Structured Abrasive Article with Shaped Platelets
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Solution Overview
Problem
Structured abrasive articles with fine grades of diluent crushed abrasive particles typically exhibit poor cut performance and are prone to deep scratches, limiting their effectiveness in finishing applications.
Innovation Solution
Incorporating specific size grades of non-magnetizable shaped abrasive platelets into the shaped abrasive composites, which are precisely formed and secured to a backing using a method that involves a production tool with shaped cavities and a curable organic binder, enhances cut performance without causing deep scratches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fine grades of diluent crushed abrasive particles are used in structured abrasive articles, then the article is suitable for fine finishing applications, but the cut performance becomes poor and deep scratches occur
Solution Approach 1:
The patent applies local quality by using different abrasive particle sizes in different regions of the abrasive composite. Specifically, it combines fine abrasive particles (for high-quality finishing) with coarser abrasive particles (for effective cutting) within the same composite structure. This allows the fine particles to handle the finishing task while the coarser particles provide the necessary cut performance, resolving the contradiction between finishing quality and productivity.
Solution Approach 2:
The patent employs composite materials by creating an abrasive composite that integrates multiple types of abrasive particles with different size characteristics. The composite structure combines fine crushed abrasive particles with larger shaped abrasive particles, allowing the material to simultaneously achieve both deep scratch prevention (from fine particles) and effective cutting (from coarser particles), thus resolving the technical contradiction.
2Manufacturing precision
If fine grades of diluent crushed abrasive particles are used in structured abrasive articles, then the article is suitable for fine finishing applications, but deep scratches are caused on the workpiece
Solution Approach 1:
The patent uses local quality by strategically distributing different particle sizes within the abrasive composite. Fine particles are positioned to provide smooth finishing without causing deep scratches, while coarser particles are distributed to handle material removal. This spatial differentiation allows the fine particles to perform their finishing function without the harmful effect of deep scratching.
Solution Approach 2:
The composite abrasive material combines fine crushed particles with larger shaped particles in a binder matrix. This composite structure ensures that fine particles perform the finishing function while the coarser particles prevent deep scratches by distributing the cutting load, thereby eliminating the harmful effect while maintaining finishing quality.
3Productivity
If non-magnetizable shaped abrasive platelets of specific size grades are incorporated into shaped abrasive composites, then superior cut performance is achieved, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the shaped abrasive platelets with specific size grades before incorporating them into the composite structure. The platelets are manufactured in advance with precise dimensional control, and then integrated into the binder matrix. This pre-preparation simplifies the overall manufacturing process by separating the complex platelet formation step from the composite assembly step.
Solution Approach 2:
The patent uses parameter changes by carefully controlling the size grades and physical parameters of the shaped abrasive platelets during manufacturing. By optimizing parameters such as platelet length, width, thickness, and aspect ratio, the patent achieves superior cut performance. The manufacturing process controls these parameters through standardized forming techniques, managing complexity through parameter optimization rather than process complication.
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 use of non-magnetizable shaped abrasive platelets in structured abrasive articles results in superior cut performance compared to other combinations, maintaining high efficiency without the deep scratches characteristic of other abrasive products, thus improving finishing capabilities.
Implementation Method 1
at least partially curing the curable organic binder precursor material to form shaped abrasive composites secured to the major surface of the backing
Data Source
Figure 1~2
AI summary
A structured abrasive article comprises a backing having first and second opposed major surfaces and an abrasive layer securely bonded to the first major surface of the backing. The abrasive layer comprises shaped abrasive composites. Each shaped abrasive composite has four sides, a height, and a base that faces the first major surface of the backing. The shaped abrasive composites have an average height of 410 to 650 microns and an average side length at the base of 550 to 1450 microns. The shaped abrasive composites comprise non-magnetizable shaped abrasive platelets that have an average side length of 150 to 350 microns and an average thickness of 40 to 120 microns. Methods of making and using are also disclosed.