Patent Application
20240300070
The following is directed to an abrasive article, and particularly, to a bonded abrasive article with an abrasive body a reinforcing member disposed with in the body and a bond material that includes an organic material.
Bonded abrasive articles, such as abrasive wheels, can be used for cutting, grinding, or shaping various materials. The industry continues to demand improved bonded abrasive articles having a low wear, high edge stability and extended lifetime.
The following description in combination with the figures is provided to assist in understanding the teachings provided herein. The following disclosure will focus on specific implementations and embodiments of the teachings. This focus is provided to assist in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.
As used herein, the terms “comprises,” “comprising,” “includes,” “including, “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent that certain details regarding specific materials and processing acts are not described, such details may include conventional approaches, which may be found in reference books and other sources within the manufacturing arts.
Embodiments disclosed herein are directed to abrasive articles including a body including a bond material, and abrasive particles contained within the bond material. The abrasive body can also include a reinforced web within the bond material. The bond material can include a bulk molding compound.
The abrasive articles described in embodiments herein can be suitable for conducting material removal operations on various types of workpieces, including, for example, but not limited to, metal, glass, etc.
In an embodiment, the mixture may include abrasive particles that may facilitate improved manufacturing and/or performance of the abrasive article. In a particular embodiment, the abrasive particles may include oxides, carbides, nitrides, borides, super-abrasives, or any combination thereof. In another embodiment, the abrasive particles may include a vitreous phase, a polycrystalline phase, or any combination thereof. In yet another embodiment, the abrasive particles may include a shaped abrasive particle, constant thickness abrasive particle, randomly shaped abrasive particle, agglomerates including binder and abrasive particles, a blend of different types of abrasive particles having at least one different abrasive characteristic, or any combination thereof. In an embodiment, the abrasive particles may include sol gel alumina.
In an embodiment, the mixture may include abrasive particles of a particular size that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive particles may have an average size of not greater than 3 microns, or not greater than 2 microns, or not greater than 1 micron, or not greater than 0.5 microns. In another embodiment, the abrasive particles may have an average size of at least 0.1 microns, or at least 0.2 microns, or at least 0.3 microns, or at least 0.4 microns. It will be appreciated that the average size of the abrasive particles may be within a range including any of the minimum and maximum amounts noted above, including, for example, but not limited to, at least 0.1 microns and not greater than 3 microns, at least 0.3 microns and not greater than 2 microns, or at least 0.4 microns and not greater than 0.5 microns.
In an embodiment, the mixture may include abrasive particles with a particular Mohs hardness that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive particles may have a Mohs hardness of not greater than 16, or not greater than 14, or not greater than 12. In another embodiment, the abrasive particles may have a Mohs hardness of at least 7, or at least 8, or at least 9. It will be appreciated that the Mohs hardness the abrasive particles may be within a range including any of the minimum and maximum amounts noted above, including for example, but not limited to, at least 7 and not greater than 16, at least 8 and not greater than 14, or at least 9 and not greater than 12.
In an embodiment, the mixture may include a particular content of abrasive particles that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the mixture may include at least 3 vol % abrasive particles for a total volume of the mixture, or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %. In an alternate embodiment, the mixture may include includes not greater than 85 vol % abrasive particles for a total volume of the mixture, or not greater than 80 vol %, or not greater than 75 vol %, or not greater than 70 vol %, or not greater than 65 vol %, or not greater than 60 vol %, or not greater than 55 vol %, or not greater than 50 vol %, or not greater than 45 vol %, or not greater than 40 vol %, or not greater than 35 vol %, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol % or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %. It will be appreciated that the vol % may be within a range including any of the minimum and maximum amounts noted above, including for example, but not limited to, at least 10 vol % and not greater than 70 vol %, or at least 20 vol % and not greater than 60 vol %, or at least 35 vol % and not greater than 50 vol %. In a preferred embodiment, the mixture may include at least 38 vol % and not greater than 44 vol % abrasive particles.
In an embodiment, the mixture may include a particular content of bond material that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the mixture may include at least 3 vol % bond material for a total volume of the mixture, or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 38%, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %. In an alternate embodiment, the mixture may include includes not greater than 85 vol % bond for a total volume of the mixture, or not greater than 80 vol %, or not greater than 75 vol %, or not greater than 70 vol %, or not greater than 65 vol %, or not greater than 60 vol %, or not greater than 55 vol %, or not greater than 50 vol %, or not greater than 45 vol %, or not greater than 48%, or not greater than 40 vol %, or not greater than 35 vol %, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol %, or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %. It will be appreciated that the vol % may be within a range including any of the minimum and maximum amounts noted above, including, for example, but not limited to, at least 20 vol % and not greater than 45 vol %.
In an embodiment, the bond material may include particular materials that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the bond material may include a bulk molding compound. In an embodiment, the bond material may include a thermoset polymer, a thermoplastic polymer, or a combination thereof. In a specific embodiment, the thermoset polymer may include a polyester resin, a vinyl ester resin, an epoxy resin, or any combination thereof. In an embodiment, the bond material may include a phenol-formaldehyde resin. In an embodiment, the bond material may include a novolac resin.
In an embodiment, the mixture may include a particular content of thermoset polymer that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the mixture may include at least 3 vol % thermoset polymer for a total volume of the mixture, or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 38%, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %. In an alternate embodiment, the mixture may include includes not greater than 85 vol % thermoset polymer for a total volume of the mixture, or not greater than 80 vol %, or not greater than 75 vol %, or not greater than 70 vol %, or not greater than 65 vol %, or not greater than 60 vol %, or not greater than 55 vol %, or not greater than 50 vol %, or not greater than 45 vol %, or not greater than 48%, or not greater than 40 vol %, or not greater than 35 vol %, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol %, or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %. It will be appreciated that the vol % may be within a range including any of the minimum and maximum amounts noted above, including, for example, but not limited to, at least 20 vol % and not greater than 45 vol %.
In an embodiment, the mixture may include other additives, including, for example, fibers, pore formers, fillers, etc. In an embodiment, the fillers can include potassium aluminum fluoride.
In an embodiment, the mixture may include a particular content of filler that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the mixture may include at least 5 vol % thermoset polymer, or at least 8 vol %, or at least 10 vol %, or at least 12 vol %, or at least 15 vol %. In an embodiment, the mixture may include not greater than 35 vol % filler, or not greater than 32%, or not greater than 30%, or not greater than 25%. It will be appreciated that the vol % of filler in the mixture may be within a range between any of the minimum and maximum values noted above, including, for example, but not limited to, at least 5 vol % and not greater than 35 vol %, or at least 12 vol % and not greater than 30 vol %.
In some embodiments, the mixture may include an additive such as fibers. In certain embodiments, the fibers may include glass. In some embodiments, the fibers can include chopped strand fibers. In some embodiments, the fibers may be uniformly distributed throughout the volume of the bond material.
In an embodiment, the mixture may include a particular content of fibers that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the mixture may include at least 1 vol % fibers, at least 2 vol %, at least 3 vol %, at least 4 vol %, or at least 5 vol %. In an embodiment, the mixture may include not greater than 20 vol % fibers, or not greater than 19 vol %, not greater than 18 vol %, not greater than 17 vol %, not greater than 16 vol %, or not greater than 15 vol %. It will be appreciated that the vol % of fibers in the mixture may be within a range between any of the minimum and maximum values noted above, including, for example, but not limited to, at least 1 vol % and not greater than 20 vol %, or at least 5 vol % and not greater than 15 vol %.
In an embodiment, the mixture may include fibers of a particular size that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the fibers may have an average length of at least 0.02 inches, or at least 0.04 inches, or at least 0.06 inches, or at least 0.08 inches, or at least 0.1 inch. In another embodiment, the fibers may have an average length of not greater than 0.15 inches, or not greater 0.18 inches, or not greater than 0.2 inches, or not greater than 0.22 inches, or not greater than 0.25 inches. It will be appreciated that the average length of the fibers may be between any of the minimum and maximum values listed above, including, for example, but not limited to, at least 0.02 inches and bot greater than 0.25 inches, or at least 0.08 inches and not greater than 0.2 inches, or at least 0.1 inch and not greater than 0.15 inches.
In an embodiment, the mixture may include fibers of a particular linear density that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the fibers may have a linear density of at least 20 TEX, or at least 22 TEX, or at least 24 TEX, or at least 26 TEX, or at least 28 TEX, or at least 30 TEX. In an embodiment, the fibers may have a linear density of not greater than 35 TEX, not greater than 37 TEX, not greater than 40 TEX, not greater than 42 TEX, or not greater than 45 TEX. It will be appreciated that the average linear density of the fibers may be between any of the minimum and maximum values listed above, including, for example, but not limited to, at least 20 TEX and bot greater than 45 TEX.
In an embodiment, the bond material and abrasive particles may be mixed under particular mixing conditions that may facilitate improved manufacturing and/or performance of the abrasive article. For example, in an embodiment, the mixture is formed at a particular rate to suitably distribute the abrasive particles, the bond material, and any other additives contained within the mixture. In an embodiment, the mixture may be mixed using double planetary mixing. In an embodiment, the mixing may be low shear mixing.
In an embodiment, mixing may occur for a particular duration that may suitably distribute the bond material, abrasive particles, and any other additives contained within the mixture. For example, in an embodiment, the mixing may occur for at least 5 minutes, at least 7, at least 9 minutes, at least 11 minutes, at least 13 minutes, or at least 15 minutes. In another embodiment, mixing may occur for not greater than 30 minutes, not greater than 35 minutes, not greater than 40 minutes, or not greater than 45 minutes. It will be appreciated that mixing may occur In an embodiment, mixing may occur at particular temperatures that facilitate improved manufacturing and/or performance of the abrasive article. For example, in an embodiment, the mixing may occur at a temperature of not greater than 85° C., not greater than 87° C., not greater than 90° C., not greater than 92° C., or not greater than 95° C.
After forming the mixture in step 101, the process may continue at step 102 by shaping the mixture. In an embodiment, the shaping process may include forming a body via a mold or production tool. In an embodiment, shaping the mixture can include warm pressing. In certain embodiments, warm pressing may be used to shape the mixture into a green body, which may be converted into an abrasive article through further processing. In alternative embodiments, warm pressing may be used to shape the mixture into a finally formed abrasive body. Without wishing to be tied to a particular theory, it is thought that warm pressing the mixture may facilitate improved manufacturing and/or performance of the abrasive article.
In an embodiment, warm pressing may occur at particular temperatures that facilitate improved manufacturing and/or performance of the abrasive article. For example, in an embodiment, the warm pressing may occur at a temperature of not greater than 100° C., not greater than 95° C., not greater than 90° C., not greater than 85° C., not greater than 80° C., not greater than 75° C., or not greater than 70° C., or not greater than 65° C., or not greater than 60° C., or not greater than 55° C., or not greater 50° C. In another embodiment, the warm pressing may occur at a temperature of at least 25° C., or at least 30° C., or at least 35° C., or at least 40° C., or at least 45° C. It will be appreciated than the warm pressing may occur at a temperature between any of the minimum and maximum values listed above, including but not limited to, at least 25° C. but not greater than 70° C., at least 30° C. but not greater than 60° C., or at least 40° C. but not greater than 50° C.
In an embodiment, warm pressing may include holding the maximum pressing at a particular pressure to facilitate improved manufacturing and/or performance of the abrasive article. For example, in an embodiment, the maximum pressing force may be at least 1000 psi, or at least 1250 psi, or at least 1500 psi, or at least 1750 psi, or at least 2000 psi. In another embodiment, the maximum pressing force may be not greater than 7360 psi, or not greater than 6500 psi, or not greater than 6000 psi, or not greater than 5500 psi, or not greater than 5000 psi, or not greater than 4908 psi, or not greater than 4250 psi, or not greater than 3700 psi. It will be appreciated that the maximum pressing may occur with a pressure between any of the minimum and maximum values listed above, including but not limited to, at least 1000 psi but not greater than 7360 psi, at least 1500 psi but not greater than 5000 psi, or at least 2000 psi, but not greater than 3700 psi.
In an embodiment, the warm pressing may include uniaxial warm pressing. In another embodiment, warm pressing may include isostatic pressing.
In an embodiment, the green body can include a porosity of not greater than 20 vol % for a total volume of the body or not greater than 15 vol %, or not greater than 12 vol %, or not greater than 10 vol %, or not greater than 8 vol %, or not greater than 5 vol %, or not greater than 3 vol %. In certain embodiments, the green body can include essentially no porosity. In certain embodiments, the green body can include a porosity of at least 0.1 vol %, or at least 0.5 vol %, or at least 1 vol %, or at least 1.5 vol %, or at least 2 vol %. It will be appreciated that the porosity of the abrasive body may be within a range including any of the minimum and maximum amounts noted above, including, for example, but not limited to, at least 0.1 vol % and not greater than 20 vol %, at least 0.5 vol % and not greater than 10 vol %, or at least 1 vol % and not greater than 3 vol %.
In an embodiment, the abrasive body may include abrasive particles that may facilitate improved manufacturing and/or performance of the abrasive article. In a particular embodiment, the abrasive particles can include oxides, carbides, nitrides, borides, super-abrasives, or any combination thereof. In another embodiment, the abrasive particles may include a vitreous phase, a polycrystalline phase, or any combination thereof. In yet another embodiment, the abrasive particles may include a shaped abrasive particle, constant thickness abrasive particle, randomly shaped abrasive particle, agglomerates including binder and abrasive particles, a blend of different types of abrasive particles having at least one different abrasive characteristic or any combination thereof. In a further embodiment, the abrasive particles may include sol gel alumina.
In an embodiment, the abrasive body may include abrasive particles of a particular size that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive particles may have an average size of not greater than 3 microns, or not greater than 2 microns, or not greater than 1 micron, or not greater than 0.5 microns. In another embodiment, the abrasive particles may have an average size of at least 0.1 microns, or at least 0.2 microns, or at least 0.3 microns, or at least 0.4 microns. It will be appreciated that the average size of the abrasive particles may be within a range including any of the minimum and maximum amounts noted above, including, for example, but not limited to, at least 0.1 microns and not greater than 3 microns, at least 0.3 microns and not greater than 2 microns, or at least 0.4 microns and not greater than 0.5 microns.
In an embodiment, the abrasive body may include abrasive particles with a particular Mohs hardness that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive particles may have a Mohs hardness of not greater than 16, or not greater than 14, or not greater than 12. In another embodiment, the abrasive particles may have a Mohs hardness of at least 7, or at least 8, or at least 9. It will be appreciated that the Mohs hardness of the abrasive particles may be within a range including any of the minimum and maximum amounts noted above, including for example, but not limited to, at least 7 and not greater than 16, at least 8 and not greater than 14, or at least 9 and not greater than 12.
In an embodiment, the abrasive body may include a particular content of abrasive particles that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive body may include at least 3 vol % abrasive particles for a total volume of the abrasive body, or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 38 vol %, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %. In an alternate embodiment, the abrasive article may include includes not greater than 85 vol % abrasive particles for a total volume of the abrasive body, or not greater than 80 vol %, or not greater than 75 vol %, or not greater than 70 vol %, or not greater than 65 vol %, or not greater than 60 vol %, or not greater than 55 vol %, or not greater than 50 vol %, or not greater than 44 vol %, or not greater than 40 vol %, or not greater than 35 vol %, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol %, or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %. It will be appreciated that the vol % may be within a range including any of the minimum and maximum amounts noted above, including, for example, but not limited to, at least 38 vol % and not greater than 44 vol %.
In an embodiment, the abrasive particles may have a particular orientation or distribution that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive particles may have a random distribution within the bond material. In an embodiment, the abrasive particles may have a random orientation relative to any surfaces of the abrasive article.
In an embodiment, the abrasive body may include a particular content of bond material that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive body may include at least 3 vol % bond material for a total volume of the abrasive body, or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 38%, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %. In an alternate embodiment, the abrasive body may include not greater than 85 vol % bond for a total volume of the abrasive body, or not greater than 80 vol %, or not greater than 75 vol %, or not greater than 70 vol %, or not greater than 65 vol %, or not greater than 60 vol %, or not greater than 55 vol %, or not greater than 50 vol %, or not greater than 45 vol %, or not greater than 48%, or not greater than 40 vol %, or not greater than 35 vol %, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol % or not greater than 15 vol % or not greater than 10 vol % or not greater than 8 vol %. It will be appreciated that the vol % may be within a range including any of the minimum and maximum amounts noted above, including, for example, but not limited to, at least 20 vol % and not greater than 45 vol %.
In an embodiment, the bond may include particular materials that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the bond material may include a bulk molding compound. In an embodiment, the bond material may include a thermoset polymer, a thermoplastic polymer, or a combination thereof. In a specific embodiment, the thermoset polymer may include a polyester resin, a vinyl ester resin, an epoxy resin, or any combination thereof. In an embodiment, the bond material may include a phenol-formaldehyde resin. In an embodiment, the bond material may include a novolac resin.
In an embodiment, the abrasive body may include a particular content of thermoset polymer that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive body may include at least 3 vol % thermoset polymer for a total volume of the abrasive body, or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 38%, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %. In an alternate embodiment, the abrasive body may include includes not greater than 85 vol % thermoset polymer for a total volume of the abrasive body, or not greater than 80 vol %, or not greater than 75 vol %, or not greater than 70 vol %, or not greater than 65 vol %, or not greater than 60 vol %, or not greater than 55 vol %, or not greater than 50 vol %, or not greater than 45 vol %, or not greater than 48%, or not greater than 40 vol %, or not greater than 35 vol %, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol %, or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %. It will be appreciated that the vol % may be within a range including any of the minimum and maximum amounts noted above, including, for example, but not limited to, at least 20 vol % and not greater than 45 vol %.
In an embodiment, the abrasive body may include other additives, including, for example, fibers, pore formers, fillers, etc. In an embodiment, the fillers can include potassium aluminum fluoride.
In an embodiment, the abrasive body may include a particular content of filler that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive body may include at least 5 vol % filler, or at least 8 vol %, or at least 10 vol %, or at least 12 vol %, or at least 15 vol %. In an embodiment, the abrasive body may include not greater than 35 vol % filler, or not greater than 32%, or not greater than 30%, or not greater than 25%. It will be appreciated that the vol % of filler in the abrasive body may be within a range between any of the minimum and maximum values noted above, including, for example, but not limited to, at least 5 vol % and not greater than 35 vol %, or at least 12 vol % and not greater than 30 vol %.
In some embodiments, the abrasive body may include an additive such as fibers. In certain embodiments, the fibers may include glass. In some embodiments, the fibers can include chopped strand fibers. In some embodiments, the fibers may be uniformly distributed throughout the volume of the bond material.
In an embodiment the abrasive body may include a particular content of fibers that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive body may include at least 1 vol % fibers, at least 2 vol %, at least 3 vol %, at least 4 vol %, or at least 5 vol %. In an embodiment, the abrasive body may include not greater than 20 vol % fibers, or not greater than 19 vol %, not greater than 18 vol %, not greater than 17 vol %, not greater than 16 vol %, or not greater than 15 vol %. It will be appreciated that the vol % of fibers in the abrasive body may be within a range between any of the minimum and maximum values noted above, including, for example, but not limited to, at least 1 vol % and not greater than 20 vol %, or at least 5 vol % and not greater than 15 vol %.
In an embodiment, the abrasive body may include fibers of a particular size that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the fibers may have an average length of at least 0.02 inches, or at least 0.04 inches, or at least 0.06 inches, or at least 0.08 inches, or at least 0.1 inch. In another embodiment, the fibers may have an average length of not greater than 0.15 inches, or not greater 0.18 inches, or not greater than 0.2 inches, or not greater than 0.22 inches, or not greater than 0.25 inches. It will be appreciated that the average length of the fibers may be between any of the minimum and maximum values listed above, including, for example, but not limited to, at least 0.02 inches and bot greater than 0.25 inches, or at least 0.08 inches and not greater than 0.2 inches, or at least 0.1 inch and not greater than 0.15 inches.
In an embodiment, the abrasive body may include fibers of a particular linear density that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the fibers may have a linear density of at least 20 TEX, or at least 22 TEX, or at least 24 TEX, or at least 26 TEX, or at least 28 TEX, or at least 30 TEX. In an embodiment, the fibers may have a linear density of not greater than 35 TEX, not greater than 37 TEX, not greater than 40 TEX, not greater than 42 TEX, or not greater than 45 TEX. It will be appreciated that the average linear density of the fibers may be between any of the minimum and maximum values listed above, including for example, but not limited to, at least 20 TEX and bot greater than 45 TEX.
In certain embodiments, the abrasive body may be made up multiple portions. In certain embodiments, the abrasive body may include a combination of abrasive portions and one or more reinforcing members disposed within the body. According to an embodiment, the reinforcing member may be coated in a bulk molding compound. According to one embodiment, shaping the abrasive article may include forming a first abrasive portion precursor in a mold. In an embodiment, the reinforcing material may be laminated with a bulk molding compound. The bulk molding compound may be the same as a bulk molding compound included in the bond material. The bulk molding compound may be different from the bulk molding compound included in the bond material. The process may further include disposing a reinforcing maybe over the first abrasive precursor in the mold. In an embodiment, the process may further include forming a second abrasive portion and disposing that over the reinforcing member in the mold. The shaping process may include shaping the first abrasive portion, the reinforcing member, and the second abrasive portion via warm pressing to form an abrasive article or abrasive article precursor that undergoes further processing to form a finally-formed abrasive article. It will be appreciated that any number of reinforcing members and abrasive portions may be used. In some embodiments, the various abrasive portions may have the same composition. In other embodiments, the abrasive portions may have different compositions.
It will be appreciated that the abrasive portions may have the properties of any of the abrasive bodies described herein, including, for example, the content of the abrasive particles, the content of the bond materials, the content and type of additives, and the like.
In one embodiment, the first abrasive portion and the second abrasive portion may include the same type of abrasive particles. In other embodiments, the first abrasive portion and the second abrasive portion may include different types of abrasive particles.
In one embodiment, the first abrasive portion and the second abrasive portion may include the same bond material. In other embodiments, the first abrasive portion and the second abrasive portion may include different bond materials.
The abrasive body may have an average thickness that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive body may have a thickness of at least 1 mm, at least 1.5 mm, at least 2 mm, at least 2.5 mm, or at least 3 mm. In another embodiment, the abrasive body may have a thickness of not greater than 15 mm, or not greater than 13 mm, or not greater than 11 mm, or not greater than 9 mm, or not greater than 7 mm. It will be appreciated that the thickness of the abrasive body can be within a range between any of the minimum and maxim values listed above, including, for example, but not limited to, at least 1 mm, and not greater than 13 mm.
The abrasive body may have an average diameter that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive body may have an average diameter of at least 10 mm, at least 15 mm, at least 20 mm, at least 25 mm, or at least 30 mm. In another embodiment, the abrasive body may have an average diameter of not greater than 300 mm, not greater than 290 mm, not greater than 280 mm, not greater than 270 mm, not greater than 260 mm, or not greater than 250 mm. It will be appreciated that the diameter of the abrasive body can be within a range between any of the minimum and maxim values listed above, including, for example, but not limited to, at least 20 mm, and not greater than 300 mm.
In one embodiment, the body 201 may include a reinforcing member. In an embodiment, the reinforcing member 207 may include an organic or inorganic material. In certain embodiments, the reinforcing member includes glass fibers. In a particular embodiment, the reinforcing member includes a woven material comprising glass fibers.
In an embodiment, the abrasive body may include a reinforcing member of a particular volume that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the abrasive body may include at least 1 vol % of the reinforcing member for a total volume of the body, or at least 2 vol % of the volume of the body, or at least 4 vol %, or at least 6 vol %, or at least 8 vol %, or at least 10 vol %. In an alternate embodiment, the abrasive article may include includes not greater than 35 vol % of the reinforcing member for a total volume of the body or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol %, or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %, or not greater than 5 vol %. It will be appreciated that the vol % may be within a range including any of the minimum and maximum amounts noted above, including for example, but not limited to, at least 1 vol % and not greater than 35 vol %, or at least 6 vol % and not greater than 20 vol %, or at least 10 vol % and not greater than 15 vol %.
In an embodiment, the abrasive body can include a porosity of not greater than 20 vol % for a total volume of the body, or not greater than 15 vol %, or not greater than 12 vol %, or not greater than 10 vol %, or not greater than 8 vol %, or not greater than 5 vol %, or not greater than 3 vol %. In certain embodiments, the abrasive body can include essentially no porosity. In certain embodiments, the abrasive body can include a porosity of at least 0.1 vol %, or at least 0.5 vol %, or at least 1 vol %, or at least 1.5 vol %, or at least 2 vol %. It will be appreciated that the porosity of the abrasive body may be within a range including any of the minimum and maximum amounts noted above, including, for example, but not limited to, at least 0.1 vol % and not greater than 20 vol %, at least 0.5 vol % and not greater than 10 vol %, or at least 1 vol % and not greater than 3 vol %. In an embodiment, the porosity can be isolated porosity. In another embodiment, the porosity can be interconnected porosity.
The reinforcing member 207 may be disposed with positions or orientations within the body 201 beyond that which is depicted in the embodiment of
In an embodiment, the abrasive body may have an aspect ratio (D:t) that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the aspect ratio (D:t) may be at least 10:1, or at least 20:1, or at least 30:1, or at least 50:1, or at least 80:1, or at least 100:1, or at least 200:1, or at least 300:1, or at least 500:1. In another embodiment, the aspect ratio may be not greater than 1000:1, or not greater than 10,000:1, or not greater than 50,000:1, or not greater than 100,000:1, or not greater than 500,000:1. It will be appreciated that the vol % may be within a range including any of the minimum and maximum amounts noted above, including for example, but not limited to, at least 10:1 to not greater than 500,000:1, or within a range of at least 20:1 to not greater than 100,000:1, or within a range of at least 20:1 and not greater than 50,000:1, or within a range of at least 20:1 to not greater than 10,000:1, or within a range of at least 20:1 to not greater than 1,000:1.
The body 301 may have a plurality of openings 312 extending through the body 301 of the reinforcing member 206.
In an embodiment, the reinforcing member 207 may include a plurality of openings 312 having an average size that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, the openings 312 may have an average size of not greater than 15 mm2, or not greater than 14 mm2, or not greater than 13 mm2, or not greater than 12 mm2, or not greater than 11 mm2, or not greater than 10 mm2, or not greater than 9 mm2. In an embodiment, the openings can have an average size of at least 0.1 mm2, or at least 0.2 mm2, or at least 0.3 mm2, or at least 0.4 mm2, or at least 0.5 mm2. In an embodiment, the opening size may depend on the average particle size of the abrasive particles within the abrasive article. In an embodiment, the openings may be at least 1.5 times the size of the average particle size of the abrasive particles, or at least 1.6, or at least 1.7, or at least 1.8, or at least 1.9, or at least 2.0, or at least 2.1, or at least 2.2, or at least 2.3, or at least 2.4, or at least 2.5 times the size of the average particle size of the abrasive particles. It will be appreciated that the size of the openings may be between any of the minimum or maximum values noted above.
In an embodiment, a certain percentage of the openings in the reinforcing member 207 can be filled with the bond material that may facilitate improved manufacturing and/or performance of the abrasive article. In an embodiment, at least 85% of openings in the reinforcing member are filled, or at least 88%, or at least 90%, or at least 92%, or at least 95%. In an embodiment, no greater than 99.9% of the openings are filled, or no greater than 99.5%, or no greater than 99%, or no greater than 98%, or no greater than 95%. It will be appreciated that the percentage of filled openings may be between any of the minimum and maximum values noted above, including, for example, but not limited to, at least 85% and not greater than 99%, or at least 92% and not greater than 99.9%.
In an embodiment, the abrasive body can experience less spalling than abrasive articles known in the art. Spalling can be measured by using the wheel for a period of time and quantifying the number of fibers extending radially out of the wheel and the length of the portion of said fibers that are outside of the wheel.
In an embodiment, the abrasive body can have a burst speed that is proportional to the circumference of the body.
wherein C is the circumference of the abrasive body in mm. In an embodiment, the abrasive body can have a burst speed that is at most
It will be appreciated that the burst speed can be in a range between the minimum and maximum burst speed values noted above.
It has been noted through empirical studies that the combination of features provided herein may facilitate formation of improved abrasive articles. For example, in the context of those embodiments utilizing one or more reinforcing members, the bond material appears to more thoroughly and bond to and through the one or more reinforcing members. This has been shown to be particularly true in comparing the abrasive articles of the embodiments herein with conventional abrasive articles.
Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.
The foregoing embodiments are directed to abrasive products and methods of making abrasive products, which represent a departure from the state-of-the-art.
Embodiment 1. An abrasive article comprising: a body having an average thickness of not greater than 15 mm2, the body comprising: abrasive particles contained in a bond material, wherein the bond material comprises an organic material; a reinforcing member disposed in the body; and a normalized average burst speed of at least
wherein c is the circumferences of the wheel in mm.
Embodiment 2. An abrasive article comprising: a body including: abrasive particles contained in a bond material, wherein the bond material comprises an organic material; a reinforcing member disposed in the body and having an average aperture size of not greater RPM than 15 mm; and an average burst speed of at least
wherein c is the circumferences of the wheel in mm.
Embodiment 3. An abrasive article comprising: a body including abrasive particles contained in a bond material, wherein the bond material comprises bulk molding compound, and wherein the bond material extends throughout the entire volume of the body, and further wherein the bond material comprises an additive having fibers of an average length at least 0.02 inches and not greater than 0.25 inches.
Embodiment 4. An abrasive article comprising: a body including: a first abrasive portion comprising abrasive particles contained in a bond material; a second abrasive portion comprising abrasive particles contained in a bond material; and a reinforcing member disposed between the first abrasive portion and the second abrasive portion; wherein the reinforcing member comprises a plurality of openings extending through the body of the reinforcing member and wherein the body comprises a fill percentage of the openings of at least 85%, or at least 88%, or at least 90%, or at least 92%, or at least 95%.
Embodiment 5. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body comprises a diameter of at least 10 mm, at least 15 mm, at least 20 mm, at least 25 mm, or at least 30 mm.
Embodiment 6. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body comprises a diameter of not greater than 300 mm, not greater than 290 mm, not greater than 280 mm, not greater than 270 mm, not greater than 260 mm, or not greater than 250 mm.
Embodiment 7. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body comprises an average thickness of not greater than 15 mm, or not greater than 13 mm, or not greater than 11 mm, or not greater than 9 mm, or not greater than 7 mm.
Embodiment 8. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body comprises an average thickness of at least 1 mm, at least 1.5 mm, at least 2 mm, at least 2.5 mm, or at least 3 mm.
Embodiment 9. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the abrasive particles comprise at least one material selected from the group consisting of oxides, carbides, nitrides, borides, superabrasives, or any combination thereof. Embodiment 10. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the abrasive particles comprise a vitreous phase, a polycrystalline phase, or any combination thereof.
Embodiment 11. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the abrasive particles comprise a Mohs hardness of at least 7, or at least 8, or at least 9.
Embodiment 12. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the abrasive particles comprise seeded sol gel alumina having an average crystallite size of not greater than 3 microns or not greater than 2 microns or not greater than 1 micron or not greater than 0.5 microns.
Embodiment 13. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the abrasive particles have a random distribution within the bond material.
Embodiment 14. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the abrasive particles have a random orientation relative to any surfaces of the body.
Embodiment 15. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the abrasive particles include at least one of a shaped abrasive particle, constant thickness abrasive particle, randomly shaped abrasive particle, agglomerates including binder and abrasive particles, a blend of different types of abrasive particles having at least one different abrasive characteristic or any combination thereof.
Embodiment 16. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body includes at least 3 vol % abrasive particles for a total volume of the body or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %.
Embodiment 17. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body includes not greater than 85 vol % abrasive particles for a total volume of the body, or not greater than 80 vol %, or not greater than 75 vol %, or not greater than 70 vol %, or not greater than 65 vol %, or not greater than 60 vol %, or not greater than 55 vol %, or not greater than 50 vol %, or not greater than 45 vol %, or not greater than 40 vol %, or not greater than 35 vol %, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol %, or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %.
Embodiment 18. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body includes at least 3 vol % bond material for a total volume of the body, or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %.
Embodiment 19. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body includes not greater than 95 vol % bond material for a total volume of the body, or not greater than 90 vol %, or not greater than 85 vol %, or not greater than 80 vol %, or not greater than 75 vol %, or not greater than 70 vol %, or not greater than 65 vol %, or not greater than 60 vol %, or not greater than 55 vol %, or not greater than 50 vol %, or not greater than 45 vol %, or not greater than 40 vol %, or not greater than 35 vol %, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol %, or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %.
Embodiment 20. The abrasive article of any one of embodiments 1, 2, and 4, wherein the bond material comprises a bulk molding compound.
Embodiment 21. The abrasive article of any one of embodiments 3 and 20, wherein the bond material comprises a thermoset polymer.
Embodiment 22. The abrasive article of embodiment 21, wherein the thermoset polymer comprises a polyester resin, a vinyl ester resin, an epoxy resin, or any combination thereof.
Embodiment 23. The abrasive article of embodiment 21, wherein the bond material comprises at least 3 vol % thermoset polymer for a total volume of the abrasive body, or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 38%, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %.
Embodiment 24. The abrasive article of any one of embodiments 1, 2, and 4, wherein the bond material comprises an additive including fibers.
Embodiment 25. The abrasive article of any one of embodiments 3 and 24, where the fibers may have an of an average length of at least 0.02 inches, or at least 0.04 inches, or at least 0.06 inches, or at least 0.08 inches, or at least 0.1 inch.
Embodiment 26. The abrasive article of any one of embodiments 3 and 24, wherein the fibers have an average length of not greater than 0.15 inches, or not greater 0.18 inches, or not greater than 0.2 inches, or not greater than 0.22 inches, or not greater than 0.25 inches.
Embodiment 27. The abrasive article of any one of embodiments 3 and 24, wherein the fibers comprise glass.
Embodiment 28. The abrasive article of any one of embodiments 3 and 24, wherein fibers include chopped strand fibers.
Embodiment 29. The abrasive article of any one of embodiments 3 and 24, wherein the fibers are uniformly distributed throughout the volume of the bond material.
Embodiment 30. The abrasive article of any one of embodiments 3 and 24, wherein the bond material comprises at least 1 vol % fibers for a total volume of the body, at least 2 vol %, at least 3 vol %, at least 4 vol %, or at least 5 vol %.
Embodiment 31. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body comprises an average thickness (t) and an average diameter (D), and wherein the body comprises an aspect ratio (D:t) of at least 10:1, or at least 20:1, or at least 30:1, or at least 50:1, or at least 80:1, or at least 100:1, or at least 200:1, or at least 300:1, or at least 500:1.
Embodiment 32. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body comprises an average thickness (t) and an average diameter (D), and wherein the body comprises an aspect ratio (D:t) within a range of at least 10:1 to not greater than 500,000:1 or within a range of at least 20:1 to not greater than 100,000:1, or within a range of at least 20:1 and not greater than 50,000:1, or within a range of at least 20:1 to not greater than 10,000:1, or within a range of at least 20:1 to not greater than 1,000:1.
Embodiment 33. The abrasive article of embodiment 3, further comprising a reinforcing member disposed in the body.
Embodiment 34. The abrasive article of any one of embodiments 1, 2, 4, and 33, wherein the reinforcing member comprises an organic or inorganic material.
Embodiment 35. The abrasive article of any one of embodiments 1, 2, 4, and 33, wherein the reinforcing member comprises glass fibers.
Embodiment 36. The abrasive article of any one of embodiments 1, 2, 4, and 33, wherein the reinforcing member comprises a woven material comprising glass fibers.
Embodiment 37. The abrasive article of any one of embodiments 1, 2, 4, and 33, wherein the body includes at least 1 vol % of the reinforcing member for a total volume of the body, or at least 2 vol % of the volume of the body, or at least 4 vol % or at least 6 vol %, or at least 8 vol %, or at least 10 vol %.
Embodiment 38. The abrasive article of any one of embodiments 1, 2, 4, and 33, wherein the body comprises not greater than 35 vol % of the reinforcing member for a total volume of the body, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol %, or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %, or not greater than 5 vol %.
Embodiment 39. The abrasive article of any one of embodiments 1, 2, 4, and 33, wherein the reinforcing member extends for a majority of a radius of the body.
Embodiment 40. The abrasive article of any one of embodiments 1, 2, 4, and 33, wherein the reinforcing member extends radially and circumferentially in the body for a majority of a radius and a majority of a circumference of the body.
Embodiment 41. The abrasive article of any one of embodiments 1, 2, 4, and 33, wherein the reinforcing member extends from an inner annular surface defined by a central opening of the body to an outer annular surface of the body.
Embodiment 42. The abrasive article of any one of embodiments 1, 4, and 33 wherein the reinforcing member comprises a plurality of openings extending through the body of the reinforcing member and wherein the plurality of openings comprise an average aperture size of not greater than 15 mm2 Embodiment 43. The abrasive article of any one of embodiments 2 and 42, wherein the average aperture size is within a range of at least 0.1 mm to not greater than 15 mm.
Embodiment 44. The abrasive article of any one of embodiments 1, 2, and 33, wherein the body comprises a fill percentage of the openings of at least 85%, or at least 88%, or at least 90%, or at least 92%, or at least 95%.
Embodiment 45. The abrasive article of any one of embodiments 4 and 44, wherein the reinforcing member is disposed between a first abrasive portion of the body and a second abrasive portion of the body, wherein the first abrasive portion comprises abrasive particles contained in a bond material and the second abrasive portion comprising abrasive particles contained in a bond material.
Embodiment 46. The abrasive article of any one of embodiments 4 and 45, wherein the first abrasive portion includes different abrasive particles as compared to the abrasive particles of the second abrasive portion.
Embodiment 47. The abrasive article of any one of embodiments 4 and 45, wherein the first abrasive portion includes different bond material as compared to the bond material of the second abrasive portion.
Embodiment 48. The abrasive article of any one of embodiments 4 and 45, wherein the first abrasive portion includes a bond material including BMC and the second abrasive portion comprises the same bond material as used in the first abrasive portion.
Embodiment 49. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body comprises a low spall factor.
Embodiment 50. The abrasive article of any one of embodiments 1, 2, 3, and 4, wherein the body comprises a porosity of not greater than 20 vol % for a total volume of the body, or not greater than 15 vol %, or not greater than 12 vol %, or not greater than 10 vol %, or not greater than 8 vol %, or not greater than 5 vol %, or not greater than 3 vol %.
Embodiment 51. The abrasive article of embodiment 50, wherein the body comprises essentially no porosity.
Embodiment 52. A method for forming an abrasive article comprising: forming a mixture including a bond material comprising bulk molding compound and abrasive particles; and shaping the mixture via warm pressing.
Embodiment 53. The method of embodiment 52, wherein forming the mixture includes low shear mixing.
Embodiment 54. The method of embodiment 52, wherein forming the mixture includes mixing the bond material and abrasive particles for a mixing duration within a range of at least 5 minutes, at least 7 minutes, at least 9 minutes, at least 11 minutes, at least 13 minutes, or at least 15 minutes.
Embodiment 55. The method of embodiment 52, wherein the mixture temperature is not greater than 85° C., not greater than 87° C., not greater than 90° C., not greater than 92° C., or not greater than 95° C.
Embodiment 56. The method of embodiment 52, wherein the abrasive particles include randomly shaped abrasive particles.
Embodiment 57. The method of embodiment 52, wherein warm pressing is conducted at a pressing temperature of not greater than 75° C., or not greater than 70° C., or not greater than 65° C., or not greater than 60° C., or not greater than 55° C., or not greater than 50° C.
Embodiment 58. The method of embodiment 52, wherein warm pressing is conducted at a pressing temperature of at least 25° C., or at least 30° C., or at least 35° C., or at least 40° C., or at least 45° C.
Embodiment 59. The method of embodiment 52, wherein warm pressing is conducted at a pressure of not greater than 7360 psi, or not greater than 6500 psi, or not greater than 6000 psi, or not greater than 5500 psi, or not greater than 5000 psi, or not greater than 4908 psi, or not greater than 4250 psi, or not greater than 3700 psi.
Embodiment 60. The method of embodiment 52, wherein warm pressing is conducted at a pressure of at least 1000 psi, or at least 1250 psi, or at least 1500 psi, or at least 1750 psi, or at least 2000 psi.
Embodiment 61. The method of embodiment 52, wherein warm pressing includes uniaxial warm pressing.
Embodiment 62. The method of embodiment 52, further comprising forming a first abrasive portion precursor in a mold, disposing a reinforcing member over the first abrasive portion precursor, and forming a second abrasive portion over the reinforcing member, and wherein shaping the mixture includes warm pressing the first abrasive portion, reinforcing member, and second abrasive portion precursor.
Embodiment 63. The method of embodiment 52, wherein the body comprises a diameter within a range of at least 10 mm and not greater than 300 mm, or at least 15 mm and not greater than 290 mm, or at least 20 mm and not greater than 280 mm, or at least 25 mm and not greater than 270 mm, or at least 30 mm and not greater than 250 mm, and further wherein the body comprises a thickness of at least 1 mm and not greater than 15 mm, at least 1.5 mm and not greater than 13 mm, at least 2 mm and not greater than 11 mm, at least 2.5 mm and not greater than 9 mm, or at least 3 mm and not greater than 7 mm.
Embodiment 64. The method of embodiment 52, wherein the abrasive particles comprise at least one material selected from the group consisting of oxides, carbides, nitrides, borides, super-abrasives, or any combination thereof.
Embodiment 65. The method of embodiment 52, wherein the abrasive particles comprise a vitreous phase, a polycrystalline phase, or any combination thereof.
Embodiment 66. The method of embodiment 52, wherein the abrasive particles comprise a Mohs hardness of at least 7, or at least 8, or at least 9.
Embodiment 67. The method of embodiment 52, wherein the abrasive particles comprise seeded sol gel alumina having an average crystallite size of not greater than 3 microns or not greater than 2 microns or not greater than 1 micron or not greater than 0.5 microns.
Embodiment 68. The method of embodiment 52, wherein the abrasive particles have a random distribution within the bond material.
Embodiment 69. The method of embodiment 52, wherein the abrasive particles have a random orientation relative to any surfaces of the body.
Embodiment 70. The method of embodiment 52, wherein the abrasive particles include at least one of a shaped abrasive particle, constant thickness abrasive particle, randomly shaped abrasive particle, agglomerates including binder and abrasive particles, a blend of different types of abrasive particles having at least one different abrasive characteristic or any combination thereof.
Embodiment 71. The method of embodiment 52, further including forming an abrasive article comprising a body including at least 3 vol % abrasive particles for a total volume of the body, or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %.
Embodiment 72. The method of embodiment 52, further including forming an abrasive article comprising a body including not greater than 85 vol % abrasive particles for a total volume of the body or not greater than 80 vol %, or not greater than 75 vol %, or not greater than 70 vol %, or not greater than 65 vol %, or not greater than 60 vol %, or not greater than 55 vol %, or not greater than 50 vol %, or not greater than 45 vol %, or not greater than 40 vol %, or not greater than 35 vol %, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol %, or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %.
Embodiment 73. The method of embodiment 52, further including forming an abrasive article comprising a body including at least 3 vol % bond material for a total volume of the body, or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %.
Embodiment 74. The method of embodiment 52, further including forming an abrasive article comprising a body including not greater than 95 vol % bond material for a total volume of the body, or not greater than 90 vol %, or not greater than 85 vol %, or not greater than 80 vol %, or not greater than 75 vol %, or not greater than 70 vol %, or not greater than 65 vol %, or not greater than 60 vol %, or not greater than 55 vol %, or not greater than 50 vol %, or not greater than 45 vol %, or not greater than 40 vol %, or not greater than 35 vol %, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol %, or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %.
Embodiment 75. The method of embodiment 52, further including forming an abrasive article comprising the bond material comprises a thermoset polymer.
Embodiment 76. The method of embodiment 74, wherein the thermoset polymer comprises a polyester resin, a vinyl ester resin, an epoxy resin, or any combination thereof.
Embodiment 77. The method of embodiment 74, wherein the bond material comprises at least 3 vol % thermoset polymer for a total volume of the abrasive body, or at least 5 vol %, or at least 8 vol %, or at least 10 vol %, or at least 15 vol %, or at least 20 vol %, or at least 25 vol %, or at least 30 vol %, or at least 35 vol %, or at least 38 vol %, or at least 40 vol %, or at least 45 vol %, or at least 50 vol %, or at least 55 vol %, or at least 60 vol %, or at least 65 vol %, or at least 70 vol %.
Embodiment 78. The method of embodiment 52, wherein the bond material comprises an additive including fibers.
Embodiment 79. The method of embodiment 77, where the fibers may have an average length of at least 0.02 inches, or at least 0.04 inches, or at least 0.06 inches, or at least 0.08 inches, or at least 0.1 inch.
Embodiment 80. The method of embodiment 77, wherein the fibers have an average length of not greater than 0.15 inches, or not greater 0.18 inches, or not greater than 0.2 inches, or not greater than 0.22 inches, or not greater than 0.25 inches.
Embodiment 81. The method of embodiment 77, wherein the fibers comprise glass.
Embodiment 82. The method of embodiment 77, wherein fibers include chopped strand fibers.
Embodiment 83. The method of embodiment 77, wherein the fibers are uniformly distributed throughout the volume of the bond material.
Embodiment 84. The method of embodiment 77, wherein the bond material comprises at least 1 vol % fibers for a total volume of the body, at least 2 vol %, at least 3 vol %, at least 4 vol %, or at least 5 vol %.
Embodiment 85. The method of embodiment 52, wherein the body comprises an average thickness (t) and an average diameter (D), and wherein the body comprises an aspect ratio (D:t) of at least 10:1, or at least 20:1, or at least 30:1, or at least 50:1, or at least 80:1, or at least 100:1, or at least 200:1, or at least 300:1, or at least 500:1, or wherein the aspect ratio (D:t) is within a range of at least 10:1 to not greater than 500,000:1, or within a range of at least 20:1 to not greater than 100,000:1, or within a range of at least 20:1 and not greater than 50,000:1, or within a range of at least 20:1 to not greater than 10,000:1, or within a range of at least 20:1 to not greater than 1,000:1.
Embodiment 86. The method of embodiment 52, wherein shaping includes forming an abrasive article having a body, wherein the body comprises a reinforcing member disposed in a body formed by shaping the mixture.
Embodiment 87. The method of embodiment 85, wherein the reinforcing member comprises a woven material comprising glass fibers.
Embodiment 88. The method of embodiment 85, wherein the body includes at least 1 vol % and not greater than 35 vol % of the reinforcing member for a total volume of the body, or not greater than 30 vol %, or not greater than 25 vol %, or not greater than 20 vol %, or not greater than 15 vol %, or not greater than 10 vol %, or not greater than 8 vol %, or not greater than 5 vol %.
Embodiment 89. The method of embodiment 85, wherein the reinforcing member extends radially and circumferentially in the body for a majority of a radius and a majority of a circumference of the body.
Embodiment 90. The method of embodiment 85, wherein the reinforcing member comprises a plurality of openings extending through the body of the reinforcing member and wherein the plurality of openings comprise an average aperture size within a range of at least 0.1 mm2 to not greater than 15 mm2.
Embodiment 91. The method of embodiment 85, wherein the body comprises a fill percentage of the openings of at least 85%, or at least 88%, or at least 90%, or at least 92%, or at least 95%.
Embodiment 92. The method of embodiment 85, wherein the body comprises a low spall factor.
Embodiment 93. The method of embodiment 85, wherein the body comprises a normalized burst speed of at least
wherein c is the circumferences of the wheel in mm.
The bond ingredients listed below in Table 1 were mixed until homogenous then charged into an Eirich mixer. The abrasive and resole ingredients were charged into a mixing bowl and mixed for 5-10 minutes using a Kitchen-aid cake mixer fitted with a standard paddle until the abrasive was completely wetted. The wetted abrasive was transferred to the Eirich bowl containing the dry bond and mixed for 5-10 minutes until a homogenously granular mixture results. The mixture was placed in a sealed bag and left untouched for 24 hrs. Then any agglomerates that formed were removed from the mix.
Approximately 108 grams of the mixture was transferred to mold cavities of a Poggi press equipped with a shuttle box spreader, followed by a glass web, followed by another 108 grams of the mixture. The sample is then pressed to form a 125 mm by 7 mm abrasive wheel. 5 samples were prepared according to this method, each being pressed with one of the pressures shown in
Two bulk molding compounds having the compositions detailed below in table 2 were prepared according to the following process.
The resin was charged into a mixer and warmed to 50-75° C. Once the resin was fluid, the fillers were added and mixed until the fillers were distributed homogenously. Mixing speed was then reduced and heating was discontinued. Then, the chopped fibers were added and mixed until the fibers were completely dispersed. The temperature was maintained below 90° C. while the fibers were being mixed. BMC was removed from the mixer and pressed at 75° C. to form a 0.76 mm thick wheel. A 22 mm diameter hole is cut from the center of the wheel and then the BMC is laminated to a glass web at 75° C.
The two laminated glass webs were then used to form abrasive wheels according to the process detailed in Example 1, using a pressure of 3700 psi with the poggi press. These wheels were then subject to burst speed testing. As noted in
Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims. Reference herein to a material including one or more components may be interpreted to include at least one embodiment wherein the material consists essentially of the one or more components identified. The term “consisting essentially” will be interpreted to include a composition including those materials identified and excluding all other materials except in minority contents (e.g., impurity contents), which do not significantly alter the properties of the material. Additionally, or in the alternative, in certain non-limiting embodiments, any of the compositions identified herein may be essentially free of materials that are not expressly disclosed. The embodiments herein include a range of contents for certain components within a material, and it will be appreciated that the contents of the components within a given material total 100%.
The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2021/073132 | 12/28/2021 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63131095 | Dec 2020 | US |
