Patent Application
20190351530
The present invention relates, in general, to grinding wheels and multi-piece grinding wheel assemblies.
Abrasive grinding wheels can be used to smooth and contour the edges of certain flat materials, e.g., sheets of glass, for safety and cosmetic reasons. Such abrasive grinding wheels may include diamond-containing abrasive wheels and may be used to shape the edges of materials for various industries, including but not limited to automotive, architectural, furniture, and appliance industries.
The industry continues to demand improved grinding wheel assemblies, particularly for applications of grinding the edges of flat materials.
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 generally directed to grinding wheel assemblies that are particularly suitable for grinding and smoothing the edges of brittle materials, such as glass.
Embodiments are directed to abrasive articles which may be in the form of grinding wheels. In one aspect, a grinding wheel assembly can include an abrasive body mounted in a head assembly that can be easily removed and replaced after the abrasive body is no longer providing sufficient abrasion during use. The grinding wheel assembly can include an arbor in which a pull stud can be installed. The arbor can further provide support for an abrasive body. In one aspect, the arbor can include a mounting plate and the abrasive body can be held between the mounting plate and a cover plate. The grinding wheel assembly can be particular suitable for operations of grinding the edges of glass, such as automobile glass and flat glass. Further, the grinding wheel assembly can allow for relatively quicker removal and replacement of the abrasive article after the abrasive article is no longer useful. The pull stud, the arbor, and the cover plate need not be replaced after the abrasive body is no longer useful.
Referring initially to
The pull stud 102, the arbor 104, and the cover plate 108 can include a metal or a metal alloy. For example, the metal can be stainless steel or titanium. Further, the metal can include a hardened metal, such as hardened steel. It is to be understood that the material utilized for the pull stud 102, the arbor 104, and the cover plate 108 will minimize wearing of these elements during use. The abrasive article 106, however, will wear during grinding operations performed on the edges of various workpieces. After the abrasive article 106 is sufficiently worn, the abrasive article 106 may be removed and replace with a new abrasive body. Alternatively, the abrasive article 106 may be removed and the outer periphery of the abrasive article 106 may be reground. Thereafter, the abrasive article 106 may be reinstalled and used to perform further grinding operations.
As shown in
Referring now to
As further shown in
As indicated in
As shown in
In a particular aspect, each manufacturing hole 332 can extends axially into the core 300 in a direction parallel to the central axis 312. Further, each manufacturing hole 332 can at least partially radially overlaps a portion of the bonded abrasive body 330. In a particular aspect, the core 300 can also include a plug (not shown) that can be fitted into each manufacturing hole 332. Further, the core 300 can include at least two plugs (not shown) and each of the plugs can be fitted into a respective manufacturing hole 332. Each of the at least two plugs can be substantially identical. On the other hand, each of the at least two plugs can be different. For example, each of the at least two plugs can have different densities. Moreover, each of the at least two plugs can have different masses.
In a particular aspect, the core 300 may include a particular polymer material that facilitates improved performance of the bonded abrasive body, including but not limited to, aspects of strength, wearability, vibration damping, and manufacturability.
In one embodiment, the core 300 of the abrasive article 106 of the present disclosure may have a particular heat deflection temperature (HDT) at 0.45 MPa of at least about 130° C., such as at least about 140° C., at least about 150° C., at least about 160° C., at least about 180° C., at least about 200° C.; at least about 230° C., at least about 250° C., or at least about 260° C. In another non-limiting embodiment, the HDT of the core at 0.45 MPa may not be not greater than 400° C., such as not greater than 380° C., or not greater than 360° C. It will be appreciated that the HDT at 0.45 MPa of the core 300 can be within a range between any of the minimum and maximum values noted above, such as from about 130° C. to about 400° C., from about 200° C. to about 350° C., or from about 250° C. to about 330° C.
In another embodiment, the core 300 of the abrasive article 106 may have a shrinkage ratio of not greater than 3%, such as not greater than 2%, not greater than 1.5%, not 1.0%, not greater than 0.8%, not greater than 0.5%, not greater than 0.3%, not greater than 0.1%, or not greater than 0.05%. In a particular embodiment, the shrinkage ratio may be not greater than 0.1%. In another embodiment, the shrinkage ratio of the core 300 is at least 0.001% or at least 0.005%. It will be appreciated that the shrinkage ratio of the core 300 can be within a range between and including any of the minimum and maximum values noted above, such as from 0.001% to 3%, from 0.005% to 1%, or from 0.001% to 0.1%.
In a further embodiment, the core 300 of the abrasive article can have a Charpy impact of at least 45 kJ/m2, such as at least 50 kJ/m2, at least 55 KJ/m2, at least 60 kJ/m2, at least 80 kJ/m2, at least 100 kJ/m2, or at least 150 kJ/m2; in another aspect, the Charpy impact may be not greater than 300 kJ/m2 or not greater than 250 kJ/m2. It will be appreciated that the Charpy impact can be within a range from any of the minimum and maximum values noted above, such as from 45 kJ/m2 to 300 kJ/m2, from 50 kJ/m2 to 250 kJ/m2, or from 100 KJ/m2 to 180 kJ/m2.
In one embodiment the core 300 can include a polymer material selected from the group of a polyamide (PA), a polybutylene terephthalate (PBT), a polyphenylene sulfide (PPS), ethylene tetrafluoroethylene (ETFE), a polyetherketone (PEEK), a polyester (PE), a polyethyleneimine (PEI), a polyethersulfone (PESU), a polyethylene terephthalate (PET), a polyphthalamide (PPA), a poly (p-phenylene sulfide), a polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), PC-ABS, or any combination thereof. In an aspect, the polymer material may be a nylon, a PBT, a PPS, or a PC-ABS. The nylon may be, for example, nylon 6, nylon 66, nylon 610, nylon 612, nylon 66/6, nylon 410, or nylon 46. In a particular embodiment, the polymer material of the core 300 may consist essentially of PPS. In another particular embodiment, the polymer material of the core 300 may consist essentially of PC-ABS. In another embodiment, the polymer material of the core 300 may be essentially free of nylon.
In another embodiment, the core 300 may further contain reinforcing fibers and/or a powder distributed within the polymer material. The reinforcing fibers may include, for example, glass fibers, carbon fibers, ceramic fibers, organic fibers, mineral fibers, or combinations thereof. Suitable powders may be, for example, calcium carbonate, glass powder, mineral powder, or talc.
In a particular embodiment, the reinforcing fibers of the core 300 may consist essentially of carbon fibers. In another particular embodiment, the reinforcing fibers of the core 300 can consist essentially of glass fibers. Consisting essentially should be understood only one specific type of fibers containing only unavoidable impurities.
The amount of reinforcing fibers and/or powder contained in the core 300 may be at least about 1 wt %, such as at least about 5 wt %, at least about 10 wt %, at least about 15 wt %, at least about 20 wt %, at least about 25 wt %, or at least about 30 wt %, based on the total weight of the core. In another aspect, the amount of reinforcing fibers and/or powder may be not greater than 60 wt %, such as not greater than 55 wt %, not greater than 50 wt %, not greater than 45 wt %, or not greater than 40 wt %. It will be appreciated that the amount of reinforcing fibers and/or powder contained in the core 300 can be within a range between any of the minimum and maximum values noted above, such as from about 5 wt % to about 50 wt %, from about 15 wt % to about 40 wt %, from about 20 wt % to about 50 wt %, or from about 30 wt % to about 50 wt % based on the total weight of the core.
In one embodiment, the reinforcing fibers can have an average aspect ratio of length to width of at least about 3, such as at least about 5, at least about 10, at least about 30, at least about 50, at least about 100, at least about 500, or at least about 800. In another embodiment the primary aspect ratio of the reinforcing fibers may be not greater than 5000, such as not greater than 3500, not greater than 2000, not greater than 1200, not greater than 1100, or not greater than 1000. It will be appreciated that the average aspect ratio of the reinforcing fibers can be within a range between any of the minimum and maximum values note above, such as from about 3 to about 5000, from about 3 to about 1300, from about 10 to about 1200, from about 100 to about 1200, from about 500 to about 1200, from about 700 to 1200, or from about 800 to about 1200.
In one embodiment, the core 300 of the abrasive article 106 of the present disclosure may consist essentially of the polymer material and the reinforcing fibers, the reinforcing fibers being present in an amount of 30 to 50 wt % based on the total weight of the core and having an average aspect ratio of length to width of 500 to 1200.
In a particular embodiment, the core 300 may comprise PPS and carbon fibers, the carbon fibers having an average aspect ratio from about 800 to about 1200, wherein the core can have a shrinkage ratio of not greater than 0.1% and a tensile modulus of at least about 20.0 GPa.
In another particular embodiment, the core 300 can comprise PC-ABS and glass fibers, the glass fibers having an average aspect ratio from about 800 to about 1200, wherein the core can have a shrinkage ratio of not greater than 0.1% and a tensile modulus of at least about 20.0 GPa.
According to one embodiment, the core 300 of the abrasive article can represent a majority of the total volume of the abrasive article. For example, in one embodiment, the core 300 can be at least about 60 vol % based on the total volume of the abrasive article, such as at least about 70 vol %, at least about 75 vol %, at least 80 vol % or at least 85 vol %. Still, in another non-limiting embodiment, the core 300 may be not greater than about 99 vol % of the abrasive article, such as at not greater than about 97 vol %, not greater than about 95 vol %, or not greater than about 90 vol %. It will be appreciated that the volume percentage of the core 300 of the abrasive article based on the total volume of the abrasive article can be within a range between any of the minimum and maximum values noted above, such as from about 65 vol % to about 99 vol %, from about 70° vol % to about 95 vol %, or from about 80 vol % to about 95 vol %.
The bonded abrasive body 330 can be disposed in the 306 recess at the peripheral surface 304 of the core 300 and can include abrasive particles fixed in a bond material. Suitable abrasive particles can include, for example, oxides, carbides, nitrides, borides, diamond, cubic boron nitride, silicon carbide, boron carbide, alumina, silicon nitride, tungsten carbide, zirconia, or a combination thereof. In a particular aspect, the abrasive particles of the bonded abrasive body 330 are diamond particles. In at least one embodiment, the abrasive particles can consist essentially of diamond.
The abrasive particles contained in the bonded abrasive body 330 can have an average particle size suitable to facilitate particular grinding performance. For example, the abrasive particles can have a size less than about 2000 μm, such as less than about 1000 μm, less than about 500 μm, or less than about 300 μm. In another aspect, the abrasive particles can have a size of at least 0.01 μm, such as at least 0.1 μm, at least about 1 μm, at least 5 μm or at least 10 μm. It will be appreciated that the size of the abrasive particles contained in the bonded abrasive body 330 can be within a range between any of the minimum and maximum values noted above, such as from about 0.01 μm to about 2000 μm, from about 1 μm to about 500 μm, from about 5 μm to about 300 μm or from about 50 μm to about 150 μm.
The bond material of the bonded abrasive body 330 an include an inorganic material, an organic material, and a combination thereof. Suitable inorganic materials for the use as bond material may include metals, glass, glass-ceramics, and a combination thereof. For example, an inorganic bond material can include one or more metal compositions or elements such as Cu, Sn, Fe, W, WC, Co, and a combination thereof. Organic materials may include resins, for example thermosets, thermoplastics, and a combination thereof. For example, some suitable resins can include phenolic resins, epoxies, polyesters, cyanate esters, shellacs, polyurethanes, rubber, polyimides and a combination thereof.
The abrasive article 106 of the present disclosure may be selected from a range of suitable sizes to facilitate efficient grinding depending upon the workpiece. In one embodiment, the abrasive article 106 can include an abrasive wheel having a diameter of at least about 25 mm, such as at least about 30 mm or at least about 50 mm. In another embodiment, the wheel diameter may be not greater than 500 mm, such as not greater than 450 mm, not greater than 300 mm or not greater than 200 mm. It will be appreciated that the wheel diameter can be within a range between any of the minimum and maximum values noted above, such as from about 25 mm to about 500 mm, from about 50 mm to about 250 mm, or from about 25 mm to about 150 mm.
As illustrated in
The abrasive article 106 of the present disclosure may be selected from a range of suitable sizes to facilitate efficient grinding depending upon the workpiece. In one embodiment, the abrasive article 106 can include a diameter of at least about 25 mm, such as at least about 30 mm or at least about 50 mm. In another embodiment, the diameter may be not greater than 500 mm, such as not greater than 450 mm, not greater than 300 mm or not greater than 200 mm. It will be appreciated that the diameter can be within a range between any of the minimum and maximum values noted above, such as from about 25 mm to about 500 mm, from about 50 mm to about 250 mm, or from about 25 mm to about 150 mm.
The abrasive article 106 of the present disclosure can be designed for shaping the edges of a workpiece. The workpiece can be an inorganic or organic material, such as, for example, glass, plastic, ceramic, or metal. In a particular embodiment, the workpiece can include glass, including but not limited to automotive glass, architectural glass, furniture glass, optical glass, and glass used in displays and/or to cover electronic devices (e.g., a phone). The workpiece can further be crystalline, such as monocrystalline or polycrystalline, including but not limited to sapphire.
In a particular embodiment, the abrasive article 106 of the present disclosure can be an abrasive wheel. In one aspect, the burst strength of the abrasive wheel may be at least 135 m/s, such as at least 150 m/s, at least 160 m/s or at least 180 m/s. In another embodiment, the burst strength may be not larger than 300 m/s, such as not larger than 280 m/s, or not larger than 250 m/s.
As illustrated in
In a particular aspect, the cover plate 108, i.e., the body 800 of the cover plate 108, has a diameter, DCP, and WRP of the core 300 of the abrasive article 106 can be greater than or equal to 10% DCP. Moreover, WRP can be greater than or equal to 12.5% DCP, such as greater than or equal to 15% DCP, greater than or equal to 17.5% DCP, or greater than or equal to 20% DCP. In another aspect, WRP can be less than or equal to 30.0% DCP, such as less than or equal to 27.5% DCP, less than or equal to 25% DCP, or less than or equal to 22.5% DCP. It is to be understood that WRP can be within a range between and including any of the maximum and minimum % DCP values described herein.
In still another aspect, the upper recessed portion 310, or the recessed surface 314 of the upper recessed portion 310, can have a surface area, ARP. Further, the cover plate 310, e.g., the upper surface 302 of the body 300 of the cover plate, can have a surface area, ACP, and ARP can less than or equal to 75.0% ACP. In another aspect, ARP can be less than or equal to 72.5% ACP, such as less than or equal to 70.0% ACP, less than or equal to 67.5% ACP, less than or equal to 65.0% Au), less than or equal to 62.5% ACP, less than or equal to 60.0% ACP, or less than or equal to 57.5% ACP. In yet another aspect, ARP can be greater than or equal to 40.0% ACP, such as greater than or equal to 42.5% ACP, greater than or equal to 45.0% ACP, greater than or equal to 47.5% ACP, greater than or equal to 50.0% ACP, greater than or equal to 52.5% ACP, or greater than or equal to 55.0% ACP. It is to be understood that ARP can be within a range between and including any of the maximum and minimum % ACP values described herein.
In another aspect, the core 300 of the abrasive article 106 can have an internal volume, VC, that is the combined volume of the upper recessed portion 310 of the core 300 of the abrasive article 106 and the central bore 318 of the core 300 of the abrasive article 106. It is to be understood that VC is the volume within the core 300 of the abrasive article 106, i.e., between the upper surface 302 of the core 300 and the lower surface 304 of the core 300, that is bound by the sidewall 316 of the upper recessed portion 310 of the core 300, the recessed surface 314 of the upper recessed portion 310 of the core 300, and the inner wall 320 of the core 300. Further, a displaced volume, VD, which is the volume displaced, or filled, by the body 800 of the cover plate 108 when the cover plate 108 is installed within the abrasive article 106, e.g. within the upper recessed portion 310 and the central bore 318 of the core 300, can be greater than or equal to 60.0% VC. In another aspect, VD can be greater than or equal to 62.5% VC, such as greater than or equal to 65.0% VC, greater than or equal to 67.5% VC, greater than or equal to 70.0% VC, greater than or equal to 72.5% VC, greater than or equal to 75.0% VC, greater than or equal to 77.5% VC, greater than or equal to 80.0% VC, or greater than or equal to 82.5% VC. In another aspect, VD can be less than or equal to 100.0% VC, such as less than or equal to 97.5% VC, less than or equal to 95.0% VC, less than or equal to 92.5% VC, less than or equal to 90.0% VC, less than or equal to 87.5% VC, or less than or equal to 85.0% VC. It is to be understood that VD can be within a range between, and including, any of the minimum and maximum values of VD described herein.
As shown in
In a particular embodiment, the cover plate 108 can be made from a metal, a metal alloy, or a combination thereof. Further, the cover plate 108 can be from a non-ferrous metal. For example, the cover plate 108 can be made from aluminum, an aluminum alloy, or a combination thereof. Moreover, the cover plate 108 can be made from copper, brass, or a combination thereof. Further still, the cover plate 108 can be made from tin, bronze, or a combination thereof.
Referring initially to
The pull stud 1302, the arbor 1304, and the cover plate 1308 can include a metal or a metal alloy. For example, the metal can be stainless steel or titanium. Further, the metal can include a hardened metal, such as hardened steel. It is to be understood that the material utilized for the pull stud 1302, the arbor 1304, and the cover plate 1308 will minimize wearing of these elements during use. The abrasive article 1306, however, will wear during grinding operations performed on the edges of various workpieces. After the abrasive article 1306 is sufficiently worn, the abrasive article 1306 may be removed and replace with a new abrasive body. Alternatively, the abrasive article 1306 may be removed and the outer periphery of the abrasive article 1306 may be reground. Thereafter, the abrasive article 1306 may be reinstalled and used to perform further grinding operations.
As shown in
Referring now to
As further shown in
As indicated in
As shown in
In a particular aspect, each manufacturing hole 1532 can extends axially into the core 1500 in a direction parallel to the central axis 1512. Further, each manufacturing hole 1532 can at least partially radially overlaps a portion of the bonded abrasive body 1530. In a particular aspect, the core 1500 can also include a plug (not shown) that can be fitted into each manufacturing hole 1532. Further, the core 1500 can include at least two plugs (not shown) and each of the plugs can be fitted into a respective manufacturing hole 1532. Each of the at least two plugs can be substantially identical. On the other hand, each of the at least two plugs can be different. For example, each of the at least two plugs can have different densities. Moreover, each of the at least two plugs can have different masses.
In a particular aspect, the core 1500 may include a particular polymer material that facilitates improved performance of the bonded abrasive body, including but not limited to, aspects of strength, wearability, vibration damping, and manufacturability.
In one embodiment, the core 1500 of the abrasive article 1506 of the present disclosure may have a particular heat deflection temperature (HDT) at 0.45 MPa of at least about 130° C., such as at least about 140° C., at least about 150° C., at least about 160° C., at least about 180° C., at least about 200° C.; at least about 230° C., at least about 250° C., or at least about 260° C. In another non-limiting embodiment, the HDT of the core at 0.45 MPa may not be not greater than 400° C., such as not greater than 380° C., or not greater than 360° C. It will be appreciated that the HDT at 0.45 MPa of the core 1500 can be within a range between any of the minimum and maximum values noted above, such as from about 130° C. to about 400° C., from about 200° C. to about 350° C., or from about 250° C. to about 330° C.
In another embodiment, the core 1500 of the abrasive article 1306 may have a shrinkage ratio of not greater than 3%, such as not greater than 2%, not greater than 1.5%, not 1.0%, not greater than 0.8%, not greater than 0.5%, not greater than 0.3%, not greater than 0.1%, or not greater than 0.05%. In a particular embodiment, the shrinkage ratio may be not greater than 0.1%. In another embodiment, the shrinkage ratio of the core 1500 is at least 0.001% or at least 0.005%. It will be appreciated that the shrinkage ratio of the core 1500 can be within a range between and including any of the minimum and maximum values noted above, such as from 0.001% to 3%, from 0.005% to 1%, or from 0.001% to 0.1%.
In a further embodiment, the core 1500 of the abrasive article can have a Charpy impact of at least 45 kJ/m2, such as at least 50 kJ/m2, at least 55 KJ/m2, at least 60 kJ/m2, at least 80 kJ/m2, at least 100 kJ/m2, or at least 150 kJ/m2; in another aspect, the Charpy impact may be not greater than 300 kJ/m2 or not greater than 250 kJ/m2. It will be appreciated that the Charpy impact can be within a range from any of the minimum and maximum values noted above, such as from 45 kJ/m2 to 300 kJ/m2, from 50 kJ/m2 to 250 kJ/m2, or from 100 KJ/m2 to 180 kJ/m2.
In one embodiment the core 1500 can include a polymer material selected from the group of a polyamide (PA), a polybutylene terephthalate (PBT), a polyphenylene sulfide (PPS), ethylene tetrafluoroethylene (ETFE), a polyetherketone (PEEK), a polyester (PE), a polyethyleneimine (PEI), a polyethersulfone (PESU), a polyethylene terephthalate (PET), a polyphthalamide (PPA), a poly (p-phenylene sulfide), a polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), PC-ABS, or any combination thereof. In an aspect, the polymer material may be a nylon, a PBT, a PPS, or a PC-ABS. The nylon may be, for example, nylon 6, nylon 66, nylon 610, nylon 612, nylon 66/6, nylon 410, or nylon 46. In a particular embodiment, the polymer material of the core 1500 may consist essentially of PPS. In another particular embodiment, the polymer material of the core 1500 may consist essentially of PC-ABS. In another embodiment, the polymer material of the core 1500 may be essentially free of nylon.
In another embodiment, the core 1500 may further contain reinforcing fibers and/or a powder distributed within the polymer material. The reinforcing fibers may include, for example, glass fibers, carbon fibers, ceramic fibers, organic fibers, mineral fibers, or combinations thereof. Suitable powders may be, for example, calcium carbonate, glass powder, mineral powder, or talc.
In a particular embodiment, the reinforcing fibers of the core 1500 may consist essentially of carbon fibers. In another particular embodiment, the reinforcing fibers of the core 1500 can consist essentially of glass fibers. Consisting essentially should be understood only one specific type of fibers containing only unavoidable impurities.
The amount of reinforcing fibers and/or powder contained in the core 1500 may be at least about 1 wt %, such as at least about 5 wt %, at least about 10 wt %, at least about 15 wt %, at least about 20 wt %, at least about 25 wt %, or at least about 30 wt %, based on the total weight of the core. In another aspect, the amount of reinforcing fibers and/or powder may be not greater than 60 wt %, such as not greater than 55 wt %, not greater than 50 wt %, not greater than 45 wt %, or not greater than 40 wt %. It will be appreciated that the amount of reinforcing fibers and/or powder contained in the core 1500 can be within a range between any of the minimum and maximum values noted above, such as from about 5 wt % to about 50 wt %, from about 15 wt % to about 40 wt %, from about 20 wt % to about 50 wt %, or from about 30 wt % to about 50 wt % based on the total weight of the core.
In one embodiment, the reinforcing fibers can have an average aspect ratio of length to width of at least about 3, such as at least about 5, at least about 10, at least about 30, at least about 50, at least about 100, at least about 500, or at least about 800. In another embodiment the primary aspect ratio of the reinforcing fibers may be not greater than 5000, such as not greater than 3500, not greater than 2000, not greater than 1200, not greater than 1100, or not greater than 1000. It will be appreciated that the average aspect ratio of the reinforcing fibers can be within a range between any of the minimum and maximum values note above, such as from about 3 to about 5000, from about 3 to about 1300, from about 10 to about 1200, from about 100 to about 1200, from about 500 to about 1200, from about 700 to 1200, or from about 2000 to about 1200.
In one embodiment, the core 1500 of the abrasive article 1306 of the present disclosure may consist essentially of the polymer material and the reinforcing fibers, the reinforcing fibers being present in an amount of 30 to 50 wt % based on the total weight of the core and having an average aspect ratio of length to width of 500 to 13200.
In a particular embodiment, the core 1500 may comprise PPS and carbon fibers, the carbon fibers having an average aspect ratio from about 800 to about 1200, wherein the core can have a shrinkage ratio of not greater than 0.1% and a tensile modulus of at least about 20.0 GPa.
In another particular embodiment, the core 1500 can comprise PC-ABS and glass fibers, the glass fibers having an average aspect ratio from about 800 to about 1200, wherein the core can have a shrinkage ratio of not greater than 0.1% and a tensile modulus of at least about 20.0 GPa.
According to one embodiment, the core 1500 of the abrasive article can represent a majority of the total volume of the abrasive article. For example, in one embodiment, the core 1500 can be at least about 60 vol % based on the total volume of the abrasive article, such as at least about 70 vol %, at least about 75 vol %, at least 80 vol % or at least 85 vol %. Still, in another non-limiting embodiment, the core 1500 may be not greater than about 99 vol % of the abrasive article, such as at not greater than about 97 vol %, not greater than about 95 vol %, or not greater than about 90 vol %. It will be appreciated that the volume percentage of the core 1500 of the abrasive article based on the total volume of the abrasive article can be within a range between any of the minimum and maximum values noted above, such as from about 65 vol % to about 99 vol %, from about 70° vol % to about 95 vol %, or from about 80 vol % to about 95 vol %.
The bonded abrasive body 1530 can be disposed in the 1506 recess at the peripheral surface 1504 of the core 1500 and can include abrasive particles fixed in a bond material. Suitable abrasive particles can include, for example, oxides, carbides, nitrides, borides, diamond, cubic boron nitride, silicon carbide, boron carbide, alumina, silicon nitride, tungsten carbide, zirconia, or a combination thereof. In a particular aspect, the abrasive particles of the bonded abrasive body 1530 are diamond particles. In at least one embodiment, the abrasive particles can consist essentially of diamond.
The abrasive particles contained in the bonded abrasive body 1530 can have an average particle size suitable to facilitate particular grinding performance. For example, the abrasive particles can have a size less than about 2000 μm, such as less than about 1000 μm, less than about 500 μm, or less than about 300 μm. In another aspect, the abrasive particles can have a size of at least 0.01 μm, such as at least 0.1 μm, at least about 1 μm, at least 5 μm or at least 10 μm. It will be appreciated that the size of the abrasive particles contained in the bonded abrasive body 1330 can be within a range between any of the minimum and maximum values noted above, such as from about 0.01 μm to about 2000 μm, from about 1 μm to about 500 μm, from about 5 μm to about 300 μm or from about 50 μm to about 150 μm.
The bond material of the bonded abrasive body 1530 an include an inorganic material, an organic material, and a combination thereof. Suitable inorganic materials for the use as bond material may include metals, glass, glass-ceramics, and a combination thereof. For example, an inorganic bond material can include one or more metal compositions or elements such as Cu, Sn, Fe, W, WC, Co, and a combination thereof. Organic materials may include resins, for example thermosets, thermoplastics, and a combination thereof. For example, some suitable resins can include phenolic resins, epoxies, polyesters, cyanate esters, shellacs, polyurethanes, rubber, polyimides and a combination thereof.
The abrasive article 1306 of the present disclosure may be selected from a range of suitable sizes to facilitate efficient grinding depending upon the workpiece. In one embodiment, the abrasive article 1306 can include an abrasive wheel having a diameter of at least about 25 mm, such as at least about 30 mm or at least about 50 mm. In another embodiment, the wheel diameter may be not greater than 500 mm, such as not greater than 450 mm, not greater than 300 mm or not greater than 200 mm. It will be appreciated that the wheel diameter can be within a range between any of the minimum and maximum values noted above, such as from about 25 mm to about 500 mm, from about 50 mm to about 250 mm, or from about 25 mm to about 150 mm.
As illustrated in
The abrasive article 1506 of the present disclosure may be selected from a range of suitable sizes to facilitate efficient grinding depending upon the workpiece. In one embodiment, the abrasive article 1506 can include a diameter of at least about 25 mm, such as at least about 30 mm or at least about 50 mm. In another embodiment, the diameter may be not greater than 500 mm, such as not greater than 450 mm, not greater than 300 mm or not greater than 200 mm. It will be appreciated that the diameter can be within a range between any of the minimum and maximum values noted above, such as from about 25 mm to about 500 mm, from about 50 mm to about 250 mm, or from about 25 mm to about 150 mm.
The abrasive article 1306 of the present disclosure can be designed for shaping the edges of a workpiece. The workpiece can be an inorganic or organic material, such as, for example, glass, plastic, ceramic, or metal. In a particular embodiment, the workpiece can include glass, including but not limited to automotive glass, architectural glass, furniture glass, optical glass, and glass used in displays and/or to cover electronic devices (e.g., a phone). The workpiece can further be crystalline, such as monocrystalline or polycrystalline, including but not limited to sapphire.
In a particular embodiment, the abrasive article 1306 of the present disclosure can be an abrasive wheel. In one aspect, the burst strength of the abrasive wheel may be at least 135 m/s, such as at least 135 m/s, at least 160 m/s or at least 180 m/s. In another embodiment, the burst strength may be not larger than 300 m/s, such as not larger than 280 m/s, or not larger than 250 m/s.
As illustrated in
In a particular aspect, the cover plate 1308, i.e., the body 2000 of the cover plate 1308, has a diameter, DCP, and WRP of the core 1500 of the abrasive article 1306 can be greater than or equal to 10% DCP. Moreover, WRP can be greater than or equal to 12.5% DCP, such as greater than or equal to 15% DCP, greater than or equal to 17.5% DCP, or greater than or equal to 20% DCP. In another aspect, WRP can be less than or equal to 30.0% DCP, such as less than or equal to 27.5% DCP, less than or equal to 25% DCP, or less than or equal to 22.5% DCP. It is to be understood that WRP can be within a range between and including any of the maximum and minimum % DCP values described herein.
In still another aspect, the upper recessed portion 1510, or the recessed surface 1514 of the upper recessed portion 1510, can have a surface area, ARP. Further, the cover plate 1510, e.g., the upper surface 1502 of the body 1500 of the cover plate, can have a surface area, ACP, and ARP can less than or equal to 75.0% ACP. In another aspect, ARP can be less than or equal to 72.5% ACP, such as less than or equal to 70.0% ACP, less than or equal to 67.5% ACP, less than or equal to 65.0% ACP, less than or equal to 62.5% ACP, less than or equal to 60.0% ACP, or less than or equal to 57.5% ACP. In yet another aspect, ARP can be greater than or equal to 40.0% ACP, such as greater than or equal to 42.5% ACP, greater than or equal to 45.0% ACP, greater than or equal to 47.5% ACP, greater than or equal to 50.0% ACP, greater than or equal to 52.5% ACP, or greater than or equal to 55.0% ACP. It is to be understood that ARP can be within a range between and including any of the maximum and minimum % ACP values described herein.
In another aspect, the core 1500 of the abrasive article 1306 can have an internal volume, VC, that is the combined volume of the upper recessed portion 1510 of the core 1500 of the abrasive article 1306 and the central bore 1518 of the core 1500 of the abrasive article 1306. It is to be understood that VC is the volume within the core 1500 of the abrasive article 1306, i.e., between the upper surface 1502 of the core 1500 and the lower surface 1504 of the core 1500, that is bound by the sidewall 1516 of the upper recessed portion 1510 of the core 1500, the recessed surface 1514 of the upper recessed portion 1510 of the core 1500, and the inner wall 1520 of the core 1500. Further, a displaced volume, VD, which is the volume displaced, or filled, by the body 2000 of the cover plate 1308 when the cover plate 1308 is installed within the abrasive article 1306, e.g. within the upper recessed portion 1510 and the central bore 1518 of the core 1500, can be greater than or equal to 60.0% VC. In another aspect, VD can be greater than or equal to 62.5% VC, such as greater than or equal to 65.0% VC, greater than or equal to 67.5% VC, greater than or equal to 70.0% VC, greater than or equal to 72.5% VC, greater than or equal to 75.0% VC, greater than or equal to 77.5% VC, greater than or equal to 80.0% VC, or greater than or equal to 82.5% VC. In another aspect, VD can be less than or equal to 100.0% VC, such as less than or equal to 97.5% VC, less than or equal to 95.0% VC, less than or equal to 92.5% VC, less than or equal to 90.0% VC, less than or equal to 87.5% VC, or less than or equal to 85.0% VC. It is to be understood that VD can be within a range between, and including, any of the minimum and maximum values of VD described herein.
As shown in
In a particular embodiment, the cover plate 1308 can be made from a metal, a metal alloy, or a combination thereof. Further, the cover plate 1308 can be from a non-ferrous metal. For example, the cover plate 1308 can be made from aluminum, an aluminum alloy, or a combination thereof. Moreover, the cover plate 1308 can be made from copper, brass, or a combination thereof. Further still, the cover plate 1308 can be made from tin, bronze, or a combination thereof.
It is to be understood that the configuration of structure described herein provides a grinding wheel assembly that substantially minimizes the splashing of cutting fluid, or coolant, on a workpiece during an edge grinding operation. This substantially minimizes swarf and debris from collecting on the workpiece and potentially causing scratches or other damage to the workpiece. Specifically, the manner in which the cover plate fits into the abrasive article and forms an enclosed surface at the top of the grinding wheel assembly can substantially minimize the splashing of coolant and swarf. Further, the shape of the cover plate relative to the upper recessed portion of the abrasive article, e.g., the complimentary shape of the lower surface of the cover plate with respect to the recessed surface, provides a structure that evenly distributes the compressive forces on the recessed surface of the abrasive article from the threaded fasteners when the grinding wheel assembly is properly assembled. This distribution of the compressive forces substantially minimizes, or eliminates, the cracking, or breaking, of the polymeric core of the abrasive article during assembly of the grinding wheel assembly. Moreover, the close fit of the cover plate within the upper recessed portion of the abrasive article can substantially minimize vibration of the abrasive article during edge grinding operations.
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 items as listed below.
An abrasive article, comprising:
a core comprising a polymer material, the core having an upper surface, an outer peripheral surface, an upper recessed portion extending into the core from the upper surface and a peripheral recess extending into the outer peripheral surface;
a bonded abrasive body disposed within the peripheral recess of the outer peripheral surface of the core; and
a cover plate having an upper surface, wherein the cover plate fits into the upper recessed portion of the upper surface the core so that the upper surface of the cover plate is substantially coplanar with the upper surface of the core.
An abrasive article, comprising:
a core, the core having an upper surface, an outer peripheral surface, an upper recessed portion extending into the core from the upper surface and an peripheral recess extending into the outer peripheral surface, wherein the upper recessed portion includes a recessed surface;
a bonded abrasive body disposed within the peripheral recess of the outer peripheral surface of the core; and
a cover plate, wherein the cover plate fits entirely within the upper recessed portion of the core and mates with the recessed surface.
An abrasive article, comprising:
a core, the core having an upper surface, an outer peripheral surface, an upper recessed portion extending into the core from the upper surface and a peripheral recess extending into the outer peripheral surface, wherein the upper recessed portion is sized and shaped to receive a complimentary sized and shaped cover plate therein; and
a bonded abrasive body disposed within the peripheral recess of the outer peripheral surface of the core.
The abrasive article of any of embodiments 1, 2, or 3, wherein the core further comprises a central bore and the cover plate extends at least partially into the central bore.
The abrasive article according to embodiment 4, wherein the bore has a depth, DB, and the cover plate extends into the bore at a depth, DE, and DE is less than or equal to 50% DB.
The abrasive article according to embodiment 5, wherein DE is less than or equal to 45% DB, such as less than or equal to 40% DB, less than or equal to 35% DB, less than or equal to 30% DB, less than or equal to 25% DB, less than or equal to 20% DB, or less than or equal to 15% DB.
The abrasive article according to embodiment 6, wherein DE is greater than or equal to 2.5% DB, such as greater than or equal to 5% DB, greater than or equal to 7.5% DB, or greater than or equal to 10% DB.
The abrasive article according to any of embodiments 1, 2, or 3, wherein the recessed portion has a radial width, WRP, and the core has a radial width, WC, and WRP is greater than or equal to 40% WC.
The abrasive article according to embodiment 8, wherein WRP is greater than or equal to 45% WC, such as greater than or equal to 50% WC, or greater than or equal to 55% WC.
The abrasive article according to embodiment 9, wherein WRP is less than or equal to 75% WC, such as less than or equal to 70% WC, less than or equal to 65% WC, or less than or equal to 60% WC.
The abrasive article according to any of embodiments 1, 2, or 3 wherein the recessed portion has a radial width, WRP, and the cover plate has a diameter, DCP, and WRP is greater than or equal to 10% DCP.
The abrasive article according to embodiment 11, wherein WRP is greater than or equal to 12.5% DCP, such as greater than or equal to 15% DCP, greater than or equal to 17.5% DCP, or greater than or equal to 20% DCP.
The abrasive article according to embodiment 12, wherein WRP is less than or equal to 30.0% DCP, such as less than or equal to 27.5% DCP, less than or equal to 25% DCP, or less than or equal to 22.5% DCP.
The abrasive article according to any of embodiments 1, 2, or 3, wherein the recessed portion has a recessed surface formed at an angle, a, with respect to the upper surface and a is greater than or equal to 5°.
The abrasive article according to embodiment 14, wherein a is greater than or equal to 7.5°, such as greater than or equal to 10°, greater than or equal to 12.5°, or greater than or equal to 15°.
The abrasive article according to embodiment 15, wherein a is less than or equal to 30°, such as less than or equal to 27.5°, less than or equal to 25°, less than or equal to 22.5°, or less than or equal to 22°.
The abrasive article according to any of embodiments 1, 2, or 3, wherein the recessed portion has a surface area, ARP, and the cover plate has a surface area, ACP, and ARP is less than or equal to 75.0% ACP.
The abrasive article according to embodiment 17, wherein ARP is less than or equal to 72.5% ACP, such as less than or equal to 70.0% ACP, less than or equal to 67.5% ACP, less than or equal to 65.0% ACP, less than or equal to 62.5% ACP, less than or equal to 60.0% ACP, or less than or equal to 57.5% ACP.
The abrasive article according to embodiment 18, wherein ARP is greater than or equal to 40.0% ACP, such as greater than or equal to 42.5% ACP, greater than or equal to 45.0% ACP, greater than or equal to 47.5% ACP, greater than or equal to 50.0% ACP, greater than or equal to 52.5% ACP, or greater than or equal to 55.0% ACP.
The abrasive article according to any of embodiments 1, 2, or 3, wherein the cover plate is made from a metal, a metal alloy, or a combination thereof.
The abrasive article according to embodiment 20, wherein the cover plate is made from non-ferrous metal.
The abrasive article according to embodiment 21, wherein the cover plate is made from aluminum, an aluminum alloy, or a combination thereof.
The abrasive article according to embodiment 21, wherein the cover plate is made from copper, brass, or a combination thereof.
The abrasive article according to embodiment 23, wherein the cover plate is made from tin, bronze, or a combination thereof.
The abrasive article according to any of embodiments 1, 2, or 3, wherein no part of the abrasive article extends above the upper surface of the core.
The abrasive article according to any of embodiments 1, 2, or 3, wherein no part of the abrasive article or the cover plate extends above the upper surface of the core.
The abrasive article according to any of embodiments 1, 2, or 3, wherein the core comprises and an inner volume, VC; the cover plate can displace a volume, VD, when the cover plate is installed within the core; and VD is greater than or equal to 60.0% VC.
The abrasive article according to embodiment 27, wherein VD is greater than or equal to 62.5% VC, such as greater than or equal to 65.0% VC, greater than or equal to 67.5% VC, greater than or equal to 70.0% VC, greater than or equal to 72.5% VC, greater than or equal to 75.0% VC, greater than or equal to 77.5% VC, greater than or equal to 80.0% VC, or greater than or equal to 82.5% VC.
The abrasive article according to embodiment 28, wherein VD is less than or equal to 100.0% VC, such as less than or equal to 97.5% VC, less than or equal to 95.0% VC, less than or equal to 92.5% VC, less than or equal to 90.0% VC, less than or equal to 87.5% VC, or less than or equal to 85.0% VC.
The abrasive article according to any of embodiments 1, 2, and 3, wherein the core comprises a polymer material.
The abrasive article according to embodiment 30, wherein the polymer material includes at least one of a polyamide (PA), a polybutylene terephthalate (PBT), a polyphenylene sulfide (PPS), ethylene tetrafluoroethylene (ETFE), a polyetherketone (PEEK), a polyester (PE), a polyethyleneimine (PEI), a polyethersulfone (PESU), a polyethylene terephthalate (PET), a polyphthalamide (PPA), a poly (p-phenylene sulfide), a polycarbonate (PC), an acrylonitrile-butadiene-styrene (ABS), a PC-ABS, or any combination thereof.
The abrasive article according to embodiment 30, wherein the core further comprises reinforcing fibers.
The abrasive article according to embodiment 32, wherein the reinforcing fibers include at least one of glass fibers, carbon fibers, ceramic fibers, organic fibers, mineral fibers, or any combination thereof.
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 subcombination. 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. 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.
The description in combination with the figures is provided to assist in understanding the teachings disclosed herein. The following discussion 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 not described herein, many details regarding specific materials and processing acts are conventional and may be found in reference books and other sources within the structural arts and corresponding manufacturing arts.
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.
This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 62/671,534, entitled “GRINDING WHEEL ASSEMBLY”, by Cecile O. MEJEAN et al., filed May 15, 2018, which is assigned to the current assignees hereof and incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62671534 | May 2018 | US |
