improved, but particles do not adhere well to the binder
Solution Approach 1:
The transfer tool acts as an intermediary that decouples the orientation maintenance function from the adhesion function. The tool's apertures maintain particle orientation mechanically, while the substrate provides adhesion through the binder. This eliminates the need for the binder to simultaneously provide both orientation maintenance and adhesion, resolving the contradiction between these two requirements.
Solution Approach 2:
Orientation is established preliminarily in the transfer tool apertures before the particles contact the binder. The aperture geometry pre-orients the particles, so that when they are transferred to the substrate and the binder is applied, the particles are already in the correct orientation. This eliminates the need for the binder to be hard enough to maintain orientation while still being soft enough to provide good adhesion.
3Productivity
If traditional embedding techniques are used to deposit particles, then particle deposition is achieved, but maintaining preferred orientation is difficult
Solution Approach 1:
The transfer tool with specifically sized apertures serves as an intermediary that simultaneously achieves high particle deposition rates and maintains precise orientation. The apertures are designed to match the particle dimensions and orientation requirements, allowing particles to be deposited efficiently while automatically maintaining the preferred orientation. This resolves the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The aperture dimensions in the transfer tool are specifically engineered to match the particle size and shape parameters, creating a geometric fit that maintains orientation during transfer. By changing the physical parameters of the transfer medium (aperture size and shape), the system achieves both high deposition rates and precise orientation control, resolving the contradiction between productivity and manufacturing precision.
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
Ensures that at least 95% of the shaped abrasive particles are deposited on the substrate in the intended orientation, enhancing the consistency and effectiveness of abrasive articles.
Implementation Method 1
the bonds in the scrim flex and the minimum dimensions of the apertures increase to a second dimension larger than the first dimension. The enlarged apertures to allow the scrim to receive a shaped particle in a predetermined orientation. When the scrim is returned to its original unextended state, the apertures return to the first original dimensions, which are suitably sized to frictionally engage the strands and lock in the shaped particles
Implementation Method 2
the apertures return to the first original dimensions, which are suitably sized to frictionally engage the strands and lock in the shaped particles in the apertures in the predetermined orientation
Data Source
AI summary
A method of transferring a shaped particle to a substrate includes providing a scrim of at least two elongate strands periodically joined together at flexible bond regions to form an array of apertures between the strands. The scrim is extended along at least one direction to increase the minimum dimension of the apertures. Shaped particles are applied to the extended scrim and at least a portion of the shaped particles enter in at least some of the apertures therein. The extended scrim is relaxed and frictionally retains the particles between the elongate strands. The particle loaded scrim is extended along at least one direction to release and transfer the shaped particles to the substrate in a predetermined orientation.