Patent Application
20140187129
1. Field of the Disclosure
The following is directed to abrasive articles, and more particularly, bonded abrasive articles having cores made of an organic material and a bonded abrasive body attached to the core comprising a bond material.
2. Description of the Related Art
Abrasives used in machining applications typically include bonded abrasive articles and coated abrasive articles. Coated abrasive articles generally include a layered article including a backing and an adhesive coat to fix abrasive grains to the backing, the most common example of which is sandpaper. Bonded abrasive tools consist of rigid, and typically monolithic, three-dimensional, abrasive composites in the form of wheels, discs, segments, mounted points, hones and other tool shapes, which can be mounted onto a machining apparatus, such as a grinding or polishing apparatus.
Bonded abrasive tools usually have three phases including abrasive grains, bond material, and porosity, and can be manufactured in a variety of “grades” and “structures” that have been defined according to practice in the art by the relative hardness and density of the abrasive composite (grade) and by the volume percentage of abrasive grain, bond, and porosity within the composite (structure).
Some bonded abrasive tools may be particularly useful in grinding and polishing hard materials, such as single crystal materials used in electronics and optics industries as well as superabrasive materials for use in industrial applications, such as earth boring. For example, polycrystalline diamond compact (PDC) cutting elements are typically affixed to the head of drill bits for earth boring applications in the oil and gas industry. The PDC cutting elements include a layer of superabrasive material (e.g., diamond), which must be ground to particular specifications. One method of shaping the PDC cutting elements is use of bonded abrasive tools, which typically incorporate abrasive grains contained within an organic bond matrix.
The industry continues to demand improved methods and articles capable of grinding superabrasive workpieces.
According to one aspect, an abrasive article comprises a core comprising an organic material and a first bonded abrasive body integrally bonded directly to the core. The first bonded abrasive body comprising a bond material including a hybrid material having an inorganic portion and an organic portion, and abrasive particles contained within the bond material.
The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
The following is directed to abrasive articles, in particular, bonded abrasive articles suitable for various applications including centerless grinding, edge grinding, tool room applications and the like. In particular instances, the abrasive articles herein may include bonded abrasive articles that may be particularly suited for grinding various workpieces, including for example metals, metal alloys, plastics, wood, composites, superabrasive materials, and a combination thereof.
As illustrated in
Still, in one embodiment, the preform can be an abrasive body. The abrasive body can include a bonded abrasive body. The bonded abrasive body can include abrasive particles in a bond material, which will be described in more detail herein. The bonded abrasive body can have an annular shape defined by a diameter da, a circumference Ca, and a height ha.
In particular instances, the preform can include a plurality of annular shaped bonded abrasive bodies attached to each other and defining a central opening for receiving the mixture comprising the organic resin. For example, the preform can include a second abrasive body, wherein the second bonded abrasive body can be adjacent the first bonded abrasive body. The first bonded abrasive can be abutting the second bonded abrasive body as further illustrated herein.
Still referring to preparing a preform 101 in
The process of forming may include pouring the liquid mixture around the liner. The liner may be removed prior to curing or after curing. In still another embodiment, the liner may not be removed and may become an integral part of the abrasive article.
It will be appreciated that the preform can include other objects facilitating the formation of an abrasive article in accordance with an embodiment. For example, the preform can include a second liner, wherein the second liner has a diameter dL substantially the same than preform diameter dP.
The liner can be made from an organic material, an inorganic material, or a combination thereof. In a particular embodiment, the liner can be made from a metal or a metal alloy. In another embodiment, the liner can be made from steel. According to one particular embodiment, the liner can be a substrate for a bonded abrasive material.
In certain instances, the liner can facilitate formation of the core. The liner can have particular thermal properties that may facilitate control of exotherms and endotherms during the forming process. In particular, the liner may have a particular geometry, size, volume, material, and a combination thereof, which facilitates removing heat from the mixture during curing and reducing the temperature and thermal gradients at the interface of the bonded abrasive body and core during forming. In one particular embodiment, the liner can have a heat capacity (e.g., a specific heat capacity) that is different than (e.g., less than or greater than) a heat capacity of the bonded abrasive body. In particular instances, the liner has a heat capacity that is at least about 5% different, such as at least about 10%, or even at least about 40% different than a heat capacity of the bonded abrasive body.
In yet another embodiment, a first liner defining an arbor hole of the core can have a first heat capacity that is different than a second liner at an interface of the core and the bonded abrasive article. The heat capacity of the first liner can be greater than or less than the heat capacity of the second liner. Moreover, the liner can have the same features of heat capacity with respect to any one of the components of the mixture.
After providing a preform, the method can continue at step 102 of
In particular instances, one or more components of the mixture can be liquid phase components. For example, the mixture can include an organic resin that is liquid phase, and in particular, the organic resin may consist essentially of a liquid phase. In an embodiment, the liquid phase organic resin can flow and take the shape of a container, such as the preform. Unlike an organic resin that is in solid phase, such as a powdered organic resin, the molecules of an organic resin in a liquid phase can flow and move freely past one another. In one embodiment, the organic resin can be in a liquid phase at room temperature. In particular instances, the liquid phase can have a viscosity of at least about 400 cps (centipoise) at a temperature of 25° C. In other embodiments, the viscosity of the liquid phase can be greater, such as at least about 700 cps, at least about 1000 cps, at least about 2000 cps, at least about 3000 cps, or even at least about 4000 cps. In another embodiment, the liquid phase can have a viscosity of not greater than about 25,000 cps, such as not greater than about 20,000 cps, not greater than about 18,000 cps, not greater than about 14,000 cps, not greater than about 12,000 cps, not greater than about 10,000 cps, or even not greater than about 8,000 cps. It will be appreciated that the liquid phase can have a viscosity within a range between any of the minimum and maximum values noted above.
The mixture can further include other components including, for example, a curing agent, a filler, a solvent or the like. For example, the organic resin can include a solvent. The solvent can modify the viscosity of the liquid. In embodiments, the solvent can be water, methanol, ethanol, diethyl ether, acetone, mineral spirits, ethyl acetate, tetrahydrofuran, or a combination thereof.
Certain organic resins of the embodiments herein can include an epoxy resin, a phenoxy resin, a polyurea resin, a polyimide resin, a polycyanate, an acrylic, a polyurethane, a melamine resin, a polyester resin, or any combination thereof. In one instance, the organic resin can include an epoxy resin, such as a bisphenol-A compound. In one particular embodiment, the bisphenol-A compound can include a bisphenol-A diglycidyl ether, and may even consist essentially of bisphenol-A diglycidyl ether.
As noted above, the mixture can include a curing agent. According to one embodiment, the curing agent can include, an oligoamine, a diol, a dithiol, an amino alcohol, an amino thiol, a thioalcohol, or any combination thereof. In particular instances, the mixture can include an epoxy resin and the curing agent can include an oligoamine. In one embodiment, the oligoamine can include an aliphatic oligoamine, a cycloaliphatic oligoamine, an aromatic oligoamine, and a combination thereof. In one embodiment, the aliphatic oligoamines can include ethylene diamine, 2-methyl-L5-pentamethylenediamine, 1,6-hexamethylenediamine, 1,3-pentanediamine, (2-aminoethyl)-1,2-ethanediamine (DETA), N,N′-bis-(2-aminoethyl)-1,2-ethanediamine) (TETA), tris-(2-aminoethyl)amine) (TAEA), bis-(aminoethyl)ether, a polyether diamine, tetraethylenepentamine (TEPA), and a combination thereof. In another embodiment, the cycloaliphatic oligoamine can include 1,2-diaminocyclohexane, N[(2-aminoethyl)2-aminoethyl]piperazine) (PEEDA), isophorone diamine (IPDA), 4,4′-bis-(aminocyclohexyl)-methane, N,N′-bis-(2-aminoethyl)piperazine) (DAEP), and a combination thereof. In one further embodiment, the aromatic oligoamine can include 2-ethyl, 2 methyl-imidazole, 4,4′-diaminodiphenyl-methane, 4,4′-diaminodiphenylether, 1,3-Bis(3-aminophenoxy) benzene, an aminobenzylamine, and a combination thereof.
In other embodiments, the epoxy resin can include a bisphenol-A diglycidyl ether and the curing agent can include a isophorone diamine. According to yet another aspect, the epoxy resin may consist essentially of a bisphenol-A diglycidyl ether and the curing agent can consist essentially of a isophorone diamine.
Further referring to the mixture in element 102, other additives, such as a filler may be provided. In particular instances, the mixture, and thus the finally-formed core, can include at least one filler from the group of organic materials, inorganic materials, fibrous materials, ceramic materials, oxides, carbides, borides, silicides, nitrides, fluorides, oxynitrides, oxycarbides, silicates, alumina, silica, silicon carbide, boron nitride, metal-hydrate compounds, hydrated oxide compounds, carbonates, phosphates, minerals, feldspar, nepheline syenite, chromites, magnesites, dolomites, pyrites, sulfides, carbon-based materials, graphite, sulfides, silicon, metal, metal alloys, inter-metallics, ceramics, hollow-ceramics, fused silica, glass, glass-ceramics, hollow glass spheres, glass fibers, polymers, polyimides, polyamides, resins, aramids, epoxies, polyesters, polyurethanes, acetates, celluloses, ethers, ethanol, wood flour, clay, talc, and a combination thereof.
According to one embodiment, the core can include a first filler material and a second filler material, wherein the first filler material is different than the second filler material by at least one of composition, average particle size, content within the mixture of core, and a combination thereof. In one instances, the core can include a first filler material including an inorganic material and a second filler material including an organic material.
In one particular aspect, the core can include a first filler material comprising an oxide, such as alumina, and more particularly, fused alumina. Moreover, the core can include a second filler material including an organic material, including for example, an organic material including a hydroxyl group. More particularly, the core can include a second filler material comprising ethanol. The second filler may further include a second filler material comprising phosphate. In one embodiment, the core can include a second filler material including ethanol and phosphate, and more particularly, a second filler material comprising ethanol, 2 chloro-phosphate (3:1), such that it can consist essentially of ethanol, 2 chloro-phosphate (3:1).
The mixture, and thus the core, can further include a third filler material in addition to at least a first filler material, wherein the third filler material can be different than the first filler material by at least one of composition, average particle size, content in the mixture or core, and a combination thereof. Moreover, the core can include a third filler material in addition to at least the second filler material, wherein the third filler material can be different than the second filler material by at least one of composition, average particle size, content in the mixture or core, and a combination thereof.
The core can have a first filler material including an inorganic material and a third filler material including an inorganic material. In one particular embodiment, the first filler material can include an oxide and the third filler material can include an oxide, and more particularly, the first filler material can include at least one metallic element different than the third filler material. For example, the core can include a third filler including iron, and more particularly, iron oxide. The third filler material may include a mineral, which may include iron, such as magnetite (Fe3O4). According to one embodiment, the third filler material may consist essentially of magnetite (e.g., black oxide).
The mixture may contain a particular content of filler. For example, the total content of filler can be present in an amount of at least about 1 vol % for the total volume of the mixture or the core. In other embodiments, the amount of filler can be greater, such as at least about 2 vol %, at least about 5 vol %, at least about 10 vol %, at least about 20 vol %, or at least about 50 vol % for a total volume of the mixture or core. Alternatively, the filler can be present in an amount of not greater than about 99 vol %, such as not greater than about 98 vol %, not greater than about 95 vol %, not greater than about 90 vol %, not greater than about 80 vol %, not greater than about 70 vol %, not greater than about 60 vol %, not greater than about 55 vol %, or even not greater than about 50 vol % for the total volume of the mixture or core. It will be appreciated that the mixture can contain an amount of filler within a range between any of the minimum and maximum percentages noted above.
The mixture, and thus the finally-formed core, can include a first filler material and a second filler material, wherein the mixture or core can have a greater content of the first filler material compared to a content of the second filler material. Alternatively, the core may have a greater content of the second filler material compared to a content of the first filler material.
For example, the mixture or core can have a ratio (V1/V2) of at least about 1, wherein V1 represents a content of a first filler (vol %) within the mixture or core and V2 represents a content of a second filler (vol %) within the mixture or core. In another embodiment, the ratio (V1/V2) can be at least about 1.1, such as at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, or even at least about 30. Still, in one non-limiting embodiment, the ratio (V1/V2) can be not greater than about 30, such as not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, not greater than about 2. It will be appreciated that the ratio (V1/V2) can be within a range between any of the minimum and maximum values noted above.
Alternatively, the core can have a ratio (V2/V1) of at least about 1, wherein V1 represents a content of a first filler (vol %) within the mixture or core and V2 represents a content of a second filler (vol %) within the mixture or core. More particularly, the ratio (V2/V1) can be at least about 1.1, such as at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, at least about 30. Still, in other embodiments, the ratio (V2/V1) can be not greater than about 30, not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, not greater than about 2. It will be appreciated that the ratio (V2/V1) can be within a range between any of the minimum and maximum values noted above.
According to a particular embodiment, the mixture or core can have at least about 0.5 vol % of the first filler for a total volume of the mixture or core. In another embodiment, the mixture or core can include at least about 1 vol %, such as at least about 1.5 vol %, at least about 2 vol %, at least about 5 vol %, at least about 8 vol %, at least about 10 vol %, at least about 12 vol %, at least about 15 vol % for a total volume of the mixture or core. In another embodiment, the mixture or core can include not greater than about 50 vol %, such as not greater than about 40 vol %, not greater than about 30 vol %, not greater than about 25 vol %, not greater than about 20 vol %, not greater than about 15 vol %, not greater than about 10 vol %, not greater than about 8 vol %, not greater than about 5 vol %, not greater than about 4 vol %, not greater than about 3 vol %, or even not greater than about 2 vol % of the first filler for the total volume of the mixture or core. It will be appreciated that the mixture can contain an amount of the first filler within a range between any of the minimum and maximum percentages noted above.
The mixture or core may also include a second filler material in an amount of at least about 0.5 vol % for a total volume of the mixture or core. In another embodiment, the mixture or core can include at least about 1 vol %, such as at least about 1.5 vol %, at least about 2 vol %, at least about 5 vol %, at least about 8 vol %, at least about 10 vol %, at least about 12 vol %, or even at least about 15 vol % or a total volume of the mixture or core. Still, the content of the second filler within the mixture or core can be not greater than about 50 vol %, such as not greater than about 40 vol %, not greater than about 30 vol %, not greater than about 25 vol %, not greater than about 20 vol %, not greater than about 15 vol %, not greater than about 10 vol %, not greater than about 8 vol %, not greater than about 5 vol %, not greater than about 4 vol %, not greater than about 3 vol %, or even not greater than about 2 vol % for the total volume of the mixture or core. It will be appreciated that the mixture can contain an amount of the second filler within a range between any of the minimum and maximum percentages noted above.
As described herein, the mixture, and thus the finally-formed core, can include a first filler material and a third filler material. The mixture or core may utilize a particular content of the first filler and third filler. For example, the mixture or core can have a greater content of the first filler material compared to a content of the third filler material. Still, in other instances, the mixture or core can include a greater content of the third filler material compared to a content of the first filler material.
In one particular embodiment, the mixture or core may have a ratio (V1/V3) of at least about 1, wherein V1 represents a content of a first filler (vol %) within the mixture or core and V3 represents a content of a third filler (vol %) within the mixture or core. In certain other instances, the ratio (V1/V3) can be at least about 1.1, such as at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, at least about 30. Still, in one non-limiting embodiment, the ratio (V1/V3) can be not greater than about 30, not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, not greater than about 2. It will be appreciated that the ratio (V1/V3) can be within a range between any of the minimum and maximum values noted above.
Alternatively, the core can have a ratio (V3/V1) of at least about 1, wherein V1 represents a content of a first filler (vol %) within the mixture or core and V3 represents a content of a third filler (vol %) within the mixture or core. More particularly, the ratio (V3/V1) can be at least about 1.1, such as at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, at least about 30. Still, in one non-limiting embodiment, the ratio (V3/V1) can be not greater than about 30, such as not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, not greater than about 2. It will be appreciated that the ratio (V3/V1) can be within a range between any of the minimum and maximum values noted above.
Moreover, the mixture or core can have a particular content of the second filler and third filler. For example, the mixture or core can have a greater content of the second filler material compared to a content of the third filler material. Still, in other instances, the mixture or core can include a greater content of the third filler material compared to a content of the second filler material.
In one particular embodiment, the mixture or core can have a ratio (V2/V3) of at least about 1, wherein V2 represents a content of a second filler (vol %) within the mixture or core and V3 represents a content of a third filler (vol %) within the mixture or core. For example, the ratio (V2/V3) can be at least about 1.1, such as at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, or even at least about 30. In yet another non-limiting embodiment, the ratio (V2/V3) can be not greater than about 30, such as not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, or even not greater than about 2. It will be appreciated that the ratio (V2/V3) can be within a range between any of the minimum and maximum values noted above.
In yet another aspect, the mixture or core may utilize a ratio (V3/V2) of at least about 1, wherein V2 represents a content of a second filler (vol %) within the mixture or core and V3 represents a content of a third filler (vol %) within the mixture or core. According to one particular embodiment, the ratio (V3/V2) can be at least about 1.1, at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, or even at least about 30. Still, in one non-limiting embodiment, the ratio (V3/V2) can be not greater than about 30, not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, or even not greater than about 2. It will be appreciated that the ratio (V3/V2) can be within a range between any of the minimum and maximum values noted above.
The mixture or core may utilize a particular content of the third filler material, including for example, at least about 0.5 vol % of the third filler for a total volume of the mixture or core. In other embodiments, the content of the third filler can be greater, such as at least about 1 vol %, at least about 1.5 vol %, at least about 2 vol %, at least about 5 vol %, at least about 8 vol %, at least about 10 vol %, at least about 12 vol %, or even at least about 15 vol % for a total volume of the mixture or core. Still, in one non-limiting embodiment, the content of the third filler can be not greater than about 50 vol %, such as not greater than about 40 vol %, not greater than about 30 vol %, not greater than about 25 vol %, not greater than about 20 vol %, not greater than about 15 vol %, not greater than about 10 vol %, not greater than about 8 vol %, not greater than about 5 vol %, not greater than about 4 vol %, not greater than about 3 vol %, or even not greater than about 2 vol % for the total volume of the mixture or core. It will be appreciated that the mixture can contain an amount of the third filler within a range between any of the minimum and maximum percentages noted above.
In further reference to aspects of the fillers in the mixture and the core, in certain instances, the first filler material can have a first average particle size and the second filler material having a second average particle size. For one embodiment, the first average particle size can be different than the second average particle size, and more particularly, the first average particle size can be greater than the second average particle size. In still other instances, the second average particle size can be greater than the first average particle size.
The first average particle size of the filler can be at least 2% different as compared to the second average particle size. In other instances, the difference can be greater, such as at least about 5%, at least about 8%, at least about 10%, at least about 15%, or even at least about 20%, at least about 40%, at least about 60%, at least about 80%, or even at least about 100%. Still, in one non-limiting embodiment, the difference in average particle size between the first average particle size and the second average particle size can be not greater than about 300%, such as not greater than about 200%, or even not greater than about 150%. It will be appreciated that the difference in average particle size between the first average particle size and the second average particle size can be within a range between any of the minimum and maximum percentages noted above. Moreover, any two particulate filler materials of the mixture or core can have the same percent difference in size relative to each other as noted above.
Moreover, the mixture or the core can include a first filler material having a first average particle size and a third filler material having a third average particle size. For certain embodiments, the first average particle size can be different than the third average particle size, and more particularly, the first average particle size can be greater than the third average particle size. In another embodiment, the third average particle size can be greater than the first average particle size.
Additionally, the mixture or the core can have a second filler material having a second average particle size and a third filler material having a third average particle size. The second average particle size can have a different than the third average particle size, such that, for example, the second average particle size can be greater than the third average particle size. In other instances, the third average particle size can be greater than the second average particle size.
After forming the mixture as illustrated in
The mixture, and thus, the core, may include one or more fillers having a certain density, which may facilitate forming a low density core. One or more fillers may be a particulate material having a density of less than about 4.0 g/cm3. In other embodiments, the density of the filler can be less, such as not greater than 3.8 g/cm3, not greater than about 3.5 g/cm3, or even not greater than about 3.0 g/cm3.
As further illustrated in
In another embodiment, curing the mixture 104 may include curing the mixture by heating the mixture, and even heating the mixture and the preform. In certain instances, curing the mixture can include a plurality of heating steps, which can have distinct processing parameters relative to each other. For example, curing may utilize a first heating step, which can include heating the mixture at a first temperature T1 (temperatures noted in ° C.). In one embodiment, the mixture can be heated to at least 25° C. In another embodiment, the first temperature can be at least 28° C., such as at least 30° C., or even at least 33° C. In yet another embodiment, the first temperature can be not greater than 40° C., such as not greater than 35° C., or not greater than 30° C. According to one particular embodiment, the first temperature can be substantially room temperature, such that essentially no external heat is applied to the mixture.
In further embodiments of the curing of the mixture 104 in method 100, the first heating can be conducted for a first duration. The first duration can be at least about one hour, such as at least about 2 hours, at least about 3 hours, at least about 6 hours, at least about 12 hours, or even at least about 24 hours. In another non-limiting embodiment, the first duration can be not greater than about 48 hours, such as not greater than about 36 hours, or not greater than about 24 hours. It will be appreciated that the first duration can be within a range between the minimum and maximum durations noted above.
In further embodiments, curing of the mixture can include a second heating of the mixture at a second temperature T2. The second heating can be undertaken after the first heating step. In particular, the second temperature T2 can be different from the first temperature T1. For example, the second temperature T2 can be greater than the first temperature T1. Moreover, in certain instances, the second temperature T2 and the first temperature T1 can be different from each other by a first temperature difference, defined by |T2-T1|, which is the absolute value of the difference between the second temperature and the first temperature.
According to an embodiment, the first temperature difference can have an absolute value of not greater than about 50° C., such as not greater than about 45° C., or not greater than about 40° C. Moreover, the first temperature difference can have an absolute value of at least about 10° C., such as at least about 20° C., or at least about 30° C. It will be appreciated that the first temperature difference can be within a range between any of the minimum and maximum values noted above.
Additionally, the second heating can include a second duration. In certain instances, the second duration can be different from the first duration. For example, the second duration can be greater than the first duration. Still, in other processes, the second duration can be less than the first duration. In yet another embodiment, the second duration can be substantially the same as the first duration.
For certain processes according to embodiments herein, curing the mixture can include a third heating of the mixture at a third temperature T3. The third heating can be undertaken after completing the second heating step and/or the first heating step. The third temperature T3 can be different from the second temperature T2. and the first temperature T1. In particular, the third temperature may be greater than the second temperature. Alternatively, the third temperature may be less than the second temperature. According to one embodiment, the third temperature T3 and the second temperature T2 can be different from each other by a second temperature difference, defined by |T3-T2|, which is the absolute value of the difference between the third temperature and the second temperature. The third temperature may be different from the first temperature in the same manner as described above with respect to the difference between the second temperature and the third temperature.
The second temperature difference can have an absolute value of not greater than about 40° C., such as not greater than about 35° C., or not greater than about 30° C. The second temperature difference can have an absolute value of at least about 10° C., such as at least about 20° C., or at least about 30° C. It will be appreciated that the second temperature difference can be within a range between any of the minimum and maximum values noted above.
Moreover, the third heating can include a third duration. The third duration can be different from the second duration and/or the first duration. For example, the third duration can be greater than the second duration or the first duration. Alternatively, the third duration can be less than the second duration or the first duration. In still another embodiment, the third duration can be substantially the same as the second duration or the first duration.
For certain processes according to embodiments herein, curing the mixture can include a fourth heating step of the mixture at a fourth temperature T4. The fourth heating can be undertaken after completing the third heating step. The fourth temperature T4 can be different from the first temperature T1, the second temperature T2, or the third temperature T3., or the In particular, the fourth temperature may be greater than the first temperature, second temperature, or third temperature. Alternatively, the fourth temperature may be less than the first temperature, second temperature, or third temperature. According to one embodiment, the fourth temperature T4 and the third temperature T3 can be different from each other by a third temperature difference, defined by |T4-T3|, which is the absolute value of the difference between the fourth temperature and the third temperature.
The third temperature difference can have an absolute value of not greater than about 60° C., such as not greater than about 55° C., or not greater than about 50° C. Moreover, the third temperature difference can have an absolute value of at least about 10° C., such as at least about 20° C., or at least about 30° C. It will be appreciated that the third temperature difference can be within a range between any of the minimum and maximum values noted above.
Moreover, the fourth heating can be conducted over a fourth duration. The fourth duration can be different from the first duration, second duration, or third duration. For example, the fourth duration can be greater than the first duration, second duration, or third duration. Alternatively, the fourth duration can be less than the first duration, second duration, or third duration. In still another embodiment, the fourth duration can be substantially the same as the third duration.
In one instance, the first heating and the second heating can have a total duration of at least about four hours, such as at least about six hours, or at least about eight hours. Furthermore, the first heating, the second heating, and the third heating can have a total duration of at least about six hours, such as at least about eight hours, or at least about twelve hours. Moreover, the first heating, the second heating, the third heating, and the fourth heating can have a total duration of at least about eight hours, such as at least about ten hours, or at least about 14 hours. Alternatively, the first heating and the second heating can have a total duration of not greater than about 72 hours, such as not greater than about 64 hours, or not greater than about 60 hours. Furthermore, the first heating, the second heating, and the third heating can have a total duration of not greater than about 96 hours, such as not greater than about 90 hours, or not greater than about 84 hours. Moreover, the first heating, the second heating, the third heating, and the fourth heating can have a total duration of not greater than about 144 hours, such as not greater than about 132 hours, or not greater about 120 hours.
The process of curing can also be conducted in an atmosphere having a particular feature. For example, curing can be conducted in a reduced pressure atmosphere as compared to standard atmospheric conditions, which may facilitate formation of a core having the properties disclosed herein. The process of providing a reduced pressure atmosphere may be conducted prior to curing. Additionally, the process of providing a reduced pressure atmosphere may be conducted during curing. For example, the pressure of the atmosphere during curing can be not greater than about 0.1 Torr, such as not greater than about 0.01 Torr or even not greater than about 0.001 Torr. Still, in at least one embodiment, the pressure of the atmosphere during curing can be at least about 1×10−5 Torr. It will be appreciated that the reduced pressure atmosphere can have a pressure within a range between any of the minimum and maximum values noted above.
Additionally, the process of curing in a reduced pressure atmosphere may be suitable for moving the mixture to particular locations. For example, a reduced pressure can be placed on the mixture to facilitate directional movement of the mixture during curing. In a particular embodiment, the pressure within the environment can be reduced to pull the mixture toward the preform, which may include bonded abrasive bodies. Accordingly, the application of a reduced pressure atmosphere may facilitate pulling the mixture into the bonded abrasive bodies during curing and the formation of an integrally bonded abrasive article.
The process of curing can include a process of managing the heat generated in the core during the curing process to reduce stress in the system. According to one embodiment, the curing process can include coupling one or more surfaces of the core to a cooling structure that may utilize a cooling medium. Coupling can include direct or indirect contact. In one particular embodiment, curing can including monitoring the temperature of the system and controlling a cooling structure coupled to the mixture, which can include but is not limited to, adjusting a temperature of the cooling structure to control heat transferred from the mixture to the bonded abrasive body. The cooling structure can include a cooling block having a cooling medium (e.g., water) flowing internally within the block. The cooling block can be indirectly coupled to the mixture, wherein a base plate is disposed between the mixture and the cooling block during curing.
In one another embodiment of the method 100, curing the mixture 104 can include monitoring a property of the mixture or the core formed during the curing. Exemplary processes that may be monitored can include flexural modulus, flexural strength, Rockwell hardness, density, glass transition temperature, coefficient of thermal expansion, and a combination thereof.
For example, the core formed by the method 100 can have a flexural modulus of at least about 4 GPa, such as at least about 5 GPa, or at least about 7 GPa. Alternatively, the core can have a flexural modulus of not greater than about 20 GPa, such as not greater than about 18 GPa, or not greater than about 15 GPa. It will be appreciated that the flexural modulus can be within a range between any of the minimum and maximum values noted above.
In other instances, the core formed by the method 100 can have a flexural strength of at least about 40 MPa, such as at least about 45 MPa, or at least about 50 MPa. Alternatively, the core can have a flexural strength of not greater than about 100 MPa, such as not greater than about 90 MPa, or not greater than about 80 MPa. It will be appreciated that the flexural strength can be within a range between any of the minimum and maximum values noted above.
In further instances, the core formed by the method 100 can have a Rockwell hardness of at least about 70, such as at least about 80, or at least about 90. Alternatively, the core can have a Rockwell hardness of not greater than about 120, such as not greater than about 110, or not greater than about 100. It will be appreciated that the Rockwell hardness can be within a range between any of the minimum and maximum values noted above.
In yet other instances, the core formed by the method 100 can have a density of at least about 0.8 g/cc, such as at least about 0.9 g/cc, or at least about 1.0 g/cc. Alternatively, the core can have a density of not greater than about 2.8 g/cc, such as not greater than about 2.5 g/cc. or not greater than about 2.0 g/cc. It will be appreciated that the density can be within a range between any of the minimum and maximum values noted above.
In other instances, the core formed by the method 100 can have a glass transition temperature Tg of at least about least about 75° C., such as at least about 80° C. at least about 90° C., at least about 100° C., at least about 110° C., at least about 120° C., or at least about 140° C. Alternatively, the core can have a glass transition temperature Tg of not greater than about 200° C., such as not greater than about 180° C., not greater than about 170° C., not greater than about 160° C., not greater than about 150° C., not greater than about 140° C., or even not greater than about 130° C. It will be appreciated that the glass transition temperature can be within a range between any of the minimum and maximum temperatures noted above.
The core can be a monolithic body, and more particularly, an essentially monolithic body. A monolithic body can be a seamless body having substantially uniform material properties throughout the volume of the body. A monolithic body may have essentially no adhesive material, since a monolithic body does not necessarily contain different components that are joined to each other. Furthermore, a monolithic body may have a substantially uniform density, a substantially uniform hardness, a substantially uniform flexural modulus, a substantially uniform flexural strength, a substantially uniform glass transition temperature, a substantially uniform coefficient of thermal expansion, and any combination of these properties.
The monolithic body may contain a reinforcing structure contained within the monolithic body or joined to the monolithic body. The reinforcing member may be an inorganic material, organic material, glass, glass fiber, ceramic, natural material, and a combination thereof. The reinforcing member may be incorporated into the body to facilitate the formation of a core having the properties described herein. The core can include at least one reinforcing structure or a plurality of reinforcing structures. According to one embodiment, the reinforcing structure can be a substantially planar layer of material, which may extend radially through the body of the core in a plane defined by a diameter. In certain instances, the reinforcing structure can include a woven material, non-woven material, composite material and a combination thereof.
In other embodiments, the monolithic body of the core 201 may have a particular diameter. For example, in one embodiment the diameter (d) of the core 201 can be at least about 6 inches (15.2 cm), such as at least about 10 inches (24.4 cm), at least about 16 inches (40.6 cm), or even at least about 20 inches (50.8 cm). Still, in one non-limiting embodiment, the diameter (d) of the core 201 can be not greater than about 50 inches (1.3 m). It will be appreciated that the monolithic body of the core 201 can have a diameter (d) within a range between any of the above minimum and maximum values.
Furthermore, the monolithic body of the core 201 may have a particular circumference, measured as the total distance around the peripheral surface 205. In accordance with a particular embodiment, the core 201 can have a circumference that is at least about 19 inches (48 cm). Still other embodiments, the circumference (C) may be greater, such as at least about 31 inches (78 cm), at least about 50 inches (128 cm), or even at least about 63 inches (160 cm). Still, in one non-limiting embodiment, the circumference (C) can be not greater than about 70 inches (178 cm). It will be appreciated that the circumference (C) of the core 101 can be within a range between any of the minimum and maximum values noted above.
According to particular forming methods herein, the core 210 can be made as a monolithic body having a particularly large volume. For example, the core 201 can have a volume of at least about 75 in3 (1229 cm3). Still other embodiments, the volume of the core 201 can be greater, such as on the order of at least about 500 in3 (8194 cm3), at least about 1000 in3 (16387 cm3), at least about 1200 in3 (19664 cm3), at least about 1600 in3 (26219 cm3), at least about 1800 in3 (29496 cm3), or even least about 2000 in3 (32774 cm3). Still, in at least in at least one non-limiting embodiment, the core 201 can have a volume that is not greater than about 20000 in3 (327741 cm3). It will be appreciated that the core 201 can have a volume within a range between any of the minimum and maximum values noted above.
As further illustrated, the core 201 can have an opening 202 that may extend through the volume of the body of the core 201. In particular instances, the opening 202 may extend through the entire height (h) of the core 201 from a first major surface 203 to a second major surface 204 opposite the first major surface 203. In particular instances, the opening 202 may be disposed at the centered at the first major surface 203 and second major surface 204 of the core 201.
The opening 202 may be an arbor hole, configured to engage a spindle for rotation of the core 201 during grinding operations. In accordance with at least one embodiment, the opening 202 may extend along the direction of height (h) between the first major surface and second major surface of the core 201. The opening 202 can extend through a volume of the monolithic body of the core 201. As illustrated, the opening 202 can extends along a direction of the height of the core 201, and in particular, the opening 202 can extend between a first major surface and a second major surface of the core 201.
The opening 202 may be formed to have particular dimensions, including for example a diameter (d). In one embodiment, the opening 202 can have a diameter of at least about 1 inch (2.5 cm). In other embodiments, the diameter of the opening 202 may be greater, such at least about 2 inches (5.1 cm), at least about 3 inches (7.6 cm), or even at least about 4 inches (10 cm). In one particular embodiment, the opening 202 can have a diameter of not greater than about 100 inches (2540 cm), and more particularly, not greater than about 50 inches (127 cm). It will be appreciated that the opening 202 may have a diameter within a range between any of the minimum and maximum values noted above.
In particular instances, the core 201 may include a liner 207 overlying at least a portion of the surface defining the opening 202. In certain instances, the liner 207 may overlie essentially the entire surface defining the opening 202 extending from the first major surface 203 to the second major surface 204. Furthermore, the liner 207 may extend around the entire inner peripheral surface defining the opening 202 and define at least a portion of the arbor hole opening configured to engage a spindle of a grinding machine. The liner 207 can include an inorganic material, such as a metal or metal alloy. The liner 207 may include a material such as aluminum, silicon, steel, carbon fiber, and a combination thereof.
The liner 207 can include various materials, including for example inorganic materials, organic materials, and a combination thereof. In particular instances, the liner 207 may be formed of a metal or a metal alloy. More particularly, the liner 207 may consist essentially of a metal or metal alloy.
As further illustrated in
As noted above, the core 201 can be a monolithic body formed of a polymer, and more particularly, a polymer such as an epoxy polymer, a phenoxy polymer, a polyurea, a polyimide, a polycyanate, an acrylic, a polyurethane, a melamine polymer, a polyester, or foamed structures of the same or a combination thereof. In certain cases, the core 201 can be a monolithic body formed of an epoxy polymer derived from a bisphenol-A compound. In one particular instance, the bisphenol-A compound is bisphenol-A diglycidyl ether.
The core may be made of at least about 5 vol % polymer material. In other embodiments, the amount of polymer material can be greater, such as at least about 10 vol %, at least about 25 vol %, at least about 50 vol %, at least about 75 vol %, or even at least about 95 vol %. In one particular embodiment, the core can consists essentially of a polymer material, and more particularly, a single polymer material.
Furthermore, the core 201 may have particular characteristics such as a particular linear coefficient of thermal expansion (CTE) as measured at room temperature or within a range between room temperature and about 100° C. In particular instances, the core 201 may have a linear coefficient of thermal expansion of at least about 15 microns/m C, such at least about 25 μm/m° C., at least about 28 μm/m° C., at least about 30 μm/m° C., at least about 33 μm/m° C., at least about 35 μm/m° C., at least about 37 μm/m° C., at least about 40 μm/m° C., at least about 43 μm/m° C., at least about 45 μm/m° C., at least about 48 μm/m° C., at least about 50 μm/m° C., or even at least about 53 μm/m° C. In other non-limiting embodiments, the core 201 may have a linear coefficient of thermal expansion of not greater than about 200 μm/m° C., such as not greater than about 180 μm/m° C., not greater than about 160 μm/m° C., not greater than about 150 μm/m° C., not greater than about 125 μm/m° C., not greater than about 100 μm/m° C., not greater than about 80 μm/m° C., or even not greater than about 70 microns/m C. Formation of a core 201 having a suitable coefficient of thermal expansion may facilitate integral bonding between the core 201 and the bonded abrasive body attached thereto.
According to one embodiment, the core can include an amount of uncured epoxy of at least about 0.1 vol % for a total volume of the core after completion of the curing process. In more particular instances, the core may include a content of uncured epoxy of at least about 0.5 vol %, such as at least about 1 vol %, at least about 2 vol %, or even at least about 5 vol %. Still, the content of uncured epoxy within the core may be not greater than about 15 vol %, such as not greater than about 12 vol %, not greater than about 10 vol %, not greater than about 5 vol %, or even not greater than about 2 vol %. The content of uncured epoxy can be within a range between any of the above minimum and maximum percentages.
The core may be formed to have a content of porosity of not greater than about 15 vol % for the total volume of the core. In other instances, the content of porosity can be less, such as not greater than about 12 vol %, not greater than about 10 vol %, not greater than about 8 vol %, not greater than about 5 vol %, or even not greater than about 3 vol %. Still, the porosity of the core may be at least about 0.1 vol %, such as at least about 0.5 vol %, or even at least about 1 vol %. The porosity of the core may be within a range between any of the minimum and maximum percentages noted above.
In accordance with one embodiment, the bonded abrasive body 301 can include a bond material made of a hybrid material including an organic portion and an inorganic portion. In certain instances, the organic portion and the inorganic portion can be substantially uniformly distributed throughout the volume of the bond material. Moreover, in other embodiments, the organic portion and the inorganic portion can be substantially uniformly distributed within each other.
According to one embodiment, the inorganic portion of the bond material can include a metal or metal alloy material. Particularly suitable metals can include transition metal elements, including but not limited to, copper, tin, silver, chromium, titanium, vanadium, manganese, iron, cobalt, nickel, zinc, gold, molybdenum, zirconium, tungsten, yttrium, tantalum, aluminum, and a combination thereof. In one particular embodiment, the bond material can include a combination of copper and tin, such that the bond material may be a bronze material. In specific embodiments, the bond material can have a greater content of copper than tin. For example, the bond material can have a copper:tin ratio of approximately 60:40 by weight.
According to another embodiment, the organic portion of the bond material can include a polymer material. Some suitable polymer materials can include thermosets, thermoplastics, rubbers, polyimides, polyamides, resins, aramids, epoxies, polyesters, polyurethanes, and a combination thereof. In particular instances, the polymer material may include an epoxy, polyester, phenolic, polyisocyanurate ester, and a combination thereof. According to a particular embodiment, the organic portion can include polybenzimidazole (PBI).
In certain other embodiments, the bond material can include a greater content of the inorganic portion (vol %) as compared to a content of the organic portion (vol %) within the bond. For example, the bond material can include a minority content of the organic portion. In at least one embodiment, the bond material can include not greater than about 40 vol % organic portion, such as not greater than about 35 vol %, not greater than about 30 vol %, not greater than about 25 vol %, not greater than about 20 vol % organic portion for the total volume of the bond material. In at least one non-limiting embodiment, the bond material can include at least about 1 vol % organic portion for the total volume of the bond. It will be appreciated that the amount of the organic portion within the bond can be within a range between the minimum and maximum percentages noted above.
In certain other aspects, the bond material can have a greater content of the organic portion (vol %) as compared to a content of the inorganic portion (vol %) within the bond. For certain embodiments, the bond material can include a minority content of the inorganic portion for the total content of the bond. In still another embodiment, the bond material can contain a majority content of the inorganic portion for the total content of the bond. For example, the bond material can include at least about 10 vol %, such as at least about 15 vol %, at least about 20 vol %, at least about 25 vol %, at least about 30 vol %, at least about 35 vol %, at least about 40 vol %, at least about 45 vol %, or even at least about 50 vol % inorganic portion for the total volume of the bond material. In one non-limiting embodiment, the bond material can contain not greater than about 99 vol %, such as not greater than about 96 vol %, or even not greater than about 94 vol % inorganic material for the total volume of the bond. It will be appreciated that the amount of the inorganic portion within the bond can be within a range between the minimum and maximum percentages noted above.
In certain instances, the bonded abrasive body 301 can be formed to include a particular amount of bond material to facilitate the formation of the abrasive article according to embodiments herein. For example, the bonded abrasive body 301 can include at least about 5 vol % bond material for the total volume of bonded abrasive body 301. In other embodiments, the amount of bond material may be greater, such as at least 10 vol %, at least about 20 vol %, at least about 30 vol %, at least about 40 vol %, at least about 50 vol % or even at least about 55 vol %. Still, in one non-limiting embodiment, the bonded abrasive body 301 may include not greater than about 75 vol %, such as not greater than 70 vol %, not greater than about 65 vol %, not greater than about 60 vol %, not greater than about 55 vol %, not greater than about 50 vol %, not greater than about 45 vol %, or even not greater than about 40 vol % bond material for the total volume of the bonded abrasive body 301. It will be appreciated that the amount of bond material within the bonded abrasive body 301 may be within range between any of the minimum and maximum percentages noted above.
In one aspect, the bonded abrasive body 301 may include a particular content of abrasive particles, which can be dispersed throughout the volume of the bond material, to facilitate the formation of abrasive articles according to embodiments herein. For example, the bonded abrasive body 301 may include at least about 5 vol % abrasive particles for the total volume of the body. In other embodiments, the amount of abrasive particles can be greater, such as at least about 10 vol %, at least about 15 vol %, at least about 20 vol %, at least about 25 vol %, at least about 30 vol %, at least about 35 vol %, or even at least about 40 vol %. Still, in one particular instance, the bonded abrasive body can contain not greater than about 75 vol % abrasive particle, such as on the order of not greater than about 65 vol %, not greater than about 60 vol %, not greater than about 55 vol %, not greater than about 50 vol %, or even not greater than about 45 vol % for the total volume of the bonded abrasive body 301. It will be appreciated that the amount of abrasive particle within the body can be within a range between any of the minimum and maximum percentages noted above.
The abrasive particles within the bonded abrasive body 301 can include oxides, carbides, nitrides, borides, oxycarbides, oxynitrides, and a combination thereof. In particular instances, the abrasive particles may be a superabrasive material, such as carbide, boron nitride, diamond, and a combination thereof. In still other instances, the abrasive particles may include alumina, silica, sulfur carbide, boron, diamond, and a combination thereof. In one particular instance, the abrasive particles can consist essentially of diamond.
The bonded abrasive body 301 may include a particular content of porosity to facilitate the formation of the abrasive articles of the embodiments herein. The porosity may be in the form of open porosity defining an interconnected network of channels extending throughout the bond material. Alternatively, the body may include a content of closed porosity described and characterized by discrete and individual pores separated from each other. In at least one embodiment, the bonded abrasive body can include a mix of open porosity and closed porosity.
The amount of porosity within the body can comprise a majority content, such as greater than 50 vol % for the total volume of the body. In still other instances, the bonded abrasive body may include a minority content of porosity, which can represent less than 50 vol % of the total volume of the bonded abrasive body. Furthermore, the body may contain a majority content of closed porosity. Still, in other instances, the bonded abrasive body may contain a majority content of open porosity.
For certain bonded abrasive bodies, the amount of porosity may be not greater than about 70 vol % for the total volume of the total bonded abrasive body. In yet other instances, the bonded abrasive body 301 may be formed such that the amount of porosity is not greater than about 60 vol %, such as not greater than about 50 vol %, not greater than about 40 vol %, not greater than about 30 vol %, not greater than about 25 vol %, not greater than about 20 vol %, not greater than about 15 vol %, not greater than about 10 vol %, not greater than about 5 vol %, or even not greater than about 2 vol %. In at least one non-limiting embodiment, the bonded abrasive body 301 may contain an amount of porosity of at least about 1 vol %, such as at least about 5 vol %, at least at about 15 vol %, at least about 20 vol %, at least about 30 vol %, or even at least about 40 vol %. Moreover, it will be appreciated that the total amount of porosity within the bonded abrasive body 301 can be within a range between any of the minimum and maximum percentages noted above.
The bonded abrasive body 301 may include some amount of filler, which can be any one or more of the filler materials described herein. The filler may be present and dispersed throughout the volume of bond material. Certain fillers may include pore formers, including materials such as glasses, glass-ceramics, ceramics, organics, and a combination thereof. According to one embodiment, certain suitable fillers can include bubble alumina, bubble mullite, hollow spheres, hollow glass spheres, hollow ceramics, hollow polymers spheres, polymers materials, organic compounds, fibrous materials, naphthalene, PBD, shells, wood, and the like. In still other, alternative embodiments, the filler material may be a particulate material, such as a powder including a material selected from a group of zirconia, silica, titania, and a combination thereof.
It will be appreciated that the bonded abrasive body 301 may contain a minor content of filler material, such that the total content of filler material may be less than about 50 vol % for the total volume of the body 301. In fact, in certain instances, the amount of filler material can be less such as not greater than about 20 vol %, not greater than about 15 vol %, not greater than about 10 vol %, not greater than about 8 vol %, or even not greater than about 5 vol % for the total volume of the body.
The abrasive article disclosed in
As further illustrated in
As further illustrated, the abrasive article illustrated in
The bonded abrasive body 302 can have the same features as the bonded abrasive body 301, including for example, the same abrasive particles, bond material, porosity, and filler as described to the bonded abrasive body 301. In fact, in certain instances, each of the bonded abrasives bodies 301, 302, 303, may be essentially identical in composition and structure.
As further illustrated in
Still, in certain instances, the bonded abrasive body 302 can be spaced apart from the core 201 by a distance of not greater than about 0.08 inches, such as not greater than about 0.05 inches, not greater than about 0.01 inches, or even not greater than about 0.008 inches.
While a particular abrasive article is illustrated in
The bonded abrasive body 301 may have particular characteristics, such as a particular coefficient of thermal expansion (CTE) as measured from 30° C. to 150° C. temperature. In particular instances, the bonded abrasive body 301 may have a coefficient of thermal expansion of at least about 1 micron/(m° C.). More particularly, the bond material of the bonded abrasive body can have a linear CTE of at least about 3 microns/(m° C.), such as at least about 5 microns/(m° C.). Still, the bond material may have a linear CTE of not greater than about 30 microns/(m° C.).
In particular instances, the bond material of the bonded abrasive body 301 may have a particular linear shrinkage. For example, the linear shrinkage may be not greater than about 8%, such as not greater than about 5%, or even not greater than about 3%. Still, the linear shrinkage of the bond material of the bonded abrasive body 301 may be at least about 0.01%, such as at least about 0.1%.
Moreover, the bond material of the bonded abrasive body 301 may have a particular flexural strength. For example, the flexural strength may be at least about 5 MPa, such as at least about 10 MPa, or even at least about 20 MPa. Still, in certain embodiments, the flexural strength of the bond material of the bonded abrasive body 301 may be not greater than about 250 MPa, such as not greater than about 220 MPa, not greater than about 180 MPa, or even not greater than about 160 MPa.
In accordance with at least one embodiment, the abrasive article 300 may be formed such that the bonded abrasive body 301 and core 201 are formed integrally with each other. As such, the core 201 and the bonded abrasive body 301 may be formed to have certain properties to facilitate the formation of abrasive articles according to embodiments herein. In particular, certain properties of the bonded abrasive body, bond of the bonded abrasive body, and the core can be match to a suitable degree to facilitate the formation of the abrasive articles of the embodiments herein. Some exemplary properties of the components that can be matched can include CTE, shrinkage, flexural strength, flexural modulus, and a combination thereof.
In a particular instance, the bonded abrasive body 301 can have a coefficient of thermal expansion (CTEba) and the core 201 can have coefficient of thermal expansion (CTEc), wherein the difference (ΔCTE) between the coefficient of thermal expansion of the core and coefficient of thermal expansion of the bond material is not greater than about 30%, wherein the difference in the coefficients of thermal expansion (ΔCTE) between the core 201 and the bonded abrasive body 301 can be defined by the equation [(CTEba−CTEc)/CTEba]×100%. In other embodiments, the difference in coefficient of thermal expansion can be less, such as not greater than about 25%, not greater than about 20%, not greater than about 18%, not greater than about 12%, or even not greater than about 5%. In one non-limiting embodiment, the difference in coefficient of thermal expansion can be at least about 0.01%, or even at least about 0.05%. It will be appreciated that the difference in coefficient of thermal expansion between the core 201 and the coefficient of thermal expansion of the bonded abrasive body 301 can be within a range between the minimum and maximum percentages noted above.
Moreover, the abrasive article 300 can be formed such that a particular difference in the coefficients of thermal expansion (ΔCTE) exists between the coefficient of thermal expansion of the core 201 (CTEc) and the coefficient of thermal expansion of the bond material (CTEbm) of the bonded abrasive body 301, as defined by the equation [(CTEbm−CTEc)/CTEbm]×100%. The difference in CTE between the bond material and the core can be the same as described in the embodiments above with regard to the difference in CTE between the bonded abrasive body and the core.
Moreover, the abrasive article 300 can be formed such that a particular difference in shrinkage exists between the core 201 and the bonded abrasive body. Notably, the difference in shrinkage between the bonded abrasive body and the core can be the same percentage difference as described in the embodiments above with regard to the difference in CTE between the bonded abrasive body and the core.
Moreover, the abrasive article 300 can be formed such that a particular difference in shrinkage exists between the core 201 and the bond material of the bonded abrasive body. Notably, the difference in shrinkage between the bond material and the core can be the same percentage difference as described in the embodiments above with regard to the difference in CTE between the bonded abrasive body and the core.
It will be appreciated that the other bonded abrasive bodies 302 and 303 of the abrasive article 300 can have the same features and properties of the bonded abrasive body 301.
A sample S1 of an abrasive article was prepared, which included an integrally formed bonded abrasive article and a core according to an embodiment. The abrasive article had an outer diameter of 8-inches and a height of greater than 3 inches
Sample S1 had a core formed from liquid epoxy, which is commercially available from Hapco, having a glass transition temperature comprised a Tg in a range of about 122° C. to about 137° C. and a CTE in a range of about 50 μm/m° C. to about 150 μm/m° C. The mixture was mixed and poured into a mold cavity defined by the center of an 8 inch diameter bonded abrasive article. A liner of aluminum was included to define an arbor hole. A reduced pressure atmosphere was used during mixing and pouring to remove bubbles from the mixture. Sample S1 included an epoxy polymer derived from bisphenol-A diglycidyl ether, and fillers of ethanol, 2 chloro-, phosphate (3:1), black oxide, and fused alumina. The mixture further included a curing agent of isophorane diamine. The bonded abrasive body of Sample S1 included a bond material comprising a hybrid material including an inorganic portion of metal including copper and tin and an organic portion of PBI.
The sample was cured using a process of a first heating process conducted at room temperature (i.e., approximately 20° C.) for approximately 4 hours, a second heating process conducted between 55° C.-60° C. for 4 hours, and a third heating process completed at a temperature between 90° C. to 95° C. for 4 hours. The curing process was conducted in a reduced pressure atmosphere The core of Sample S1 also contained an amount of uncured epoxy in a range of about 0 vol % to about 2 vol %.
Sample S1 experienced no cracking, shrinkage or delamination problems. In particular, the bonded abrasive article and the core maintained good adhesion at its core/abrasive interface.
A sample S2 of an abrasive article was prepared, which included an integrally formed bonded abrasive article and a core. The abrasive had an outer diameter of 20.5-inches, an axial thickness of 8-inches (made by combing two sections having an axial thickness of 4 inches) and an interior diameter of 12 inches.
Sample S2 had a core formed from a two part-epoxy (i.e., Epoxy Part A and Epoxy Part B), which are commercially available from Hapco. Epoxy Part A was stirred well using an overhead mixer. Epoxy Part B, which acted as the curing agent, was added at an A:B ratio of 100:11. The two parts were mixed using an overhead mixer and then a vacuum was applied to remove any air entrained during mixing. The bonded abrasive body of Sample S2 included a bond material comprising a hybrid material including an inorganic portion of metal including copper and tin and an organic portion of PBI.
The bonded abrasive section of the wheel, having an outer diameter of 20.5-inches, an axial thickness of 4-inches and an interior diameter of 18 inches was placed on a waxed stainless steel plate, and a waxed aluminum having an outer diameter of 12-inches, an axial thickness of 0.75-inches and an interior diameter of 18-inches was placed in the center of the wheel. A steel band, having an outer diameter of 20.5-inches, an axial thickness of 0.75-inches and an interior diameter of 18 inches, was placed over the abrasive section to hold excess epoxy. The epoxy mixture was slowly poured into the space between the grinding wheel and the aluminum sleeve and then a vacuum was applied to remove air entrained during pouring. The wheel was allowed to cure at 60° C. for 4 hours.
Even though this cured the epoxy in a short time, Sample S2 experienced a delamination at the interface and the wheel was rejected.
A sample S3 of an abrasive article was prepared, which included an integrally formed bonded abrasive article and a core. The abrasive had an outer diameter of 20.5-inches, an axial thickness of fl-inches (made by combing two sections having an axial thickness of 4 inches) and an interior diameter of 12 inches.
Sample S3 had a core formed from a two part-epoxy (i.e., Epoxy Part A and Epoxy Part B), which are commercially available from Hapco. Epoxy Part A was stirred well using an overhead mixer. Epoxy Part B, which acted as the curing agent, was added at an A:B ratio of 100:11. The two parts were mixed using an overhead mixer and then a vacuum was applied to remove any air entrained during mixing. The bonded abrasive body of Sample S3 included a bond material comprising a hybrid material including an inorganic portion of metal including copper and tin and an organic portion of PBI.
The bonded abrasive section of the wheel, having an outer diameter of 20.5-inches, an axial thickness of 4-inches and an interior diameter of 18 inches was placed on a waxed stainless steel plate, and a waxed aluminum having an outer diameter of 12-inches, an axial thickness of 0.75-inches and an interior diameter of 18-inches was placed in the center of the wheel. A steel band, having an outer diameter of 20.5-inches, an axial thickness of 0.75-inches and an interior diameter of 18 inches, was placed over the abrasive section to hold excess epoxy. The epoxy mixture was slowly poured into the space between the grinding wheel and the aluminum sleeve and then a vacuum was applied to remove air entrained during pouring. The wheel was allowed to cure at room temperature, which took five times the amount of cooling time as compared to the cooling of Sample S2 discussed in Example 2.
Sample S3 cracked at the interface of the abrasive section and epoxy after curing.
A sample S4 of an abrasive article was prepared, which included an integrally formed bonded abrasive article and a core. The abrasive had an outer diameter of 20.5-inches, an axial thickness of fl-inches (made by combing two sections having an axial thickness of 4 inches) and an interior diameter of 12 inches.
Sample S4 had a core formed from a two part-epoxy (i.e., Epoxy Part A and Epoxy Part B), which are commercially available from Hapco. Epoxy Part A was stirred well using an overhead mixer. Epoxy Part B, which acted as the curing agent, was added at an A:B ratio of 100:11. The two parts were mixed using an overhead mixer and then a vacuum was applied to remove any air entrained during mixing. The bonded abrasive body of Sample S4 included a bond material comprising a hybrid material including an inorganic portion of metal including copper and tin and an organic portion of PBI.
The bonded abrasive section of the wheel, having an outer diameter of 20.5-inches, an axial thickness of 4-inches and an interior diameter of 18 inches was placed on a waxed stainless steel plate, and a waxed aluminum having an outer diameter of 12-inches, an axial thickness of 0.75-inches and an interior diameter of 18-inches was placed in the center of the wheel. A steel band, having an outer diameter of 20.5-inches, an axial thickness of 0.75-inches and an interior diameter of 18 inches, was placed over the abrasive section to hold excess epoxy. The epoxy mixture was slowly poured into the space between the grinding wheel and the aluminum sleeve. No vacuum was applied to remove air entrained during pouring. The wheel was allowed to cure at room temperature.
Sample S4 crack at the interface of the abrasive section and epoxy. In addition to the cracking, the epoxy core was also porous and had about 20% lower strength.
A sample S5 of an abrasive article was prepared, which included an integrally formed bonded abrasive article and a core. The abrasive had an outer diameter of 20.5-inches, a axial thickness of fl-inches (made by combing two sections having an axial thickness of 4 inches) and an interior diameter of 12 inches.
Sample S5 had a core formed from a two part-epoxy (i.e., Epoxy Part A and Epoxy Part B), which are commercially available from Hapco. Epoxy Part A was stirred well using an overhead mixer. Epoxy Part B, which acted as the curing agent, was added at an A:B ratio of 100:11. The two parts were mixed using an overhead mixer and then a vacuum was applied to remove any air entrained during mixing. The bonded abrasive body of Sample S5 included a bond material comprising a hybrid material including an inorganic portion of metal including copper and tin and an organic portion of PBI.
The bonded abrasive section of the wheel, having an outer diameter of 20.5-inches, an axial thickness of 4-inches and an interior diameter of 18 inches was placed on a waxed stainless steel plate, and a waxed aluminum having an outer diameter of 12-inches, an axial thickness of 0.75-inches and an interior diameter of 18-inches was placed in the center of the wheel. A steel band, having an outer diameter of 20.5-inches, an axial thickness of 0.75-inches and an interior diameter of 18 inches, was placed over the abrasive section to hold excess epoxy. The epoxy mixture was slowly poured into the space between the grinding wheel and the aluminum sleeve. Then a vacuum was applied to remove air entrained during pouring The wheel was allowed to cure at room temperature on a cooling deck, which had cold water flowing through it to extract the heat generated. The wheel remained on the cooling deck for 24 hours, and then further cured at room temperature without the cooling deck.
Sample S5 experienced no cracking, shrinkage or delamination problems. In particular, the bonded abrasive article and the core maintained good adhesion at its core/abrasive interface.
In the foregoing, reference to specific embodiments and the connections of certain components is illustrative. It will be appreciated that reference to components as being coupled or connected is intended to disclose either direct connection between said components or indirect connection through one or more intervening components as will be appreciated to carry out the methods as discussed herein. As such, the above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description.
The Abstract of the Disclosure is provided to comply with Patent Law and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description, with each claim standing on its own as defining separately claimed subject matter.
Item 1. An abrasive article comprising:
a core comprising an organic material; and
a first bonded abrasive body integrally bonded directly to the core, the bonded abrasive body comprising:
a bond material comprising a hybrid material including an inorganic portion and an organic portion; and
abrasive particles contained within the bond material.
Item 2. The abrasive article of item 1, wherein the first bonded abrasive body is integrally bonded to a peripheral surface of the core.
Item 3. The abrasive article of item 1, wherein the core comprises a volume of at least about 75 in3 (1229 cm3), at least about 500 in3 (8194 cm3), at least about 1000 in3 (16387 cm3), at least about 1200 in3 (19664 cm3), at least about 1600 in3 (26219 cm3), at least about 1800 in3 (29496 cm3), at least about 2000 in3 (32774 cm3), and not greater than about 20000 in3 (327741 cm3).
Item 4. The abrasive article of item 1, wherein the core has a monolithic body, wherein the core has a cylindrical shape defined by a diameter (d), a circumference (C), and a height (h), wherein the height is at least about 3 inches (7.6 cm).
Item 5. The abrasive article of item 4, wherein the diameter is at least about 6 inches (15.2 cm), at least about 10 inches (25.4 cm), at least about 16 inches (40.6 cm), at least about 20 inches (50.8 cm), and not greater than about 500 inches (1.3 m).
Item 6. The abrasive article of item 4, wherein the circumference is at least about 19 inches (48 cm), at least about 31 inches (78 cm), at least about 50 inches (128 cm), at least about 63 inches (160 cm), and not greater than about 157 inches (4 m).
Item 7. The abrasive article of item 4, wherein the height is at least about 3.5 inches (8.9 cm), at least about 4 inches (10.2 cm), at least about 4.5 inches (11.4 cm), at least about 5 inches (12.7 cm), at least about 5.5 inches (14 cm), at least about 6 inches (15.2 cm), at least about 6.5 inches (16.5 cm), at least about 7 inches (17.8 cm), and not greater than about 30 inches (76.2 cm).
Item 8. The abrasive article of item 1, wherein the core comprises an opening defining an arbor hole, wherein the opening is configured to engage a spindle for a grinding operation, wherein the opening extends through a volume of the monolithic body, wherein the opening extends along a direction of the height, wherein the opening extends between a first major surface and a second major surface of the core.
Item 9. The abrasive article of item 8, wherein the core comprises a liner overlying at least a portion of the surface defining the opening, wherein the liner overlies essentially the entire surface defining the opening, wherein the liner comprises a material selected from the group consisting of inorganic materials, organic materials, and a combination thereof, wherein the liner comprises a metal or metal alloy.
Item 10. The abrasive article of item 8, wherein the core comprises a liner overlying at least a portion of the surface defining the opening, wherein the liner has a heat capacity greater than a heat capacity of the material of the core, wherein the liner has a heat capacity less than a heat capacity of the material of the core.
Item 11. The abrasive article of item 1, wherein the core consists essentially of the organic material, wherein the organic material comprises a polymer, wherein the organic material comprises a polymeric material selected from the group consisting of an epoxy polymer, a phenoxy polymer, a polyurea, a polyimide, a polycyanate, a polyurethane, a melamine polymer, a polyester, or foamed structures of the same, or any combination thereof.
Item 12. The abrasive article of item 1, wherein the core comprises a linear coefficient of thermal expansion (CTE) of at least about 15 microns/(m ° C.), and not greater than about 70 microns/(m ° C.).
Item 13. The abrasive article of item 1, wherein the organic portion and the inorganic portion are substantially uniformly distributed throughout the volume of the bond material of the first bonded abrasive body, wherein the organic portion and the inorganic portion are substantially uniformly distributed within each other.
Item 14. The abrasive article of item 1, wherein the inorganic portion of the bond material comprises a metal material, wherein the metal material comprises a transition metal element, wherein the metal material comprises a metal selected from the group consisting of copper, tin, silver, chromium, titanium, vanadium, manganese, iron, cobalt, nickel, zinc, gold, molybdenum, zirconium, tungsten, yttrium, tantalum, aluminum, and a combination thereof.
Item 15. The abrasive article of item 14, wherein the metal material of the bond material comprises a combination of copper and tin, wherein the metal material comprises a bronze, wherein the metal material comprises a greater content of copper than tin, wherein the bond material comprises a ratio of copper:tin of approximately 60:40 by weight.
Item 16. The abrasive article of item 1, wherein the organic portion of the bond material comprises a polymer, wherein the polymer comprises a material selected from the group of materials consisting of thermosets, thermoplastics, and a combination thereof, wherein the polymer comprises a material selected from the group of materials consisting of polyimides, polyamides, resins, aramids, epoxies, polyesters, polyurethanes, and a combination thereof, wherein the polymer material comprises polyarenazole, wherein the polymer material comprises polybenzimidazole (PBI), wherein the polymer material comprises phenolic resin.
Item 17. The abrasive article of item 1, wherein the bond material comprises a greater content of the inorganic portion (vol %) as compared to a content of the organic portion (vol %) within the bond, wherein the bond material comprises a greater content of the organic portion (vol %) as compared to a content of the inorganic portion (vol %) within the bond.
Item 18. The abrasive article of item 1, wherein the bond material comprises a minority content of the organic portion, wherein the bond material comprises not greater than about 40 vol % organic portion for the total volume of the bond, not greater than about 35 vol %, not greater than about 30 vol %, not greater than about 25 vol %, not greater than about 20 vol %, and at least about 1 vol % organic portion for the total volume of the bond.
Item 19. The abrasive article of item 1, wherein the bond material comprises a minority content of the inorganic portion for the total content of the bond, wherein the bond material comprises a majority content of the inorganic portion for the total content of the bond, wherein the bond material comprises at least about 10 vol % inorganic portion for the total volume of the bond, at least about 15 vol %, at least about 20 vol %, at least about 25 vol %, at least about 30 vol %, at least about 35 vol %, at least about 40 vol %, at least about 45 vol %, at least about 50 vol %, and not greater than about 99 vol %, not greater than about 96 vol %, not greater than about 94 vol % inorganic material for the total volume of the bond.
Item 20. The abrasive article of item 1, wherein the first bonded abrasive body comprises at least about 5 vol % bond material for the total volume of the body, at least about 10 vol %, at least about 20 vol %, and not greater than about 90 vol %.
Item 21. The abrasive article of item 1, wherein the first bonded abrasive body comprises porosity, wherein the first bonded abrasive body comprises a majority content of porosity (vol %) for the total volume of the first bonded abrasive body, wherein the first bonded abrasive body comprises a minority content of porosity (vol %) for the total volume of the first bonded abrasive body.
Item 22. The abrasive article of item 21, wherein the porosity comprises a majority content of closed porosity, wherein the porosity comprises a majority content of open porosity.
Item 23. The abrasive article of item 1, wherein the first bonded abrasive body comprises a content of porosity of not greater than about 70 vol % for the total volume of the body, not greater than about 60 vol %, not greater than about 50 vol %, not greater than about 40 vol %, not greater than about 30 vol %, not greater than about 25 vol %, not greater than about 20 vol %, not greater than about 15 vol %, not greater than about 10 vol %, not greater than about 5 vol %, not greater than about 2 vol %.
Item 24. The abrasive article of item 1, wherein the first bonded abrasive body comprises at least about 5 vol % abrasive particles for the total volume of the body, at least about 10 vol %, at least about 15 vol %, and not greater than about 75 vol %.
Item 25. The abrasive article of item 1, wherein the abrasive particles comprise a material selected from the group consisting of oxides, carbides, nitrides, borides, oxycarbides, oxynitrides, and a combination thereof, wherein the abrasive particles comprise a superabrasive material, wherein the abrasive particles comprise a material selected from the group consisting of alumina, silica, silicon carbide, boron nitride, diamond, and a combination thereof, wherein the abrasive particles consist essentially of diamond.
Item 26. The abrasive article of item 1, wherein the first bonded abrasive body comprises a filler contained in a bond material, wherein the filler comprises a pore former, wherein the filler comprises a material selected from the group consisting of glass, glass-ceramic, ceramic, organic, and a combination thereof, wherein the filler comprises a material selected from the group consisting of bubble alumina, bubble mullite, hollow spheres, hollow glass spheres, hollow ceramic spheres, hollow polymer spheres, polymer materials, organic compounds, fibrous materials, naphthalene, PDB, shells, wood, and the like, wherein the filler comprises a material selected from the group of materials consisting of zirconia, silica, titania, and a combination thereof.
Item 27. The abrasive article of item 1, wherein the first bonded abrasive body comprises a minor content of filler (vol %) for the total volume of the body.
Item 28. The abrasive article of item 1, wherein the first bonded abrasive body is coupled to at least one of a first major surface of the core, a second major surface of the core, a peripheral surface of the core defining the circumference, wherein the first bonded abrasive body is positioned proximate to the peripheral surface of the core, wherein the first bonded abrasive body is abutting the peripheral surface of the core, wherein the first bonded abrasive body extends radially from a surface of the core, wherein the first bonded abrasive body extends axially from a surface of the core.
Item 29. The abrasive article of item 1, wherein the first bonded abrasive body comprises an annular shape, wherein the first bonded abrasive body extends around at least a portion of a peripheral surface of the core defining a circumference of the core, wherein the first bonded abrasive body extends entirely around a peripheral surface of the core defining a circumference of the core.
Item 30. The abrasive article of item 1, further comprising a second bonded abrasive body coupled to the core, wherein the second bonded abrasive body is adjacent the first bonded abrasive body, wherein the first bonded abrasive is abutting the second bonded abrasive body, wherein the first and second bonded abrasive bodies are coupled to a peripheral surface of the core defining a circumference of the core, wherein the first and second bonded abrasive bodies are oriented in a coaxial relationship relative to the core.
Item 31. The abrasive article of item 30, wherein the second bonded abrasive body comprises abrasive particles contained in a bond material, wherein the bond material of the second bonded abrasive body is a same composition as the bond material of the first bonded abrasive body.
Item 32. A method of forming an abrasive article, the method comprising:
preparing a preform comprising an abrasive article;
forming a mixture comprising a thermoset;
pouring the mixture into the preform; and
curing the mixture to form the core on the abrasive article, wherein the curing comprises a phase change of a liquid phase to a solid phase, the core having a cylindrical shape defined by a diameter (d), a circumference (C), and a height (h), wherein the height is at least about 3 inches (7.6 cm).
Item 33. The method of item 32, wherein curing the mixture includes curing by heating.
Item 34. The method of item 32, wherein curing the mixture includes a first heating of the mixture at a first temperature T1.
Item 35. The method of item 34, wherein the first heating includes a first duration.
Item 36. The method of item 35, wherein the first duration is at least about one hour.
Item 37. The method of item 34, further including a second heating of the mixture at a second temperature T2, wherein the second temperature T2 is different from the first temperature T1.
Item 38. The method of item 37, wherein the second heating includes a second duration.
Item 39. The method of item 38, wherein the second duration is substantially the same than the first duration.
Item 40. The method of item 37, wherein the second temperature T2 and the first temperature T1 are different from each other by a first temperature difference, defined by |T2-T1|, the first temperature difference having an absolute value of not greater than about 50° C., such as not greater than about 45° C., or not greater than about 40° C.
Item 41. The method of item 37, wherein the first heating and the second heating have a total duration of at least about four hours, such as at least about six hours, or at least about eight hours.
Item 42. The method of item 37, further including a third heating of the mixture at a third temperature T3, the third temperature T3 being different from the second temperature T2.
Item 43. The method of item 42, wherein the third heating includes a third duration, wherein the third duration is different from the second duration.
Item 44. The method of item 43, wherein the third duration is substantially the same than the second duration.
Item 45. The method of item 42, wherein the third temperature T3 and the second temperature T2 are different from each other by a second temperature difference, defined by |T3-T2|, the second temperature difference having an absolute value of not greater than about 40° C., such as not greater than about 35° C., or not greater than about 30° C.
Item 46. The method of item 42, wherein the first heating, the second heating, and the third heating have a total duration of at least about six hours, such as at least about eight hours, or at least about twelve hours.
Item 47. The method of item 42, further including a fourth heating of the mixture at a fourth temperature T4, the fourth temperature T4 being different from the third temperature T3.
Item 48. The method of item 47, wherein the fourth heating includes a fourth duration, wherein the fourth duration is different from the third duration.
Item 49. The method of item 48, wherein the fourth duration is substantially the same than the third duration.
Item 50. The method of item 47, wherein the fourth temperature T4 and the third temperature T3 are different from each other by a third temperature difference, defined by |T4-T3|, the third temperature difference having an absolute value of not greater than about 60° C., such as not greater than about 55° C., or not greater than about 50° C.
Item 51. The method of item 47, wherein the first heating, the second heating, the third heating, and the fourth heating have a total duration of at least about eight hours, such as at least about ten hours, or at least about 14 hours.
Item 52. The method of item 32, wherein the mixture includes a curing agent.
Item 53. The method of item 52, wherein the curing agent is selected from the group consisting of an oligoamine, a diol, a dithiol, an amino alcohol, an amino thiol, a thioalcohol, and any combination thereof.
Item 54. The method of item 53, wherein the oligoamine is selected from the group consisting of an aliphatic oligoamine, a cycloaliphatic oligoamine, and an aromatic oligoamine, and a combination thereof.
Item 55. The method of item 54, wherein the aliphatic oligoamine is selected from the group consisting of ethylene diamine, 2-methyl-1,5-pentamethylenediamine, 1,6-hexamethylenediamine, 1,3-pentanediamine, (2-aminoethyl)-1,2-ethanediamine (DETA), N,N′-bis-(2-aminoethyl)-1,2-ethanediamine) (TETA), tris-(2-aminoethyl)amine) (TAEA), bis-(aminoethyl)ether, a polyether diamine, tetraethylenepentamine (TEPA), and a combination thereof.
Item 56. The method of item 54, wherein the cycloaliphatic oligoamine is selected from the group consisting of 1,2-diaminocyclohexane, N[(2-aminoethyl)2-aminoethyl]piperazine) (PEEDA), isophorone diamine (IPDA), 4,4′-bis-(aminocyclohexyl)-methane, N,N′-bis-(2-aminoethyl)piperazine) (DAEP), and a combination thereof.
Item 57. The method of item 54, wherein the aromatic oligoamine is selected from the group of 2-ethyl, 2 methyl-imidazole, 4,4′-diaminodiphenyl-methane, 4,4′-diaminodiphenylether, 1,3-Bis(3-aminophenoxy) benzene, an aminobenzylamine, and a combination thereof.
Item 58. The method of item 32, wherein the mixture includes an epoxy resin and the curing agent includes an oligoamine.
Item 59. The method of item 58, wherein the epoxy resin includes a bisphenol-A diglycidyl ether and the curing agent includes a isophorone diamine.
Item 60. The method of item 58, wherein the epoxy resin consists essentially of a bisphenol-A diglycidyl ether and the curing agent consists essentially of a isophorone diamine.
Item 61. The method of item 32, wherein curing comprises conducting a first curing process of at least about 2 hours and not greater than about 4 hours at a first temperature of not greater than about 50° C.
Item 62. The method of item 61, wherein curing comprises conducting a second curing process after the first curing process, wherein the second curing process is at least about 2 hours and not greater than about 4 hours at a second temperature of greater than about 50° C. and not greater than about 100° C.
Item 63. The method of item 62, wherein curing comprises conducting a third curing process after the second curing process, wherein the third curing process is at least about 2 hours and not greater than about 4 hours at a second temperature of greater than about 70° C. and not greater than about 150° C.
Item 64. The method of item 32, further comprising placing an liner in the preform, pouring comprises pouring the mixture into the preform around the liner, and then removing the liner prior to curing, wherein the liner is configured to define an arbor hole in the core.
Item 65. The method of item 64, wherein the liner comprises an inorganic material, wherein the liner comprises a metal, wherein the liner comprises a material selected from the group consisting of aluminum, silicon, steel, carbon fiber, and a combination thereof.
Item 66. The method of item 32, further comprising cooling at least a portion of the mixture during curing to control heat transferred from the mixture to the abrasive article.
Item 67. The method of item 32, further comprising providing an atmosphere having a pressure lower than standard atmospheric pressure prior to curing.
Item 68. An abrasive article, comprising:
a first bonded abrasive body comprising:
a bond material comprising a hybrid material including an inorganic portion and an organic portion; and
abrasive particles contained within the bond material; and
a core comprising an organic material and bonded to the first bonded abrasive body, the core having a monolithic body including a cylindrical shaped defined by a diameter (d), a circumference (C), and a height (h), wherein the height is at least about 3 inches (7.6 cm);
wherein the core comprises at least one filler selected from the group consisting of oxides, carbides, borides, silicides, nitrides, fluorides, oxynitrides, oxycarbides, silicates, metal-hydrate compounds, hydrated oxide compounds, carbonates, phosphates, minerals, feldspar, nepheline syenite, chromites, magnesites, dolomites, pyrites, sulfides, carbon-based materials, graphite, sulfides, silicon, metal, metal alloys, inter-metallics, ceramics, hollow-ceramics, fused silica, glass, glass-ceramics, hollow glass spheres, glass fibers, polymers, polyimides, polyamides, resins, aramids, epoxies, polyesters, polyurethanes, acetates, celluloses, ethers, ethanol, wood flour, clay, talc, and a combination thereof.
Item 69. The abrasive article of item 68, wherein the core comprises at least two filler materials selected from the group consisting of oxides, carbides, borides, silicides, nitrides, oxynitrides, oxycarbides, silicates, graphite, metal-hydrate compounds, hydrated oxide compounds, carbonates, phosphates, silicon, metal, metal alloys, inter-metallics, ceramics, hollow-ceramics, fused silica, glass, glass-ceramics, hollow glass spheres, glass fibers, polymers, polyimides, polyamides, resins, aramids, epoxies, polyesters, polyurethanes, acetates, celluloses, ethers, ethanol, and a combination thereof.
Item 70. The abrasive article of item 68, wherein the core comprises a first filler material and a second filler material, wherein the first filler material is different than the second filler material by at least one of composition, average particle size, content, and a combination thereof, wherein the core comprises a first filler material comprising an inorganic material and a second filler material comprising an organic material.
Item 71. The abrasive article of item 68, wherein the core comprises a first filler material comprising an oxide.
Item 72. The abrasive article of item 68, wherein the core comprises a first filler material comprising alumina.
Item 73. The abrasive article of item 68, wherein the core comprises a first filler consisting essentially of fused alumina.
Item 74. The abrasive article of item 68, wherein the core comprises a second filler material comprising an organic material including a hydroxyl group.
Item 75. The abrasive article of item 68, wherein the core comprises a second filler material comprising ethanol.
Item 76. The abrasive article of item 68, wherein the core comprises a second filler material comprising phosphate.
Item 77. The abrasive article of item 68, wherein the core comprises a second filler material comprising ethanol and phosphate, wherein the core comprises a second filler material comprising ethanol, 2 chloro-phosphate (3:1), wherein the core comprises a second filler material consisting essentially of ethanol, 2 chloro-phosphate (3:1).
Item 78. The abrasive article of item 68, wherein the core comprises a first filler material and a second filler material, wherein the core comprises a greater content of the first filler material compared to a content of the second filler material, wherein the core comprises a greater content of the second filler material compared to a content of the first filler material
Item 79. The abrasive article of item 68, wherein the core comprises a ratio (V1N2) of at least about 1, wherein V1 represents a content of a first filler (vol %) within the core and V2 represents a content of a second filler (vol %) within the core, wherein the ratio (V1/V2) is at least about 1.1, at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, at least about 30, and wherein the ratio (V1/V2) is not greater than about 30, not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, not greater than about 2.
Item 80. The abrasive article of item 68, wherein the core comprises a ratio (V2/V1) of at least about 1, wherein V1 represents a content of a first filler (vol %) within the core and V2 represents a content of a second filler (vol %) within the core, wherein the ratio (V2/V1) is at least about 1.1, at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, at least about 30, and wherein the ratio (V2/V1) is not greater than about 30, not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, not greater than about 2.
Item 81. The abrasive article of item 68, wherein the core comprises a first filler material, and wherein the core comprises at least about 0.5 vol % of the first filler for a total volume of the core, at least about 1 vol %, at least about 1.5 vol %, at least about 2 vol %, at least about 5 vol %, at least about 8 vol %, at least about 10 vol %, at least about 12 vol %, at least about 15 vol %, and not greater than about 50 vol %, not greater than about 40 vol %, not greater than about 30 vol %, not greater than about 25 vol %, not greater than about 20 vol %, not greater than about 15 vol %, not greater than about 10 vol %, not greater than about 8 vol %, not greater than about 5 vol %, not greater than about 4 vol %, not greater than about 3 vol %, not greater than about 2 vol %.
Item 82. The abrasive article of item 68, wherein the core comprises a second filler material, and wherein the core comprises at least about 0.5 vol % of the second filler for a total volume of the core, at least about 1 vol %, at least about 1.5 vol %, at least about 2 vol %, at least about 5 vol %, at least about 8 vol %, at least about 10 vol %, at least about 12 vol %, at least about 15 vol %, and not greater than about 50 vol %, not greater than about 40 vol %, not greater than about 30 vol %, not greater than about 25 vol %, not greater than about 20 vol %, not greater than about 15 vol %, not greater than about 10 vol %, not greater than about 8 vol %, not greater than about 5 vol %, not greater than about 4 vol %, not greater than about 3 vol %, not greater than about 2 vol %.
Item 83. The abrasive article of item 68, wherein the core comprises a third filler material in addition to at least a first filler material, wherein the third filler material is different than the first filler material by at least one of composition, average particle size, content, and a combination thereof.
Item 84. The abrasive article of item 68, wherein the core comprises a third filler material in addition to at least a second filler material, wherein the third filler material is different than the second filler material by at least one of composition, average particle size, content, and a combination thereof.
Item 85. The abrasive article of item 68, wherein the core comprises a first filler material comprising an inorganic material and a third filler material comprising an inorganic material, wherein the first filler material comprises an oxide, wherein the third filler material comprises an oxide, wherein the first filler material comprises at least one metallic element different than the third filler material.
Item 86. The abrasive article of item 68, wherein the core comprises a third filler comprising iron, wherein the third filler material comprises iron oxide, wherein the third filler material comprises a mineral, wherein the third filler material comprises magnetite (Fe3O4), wherein the third filler material consists essentially of magnetite, wherein the third filler comprises black oxide.
Item 87. The abrasive article of item 68, wherein the core comprises a first filler material and a third filler material, wherein the core comprises a greater content of the first filler material compared to a content of the third filler material, wherein the core comprises a greater content of the third filler material compared to a content of the first filler material.
Item 88. The abrasive article of item 68, wherein the core comprises a ratio (V1/V3) of at least about 1, wherein V1 represents a content of a first filler (vol %) within the core and V3 represents a content of a third filler (vol %) within the core, wherein the ratio (V1/V3) is at least about 1.1, at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, at least about 30, and wherein the ratio (V1/V3) is not greater than about 30, not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, not greater than about 2.
Item 89. The abrasive article of item 68, wherein the core comprises a ratio (V3/V1) of at least about 1, wherein V1 represents a content of a first filler (vol %) within the core and V3 represents a content of a third filler (vol %) within the core, wherein the ratio (V3/V1) is at least about 1.1, at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, at least about 30, and wherein the ratio (V3/V1) is not greater than about 30, not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, not greater than about 2.
Item 90. The abrasive article of item 68, wherein the core comprises a ratio (V2/V3) of at least about 1, wherein V2 represents a content of a second filler (vol %) within the core and V3 represents a content of a third filler (vol %) within the core, wherein the ratio (V2/V3) is at least about 1.1, at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, at least about 30, and wherein the ratio (V2/V3) is not greater than about 30, not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, not greater than about 2.
Item 91. The abrasive article of item 68, wherein the core comprises a ratio (V3/V2) of at least about 1, wherein V2 represents a content of a second filler (vol %) within the core and V3 represents a content of a third filler (vol %) within the core, wherein the ratio (V3/V2) is at least about 1.1, at least about 1.2, at least about 2, at least about 3, at least about 4, at least about 5, at least about 10, at least about 20, at least about 30, and wherein the ratio (V3/V2) is not greater than about 30, not greater than about 20, not greater than about 15, not greater than about 10, not greater than about 5, not greater than about 4, not greater than about 3, not greater than about 2.
Item 92. The abrasive article of item 68, wherein the core comprises a third filler material, and wherein the core comprises at least about 0.5 vol % of the third filler for a total volume of the core, at least about 1 vol %, at least about 1.5 vol %, at least about 2 vol %, at least about 5 vol %, at least about 8 vol %, at least about 10 vol %, at least about 12 vol %, at least about 15 vol %, and not greater than about 50 vol %, not greater than about 40 vol %, not greater than about 30 vol %, not greater than about 25 vol %, not greater than about 20 vol %, not greater than about 15 vol %, not greater than about 10 vol %, not greater than about 8 vol %, not greater than about 5 vol %, not greater than about 4 vol %, not greater than about 3 vol %, not greater than about 2 vol %.
Item 93. The abrasive article of item 68, wherein the core comprises a first filler material having a first average particle size and a second filler material having a second average particle size, wherein the first average particle size is different than the second average particle size, wherein the first average particle size is greater than the second average particle size, wherein the second average particle size is greater than the first average particle size.
Item 94. The abrasive article of item 68, wherein the core comprises a first filler material having a first average particle size and a third filler material having a third average particle size, wherein the first average particle size is different than the third average particle size, wherein the first average particle size is greater than the third average particle size, wherein the third average particle size is greater than the first average particle size.
Item 95. The abrasive article of item 68, wherein the core comprises a second filler material having a second average particle size and a third filler material having a third average particle size, wherein the second average particle size is different than the third average particle size, wherein the second average particle size is greater than the third average particle size, wherein the third average particle size is greater than the second average particle size.
Item 96. The abrasive article of item 68, wherein the first bonded abrasive body is integrally bonded directly to the core.
Item 97. The abrasive article of item 68, wherein the core comprises an epoxy, wherein the mixture includes an epoxy resin and the curing agent includes an oligoamine, wherein the epoxy resin includes a bisphenol-A diglycidyl ether and the curing agent includes a isophorone diamine.
Item 98. The abrasive article of item 68, wherein the inorganic portion of the bond material comprises a metal material, wherein the metal material comprises a transition metal element, wherein the metal material comprises a metal selected from the group consisting of copper, tin, silver, chromium, titanium, vanadium, manganese, iron, cobalt, nickel, zinc, gold, molybdenum, zirconium, tungsten, yttrium, tantalum, aluminum, and a combination thereof, wherein the metal material of the bond material comprises a combination of copper and tin, wherein the metal material comprises a bronze, wherein the metal material comprises a greater content of copper than tin, wherein the bond material comprises a ratio of copper:tin of approximately 60:40 by weight.
Item 99. The abrasive article of item 68, wherein the organic portion of the bond material comprises a polymer, wherein the polymer comprises a material selected from the group of materials consisting of thermosets, thermoplastics, and a combination thereof, wherein the polymer comprises a material selected from the group of materials consisting of polyimides, polyamides, resins, aramids, epoxies, polyesters, polyurethanes, and a combination thereof, wherein the polymer material comprises polyarenazole, wherein the polymer material comprises polybenzimidazole (PBI), wherein the polymer material comprises phenolic resin.
Item 100. The abrasive article of item 68, wherein the bond material comprises a greater content of the inorganic portion (vol %) as compared to a content of the organic portion (vol %) within the bond material, wherein the bond material comprises a greater content of the organic portion (vol %) as compared to a content of the inorganic portion (vol %) within the bond.
Item 101. The abrasive article of item 68, wherein the core contains an amount of uncured epoxy of at least about 0.1 vol % for a total volume of the core, at least about 0.5 vol %, at least about 1 vol %, at least about 2 vol %, at least about 5 vol %, and not greater than about 30 vol %, not greater than about 20 vol %, not greater than about 10 vol %, not greater than about 5 vol %, not greater than about 2 vol %.
Item 102. The abrasive article of item 68, wherein the core comprises a material with a Tg of at least about 75° C., at least about 80° C. at least about 90° C., at least about 100° C., at least about 110° C., at least about 120° C., and not greater than about 170° C., not greater than about 160° C., not greater than about 150° C., not greater than about 140° C., not greater than about 130° C.
Item 103. The abrasive article of item 68, wherein the core comprises a material with a CTE of at least about 25 μm/m° C., at least about 28 μm/m° C., at least about 30 μm/m° C., at least about 33 μm/m° C., at least about 35 μm/m° C., at least about 37 μm/m° C., at least about 40 μm/m° C., at least about 43 μm/m° C., at least about 45 μm/m° C., at least about 48 μm/m° C., at least about 50 μm/m° C., at least about 53 μm/m° C., and not greater than about 200 μm/m° C., not greater than about 180 μm/m° C., not greater than about 160 μm/m° C., not greater than about 150 μm/m° C., not greater than about 125 μm/m° C., not greater than about 100 μm/m° C., not greater than about 80 μm/m° C.
Item 104. The abrasive article of item 68, wherein the core comprises a linear coefficient of thermal expansion (CTEba) and the bonded abrasive body comprises a linear coefficient of thermal expansion (CTEc), and wherein the core and the bonded abrasive body comprise a difference in the coefficients of thermal expansion (ΔCTE) defined by the equation [(CTEba−CTEc)/CTEba]×100% of not greater than about 30%, not greater than about 20%, not greater than about 18%, not greater than about 12%, not greater than about 5%.
Item 105. The abrasive article of item 68, wherein the core further comprises at least one reinforcing structure, wherein the reinforcing structure comprises a substantially planar layer of material, wherein the reinforcing structure comprises a material selected from the group consisting of an inorganic material, an organic material, and a combination thereof, wherein the reinforcing structure comprises a woven material, wherein the reinforcing structure comprises a non-woven material, wherein the reinforcing structure comprises a composite material.
Item 106. The abrasive article of item 68, wherein the core comprises a porosity of not greater than about 15 vol % for a total volume of the core.
Item 107. The abrasive article of item 68, wherein the filler comprises a particulate material having a density of not greater than about 4.0 g/cm3.
Item 108. The abrasive article of item 68, wherein the core comprises a density of at least about 0.8 g/cc and not greater than about 2.8 g/cc.
This application claims priority under 35 U.S.C. §119(e) to U.S. Patent Application No. 61/747,994 entitled “ABRASIVE ARTICLE HAVING A CORE OF AN ORGANIC MATERIAL AND A BONDED ABRASIVE BODY COMPRISING A HYBRID BOND,” by Sivasubramanian et al., filed Dec. 31, 2012, which is assigned to the current assignee hereof and incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61747994 | Dec 2012 | US |
