Thermoplastic Resin Abrasive Block Tool for Surface Finishing
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Solution Overview
Problem
Conventional block tools for surface finishing operations suffer from brittleness, high abrasion, high costs, and manufacturing challenges such as uneven heat propagation, sedimentation of components, and exothermic reactions, leading to mechanical defects and increased production costs.
Innovation Solution
A block tool with a support member and an abrasive block obtained from a solution or emulsion of granular abrasive material dispersed in a thermoplastic resin matrix, where the resin is injected into a mold and allowed to set, ensuring uniform distribution and high impact strength, and the tool is produced using thermoplastic resins with additives like glass fibers for improved mechanical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermosetting resins are used with heated molds for manufacturing block tools, then the resin can be molded and cured, but uneven heat propagation occurs resulting in non-uniform mechanical characteristics and high production costs
Solution Approach 1:
The patent changes the fundamental parameter of resin type from thermosetting to thermoplastic resin. This eliminates the need for high-temperature heated molds and post-curing processes, thereby avoiding uneven heat propagation and achieving uniform mechanical characteristics throughout the block tool while reducing manufacturing complexity
Solution Approach 2:
The invention extracts and eliminates the problematic heating and curing processes associated with thermosetting resins. By using thermoplastic resin that can be molded at lower temperatures without post-curing, the patent removes the source of uneven heat propagation and associated manufacturing difficulties
2Ease of manufacture
If semi-liquid or pasty inert fillers and thermosetting resins are cast, then the mixture can be poured into molds, but sedimentation and separation of components occur due to different specific weights
Solution Approach 1:
The patent changes the physical state parameter of the resin from semi-liquid or pasty to a properly formulated thermoplastic resin system that maintains homogeneous mixing with abrasive particles. This prevents sedimentation and separation while still allowing easy pouring and casting into molds
Solution Approach 2:
The invention creates a stable composite material system where thermoplastic resin and abrasive particles are uniformly distributed. The composite maintains its homogeneity during casting due to the improved rheological properties of the thermoplastic resin system, preventing component separation
3Ease of manufacture
If polyester or epoxidic resins are used with catalysts for casting, then the mixture can be poured and cured, but exothermic reactions occur that are difficult to control and cause cracks or deformations
Solution Approach 1:
The patent changes the chemical parameter by selecting thermoplastic resin instead of thermosetting resins that undergo exothermic curing reactions. This eliminates the uncontrolled exothermic activity that causes cracking and deformations, while still allowing the mixture to be poured and shaped in molds through thermoplastic processing
Solution Approach 2:
The invention converts the potential harm of uncontrolled exothermic reactions into a benefit by using thermoplastic resin that cures without such reactions. The manufacturing process becomes more controllable and reliable, transforming a hazardous chemical process into a safer, more predictable thermal processing operation
4Ease of manufacture
If metal powders of granular size are used as binders with industrial diamonds, then sintering can be performed, but the metal powders oxidize requiring permanent monitoring and preservation
Solution Approach 1:
The patent changes the material parameter from metal powder binder to thermoplastic resin binder. This eliminates the oxidation susceptibility of metal powders, removing the need for permanent monitoring and special preservation conditions while maintaining the ability to bind abrasive particles effectively through thermoplastic processing
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 solution provides a block tool with high impact strength and effective surface finishing capabilities at competitive costs, with improved mechanical characteristics and reduced risk of defects, achieving efficient smoothing and polishing operations without corner breakages or tool failure.
Implementation Method 1
at least one solution or emulsion of at least one granular abrasive material dispersed in a matrix comprising at least one thermoplastic resin
Implementation Method 2
obtained from at least one solution or emulsion of at least one granular abrasive material dispersed in a matrix comprising at least one thermoplastic resin
Data Source
AI summary
A block tool for surface finishing operations, which has a support and coupling member (2) for connection to a machine tool, and an abrasive block (3) held by the support member (2), the abrasive block being obtained from a solution or emulsion of a granular abrasive material dispersed in a matrix comprising a thermoplastic resin.