Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
  • B28B11/12—Apparatus or processes for treating or working the shaped or preshaped articles for removing parts of the articles by cutting
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
  • B23D45/00—Sawing machines or sawing devices with circular saw blades or with friction saw discs
  • B23D45/10—Sawing machines or sawing devices with circular saw blades or with friction saw discs with a plurality of circular saw blades
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
  • B23D49/00—Machines or devices for sawing with straight reciprocating saw blades, e.g. hacksaws
  • B23D49/003—Machines or devices for sawing with straight reciprocating saw blades, e.g. hacksaws having a plurality of saw blades or saw blades having plural cutting zones
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
  • B23D53/00—Machines or devices for sawing with strap saw-blades which are effectively endless in use, e.g. for contour cutting
  • B23D53/005—Machines or devices for sawing with strap saw-blades which are effectively endless in use, e.g. for contour cutting with a plurality of band saw blades or band saw blades having plural cutting zones, e.g. contiguous oppositely-moving saw blade portions

Definitions

• the resent invention relates generally to a method and ap aratus for preparing one or more ceramic bodies (logs) with an improved end shap profile and to filters prepared from the ceramic bodies. More particularly, to a method and apparatus to cut one or more edge surfaces of the ceramic bodies down to a, desired segment length and providing an improved end shape profile,
• soot filters constructed of ceramic bodies have bee used.
• ceramic bodies that include an internal honeycomb structure and at least partially surrounded by a skin layer have been developed.
• defects in the e d surfaces of the log may foe defined broadly as an abnormality in the surface, More explicitly, defects may include- cracks or chips (typically greater than about O.Smm) in the outer skin layer and/pr missing, damaged, or deformed honeycomb walls,
• Th present invention addresses is focused on a: new and Inventive wa to produce: ceramic logs at. a desired segment length, in a relatively short process cycle time,, ail while minimizing defects.
• the presen invention disclosed herein ma be generally described as a method and/or an apparatus that Includes -cutting, device with a dual bladed cutting member thai simultaneously provides a "finished surface" for the log and removes scrap from above the finished surface,
• the dual biaded cutting member may be comprised of two copianar blades that have off-set cutting surfaces (off -set relative to each other parallel to its cutting: direction).
• the off-set may be at least a sufficient distance such that a sufficient amoun of scrap is removed to prevent one or more defects proximate to an exit edge of the cut in the ceramic log, it is preferred that the offset be at least about 2.0mm, although other off-set values may be desirable depending on other factors, such as type of cutting device, size of the ceramic Sog s and/or size of the cutting member (e,g. particularly in the case of a circular saw). It is also contemplated that this cutting member be part of a larger cutting apparatus.
• a defect may be further defined as an imperfection in an outer wall of the log or in any internal structures (e.g. honeycom wails).
• any internal structures e.g. honeycom wails.
• these defects may ⁇ be caused by a cuffing process and are generally proximate to (e.g. within about ,20mm ⁇ an exit edge of the cutting surface. More particularly, when the defect ⁇ s) are about 1mm otmore in depth,
• the dual blasted cutting member may comprise two distinct biade types. It is contemplated thai s at least one preferred configuration, the first blade comprises an abrasive biade and the second comprises a blade that removes scrap,
• the abrasive blade may be a diamond grit blade and he second biade is a serrated blade, preferably a carbide lipped blade,
• the ceramic log that is to be cut in ibis inventive method/apparatus may have a relatively low moisture content (e.g. amount of water or other applicable liquid medium), in at least on ⁇ preferred configuration, the log's moisture content is no more than about 10 percent (by weight), more preferably iess than about S percent, and most preferably less than about 2.S percent.
• a relatively low moisture content e.g. amount of water or other applicable liquid medium
• the log's moisture content is no more than about 10 percent (by weight), more preferably iess than about S percent, and most preferably less than about 2.S percent.
• the invention constitutes a new and Inventive way to produce logs at a desired segment length, in a relatively short process cycle time, all while minimizing defects. It should be appreciated that the above referenced aspects and examples are non-iim iting, as others exist within the present invention, as shown and described herein.
• Figure 1 illustrates the. relationship of a blades of the cutting apparatus with respect to a ceramic log to be cut.
• Figure 3A illustrates differences in orientation of a cutting blade to a ceramic log between passing through a ceramic log to be cut the centerilne of a blade, cutting direction:, ⁇ arid ' a portion of the blade below the centerline,
• Ftgu re 38 is a bar chart of the results of Example 3 .
• Figure 4 ⁇ shows a cutting apparatus of the invention with a ceramic log disposed thereupon
• FIG. 48 shows a cutting blade of the apparatus passing through a ceramic log.
• the invention relates to a method comprising: providing a ceramic log with a first end and an apposing second end; providing one or more cutting devices comprised of a dual bladed cutting member; and: removing material by cutting at least the first end with the dual bladed cuffing member, wherein a first blade of the dual bladed cutting member provides a finished surface and a second blade removes a percentage of scrap above the finished surface.
• the invention in another aspect relates to a ceramic fog cutting apparatus, comprising: a nesting fixture for holding the ceramic log; one or more cutting devices, the cutting device comprised of a motor and a dual bladed cutting member; wherein a first blade of th dual bladed cutting member provides a finished surface and an off-set second blade removes a percentage of scrap above the finished surface.
• the invention may be further characterized- by one or any combination of the features described herein, such as; the percentage of scrap removed by the second blade is sufficient to prevent one or more defects proximate to an exit edge of the cut in the ceramic log; the one or more defects proximate to the exit edge of the cut comprises an area of ceramic material that is missing from the finished surface; the one or more defects proximate to the exit edge of the cut comprise at least one chi with a depth of at least 1 mm.; the second blade provides increased structural rigidity to the firs! blade; a leading edge of a.
• the cutting surface of the second blade is off-set inside that: of a leading edge of a cutting surface ' of the first blade a sufficient distance such that a sufficient amount of scrap is removed to prevent one or mor defects proximate to an exit edge of the out In the ceramic log;
• the second blade is off-set at least 2mm inside that of the leading edge of the ' cutting surface of the first blade;
• the first blade comprises a first blade type and the off-set second blade comprise a second blade type;
• the first blade type and the: second blade typo are identical: the first blade typo is an abrasive saw;
• the second blade type is & serrated blade with a single sided set;
• the serrated blade has a kerf that ranges between 4mm to SOnim;
• the ceramic log has a moisture content below 1 ⁇ percent;
• the ceramic log has a moisture content below 0 percent;
• the ceramic log has a moisture content belo ,5 percent; comprising the steps of removing material by cutting at least the oppos
• the present invention relates to an Improved method and apparatus for the preparation of ceramic products (!ogsj at a desired segment length, In a relatively short process cycle time, all while minimizing defects, defects particularly at or proximate to the exit edge of the cut
• Ceramic products are generally prepared by multi-step process.
• the process begins by contacting one or more precursors for the ceramic structure, ceramic precursors, optionally: one or more binders and one or more liquid carriers.
• the next step generally includes the formation of the desired shape, which can be completed by numerous shaping processes, but most commonly by extrusion, then cut to a nea net dimension (e.g. length, width, thickness) bef ore the next processing step.
• the product typically is then dried to a point where the moisture content ranges from about 0 to 0 percent.
• inventive metno apparaius If is at thi point whore the inventive metno apparaius ma be used (although it is contemplated that the inventive method ⁇ apparatus can be used on ceramic products that have been further processed). After the product Is cut to a "finished" length, then it may be further processed ⁇ e,:g.
• the ceramic precursors are generall the reaefants or components which when exposed to certain conditions form a ceramic bod or part, which may include materials such as disclosed in US 7,485,594; US 6,953,554; US 4,948,768 and US 5, 73,349 all incorporated herein by reference, for example a porous rnuiiite composition made by forming a mixture of one or more precursor compounds having the elements present in muH ' ite (e.g.,. clay, alumina, silica) and a property enhancing compound.
• a porous rnuiiite composition made by forming a mixture of one or more precursor compounds having the elements present in muH ' ite (e.g. clay, alumina, silica) and a property enhancing compound.
• the property enhancing compound may be a compound having an element selected from the group consisting of Mg, Qa, Fe, Na, , Ce, Pi, Nd ⁇ /Sm, Eu, Gd, Tb, Dy Mo, Er, Tm, Yb, ty, B, Y, Sc, La and combination thereof.
• a ceramic precursor comprising silicon carbide * eordiente, aluminum fit&nate, alumina, zirconia, silicon nitride, aluminum nitr de ⁇ silicon ⁇ xynifrlde 3 ⁇ 4 silicon carbonithde, beta spodumene, strontium aluminum silicates, lithium: aiuminurrv silicates, and the like.
• Organic binders useful in this invention include any known materials which render the wet ceramic green ware shapeable.
• the binders are organic materials that decompose or burn at temperatures below the temperature wherein the ceramic precursors react to form ceramic bodies or parts.
• preferred binders are those described i introduction to the : Principles, of Ceramic Processing, J. Reed, Wiley interscience, 1988 ⁇ incorporated herein b reference.
• a particularly preferred binder is methyl cellulose (such as jETHOCEL A15LV .methyl cellulose, The Dow Chemical Co., Midland, Mich.)
• Liquid carriers include any liquid that facilitates formation of a shapeabie wet ceramic mixture.
• preferred liquid carriers are those materials described In introduction to the Principles [ Of Ceramic Processing, J.
• a particularly preferred liquid carrier is water.
• The: mixture useful in preparing wet ceramic green ware bodies may be made by an suitable method such as those known in the art. Examples include bail milling, ribbon blending, vertical screw mixing, V-biending and attrition milling. The mixture may be prepared dr (i.e., in the absence of a liquid carrier) or wet. Where, the mixture ' is prepare in the absence of a liquid carrier, a liquid carrier is added subsequently utilizing any of the methods described in this paragraph,
• Th mixture of ceramic precursors, optionally binders, and liquid carriers may be shaped by an means known In the art, Examples include ' injection molding, extrusion, rsostatie pressing, slip casting, roll compaction and tape casting. Each of these is described in more detail in introduction to ihe Principles of C&mmic Processing,
• the mixture is shaped into the near net: shape and size of the ultimate desired ceramic bod ⁇ such as a flow through filter.
• Near net shape and size means the size of the wet ceramic green ware . ody may be within about TO to 15 percent by volume of the size of the final ceramic body; * and preferably the size and shape may be within 5 percent by volume of the size of the final ceramic body.
• the ceramic structures comprise a -honeycomb structure and an outer skin layer.
• the honeycomb structure is disposed In planes perpendicular to the extrusion direction.
• the outer skin layer and the walls of the honeycomb structure generally have a thickness of between about .250 and 600 microns, although structures with thicknesses of u to about 50 percent larger or smaller are contemplated.
• each channel formed is plugged at one end or th other. On a face the channels are plugged in an alternating fashion.
• the wet ceramic green ware body does not have any of the channels or flow passages blocked or plugged, in practicing: the invention, the porous, ceramic honeycomb as well ' as the plugs (note, the plugs may be the same or a different ceramic than the honeycomb as well as may simply be fhe : partition wails of the honeycomb pinched together to close off a channel) may he any suitable ceramic or combinations of ceramics,
• the wet ceramic g een ware body is shaped such that st can be utilized as a flow through filter.
• the wet ceramic green ware body has tw opposing faces which ar substantially planar.
• the wet ceramic green ware body exhibits a cross sectional shape which is consistent for all planes parallel to the two opposing faces.
• the cross-sectional shape can be any shape which Is suitable for the intended use and may be Irregular or may be of an known shape, such as round oval or polygonal.
• the cross sectional shape exhibits a flat surface capable of supporting the ceramic body, Preferabl the cross-sectional shape is polygonal * in one preferred embodiment, the shape is rectangular or square.
• the shape is i egular, it must have at least one linear path or one surface that is planar such that the wet ceramic bod can be disposed on the carrier ' on the linear path or planar surface.
• he wet ceramic green ware foody has a plurality of walls formed which extend from one opposing face to the other opposing face. The walls form a plurality of flow passages that extend from one opposing face to the other opposing face. Preferably, at. this stage, all of the flow passages are open to both opposing faces. This allows more efficient removal of liquid carrier. Thereafter the.
• wet ceramic green ware body is subjected to conditions to remove the liquid carrier, thai is to dry the wet ceramic green ware body, preferably to a point where t e moisture content is about 10 erc nt or less, more preferably about 5 percent or less arid: most preferably about 2.5 percent or less.
• Preferred drying methods are described In co-owned co-pending application lifted "DRYING: METHOD FOR CERAMIC C3REE WARE" filed June 22, 2011 Serial Number 13 168,298 ⁇ and filed in the PCT June 22 » 201 1 application number PCT/US/11/41410 both incorporated herein by reference,
• th ceramic green war body can be prepared fo conversion to a ceramic body* and wherein the present inventive process/apparatus is most likely utilized, by cutting the bod (log) to a desired length- (although present Invention may be equally effective when the ceramic Is furthe cured or mui!itized ⁇ .
• the ceramic green ware bod is exposed to conditions to burn out the binder and to form the ceramic structure. Processes to achieve this are well known in the art.
• the dry ceramic green ware parts are calcined by heating the dry ceramic green ware parts to temperatures at which organic additives and binders are-: volatilized- or burned away.
• the parts are further heated to temperatures at which the ceramic particles fuse or sinter together or create new particulates that subsequently fuse together.
• Such methods are described by numerous patents and open literature i cludi g * for example, US 4,329,162; 4,471 ,792 4,001 ,028; 4,182,285; 3 S 8$$,326; 4,786,542; 4,837,943 and 5,538,681; all incorporated herein by reference.
• p32SJ It is contemplated that the present invention may be applicable to any porous particulate bodies, Most prefereabSy to green ware, debindered greenware, and even calcined where particulates are fused but later fused or reacted to form stronger body,
• a "defect" as If relates to the present invention may be broadly defined as a surface irregularity on: or near the end surface of the cut log.
• This surface irregularity may be in the wails of honeycomb structure, in the outer skin layer, or both. Illustrative examples are show in Figs. 2A-F, where "chips" of the outer skin layer are missing ami/or where parts of the honeycomb wail are absent.
• a defect may fee defined as surface irregularity that causes problems with the downstream processing of the part, for example preventing the honeycomb, channel from being plugged.
• the defect may be defined as at least, one chip with a depth of at least 1mm (dept -from the finished surface) at or near (e.g. -with about 25mm) the exit edge of the cut.
• a cutting device and method is provided that Is capable of cutting ceramic bodies:, and more preferably wet (e.g, containing less than about 10% liquid by weight) ceramic green ware bodies, to a desired dimension (e.g. length), while maintaining o creating an acceptable surface -finish ' on the part.
• the cuffing process should be relatively quick " , for example it should be able to cut the ceramic body to a desired length in less than about 2 minutes, and preferably less than about 20 seconds, and preferably greater than about 5 seconds (too fast may damage the body), ft is also preferred that it should only take one cutting pass (per end) to achieve the desired length and surface finish.
• the scrap materia! removed from the end being cut is sufficient to prevent one or more defects proximate to an exit edge of the cut in the ceramic log.
• the rotation of the blade may vary from as low as about 500 rpm to as high as about 3000 rpm or higher. I a preferred embodiment, the rotation is about 750 to 2500 rpm, and mora preferably about l OQQ to 2000 rpm.
• the linear movement of the blade Is in terms of meters per minute (m/min). It is contemplated that this could range from as low as about 900m/min to as hig as about i*000m/min.
• the linear movement of the blade Is about 1 SOOm/min to about 17£K5m min s and more preferably from about " 600m7min to 1700m min>
• the cutting device may be included: ' in a ceramic log cutting apparatus.
• The: apparatus may include a nesting fixture that functions to hold the ceramic part. It may also -include a power source (e.g. motor) thai functions to move the cutting devloe(s).. It may also include one or more cutting devices, for example cutting devices disposed a distance apart from each ether such that each device can cut opposing edges of the ceramic part either simultaneousl or in close temporal proximity.
• the cuffing device may fee configured in many different forms. Functionally, the device both removes an amount of the log (e.g. scrap) and provides a relatively defect free end surface (e.g. one: or less chips).
• the device may be In the form of a circular saw, a band saw, or a reciprocating saw. No matter the form of the cutting device;, the device should be configured to have two or more cutting surfaces that are. immediately adjacent (e.g. with about 10mm) to one another or are in- contact.
• the cutting: de ic preferably consists of a. dual bSaded cutting member, where one blade functions to directl cut the finished surface of the log and a second blade that functions to aid in the removal of the scrap material. These two blades may abut one another along one plane (or ma be spaced apart as much as about iOrrsm) and are preferably off-set along the cutting surface, it is preferred that a leading edge of a- cutting surface of the second blade may be off-set inside that of a leading edge of a cutting surface of the first blade a sufficient distance: such that a sufficient amount of scrap is removed to prevent one or more defects proximate to an exit edge of the cut in the ceramic log.
• the second blade is oft-set about 2.0mm or mo ,, more preferably about 5.0mm or more, most preferably about 12.5mm or more, and off-set about SO.O im of less, more preferably about 45mm or less, most preferably about 40,0mm or less, all inside the leading edge of the cutting surface of the first blade.
• the blades may comprise the same or different blade types, so long as they provide the functionaliti? discussed within this disclosure.
• the blades consist of the same type of blade.
• the blades ana two different types.
• the type of blades useful include for example, abrasive saw blades and serrated saw blades.
• An abrasive saw b!ade is similar to a thi grinding, wheel, and a serrated saw blade is a blade with a cutting edge that has many small points of contact with the material being cut.
• the blades are different types, wherein the first blade is an abrasive blade and the second blade is a serrate blade, !vsore particularly, the abrasive blade comprises a diamond grit blade and the serrated blade: is a carbide tipped blade, and more ⁇ particularly a blade with a single sided set.
• the blade ma comprise a grit rating that ma range from as iow as 40/80 to as high as 200/220 and: stiSi may perform as required.
• the grit value should be appropriate to cut the tog without creating excessive defects, If is believed- that the highe the grit value: (e.g. the finer the abrasive), the better the chance to have a defect free cut, but the higher the chance that the blade will become clogged soone and would have to be cleaned ("dressed") more often than would be desired, particularly in a production environment It is believed that there is a relationship between the: moisture content of the log and: the limit on how high a grit value that can be used.
• a grit value of about BO/80 or less may be used ⁇ n logs with a moisture content below about 10 percent: by weight or less, more preferably a grit value f about 100/120 or less on logs with a moisture content below about $ percent by weight or less, and most preferably a grit value of about 200/220 or less on logs with moisture content below about 2.5 percent by weight or less.
• the cutting member has a kerf that is about 2mm or more, more preferably about 4mm or more and roost preferabl about 7mm or more, It is also preferred that the kerf Is about 50mm or less . ,, more preferably about 40mm or less, and most preferably about 30mm or less.
• the blades provide ⁇ complementary structural reinforcement o increased structural rigidity, particularly in the case where the two blades abut one another along one plane.
• the blades in combination provide sufficient stillness to reduce or eliminate any deflectio that may induce defects.
• the two blades together are at least 100% more-stiff than if the blades were not together. This ma function to allow the blades to be run while preventing excessive movement or flexing that could cause surface defects onlhe ceramic part,
• the device is a circular saw, where the device includes dual blades that rotate irV the same direction about a central axis. It is preferred that the dual blades abut one another in one plane and have cuffing surfaces that are radially off-set (a first larger and a second sfnat!e blade), it is contemplated: that the diameter of the blades should be larger than the cross length of the ceramic body to be cut. In one preferred embodiment the blades diameter is sufficientl large such that it cuts the: log in one pass.
• the blade diameter Is at least about 240 percent or more larger than the cross length: of the ceramic body (e.g. area to be cut),, more preferably about 300: or more, and most preferably about 385 or more;: and at most about 600 percent: larger, more preferably at most about 500 larger, and most preferably: at most about 420 larger.
• the center of the ceramic body should be proximate to the axis of rotation: of the circular blade.
• the center axis of the ceramic body be the same as that of the axis of rotation of the circular blade or laterally off-set at most about 1 ⁇ 2 the radius of the larger first blade, more preferably no more than about 1/3, and most preferably no more than about ,14, -
• An: llustrative ' example (Example No. 3) is provided below.
• Figure: 3 ⁇ shows the axis of rotation 400 (center of blade in the cutting direction) with respect to two orientations of the ceramic body with respect to the blade.
• a method of cutting includes at least the steps of: providing a ceramic log with a first end and an opposing second end; providing one -or more cutting devices comprised of a dual bladed cutting member; and removing material by cutting at least the first end with the dual biaded cutting member, wherein a first blade of the dual bladed cutting member provides a finished surface and a second blade removes a percentage of scrap above the finished surface.
• the percentage of the scrap removed by the second blade is sufficient to prevent the defects discussed in this application.
• the second biade removes at least about 50 percent of the scrap, more preferably at least about 80 percent, most preferably at least about 70 percent of the total scrap, and at most about 95 percent, more preferably at most about 90 percent, and most preferably at most 85 of the total scrap before the first blade nears (or reaches) the exit edge of the cut.
• JQ045J There Is a relationship between the kerf of the serrated biad and the position of the cut being made below the end of the log.
• the distance 'TF is the distance from the end of the uncut log to " the finished cut surface.
• "D" b small enough so the cutting member can effectively remove the scrap and prevent defects in the log from the cutting, but large enough allow for the process to require only one cot per side.
• "D" is about 0.5 times to about 3.0 times the kerf of the second blade, more preferably about 0.75 times to 2,0 tiroes and most - preferably about 1.0 to 1.5 times the kerf.
• a circular saw style ceramic log cutting apparatus 100 is presented.
• the apparatus 1.00 includes a dual bladed cutting member 2O0 f a ceramic log 30O, : a nesting fixture 110, and motors (not shown) that drive the member 200.
• the dual bladed ⁇ cutting member 200 In this example consists of a first blade 210 and a second blade 220 abutting one another, as illustrated in Figure 1.
• the first blade 2 0 is circular ' blade with a diameter of about 16 n (408mm) and the second blade with a diameter of about 15.0in. (381 mm). Both blades rotate about a common axis 9in the same direction) and a leading edge 222 of the cutting surface of the second blade 220 is off-set inside that of a leading edge 212 of the cutting surface of the first: blade 210 by about O.Sin, (12.5mm). Blade 210 is.
• an abrasive saw in this example a .diamond grit blade (O.OSOin, (1 ,3mm ⁇ :) core thickness and an 80/100 diamond grit) and blade 220 is a serrated blade with a single sided set, more specifically a carbide tipped blade (0,12Sln. kerf (3,2mm) ⁇ ,
• the member 200 is rotated at a rate of about 500rpm and feed into the log 300 at a rate ranging from about 10 to 40cm/minute to perform the cutting of the log 300, The cut is made below the end of the log: a distance that Is equal to or as much as 1.5 times the kerf of blade 220.
• a band saw/reeiproeating saw style ceramic log cutting apparatus 100 is presented.
• the cutting member 600 is similar to thai presented In the circular saw example above in that leading edge 522 of the cutting surface of the second blade 520 is off-set inside that of a leading edge S12 of the cutting surface of the first blade 510 by about O.Sin, ( i.2..5mm).
• Blade 510 is an abrasive saw, in this exampie a diamond grit blade (O.OSOin, (1 ,3mm)) core thickness and an 80/100 diamond grit) and blade 620 is a serrated blade with a single sided set, more specifically a carbide tipped blade (0.125in, kerf (3.2mm)),
• the member doe not rotate, but has a linear motion (one direction for th band saw and two fo the reciprocating saw of about 1 OOm/minute and feed into the log 300 at a rate: ranging from about 10 to 40cm/minute to perform the cutting of the log 300.
• Examples are run between a dual blade member 200 and three single blade configurations, in set-up number one, a single blade with a 0,055" core thickness and an 80/100 diamond grit is used, set-u numbe two-, a single blade with a 0.040 * core thickness aa a 80/80 diamond grit is used, set-up number three, a single blade with a 0.040" core thickness and an 80/100 diamond grit is used, and in the fourth set-up, a dual blade as described in Example 1 is used).
• the various blade configurations are defined in labia 2 belo
• the blades are rotated at a rata of about ISOQrpm and feed into the logs 300 at a rata ranging from about 10 to 40cm/rrnnute to perform the cutting of the log 300>
• At feast 2000 logs 300 are cut in each set-up and the resulting percent of defect free logs is presented in Fig * 8.
• a defect being defined: as at: least two chips with a depth of at least im at or near (e.g. with about 25m m) the exit edge of the cut.
• Tukey- ranier method (Tuiie -Kraraer method is a single-step multiple comparison procedure and statistical test gen ally used in conjunction with an AN OVA to find which means are significantly different from one another) it s shown that the inventive dual blade approach produces a significantly larger percentage of acceptable ("prime") parts or segments.
• the results are shown in the chart of Figure 5. The circles on the right of the chart show the range of results for each blade configuration.
• any numerical values recited in the above application include ail values- from the lower value to the upper value in Increments of one unit provided tha there is a separation of at least 2 units between an lower value and any higher value:.
• the amount of a com onent or a value of a process variable: such as, for example, temperature,, pressure, time and the like is, for example, from 1 to SO. preferably: from 20 to 80, more preferably from 30 to 70, it is intended that values such as 16 to 85, 22 to 68, 4-3 to 6i , 30 to 32 etc, are expressly enumerated in this specification.
• Plural elements, ingredients,: components or steps can be provided b a single integrated element, ingredient, component or step.

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• Engineering & Computer Science (AREA)
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• Structural Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Ceramic Engineering (AREA)
• Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
• Processing Of Stones Or Stones Resemblance Materials (AREA)

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• 2012
  • 2012-12-14 CN CN201280062661.6A patent/CN104023926B/zh not_active Expired - Fee Related
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  • 2012-12-14 WO PCT/US2012/069714 patent/WO2013096113A1/en not_active Ceased
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