U.S. patent application number 14/144028 was filed with the patent office on 2014-07-03 for abrasive article having a core of an organic material and a bonded abrasive body comprising a bond material.
This patent application is currently assigned to SAINT-GOBAIN ABRASIFS. The applicant listed for this patent is SAINT-GOBAIN ABRASIFS, SAINT-GOBAIN ABRASIVES, INC.. Invention is credited to Steven W. Dumas, John E. Gillespie, Rachel Z. Pytel, Srinivasan Ramanath, Shivshankar Sivasubramanian, Robert N. Smith, Rachana Upadhyay.
Application Number | 20140187129 14/144028 |
Document ID | / |
Family ID | 51017690 |
Filed Date | 2014-07-03 |
United States Patent
Application |
20140187129 |
Kind Code |
A1 |
Sivasubramanian; Shivshankar ;
et al. |
July 3, 2014 |
ABRASIVE ARTICLE HAVING A CORE OF AN ORGANIC MATERIAL AND A BONDED
ABRASIVE BODY COMPRISING A BOND MATERIAL
Abstract
An abrasive article includes a core comprising an organic
material and a first bonded abrasive body integrally bonded
directly to the core, wherein the bonded abrasive body includes a
bond material, and abrasive particles contained within the bond
material.
Inventors: |
Sivasubramanian; Shivshankar;
(Lowell, MA) ; Ramanath; Srinivasan; (Holden,
MA) ; Upadhyay; Rachana; (Shrewsbury, MA) ;
Dumas; Steven W.; (Worcester, MA) ; Gillespie; John
E.; (Dudley, MA) ; Smith; Robert N.; (Grafton,
MA) ; Pytel; Rachel Z.; (Newton, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAINT-GOBAIN ABRASIFS
SAINT-GOBAIN ABRASIVES, INC. |
Conflans-Sainte-Honorine
Worcester |
MA |
FR
US |
|
|
Assignee: |
SAINT-GOBAIN ABRASIFS
Conflans-Sainte-Honorine
MA
SAINT-GOBAIN ABRASIVES, INC.
Worcester
|
Family ID: |
51017690 |
Appl. No.: |
14/144028 |
Filed: |
December 30, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61747994 |
Dec 31, 2012 |
|
|
|
Current U.S.
Class: |
451/541 ;
51/298 |
Current CPC
Class: |
B24D 3/001 20130101;
B24D 5/16 20130101; B24D 5/066 20130101; B24D 3/20 20130101; B24D
3/04 20130101; B24D 5/00 20130101 |
Class at
Publication: |
451/541 ;
51/298 |
International
Class: |
B24D 3/28 20060101
B24D003/28; B24D 18/00 20060101 B24D018/00; B24D 5/00 20060101
B24D005/00 |
Claims
1. An abrasive article comprising: a core comprising an organic
material; and a first bonded abrasive body integrally bonded
directly to the core, the bonded abrasive body comprising: a bond
material comprising a hybrid material including an inorganic
portion and an organic portion; and abrasive particles contained
within the bond material.
2. The abrasive article of claim 1, wherein the first bonded
abrasive body is integrally bonded to a peripheral surface of the
core.
3. The abrasive article of claim 1, wherein the core comprises a
volume of at least about 75 in.sup.3 (1229 cm.sup.3).
4. The abrasive article of claim 1, wherein the core has a
monolithic body, wherein the core has a cylindrical shape defined
by a diameter (d), a circumference (C), and a height (h), wherein
the height is at least about 3 inches (7.6 cm).
5. The abrasive article of claim 4, wherein the diameter is at
least about 6 inches (15.2 cm).
6. The abrasive article of claim 1, wherein the core comprises an
opening defining an arbor hole, wherein the opening is configured
to engage a spindle for a grinding operation, wherein the opening
extends through a volume of the monolithic body, wherein the
opening extends along a direction of the height, wherein the
opening extends between a first major surface and a second major
surface of the core.
7. The abrasive article of claim 6, wherein the core comprises a
liner overlying at least a portion of the surface defining the
opening.
8. The abrasive article of claim 1, wherein the core consists
essentially of the organic material.
9. The abrasive article of claim 1, wherein the organic portion and
the inorganic portion are substantially uniformly distributed
throughout the volume of the bond material of the first bonded
abrasive body.
10. The abrasive article of claim 1, wherein the inorganic portion
of the bond material comprises a metal material.
11. The abrasive article of claim 10, wherein the metal material of
the bond material comprises a combination of copper and tin.
12. The abrasive article of claim 1, wherein the organic portion of
the bond material comprises a polymer.
13. A method of forming an abrasive article, the method comprising:
preparing a preform comprising an abrasive article; forming a
mixture comprising a thermoset; pouring the mixture into the
preform; and curing the mixture to form the core on the abrasive
article, wherein the curing comprises a phase change of a liquid
phase to a solid phase, the core having a cylindrical shape defined
by a diameter (d), a circumference (C), and a height (h), wherein
the height is at least about 3 inches (7.6 cm).
14. The method of claim 13, wherein the mixture includes a curing
agent.
15. The method of claim 14, wherein the curing agent is selected
from the group consisting of an oligoamine, a diol, a dithiol, an
amino alcohol, an amino thiol, a thioalcohol, and any combination
thereof.
16. The method of claim 15, wherein the oligoamine is selected from
the group consisting of an aliphatic oligoamine, a cycloaliphatic
oligoamine, and an aromatic oligoamine, and a combination
thereof.
17. The method of claim 16, wherein the aliphatic oligoamine is
selected from the group consisting of ethylene diamine,
2-methyl-1,5-pentamethylenediamine, 1,6-hexamethylenediamine,
1,3-pentanediamine, (2-aminoethyl)-1,2-ethanediamine (DETA),
N,N'-bis-(2-aminoethyl)-1,2-ethanediamine) (TETA),
tris-(2-aminoethyl)amine) (TAEA), bis-(aminoethyl)ether, a
polyether diamine, tetraethylenepentamine (TEPA), and a combination
thereof.
18. The method of claim 13, wherein the mixture includes an epoxy
resin and the curing agent includes an oligoamine.
19. The method of claim 18, wherein the epoxy resin includes a
bisphenol-A diglycidyl ether and the curing agent includes a
isophorone diamine.
20. An abrasive article, comprising: a first bonded abrasive body
comprising: a bond material comprising a hybrid material including
an inorganic portion and an organic portion; and abrasive particles
contained within the bond material; and a core comprising an
organic material and bonded to the first bonded abrasive body, the
core having a monolithic body including a cylindrical shaped
defined by a diameter (d), a circumference (C), and a height (h),
wherein the height is at least about 3 inches (7.6 cm); wherein the
core comprises at least one filler selected from the group
consisting of oxides, carbides, borides, silicides, nitrides,
fluorides, oxynitrides, oxycarbides, silicates, metal-hydrate
compounds, hydrated oxide compounds, carbonates, phosphates,
minerals, feldspar, nepheline syenite, chromites, magnesites,
dolomites, pyrites, sulfides, carbon-based materials, graphite,
sulfides, silicon, metal, metal alloys, inter-metallics, ceramics,
hollow-ceramics, fused silica, glass, glass-ceramics, hollow glass
spheres, glass fibers, polymers, polyimides, polyamides, resins,
aramids, epoxies, polyesters, polyurethanes, acetates, celluloses,
ethers, ethanol, wood flour, clay, talc, and a combination thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Patent Application No. 61/747,994 entitled
"ABRASIVE ARTICLE HAVING A CORE OF AN ORGANIC MATERIAL AND A BONDED
ABRASIVE BODY COMPRISING A HYBRID BOND," by Sivasubramanian et al.,
filed Dec. 31, 2012, which is assigned to the current assignee
hereof and incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Disclosure
[0003] The following is directed to abrasive articles, and more
particularly, bonded abrasive articles having cores made of an
organic material and a bonded abrasive body attached to the core
comprising a bond material.
[0004] 2. Description of the Related Art
[0005] Abrasives used in machining applications typically include
bonded abrasive articles and coated abrasive articles. Coated
abrasive articles generally include a layered article including a
backing and an adhesive coat to fix abrasive grains to the backing,
the most common example of which is sandpaper. Bonded abrasive
tools consist of rigid, and typically monolithic,
three-dimensional, abrasive composites in the form of wheels,
discs, segments, mounted points, hones and other tool shapes, which
can be mounted onto a machining apparatus, such as a grinding or
polishing apparatus.
[0006] Bonded abrasive tools usually have three phases including
abrasive grains, bond material, and porosity, and can be
manufactured in a variety of "grades" and "structures" that have
been defined according to practice in the art by the relative
hardness and density of the abrasive composite (grade) and by the
volume percentage of abrasive grain, bond, and porosity within the
composite (structure).
[0007] Some bonded abrasive tools may be particularly useful in
grinding and polishing hard materials, such as single crystal
materials used in electronics and optics industries as well as
superabrasive materials for use in industrial applications, such as
earth boring. For example, polycrystalline diamond compact (PDC)
cutting elements are typically affixed to the head of drill bits
for earth boring applications in the oil and gas industry. The PDC
cutting elements include a layer of superabrasive material (e.g.,
diamond), which must be ground to particular specifications. One
method of shaping the PDC cutting elements is use of bonded
abrasive tools, which typically incorporate abrasive grains
contained within an organic bond matrix.
[0008] The industry continues to demand improved methods and
articles capable of grinding superabrasive workpieces.
SUMMARY
[0009] According to one aspect, an abrasive article comprises a
core comprising an organic material and a first bonded abrasive
body integrally bonded directly to the core. The first bonded
abrasive body comprising a bond material including a hybrid
material having an inorganic portion and an organic portion, and
abrasive particles contained within the bond material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] 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.
[0011] FIG. 1 includes a flowchart in accordance an embodiment of a
method.
[0012] FIG. 2 includes a perspective view illustration of a core in
accordance with an embodiment.
[0013] FIG. 3 includes a perspective view illustration of an
abrasive article in accordance with an embodiment.
DETAILED DESCRIPTION
[0014] The following is directed to abrasive articles, in
particular, bonded abrasive articles suitable for various
applications including centerless grinding, edge grinding, tool
room applications and the like. In particular instances, the
abrasive articles herein may include bonded abrasive articles that
may be particularly suited for grinding various workpieces,
including for example metals, metal alloys, plastics, wood,
composites, superabrasive materials, and a combination thereof.
[0015] As illustrated in FIG. 1, a method of forming an abrasive
article 100 can include providing a preform as shown in element
101. The preform can have an opening for receiving and holding a
mixture including an organic resin. The preform can be different
articles, including for example, a mold. The preform can have any
conventional shape. In one embodiment, the preform can be annular
in shape, thereby creating a volume that is defined by a diameter
d.sub.P, a circumference C.sub.P, and a height h.sub.P.
[0016] Still, in one embodiment, the preform can be an abrasive
body. The abrasive body can include a bonded abrasive body. The
bonded abrasive body can include abrasive particles in a bond
material, which will be described in more detail herein. The bonded
abrasive body can have an annular shape defined by a diameter
d.sub.a, a circumference C.sub.a, and a height h.sub.a.
[0017] In particular instances, the preform can include a plurality
of annular shaped bonded abrasive bodies attached to each other and
defining a central opening for receiving the mixture comprising the
organic resin. For example, the preform can include a second
abrasive body, wherein the second bonded abrasive body can be
adjacent the first bonded abrasive body. The first bonded abrasive
can be abutting the second bonded abrasive body as further
illustrated herein.
[0018] Still referring to preparing a preform 101 in FIG. 1, the
preform can include a liner, which may be in the form of an insert
spaced apart from the bonded abrasive article. In one embodiment,
the liner can overlie a surface of the preform. In one embodiment,
the liner can form a wheel defined by a diameter d.sub.L, height
h.sub.L, and thickness t.sub.L. In instances, d.sub.L can be
smaller than the preform diameter d.sub.P. In a particular
embodiment, the liner can form an arbor hole within the core of the
finally-formed article, as will be described in more detail herein.
In accordance with at least one embodiment, the liner may extend
along the direction of preform height h.sub.P. In other instances,
h.sub.L can be the substantially the same as preform height
h.sub.P. In other instances, h.sub.L can be a portion of preform
height h.sub.P.
[0019] The process of forming may include pouring the liquid
mixture around the liner. The liner may be removed prior to curing
or after curing. In still another embodiment, the liner may not be
removed and may become an integral part of the abrasive
article.
[0020] It will be appreciated that the preform can include other
objects facilitating the formation of an abrasive article in
accordance with an embodiment. For example, the preform can include
a second liner, wherein the second liner has a diameter d.sub.L
substantially the same than preform diameter d.sub.P.
[0021] The liner can be made from an organic material, an inorganic
material, or a combination thereof. In a particular embodiment, the
liner can be made from a metal or a metal alloy. In another
embodiment, the liner can be made from steel. According to one
particular embodiment, the liner can be a substrate for a bonded
abrasive material.
[0022] In certain instances, the liner can facilitate formation of
the core. The liner can have particular thermal properties that may
facilitate control of exotherms and endotherms during the forming
process. In particular, the liner may have a particular geometry,
size, volume, material, and a combination thereof, which
facilitates removing heat from the mixture during curing and
reducing the temperature and thermal gradients at the interface of
the bonded abrasive body and core during forming. In one particular
embodiment, the liner can have a heat capacity (e.g., a specific
heat capacity) that is different than (e.g., less than or greater
than) a heat capacity of the bonded abrasive body. In particular
instances, the liner has a heat capacity that is at least about 5%
different, such as at least about 10%, or even at least about 40%
different than a heat capacity of the bonded abrasive body.
[0023] In yet another embodiment, a first liner defining an arbor
hole of the core can have a first heat capacity that is different
than a second liner at an interface of the core and the bonded
abrasive article. The heat capacity of the first liner can be
greater than or less than the heat capacity of the second liner.
Moreover, the liner can have the same features of heat capacity
with respect to any one of the components of the mixture.
[0024] After providing a preform, the method can continue at step
102 of FIG. 1, forming a mixture. The mixture can include an
organic resin. In particular, at least a portion of the mixture can
include a liquid phase as shown in element 102. For example, the
mixture may include at least one solid phase component and at least
one liquid phase component. In one exemplary embodiment, the
mixture can consist essentially of a liquid phase, such that all
components within the mixture are in liquid phase.
[0025] In particular instances, one or more components of the
mixture can be liquid phase components. For example, the mixture
can include an organic resin that is liquid phase, and in
particular, the organic resin may consist essentially of a liquid
phase. In an embodiment, the liquid phase organic resin can flow
and take the shape of a container, such as the preform. Unlike an
organic resin that is in solid phase, such as a powdered organic
resin, the molecules of an organic resin in a liquid phase can flow
and move freely past one another. In one embodiment, the organic
resin can be in a liquid phase at room temperature. In particular
instances, the liquid phase can have a viscosity of at least about
400 cps (centipoise) at a temperature of 25.degree. C. In other
embodiments, the viscosity of the liquid phase can be greater, such
as at least about 700 cps, at least about 1000 cps, at least about
2000 cps, at least about 3000 cps, or even at least about 4000 cps.
In another embodiment, the liquid phase can have a viscosity of not
greater than about 25,000 cps, such as not greater than about
20,000 cps, not greater than about 18,000 cps, not greater than
about 14,000 cps, not greater than about 12,000 cps, not greater
than about 10,000 cps, or even not greater than about 8,000 cps. It
will be appreciated that the liquid phase can have a viscosity
within a range between any of the minimum and maximum values noted
above.
[0026] The mixture can further include other components including,
for example, a curing agent, a filler, a solvent or the like. For
example, the organic resin can include a solvent. The solvent can
modify the viscosity of the liquid. In embodiments, the solvent can
be water, methanol, ethanol, diethyl ether, acetone, mineral
spirits, ethyl acetate, tetrahydrofuran, or a combination
thereof.
[0027] Certain organic resins of the embodiments herein can include
an epoxy resin, a phenoxy resin, a polyurea resin, a polyimide
resin, a polycyanate, an acrylic, a polyurethane, a melamine resin,
a polyester resin, or any combination thereof. In one instance, the
organic resin can include an epoxy resin, such as a bisphenol-A
compound. In one particular embodiment, the bisphenol-A compound
can include a bisphenol-A diglycidyl ether, and may even consist
essentially of bisphenol-A diglycidyl ether.
[0028] As noted above, the mixture can include a curing agent.
According to one embodiment, the curing agent can include, an
oligoamine, a diol, a dithiol, an amino alcohol, an amino thiol, a
thioalcohol, or any combination thereof. In particular instances,
the mixture can include an epoxy resin and the curing agent can
include an oligoamine. In one embodiment, the oligoamine can
include an aliphatic oligoamine, a cycloaliphatic oligoamine, an
aromatic oligoamine, and a combination thereof. In one embodiment,
the aliphatic oligoamines can include ethylene diamine,
2-methyl-L5-pentamethylenediamine, 1,6-hexamethylenediamine,
1,3-pentanediamine, (2-aminoethyl)-1,2-ethanediamine (DETA),
N,N'-bis-(2-aminoethyl)-1,2-ethanediamine) (TETA),
tris-(2-aminoethyl)amine) (TAEA), bis-(aminoethyl)ether, a
polyether diamine, tetraethylenepentamine (TEPA), and a combination
thereof. In another embodiment, the cycloaliphatic oligoamine can
include 1,2-diaminocyclohexane,
N[(2-aminoethyl)2-aminoethyl]piperazine) (PEEDA), isophorone
diamine (IPDA), 4,4'-bis-(aminocyclohexyl)-methane,
N,N'-bis-(2-aminoethyl)piperazine) (DAEP), and a combination
thereof. In one further embodiment, the aromatic oligoamine can
include 2-ethyl, 2 methyl-imidazole, 4,4'-diaminodiphenyl-methane,
4,4'-diaminodiphenylether, 1,3-Bis(3-aminophenoxy) benzene, an
aminobenzylamine, and a combination thereof.
[0029] In other embodiments, the epoxy resin can include a
bisphenol-A diglycidyl ether and the curing agent can include a
isophorone diamine. According to yet another aspect, the epoxy
resin may consist essentially of a bisphenol-A diglycidyl ether and
the curing agent can consist essentially of a isophorone
diamine.
[0030] Further referring to the mixture in element 102, other
additives, such as a filler may be provided. In particular
instances, the mixture, and thus the finally-formed core, can
include at least one filler from the group of organic materials,
inorganic materials, fibrous materials, ceramic materials, oxides,
carbides, borides, silicides, nitrides, fluorides, oxynitrides,
oxycarbides, silicates, alumina, silica, silicon carbide, boron
nitride, metal-hydrate compounds, hydrated oxide compounds,
carbonates, phosphates, minerals, feldspar, nepheline syenite,
chromites, magnesites, dolomites, pyrites, sulfides, carbon-based
materials, graphite, sulfides, silicon, metal, metal alloys,
inter-metallics, ceramics, hollow-ceramics, fused silica, glass,
glass-ceramics, hollow glass spheres, glass fibers, polymers,
polyimides, polyamides, resins, aramids, epoxies, polyesters,
polyurethanes, acetates, celluloses, ethers, ethanol, wood flour,
clay, talc, and a combination thereof.
[0031] According to one embodiment, the core can include a first
filler material and a second filler material, wherein the first
filler material is different than the second filler material by at
least one of composition, average particle size, content within the
mixture of core, and a combination thereof. In one instances, the
core can include a first filler material including an inorganic
material and a second filler material including an organic
material.
[0032] In one particular aspect, the core can include a first
filler material comprising an oxide, such as alumina, and more
particularly, fused alumina. Moreover, the core can include a
second filler material including an organic material, including for
example, an organic material including a hydroxyl group. More
particularly, the core can include a second filler material
comprising ethanol. The second filler may further include a second
filler material comprising phosphate. In one embodiment, the core
can include a second filler material including ethanol and
phosphate, and more particularly, a second filler material
comprising ethanol, 2 chloro-phosphate (3:1), such that it can
consist essentially of ethanol, 2 chloro-phosphate (3:1).
[0033] The mixture, and thus the core, can further include a third
filler material in addition to at least a first filler material,
wherein the third filler material can be different than the first
filler material by at least one of composition, average particle
size, content in the mixture or core, and a combination thereof.
Moreover, the core can include a third filler material in addition
to at least the second filler material, wherein the third filler
material can be different than the second filler material by at
least one of composition, average particle size, content in the
mixture or core, and a combination thereof.
[0034] The core can have a first filler material including an
inorganic material and a third filler material including an
inorganic material. In one particular embodiment, the first filler
material can include an oxide and the third filler material can
include an oxide, and more particularly, the first filler material
can include at least one metallic element different than the third
filler material. For example, the core can include a third filler
including iron, and more particularly, iron oxide. The third filler
material may include a mineral, which may include iron, such as
magnetite (Fe.sub.3O.sub.4). According to one embodiment, the third
filler material may consist essentially of magnetite (e.g., black
oxide).
[0035] The mixture may contain a particular content of filler. For
example, the total content of filler can be present in an amount of
at least about 1 vol % for the total volume of the mixture or the
core. In other embodiments, the amount of filler can be greater,
such as at least about 2 vol %, at least about 5 vol %, at least
about 10 vol %, at least about 20 vol %, or at least about 50 vol %
for a total volume of the mixture or core. Alternatively, the
filler can be present in an amount of not greater than about 99 vol
%, such as not greater than about 98 vol %, not greater than about
95 vol %, not greater than about 90 vol %, not greater than about
80 vol %, not greater than about 70 vol %, not greater than about
60 vol %, not greater than about 55 vol %, or even not greater than
about 50 vol % for the total volume of the mixture or core. It will
be appreciated that the mixture can contain an amount of filler
within a range between any of the minimum and maximum percentages
noted above.
[0036] The mixture, and thus the finally-formed core, can include a
first filler material and a second filler material, wherein the
mixture or core can have a greater content of the first filler
material compared to a content of the second filler material.
Alternatively, the core may have a greater content of the second
filler material compared to a content of the first filler
material.
[0037] For example, the mixture or core can have a ratio (V1/V2) of
at least about 1, wherein V1 represents a content of a first filler
(vol %) within the mixture or core and V2 represents a content of a
second filler (vol %) within the mixture or core. In another
embodiment, the ratio (V1/V2) can be at least about 1.1, such as at
least about 1.2, at least about 2, at least about 3, at least about
4, at least about 5, at least about 10, at least about 20, or even
at least about 30. Still, in one non-limiting embodiment, the ratio
(V1/V2) can be not greater than about 30, such as not greater than
about 20, not greater than about 15, not greater than about 10, not
greater than about 5, not greater than about 4, not greater than
about 3, not greater than about 2. It will be appreciated that the
ratio (V1/V2) can be within a range between any of the minimum and
maximum values noted above.
[0038] Alternatively, the core can have a ratio (V2/V1) of at least
about 1, wherein V1 represents a content of a first filler (vol %)
within the mixture or core and V2 represents a content of a second
filler (vol %) within the mixture or core. More particularly, the
ratio (V2/V1) can be at least about 1.1, such as at least about
1.2, at least about 2, at least about 3, at least about 4, at least
about 5, at least about 10, at least about 20, at least about 30.
Still, in other embodiments, the ratio (V2/V1) can be not greater
than about 30, not greater than about 20, not greater than about
15, not greater than about 10, not greater than about 5, not
greater than about 4, not greater than about 3, not greater than
about 2. It will be appreciated that the ratio (V2/V1) can be
within a range between any of the minimum and maximum values noted
above.
[0039] According to a particular embodiment, the mixture or core
can have at least about 0.5 vol % of the first filler for a total
volume of the mixture or core. In another embodiment, the mixture
or core can include at least about 1 vol %, such as at least about
1.5 vol %, at least about 2 vol %, at least about 5 vol %, at least
about 8 vol %, at least about 10 vol %, at least about 12 vol %, at
least about 15 vol % for a total volume of the mixture or core. In
another embodiment, the mixture or core can include not greater
than about 50 vol %, such as not greater than about 40 vol %, not
greater than about 30 vol %, not greater than about 25 vol %, not
greater than about 20 vol %, not greater than about 15 vol %, not
greater than about 10 vol %, not greater than about 8 vol %, not
greater than about 5 vol %, not greater than about 4 vol %, not
greater than about 3 vol %, or even not greater than about 2 vol %
of the first filler for the total volume of the mixture or core. It
will be appreciated that the mixture can contain an amount of the
first filler within a range between any of the minimum and maximum
percentages noted above.
[0040] The mixture or core may also include a second filler
material in an amount of at least about 0.5 vol % for a total
volume of the mixture or core. In another embodiment, the mixture
or core can include at least about 1 vol %, such as at least about
1.5 vol %, at least about 2 vol %, at least about 5 vol %, at least
about 8 vol %, at least about 10 vol %, at least about 12 vol %, or
even at least about 15 vol % or a total volume of the mixture or
core. Still, the content of the second filler within the mixture or
core can be not greater than about 50 vol %, such as not greater
than about 40 vol %, not greater than about 30 vol %, not greater
than about 25 vol %, not greater than about 20 vol %, not greater
than about 15 vol %, not greater than about 10 vol %, not greater
than about 8 vol %, not greater than about 5 vol %, not greater
than about 4 vol %, not greater than about 3 vol %, or even not
greater than about 2 vol % for the total volume of the mixture or
core. It will be appreciated that the mixture can contain an amount
of the second filler within a range between any of the minimum and
maximum percentages noted above.
[0041] As described herein, the mixture, and thus the
finally-formed core, can include a first filler material and a
third filler material. The mixture or core may utilize a particular
content of the first filler and third filler. For example, the
mixture or core can have a greater content of the first filler
material compared to a content of the third filler material. Still,
in other instances, the mixture or core can include a greater
content of the third filler material compared to a content of the
first filler material.
[0042] In one particular embodiment, the mixture or core may have a
ratio (V1/V3) of at least about 1, wherein V1 represents a content
of a first filler (vol %) within the mixture or core and V3
represents a content of a third filler (vol %) within the mixture
or core. In certain other instances, the ratio (V1/V3) can be at
least about 1.1, such as at least about 1.2, at least about 2, at
least about 3, at least about 4, at least about 5, at least about
10, at least about 20, at least about 30. Still, in one
non-limiting embodiment, the ratio (V1/V3) can be not greater than
about 30, not greater than about 20, not greater than about 15, not
greater than about 10, not greater than about 5, not greater than
about 4, not greater than about 3, not greater than about 2. It
will be appreciated that the ratio (V1/V3) can be within a range
between any of the minimum and maximum values noted above.
[0043] Alternatively, the core can have a ratio (V3/V1) of at least
about 1, wherein V1 represents a content of a first filler (vol %)
within the mixture or core and V3 represents a content of a third
filler (vol %) within the mixture or core. More particularly, the
ratio (V3/V1) can be at least about 1.1, such as at least about
1.2, at least about 2, at least about 3, at least about 4, at least
about 5, at least about 10, at least about 20, at least about 30.
Still, in one non-limiting embodiment, the ratio (V3/V1) can be not
greater than about 30, such as not greater than about 20, not
greater than about 15, not greater than about 10, not greater than
about 5, not greater than about 4, not greater than about 3, not
greater than about 2. It will be appreciated that the ratio (V3/V1)
can be within a range between any of the minimum and maximum values
noted above.
[0044] Moreover, the mixture or core can have a particular content
of the second filler and third filler. For example, the mixture or
core can have a greater content of the second filler material
compared to a content of the third filler material. Still, in other
instances, the mixture or core can include a greater content of the
third filler material compared to a content of the second filler
material.
[0045] In one particular embodiment, the mixture or core can have a
ratio (V2/V3) of at least about 1, wherein V2 represents a content
of a second filler (vol %) within the mixture or core and V3
represents a content of a third filler (vol %) within the mixture
or core. For example, the ratio (V2/V3) can be at least about 1.1,
such as at least about 1.2, at least about 2, at least about 3, at
least about 4, at least about 5, at least about 10, at least about
20, or even at least about 30. In yet another non-limiting
embodiment, the ratio (V2/V3) can be not greater than about 30,
such as not greater than about 20, not greater than about 15, not
greater than about 10, not greater than about 5, not greater than
about 4, not greater than about 3, or even not greater than about
2. It will be appreciated that the ratio (V2/V3) can be within a
range between any of the minimum and maximum values noted
above.
[0046] In yet another aspect, the mixture or core may utilize a
ratio (V3/V2) of at least about 1, wherein V2 represents a content
of a second filler (vol %) within the mixture or core and V3
represents a content of a third filler (vol %) within the mixture
or core. According to one particular embodiment, the ratio (V3/V2)
can be at least about 1.1, at least about 1.2, at least about 2, at
least about 3, at least about 4, at least about 5, at least about
10, at least about 20, or even at least about 30. Still, in one
non-limiting embodiment, the ratio (V3/V2) can be not greater than
about 30, not greater than about 20, not greater than about 15, not
greater than about 10, not greater than about 5, not greater than
about 4, not greater than about 3, or even not greater than about
2. It will be appreciated that the ratio (V3/V2) can be within a
range between any of the minimum and maximum values noted
above.
[0047] The mixture or core may utilize a particular content of the
third filler material, including for example, at least about 0.5
vol % of the third filler for a total volume of the mixture or
core. In other embodiments, the content of the third filler can be
greater, such as at least about 1 vol %, at least about 1.5 vol %,
at least about 2 vol %, at least about 5 vol %, at least about 8
vol %, at least about 10 vol %, at least about 12 vol %, or even at
least about 15 vol % for a total volume of the mixture or core.
Still, in one non-limiting embodiment, the content of the third
filler can be not greater than about 50 vol %, such as not greater
than about 40 vol %, not greater than about 30 vol %, not greater
than about 25 vol %, not greater than about 20 vol %, not greater
than about 15 vol %, not greater than about 10 vol %, not greater
than about 8 vol %, not greater than about 5 vol %, not greater
than about 4 vol %, not greater than about 3 vol %, or even not
greater than about 2 vol % for the total volume of the mixture or
core. It will be appreciated that the mixture can contain an amount
of the third filler within a range between any of the minimum and
maximum percentages noted above.
[0048] In further reference to aspects of the fillers in the
mixture and the core, in certain instances, the first filler
material can have a first average particle size and the second
filler material having a second average particle size. For one
embodiment, the first average particle size can be different than
the second average particle size, and more particularly, the first
average particle size can be greater than the second average
particle size. In still other instances, the second average
particle size can be greater than the first average particle
size.
[0049] The first average particle size of the filler can be at
least 2% different as compared to the second average particle size.
In other instances, the difference can be greater, such as at least
about 5%, at least about 8%, at least about 10%, at least about
15%, or even at least about 20%, at least about 40%, at least about
60%, at least about 80%, or even at least about 100%. Still, in one
non-limiting embodiment, the difference in average particle size
between the first average particle size and the second average
particle size can be not greater than about 300%, such as not
greater than about 200%, or even not greater than about 150%. It
will be appreciated that the difference in average particle size
between the first average particle size and the second average
particle size can be within a range between any of the minimum and
maximum percentages noted above. Moreover, any two particulate
filler materials of the mixture or core can have the same percent
difference in size relative to each other as noted above.
[0050] Moreover, the mixture or the core can include a first filler
material having a first average particle size and a third filler
material having a third average particle size. For certain
embodiments, the first average particle size can be different than
the third average particle size, and more particularly, the first
average particle size can be greater than the third average
particle size. In another embodiment, the third average particle
size can be greater than the first average particle size.
[0051] Additionally, the mixture or the core can have a second
filler material having a second average particle size and a third
filler material having a third average particle size. The second
average particle size can have a different than the third average
particle size, such that, for example, the second average particle
size can be greater than the third average particle size. In other
instances, the third average particle size can be greater than the
second average particle size.
[0052] After forming the mixture as illustrated in FIG. 1, the
method can continue with pouring the mixture into the preform as
shown in element 103. The mixture can be poured in the opening of
the preform, which defines a cavity for containing the mixture. The
mixture can fill any portion of the cavity of the preform. In one
embodiment, the mixture can fill substantially the entire volume of
the cavity created by the preform.
[0053] The mixture, and thus, the core, may include one or more
fillers having a certain density, which may facilitate forming a
low density core. One or more fillers may be a particulate material
having a density of less than about 4.0 g/cm.sup.3. In other
embodiments, the density of the filler can be less, such as not
greater than 3.8 g/cm.sup.3, not greater than about 3.5 g/cm.sup.3,
or even not greater than about 3.0 g/cm.sup.3.
[0054] As further illustrated in FIG. 1, the method can include
curing the mixture as shown in element 104. Curing the mixture can
change at least a portion of the liquid phase into a solid phase to
facilitate forming a core of an abrasive article. Curing the
mixture 104 can include curing the mixture by radiation. In one
instance, the radiation can include UV radiation. In one example,
the radiation can have a wavelength of at least about 100 nm, such
as at least about 150 nm, at least about 200 nm, or at least about
250 nm. Alternatively, the radiation can include a wavelength of
not greater than about 400 nm, such as not greater than about 380
nm, or not greater than about 350 nm. The radiation can have a
wavelength within a range between any of the minimum and maximum
wavelengths noted above.
[0055] In another embodiment, curing the mixture 104 may include
curing the mixture by heating the mixture, and even heating the
mixture and the preform. In certain instances, curing the mixture
can include a plurality of heating steps, which can have distinct
processing parameters relative to each other. For example, curing
may utilize a first heating step, which can include heating the
mixture at a first temperature T.sub.1 (temperatures noted in
.degree. C.). In one embodiment, the mixture can be heated to at
least 25.degree. C. In another embodiment, the first temperature
can be at least 28.degree. C., such as at least 30.degree. C., or
even at least 33.degree. C. In yet another embodiment, the first
temperature can be not greater than 40.degree. C., such as not
greater than 35.degree. C., or not greater than 30.degree. C.
According to one particular embodiment, the first temperature can
be substantially room temperature, such that essentially no
external heat is applied to the mixture.
[0056] In further embodiments of the curing of the mixture 104 in
method 100, the first heating can be conducted for a first
duration. The first duration can be at least about one hour, such
as at least about 2 hours, at least about 3 hours, at least about 6
hours, at least about 12 hours, or even at least about 24 hours. In
another non-limiting embodiment, the first duration can be not
greater than about 48 hours, such as not greater than about 36
hours, or not greater than about 24 hours. It will be appreciated
that the first duration can be within a range between the minimum
and maximum durations noted above.
[0057] In further embodiments, curing of the mixture can include a
second heating of the mixture at a second temperature T.sub.2. The
second heating can be undertaken after the first heating step. In
particular, the second temperature T.sub.2 can be different from
the first temperature T.sub.1. For example, the second temperature
T.sub.2 can be greater than the first temperature T.sub.1.
Moreover, in certain instances, the second temperature T.sub.2 and
the first temperature T.sub.1 can be different from each other by a
first temperature difference, defined by |T.sub.2-T.sub.1|, which
is the absolute value of the difference between the second
temperature and the first temperature.
[0058] According to an embodiment, the first temperature difference
can have an absolute value of not greater than about 50.degree. C.,
such as not greater than about 45.degree. C., or not greater than
about 40.degree. C. Moreover, the first temperature difference can
have an absolute value of at least about 10.degree. C., such as at
least about 20.degree. C., or at least about 30.degree. C. It will
be appreciated that the first temperature difference can be within
a range between any of the minimum and maximum values noted
above.
[0059] Additionally, the second heating can include a second
duration. In certain instances, the second duration can be
different from the first duration. For example, the second duration
can be greater than the first duration. Still, in other processes,
the second duration can be less than the first duration. In yet
another embodiment, the second duration can be substantially the
same as the first duration.
[0060] For certain processes according to embodiments herein,
curing the mixture can include a third heating of the mixture at a
third temperature T.sub.3. The third heating can be undertaken
after completing the second heating step and/or the first heating
step. The third temperature T.sub.3 can be different from the
second temperature T.sub.2. and the first temperature T.sub.1. In
particular, the third temperature may be greater than the second
temperature. Alternatively, the third temperature may be less than
the second temperature. According to one embodiment, the third
temperature T.sub.3 and the second temperature T.sub.2 can be
different from each other by a second temperature difference,
defined by |T.sub.3-T.sub.2|, which is the absolute value of the
difference between the third temperature and the second
temperature. The third temperature may be different from the first
temperature in the same manner as described above with respect to
the difference between the second temperature and the third
temperature.
[0061] The second temperature difference can have an absolute value
of not greater than about 40.degree. C., such as not greater than
about 35.degree. C., or not greater than about 30.degree. C. The
second temperature difference can have an absolute value of at
least about 10.degree. C., such as at least about 20.degree. C., or
at least about 30.degree. C. It will be appreciated that the second
temperature difference can be within a range between any of the
minimum and maximum values noted above.
[0062] Moreover, the third heating can include a third duration.
The third duration can be different from the second duration and/or
the first duration. For example, the third duration can be greater
than the second duration or the first duration. Alternatively, the
third duration can be less than the second duration or the first
duration. In still another embodiment, the third duration can be
substantially the same as the second duration or the first
duration.
[0063] For certain processes according to embodiments herein,
curing the mixture can include a fourth heating step of the mixture
at a fourth temperature T.sub.4. The fourth heating can be
undertaken after completing the third heating step. The fourth
temperature T.sub.4 can be different from the first temperature
T.sub.1, the second temperature T.sub.2, or the third temperature
T.sub.3., or the In particular, the fourth temperature may be
greater than the first temperature, second temperature, or third
temperature. Alternatively, the fourth temperature may be less than
the first temperature, second temperature, or third temperature.
According to one embodiment, the fourth temperature T.sub.4 and the
third temperature T.sub.3 can be different from each other by a
third temperature difference, defined by |T.sub.4-T.sub.3|, which
is the absolute value of the difference between the fourth
temperature and the third temperature.
[0064] The third temperature difference can have an absolute value
of not greater than about 60.degree. C., such as not greater than
about 55.degree. C., or not greater than about 50.degree. C.
Moreover, the third temperature difference can have an absolute
value of at least about 10.degree. C., such as at least about
20.degree. C., or at least about 30.degree. C. It will be
appreciated that the third temperature difference can be within a
range between any of the minimum and maximum values noted
above.
[0065] Moreover, the fourth heating can be conducted over a fourth
duration. The fourth duration can be different from the first
duration, second duration, or third duration. For example, the
fourth duration can be greater than the first duration, second
duration, or third duration. Alternatively, the fourth duration can
be less than the first duration, second duration, or third
duration. In still another embodiment, the fourth duration can be
substantially the same as the third duration.
[0066] In one instance, the first heating and the second heating
can have a total duration of at least about four hours, such as at
least about six hours, or at least about eight hours. Furthermore,
the first heating, the second heating, and the third heating can
have a total duration of at least about six hours, such as at least
about eight hours, or at least about twelve hours. Moreover, the
first heating, the second heating, the third heating, and the
fourth heating can have a total duration of at least about eight
hours, such as at least about ten hours, or at least about 14
hours. Alternatively, the first heating and the second heating can
have a total duration of not greater than about 72 hours, such as
not greater than about 64 hours, or not greater than about 60
hours. Furthermore, the first heating, the second heating, and the
third heating can have a total duration of not greater than about
96 hours, such as not greater than about 90 hours, or not greater
than about 84 hours. Moreover, the first heating, the second
heating, the third heating, and the fourth heating can have a total
duration of not greater than about 144 hours, such as not greater
than about 132 hours, or not greater about 120 hours.
[0067] The process of curing can also be conducted in an atmosphere
having a particular feature. For example, curing can be conducted
in a reduced pressure atmosphere as compared to standard
atmospheric conditions, which may facilitate formation of a core
having the properties disclosed herein. The process of providing a
reduced pressure atmosphere may be conducted prior to curing.
Additionally, the process of providing a reduced pressure
atmosphere may be conducted during curing. For example, the
pressure of the atmosphere during curing can be not greater than
about 0.1 Torr, such as not greater than about 0.01 Torr or even
not greater than about 0.001 Torr. Still, in at least one
embodiment, the pressure of the atmosphere during curing can be at
least about 1.times.10.sup.-5 Torr. It will be appreciated that the
reduced pressure atmosphere can have a pressure within a range
between any of the minimum and maximum values noted above.
[0068] Additionally, the process of curing in a reduced pressure
atmosphere may be suitable for moving the mixture to particular
locations. For example, a reduced pressure can be placed on the
mixture to facilitate directional movement of the mixture during
curing. In a particular embodiment, the pressure within the
environment can be reduced to pull the mixture toward the preform,
which may include bonded abrasive bodies. Accordingly, the
application of a reduced pressure atmosphere may facilitate pulling
the mixture into the bonded abrasive bodies during curing and the
formation of an integrally bonded abrasive article.
[0069] The process of curing can include a process of managing the
heat generated in the core during the curing process to reduce
stress in the system. According to one embodiment, the curing
process can include coupling one or more surfaces of the core to a
cooling structure that may utilize a cooling medium. Coupling can
include direct or indirect contact. In one particular embodiment,
curing can including monitoring the temperature of the system and
controlling a cooling structure coupled to the mixture, which can
include but is not limited to, adjusting a temperature of the
cooling structure to control heat transferred from the mixture to
the bonded abrasive body. The cooling structure can include a
cooling block having a cooling medium (e.g., water) flowing
internally within the block. The cooling block can be indirectly
coupled to the mixture, wherein a base plate is disposed between
the mixture and the cooling block during curing.
[0070] In one another embodiment of the method 100, curing the
mixture 104 can include monitoring a property of the mixture or the
core formed during the curing. Exemplary processes that may be
monitored can include flexural modulus, flexural strength, Rockwell
hardness, density, glass transition temperature, coefficient of
thermal expansion, and a combination thereof.
[0071] For example, the core formed by the method 100 can have a
flexural modulus of at least about 4 GPa, such as at least about 5
GPa, or at least about 7 GPa. Alternatively, the core can have a
flexural modulus of not greater than about 20 GPa, such as not
greater than about 18 GPa, or not greater than about 15 GPa. It
will be appreciated that the flexural modulus can be within a range
between any of the minimum and maximum values noted above.
[0072] In other instances, the core formed by the method 100 can
have a flexural strength of at least about 40 MPa, such as at least
about 45 MPa, or at least about 50 MPa. Alternatively, the core can
have a flexural strength of not greater than about 100 MPa, such as
not greater than about 90 MPa, or not greater than about 80 MPa. It
will be appreciated that the flexural strength can be within a
range between any of the minimum and maximum values noted
above.
[0073] In further instances, the core formed by the method 100 can
have a Rockwell hardness of at least about 70, such as at least
about 80, or at least about 90. Alternatively, the core can have a
Rockwell hardness of not greater than about 120, such as not
greater than about 110, or not greater than about 100. It will be
appreciated that the Rockwell hardness can be within a range
between any of the minimum and maximum values noted above.
[0074] In yet other instances, the core formed by the method 100
can have a density of at least about 0.8 g/cc, such as at least
about 0.9 g/cc, or at least about 1.0 g/cc. Alternatively, the core
can have a density of not greater than about 2.8 g/cc, such as not
greater than about 2.5 g/cc. or not greater than about 2.0 g/cc. It
will be appreciated that the density can be within a range between
any of the minimum and maximum values noted above.
[0075] In other instances, the core formed by the method 100 can
have a glass transition temperature Tg of at least about least
about 75.degree. C., such as at least about 80.degree. C. at least
about 90.degree. C., at least about 100.degree. C., at least about
110.degree. C., at least about 120.degree. C., or at least about
140.degree. C. Alternatively, the core can have a glass transition
temperature Tg of not greater than about 200.degree. C., such as
not greater than about 180.degree. C., not greater than about
170.degree. C., not greater than about 160.degree. C., not greater
than about 150.degree. C., not greater than about 140.degree. C.,
or even not greater than about 130.degree. C. It will be
appreciated that the glass transition temperature can be within a
range between any of the minimum and maximum temperatures noted
above.
[0076] The core can be a monolithic body, and more particularly, an
essentially monolithic body. A monolithic body can be a seamless
body having substantially uniform material properties throughout
the volume of the body. A monolithic body may have essentially no
adhesive material, since a monolithic body does not necessarily
contain different components that are joined to each other.
Furthermore, a monolithic body may have a substantially uniform
density, a substantially uniform hardness, a substantially uniform
flexural modulus, a substantially uniform flexural strength, a
substantially uniform glass transition temperature, a substantially
uniform coefficient of thermal expansion, and any combination of
these properties.
[0077] The monolithic body may contain a reinforcing structure
contained within the monolithic body or joined to the monolithic
body. The reinforcing member may be an inorganic material, organic
material, glass, glass fiber, ceramic, natural material, and a
combination thereof. The reinforcing member may be incorporated
into the body to facilitate the formation of a core having the
properties described herein. The core can include at least one
reinforcing structure or a plurality of reinforcing structures.
According to one embodiment, the reinforcing structure can be a
substantially planar layer of material, which may extend radially
through the body of the core in a plane defined by a diameter. In
certain instances, the reinforcing structure can include a woven
material, non-woven material, composite material and a combination
thereof.
[0078] FIG. 2 includes a perspective view illustration of a core of
an abrasive article in accordance with an embodiment. As noted
herein, the core can include a monolithic body comprising an
organic material. Furthermore, the core 201 may have a cylindrical
shape defined by a diameter (d), a circumference (C), and a height
(h). As described herein, the method of forming may facilitate
making a core having features significantly different than
conventional cores. Notably, the core 201 can be a monolithic body
having a height (h) of at least about 3 inches (7.6 cm). As
illustrated, the core 201 can have a cylindrical body, wherein the
height (h) is defined as a distance between a first major surface
203 and a second major surface 204 opposite the first major surface
203 and separated by a peripheral surface 205. In particular
instances, the height (h) of the core 201 can be greater, such as
at least about 3.5 inches (8.9 cm), at least about 4 inches (10.2
cm), at least about 4.5 inches (11.4 cm), at least about 5 inches
(12.7 cm), at least about 5.5 inches (14 cm) at least about 6
inches (15.2 cm), at least about 6.5 inches (16.5 cm) or even at
least about 7 inches (17.8 cm). In at least one non-limiting
embodiment, the height (h) of the core 201 may be not greater than
about 30 inches (76.2 cm). It will be appreciated that the height
(h) of the core 201 may be within a range between any of the
minimum and maximum values noted above.
[0079] In other embodiments, the monolithic body of the core 201
may have a particular diameter. For example, in one embodiment the
diameter (d) of the core 201 can be at least about 6 inches (15.2
cm), such as at least about 10 inches (24.4 cm), at least about 16
inches (40.6 cm), or even at least about 20 inches (50.8 cm).
Still, in one non-limiting embodiment, the diameter (d) of the core
201 can be not greater than about 50 inches (1.3 m). It will be
appreciated that the monolithic body of the core 201 can have a
diameter (d) within a range between any of the above minimum and
maximum values.
[0080] Furthermore, the monolithic body of the core 201 may have a
particular circumference, measured as the total distance around the
peripheral surface 205. In accordance with a particular embodiment,
the core 201 can have a circumference that is at least about 19
inches (48 cm). Still other embodiments, the circumference (C) may
be greater, such as at least about 31 inches (78 cm), at least
about 50 inches (128 cm), or even at least about 63 inches (160
cm). Still, in one non-limiting embodiment, the circumference (C)
can be not greater than about 70 inches (178 cm). It will be
appreciated that the circumference (C) of the core 101 can be
within a range between any of the minimum and maximum values noted
above.
[0081] According to particular forming methods herein, the core 210
can be made as a monolithic body having a particularly large
volume. For example, the core 201 can have a volume of at least
about 75 in.sup.3 (1229 cm.sup.3). Still other embodiments, the
volume of the core 201 can be greater, such as on the order of at
least about 500 in.sup.3 (8194 cm.sup.3), at least about 1000
in.sup.3 (16387 cm.sup.3), at least about 1200 in.sup.3 (19664
cm.sup.3), at least about 1600 in.sup.3 (26219 cm.sup.3), at least
about 1800 in.sup.3 (29496 cm.sup.3), or even least about 2000
in.sup.3 (32774 cm.sup.3). Still, in at least in at least one
non-limiting embodiment, the core 201 can have a volume that is not
greater than about 20000 in.sup.3 (327741 cm.sup.3). It will be
appreciated that the core 201 can have a volume within a range
between any of the minimum and maximum values noted above.
[0082] As further illustrated, the core 201 can have an opening 202
that may extend through the volume of the body of the core 201. In
particular instances, the opening 202 may extend through the entire
height (h) of the core 201 from a first major surface 203 to a
second major surface 204 opposite the first major surface 203. In
particular instances, the opening 202 may be disposed at the
centered at the first major surface 203 and second major surface
204 of the core 201.
[0083] The opening 202 may be an arbor hole, configured to engage a
spindle for rotation of the core 201 during grinding operations. In
accordance with at least one embodiment, the opening 202 may extend
along the direction of height (h) between the first major surface
and second major surface of the core 201. The opening 202 can
extend through a volume of the monolithic body of the core 201. As
illustrated, the opening 202 can extends along a direction of the
height of the core 201, and in particular, the opening 202 can
extend between a first major surface and a second major surface of
the core 201.
[0084] The opening 202 may be formed to have particular dimensions,
including for example a diameter (d). In one embodiment, the
opening 202 can have a diameter of at least about 1 inch (2.5 cm).
In other embodiments, the diameter of the opening 202 may be
greater, such at least about 2 inches (5.1 cm), at least about 3
inches (7.6 cm), or even at least about 4 inches (10 cm). In one
particular embodiment, the opening 202 can have a diameter of not
greater than about 100 inches (2540 cm), and more particularly, not
greater than about 50 inches (127 cm). It will be appreciated that
the opening 202 may have a diameter within a range between any of
the minimum and maximum values noted above.
[0085] In particular instances, the core 201 may include a liner
207 overlying at least a portion of the surface defining the
opening 202. In certain instances, the liner 207 may overlie
essentially the entire surface defining the opening 202 extending
from the first major surface 203 to the second major surface 204.
Furthermore, the liner 207 may extend around the entire inner
peripheral surface defining the opening 202 and define at least a
portion of the arbor hole opening configured to engage a spindle of
a grinding machine. The liner 207 can include an inorganic
material, such as a metal or metal alloy. The liner 207 may include
a material such as aluminum, silicon, steel, carbon fiber, and a
combination thereof.
[0086] The liner 207 can include various materials, including for
example inorganic materials, organic materials, and a combination
thereof. In particular instances, the liner 207 may be formed of a
metal or a metal alloy. More particularly, the liner 207 may
consist essentially of a metal or metal alloy.
[0087] As further illustrated in FIG. 2, the liner 207 may be in
direct contact with the core 201. For example, the liner 207 may be
bonded directly to the core 201, and more particularly, the inner
surface of the opening 202. Alternatively the liner 207 may be
fastened to the core 201 via a mechanism, such as an engagement
structure. Some suitable types of engagement structures can include
a threaded surface, an interference fit, a fastener, a clip, and a
combination thereof.
[0088] As noted above, the core 201 can be a monolithic body formed
of a polymer, and more particularly, a polymer such as an epoxy
polymer, a phenoxy polymer, a polyurea, a polyimide, a polycyanate,
an acrylic, a polyurethane, a melamine polymer, a polyester, or
foamed structures of the same or a combination thereof. In certain
cases, the core 201 can be a monolithic body formed of an epoxy
polymer derived from a bisphenol-A compound. In one particular
instance, the bisphenol-A compound is bisphenol-A diglycidyl
ether.
[0089] The core may be made of at least about 5 vol % polymer
material. In other embodiments, the amount of polymer material can
be greater, such as at least about 10 vol %, at least about 25 vol
%, at least about 50 vol %, at least about 75 vol %, or even at
least about 95 vol %. In one particular embodiment, the core can
consists essentially of a polymer material, and more particularly,
a single polymer material.
[0090] Furthermore, the core 201 may have particular
characteristics such as a particular linear coefficient of thermal
expansion (CTE) as measured at room temperature or within a range
between room temperature and about 100.degree. C. In particular
instances, the core 201 may have a linear coefficient of thermal
expansion of at least about 15 microns/m C, such at least about 25
.mu.m/m.degree. C., at least about 28 .mu.m/m.degree. C., at least
about 30 .mu.m/m.degree. C., at least about 33 .mu.m/m.degree. C.,
at least about 35 .mu.m/m.degree. C., at least about 37
.mu.m/m.degree. C., at least about 40 .mu.m/m.degree. C., at least
about 43 .mu.m/m.degree. C., at least about 45 .mu.m/m.degree. C.,
at least about 48 .mu.m/m.degree. C., at least about 50
.mu.m/m.degree. C., or even at least about 53 .mu.m/m.degree. C. In
other non-limiting embodiments, the core 201 may have a linear
coefficient of thermal expansion of not greater than about 200
.mu.m/m.degree. C., such as not greater than about 180
.mu.m/m.degree. C., not greater than about 160 .mu.m/m.degree. C.,
not greater than about 150 .mu.m/m.degree. C., not greater than
about 125 .mu.m/m.degree. C., not greater than about 100
.mu.m/m.degree. C., not greater than about 80 .mu.m/m.degree. C.,
or even not greater than about 70 microns/m C. Formation of a core
201 having a suitable coefficient of thermal expansion may
facilitate integral bonding between the core 201 and the bonded
abrasive body attached thereto.
[0091] According to one embodiment, the core can include an amount
of uncured epoxy of at least about 0.1 vol % for a total volume of
the core after completion of the curing process. In more particular
instances, the core may include a content of uncured epoxy of at
least about 0.5 vol %, such as at least about 1 vol %, at least
about 2 vol %, or even at least about 5 vol %. Still, the content
of uncured epoxy within the core may be not greater than about 15
vol %, such as not greater than about 12 vol %, not greater than
about 10 vol %, not greater than about 5 vol %, or even not greater
than about 2 vol %. The content of uncured epoxy can be within a
range between any of the above minimum and maximum percentages.
[0092] The core may be formed to have a content of porosity of not
greater than about 15 vol % for the total volume of the core. In
other instances, the content of porosity can be less, such as not
greater than about 12 vol %, not greater than about 10 vol %, not
greater than about 8 vol %, not greater than about 5 vol %, or even
not greater than about 3 vol %. Still, the porosity of the core may
be at least about 0.1 vol %, such as at least about 0.5 vol %, or
even at least about 1 vol %. The porosity of the core may be within
a range between any of the minimum and maximum percentages noted
above.
[0093] FIG. 3 includes a perspective view illustration of an
abrasive article in accordance with an embodiment. As illustrated,
the abrasive article 300 can include a core 201, and a first bonded
abrasive article 301 integrally bonded to the peripheral surface
205 of the core 201. As used herein, the term integrally bonded is
reference to a bond interface defined by interfusion of material
from the core 201 and a bond material within the bonded abrasive
article. That is, in particular instances, integrally bonded
components can be joined directly to each other without the use of
an intervening compound, such as an adhesive material.
[0094] In accordance with one embodiment, the bonded abrasive body
301 can include a bond material made of a hybrid material including
an organic portion and an inorganic portion. In certain instances,
the organic portion and the inorganic portion can be substantially
uniformly distributed throughout the volume of the bond material.
Moreover, in other embodiments, the organic portion and the
inorganic portion can be substantially uniformly distributed within
each other.
[0095] According to one embodiment, the inorganic portion of the
bond material can include a metal or metal alloy material.
Particularly suitable metals can include transition metal elements,
including but not limited to, copper, tin, silver, chromium,
titanium, vanadium, manganese, iron, cobalt, nickel, zinc, gold,
molybdenum, zirconium, tungsten, yttrium, tantalum, aluminum, and a
combination thereof. In one particular embodiment, the bond
material can include a combination of copper and tin, such that the
bond material may be a bronze material. In specific embodiments,
the bond material can have a greater content of copper than tin.
For example, the bond material can have a copper:tin ratio of
approximately 60:40 by weight.
[0096] According to another embodiment, the organic portion of the
bond material can include a polymer material. Some suitable polymer
materials can include thermosets, thermoplastics, rubbers,
polyimides, polyamides, resins, aramids, epoxies, polyesters,
polyurethanes, and a combination thereof. In particular instances,
the polymer material may include an epoxy, polyester, phenolic,
polyisocyanurate ester, and a combination thereof. According to a
particular embodiment, the organic portion can include
polybenzimidazole (PBI).
[0097] In certain other embodiments, the bond material can include
a greater content of the inorganic portion (vol %) as compared to a
content of the organic portion (vol %) within the bond. For
example, the bond material can include a minority content of the
organic portion. In at least one embodiment, the bond material can
include not greater than about 40 vol % organic portion, such as
not greater than about 35 vol %, not greater than about 30 vol %,
not greater than about 25 vol %, not greater than about 20 vol %
organic portion for the total volume of the bond material. In at
least one non-limiting embodiment, the bond material can include at
least about 1 vol % organic portion for the total volume of the
bond. It will be appreciated that the amount of the organic portion
within the bond can be within a range between the minimum and
maximum percentages noted above.
[0098] In certain other aspects, the bond material can have a
greater content of the organic portion (vol %) as compared to a
content of the inorganic portion (vol %) within the bond. For
certain embodiments, the bond material can include a minority
content of the inorganic portion for the total content of the bond.
In still another embodiment, the bond material can contain a
majority content of the inorganic portion for the total content of
the bond. For example, the bond material can include at least about
10 vol %, such as at least about 15 vol %, at least about 20 vol %,
at least about 25 vol %, at least about 30 vol %, at least about 35
vol %, at least about 40 vol %, at least about 45 vol %, or even at
least about 50 vol % inorganic portion for the total volume of the
bond material. In one non-limiting embodiment, the bond material
can contain not greater than about 99 vol %, such as not greater
than about 96 vol %, or even not greater than about 94 vol %
inorganic material for the total volume of the bond. It will be
appreciated that the amount of the inorganic portion within the
bond can be within a range between the minimum and maximum
percentages noted above.
[0099] In certain instances, the bonded abrasive body 301 can be
formed to include a particular amount of bond material to
facilitate the formation of the abrasive article according to
embodiments herein. For example, the bonded abrasive body 301 can
include at least about 5 vol % bond material for the total volume
of bonded abrasive body 301. In other embodiments, the amount of
bond material may be greater, such as at least 10 vol %, at least
about 20 vol %, at least about 30 vol %, at least about 40 vol %,
at least about 50 vol % or even at least about 55 vol %. Still, in
one non-limiting embodiment, the bonded abrasive body 301 may
include not greater than about 75 vol %, such as not greater than
70 vol %, not greater than about 65 vol %, not greater than about
60 vol %, not greater than about 55 vol %, not greater than about
50 vol %, not greater than about 45 vol %, or even not greater than
about 40 vol % bond material for the total volume of the bonded
abrasive body 301. It will be appreciated that the amount of bond
material within the bonded abrasive body 301 may be within range
between any of the minimum and maximum percentages noted above.
[0100] In one aspect, the bonded abrasive body 301 may include a
particular content of abrasive particles, which can be dispersed
throughout the volume of the bond material, to facilitate the
formation of abrasive articles according to embodiments herein. For
example, the bonded abrasive body 301 may include at least about 5
vol % abrasive particles for the total volume of the body. In other
embodiments, the amount of abrasive particles can be greater, such
as at least about 10 vol %, at least about 15 vol %, at least about
20 vol %, at least about 25 vol %, at least about 30 vol %, at
least about 35 vol %, or even at least about 40 vol %. Still, in
one particular instance, the bonded abrasive body can contain not
greater than about 75 vol % abrasive particle, such as on the order
of not greater than about 65 vol %, not greater than about 60 vol
%, not greater than about 55 vol %, not greater than about 50 vol
%, or even not greater than about 45 vol % for the total volume of
the bonded abrasive body 301. It will be appreciated that the
amount of abrasive particle within the body can be within a range
between any of the minimum and maximum percentages noted above.
[0101] The abrasive particles within the bonded abrasive body 301
can include oxides, carbides, nitrides, borides, oxycarbides,
oxynitrides, and a combination thereof. In particular instances,
the abrasive particles may be a superabrasive material, such as
carbide, boron nitride, diamond, and a combination thereof. In
still other instances, the abrasive particles may include alumina,
silica, sulfur carbide, boron, diamond, and a combination thereof.
In one particular instance, the abrasive particles can consist
essentially of diamond.
[0102] The bonded abrasive body 301 may include a particular
content of porosity to facilitate the formation of the abrasive
articles of the embodiments herein. The porosity may be in the form
of open porosity defining an interconnected network of channels
extending throughout the bond material. Alternatively, the body may
include a content of closed porosity described and characterized by
discrete and individual pores separated from each other. In at
least one embodiment, the bonded abrasive body can include a mix of
open porosity and closed porosity.
[0103] The amount of porosity within the body can comprise a
majority content, such as greater than 50 vol % for the total
volume of the body. In still other instances, the bonded abrasive
body may include a minority content of porosity, which can
represent less than 50 vol % of the total volume of the bonded
abrasive body. Furthermore, the body may contain a majority content
of closed porosity. Still, in other instances, the bonded abrasive
body may contain a majority content of open porosity.
[0104] For certain bonded abrasive bodies, the amount of porosity
may be not greater than about 70 vol % for the total volume of the
total bonded abrasive body. In yet other instances, the bonded
abrasive body 301 may be formed such that the amount of porosity is
not greater than about 60 vol %, such as not greater than about 50
vol %, not greater than about 40 vol %, not greater than about 30
vol %, not greater than about 25 vol %, not greater than about 20
vol %, not greater than about 15 vol %, not greater than about 10
vol %, not greater than about 5 vol %, or even not greater than
about 2 vol %. In at least one non-limiting embodiment, the bonded
abrasive body 301 may contain an amount of porosity of at least
about 1 vol %, such as at least about 5 vol %, at least at about 15
vol %, at least about 20 vol %, at least about 30 vol %, or even at
least about 40 vol %. Moreover, it will be appreciated that the
total amount of porosity within the bonded abrasive body 301 can be
within a range between any of the minimum and maximum percentages
noted above.
[0105] The bonded abrasive body 301 may include some amount of
filler, which can be any one or more of the filler materials
described herein. The filler may be present and dispersed
throughout the volume of bond material. Certain fillers may include
pore formers, including materials such as glasses, glass-ceramics,
ceramics, organics, and a combination thereof. According to one
embodiment, certain suitable fillers can include bubble alumina,
bubble mullite, hollow spheres, hollow glass spheres, hollow
ceramics, hollow polymers spheres, polymers materials, organic
compounds, fibrous materials, naphthalene, PBD, shells, wood, and
the like. In still other, alternative embodiments, the filler
material may be a particulate material, such as a powder including
a material selected from a group of zirconia, silica, titania, and
a combination thereof.
[0106] It will be appreciated that the bonded abrasive body 301 may
contain a minor content of filler material, such that the total
content of filler material may be less than about 50 vol % for the
total volume of the body 301. In fact, in certain instances, the
amount of filler material can be less such as not greater than
about 20 vol %, not greater than about 15 vol %, not greater than
about 10 vol %, not greater than about 8 vol %, or even not greater
than about 5 vol % for the total volume of the body.
[0107] The abrasive article disclosed in FIG. 3 can include a
bonded abrasive body 301 integrally bonded to the core 201 at the
peripheral surface 205. In accordance with an embodiment, the
bonded abrasive body 301 and core 201 can be integrally bonded at
the interface 306 defined by a portion of the peripheral surface
205 of the core 201. The interface 306 may be characterized by
interfusion of material of the core 201 and bond material within
the bonded abrasive body 301.
[0108] As further illustrated in FIG. 3, the bonded abrasive body
301 can have a generally annular shape having a central opening
configured to fit around the peripheral surface 205 of the core
201. As such, at least a portion of the bonded abrasive body 301
can extend around at least a portion of the peripheral surface of
the core 201. More particularly, as illustrated in FIG. 3, the
bonded abrasive body 301 can extend essentially around the entire
distance of the peripheral surface 205 of the core 201.
[0109] As further illustrated, the abrasive article illustrated in
FIG. 3 can include a bonded abrasive body 302 that can be
integrally bonded to the core 201. The bonded abrasive body 302 can
be coupled to a peripheral surface 205 of the core 201. In
particular instances, the bonded abrasive body 302 can be adjacent
to the bonded abrasive body 301 and more particularly, abutting the
bonded abrasive body 301. As such, the bonded abrasive body 301 can
be in a coaxial relationship with a bonded abrasive body 302
relative to the core 201. Moreover, as illustrated in FIG. 3, the
bonded abrasive body 301 can be coupled directly to the next
abrasive body 302 at a bond seam 304. In particular instances, the
bonded abrasive body 301 can be bonded to the bonded abrasive body
302 using an adhesive or epoxy material.
[0110] The bonded abrasive body 302 can have the same features as
the bonded abrasive body 301, including for example, the same
abrasive particles, bond material, porosity, and filler as
described to the bonded abrasive body 301. In fact, in certain
instances, each of the bonded abrasives bodies 301, 302, 303, may
be essentially identical in composition and structure.
[0111] As further illustrated in FIG. 3, the abrasive article 300
can include a bonded abrasive body 303 coupled to the bonded
abrasive body 302 in the same manner as described in embodiments
herein. The bonded abrasive 303 can be integrally bonded to the
core 201. Moreover, the bonded abrasive body 303 can be directly
abutting, and more particularly, bonded directly to the bonded
abrasive body 302. The bonded abrasive bodies 302 and 303 can be
bonded to each other at a bond seam 305.
[0112] Still, in certain instances, the bonded abrasive body 302
can be spaced apart from the core 201 by a distance of not greater
than about 0.08 inches, such as not greater than about 0.05 inches,
not greater than about 0.01 inches, or even not greater than about
0.008 inches.
[0113] While a particular abrasive article is illustrated in FIG.
3, it will be appreciated that other embodiments having various
other features are feasible. For example, the abrasive article may
have a bonded abrasive body coupled to the first major surface 203
or second major surface 204 of the core 201. Furthermore, the
bonded abrasive body may be coupled to the core 201 proximate to
the peripheral surface, yet abutting the first major surface 203.
Alternatively, the bonded abrasive body may be coupled to the core
201 proximate to the peripheral surface, yet abutting the second
major surface 204. In certain instances, the abrasive article may
be formed such that a bonded abrasive body is integrally bonded to
the first major surface 203 and second major surface 204. It will
be appreciated that the bonded abrasive article may be coupled to
the core in various configurations, such that it may extend
radially from a surface of the core 201, or alternatively, axially
from a surface of the core 201.
[0114] The bonded abrasive body 301 may have particular
characteristics, such as a particular coefficient of thermal
expansion (CTE) as measured from 30.degree. C. to 150.degree. C.
temperature. In particular instances, the bonded abrasive body 301
may have a coefficient of thermal expansion of at least about 1
micron/(m.degree. C.). More particularly, the bond material of the
bonded abrasive body can have a linear CTE of at least about 3
microns/(m.degree. C.), such as at least about 5 microns/(m.degree.
C.). Still, the bond material may have a linear CTE of not greater
than about 30 microns/(m.degree. C.).
[0115] In particular instances, the bond material of the bonded
abrasive body 301 may have a particular linear shrinkage. For
example, the linear shrinkage may be not greater than about 8%,
such as not greater than about 5%, or even not greater than about
3%. Still, the linear shrinkage of the bond material of the bonded
abrasive body 301 may be at least about 0.01%, such as at least
about 0.1%.
[0116] Moreover, the bond material of the bonded abrasive body 301
may have a particular flexural strength. For example, the flexural
strength may be at least about 5 MPa, such as at least about 10
MPa, or even at least about 20 MPa. Still, in certain embodiments,
the flexural strength of the bond material of the bonded abrasive
body 301 may be not greater than about 250 MPa, such as not greater
than about 220 MPa, not greater than about 180 MPa, or even not
greater than about 160 MPa.
[0117] In accordance with at least one embodiment, the abrasive
article 300 may be formed such that the bonded abrasive body 301
and core 201 are formed integrally with each other. As such, the
core 201 and the bonded abrasive body 301 may be formed to have
certain properties to facilitate the formation of abrasive articles
according to embodiments herein. In particular, certain properties
of the bonded abrasive body, bond of the bonded abrasive body, and
the core can be match to a suitable degree to facilitate the
formation of the abrasive articles of the embodiments herein. Some
exemplary properties of the components that can be matched can
include CTE, shrinkage, flexural strength, flexural modulus, and a
combination thereof.
[0118] In a particular instance, the bonded abrasive body 301 can
have a coefficient of thermal expansion (CTE.sub.ba) and the core
201 can have coefficient of thermal expansion (CTE.sub.c), wherein
the difference (.DELTA.CTE) between the coefficient of thermal
expansion of the core and coefficient of thermal expansion of the
bond material is not greater than about 30%, wherein the difference
in the coefficients of thermal expansion (.DELTA.CTE) between the
core 201 and the bonded abrasive body 301 can be defined by the
equation [(CTE.sub.ba-CTE.sub.c)/CTE.sub.ba].times.100%. In other
embodiments, the difference in coefficient of thermal expansion can
be less, such as not greater than about 25%, not greater than about
20%, not greater than about 18%, not greater than about 12%, or
even not greater than about 5%. In one non-limiting embodiment, the
difference in coefficient of thermal expansion can be at least
about 0.01%, or even at least about 0.05%. It will be appreciated
that the difference in coefficient of thermal expansion between the
core 201 and the coefficient of thermal expansion of the bonded
abrasive body 301 can be within a range between the minimum and
maximum percentages noted above.
[0119] Moreover, the abrasive article 300 can be formed such that a
particular difference in the coefficients of thermal expansion
(.DELTA.CTE) exists between the coefficient of thermal expansion of
the core 201 (CTE.sub.c) and the coefficient of thermal expansion
of the bond material (CTE.sub.bm) of the bonded abrasive body 301,
as defined by the equation
[(CTE.sub.bm-CTE.sub.c)/CTE.sub.bm].times.100%. The difference in
CTE between the bond material and the core can be the same as
described in the embodiments above with regard to the difference in
CTE between the bonded abrasive body and the core.
[0120] Moreover, the abrasive article 300 can be formed such that a
particular difference in shrinkage exists between the core 201 and
the bonded abrasive body. Notably, the difference in shrinkage
between the bonded abrasive body and the core can be the same
percentage difference as described in the embodiments above with
regard to the difference in CTE between the bonded abrasive body
and the core.
[0121] Moreover, the abrasive article 300 can be formed such that a
particular difference in shrinkage exists between the core 201 and
the bond material of the bonded abrasive body. Notably, the
difference in shrinkage between the bond material and the core can
be the same percentage difference as described in the embodiments
above with regard to the difference in CTE between the bonded
abrasive body and the core.
[0122] It will be appreciated that the other bonded abrasive bodies
302 and 303 of the abrasive article 300 can have the same features
and properties of the bonded abrasive body 301.
EXAMPLES
Example 1
[0123] A sample S1 of an abrasive article was prepared, which
included an integrally formed bonded abrasive article and a core
according to an embodiment. The abrasive article had an outer
diameter of 8-inches and a height of greater than 3 inches
[0124] Sample S1 had a core formed from liquid epoxy, which is
commercially available from Hapco, having a glass transition
temperature comprised a Tg in a range of about 122.degree. C. to
about 137.degree. C. and a CTE in a range of about 50
.mu.m/m.degree. C. to about 150 .mu.m/m.degree. C. The mixture was
mixed and poured into a mold cavity defined by the center of an 8
inch diameter bonded abrasive article. A liner of aluminum was
included to define an arbor hole. A reduced pressure atmosphere was
used during mixing and pouring to remove bubbles from the mixture.
Sample S1 included an epoxy polymer derived from bisphenol-A
diglycidyl ether, and fillers of ethanol, 2 chloro-, phosphate
(3:1), black oxide, and fused alumina. The mixture further included
a curing agent of isophorane diamine. The bonded abrasive body of
Sample S1 included a bond material comprising a hybrid material
including an inorganic portion of metal including copper and tin
and an organic portion of PBI.
[0125] The sample was cured using a process of a first heating
process conducted at room temperature (i.e., approximately
20.degree. C.) for approximately 4 hours, a second heating process
conducted between 55.degree. C.-60.degree. C. for 4 hours, and a
third heating process completed at a temperature between 90.degree.
C. to 95.degree. C. for 4 hours. The curing process was conducted
in a reduced pressure atmosphere The core of Sample S1 also
contained an amount of uncured epoxy in a range of about 0 vol % to
about 2 vol %.
[0126] Sample S1 experienced no cracking, shrinkage or delamination
problems. In particular, the bonded abrasive article and the core
maintained good adhesion at its core/abrasive interface.
Example 2
[0127] A sample S2 of an abrasive article was prepared, which
included an integrally formed bonded abrasive article and a core.
The abrasive had an outer diameter of 20.5-inches, an axial
thickness of 8-inches (made by combing two sections having an axial
thickness of 4 inches) and an interior diameter of 12 inches.
[0128] Sample S2 had a core formed from a two part-epoxy (i.e.,
Epoxy Part A and Epoxy Part B), which are commercially available
from Hapco. Epoxy Part A was stirred well using an overhead mixer.
Epoxy Part B, which acted as the curing agent, was added at an A:B
ratio of 100:11. The two parts were mixed using an overhead mixer
and then a vacuum was applied to remove any air entrained during
mixing. The bonded abrasive body of Sample S2 included a bond
material comprising a hybrid material including an inorganic
portion of metal including copper and tin and an organic portion of
PBI.
[0129] The bonded abrasive section of the wheel, having an outer
diameter of 20.5-inches, an axial thickness of 4-inches and an
interior diameter of 18 inches was placed on a waxed stainless
steel plate, and a waxed aluminum having an outer diameter of
12-inches, an axial thickness of 0.75-inches and an interior
diameter of 18-inches was placed in the center of the wheel. A
steel band, having an outer diameter of 20.5-inches, an axial
thickness of 0.75-inches and an interior diameter of 18 inches, was
placed over the abrasive section to hold excess epoxy. The epoxy
mixture was slowly poured into the space between the grinding wheel
and the aluminum sleeve and then a vacuum was applied to remove air
entrained during pouring. The wheel was allowed to cure at
60.degree. C. for 4 hours.
[0130] Even though this cured the epoxy in a short time, Sample S2
experienced a delamination at the interface and the wheel was
rejected.
Example 3
[0131] A sample S3 of an abrasive article was prepared, which
included an integrally formed bonded abrasive article and a core.
The abrasive had an outer diameter of 20.5-inches, an axial
thickness of fl-inches (made by combing two sections having an
axial thickness of 4 inches) and an interior diameter of 12
inches.
[0132] Sample S3 had a core formed from a two part-epoxy (i.e.,
Epoxy Part A and Epoxy Part B), which are commercially available
from Hapco. Epoxy Part A was stirred well using an overhead mixer.
Epoxy Part B, which acted as the curing agent, was added at an A:B
ratio of 100:11. The two parts were mixed using an overhead mixer
and then a vacuum was applied to remove any air entrained during
mixing. The bonded abrasive body of Sample S3 included a bond
material comprising a hybrid material including an inorganic
portion of metal including copper and tin and an organic portion of
PBI.
[0133] The bonded abrasive section of the wheel, having an outer
diameter of 20.5-inches, an axial thickness of 4-inches and an
interior diameter of 18 inches was placed on a waxed stainless
steel plate, and a waxed aluminum having an outer diameter of
12-inches, an axial thickness of 0.75-inches and an interior
diameter of 18-inches was placed in the center of the wheel. A
steel band, having an outer diameter of 20.5-inches, an axial
thickness of 0.75-inches and an interior diameter of 18 inches, was
placed over the abrasive section to hold excess epoxy. The epoxy
mixture was slowly poured into the space between the grinding wheel
and the aluminum sleeve and then a vacuum was applied to remove air
entrained during pouring. The wheel was allowed to cure at room
temperature, which took five times the amount of cooling time as
compared to the cooling of Sample S2 discussed in Example 2.
[0134] Sample S3 cracked at the interface of the abrasive section
and epoxy after curing.
Example 4
[0135] A sample S4 of an abrasive article was prepared, which
included an integrally formed bonded abrasive article and a core.
The abrasive had an outer diameter of 20.5-inches, an axial
thickness of fl-inches (made by combing two sections having an
axial thickness of 4 inches) and an interior diameter of 12
inches.
[0136] Sample S4 had a core formed from a two part-epoxy (i.e.,
Epoxy Part A and Epoxy Part B), which are commercially available
from Hapco. Epoxy Part A was stirred well using an overhead mixer.
Epoxy Part B, which acted as the curing agent, was added at an A:B
ratio of 100:11. The two parts were mixed using an overhead mixer
and then a vacuum was applied to remove any air entrained during
mixing. The bonded abrasive body of Sample S4 included a bond
material comprising a hybrid material including an inorganic
portion of metal including copper and tin and an organic portion of
PBI.
[0137] The bonded abrasive section of the wheel, having an outer
diameter of 20.5-inches, an axial thickness of 4-inches and an
interior diameter of 18 inches was placed on a waxed stainless
steel plate, and a waxed aluminum having an outer diameter of
12-inches, an axial thickness of 0.75-inches and an interior
diameter of 18-inches was placed in the center of the wheel. A
steel band, having an outer diameter of 20.5-inches, an axial
thickness of 0.75-inches and an interior diameter of 18 inches, was
placed over the abrasive section to hold excess epoxy. The epoxy
mixture was slowly poured into the space between the grinding wheel
and the aluminum sleeve. No vacuum was applied to remove air
entrained during pouring. The wheel was allowed to cure at room
temperature.
[0138] Sample S4 crack at the interface of the abrasive section and
epoxy. In addition to the cracking, the epoxy core was also porous
and had about 20% lower strength.
Example 5
[0139] A sample S5 of an abrasive article was prepared, which
included an integrally formed bonded abrasive article and a core.
The abrasive had an outer diameter of 20.5-inches, a axial
thickness of fl-inches (made by combing two sections having an
axial thickness of 4 inches) and an interior diameter of 12
inches.
[0140] Sample S5 had a core formed from a two part-epoxy (i.e.,
Epoxy Part A and Epoxy Part B), which are commercially available
from Hapco. Epoxy Part A was stirred well using an overhead mixer.
Epoxy Part B, which acted as the curing agent, was added at an A:B
ratio of 100:11. The two parts were mixed using an overhead mixer
and then a vacuum was applied to remove any air entrained during
mixing. The bonded abrasive body of Sample S5 included a bond
material comprising a hybrid material including an inorganic
portion of metal including copper and tin and an organic portion of
PBI.
[0141] The bonded abrasive section of the wheel, having an outer
diameter of 20.5-inches, an axial thickness of 4-inches and an
interior diameter of 18 inches was placed on a waxed stainless
steel plate, and a waxed aluminum having an outer diameter of
12-inches, an axial thickness of 0.75-inches and an interior
diameter of 18-inches was placed in the center of the wheel. A
steel band, having an outer diameter of 20.5-inches, an axial
thickness of 0.75-inches and an interior diameter of 18 inches, was
placed over the abrasive section to hold excess epoxy. The epoxy
mixture was slowly poured into the space between the grinding wheel
and the aluminum sleeve. Then a vacuum was applied to remove air
entrained during pouring The wheel was allowed to cure at room
temperature on a cooling deck, which had cold water flowing through
it to extract the heat generated. The wheel remained on the cooling
deck for 24 hours, and then further cured at room temperature
without the cooling deck.
[0142] Sample S5 experienced no cracking, shrinkage or delamination
problems. In particular, the bonded abrasive article and the core
maintained good adhesion at its core/abrasive interface.
[0143] In the foregoing, reference to specific embodiments and the
connections of certain components is illustrative. It will be
appreciated that reference to components as being coupled or
connected is intended to disclose either direct connection between
said components or indirect connection through one or more
intervening components as will be appreciated to carry out the
methods as discussed herein. As such, the above-disclosed subject
matter is to be considered illustrative, and not restrictive, and
the appended claims are intended to cover all such modifications,
enhancements, and other embodiments, which fall within the true
scope of the present invention. Thus, to the maximum extent allowed
by law, the scope of the present invention is to be determined by
the broadest permissible interpretation of the following claims and
their equivalents, and shall not be restricted or limited by the
foregoing detailed description.
[0144] The Abstract of the Disclosure is provided to comply with
Patent Law and is submitted with the understanding that it will not
be used to interpret or limit the scope or meaning of the claims.
In addition, in the foregoing Detailed Description, various
features may be grouped together or described in a single
embodiment for the purpose of streamlining the disclosure. This
disclosure is not to be interpreted as reflecting an intention that
the claimed embodiments require more features than are expressly
recited in each claim. Rather, as the following claims reflect,
inventive subject matter may be directed to less than all features
of any of the disclosed embodiments. Thus, the following claims are
incorporated into the Detailed Description, with each claim
standing on its own as defining separately claimed subject
matter.
[0145] Item 1. An abrasive article comprising:
a core comprising an organic material; and a first bonded abrasive
body integrally bonded directly to the core, the bonded abrasive
body comprising: a bond material comprising a hybrid material
including an inorganic portion and an organic portion; and abrasive
particles contained within the bond material.
[0146] Item 2. The abrasive article of item 1, wherein the first
bonded abrasive body is integrally bonded to a peripheral surface
of the core.
[0147] Item 3. The abrasive article of item 1, wherein the core
comprises a volume of at least about 75 in.sup.3 (1229 cm.sup.3),
at least about 500 in.sup.3 (8194 cm.sup.3), at least about 1000
in.sup.3 (16387 cm.sup.3), at least about 1200 in.sup.3 (19664
cm.sup.3), at least about 1600 in.sup.3 (26219 cm.sup.3), at least
about 1800 in.sup.3 (29496 cm.sup.3), at least about 2000 in.sup.3
(32774 cm.sup.3), and not greater than about 20000 in.sup.3 (327741
cm.sup.3).
[0148] Item 4. The abrasive article of item 1, wherein the core has
a monolithic body, wherein the core has a cylindrical shape defined
by a diameter (d), a circumference (C), and a height (h), wherein
the height is at least about 3 inches (7.6 cm).
[0149] Item 5. The abrasive article of item 4, wherein the diameter
is at least about 6 inches (15.2 cm), at least about 10 inches
(25.4 cm), at least about 16 inches (40.6 cm), at least about 20
inches (50.8 cm), and not greater than about 500 inches (1.3
m).
[0150] Item 6. The abrasive article of item 4, wherein the
circumference is at least about 19 inches (48 cm), at least about
31 inches (78 cm), at least about 50 inches (128 cm), at least
about 63 inches (160 cm), and not greater than about 157 inches (4
m).
[0151] Item 7. The abrasive article of item 4, wherein the height
is at least about 3.5 inches (8.9 cm), at least about 4 inches
(10.2 cm), at least about 4.5 inches (11.4 cm), at least about 5
inches (12.7 cm), at least about 5.5 inches (14 cm), at least about
6 inches (15.2 cm), at least about 6.5 inches (16.5 cm), at least
about 7 inches (17.8 cm), and not greater than about 30 inches
(76.2 cm).
[0152] Item 8. The abrasive article of item 1, wherein the core
comprises an opening defining an arbor hole, wherein the opening is
configured to engage a spindle for a grinding operation, wherein
the opening extends through a volume of the monolithic body,
wherein the opening extends along a direction of the height,
wherein the opening extends between a first major surface and a
second major surface of the core.
[0153] Item 9. The abrasive article of item 8, wherein the core
comprises a liner overlying at least a portion of the surface
defining the opening, wherein the liner overlies essentially the
entire surface defining the opening, wherein the liner comprises a
material selected from the group consisting of inorganic materials,
organic materials, and a combination thereof, wherein the liner
comprises a metal or metal alloy.
[0154] Item 10. The abrasive article of item 8, wherein the core
comprises a liner overlying at least a portion of the surface
defining the opening, wherein the liner has a heat capacity greater
than a heat capacity of the material of the core, wherein the liner
has a heat capacity less than a heat capacity of the material of
the core.
[0155] Item 11. The abrasive article of item 1, wherein the core
consists essentially of the organic material, wherein the organic
material comprises a polymer, wherein the organic material
comprises a polymeric material selected from the group consisting
of an epoxy polymer, a phenoxy polymer, a polyurea, a polyimide, a
polycyanate, a polyurethane, a melamine polymer, a polyester, or
foamed structures of the same, or any combination thereof.
[0156] Item 12. The abrasive article of item 1, wherein the core
comprises a linear coefficient of thermal expansion (CTE) of at
least about 15 microns/(m .degree. C.), and not greater than about
70 microns/(m .degree. C.).
[0157] Item 13. The abrasive article of item 1, wherein the organic
portion and the inorganic portion are substantially uniformly
distributed throughout the volume of the bond material of the first
bonded abrasive body, wherein the organic portion and the inorganic
portion are substantially uniformly distributed within each
other.
[0158] Item 14. The abrasive article of item 1, wherein the
inorganic portion of the bond material comprises a metal material,
wherein the metal material comprises a transition metal element,
wherein the metal material comprises a metal selected from the
group consisting of copper, tin, silver, chromium, titanium,
vanadium, manganese, iron, cobalt, nickel, zinc, gold, molybdenum,
zirconium, tungsten, yttrium, tantalum, aluminum, and a combination
thereof.
[0159] Item 15. The abrasive article of item 14, wherein the metal
material of the bond material comprises a combination of copper and
tin, wherein the metal material comprises a bronze, wherein the
metal material comprises a greater content of copper than tin,
wherein the bond material comprises a ratio of copper:tin of
approximately 60:40 by weight.
[0160] Item 16. The abrasive article of item 1, wherein the organic
portion of the bond material comprises a polymer, wherein the
polymer comprises a material selected from the group of materials
consisting of thermosets, thermoplastics, and a combination
thereof, wherein the polymer comprises a material selected from the
group of materials consisting of polyimides, polyamides, resins,
aramids, epoxies, polyesters, polyurethanes, and a combination
thereof, wherein the polymer material comprises polyarenazole,
wherein the polymer material comprises polybenzimidazole (PBI),
wherein the polymer material comprises phenolic resin.
[0161] Item 17. The abrasive article of item 1, wherein the bond
material comprises a greater content of the inorganic portion (vol
%) as compared to a content of the organic portion (vol %) within
the bond, wherein the bond material comprises a greater content of
the organic portion (vol %) as compared to a content of the
inorganic portion (vol %) within the bond.
[0162] Item 18. The abrasive article of item 1, wherein the bond
material comprises a minority content of the organic portion,
wherein the bond material comprises not greater than about 40 vol %
organic portion for the total volume of the bond, not greater than
about 35 vol %, not greater than about 30 vol %, not greater than
about 25 vol %, not greater than about 20 vol %, and at least about
1 vol % organic portion for the total volume of the bond.
[0163] Item 19. The abrasive article of item 1, wherein the bond
material comprises a minority content of the inorganic portion for
the total content of the bond, wherein the bond material comprises
a majority content of the inorganic portion for the total content
of the bond, wherein the bond material comprises at least about 10
vol % inorganic portion for the total volume of the bond, at least
about 15 vol %, at least about 20 vol %, at least about 25 vol %,
at least about 30 vol %, at least about 35 vol %, at least about 40
vol %, at least about 45 vol %, at least about 50 vol %, and not
greater than about 99 vol %, not greater than about 96 vol %, not
greater than about 94 vol % inorganic material for the total volume
of the bond.
[0164] Item 20. The abrasive article of item 1, wherein the first
bonded abrasive body comprises at least about 5 vol % bond material
for the total volume of the body, at least about 10 vol %, at least
about 20 vol %, and not greater than about 90 vol %.
[0165] Item 21. The abrasive article of item 1, wherein the first
bonded abrasive body comprises porosity, wherein the first bonded
abrasive body comprises a majority content of porosity (vol %) for
the total volume of the first bonded abrasive body, wherein the
first bonded abrasive body comprises a minority content of porosity
(vol %) for the total volume of the first bonded abrasive body.
[0166] Item 22. The abrasive article of item 21, wherein the
porosity comprises a majority content of closed porosity, wherein
the porosity comprises a majority content of open porosity.
[0167] Item 23. The abrasive article of item 1, wherein the first
bonded abrasive body comprises a content of porosity of not greater
than about 70 vol % for the total volume of the body, not greater
than about 60 vol %, not greater than about 50 vol %, not greater
than about 40 vol %, not greater than about 30 vol %, not greater
than about 25 vol %, not greater than about 20 vol %, not greater
than about 15 vol %, not greater than about 10 vol %, not greater
than about 5 vol %, not greater than about 2 vol %.
[0168] Item 24. The abrasive article of item 1, wherein the first
bonded abrasive body comprises at least about 5 vol % abrasive
particles for the total volume of the body, at least about 10 vol
%, at least about 15 vol %, and not greater than about 75 vol
%.
[0169] Item 25. The abrasive article of item 1, wherein the
abrasive particles comprise a material selected from the group
consisting of oxides, carbides, nitrides, borides, oxycarbides,
oxynitrides, and a combination thereof, wherein the abrasive
particles comprise a superabrasive material, wherein the abrasive
particles comprise a material selected from the group consisting of
alumina, silica, silicon carbide, boron nitride, diamond, and a
combination thereof, wherein the abrasive particles consist
essentially of diamond.
[0170] Item 26. The abrasive article of item 1, wherein the first
bonded abrasive body comprises a filler contained in a bond
material, wherein the filler comprises a pore former, wherein the
filler comprises a material selected from the group consisting of
glass, glass-ceramic, ceramic, organic, and a combination thereof,
wherein the filler comprises a material selected from the group
consisting of bubble alumina, bubble mullite, hollow spheres,
hollow glass spheres, hollow ceramic spheres, hollow polymer
spheres, polymer materials, organic compounds, fibrous materials,
naphthalene, PDB, shells, wood, and the like, wherein the filler
comprises a material selected from the group of materials
consisting of zirconia, silica, titania, and a combination
thereof.
[0171] Item 27. The abrasive article of item 1, wherein the first
bonded abrasive body comprises a minor content of filler (vol %)
for the total volume of the body.
[0172] Item 28. The abrasive article of item 1, wherein the first
bonded abrasive body is coupled to at least one of a first major
surface of the core, a second major surface of the core, a
peripheral surface of the core defining the circumference, wherein
the first bonded abrasive body is positioned proximate to the
peripheral surface of the core, wherein the first bonded abrasive
body is abutting the peripheral surface of the core, wherein the
first bonded abrasive body extends radially from a surface of the
core, wherein the first bonded abrasive body extends axially from a
surface of the core.
[0173] Item 29. The abrasive article of item 1, wherein the first
bonded abrasive body comprises an annular shape, wherein the first
bonded abrasive body extends around at least a portion of a
peripheral surface of the core defining a circumference of the
core, wherein the first bonded abrasive body extends entirely
around a peripheral surface of the core defining a circumference of
the core.
[0174] Item 30. The abrasive article of item 1, further comprising
a second bonded abrasive body coupled to the core, wherein the
second bonded abrasive body is adjacent the first bonded abrasive
body, wherein the first bonded abrasive is abutting the second
bonded abrasive body, wherein the first and second bonded abrasive
bodies are coupled to a peripheral surface of the core defining a
circumference of the core, wherein the first and second bonded
abrasive bodies are oriented in a coaxial relationship relative to
the core.
[0175] Item 31. The abrasive article of item 30, wherein the second
bonded abrasive body comprises abrasive particles contained in a
bond material, wherein the bond material of the second bonded
abrasive body is a same composition as the bond material of the
first bonded abrasive body.
[0176] Item 32. A method of forming an abrasive article, the method
comprising:
preparing a preform comprising an abrasive article; forming a
mixture comprising a thermoset; pouring the mixture into the
preform; and curing the mixture to form the core on the abrasive
article, wherein the curing comprises a phase change of a liquid
phase to a solid phase, the core having a cylindrical shape defined
by a diameter (d), a circumference (C), and a height (h), wherein
the height is at least about 3 inches (7.6 cm).
[0177] Item 33. The method of item 32, wherein curing the mixture
includes curing by heating.
[0178] Item 34. The method of item 32, wherein curing the mixture
includes a first heating of the mixture at a first temperature
T.sub.1.
[0179] Item 35. The method of item 34, wherein the first heating
includes a first duration.
[0180] Item 36. The method of item 35, wherein the first duration
is at least about one hour.
[0181] Item 37. The method of item 34, further including a second
heating of the mixture at a second temperature T.sub.2, wherein the
second temperature T.sub.2 is different from the first temperature
T.sub.1.
[0182] Item 38. The method of item 37, wherein the second heating
includes a second duration.
[0183] Item 39. The method of item 38, wherein the second duration
is substantially the same than the first duration.
[0184] Item 40. The method of item 37, wherein the second
temperature T.sub.2 and the first temperature T.sub.1 are different
from each other by a first temperature difference, defined by
|T.sub.2-T.sub.1|, the first temperature difference having an
absolute value of not greater than about 50.degree. C., such as not
greater than about 45.degree. C., or not greater than about
40.degree. C.
[0185] Item 41. The method of item 37, wherein the first heating
and the second heating have a total duration of at least about four
hours, such as at least about six hours, or at least about eight
hours.
[0186] Item 42. The method of item 37, further including a third
heating of the mixture at a third temperature T.sub.3, the third
temperature T.sub.3 being different from the second temperature
T.sub.2.
[0187] Item 43. The method of item 42, wherein the third heating
includes a third duration, wherein the third duration is different
from the second duration.
[0188] Item 44. The method of item 43, wherein the third duration
is substantially the same than the second duration.
[0189] Item 45. The method of item 42, wherein the third
temperature T.sub.3 and the second temperature T.sub.2 are
different from each other by a second temperature difference,
defined by |T.sub.3-T.sub.2|, the second temperature difference
having an absolute value of not greater than about 40.degree. C.,
such as not greater than about 35.degree. C., or not greater than
about 30.degree. C.
[0190] Item 46. The method of item 42, wherein the first heating,
the second heating, and the third heating have a total duration of
at least about six hours, such as at least about eight hours, or at
least about twelve hours.
[0191] Item 47. The method of item 42, further including a fourth
heating of the mixture at a fourth temperature T.sub.4, the fourth
temperature T.sub.4 being different from the third temperature
T.sub.3.
[0192] Item 48. The method of item 47, wherein the fourth heating
includes a fourth duration, wherein the fourth duration is
different from the third duration.
[0193] Item 49. The method of item 48, wherein the fourth duration
is substantially the same than the third duration.
[0194] Item 50. The method of item 47, wherein the fourth
temperature .sub.T4 and the third temperature T.sub.3 are different
from each other by a third temperature difference, defined by
|T.sub.4-T.sub.3|, the third temperature difference having an
absolute value of not greater than about 60.degree. C., such as not
greater than about 55.degree. C., or not greater than about
50.degree. C.
[0195] Item 51. The method of item 47, wherein the first heating,
the second heating, the third heating, and the fourth heating have
a total duration of at least about eight hours, such as at least
about ten hours, or at least about 14 hours.
[0196] Item 52. The method of item 32, wherein the mixture includes
a curing agent.
[0197] Item 53. The method of item 52, wherein the curing agent is
selected from the group consisting of an oligoamine, a diol, a
dithiol, an amino alcohol, an amino thiol, a thioalcohol, and any
combination thereof.
[0198] Item 54. The method of item 53, wherein the oligoamine is
selected from the group consisting of an aliphatic oligoamine, a
cycloaliphatic oligoamine, and an aromatic oligoamine, and a
combination thereof.
[0199] Item 55. The method of item 54, wherein the aliphatic
oligoamine is selected from the group consisting of ethylene
diamine, 2-methyl-1,5-pentamethylenediamine,
1,6-hexamethylenediamine, 1,3-pentanediamine,
(2-aminoethyl)-1,2-ethanediamine (DETA),
N,N'-bis-(2-aminoethyl)-1,2-ethanediamine) (TETA),
tris-(2-aminoethyl)amine) (TAEA), bis-(aminoethyl)ether, a
polyether diamine, tetraethylenepentamine (TEPA), and a combination
thereof.
[0200] Item 56. The method of item 54, wherein the cycloaliphatic
oligoamine is selected from the group consisting of
1,2-diaminocyclohexane, N[(2-aminoethyl)2-aminoethyl]piperazine)
(PEEDA), isophorone diamine (IPDA),
4,4'-bis-(aminocyclohexyl)-methane,
N,N'-bis-(2-aminoethyl)piperazine) (DAEP), and a combination
thereof.
[0201] Item 57. The method of item 54, wherein the aromatic
oligoamine is selected from the group of 2-ethyl, 2
methyl-imidazole, 4,4'-diaminodiphenyl-methane,
4,4'-diaminodiphenylether, 1,3-Bis(3-aminophenoxy) benzene, an
aminobenzylamine, and a combination thereof.
[0202] Item 58. The method of item 32, wherein the mixture includes
an epoxy resin and the curing agent includes an oligoamine.
[0203] Item 59. The method of item 58, wherein the epoxy resin
includes a bisphenol-A diglycidyl ether and the curing agent
includes a isophorone diamine.
[0204] Item 60. The method of item 58, wherein the epoxy resin
consists essentially of a bisphenol-A diglycidyl ether and the
curing agent consists essentially of a isophorone diamine.
[0205] Item 61. The method of item 32, wherein curing comprises
conducting a first curing process of at least about 2 hours and not
greater than about 4 hours at a first temperature of not greater
than about 50.degree. C.
[0206] Item 62. The method of item 61, wherein curing comprises
conducting a second curing process after the first curing process,
wherein the second curing process is at least about 2 hours and not
greater than about 4 hours at a second temperature of greater than
about 50.degree. C. and not greater than about 100.degree. C.
[0207] Item 63. The method of item 62, wherein curing comprises
conducting a third curing process after the second curing process,
wherein the third curing process is at least about 2 hours and not
greater than about 4 hours at a second temperature of greater than
about 70.degree. C. and not greater than about 150.degree. C.
[0208] Item 64. The method of item 32, further comprising placing
an liner in the preform, pouring comprises pouring the mixture into
the preform around the liner, and then removing the liner prior to
curing, wherein the liner is configured to define an arbor hole in
the core.
[0209] Item 65. The method of item 64, wherein the liner comprises
an inorganic material, wherein the liner comprises a metal, wherein
the liner comprises a material selected from the group consisting
of aluminum, silicon, steel, carbon fiber, and a combination
thereof.
[0210] Item 66. The method of item 32, further comprising cooling
at least a portion of the mixture during curing to control heat
transferred from the mixture to the abrasive article.
[0211] Item 67. The method of item 32, further comprising providing
an atmosphere having a pressure lower than standard atmospheric
pressure prior to curing.
[0212] Item 68. An abrasive article, comprising:
a first bonded abrasive body comprising: a bond material comprising
a hybrid material including an inorganic portion and an organic
portion; and abrasive particles contained within the bond material;
and a core comprising an organic material and bonded to the first
bonded abrasive body, the core having a monolithic body including a
cylindrical shaped defined by a diameter (d), a circumference (C),
and a height (h), wherein the height is at least about 3 inches
(7.6 cm); wherein the core comprises at least one filler selected
from the group consisting of oxides, carbides, borides, silicides,
nitrides, fluorides, oxynitrides, oxycarbides, silicates,
metal-hydrate compounds, hydrated oxide compounds, carbonates,
phosphates, minerals, feldspar, nepheline syenite, chromites,
magnesites, dolomites, pyrites, sulfides, carbon-based materials,
graphite, sulfides, silicon, metal, metal alloys, inter-metallics,
ceramics, hollow-ceramics, fused silica, glass, glass-ceramics,
hollow glass spheres, glass fibers, polymers, polyimides,
polyamides, resins, aramids, epoxies, polyesters, polyurethanes,
acetates, celluloses, ethers, ethanol, wood flour, clay, talc, and
a combination thereof.
[0213] Item 69. The abrasive article of item 68, wherein the core
comprises at least two filler materials selected from the group
consisting of oxides, carbides, borides, silicides, nitrides,
oxynitrides, oxycarbides, silicates, graphite, metal-hydrate
compounds, hydrated oxide compounds, carbonates, phosphates,
silicon, metal, metal alloys, inter-metallics, ceramics,
hollow-ceramics, fused silica, glass, glass-ceramics, hollow glass
spheres, glass fibers, polymers, polyimides, polyamides, resins,
aramids, epoxies, polyesters, polyurethanes, acetates, celluloses,
ethers, ethanol, and a combination thereof.
[0214] Item 70. The abrasive article of item 68, wherein the core
comprises a first filler material and a second filler material,
wherein the first filler material is different than the second
filler material by at least one of composition, average particle
size, content, and a combination thereof, wherein the core
comprises a first filler material comprising an inorganic material
and a second filler material comprising an organic material.
[0215] Item 71. The abrasive article of item 68, wherein the core
comprises a first filler material comprising an oxide.
[0216] Item 72. The abrasive article of item 68, wherein the core
comprises a first filler material comprising alumina.
[0217] Item 73. The abrasive article of item 68, wherein the core
comprises a first filler consisting essentially of fused
alumina.
[0218] Item 74. The abrasive article of item 68, wherein the core
comprises a second filler material comprising an organic material
including a hydroxyl group.
[0219] Item 75. The abrasive article of item 68, wherein the core
comprises a second filler material comprising ethanol.
[0220] Item 76. The abrasive article of item 68, wherein the core
comprises a second filler material comprising phosphate.
[0221] Item 77. The abrasive article of item 68, wherein the core
comprises a second filler material comprising ethanol and
phosphate, wherein the core comprises a second filler material
comprising ethanol, 2 chloro-phosphate (3:1), wherein the core
comprises a second filler material consisting essentially of
ethanol, 2 chloro-phosphate (3:1).
[0222] Item 78. The abrasive article of item 68, wherein the core
comprises a first filler material and a second filler material,
wherein the core comprises a greater content of the first filler
material compared to a content of the second filler material,
wherein the core comprises a greater content of the second filler
material compared to a content of the first filler material
[0223] Item 79. The abrasive article of item 68, wherein the core
comprises a ratio (V1N2) of at least about 1, wherein V1 represents
a content of a first filler (vol %) within the core and V2
represents a content of a second filler (vol %) within the core,
wherein the ratio (V1/V2) is at least about 1.1, at least about
1.2, at least about 2, at least about 3, at least about 4, at least
about 5, at least about 10, at least about 20, at least about 30,
and wherein the ratio (V1/V2) is not greater than about 30, not
greater than about 20, not greater than about 15, not greater than
about 10, not greater than about 5, not greater than about 4, not
greater than about 3, not greater than about 2.
[0224] Item 80. The abrasive article of item 68, wherein the core
comprises a ratio (V2/V1) of at least about 1, wherein V1
represents a content of a first filler (vol %) within the core and
V2 represents a content of a second filler (vol %) within the core,
wherein the ratio (V2/V1) is at least about 1.1, at least about
1.2, at least about 2, at least about 3, at least about 4, at least
about 5, at least about 10, at least about 20, at least about 30,
and wherein the ratio (V2/V1) is not greater than about 30, not
greater than about 20, not greater than about 15, not greater than
about 10, not greater than about 5, not greater than about 4, not
greater than about 3, not greater than about 2.
[0225] Item 81. The abrasive article of item 68, wherein the core
comprises a first filler material, and wherein the core comprises
at least about 0.5 vol % of the first filler for a total volume of
the core, at least about 1 vol %, at least about 1.5 vol %, at
least about 2 vol %, at least about 5 vol %, at least about 8 vol
%, at least about 10 vol %, at least about 12 vol %, at least about
15 vol %, and not greater than about 50 vol %, not greater than
about 40 vol %, not greater than about 30 vol %, not greater than
about 25 vol %, not greater than about 20 vol %, not greater than
about 15 vol %, not greater than about 10 vol %, not greater than
about 8 vol %, not greater than about 5 vol %, not greater than
about 4 vol %, not greater than about 3 vol %, not greater than
about 2 vol %.
[0226] Item 82. The abrasive article of item 68, wherein the core
comprises a second filler material, and wherein the core comprises
at least about 0.5 vol % of the second filler for a total volume of
the core, at least about 1 vol %, at least about 1.5 vol %, at
least about 2 vol %, at least about 5 vol %, at least about 8 vol
%, at least about 10 vol %, at least about 12 vol %, at least about
15 vol %, and not greater than about 50 vol %, not greater than
about 40 vol %, not greater than about 30 vol %, not greater than
about 25 vol %, not greater than about 20 vol %, not greater than
about 15 vol %, not greater than about 10 vol %, not greater than
about 8 vol %, not greater than about 5 vol %, not greater than
about 4 vol %, not greater than about 3 vol %, not greater than
about 2 vol %.
[0227] Item 83. The abrasive article of item 68, wherein the core
comprises a third filler material in addition to at least a first
filler material, wherein the third filler material is different
than the first filler material by at least one of composition,
average particle size, content, and a combination thereof.
[0228] Item 84. The abrasive article of item 68, wherein the core
comprises a third filler material in addition to at least a second
filler material, wherein the third filler material is different
than the second filler material by at least one of composition,
average particle size, content, and a combination thereof.
[0229] Item 85. The abrasive article of item 68, wherein the core
comprises a first filler material comprising an inorganic material
and a third filler material comprising an inorganic material,
wherein the first filler material comprises an oxide, wherein the
third filler material comprises an oxide, wherein the first filler
material comprises at least one metallic element different than the
third filler material.
[0230] Item 86. The abrasive article of item 68, wherein the core
comprises a third filler comprising iron, wherein the third filler
material comprises iron oxide, wherein the third filler material
comprises a mineral, wherein the third filler material comprises
magnetite (Fe.sub.3O.sub.4), wherein the third filler material
consists essentially of magnetite, wherein the third filler
comprises black oxide.
[0231] Item 87. The abrasive article of item 68, wherein the core
comprises a first filler material and a third filler material,
wherein the core comprises a greater content of the first filler
material compared to a content of the third filler material,
wherein the core comprises a greater content of the third filler
material compared to a content of the first filler material.
[0232] Item 88. The abrasive article of item 68, wherein the core
comprises a ratio (V1/V3) of at least about 1, wherein V1
represents a content of a first filler (vol %) within the core and
V3 represents a content of a third filler (vol %) within the core,
wherein the ratio (V1/V3) is at least about 1.1, at least about
1.2, at least about 2, at least about 3, at least about 4, at least
about 5, at least about 10, at least about 20, at least about 30,
and wherein the ratio (V1/V3) is not greater than about 30, not
greater than about 20, not greater than about 15, not greater than
about 10, not greater than about 5, not greater than about 4, not
greater than about 3, not greater than about 2.
[0233] Item 89. The abrasive article of item 68, wherein the core
comprises a ratio (V3/V1) of at least about 1, wherein V1
represents a content of a first filler (vol %) within the core and
V3 represents a content of a third filler (vol %) within the core,
wherein the ratio (V3/V1) is at least about 1.1, at least about
1.2, at least about 2, at least about 3, at least about 4, at least
about 5, at least about 10, at least about 20, at least about 30,
and wherein the ratio (V3/V1) is not greater than about 30, not
greater than about 20, not greater than about 15, not greater than
about 10, not greater than about 5, not greater than about 4, not
greater than about 3, not greater than about 2.
[0234] Item 90. The abrasive article of item 68, wherein the core
comprises a ratio (V2/V3) of at least about 1, wherein V2
represents a content of a second filler (vol %) within the core and
V3 represents a content of a third filler (vol %) within the core,
wherein the ratio (V2/V3) is at least about 1.1, at least about
1.2, at least about 2, at least about 3, at least about 4, at least
about 5, at least about 10, at least about 20, at least about 30,
and wherein the ratio (V2/V3) is not greater than about 30, not
greater than about 20, not greater than about 15, not greater than
about 10, not greater than about 5, not greater than about 4, not
greater than about 3, not greater than about 2.
[0235] Item 91. The abrasive article of item 68, wherein the core
comprises a ratio (V3/V2) of at least about 1, wherein V2
represents a content of a second filler (vol %) within the core and
V3 represents a content of a third filler (vol %) within the core,
wherein the ratio (V3/V2) is at least about 1.1, at least about
1.2, at least about 2, at least about 3, at least about 4, at least
about 5, at least about 10, at least about 20, at least about 30,
and wherein the ratio (V3/V2) is not greater than about 30, not
greater than about 20, not greater than about 15, not greater than
about 10, not greater than about 5, not greater than about 4, not
greater than about 3, not greater than about 2.
[0236] Item 92. The abrasive article of item 68, wherein the core
comprises a third filler material, and wherein the core comprises
at least about 0.5 vol % of the third filler for a total volume of
the core, at least about 1 vol %, at least about 1.5 vol %, at
least about 2 vol %, at least about 5 vol %, at least about 8 vol
%, at least about 10 vol %, at least about 12 vol %, at least about
15 vol %, and not greater than about 50 vol %, not greater than
about 40 vol %, not greater than about 30 vol %, not greater than
about 25 vol %, not greater than about 20 vol %, not greater than
about 15 vol %, not greater than about 10 vol %, not greater than
about 8 vol %, not greater than about 5 vol %, not greater than
about 4 vol %, not greater than about 3 vol %, not greater than
about 2 vol %.
[0237] Item 93. The abrasive article of item 68, wherein the core
comprises a first filler material having a first average particle
size and a second filler material having a second average particle
size, wherein the first average particle size is different than the
second average particle size, wherein the first average particle
size is greater than the second average particle size, wherein the
second average particle size is greater than the first average
particle size.
[0238] Item 94. The abrasive article of item 68, wherein the core
comprises a first filler material having a first average particle
size and a third filler material having a third average particle
size, wherein the first average particle size is different than the
third average particle size, wherein the first average particle
size is greater than the third average particle size, wherein the
third average particle size is greater than the first average
particle size.
[0239] Item 95. The abrasive article of item 68, wherein the core
comprises a second filler material having a second average particle
size and a third filler material having a third average particle
size, wherein the second average particle size is different than
the third average particle size, wherein the second average
particle size is greater than the third average particle size,
wherein the third average particle size is greater than the second
average particle size.
[0240] Item 96. The abrasive article of item 68, wherein the first
bonded abrasive body is integrally bonded directly to the core.
[0241] Item 97. The abrasive article of item 68, wherein the core
comprises an epoxy, wherein the mixture includes an epoxy resin and
the curing agent includes an oligoamine, wherein the epoxy resin
includes a bisphenol-A diglycidyl ether and the curing agent
includes a isophorone diamine.
[0242] Item 98. The abrasive article of item 68, wherein the
inorganic portion of the bond material comprises a metal material,
wherein the metal material comprises a transition metal element,
wherein the metal material comprises a metal selected from the
group consisting of copper, tin, silver, chromium, titanium,
vanadium, manganese, iron, cobalt, nickel, zinc, gold, molybdenum,
zirconium, tungsten, yttrium, tantalum, aluminum, and a combination
thereof, wherein the metal material of the bond material comprises
a combination of copper and tin, wherein the metal material
comprises a bronze, wherein the metal material comprises a greater
content of copper than tin, wherein the bond material comprises a
ratio of copper:tin of approximately 60:40 by weight.
[0243] Item 99. The abrasive article of item 68, wherein the
organic portion of the bond material comprises a polymer, wherein
the polymer comprises a material selected from the group of
materials consisting of thermosets, thermoplastics, and a
combination thereof, wherein the polymer comprises a material
selected from the group of materials consisting of polyimides,
polyamides, resins, aramids, epoxies, polyesters, polyurethanes,
and a combination thereof, wherein the polymer material comprises
polyarenazole, wherein the polymer material comprises
polybenzimidazole (PBI), wherein the polymer material comprises
phenolic resin.
[0244] Item 100. The abrasive article of item 68, wherein the bond
material comprises a greater content of the inorganic portion (vol
%) as compared to a content of the organic portion (vol %) within
the bond material, wherein the bond material comprises a greater
content of the organic portion (vol %) as compared to a content of
the inorganic portion (vol %) within the bond.
[0245] Item 101. The abrasive article of item 68, wherein the core
contains an amount of uncured epoxy of at least about 0.1 vol % for
a total volume of the core, at least about 0.5 vol %, at least
about 1 vol %, at least about 2 vol %, at least about 5 vol %, and
not greater than about 30 vol %, not greater than about 20 vol %,
not greater than about 10 vol %, not greater than about 5 vol %,
not greater than about 2 vol %.
[0246] Item 102. The abrasive article of item 68, wherein the core
comprises a material with a Tg of at least about 75.degree. C., at
least about 80.degree. C. at least about 90.degree. C., at least
about 100.degree. C., at least about 110.degree. C., at least about
120.degree. C., and not greater than about 170.degree. C., not
greater than about 160.degree. C., not greater than about
150.degree. C., not greater than about 140.degree. C., not greater
than about 130.degree. C.
[0247] Item 103. The abrasive article of item 68, wherein the core
comprises a material with a CTE of at least about 25
.mu.m/m.degree. C., at least about 28 .mu.m/m.degree. C., at least
about 30 .mu.m/m.degree. C., at least about 33 .mu.m/m.degree. C.,
at least about 35 .mu.m/m.degree. C., at least about 37
.mu.m/m.degree. C., at least about 40 .mu.m/m.degree. C., at least
about 43 .mu.m/m.degree. C., at least about 45 .mu.m/m.degree. C.,
at least about 48 .mu.m/m.degree. C., at least about 50
.mu.m/m.degree. C., at least about 53 .mu.m/m.degree. C., and not
greater than about 200 .mu.m/m.degree. C., not greater than about
180 .mu.m/m.degree. C., not greater than about 160 .mu.m/m.degree.
C., not greater than about 150 .mu.m/m.degree. C., not greater than
about 125 .mu.m/m.degree. C., not greater than about 100
.mu.m/m.degree. C., not greater than about 80 .mu.m/m.degree.
C.
[0248] Item 104. The abrasive article of item 68, wherein the core
comprises a linear coefficient of thermal expansion (CTEba) and the
bonded abrasive body comprises a linear coefficient of thermal
expansion (CTEc), and wherein the core and the bonded abrasive body
comprise a difference in the coefficients of thermal expansion
(.DELTA.CTE) defined by the equation
[(CTEba-CTEc)/CTEba].times.100% of not greater than about 30%, not
greater than about 20%, not greater than about 18%, not greater
than about 12%, not greater than about 5%.
[0249] Item 105. The abrasive article of item 68, wherein the core
further comprises at least one reinforcing structure, wherein the
reinforcing structure comprises a substantially planar layer of
material, wherein the reinforcing structure comprises a material
selected from the group consisting of an inorganic material, an
organic material, and a combination thereof, wherein the
reinforcing structure comprises a woven material, wherein the
reinforcing structure comprises a non-woven material, wherein the
reinforcing structure comprises a composite material.
[0250] Item 106. The abrasive article of item 68, wherein the core
comprises a porosity of not greater than about 15 vol % for a total
volume of the core.
[0251] Item 107. The abrasive article of item 68, wherein the
filler comprises a particulate material having a density of not
greater than about 4.0 g/cm.sup.3.
[0252] Item 108. The abrasive article of item 68, wherein the core
comprises a density of at least about 0.8 g/cc and not greater than
about 2.8 g/cc.
* * * * *