U.S. patent application number 14/985762 was filed with the patent office on 2016-06-30 for colored abrasive articles and method of making colored abrasive articles.
The applicant listed for this patent is SAINT-GOBAIN ABRASIFS, SAINT-GOBAIN ABRASIVES, INC.. Invention is credited to Davinder S. DHAMI, MICHAEL W. KLETT.
Application Number | 20160184971 14/985762 |
Document ID | / |
Family ID | 56163171 |
Filed Date | 2016-06-30 |
United States Patent
Application |
20160184971 |
Kind Code |
A1 |
KLETT; MICHAEL W. ; et
al. |
June 30, 2016 |
COLORED ABRASIVE ARTICLES AND METHOD OF MAKING COLORED ABRASIVE
ARTICLES
Abstract
Embodiments of the present disclosure are directed to methods of
making high grade colored abrasive articles that are color stable
at high temperatures, such as color stable at temperatures of at
least about 185 degrees Celsius such that the bonded abrasive body
can be cured at such elevated temperatures without substantially
changing the color of the bonded abrasive body.
Inventors: |
KLETT; MICHAEL W.; (Holden,
MA) ; DHAMI; Davinder S.; (Millbury, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAINT-GOBAIN ABRASIVES, INC.
SAINT-GOBAIN ABRASIFS |
Worcester
Conflans-Sainte-Honorine |
MA |
US
FR |
|
|
Family ID: |
56163171 |
Appl. No.: |
14/985762 |
Filed: |
December 31, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62098954 |
Dec 31, 2014 |
|
|
|
62098949 |
Dec 31, 2014 |
|
|
|
Current U.S.
Class: |
51/295 ;
51/298 |
Current CPC
Class: |
B24D 3/285 20130101;
B24D 18/0027 20130101; B24D 3/344 20130101; B24D 7/02 20130101 |
International
Class: |
B24D 3/34 20060101
B24D003/34; B24D 3/28 20060101 B24D003/28; B24D 7/02 20060101
B24D007/02; B24D 18/00 20060101 B24D018/00 |
Claims
1. A method of forming an abrasive article comprising a bonded
abrasive body, the method comprising: forming a mixture comprising
abrasive particles dispersed within a bond material; and curing the
mixture at a temperature of at least 185.degree. C. in a
non-oxidizing atmosphere to form a bonded abrasive body.
2. The method of claim 1, wherein the bond material includes a
significant amount of methylene and dimethylene amino crosslink
bridges.
3. The method of claim 1, wherein the non-oxidizing atmosphere
consists essentially of an inert gas.
4. The method of claim 1, wherein the non-oxidizing atmosphere
consists essentially of an inert gas comprising nitrogen.
5. The method of claim 1, wherein the non-oxidizing atmosphere
consists essentially of nitrogen.
6. The method of claim 1, wherein the bond material is essentially
free of an acrylate.
7. A method of forming an abrasive article comprising a bonded
abrasive body, the method comprising: forming a mixture comprising
abrasive particles dispersed within a phenyl-formaldehyde based
bond material; and curing the mixture, wherein the bonded abrasive
body has substantially the same color before and after curing.
8. The method of claim 7, wherein the bond material includes a
significant amount of methylene and dimethylene amino crosslink
bridges.
9. The method of claim 7, wherein the non-oxidizing atmosphere
consists essentially of an inert gas.
10. The method of claim 7, wherein the non-oxidizing atmosphere
consists essentially of an inert gas comprising nitrogen.
11. The method of claim 7, wherein the non-oxidizing atmosphere
consists essentially of nitrogen.
12. The method of claim 7, wherein the bond material is essentially
free of an acrylate.
13. An abrasive article comprising: a bonded abrasive body
comprising abrasive particles contained within a bond material,
wherein the bond material has a glass transition temperature of at
least about 200.degree. C.; and wherein the bonded abrasive body is
color stable.
14. The abrasive article of claim 13, wherein the bond material is
essentially free of an acrylate.
15. The abrasive article of claim 13, wherein the bonded abrasive
body has a bond material content of at least about 5 wt. % based on
the total weight of the body.
16. The abrasive article of claim 13, wherein the bond material
comprises a cured and cross-linked reaction product of a first
resin and a second resin distinct from the first resin.
17. The abrasive article of claim 13, wherein the bonded abrasive
body comprises a pigment.
18. The abrasive article of claim 13, wherein the bonded abrasive
body comprises an organic pigment.
19. The abrasive article of claim 13, wherein the bonded abrasive
body comprises a pigment having a thermal stability of at least
about at least about 180.degree. C.
20. The abrasive article of claim 13, wherein the bond material has
a color defined by the CIELAB color system of an L* in a range of
from 20 to 80; AND an a* of greater than 20 or less than about -20
and a b* in a range of from about -256 to about 256; OR a b* of
greater than about 20 or less than about -20 and an a* in a range
of from about -256 to about 256.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Patent Application No. 62/098,954 entitled
"Method of Making Colored Abrasive Articles," by Michael W. Klett
and Davinder S. Dhami, filed Dec. 31, 2014, and further claims
priority under 35 U.S.C. .sctn.119(e) to U.S. Patent Application
No. 62/098,949 entitled "Colored Abrasive Articles," by Michael W.
Klett and Davinder S. Dhami, filed Dec. 31, 2014, which both
applications are incorporated by reference herein in their
entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to abrasive articles and
methods of making abrasive articles, and more particularly to
colored abrasive articles and methods of making colored abrasive
articles.
RELATED ART
[0003] Colored bonded abrasive articles formed from high grade bond
materials have not been able to be produced with traditional
methods. During curing and ageing of such abrasive articles formed
form high grade bond materials, the bond material substantially
darkens such that a dark brown to black color is created. Further,
traditional color additives and processes used in making colored
bonded abrasive articles formed from lower grade bond materials
could not overcome the substantial darkening of the bond material
and/or would degrade the strength and toughness of the bond
material. As such, colored bonded abrasive articles formed from
high grade bond materials that retain their high strength and
toughness have been unachievable.
[0004] In contrast to the state of art, the present inventors have
surprisingly discovered the ability to create colored bonded
abrasive articles formed from high grade bond materials that do not
suffer from performance degradations due to the impartation of
color.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Embodiments are illustrated by way of example and are not
limited in the accompanying figures.
[0006] FIG. 1 includes an illustration of a top view of an abrasive
article according to one embodiment, and
[0007] FIG. 2 includes an illustration of a side view of the
abrasive article of FIG. 1.
[0008] Skilled artisans appreciate that elements in the figures are
illustrated for simplicity and clarity and have not necessarily
been drawn to scale. For example, the dimensions of some of the
elements in the figures may be exaggerated relative to other
elements to help to improve understanding of embodiments of the
invention.
DETAILED DESCRIPTION
[0009] The following description in combination with the figures is
provided to assist in understanding the teachings disclosed herein.
The following discussion will focus on specific implementations and
embodiments of the teachings. This focus is provided to assist in
describing the teachings and should not be interpreted as a
limitation on the scope or applicability of the teachings. However,
other embodiments can be used based on the teachings as disclosed
in this application.
[0010] As used herein, the phrase "color instability" refers to the
material's tendency to substantially darken during curing.
[0011] The terms "comprises," "comprising," "includes,"
"including," "has," "having" or any other variation thereof, are
intended to cover a non-exclusive inclusion. For example, a method,
article, or apparatus that comprises a list of features is not
necessarily limited only to those features but may include other
features not expressly listed or inherent to such method, article,
or apparatus. Further, unless expressly stated to the contrary,
"or" refers to an inclusive-or and not to an exclusive-or. For
example, a condition A or B is satisfied by any one of the
following: A is true (or present) and B is false (or not present),
A is false (or not present) and B is true (or present), and both A
and B are true (or present).
[0012] Also, the use of "a" or "an" is employed to describe
elements and components described herein. This is done merely for
convenience and to give a general sense of the scope of the
invention. This description should be read to include one, at least
one, or the singular as also including the plural, or vice versa,
unless it is clear that it is meant otherwise. For example, when a
single item is described herein, more than one item may be used in
place of a single item. Similarly, where more than one item is
described herein, a single item may be substituted for that more
than one item.
[0013] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
materials, methods, and examples are illustrative only and not
intended to be limiting. To the extent not described herein, many
details regarding specific materials and processing acts are
conventional and may be found in textbooks and other sources within
the abrasive arts.
[0014] Certain embodiments of the present disclosure are generally
directed to colored abrasive articles and methods of making colored
abrasive articles, where the bond material is a high grade bond
material that is susceptible to color instability during curing.
The bond material can include a color additive that substantially
changes the inherent color of the bond material, and the new color
is generally maintained after formation and curing of the bonded
abrasive body. The concepts are better understood in view of the
embodiments described below that illustrate and do not limit the
scope of the present invention.
[0015] Referring now to FIG. 1, an abrasive article 10 can include
a bonded abrasive body 20 comprising abrasive particles 40
contained within a bond material 30.
[0016] As described above, in particular embodiments, the bond
material 30 can be susceptible to color instability during curing.
For example, the bond material 30 can be susceptible to color
instability during curing due to the presence of a particular
content of certain reactive groups, such as oxidizable reactive
groups.
[0017] In certain embodiments, the bond material 30 can have a high
glass transition temperature (Tg). For example, the bond material
can have a glass transition temperature (Tg) of at least about
150.degree. C., at least about 155.degree. C., at least about
160.degree. C., at least about 165.degree. C., at least about
170.degree. C., at least about 175.degree. C., at least about
180.degree. C., at least about 185.degree. C., or even at least
about 190.degree. C., at least about 195.degree. C., at least about
200.degree. C., at least about 205.degree. C., at least about
210.degree. C., at least about 215.degree. C., at least about
220.degree. C., or even at least about 225.degree. C. Further, the
bond material can have a glass transition temperature (Tg) of not
greater than about 350.degree. C., not greater than about
320.degree. C. or not greater than about 300.degree. C. Moreover,
the bond material can have a glass transition temperature (Tg) in a
range of any of the minimums and maximums provided above, such as
in a range of from about 150.degree. C. to about 350.degree. C., or
even from about 155.degree. C. to about 300.degree. C.
[0018] In certain embodiments, the bond material 30 can be a
reaction product of various reaction constituents. For example, in
certain embodiments, the bond material 30 can be a reaction product
of constituents including a first resin and a second resin that is
distinct from the first resin.
[0019] In particular embodiments, the first resin can be a resole.
As used herein, a resole resin refers to a phenol-formaldehyde
resin having a formaldehyde to phenol molar ratio of greater than
one and is a base-catalyzed resin.
[0020] In certain embodiments, the bonded abrasive body can have a
particular content of the first resin based on the total weight of
the first and second resin. For example, the bonded abrasive body
can have a content of the first resin of at least about 5 wt. %, at
least about 8 wt. %, at least about 10 wt. %, or at least about 12
wt. % based on the total weight of the first and second resins.
Further, the bonded abrasive body can have a content of the first
resin of not greater than about 80 wt. %, not greater than about 75
wt. %, or even not greater than about 70 wt. % based on the total
weight of the first and second resins. Moreover, the bonded
abrasive body can have a content of the first resin in a range of
any of the minimums and maximums provided above, such as in a range
of from about 5 wt. % to about 80 wt. %, or even 10 wt. % to 75 wt.
%, based on the total weight of the first and second resins.
[0021] In particular embodiments, the second resin can be a novolac
resin. As used herein, a novolac resin refers to a
phenol-formaldehyde resin having a formaldehyde to phenol molar
ratio of less than one and is an acid-catalyzed resin.
[0022] In certain embodiments, the bonded abrasive body can have a
particular content of the second resin. For example, the bonded
abrasive body can have a content of the second resin of at least
about 5 wt. %, at least about 8 wt. %, at least about 10 wt. %, or
at least about 12 wt. % based on the total weight of the first and
second resins. Further, the bonded abrasive body can have a content
of the second resin of not greater than about 80 wt. %, not greater
than about 75 wt. %, or even not greater than about 70 wt. % based
on the total weight of the first and second resins. Moreover, the
bonded abrasive body can have a content of the second resin in a
range of any of the minimums and maximums provided above, such as
in a range of from about 5 wt. % to about 80 wt. %, or even 10 wt.
% to 75 wt. %, based on the first and second resins.
[0023] In certain embodiments, the bond material 30 can further
include a hardener. The hardener can be present in the first resin,
the second resin, or a combination thereof. In particular
embodiments, the hardener can be present in the second resin. The
hardener can serve to increase the crosslinking density of the bond
material, and therefore increase its hardness.
[0024] In particular embodiments, the hardener can include
hexamethylenetetramine (HMTA).
[0025] In certain embodiments, the bond material 30 can further be
described by the type of crosslink bridges that are formed after
curing. In particular embodiments, the bond material can include a
significant amount of methylene and/or dimethylene amino crosslink
bridges. For example, in certain embodiments, the bond material can
include an average of at least about 40%, at least about 50%, at
least about 60%, or even at least about 70% of dimethylene amino
crosslink bridges based on the total average amount of crosslink
bridges in the cured bond material.
[0026] As discussed herein, the abrasive article 10 can include a
bonded abrasive body 20 containing abrasive particles 40 dispersed
within the bond material 30.
[0027] In certain embodiments, the bonded abrasive body 20 can
further include a color additive. For example, a color additive can
be combined with a mixture including the bond material 30 and the
abrasive particles 40 and cured to form a colored bonded abrasive
article that has a different color than the bonded abrasive body
without the color additive.
[0028] In certain embodiments, the color additive can include a
pigment, a dye, or combinations thereof. In particular embodiments,
the color additive can include a pigment.
[0029] In particular embodiments, the color additive can be an
organic color additive.
[0030] In certain embodiments, the color additive can be described
as a thermally stable color additive. As used herein, a color
additive is thermally stable at a particular temperature if the
color additive does not break down at that temperature.
[0031] Accordingly, in particular embodiments, the color additive
can have a thermal stability of at least about 150.degree. C., at
least about 155.degree. C., at least about 160.degree. C., at least
about 165.degree. C., at least about 170.degree. C., at least about
175.degree. C., at least about 180.degree. C., at least about
185.degree. C., at least about 190.degree. C., at least about
195.degree. C., at least about 200.degree. C., at least about
205.degree. C., at least about 210.degree. C., at least about
215.degree. C., at least about 220.degree. C., or even at least
about 225.degree. C.
[0032] Another characteristic to describe particular color
additives is their solubility. In particular embodiments, the color
additive can be soluble in the same solvent used with the bond
material. In this way, the color additive can have good
dispersability and mixing with the bond material resins and
abrasive particles during production. In very particular
embodiments, the color additive can be an organic pigment that is
soluble with at least one resin forming the bond material.
[0033] In certain embodiments, the bonded abrasive body 20 can
further include a filler material that is distinct from the
abrasive particles 40, and also dispersed within the bond material
30. For example, the filler can have a hardness that is less than
the hardness of the abrasive particle. Like the abrasive particles,
the filler material can be disposed within the bond material
30.
[0034] In certain embodiments, the filler can be in the form of
powders, granules, spheres, fibers, or a combination thereof.
[0035] In certain embodiments, the filler can be an inorganic
material. In other embodiments, the filler can be an organic
material. In still further embodiments, the filler can include a
combination of inorganic fillers and organic fillers.
[0036] In particular embodiments, the filler can include nepheline
syenite, sand, bubble alumina, bauxite, chromites, magnesite,
dolomites, bubble mullite, borides, titanium dioxide, carbon
products, flour, clay, talc, hexagonal boron nitride, molybdenum
disulfide, feldspar, glass spheres, glass fibers, CaF.sub.2,
KBF.sub.4, Cryolite (Na.sub.3AlF.sub.6), potassium Cryolite
(K.sub.3AlF.sub.6), pyrites, ZnS, copper sulfide, mineral oil,
fluorides, carbonates, calcium carbonate, or a combination
thereof.
[0037] In certain embodiments, the filler can also have a
particular color. For example, the filler can have any of the
colors identified below in regards to the bond material as
quantified in the CIELAB color system. In further embodiments, the
filler can have a color that is substantially similar to the color
of the pigmented bond material. In very particular embodiments, the
filler can be essentially free of a black filler, such as carbon
black. For example, traditionally, carbon black filler was the
typical filler employed due to the color instability of the bond
material causing the bond material to substantially darken during
curing.
[0038] In addition to the filler, the bonded abrasive body can
further include other additives. For example, other desirable
additives can include an antistatic agent, a metal oxide, a
lubricant, a porosity inducer, coloring agent, or a combination
thereof.
[0039] In certain embodiments, the bonded abrasive body can have a
particular content of bond material. For example, the bonded
abrasive body can have a content of bond material of at least about
5 wt. %, at least about 10 wt. %, at least about 15 wt. %, or even
at least about 20 wt. % based on the total weight of the bonded
abrasive body. Further, the bonded abrasive body can have a content
of bond material of not greater than about 80 wt. %, not greater
than about 75 wt. %, or even not greater than about 70 wt. % based
on the total weight of the bonded abrasive body. Moreover, the
bonded abrasive body can have a content of bond material in a range
of any of the minimums and maximums provided above, such as in a
range of from about 5 wt. % to about 80 wt. %, or even 10 wt. % to
75 wt. %, based on the total weight of the bonded abrasive
body.
[0040] In certain embodiments, the bonded abrasive body can have a
particular content of abrasive particles. For example, the bonded
abrasive body can have a content of abrasive particles of at least
about 5 wt. %, at least about 10 wt. %, or even at least about 15
wt. % based on the total weight of the bonded abrasive body.
Further, the bonded abrasive body can have a content of abrasive
particles of not greater than about 50 wt. %, not greater than
about 45 wt. %, or even not greater than about 40 wt. % based on
the total weight of the bonded abrasive body. Moreover, the bonded
abrasive body can have a content of abrasive particles in a range
of any of the minimums and maximums provided above, such as in a
range of from about 5 wt. % to about 50 wt. %, or even from about
10 wt. % to about 45 wt. % based on the total weight of the bonded
abrasive body.
[0041] In certain embodiments, the bonded abrasive body can have a
particular content of color additive. For example, the bonded
abrasive body can have a content of color additive of at least
about 0.01 wt. %, at least about 0.05 wt. %, at least about 0.1 wt.
%, or even at least about 1 wt. % based on the total weight of the
bonded abrasive body. Further, the bonded abrasive body can have a
content of color additive of not greater than about 20 wt. %, not
greater than about 15 wt. %, no greater than about 10 wt. %, or
even not greater than about 5 wt. % based on the total weight of
the bonded abrasive body. Moreover, the bonded abrasive body can
have a content of color additive in a range of any of the minimums
and maximums provided above, such as in a range of from about 0.01
wt. % to about 10 wt. % based on the total weight of the bonded
abrasive body.
[0042] In certain embodiments, the bonded abrasive body can have a
particular content of filler material. For example, the bonded
abrasive body can have a filler content of at least about 1 wt. %,
at least about 3 wt. %, or even at least about 5 wt. % based on the
total weight of the bonded abrasive body. Further, the bonded
abrasive body can have a filler content of not greater than about
30 wt. %, not greater than about 25 wt. %, or even not greater than
about 20 wt. % based on the total weight of the bonded abrasive
body. Moreover, the bonded abrasive body can have a filler content
in a range of any of the minimums and maximums provided above, such
as in a range of from about 1 wt. % to about 30 wt. %, or even from
about 3 wt. % to about 25 wt. % based on the total weight of the
bonded abrasive body.
[0043] In certain embodiments, the bonded abrasive body can have a
particle shape. For example, and referring to FIGS. 1 and 2, the
bonded abrasive body can have a thickness (t) extending axially
across the body, and a diameter (D) extending radially across the
body.
[0044] In particular embodiments, the bonded abrasive body can have
a particular ratio of the diameter to the thickness. For example,
the ratio of the diameter to the thickness can be at least about
10:1, at least about 20:1, at least about 50:1, or at least about
100:1. In further embodiments, the ratio can be not greater than
about 10,000:1, or not greater than 5,000:1. Moreover, the ratio of
the diameter to the thickness can be in a range of any of the
minimums and maximums provided above, such as in a range of from
about 10:1 to about 10,000:1.
[0045] As described throughout this document, the bonded abrasive
article can have a desired color, and particularly a color other
than the inherent color of the bond material, such a color other
than generally black or dark brown.
[0046] As used herein, color can be described and quantified using
the CIE L*a*b* color system, as is well understood in the art.
[0047] The CIE L*a*b* color system includes a three dimensional
coordinate system to assign a numerical value to a color. The
vertical L* axis represents Lightness, ranging from 0-100. The
other (horizontal) axes are represented by a* and b*. These are at
right angles to each other and cross each other in the center,
which is neutral (grey, black or white). They are based on the
principal that a color cannot be both red and green, or blue and
yellow. The a* axis is green at one extremity (represented by -a),
and red at the other (+a). The b* axis has blue at one end (-b),
and yellow (+b) at the other. The center of each axis is 0. A value
of 0, or very low numbers of both a* and b* will describe a neutral
or near neutral color. In theory there are no maximum values of a*
and b*, but in practice they are usually numbered from -128 to +127
(256 levels). The CIE Lab color model encompasses the entire
spectrum, including colors outside of human vision.
[0048] Traditional methods and materials used to make the high
grade bond material described herein could only be produced in a
dark color, such as dark brown to black. Within the CIELAB color
system, the general colors of dark brown to black can have a CIELAB
values of L* less than about 20. Accordingly, in particular
embodiments, the bonded abrasive body can have a color other than
generally dark brown to black, i.e., a color having CIELAB values
other than an L* of less than about 20.
[0049] Put another way, in certain embodiments, the bonded abrasive
body can have a color having: [0050] a. a L* of at least about 20,
at least about 30, or even at least about 35; an L* of not greater
than about 95, not greater than about 90, not greater than about
85, not greater than about 80, or even not greater than about 75;
or an L* in a range of any of the minimums and maximums provided
above; [0051] b. an a* of at least about 20 or less than -20, at
least about 40 or less than -40, or even at least about 50 or less
than -50; an a* of not great than 1000 or greater than -1000, not
greater than 500 or greater than -500; not greater than about 256
or greater than -256; or an a* in a range of any of the minimums
and maximums provided above; and [0052] c. a b* of at least about
20 or less than -20, at least about 40 or less than -40, or even at
least about 50 or less than -50; a b* of not greater than 1000 or
greater than -1000, not greater than 500 or greater than -500; not
greater than about 256 or greater than -256; or a b* in a range of
any of the minimums and maximums provided above.
[0053] In particular embodiments, a bonded abrasive body can have
an a* of greater than 20 or less than about -20 and a b* in a range
of from about -256 to about 256.
[0054] In further particular embodiments, a bonded abrasive body
can have a b* of greater than about 20 or less than about -20 and
an a* in a range of from about -256 to about 256.
[0055] In particular embodiments, the bonded abrasive body can have
a generally green color having a L* in a range of from about 20 to
about 80; an a* of less than about -20; and a b* in a range of from
-256 to 256.
[0056] In particular embodiments, the bonded abrasive body can have
a generally red color having a L* in a range of from about 20 to
about 80; an a* of at least about 20 and a b* in a range of from
-256 to 256.
[0057] In particular embodiments, the bonded abrasive body can have
a generally orange color having a L* in a range of from about 20 to
about 80; an a* in a range of at least about 20 and a b* of at
least about 20.
[0058] In particular embodiments, the bonded abrasive body can have
a generally yellow color having a L* in a range of from about 20 to
about 80; a b* in a range of at least about 20 and an a* in a range
of from -256 to 256.
[0059] In particular embodiments, the bonded abrasive body can have
a generally green color having a L* in a range of from 20 to 80; an
a* of not greater than -20; and a b* in a range of from -256 to
256.
[0060] In particular embodiments, the bonded abrasive body can have
a desirable color difference from the same bonded abrasive body
without a color additive. In further embodiments, the bonded
abrasive body can have a desirable color difference from the same
bonded abrasive body except cured in an ambient air atmosphere. For
example, traditional color additives were ineffective in producing
a substantial different color due to the inherent color instability
of the bond material at elevated cure temperatures. In contrast,
the present inventors have surprisingly discovered that a
substantial color difference from the inherent color of the cured
bond material can be obtained without sacrificing performance of
the abrasive article. Accordingly, the current inventors were
surprisingly able to construct bonded abrasive bodies having a
multitude of different color possibilities.
[0061] To standardize color differences, the International
Commission on Illumination (CIE) has developed a color difference
formula, .DELTA.E*ab (also called .DELTA.E* or .DELTA.E) used to
denote difference of color sensation. Using
(L.sub.2*,a.sub.2*,b.sub.2*), and (L.sub.2*,a.sub.2*,b.sub.2*) of
two colors in L*a*b*, .DELTA.E is:
.DELTA.E*= {square root over
((L.sub.2*-L.sub.1*).sup.2+(a.sub.2*-a.sub.1*).sup.2+(b.sub.2*-b.sub.1*).-
sup.2)}
[0062] Accordingly, in particular embodiments, the bonded abrasive
body can have a color difference (.DELTA.E) of at least about 5, at
least about 10, at least about 15, at least about 20, at least
about 30, at least about 40, at least about 50, or even at least
about 60 compared to the inherent color of the cured bond material
without a color additive.
[0063] In certain embodiments, the bonded abrasive body can have an
advantageous wear rate. The wear rate is a measure of the amount of
material that is removed from the bonded abrasive body when
subjected to a standardized abrading procedure.
[0064] The wear rate value of the bonded abrasive bond can be
useful to distinguish between different grades of abrasive
articles. For example, the stronger and tougher the bond material
is, the lower the wear rate value will be. Furthermore,
traditionally, it was not possible to create a colored bonded
abrasive body using materials that gave the bonded abrasive body a
lower rate. Attempts to impart such color resulted in deterioration
of the strength and toughness of the bonded abrasive body, and
therefore increased the wear rate. In contrast, the current
inventors surprisingly discovered the ability to create a colored
bonded abrasive body without deteriorating the toughness and
strength, and therefore maintaining desirable wear rates.
[0065] Accordingly, in certain embodiments, the bonded abrasive
body can have an advantageous wear rate, consistent with the same
abrasive article without the impartation of color.
[0066] In certain embodiments, the bonded abrasive body can have an
advantageous material removal rate. The material removal rate is
measure of the amount of material that is removed from the
workpiece when subjected to a standardized abrading procedure.
[0067] In further embodiments, the material removal rate (MRR) of
the bonded abrasive bond can be useful to distinguish between
different grades of abrasive articles. For example, the stronger
and tougher the bond material is, the higher the material removal
rate value will be. Furthermore, traditionally, it was not possible
to create a colored bonded abrasive body using materials that gave
the bonded abrasive body a higher rate. Attempts to impart such
color resulted in deterioration of the strength and toughness of
the bonded abrasive body, and therefore decreased the material
removal rate. In contrast, the current inventors surprisingly
discovered the ability to create a colored bonded abrasive body
without deteriorating the toughness and strength, and therefore
maintaining desirable material removal rates.
[0068] Accordingly, in certain embodiments, the bonded abrasive
body can have an advantageous material removal rate consistent with
the removal rate of the same bonded abrasive article without the
impartation of color.
[0069] Another aspect of certain embodiments of the present
disclosure is directed to a method of forming an abrasive article.
It is to be understood that all of the characteristics and features
of the abrasive article described above also apply to embodiments
directed to a method of forming the abrasive article. For example,
the method can include forming a bonded abrasive body having the
dimensions, color, and wear rates, among other properties, provided
above.
[0070] In general, certain embodiments of the method can include:
[0071] a. providing a bond material precursor; [0072] b. providing
abrasive particles; [0073] c. mixing the abrasive particles with
the bond material precursor; [0074] d. curing the mixture to form a
bonded abrasive body with abrasive particles dispersed within a
cured bond material.
[0075] In certain embodiments, providing the bond material
precursor can include providing a first resin and a second resin
which is different from the first resin.
[0076] For example, in particular embodiments, mixing the abrasive
particles with the bond material precursor can include pre-coating
the abrasive particles with the first resin. Furthermore, the
method can further include mixing the second resin with the coated
abrasive particles. It is to be understood that the first and
second resins can be those described above. For example, the first
resin can be a resole and the second resin can be a novolac
resin.
[0077] In particular embodiments, curing the mixture to form a
bonded abrasive body can include curing the mixture in a
non-oxidative atmosphere. For example, the non-oxidative atmosphere
can consist essentially of an inert gas, such as nitrogen. In very
particular embodiments, curing the mixture to form a bonded
abrasive body can include curing the mixture in an atmosphere
consisting essentially of nitrogen.
[0078] In certain embodiments, curing the mixture to form a bonded
abrasive body can include curing the mixture at a relatively high
temperature. For example, as discussed above, particular advantages
of certain embodiments of the present disclosure is the ability to
impart a desired color to high grade bond materials that a have a
high strength and high toughness. Typically, such high grade bond
materials have a high cure temperature to obtain the high strength
and toughness. Without wishing to be bound by any one theory, it is
believed that the high cure temperature is partly responsible for
the extreme difficulty in creating high performing, colored, bonded
abrasive bodies due in part to the limitation on color additives
and the inherent color instability of the bond material at such
high cure temperatures.
[0079] Accordingly, in particular embodiments, curing the mixture
to form a bonded abrasive body can include curing the mixture at a
temperature of at least about 150.degree. C., at least about
155.degree. C., at least about 160.degree. C., at least about
165.degree. C., at least about 170.degree. C., at least about
175.degree. C., at least about 180.degree. C., at least about
185.degree. C., or even at least about 190.degree. C., at least
about 195.degree. C., at least about 200.degree. C., at least about
205.degree. C., at least about 210.degree. C., at least about
215.degree. C., at least about 220.degree. C., or even at least
about 225.degree. C. In further embodiments, curing the mixture to
form a bonded abrasive body can include curing the mixture at a
temperature of no greater than about 350.degree. C., not greater
than about 320.degree. C. or not greater than about 300.degree. C.
Moreover, curing the mixture to form a bonded abrasive body can
include curing the mixture at a temperature in a range of any of
the minimums and maximums provided above, such as in a range of
from about 150.degree. C. to about 350.degree. C., or even from
about 155.degree. C. to about 300.degree. C.
[0080] The present disclosure represents a departure from the state
of the art. Heretofore, it was not possible to create a colored
high grade bonded abrasive body that maintained its high grade
attributes such as strength and toughness while imparting a desired
color. For example, traditional materials and processes used to
create a high grade bonded abrasive body would substantially darken
during curing to give a generally black or dark brown color.
Addition of color additives could not overcome the substantial
darkening of the bond material that traditionally, inherently
occurred. Further, attempts to prevent the substantial darkening of
the bond material during curing and ageing resulted in a
degradation of the performance of the bonded abrasive body, in, for
example, strength, toughness, and crosslink density and therefore
wear rate. Accordingly, such high grade bonded abrasive bodies were
only able to be produced in a black or a dark brown color.
Moreover, it was unknown what was causing the substantial darkening
during curing and ageing and how to alleviate such inherent effect
without deteriorating the performance of the high grade bonded
abrasive bodies. In contrast, and as illustrated in more detail by
the Examples below, the bonded abrasive bodies according to certain
embodiments of the present disclosure were surprisingly able to
have a color other than black or dark brown and maintain desired
performances in strength, toughness, crosslink density, wear rate,
and others. Without wishing to be bound by any one theory, the
modification to the processing and particularly curing of the
bonded abrasive body described herein has generally prevented the
bond material from substantially darkening during curing and ageing
without significantly affecting its performance. For example, at
least, the modification to an inert atmosphere during curing is
believed to have substantially decreased the oxidation in the bond
material which is theorized to have resulted in the general
prevention of substantial darkening during curing and ageing thus
allowing particular color additives to impart color while
maintaining performance.
[0081] Many different aspects and embodiments are possible. Some of
those aspects and embodiments are described below. After reading
this specification, skilled artisans will appreciate that those
aspects and embodiments are only illustrative and do not limit the
scope of the present invention. Embodiments may be in accordance
with any one or more of the items as listed below.
Embodiment 1
[0082] An abrasive article comprising: a bonded abrasive body
comprising abrasive particles contained within a bond material,
wherein the bond material has a glass transition temperature of at
least about 200.degree. C.; and wherein the bonded abrasive body is
color stable.
Embodiment 2
[0083] An abrasive article comprising: a bonded abrasive body
comprising abrasive particles contained within a bond material,
wherein the bond material has a glass transition temperature of at
least about 200.degree. C.; and wherein the bonded abrasive body
further comprises at least one pigment.
Embodiment 3
[0084] An abrasive article comprising: a bonded abrasive body
comprising abrasive particles contained within a bond material,
wherein the bond material has a glass transition temperature of at
least about 200.degree. C., and wherein the bond material has a
color defined by the CIELAB color system of a L* in a range of from
20 to 80; AND an a* of greater than 20 or less than about -20 and a
b* in a range of from about -256 to about 256; OR a b* of greater
than about 20 or less than about -20 and an a* in a range of from
about -256 to about 256.
Embodiment 4
[0085] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bond material is essentially free of an acrylate.
Embodiment 5
[0086] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bond material has a glass transition temperature of at
least at least about 150.degree. C., or at least about 155.degree.
C., or at least about 160.degree. C., or at least about 165.degree.
C., or at least about 170.degree. C., or at least about 175.degree.
C., or at least about 180.degree. C., or at least about 185.degree.
C., or even at least about 190.degree. C., at least about
195.degree. C., or at least about 200.degree. C., or at least about
205.degree. C., or at least about 210.degree. C., or at least about
215.degree. C., or at least about 220.degree. C., or even at least
about 225.degree. C.
Embodiment 6
[0087] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bond material comprises a glass transition temperature
of not greater than 350.degree. C., or not greater than 320.degree.
C. or at least 300.degree. C.
Embodiment 7
[0088] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has a bond material content of at
least about 5 wt. % based on the total weight of the body, and
wherein the bonded abrasive body has a bond material content of not
greater than about 80 wt. % based on the total weight of the
body.
Embodiment 8
[0089] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bond material comprises a cured and cross-linked
reaction product of a first resin and a second resin distinct from
the first resin.
Embodiment 9
[0090] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the first resin is a resole.
Embodiment 10
[0091] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the first resin is a phenol-formaldehyde resin having
formaldehyde to phenol molar ratio of greater than one.
Embodiment 11
[0092] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the first resin is a base-catalyzed resin.
Embodiment 12
[0093] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the second resin comprises a novolac resin.
Embodiment 13
[0094] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the second resin is a phenol-formaldehyde resin having
formaldehyde to phenol molar ratio of less than one.
Embodiment 14
[0095] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the second resin is an acid-catalyzed resin.
Embodiment 15
[0096] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has a content of the second resin
of at least about 5 wt. %, or at least about 8 wt. %, or at least
about 10 wt. %, or at least about 12 wt. % based on the total
weight of the bonded abrasive body; and wherein the bonded abrasive
body has a content of the second resin of not greater than about 90
wt. %.
Embodiment 16
[0097] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the second resin comprises a hardener comprising
hexamethylenetetramine (HMTA).
Embodiment 17
[0098] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bond material includes a significant amount of
methylene and dimethylene amino crosslink bridges.
Embodiment 18
[0099] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body comprises a pigment.
Embodiment 19
[0100] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body comprises an organic pigment.
Embodiment 20
[0101] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body comprises a pigment having a
thermal stability of at least about 150.degree. C., or at least
about 155.degree. C., or at least about 160.degree. C., or at least
about 165.degree. C., or at least about 170.degree. C., or at least
about 175.degree. C., or at least about 180.degree. C., or at least
about 185.degree. C., or even at least about 190.degree. C., at
least about 195.degree. C., or at least about 200.degree. C., or at
least about 205.degree. C., or at least about 210.degree. C., or at
least about 215.degree. C., or at least about 220.degree. C., or
even at least about 225.degree. C.
Embodiment 21
[0102] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body comprises a pigment that is
soluble in an aqueous solvent.
Embodiment 22
[0103] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body comprises an inorganic
pigment.
Embodiment 23
[0104] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has an abrasive particle content
of at least about 5 wt. % based on the total weight of the body,
and wherein the bonded abrasive body has an abrasive particle
content of not greater than about 50 wt. % based on the total
weight of the body.
Embodiment 24
[0105] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body further comprises a filler that is
distinct from the abrasive particles.
Embodiment 25
[0106] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body further comprises a filler in the
form of powders, granules, spheres, fibers, or a combination
thereof.
Embodiment 26
[0107] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body further comprises a filler
comprising an inorganic material.
Embodiment 27
[0108] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body further comprises a filler
comprising an organic material.
Embodiment 28
[0109] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body further comprises a filler
disposed within the bond material.
Embodiment 29
[0110] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body further comprises a filler
comprising nepheline syenite, sand, bubble alumina, bauxite,
chromites, magnesite, dolomites, bubble mullite, borides, titanium
dioxide, carbon products, flour, clay, talc, hexagonal boron
nitride, molybdenum disulfide, feldspar, glass spheres, glass
fibers, CaF.sub.2, KBF.sub.4, Cryolite (Na.sub.3AlF.sub.6),
potassium Cryolite (K.sub.3AlF.sub.6), pyrites, ZnS, copper
sulfide, mineral oil, fluorides, carbonates, calcium carbonate, or
a combination thereof.
Embodiment 30
[0111] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body further comprises a filler
comprising an antistatic agent, a metal oxide, a lubricant, a
porosity inducer, coloring agent, and a combination thereof and
wherein the filler is distinct from the abrasive particles.
Embodiment 31
[0112] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has a filler content of at least
about 1 wt. % based on the total weight of the body, and wherein
the bonded abrasive body has a filler content of not greater than
about 30 wt. % based on the total weight of the body.
Embodiment 32
[0113] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body is essentially free of a black
filler.
Embodiment 33
[0114] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has a porosity of at least about 1
vol. % based on the total volume of the body, and wherein the
bonded abrasive body has a porosity of not greater than about 50
vol. % based on the total volume of the body.
Embodiment 34
[0115] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has a diameter (D) extending
radially across the body and a thickness (t) extending axially
across the body, wherein the body comprises a ratio of the diameter
to the thickness of at least about 10:1, or at least about 20:1, or
at least about 50:1, or at least about 100:1.
Embodiment 35
[0116] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has a color defined by the CIELAB
color system of: [0117] a. a L* in a range of 20 to 80, or 30 to
75, or even 35 to 75; [0118] b. an a* of at least about 20 or less
than -20, at least about 40 or less than -40, or even at least
about 50 or less than -50; AND a b* of not greater than 1000 or
greater than -1000, not greater than 500 or greater than -500; not
greater than about 256 or greater than -256; OR [0119] c. an a* of
not great than 1000 or greater than -1000, not greater than 500 or
greater than -500; not greater than about 256 or greater than -256;
AND b* of at least about 20 or less than -20, at least about 40 or
less than -40, or even at least about 50 or less than -50.
Embodiment 36
[0120] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has a generally green color
defined by the CIELAB color system of a L* in a range of from about
20 to about 80; an a* of less than about -20; and a b* in a range
of from -256 to 256.
Embodiment 37
[0121] The abrasive article of any one of the preceding
embodiments, wherein the bonded abrasive body has a generally red
color defined by the CIELAB color system of a L* in a range of from
about 20 to about 80; an a* of at least about 20 and a b* in a
range of from -256 to 256.
Embodiment 38
[0122] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has a generally orange color
defined by the CIELAB color system of a L* in a range of from about
20 to about 80; an a* in a range of at least about 20 and a b* of
at least about 20.
Embodiment 39
[0123] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has a generally yellow color
defined by the CIELAB color system of a L* in a range of from about
20 to about 80; a b* in a range of at least about 20 and an a* in a
range of from -256 to 256.
Embodiment 40
[0124] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has a generally green color
defined by the CIELAB color system of a L* in a range of from 20 to
80; an a* of not greater than -20; and a b* in a range of from -256
to 256.
Embodiment 41
[0125] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body comprises a reinforcing layer
extending radially through at least a portion of the body, wherein
the reinforcing layer comprises a reinforcing material comprising a
fabric, a fiber, a film, a woven material, a non-woven material, a
glass, a fiberglass, a ceramic, a polymer, a resin, a polymer, a
fluorinated polymer, an epoxy resin, a polyester resin, a
polyurethane, a polyester, a rubber, a polyimide, a
polybenzimidazole, an aromatic polyamide, a modified phenolic
resin, or a combination thereof.
Embodiment 42
[0126] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body is essentially free of a reducing
agent.
Embodiment 43
[0127] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the bonded abrasive body has a ratio of the diameter to the
thickness of at least about 10:1, or at least about 20:1, or at
least about 50:1, or at least about 100:1; and wherein the bonded
abrasive body has a ratio of the diameter to the thickness of not
greater than about 10,000:1, or not greater than 5,000:1.
Embodiment 44
[0128] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the abrasive article has a generally similar wear rate to
the same abrasive article except without the impartation of
color.
Embodiment 45
[0129] The abrasive article of any one of embodiments 1, 2 and 3,
wherein the abrasive article has a generally similar material
removal rate to the same abrasive article except without the
impartation of color.
Embodiment 46
[0130] A method of forming an abrasive article comprising a bonded
abrasive body, the method comprising: forming a mixture comprising
abrasive particles dispersed within a bond material; and curing the
mixture at a temperature of at least 200.degree. C. in a
non-oxidizing atmosphere to form a bonded abrasive body.
Embodiment 47
[0131] A method of forming an abrasive article comprising a bonded
abrasive body, the method comprising: forming a mixture comprising
abrasive particles dispersed within a phenyl-formaldehyde based
bond material; and curing the mixture, wherein the bonded abrasive
body has color defined by the CIELAB color system of an L* in a
range of from 20 to 80; AND an a* of greater than 20 or less than
about -20 and a b* in a range of from about -256 to about 256; OR a
b* of greater than about 20 or less than about -20 and an a* in a
range of from about -256 to about 256.
Embodiment 48
[0132] A method of forming an abrasive article comprising a bonded
abrasive body, the method comprising: forming a mixture comprising
abrasive particles dispersed within a bond material; and curing the
mixture at a temperature of at least 200.degree. C. in a
non-oxidizing atmosphere to form a bonded abrasive body wherein the
bonded abrasive body has color defined by the CIELAB color system
of an L* in a range of from 20 to 80; AND an a* of greater than 20
or less than about -20 and a b* in a range of from about -256 to
about 256; OR a b* of greater than about 20 or less than about -20
and an a* in a range of from about -256 to about 256.
Embodiment 49
[0133] A method of forming an abrasive article comprising a bonded
abrasive body, the method comprising: forming a mixture comprising
abrasive particles dispersed within a phenyl-formaldehyde based
bond material; and curing the mixture, wherein the bonded abrasive
body has substantially the same color before and after curing.
Embodiment 50
[0134] The method of any of embodiments 46, 47, 48 and 49, wherein
forming the mixture comprises: coating the abrasive particles with
a first resin; adding a second resin to the mixture, wherein the
second resin is distinct from the first resin.
Embodiment 51
[0135] The method of any of embodiments 46, 47, 48 and 49, wherein
forming the mixture comprises: coating the abrasive particles with
a mixture of the first resin and a solvent; wherein the pigment and
the first resin are soluble with the solvent.
Embodiment 52
[0136] The method of any of embodiments 46, 47, 48 and 49, wherein
the novolac resin comprises a hardener comprising
hexamethylenetetramine (HMTA).
Embodiment 53
[0137] The method of any of embodiments 46, 47, 48 and 49, wherein
the bond material includes a significant amount of methylene and
dimethylene amino crosslink bridges.
Embodiment 54
[0138] The method of any of embodiments 46, 47, 48 and 49, wherein
the non-oxidizing atmosphere consists essentially of an inert
gas.
Embodiment 55
[0139] The method of any of embodiments 46, 47, 48 and 49, wherein
the non-oxidizing atmosphere consists essentially of an inert gas
comprising nitrogen.
Embodiment 56
[0140] The method of any of embodiments 46, 47, 48 and 49, wherein
the non-oxidizing atmosphere consists essentially of nitrogen.
Embodiment 57
[0141] The method of any of embodiments 46, 47, 48 and 49, wherein
curing the mixture comprises curing the mixture at a temperature of
at least about 150.degree. C., at least about 155.degree. C., at
least about 160.degree. C., at least about 165.degree. C., at least
about 170.degree. C., at least about 175.degree. C., at least about
180.degree. C., at least about 185.degree. C., or even at least
about 190.degree. C., at least about 195.degree. C., at least about
200.degree. C., at least about 205.degree. C., at least about
210.degree. C., at least about 215.degree. C., at least about
220.degree. C., or even at least about 225.degree. C.
Embodiment 58
[0142] The method of any of embodiments 46, 47, 48 and 49, wherein
curing the mixture comprises preventing the mixture from oxidizing
during curing.
Embodiment 59
[0143] The method of any of embodiments 46, 47, 48 and 49, wherein
the bond material is essentially free of an acrylate.
Embodiment 60
[0144] The method of any of embodiments 46, 47, 48 and 49, wherein
the bond material has a glass transition temperature of at least at
least about 150.degree. C., at least about 155.degree. C., at least
about 160.degree. C., at least about 165.degree. C., at least about
170.degree. C., at least about 175.degree. C., at least about
180.degree. C., at least about 185.degree. C., or even at least
about 190.degree. C., at least about 195.degree. C., at least about
200.degree. C., at least about 205.degree. C., at least about
210.degree. C., at least about 215.degree. C., at least about
220.degree. C., or even at least about 225.degree. C.
Embodiment 61
[0145] The method of any of embodiments 46, 47, 48 and 49, wherein
the bond material comprises a glass transition temperature of not
greater than 350.degree. C., not greater than 320.degree. C. or at
least 300.degree. C.
Embodiment 62
[0146] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has a bond material content of at least
about 5 wt. % based on the total weight of the body, and wherein
the bonded abrasive body has a bond material content of not greater
than about 80 wt. % based on the total weight of the body.
Embodiment 63
[0147] The method of any of embodiments 46, 47, 48 and 49, wherein
the first resin is a resole.
Embodiment 64
[0148] The method of any of embodiments 46, 47, 48 and 49, wherein
the first resin is a phenol-formaldehyde resin having a
formaldehyde to phenol molar ratio of greater than one.
Embodiment 65
[0149] The method of any of embodiments 46, 47, 48 and 49, wherein
the first resin is a base-catalyzed resin.
Embodiment 66
[0150] The method of any of embodiments 46, 47, 48 and 49, wherein
the second resin comprises a novolac resin.
Embodiment 67
[0151] The method of any of embodiments 46, 47, 48 and 49, wherein
the second resin is a phenol-formaldehyde resin having a
formaldehyde to phenol molar ratio of less than one.
Embodiment 68
[0152] The method of any of embodiments 46, 47, 48 and 49, wherein
the second resin is an acid-catalyzed resin.
Embodiment 69
[0153] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has a content of the second resin of at
least about 5 wt. %, at least about 8 wt. %, at least about 10 wt.
%, or at least about 12 wt. % based on the total weight of the
bonded abrasive body; and wherein the bonded abrasive body has a
content of the second resin of not greater than about 90 wt. %.
Embodiment 70
[0154] The method of any of embodiments 46, 47, 48 and 49, wherein
the bond material includes a significant amount of methylene and
dimethylene amino crosslink bridges.
Embodiment 71
[0155] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body comprises a pigment.
Embodiment 72
[0156] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body comprises an organic pigment.
Embodiment 73
[0157] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body comprises a pigment having a thermal
stability of at least about 150.degree. C., at least about
155.degree. C., at least about 160.degree. C., at least about
165.degree. C., at least about 170.degree. C., at least about
175.degree. C., at least about 180.degree. C., at least about
185.degree. C., or even at least about 190.degree. C., at least
about 195.degree. C., at least about 200.degree. C., at least about
205.degree. C., at least about 210.degree. C., at least about
215.degree. C., at least about 220.degree. C., or even at least
about 225.degree. C.
Embodiment 74
[0158] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body comprises a pigment that is soluble in an
aqueous solvent.
Embodiment 75
[0159] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body comprises an inorganic pigment.
Embodiment 76
[0160] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has an abrasive particle content of at
least about 5 wt. % based on the total weight of the body, and
wherein the bonded abrasive body has an abrasive particle content
of not greater than about 50 wt. % based on the total weight of the
body.
Embodiment 77
[0161] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body further comprises a filler that is
distinct from the abrasive particles.
Embodiment 78
[0162] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body further comprises a filler in the form of
powders, granules, spheres, fibers, or a combination thereof.
Embodiment 79
[0163] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body further comprises a filler comprising an
inorganic material.
Embodiment 80
[0164] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body further comprises a filler comprising an
organic material.
Embodiment 81
[0165] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body further comprises a filler disposed within
the bond material.
Embodiment 82
[0166] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body further comprises a filler comprising
nepheline syenite, sand, bubble alumina, bauxite, chromites,
magnesite, dolomites, bubble mullite, borides, titanium dioxide,
carbon products, flour, clay, talc, hexagonal boron nitride,
molybdenum disulfide, feldspar, glass spheres, glass fibers,
CaF.sub.2, KBF.sub.4, Cryolite (Na.sub.3AlF.sub.6), potassium
Cryolite (K.sub.3AlF.sub.6), pyrites, ZnS, copper sulfide, mineral
oil, fluorides, carbonates, calcium carbonate, or a combination
thereof.
Embodiment 83
[0167] The method of any one of the preceding embodiments, wherein
the bonded abrasive body further comprises a filler comprising an
antistatic agent, a metal oxide, a lubricant, a porosity inducer,
coloring agent, and a combination thereof and wherein the filler is
distinct from the abrasive particles.
Embodiment 84
[0168] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has a filler content of at least about 1
wt. % based on the total weight of the body, and wherein the bonded
abrasive body has a filler content of not greater than about 30 wt.
% based on the total weight of the body.
Embodiment 85
[0169] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body is essentially free of a black filler.
Embodiment 86
[0170] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has a porosity of at least about 1 vol. %
based on the total volume of the body, and wherein the bonded
abrasive body has a porosity of not greater than about 50 vol. %
based on the total volume of the body.
Embodiment 87
[0171] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has a diameter (D) extending radially
across the body and a thickness (t) extending axially across the
body, wherein the body comprises a ratio of the diameter to the
thickness of at least about 10:1, at least about 20:1, at least
about 50:1, or at least about 100:1.
Embodiment 88
[0172] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has a color after curing defined by the
CIELAB color system of: [0173] a. a L* in a range of 20 to 80, 30
to 75, or even 35 to 75; [0174] b. an a* of at least about 20 or
less than -20, at least about 40 or less than -40, or even at least
about 50 or less than -50; AND a b* of not greater than 1000 or
greater than -1000, not greater than 500 or greater than -500; not
greater than about 256 or greater than -256; OR [0175] c. an a* of
not great than 1000 or greater than -1000, not greater than 500 or
greater than -500; not greater than about 256 or greater than -256;
AND b* of at least about 20 or less than -20, at least about 40 or
less than -40, or even at least about 50 or less than -50.
Embodiment 89
[0176] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has a generally green color after curing
defined by the CIELAB color system of a L* in a range of from about
20 to about 80; an a* of less than about -20; and a b* in a range
of from -256 to 256.
Embodiment 90
[0177] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has a generally red color after curing
defined by the CIELAB color system of a L* in a range of from about
20 to about 80; an a* of at least about 20 and a b* in a range of
from -256 to 256.
Embodiment 91
[0178] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has a generally orange color after curing
defined by the CIELAB color system of a L* in a range of from about
20 to about 80; an a* in a range of at least about 20 and a b* of
at least about 20.
Embodiment 92
[0179] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has a generally yellow color after curing
defined by the CIELAB color system of a L* in a range of from about
20 to about 80; a b* in a range of at least about 20 and an a* in a
range of from -256 to 256.
Embodiment 93
[0180] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has a generally green color after curing
defined by the CIELAB color system of a L* in a range of from 20 to
80; an a* of not greater than -20; and a b* in a range of from -256
to 256.
Embodiment 94
[0181] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body comprises a reinforcing layer extending
radially through at least a portion of the body, wherein the
reinforcing layer comprises a reinforcing material comprising a
fabric, a fiber, a film, a woven material, a non-woven material, a
glass, a fiberglass, a ceramic, a polymer, a resin, a polymer, a
fluorinated polymer, an epoxy resin, a polyester resin, a
polyurethane, a polyester, a rubber, a polyimide, a
polybenzimidazole, an aromatic polyamide, a modified phenolic
resin, or a combination thereof.
Embodiment 95
[0182] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body is essentially free of a reducing
agent.
Embodiment 96
[0183] The method of any of embodiments 46, 47, 48 and 49, wherein
the bonded abrasive body has ratio of the diameter to the thickness
is be at least about 10:1, at least about 20:1, at least about
50:1, or at least about 100:1; and wherein the bonded abrasive body
has a ratio of the diameter to the thickness of not greater than
about 10,000:1, or not greater than 5,000:1.
Embodiment 97
[0184] The method of any of embodiments 46, 47, 48 and 49, wherein
the abrasive article has a generally similar wear rate to the same
abrasive article except without the impartation of color.
Embodiment 98
[0185] The method of any of embodiments 46, 47, 48 and 49, wherein
the abrasive article has a generally similar material removal rate
to the same abrasive article except without the impartation of
color.
EXAMPLES
[0186] The concepts described herein will be further described in
the following Examples, which do not limit the scope of the
invention described in the claims.
Example 1
Uncured Sample Abrasive Wheels
[0187] Uncured comparison sample abrasive wheels UCS1, UCS2, UCS3
and UCS4 were prepared having compositions as shown in Table 1
below:
TABLE-US-00001 TABLE 1 Uncured Comparison Sample Abrasive Wheel
Compositions Density SAMPLE ABRASIVE WHEELS (g/cc) Material Name
UCS1 UCS2 UCS3 UCS4 3.95 Sol gel abrasive -20 4277 4282 3954 3956
grit (g) 2.61 Nepheline syenite-30 892 894 826 826 grit (g) 1.2
Liquid resin (g) 312 312 296 296 1.28 Powder Resin 612 612 Varcuum
29346 (g) 1.28 Powder Resin 675 676 Varcuum 29722 (g) 4 Titanium
dioxide 84 84 2.85 Cyrolite (g) 721 722 2.85 Potassium aluminum 843
828 fluoride (g) 1.56 Red Color (260- 8.5 5.2 5645) Pigment (g) 2.3
Green Color (264- 0414) Pigment (g) 1.61 Blue Color (249- 5.3 1284)
Pigment (g)
[0188] Color characteristics for each of the uncured comparison
sample abrasive wheels UCS1, UCS2, UCS3 and UCS4 were observed
visually and quantified using the CIE L*a*b* color system as
described herein. A summary of these color characteristics for each
uncured comparison sample abrasive wheels is provided in Table 2
below:
TABLE-US-00002 TABLE 2 Uncured Comparison Sample Abrasive Wheel
Color Characteristics SAMPLE ABRASIVE VISUAL CIE L*a*b* WHEELS
OBSERVATION L* a* b* USC1 YELLOW 66.8 -0.9 6.0 USC2 RED 49.4 27.1
9.4 USC3 PINK 52.4 26.6 7.5 USC4 BLUE 56.1 -20.9 -4.5
Example 2
Oxygen Cured Sample Abrasive Wheels
[0189] Comparison sample abrasive wheels CS1, CS2 and CS3 were
prepared having compositions as shown in Table 3 below and cured in
a standard oxygen atmosphere.
TABLE-US-00003 TABLE 3 Oxygen Cured Comparison Sample Abrasive
Wheel Compositions Density SAMPLE ABRASIVE WHEELS (g/cc) Material
Name CS1 CS2 CS3 3.95 Sol gel abrasive -20 4277 4282 3956 grit (g)
2.61 Nepheline syenite-30 892 894 826 grit (g) 1.2 Liquid resin (g)
312 312 296 1.28 Powder Resin 612 Varcuum 29346 (g) 1.28 Powder
Resin 675 676 Varcuum 29722 (g) 4 Titanium dioxide 84 2.85 Cyrolite
(g) 722 2.85 Potassium aluminum 843 828 fluoride (g) 1.56 Red Color
(260-5645) 8.5 Pigment (g) 2.3 Green Color (264- 0414) Pigment (g)
1.61 Blue Color (249- 5.3 1284) Pigment (g)
[0190] Color characteristics for each of the cured comparison
sample abrasive wheels CS1, CS2 and CS3 were observed visually and
quantified using the CIE L*a*b* color system as described herein. A
summary of these color characteristics for each oxygen cured
comparison sample abrasive wheels is provided in Table 4 below:
TABLE-US-00004 TABLE 4 Oxygen Cured Comparison Sample Abrasive
Wheel Color Characteristics SAMPLE ABRASIVE VISUAL CIE L*a*b*
WHEELS OBSERVATION L* a* b* CS1 Dark Brown 44.1 4.6 1.7 CS2
Black/Dark Brown 43.9 5.4 1.6 CS3 Black/Dark Brown 42.8 0.51
-0.02
[0191] As can been seen by comparing the color characteristics of
uncured sample abrasive wheels UCS1, UCS2, UCS3 and UCS4 (see Table
2) and the color characteristics of oxygen cured sample abrasive
wheels CS1, CS2 and CS3 (see Table 4), the color of the uncured
abrasive wheels changes from the combined color of any pigments in
the wheel and the yellow color of the resin to black or dark brown
after being cured in a standard oxygen atmosphere. Without wishing
to be bound by any one theory, it is believed that the original
yellow color of the resin in the abrasive wheels deteriorates
during conventional curing procedures in a standard oxygen
atmosphere leading to discoloration that obscures the color of the
pigments and results in black or dark brown abrasive wheels.
Example 3
Inert Atmosphere Cured Sample Abrasive Wheels
[0192] Sample abrasive wheels S1, S2, S3, S4 and S5 formed
according to embodiments described herein were prepared having
compositions as shown in Table 5 below and cured in an inert
atmosphere of nitrogen gas.
TABLE-US-00005 TABLE 5 Inert Atmosphere Cured Sample Abrasive Wheel
Compositions Density SAMPLE ABRASIVE WHEELS (g/cc) Material Name S1
S2 S3 S4 S5 3.95 Sol gel abrasive -20 4277 4282 3954 3956 3056 grit
(g) 2.61 Nepheline syenite- 892 894 826 826 638 30 grit (g) 1.2
Liquid resin (g) 312 312 296 296 221 1.28 Powder Resin 612 612 480
Varcuum 29346 (g) 1.28 Powder Resin 675 676 Varcuum 29722 (g) 4
Titanium dioxide 84 84 2.85 Cyrolite (g) 721 722 578 2.85 Potassium
843 828 aluminum fluoride (g) 1.56 Red Color (260- 8.5 5.2 5645)
Pigment (g) 2.3 Green Color (264- 25 0414) Pigment (g) 1.61 Blue
Color (249- 5.3 1284) Pigment (g)
[0193] Color characteristics for each of the inert atmosphere cured
sample abrasive wheels S1, S2, S3, S4 and S5 were observed visually
and quantified using the CIE L*a*b* color system as described
herein. A summary of these color characteristics for each inert
atmosphere cured sample abrasive wheels is provided in Table 6
below:
TABLE-US-00006 TABLE 6 Inert Atmosphere Cured Sample Abrasive Color
Characteristics SAMPLE ABRASIVE VISUAL CIE L*a*b* WHEELS
OBSERVATION L* a* b* S1 YELLOW 50.4 8.2 14.3 S2 RED 46.6 17.7 8.2
S3 PINK 51.8 17.6 5.3 S4 GREEN 50.1 -11.8 7.3 S5 GREEN 43.9 -8.3
3.2
[0194] As can been seen by comparing the color characteristics of
uncured sample abrasive wheels UCS1, UCS2, UCS3 and UCS4 (see Table
2) and the color characteristics of inert atmosphere cured sample
abrasive wheels S1, S2, S3, S4, and S5 formed according to
embodiments described herein (see Table 6), the original color of
the uncured abrasive wheels provided from the color of any pigments
in the wheel in combination with the yellow color of the resin is
maintained with minimal color change after being cured in an inert
atmosphere (i.e. nitrogen) according to embodiments described
herein. Without wishing to be bound by any one theory, it is
believed that the original yellow color of the resin in the
abrasive wheels does not deteriorate when cured in an inert
atmosphere leading to minimal or no discoloration, which therefore
does not obscure the color of any pigments in the abrasive
wheels.
Example 4
Grinding Performance
[0195] Sample abrasive wheels were prepared having compositions
COMP1, COMP2 and COMPS as shown in Table 7 below:
TABLE-US-00007 TABLE 7 Abrasive Wheel Compositions for Grinding
Performance Testing Density Abrasive Wheel Compositions (g/cc)
Material Name COMP1 COMP2 COMP3 3.95 Sol gel abrasive -20 grit (g)
2140 2138 2139 2.61 Nepheline syenite-30 grit(g) 446 446 446 1.2
Liquid resin (g) 180 179 179 1.28 Powder Resin Varcuum 312 309 307
29346 (g) 2.85 Cyrolite (g) 422 422 422 2.3 Green Color (264-0414)
6 Pigment (g) 1.56 Red Color (260-5645) 6 Pigment (g)
[0196] Sample abrasive wheels for each composition (COMP1, COMP2
and COMP3) were prepared and cured in a standard oxygen atmosphere
with a 185.degree. C. soak (hereinafter "185-0"). Sample abrasive
wheels for each composition (COMP1, COMP2 and COMP3) were also
prepared and cured in an inert atmosphere of nitrogen with a
185.degree. C. soak (hereinafter "185-AC"). Sample abrasive wheels
for each composition (COMP1, COMP2 and COMP3) were also prepared
and cured in an inert atmosphere of nitrogen with a 195.degree. C.
soak (hereinafter "185-AC").
[0197] The material removal rate (MRR) achieved by each sample
abrasive wheel. The mean MRR for all three abrasive wheels formed
using 185-O was calculated and recorded. The mean MRR for all three
abrasive wheels formed using 185-O was also calculated and
recorded. The mean MRR for all three abrasive wheel formed using
185-O was also calculated and recorded. A summary of these MRR
results is provided in Table 8 below:
TABLE-US-00008 TABLE 8 Abrasive Wheel Grinding Performance - MRR #
of Mean Cure Samples MRR Procedure Tested (g/min) Std. Error Lower
95% Upper 95% 185-AC 3 62.9267 3.8769 53.440 72.413 185-O 3 71.6433
3.8769 62.157 81.130 195-AC 3 66.0633 3.8769 56.577 75.550
[0198] The wheel wear rate (WWR) achieved by each sample abrasive
wheel. The mean WWR for all three abrasive wheels formed using
185-O was calculated and recorded. The mean WWR for all three
abrasive wheels formed using 185-O was calculated and recorded. The
mean WWR for all three abrasive wheels formed using 185-O was
calculated and recorded. A summary of these WWR results is provided
in Table 9 below:
TABLE-US-00009 TABLE 9 Abrasive Wheel Grinding Performance - WWR #
of Mean Cure Samples WWR Procedure Tested (g/min) Std. Error Lower
95% Upper 95% 185-AC 3 0.816667 0.12225 0.51754 1.1158 185-O 3
0.916667 0.12225 0.61754 1.2158 195-AC 3 0.846667 0.12225 0.54754
1.1458
[0199] Note that not all of the activities described above in the
general description or the examples are required, that a portion of
a specific activity may not be required, and that one or more
further activities may be performed in addition to those described.
Still further, the order in which activities are listed is not
necessarily the order in which they are performed.
[0200] Benefits, other advantages, and solutions to problems have
been described above with regard to specific embodiments. However,
the benefits, advantages, solutions to problems, and any feature(s)
that may cause any benefit, advantage, or solution to occur or
become more pronounced are not to be construed as a critical,
required, or essential feature of any or all the claims.
[0201] The specification and illustrations of the embodiments
described herein are intended to provide a general understanding of
the structure of the various embodiments. The specification and
illustrations are not intended to serve as an exhaustive and
comprehensive description of all of the elements and features of
apparatus and systems that use the structures or methods described
herein. Separate embodiments may also be provided in combination in
a single embodiment, and conversely, various features that are, for
brevity, described in the context of a single embodiment, may also
be provided separately or in any subcombination. Further, reference
to values stated in ranges includes each and every value within
that range. Many other embodiments may be apparent to skilled
artisans only after reading this specification. Other embodiments
may be used and derived from the disclosure, such that a structural
substitution, logical substitution, or another change may be made
without departing from the scope of the disclosure. Accordingly,
the disclosure is to be regarded as illustrative rather than
restrictive.
* * * * *