U.S. patent application number 15/560120 was filed with the patent office on 2018-03-29 for abrasive tools and methods for forming same.
The applicant listed for this patent is SAINT-GOBAIN ABRASIFS, SAINT-GOBAIN ABRASIVES, INC.. Invention is credited to Dibyendu DAS, Udayan PARAMBAN, Jagadis SANKARANARAYANAN, Adiseshaiah K. SATHYANARAYANAIAH.
Application Number | 20180085896 15/560120 |
Document ID | / |
Family ID | 56979241 |
Filed Date | 2018-03-29 |
United States Patent
Application |
20180085896 |
Kind Code |
A1 |
PARAMBAN; Udayan ; et
al. |
March 29, 2018 |
ABRASIVE TOOLS AND METHODS FOR FORMING SAME
Abstract
An abrasive tool including a bonded abrasive including a body
comprising abrasive particles contained within a three-dimensional
matrix of bond material, the bond material including an organic
material, the abrasive tool further including a first filler
contained within the three-dimensional matrix of bond material
including a silicate in a first content and a second filler
contained within the three-dimensional matrix of bond material
including a sulfate in a second content, and the first content is
greater than the second content.
Inventors: |
PARAMBAN; Udayan; (Chennai,
IN) ; SATHYANARAYANAIAH; Adiseshaiah K.; (CHENNAI,
IN) ; SANKARANARAYANAN; Jagadis; (Adambakkam, IN)
; DAS; Dibyendu; (Madipakkam, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAINT-GOBAIN ABRASIVES, INC.
SAINT-GOBAIN ABRASIFS |
Worcester
Conflans-Sainte-Honorine |
MA |
US
FR |
|
|
Family ID: |
56979241 |
Appl. No.: |
15/560120 |
Filed: |
March 21, 2016 |
PCT Filed: |
March 21, 2016 |
PCT NO: |
PCT/US2016/023447 |
371 Date: |
September 20, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B24D 3/20 20130101; B24D
3/344 20130101; B24D 5/02 20130101; B24D 5/14 20130101; B24D 7/14
20130101; B24D 5/12 20130101 |
International
Class: |
B24D 3/34 20060101
B24D003/34; B24D 3/20 20060101 B24D003/20; B24D 5/02 20060101
B24D005/02 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 21, 2015 |
IN |
1432/CHE/2015 |
Claims
1. An abrasive tool comprising: a bonded abrasive including a body
comprising a first abrasive region including: abrasive particles
contained within a bond material, the bond material comprising an
organic material; a first filler contained within the bond material
comprising a silicate in a first content; and a second filler
contained within the bond material comprising a sulfate in a second
content; and wherein the first content is greater than the second
content.
2. The abrasive tool of claim 1, wherein the first filler comprises
a calcium silicate compound.
3. The abrasive tool of claim 2, wherein the first filler comprises
wollastonite.
4. The abrasive tool of claim 1, wherein the first content is
within a range including at least 0.2 wt % and not greater than 20
wt % for a total weight of the first abrasive region.
5. The abrasive tool of claim 4, wherein the first content is
within a range including at least 2.8 wt % and not greater than 8
wt % for a total weight of the first abrasive region.
6. The abrasive tool of claim 1, the second filler comprises a
potassium sulfate compound.
7. The abrasive tool of claim 6, wherein the second filler consists
essentially of potassium sulfate.
8. The abrasive tool of claim 1, wherein the second content of the
second filler is within a range including 1 wt % and not greater
than 4 wt % for a total weight of the first abrasive region.
9. The abrasive tool of claim 1, wherein the abrasive region
comprises a ratio (C1:C2) of the first content (C1) to the second
content (C2) of at least 1.5:1 and not greater than 3.5:1.
10. The abrasive tool of claim 1, further comprising a third filler
contained within the bond material comprising a halide-containing
compound in a third content.
11. The abrasive tool of claim 10, wherein the third filler
comprises sodium hexafluoroaluminate (Na.sub.3AlF.sub.6).
12. The abrasive tool of claim 10, wherein the third filler has a
third content of at least 2.6 wt % and not greater than 4 wt %.
13. The abrasive tool of claim 1, wherein the first filler is a
particle having an aspect ratio of length:width within a range
including greater than 5:1 and less than 15:1.
14. The abrasive tool of claim 13, wherein the first filler is a
particle having an aspect ratio within a range including at least
7:1 and not greater than 10:1.
15. An abrasive tool comprising: a bonded abrasive including a body
having a thickness not greater than 10 mm comprising: a first
abrasive region including abrasive particles contained within a
bond material, the bond material comprising an organic material,
wherein the first abrasive region comprises a first filler in a
first content comprising a silicate contained within the bond
material, wherein the first filler is a particle having an aspect
ratio of length:width of at least 1.5:1, and a second filler
contained within the bond material comprising a sulfate in a second
content
16. The abrasive tool of claim 15, wherein the abrasive region
comprises a ratio (C1:C2) of the first content (C1) to the second
content (C2) of at least 1.1:1.
17. The abrasive tool of claim 15, wherein the first filler
comprises an inosilicate compound.
18. The abrasive tool of claim 15, wherein the first filler
comprises an aspect ratio within a range including at least 7:1 and
not greater than 10:1.
19. The abrasive tool of claim 15, wherein the second filler
comprises a potassium sulfate compound.
20. The abrasive tool of claim 15, wherein the first abrasive
region includes a content of abrasive particles within a range
including at least 30 wt % and not greater than 90 wt % for a total
weight of the first abrasive region.
Description
FIELD OF THE DISCLOSURE
[0001] The present invention relates in general to abrasive tools
and, in particular, to a bonded abrasive.
DESCRIPTION OF RELATED ART
[0002] Bonded abrasive articles can be prepared by blending
abrasive grains with a bond and optional additives and shaping the
resulting mixture, using, for instance, a suitable mold. The
mixture can be shaped to form a green body which can be thermally
processed, for example, by curing, to produce an article in which
the abrasive grains are held in a three dimensional bond matrix.
Among bonded abrasive tools, various bond matrix materials exist,
including for example organic materials, such as resin. A need for
improved abrasive articles continues to exist.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] Embodiments are illustrated by way of example and are not
limited in the accompanying figures.
[0004] FIG. 1 includes a cross-sectional view of an abrasive tool
in accordance with an embodiment described herein.
[0005] FIG. 2 includes a cross-sectional view of a portion of an
abrasive tool in accordance with an embodiment.
[0006] FIG. 3 includes a top down view of an abrasive tool
according to an embodiment.
[0007] FIG. 4 includes a top down view of an abrasive tool
according to an embodiment.
[0008] FIG. 5 includes a histogram of grinding ratio of abrasive
tool samples having different compositions.
[0009] FIG. 6A includes an image of a filler having a certain
aspect ratio according to an embodiment.
[0010] FIG. 6B includes an image of a filler having an aspect ratio
according to an embodiment.
[0011] FIG. 6C includes an image of a filler having an aspect ratio
according to an embodiment.
[0012] FIG. 7 includes a histogram of grinding ratio of abrasive
tool samples.
[0013] FIG. 8 includes a histogram of grinding ratio of abrasive
tool samples.
[0014] 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
[0015] Embodiments disclosed herein are related to abrasive tools
including a bonded abrasive that may include one or more abrasive
regions. The abrasive tools may be in the form of thin wheels,
utilized for grinding, cutting, and general material removal
operations. The bonded abrasive can include a body including
abrasive particles contained within a bond material. In an
embodiment, the barrier layer can be bonded to a major surface of
the body.
[0016] FIG. 1 includes a cross-sectional illustration of a portion
of an abrasive tool according to an embodiment. The abrasive tool
10 can include a body including a rear (top) face 12 and a front
(bottom) face 14. In certain instances, such as illustrated in FIG.
1, the abrasive tool can have a rear face 12 that may include a
raised hub region 16 and outer flat rear wheel region 18. The front
face 14 can include a depressed center region 20 and outer flat
front wheel region 22. In turn, raised hub region 16 can have
raised hub surface 24 and back sloping (or slanted) surface 26;
depressed center region 20 can include depressed center 28 and
front sloping (or slanted) surface 30. The body of the abrasive
tool 10 can have central opening 32 for mounting the abrasive tool
10 on the rotating spindle of a tool, e.g., a hand-held angle
grinder. During operation, the abrasive tool 10 can be secured by
mounting hardware such as, for instance, a suitable flange system.
The abrasive tool 10 can also be part of an integrated arrangement
that includes mounting hardware.
[0017] The abrasive tools of the embodiments herein can include any
suitable type of abrasive wheel as known in the art, including thin
disc shaped abrasive articles. For example, the abrasive tool can
be a depressed center wheel, such as, for example, ANSI (American
National Standards Institute) Type 27, Type 28 or Type 29 wheels,
or European Standard (EN 14312) Type 42 wheel. In particular
embodiments, the abrasive tool may include a Type 41 or Type 1
wheel, which may be referred to as straight wheels, having no
depression in the interior but having the same contour and
extending along the same plane along the length of the diameter of
the wheel. Still, essentially any bonded abrasive wheel
construction may be utilized with the present embodiments.
Moreover, the abrasive tools may be in the form of cut-off
wheels.
[0018] The body of the abrasive tool 10 can have a thickness "t"
that can be measured at various positions, including at the
periphery of the bonded abrasive body. The thickness (t) of the
body of the abrasive tool 10 can be the same or essentially the
same along a radial direction from the central opening 36 to the
outer edge (periphery) 38 of the abrasive tool 10. In other
designs, the thickness (t) of the body can vary (can increase or
decrease) along a radial distance from the central opening 36 to
the periphery 38. Reference herein to a thickness can be reference
to an average thickness of the abrasive tool 10. For example, the
body of the abrasive tool 10 can have a thickness (t) of not
greater than 10 mm, such as not greater than 9.5 mm or not greater
than 9 mm or not greater than 8.5 mm or not greater than 8 mm or
not greater than 7.5 mm or not greater than 7 mm or not greater
than 6.5 mm or not greater than 6 mm or not greater than 5.5 mm or
not greater than 5 mm or not greater than 4.5 mm or not greater
than 4 mm. Still, in at least one non-limiting embodiment, the
thickness (t) of the abrasive tool 10 can be at least 0.3 mm, such
as at least 0.5 mm or at least 0.8 mm or at least 1 mm or at least
1.3 mm or even at least 1.5 mm. It will be appreciated that the
body of the abrasive tool 10 can have a thickness (t) within a
range including any of the minimum and maximum values noted above,
including for example, within a range including at least 0.3 mm to
not greater than 10 mm, such as within a range including at least
0.3 mm to not greater than 9 mm, or even within range including at
least 0.5 mm to not greater than 8 mm.
[0019] Further, the body of the abrasive tool 10 of the embodiments
herein can include a diameter (d), which defines the length of
extending between two points on the perimeter and through the
center of the body. In a non-limiting embodiment, the diameter (d)
can be at least 10 mm, such as at least 25 mm or at least 50 mm or
at least 55 mm or at least 60 mm or at least 65 mm or at least 70
mm or at least 75 mm or at least 80 mm or at least 90 mm, or even
at least 100 mm. In another non-limiting embodiment, the diameter
(d) may be not greater than 400 mm, such as not greater than 350 mm
or not greater than 300 mm or not greater than 275 mm or not
greater than 250 mm, or even not greater than 230 mm. It will be
appreciated that the diameter (d) of the bonded abrasive body can
be within a range including any of the minimum to maximum values
noted above, for example, within a range including at least mm 10
mm to not greater than 400 mm, such as within a range including at
least 50 mm to not greater than 300 mm, or even within a range
including at least 50 mm to not greater than 230 mm.
[0020] The body of the abrasive tool 10 may have a particular
aspect ratio, which is a ratio of the diameter (d) of the body to
the thickness (t) of the body (diameter:thickness) that may
facilitate certain abrasive operations. For example, the body can
have an aspect ratio of at least 10:1 or at least 15:1 or at least
20:1 or at least 35:1 or at least 50:1 or at least 75:1 or at least
100:1, or even at least 125:1. In other instances, the body of the
abrasive tool 10 can have an aspect ratio (diameter:thickness) of
not greater than 1000:1, such as not greater than 800:1 or not
greater than 500:1 or not greater than 400:1 or not greater than
350:1 or not greater than 300:1 or not greater than 250:1, or even
not greater than 200:1. The ratio can be within a range including
any of the above minimum and maximum values, such as within a range
including at least 10:1 to not greater than 1000:1, such as within
a range including at least 10:1 and not greater than 500:1, or even
within a range including at least 10:1 and not greater than
200:1.
[0021] The abrasive tools of the embodiments herein can have
various constructions. The abrasive tools of the embodiments herein
may be monolithic articles formed of a single material, having a
single construction, having a substantially uniform grade and
structure throughout the volume of the body of the abrasive tool.
Alternatively, the body of the embodiments herein can be composite
bodies having one or more elements (e.g., abrasive regions,
abrasive layers, reinforcing members, etc.), wherein at least two
of the elements are different from each other based on a
characteristic such as, abrasive particle type, content of abrasive
particles, porosity type (e.g., closed or open), content of
porosity, type of bond material, content of bond material,
distribution of abrasive particles, hardness, flexibility, filler
content, type of filler materials including individual filler
materials and filler compositions as a whole (i.e., taking into
account all of the filler materials, such as a first filler, a
second filler, a third filler, and the like), shape of the layer,
size (e.g., thickness, width, diameter, circumference, or length)
of the layer, construction of the layer (e.g., solid, woven,
non-woven, etc.) and a combination thereof.
[0022] FIG. 2 includes a cross-sectional view of a portion of an
abrasive tool according to an embodiment. As illustrated, the
abrasive tool 200 can be a bonded abrasive having a body 201
including a first abrasive region 202, which can include abrasive
particles 203 contained within a three-dimensional matrix of bond
material 204. The first abrasive region may also include fillers
205 contained within the bond material 204. As will be described
herein, in certain embodiments, the fillers 205 can include one or
more elements or compositions, including for example, a particular
combination of a first filler, a second filler, a third filler, and
the like that may define a filler composition for the first
abrasive region 202.
[0023] As further illustrated, the body 201 of the abrasive tool
200 can include a second abrasive region 207, which can include
abrasive particles 208 contained within a three-dimensional matrix
of bond material 209. The second abrasive region 207 may also
include fillers 210 contained within the three-dimensional matrix
of the bond material 209. As noted herein, the first and second
abrasive regions 202 and 207 can have include the same features or
different features, including but not limited to, abrasive particle
type, content of abrasive particles, porosity type (e.g., closed or
open), content of porosity, type of bond material, content of bond
material, distribution of abrasive particles, hardness,
flexibility, filler content, type of filler materials including
individual filler materials and filler compositions as a whole
(i.e., taking into account all of the filler materials, such as a
first filler, a second filler, a third filler, and the like), shape
of the layer, size (e.g., thickness, width, diameter,
circumference, or length) of the layer, construction of the layer
(e.g., solid, woven, non-woven, etc.) and a combination thereof. In
at least one embodiment, the first abrasive region 202 and second
abrasive region 207 can be in the form of layers that are axially
spaced apart from each other within the body 201. The layers can
extend for the entire diameter of the body 201 with the exception
of an arbor hole or opening at the center of the body as described
herein. In still other instances, the body of the abrasive tool can
be formed such that the first abrasive region and second abrasive
region define distinct annular regions within the body that are
radially spaced apart from each other within the body.
[0024] According to one embodiment, as illustrated in FIG. 2, the
body 201 may also include a reinforcing member 206 disposed between
the first and second abrasive regions 202 and 207. While FIG. 2
depicts a particular arrangement of the first and second abrasive
regions 202 and 207 relative to each other and relative to the
reinforcing member 206, it will be appreciated that other
constructions of the abrasive tool are within the scope of the
embodiments herein. The abrasive tools may include a plurality of
abrasive regions, which may be in the form of layers, extending for
at least a portion of the diameter of the abrasive tool. The
plurality of abrasive regions can be separated from each other by
one or more reinforcing members. Additionally, the body 201 can
include first and second major surfaces 211 and 212, which may
generally correspond to surface 18 and 22, which can define the
exterior surfaces of the body 201. In certain instances, one or
more layers of material, including for example, a reinforcing
member or paper backing with indicia may be applied to the first
and second major surfaces 211 and 212 of the body 201.
[0025] According to one embodiment, the first abrasive region 202
can include filler 205, which can include a first filler. The first
filler may be distinct from the abrasive particles with regard to
at least one of average particle size, hardness, composition,
shape, and the like. The first filler may include a silicate. For
example, the first filler may include calcium, and more
particularly, may include a calcium silicate compound. In one
instance, the first filler can include an inosilicate compound,
which may be a single chain inosilicate. An inosilicate compound
includes interlocking chains of silicate tetrahedral. According to
a particular embodiment, the first filler comprises wollastonite,
and more particularly, can consist essentially of wollastonite
(CaSiO.sub.3). Utilization of a first filler may facilitate
improved performance of the abrasive tool 200 as the first filler
may be configured to provide suitable mechanical reinforcement to
the bond material 204. Moreover, in more particular instances, the
first filler can be a reinforcing agent configured to reduce the
wear and/or fracture of the bond during grinding operations.
[0026] In certain embodiments, the first filler may have a
particular median particle size (D50), which may facilitate
improved performance of the abrasive tool 10. For example, the
first filler can have a median particle size of at least 1 micron,
such at least 2 microns or at least 3 microns or at least 4 microns
or at least 5 microns or at least 6 microns or at least 7 microns
or at least 8 microns or at least 9 microns or at least 10 microns
or at least 11 microns or at least 12 microns, or even at least 13
microns. Still, in another non-limiting embodiment, the first
filler can have a median particle size (D50) of not greater than
100 microns, such as not greater than 95 microns or not greater
than 90 microns or not greater than 85 microns or not greater than
80 microns or not greater than 75 microns or not greater than 70
microns or not greater than 65 microns or not greater than 60
microns or not greater than 55 microns or not greater than 50
microns or not greater than 45 microns or not greater than 40
microns or not greater than 35 microns or not greater than 30
microns or not greater than 25 microns. It will be appreciated that
the median particle size of the first filler can be within a range
including any of the minimum and maximum values noted above.
Moreover, in certain instances, reference to the foregoing median
particle size may be reference to a maximum particle size,
depending upon the sieving technique and the shape of the first
filler particle.
[0027] According to one embodiment, the first filler may have a
particular shape, which may make it more suitable for use in the
abrasive tools of the embodiments herein. Furthermore, the shape of
the first filler may facilitate improved performance of the
abrasive tools of the embodiments herein. According to one
embodiment, the first filler can have an aspect ratio
(length:width) when viewing the first filler using a suitable
two-dimensional image of at least 1.2:1, such as at least 1.3:1 or
at least 1.4:1 or at least 1.5:1 or at least 1.6:1 or at least
1.7:1 or at least 1.8:1 or at least 1.9:1 or at least 2:1, or even
at least 3:1. In a further embodiment, the first filler can have an
aspect ratio greater than 5:1, such as at least 5.5:1 or at least
6:1 or at least 6.5:1 or even at least 7:1. Still, in one
non-limiting embodiment, the first filler can have an aspect ratio
of not greater than 100:1, such as not greater than 90:1 or not
greater than 80:1 or not greater than 70:1 or not greater than 60:1
or not greater than 50:1 or not greater than 40:1 or not greater
than 30:1 or not greater than 20:1. Still, in another non-limiting
embodiment, the first filler can have an aspect ratio less than
15:1, such as not greater than 14.5:1, or not greater than 14:1, or
not greater than 13.5:1, or not greater than 13:1, or not greater
than or not greater than 12:1, or not greater than 11.5:1, or even
not greater than 10:1. It will be appreciated that the aspect ratio
of the first filler can be within a range including any of the
minimum and maximum ratios noted above. For example, the aspect
ratio of the first filler can be greater than 5:1 and less than
15:1, such as within a range from at least 5.5:1 to not greater
than 14.5:1, or within a range from at least 6:1 to not greater
than 13:1, or within a range from at least 7:1 to not greater than
10:1.
[0028] In certain situations, the first filler may be present in a
particular content that may facilitate improved performance of the
abrasive tool. For example, the first filler can be present in the
first abrasive region 202 in a first content. According to one
embodiment, the first content can be at least 0.1 wt % of the total
weight of the first abrasive region 202, such as at least 0.5 wt %
or at least 0.8 wt % or at least 1 wt % or at least 1.2 wt % or at
least 1.4 wt % or at least 1.6 wt % or at least 1.8 wt % or at
least 2 wt % or at least 2.2 wt % or at least 2.4 wt % or at least
2.6 wt % or at least 2.8 wt % or at least 3 wt % or at least 3.2 wt
% or at least 3.4 wt % or at least 3.6 wt % or at least 3.8 wt % or
at least 4 wt %, such as at least 4.2 wt % or at least 4.5 wt % or
at least 5 wt %. Still, in another non-limiting embodiment, the
first content can be not greater than 19 wt % of the total weight
of the first abrasive region 202, such as or not greater than 18 wt
% or not greater than 17 wt % or not greater than 16 wt % or not
greater than 15 wt % or not greater than 14 wt % or not greater
than 13 wt % or not greater than 12 wt % or not greater than 11 wt
% or not greater than 10 wt % or not greater than 9 wt % or not
greater than 8 wt % or not greater than 7.8 wt % or not greater
than 7.5 wt % or not greater than 7 wt % or not greater than 6 wt %
or not greater than 5.5 wt %, or even not greater than 5 wt %. It
will be appreciated that the first content can be within a range
including any of the minimum and maximum ratios noted above,
including for example, at least 0.2 wt % and not greater than 20 wt
% for a total weight of the first abrasive region 202, or within a
range including at least 2 wt % and not greater than 12 wt %. In a
particular example, the first content can be within a range
including at least 2.8 wt % and not greater than 8 wt %.
[0029] According to another embodiment, the first abrasive region
202 can include a filler 205, which may include a first filler and
a second filler, wherein the second filler is distinct from the
first filler. Provision of a second filler as part of the filler
composition of the abrasive tool may facilitate improved
performance. Some suitable examples of fillers that may be used as
a second filler can include powders, granules, spheres, fibers, or
a combination thereof. In another embodiment, the second filler can
include an inorganic material, an organic material, or a
combination thereof. For example, suitable fillers for use as the
second filler can include sand, silicon carbide, bubble alumina,
bauxite, chromites, magnesite, dolomites, bubble mullite, borides,
titanium dioxide, carbon products (e.g., carbon black, coke or
graphite), wood flour, clay, talc, hexagonal boron nitride,
molybdenum disulfide, feldspar, nepheline syenite, glass fibers,
glass spheres, chlorides (e.g., MgCl.sub.2 and CaCl.sub.2),
fluorides (e.g., 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, carbonates, calcium
carbonate, sulphates, dechlorane, and a combination thereof. In a
further embodiment, the second filler can include an antistatic
agent, a metal oxide, a lubricant, a porosity inducer, a coloring
agent, or a combination thereof. Examples of the lubricants can
include stearic acid, glycerol monostearate, graphite, carbon,
molybdenum disulfide, wax beads, calcium carbonate, calcium
fluoride, or any combination thereof. Examples of the metal oxides
can include lime, zinc oxide, magnesium oxide, or any combination
thereof. Note that the second filler may be functional, such as,
grinding aids, lubricants, and porosity inducers. In alternative
instances, the second filler can be used for functional and/or
aesthetics, such as a coloring agent. According to an embodiment,
the second filler can be distinct from the abrasive particles,
including primary abrasive particles and secondary abrasive
particles. In one particular embodiment, the second filler can
include a sulfate. In more particular instances, the second filler
can include potassium, and may be a compound including potassium.
For one particular embodiment, the second filler may include a
potassium sulfate compound, and even more particularly, may consist
essentially of potassium sulfate.
[0030] In one embodiment, the second filler may have a particular
median particle size (D50), which may facilitate improved
performance of the abrasive tool. For example, the second filler
can have a median particle size of at least 0.1 microns, such at
least 0.5 microns or at least 1 micron or at least 1.5 microns or
at least 2 microns, or even at least 5 microns. Still, in another
non-limiting embodiment, the second filler can have a median
particle size (D50) of not greater than 500 microns, such as not
greater than 450 microns or not greater than 400 microns or not
greater than 350 microns or not greater than 300 microns or not
greater than 275 microns or not greater than 250 microns or not
greater than 200 microns or not greater than 175 microns or not
greater than 150 microns, or even not greater than 100 microns. It
will be appreciated that the median particle size of the second
filler can be within a range including any of the minimum and
maximum values noted above. Moreover, in certain instances,
reference to the foregoing median particle size may be reference to
a maximum particle size, depending upon the sieving technique and
the shape of the second filler particle.
[0031] In certain instances, the second filler may have a
particular aspect ratio (length:width), which may facilitate
improved performance of the abrasive tool. The second filler may
have an aspect ratio that is substantially the same as the aspect
ratio of the first filler. Still, in at least one other embodiment,
the second filler can have an aspect ratio that is different
compared to the aspect ratio of the first filler. For example, the
second filler can have an aspect ratio (length:width) when viewing
the second filler using a suitable two-dimensional image of at
least 1.1:1, such as at least 1.3:1 or at least 1.4:1 or at least
1.5:1 or at least 1.6:1 or at least 1.7:1 or at least 1.8:1 or at
least 1.9:1, or even at least 2:1. Still, in one non-limiting
embodiment, the second filler can have an aspect ratio of not
greater than 100:1, such as not greater than 90:1 or not greater
than 80:1 or not greater than 70:1 or not greater than 60:1 or not
greater than 50:1 or not greater than 40:1 or not greater than 30:1
or not greater than 20:1, or not greater than 10:1 or not greater
than 5:1, or even not greater than 2:1. In at least one embodiment,
the second filler may be substantially equiaxed having an aspect
ratio of approximately 1:1. It will be appreciated that the aspect
ratio of the second filler can be within a range including any of
the minimum and maximum ratios noted above.
[0032] In certain situations, the second filler may be present in a
particular content that may facilitate improved performance of the
abrasive tool. For example, the second filler can be present in the
first abrasive region 202 in a second content. According to one
embodiment, the second content can be at least 0.01 wt % of the
total weight of the first abrasive region 202, such as at least 0.1
wt % or at least 0.5 wt % or at least 0.8 wt % or at least 1 wt %
or at least 1.2 wt % or at least 1.4 wt % or at least 1.6 wt % or
at least 1.8 wt % or at least 2 wt %, or even at least 2.2 wt %.
Still, in another non-limiting embodiment, the second content can
be not greater than 15 wt % of the total weight of the first
abrasive region 202, such as not greater than 14 wt % or not
greater than 13 wt % or not greater than 12 wt % or not greater
than 11 wt % or not greater than 10 wt % or not greater than 9 wt %
or not greater than 8 wt % or not greater than 7 wt % or not
greater than 6 wt % or not greater than 5 wt % or not greater than
4.5 wt % or not greater than 4 wt % or not greater than 3.5 wt % or
not greater than 3 wt % or not greater than 2.8 wt % or not greater
than 2.5 wt %, or even not greater than 2.2 wt %. It will be
appreciated that the second content can be within a range including
any of the minimum and maximum ratios noted above, including for
example, at least 0.01 wt % and not greater than 15 wt % for a
total weight of the first abrasive region 202, or within a range
including at least 1 wt % and not greater than 4 wt %, or within a
range including at least 1.5 wt % and not greater than 2.5 wt
%.
[0033] The first abrasive region 202 may utilize particular
contents of the first filler and second filler with respect to each
other, which may facilitate improved operation of the abrasive tool
200. In certain instances, the first content of the first filler
and second content of the second filler can be substantially the
same with respect to each other. In still other instances, the
first content of the first filler and second content of the second
filler can be different with respect to each other. According to
one embodiment, the first abrasive region 202 can include a ratio
(C1:C2) of the first content (C1) to the second content (C2) as
measured in wt % of the first filler and second filler,
respectively. According to one embodiment, the first abrasive
region 202 can have a ratio (C1:C2) of at least 1.1:1, such as at
least 1.2:1 or at least 1.3:1 or at least 1.4:1 or at least 1.5:1
or at least 1.6:1 or at least 1.7:1 or at least 1.8:1 or at least
1.9:1 or at least 2.1:1 or at least 2.4:1 or even at least 2.5:1.
Still, in a non-limiting embodiment, the first abrasive region 202
can have a ratio (C1:C2) of the first content (C1) to the second
content (C2) of not greater than 100:1, such as not greater than
90:1 or not greater than 80:1 or not greater than 70:1 or not
greater than 60:1 or not greater than 50:1 or not greater than 40:1
or not greater than 30:1 or not greater than 20:1 or not greater
than 10:1 or not greater than 8:1 or not greater than 6:1 or not
greater than 5:1 or not greater than 4:1 or not greater than 3.9:1
or not greater than 3.5:1 or not greater than 3.2:1 or not greater
than 3:1 or even not greater than 2.5:1. It will be appreciated
that the ratio (C1:C2) can be within a range including any of the
minimum and maximum ratios noted above, including for example, at
least 1.5:1 and not greater than 3.5:1, or within a range including
at least 2.4:1 and not greater than 3.2:1.
[0034] According to another embodiment, the first abrasive region
202 can include a filler 205, which may include a first filler and
a third filler, wherein the third filler can be distinct from the
first filler. Provision of a third filler as part of the filler
composition of the abrasive tool may facilitate improved
performance. Note that reference herein to a third filler does not
necessitate the inclusion of a second filler, but reference to
third filler is a convention to distinguish one filler (e.g., first
filler) from another filler (e.g., the third filler). Some suitable
examples of fillers that may be used as a third filler can include
powders, granules, spheres, fibers, or a combination thereof. In
another embodiment, the third filler can include an inorganic
material, an organic material, or a combination thereof. For
example, suitable materials for use as the third fillers can
include sand, silicon carbide, bubble alumina, bauxite, chromites,
magnesite, dolomites, bubble mullite, borides, titanium dioxide,
carbon products (e.g., carbon black, coke or graphite), wood flour,
clay, talc, hexagonal boron nitride, molybdenum disulfide,
feldspar, nepheline syenite, glass fibers, glass spheres, chlorides
(e.g., MgCl.sub.2 and CaCl.sub.2), fluorides (e.g., 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,
carbonates, calcium carbonate, sulphates, dechlorane, and a
combination thereof. In a further embodiment, the third filler can
include an antistatic agent, a metal oxide, a lubricant, a porosity
inducer, a coloring agent, or a combination thereof. Examples of
the lubricants can include stearic acid, glycerol monostearate,
graphite, carbon, molybdenum disulfide, wax beads, calcium
carbonate, calcium fluoride, or any combination thereof. Examples
of the metal oxides can include lime, zinc oxide, magnesium oxide,
or any combination thereof. Note that the third filler may be
functional, such as, grinding aids, lubricants, and porosity
inducers. In alternative instances, the third filler can be used
for functional and/or aesthetics, such as a coloring agent.
According to an embodiment, the third filler can be distinct from
the abrasive particles, including primary abrasive particles and
secondary abrasive particles. In at least one embodiment, the third
filler can include a halide-containing compound. In more particular
instances, the third filler can include sodium. Moreover, the third
filler may include aluminum. In one particular embodiment, the
third filler can include sodium hexafluoroaluminate
(Na.sub.3AlF.sub.6) and more particularly, can consist essentially
of hexafluoroaluminate (Na.sub.3AlF.sub.6).
[0035] In one embodiment, the third filler may have a particular
median particle size (D50), which may facilitate improved
performance of the abrasive tool. For example, the third filler can
have a median particle size of at least 0.1 microns, such at least
0.5 microns or at least 1 micron or at least 1.5 microns or at
least 2 microns, or even at least 5 microns. Still, in another
non-limiting embodiment, the third filler can have a median
particle size (D50) of not greater than 500 microns, such as not
greater than 200 microns or not greater than 100 microns or not
greater than 90 microns or not greater than 80 microns or not
greater than 70 microns or not greater than 60 microns or not
greater than 50 microns or not greater than 40 microns or even not
greater than 30 microns. It will be appreciated that the median
particle size of the third filler can be within a range including
any of the minimum and maximum values noted above. Moreover, in
certain instances, reference to the foregoing median particle size
may be reference to a maximum particle size, depending upon the
sieving technique and the shape of the third filler particle.
[0036] In certain instances, the third filler may have a particular
aspect ratio (length:width), which may facilitate improved
performance of the abrasive tool. The third filler may have an
aspect ratio that is substantially the same as the aspect ratio of
the first filler and/or second filler. Still, in at least one other
embodiment, the third filler can have an aspect ratio that is
different compared to the aspect ratio of the first filler and/or
second filler. For example, the third filler can have an aspect
ratio (length:width) when viewing the second filler using a
suitable two-dimensional image of at least 1.1:1, such as at least
1.3:1 or at least 1.4:1 or at least 1.5:1 or at least 1.6:1 or at
least 1.7:1 or at least 1.8:1 or at least 1.9:1, or even at least
2:1. Still, in one non-limiting embodiment, the third filler can
have an aspect ratio of not greater than 100:1, such as not greater
than 90:1 or not greater than 80:1 or not greater than 70:1 or not
greater than 60:1 or not greater than 60:1 or not greater than 50:1
or not greater than 40:1 or not greater than 30:1 or not greater
than 20:1, or not greater than 10:1 or not greater than 5:1, or
even not greater than 2:1. In at least one embodiment, the third
filler may be substantially equiaxed having an aspect ratio of
approximately 1:1. It will be appreciated that the aspect ratio of
the third filler can be within a range including any of the minimum
and maximum ratios noted above.
[0037] In certain situations, the third filler may be present in a
particular content that may facilitate improved performance of the
abrasive tool. For example, the third filler can be present in the
first abrasive region 202 in a third content. According to one
embodiment, the third content can be at least 0.01 wt % of the
total weight of the first abrasive region 202, such as at least 0.1
wt % or at least 0.5 wt % or at least 0.8 wt % or at least 1 wt %
or at least 1.2 wt % or at least 1.4 wt % or at least 1.6 wt % or
at least 1.8 wt % or at least 2 wt %, or even at least 2.2 wt % or
at least 2.4 wt % or at least 2.6 wt % or at least 2.8 wt % or at
least 3 wt % or at least 3.1 wt % or at least 3.2 wt %. Still, in
another non-limiting embodiment, the third content can be not
greater than 18 wt % of the total weight of the first abrasive
region 202, such as not greater than 17 wt % or not greater than 16
wt % or not greater than 15 wt % or not greater than 14 wt % or not
greater than 13 wt % or not greater than 12 wt % or not greater
than 11 wt % or not greater than 10 wt % or not greater than 9 wt %
or not greater than 8 wt % or not greater than 7 wt % or not
greater than 6 wt %, not greater than 5 wt % or not greater than 4
wt % or even not greater than 3.5 wt %. It will be appreciated that
the third content can be within a range including any of the
minimum and maximum ratios noted above, including for example, at
least 0.01 wt % and not greater than 18 wt % for a total weight of
the first abrasive region 202, or within a range including at least
2.6 wt % and not greater than 4 wt %.
[0038] The first abrasive region 202 may utilize particular
contents of the first filler and third filler with respect to each
other, which may facilitate improved operation of the abrasive
tool. In certain instances, the first content of the first filler
and third content of the third filler can be substantially the same
with respect to each other. In still other instances, the first
content of the first filler and third content of the third filler
can be different with respect to each other. For example, according
to an embodiment, the third content of the third filler may be
greater than the first content of the first filler, or in another
instance, the third content of the third filler may be smaller than
the first content of the first filler. According to one embodiment,
the first abrasive region 202 can include a ratio (C1:C3) of the
first content (C1) to the third content (C3) as measured in wt % of
the first filler and third filler, respectively. According to one
embodiment, the first abrasive region 202 can have a ratio (C1:C3)
of at least 1.1:1, such as at least 1.2:1 or at least 1.3:1 or at
least 1.4:1 or at least 1.5:1 or at least 1.6:1 or at least 1.7:1
or at least 1.8:1 or at least 1.9:1 or even at least 2:1. Still, in
a non-limiting embodiment, the first abrasive region 202 can have a
ratio (C1:C3) of the first content (C1) to the third content (C3)
of not greater than 100:1, such as not greater than 90:1 or not
greater than 80:1 or not greater than 70:1 or not greater than 60:1
or not greater than 50:1 or not greater than 40:1 or not greater
than 30:1 or not greater than 20:1 or not greater than 10:1 or not
greater than 8:1 or not greater than 6:1 or not greater than 5:1 or
not greater than 4:1 or not greater than 3:1 or not greater than
2.5:1 or not greater than 2.2:1 or even not greater than 1.9:1. It
will be appreciated that the ratio (C1:C3) can be within a range
including any of the minimum and maximum ratios noted above, for
instant including at least 1.1:1 and not greater than 2.5:1.
[0039] Moreover, the first abrasive region 202 may utilize
particular contents of the second filler and third filler with
respect to each other, which may facilitate improved operation of
the abrasive tool. In certain instances, the second content of the
second filler and third content of the third filler can be
substantially the same with respect to each other. In still other
instances, the second content of the second filler and third
content of the third filler can be different with respect to each
other. According to one embodiment, the first abrasive region 202
can include a ratio (C3:C2) of the third content (C2) to the second
content (C2) as measured in wt % of the third filler and second
filler, respectively. According to one embodiment, the first
abrasive region 202 can have a ratio (C3:C2) of at least 1.1:1,
such as at least 1.2:1 or at least 1.3:1 or at least 1.4:1 or at
least 1.5:1 or at least 1.6:1 or at least 1.7:1 or at least 1.8:1
or at least 1.9:1 or even at least 2:1. Still, in a non-limiting
embodiment, the first abrasive region 202 can have a ratio (C3:C2)
of the third content (C1) to the second content (C2) of not greater
than 100:1, such as not greater than 90:1 or not greater than 80:1
or not greater than 70:1 or not greater than 60:1 or not greater
than 50:1 or not greater than 40:1 or not greater than 30:1 or not
greater than 20:1 or not greater than 10:1 or not greater than 8:1
or not greater than 6:1 or not greater than 5:1 or not greater than
4:1 or not greater than 3:1 or not greater than 2.5:1 or even not
greater than 2:1. It will be appreciated that the ratio (C3:C2) can
be within a range including any of the minimum and maximum ratios
noted above.
[0040] It will be appreciated that reference herein to a filler
including a first filler, second filler, and third filler is not to
be interpreted as limited to only three fillers. Other filler
compositions may be utilized that include more than two or three
fillers as noted herein. Still, in at least one embodiment, the
abrasive tool 200 may include one or more abrasive layers
consisting essentially of the first filler, second filler, and
third filler.
[0041] One or more of the filler materials of the embodiments
herein can include a coating. The coating can overlie at least a
portion of the surfaces of one or more types of fillers (i.e., the
first filler, second filler, third filler, etc.) contained in the
body. The coating can be a material distinct from the bond
material. In particular instances, the first filler comprises a
coating, and may be the only filler material having a coating
within the body. The coating can be selected from a group of
materials including an inorganic material, an organic material, a
resin, an epoxy, or a combination thereof. In one particular
instance, the coating can include a silane, and more particularly,
may include a silane-based material including a majority content of
silane. In some cases, the coating may facilitate improved bonding
between the filler and the bond material, which may facilitate
improved performance of the abrasive tool.
[0042] According to an embodiment herein, the body 201 can include
a first abrasive region 202 that may have a particular content of
bond material relative to the content of one of the fillers, which
may facilitate improved performance. For example, the body 201 can
have a ratio (Cff/Cb) of at least 0.2, wherein Cff represents a
content of the first filler (wt %) for the first abrasive region
202 and Cb represents a content of the bond material (wt %) for the
first abrasive region 202. In other instances, the ratio (Cff/Cb)
at least 0.22, such as at least 0.24 or at least 0.26 or even at
least 0.28. Still, in other non-limiting embodiments, the ratio
(Cff/Cb) can be not greater than 1, such as not greater than 0.9 or
not greater than 0.8 or not greater than 0.7 or not greater than
0.6 or not greater than 0.5 or even not greater than 0.4. It will
be appreciated that the ratio (Cff/Cb) can be within a range
between any of the minimum and maximum values noted above.
[0043] The filler, including each of the first filler, second
filler, and third filler can be substantially uniformly distributed
throughout the thickness (t1) of the first abrasive region 202. In
other embodiments, it is contemplated that a non-uniform
distribution of the filler may be utilized with respect to the
thickness. For example, in certain instances, the content of the
filler in the first abrasive region 202 at the major surface 211
may be significantly different compared to the content of filler at
the interface of the first abrasive region 202 and the reinforcing
member 206. The filler content in the first abrasive region 202 can
define a content gradient that is gradually changing along the axis
defined by the thickness (i.e., the axial direction) of the
abrasive tool 200.
[0044] FIG. 3 includes a top-down view of an abrasive tool
according to an embodiment. As illustrated, the abrasive tool 300
includes a body 301 that can include a bonded abrasive as described
herein. The body 301 can include an annular region 302 defined
between the inner annual edge 305 and outer peripheral edge 304.
According to one embodiment, at least one filler, such as the first
filler, can be substantially uniformly radially distributed
throughout the entire volume of the bond material. That is, for a
given abrasive region within the body 301, the content of the
filler (e.g., first filler) at the inner annular edge 305 to the
outer peripheral edge 304 can be substantially the same in a radial
direction. In one particular embodiment, the body 301 can include
an abrasive region wherein the first filler is substantially
uniformly radially distributed throughout the entirety of the first
abrasive region, which can extend between the inner annular edge
305 to the outer peripheral edge 304. It will be appreciated that
such a uniform distribution can exist for any and all components of
the body, including any and all fillers and the abrasive particles.
Moreover, while certain abrasive tools may utilize a substantially
uniform radial distribution of at least one filler, it will be
appreciated that such uniformity may be attributed to one or more
abrasive layers of the body 301. Furthermore, an abrasive article
may utilize at least one filler that has a substantially uniform
radial distribution within one abrasive region, and a non-uniform
distribution within another, different abrasive region of the body.
The non-uniform distribution may extend axially (i.e., in the
direction of the thickness of the body), radially, or both.
[0045] FIG. 4 includes a top-down view of an abrasive tool
according to an embodiment. As illustrated, the abrasive tool 400
can have a body 401 that can include a bonded abrasive as described
herein. As illustrated, the body 401 may include different annular
regions, including for example, an inner annular region 403
including the inner annular edge 405 of the body 401, which may
define the opening 406. The body 401 may also include an outer
annular region 402 including the outer peripheral edge 404 of the
body 401. It will be appreciated that the inner annular region 403
and outer annular region 402 can be any size and shape as suitable
for forming and function of the abrasive tool 400.
[0046] According to one embodiment, at least one filler (e.g., the
first filler) can have a difference in content (wt %) in the inner
annular region 403 compared to the outer annular region 402. For
example, in certain instances, the inner annular region 403 can
have a different content (wt %) of at least one filler (e.g., the
first filler) compared to the content (wt %) of the same filler in
the outer annular region 402. In a more particular embodiment, the
content of at least one filler, such as the first filler, can be
greater in the outer annular region 402 compared to the content of
the same filler (e.g., the first filler) in the inner annular
region 403. In yet another embodiment, the content of a filler,
such as the first filler can be less in the outer annular region
402 compared to the content of the same filler in the inner annular
region 403.
[0047] According to an embodiment, any one of the abrasive regions
of the body can have one or more annular regions, including an
inner annular region and outer annular region as illustrated in
FIG. 4. Moreover, the body of an abrasive tool may utilize multiple
abrasive regions, wherein each of the abrasive regions may have the
same arrangement of one or more annular regions or a different
arrangement of one or more annular regions compared to each other.
According to one embodiment, the body of the abrasive tool can have
a first abrasive region and a second abrasive region distinct from
the first abrasive region, wherein the first abrasive region and
the second abrasive region have at least one of 1) a first content
of abrasive particles in the first abrasive region different than a
second content of abrasive particles in the second abrasive region
or 2) a first type of abrasive particles in the first abrasive
region different than a second type of abrasive particles in the
second abrasive region or 3) a first content of the first filler in
the first abrasive region different than a first content of the
first filler in the second abrasive region or 4) a first filler
composition in the first abrasive region different than a second
filler composition in the second abrasive region or 5) a first
content of bond material in the first abrasive region different
than a second content of bond material in the second abrasive
region or 6) a first type of bond material in the first abrasive
region different than a second type of bond material in the second
abrasive region or 7) a second content of a second filler in the
first abrasive region different than a second content of the second
filler in the second abrasive region or 8) a third content of a
third filler in the first abrasive region different than a third
content of the third filler in the second abrasive region, or a
combination thereof.
[0048] In further reference to certain aspects of the abrasive
articles of the embodiments herein, the abrasive particles of the
abrasive tool may include inorganic materials, organic materials,
naturally occurring materials (e.g., minerals), superabrasive
materials, synthesized materials (e.g., polycrystalline diamond
compacts) or a combination thereof. Some exemplary abrasive
particles can include oxides, carbides (e.g., silicon carbide),
carbon-based materials, nitrides, borides, oxycarbides,
oxynitrides, oxyborides, agglomerated particles, non-agglomerated
particles, shaped abrasive particles, non-shaped abrasive
particles, or a combination thereof. In at least one embodiment,
the abrasive particles can include alumina-based abrasive
particles. As used herein, the term "alumina," "Al.sub.2O.sub.3"
and "aluminum oxide" are used interchangeably. Specific examples of
suitable alumina-based abrasive grains that can be employed in the
present invention include white alundum grain, or pink alundum,
mono-crystalline alumina, brown fused alumina, heat-treated
alumina, alumina-zirconia abrasive particles, and a combination
thereof.
[0049] Other abrasive particles can include seeded or unseeded
sintered sol gel alumina, with or without chemical modification,
such as rare earth oxides, MgO, and the like can be utilized. In
yet another embodiment, the abrasive particles can include silica,
zirconia, alumina-zirconia, silicon carbide, garnet, boron-alumina,
diamond, cubic boron nitride, aluminum-oxynitride, ceria, titanium
dioxide, titanium diboride, boron carbide, tin oxide, tungsten
carbide, titanium carbide, iron oxide, chromia, flint, emery,
bauxite, and utilized combination thereof. Furthermore, it will be
appreciated that the abrasive particles can include a blend of one
or more different types of abrasive particles as described herein.
In one particular embodiment, the abrasive tool includes a blend of
different types of abrasive particles, including a first type
comprising alumina and a second type including silicon carbide. The
abrasive particles of the embodiments herein can consist
essentially of any one or more compositions provided herein.
[0050] As noted herein, the abrasive particles can include shaped
abrasive particles. Shaped abrasive particles can have a
well-defined and regular arrangement (i.e., non-random) of edges
and sides, thus defining an identifiable and controlled shape from
particle-to-particle. Moreover, shaped abrasive particles are
distinct from traditional crushed or non-shaped abrasive particles
as the shaped abrasive particles have substantially the same shape
with respect to each other, wherein traditional crushed abrasive
particles vary significantly in their shape with respect to each
other. For example, a shaped abrasive particle may have a polygonal
shape as viewed in a plane defined by any two dimensions of length,
width, and height (e.g., viewed in a plane defined by a length and
a width). Some exemplary polygonal shapes can be triangular,
quadrilateral (e.g., rectangular, square, trapezoidal,
parallelogram), a pentagon, a hexagon, a heptagon, an octagon, a
nonagon, a decagon, and the like. Additionally, the shaped abrasive
particle can have a three-dimensional shape defined by a polyhedral
shape, such as a prismatic shape or the like. Further, the shaped
abrasive particles may have curved edges and/or surfaces, such that
the shaped abrasive particles can have convex, concave, ellipsoidal
shapes. Exemplary shaped abrasive particles are disclosed in U.S.
Pat. No. 8,758,461, which is incorporated herein in its
entirety.
[0051] The size of abrasive particles can be expressed as a grit
size, and charts showing a relation between a grit size and its
corresponding average particle size, expressed in microns or
inches, are known in the art as are correlations to the
corresponding United States Standard Sieve (USSS) mesh size.
Particle size selection depends upon the application or process for
which the abrasive tool is intended and may range from 10 to 325 as
per ANSI grit size designation. Specifically, grit sizes may range
from 16 to 120 or 16 to 80.
[0052] According to one particular embodiment, the abrasive
particles can have an average particle size (D50) of at least 1
micron, such as at least 10 microns or at least 20 microns or at
least 30 microns or at least 40 microns. Still, in another
non-limiting embodiment, the abrasive particles can have an average
particle size of not greater than 2 mm, such as not greater than 1
mm or not greater than 800 microns or not greater than 600 microns
or not greater than 500 microns or not greater than 400 microns or
not greater than 300 microns or not greater than 280 microns or not
greater than 250 microns or not greater than 200 microns. It will
be appreciated that the abrasive particles can have an average
particle size within a range including any of the minimum and
maximum values noted above, including for example, within a range
between 1 micron and 2 mm, within a range between 10 microns and 1
mm, or even within a range between 20 microns and 200 microns.
[0053] In at least one embodiment, an abrasive region of the
abrasive tool may include a particular content of abrasive
particles, which may facilitate improved performance. For example,
the content of abrasive particles in the first abrasive region 202
can be at least 1 wt % of the total weight of the first abrasive
region 202, such as at least 5 wt % or at least 10 wt % or at least
20 wt % or at least 30 wt % or at least 40 wt % or at least 50 wt %
or at least 60 wt % or at least 65wt % or at least 70 wt %. Still,
in another non-limiting embodiment, the content of abrasive
particles in the first abrasive region 202 can be not greater than
90 wt % of the total weight of the first abrasive region 202, such
as not greater than 85 wt % or not greater than 83 wt % or not
greater than 80 wt % or not greater than 78 wt % or even not
greater than 75 wt %. It will be appreciated that the content of
abrasive particles can be within a range including any of the
minimum and maximum ratios noted above, including for example, at
least 30 wt % and not greater than 90 wt % for a total weight of
the first abrasive region 202.
[0054] The bond material of one or more abrasive regions of the
abrasive tool can include an organic material. In specific
implementations, the bond material can be a polymeric or resin
material, which may be formed into the finally-formed bond material
by curing. An example of an organic bond material that can be
employed to fabricate bonded abrasive articles can include a
phenolic resin. Such resins can be obtained by polymerizing phenols
with aldehydes, in particular, formaldehyde, paraformaldehyde or
furfural. In addition to phenols, cresols, xylenols and substituted
phenols can be employed. Comparable formaldehyde-free resins also
can be utilized. Examples of other suitable organic bond materials
include epoxy resins, polyester resins, polyurethanes, polyester,
rubber, polyimide, polybenzimidazole, aromatic polyamide, modified
phenolic resins (such as: epoxy modified and rubber modified
resins, or phenolic resin blended with plasticizers, etc.), and so
forth, as well as mixtures thereof.
[0055] In at least one embodiment, an abrasive region of the
abrasive tool may include a particular content of bond material,
which may facilitate improved performance. For example, the content
of bond material in the first abrasive region 202 can be at least 1
wt % of the total weight of the first abrasive region 202, such as
at least 5 wt % or at least 10 wt % or at least 12 wt % or at least
13 wt % or at least 14 wt %. In another non-limiting embodiment,
the content of bond material in the first abrasive region can be at
least 20 wt %, such as at least 30 wt % or at least 40 wt % or at
least 50 wt % or at least 60 wt % or at least 65wt % or at least 70
wt %. Still, in another non-limiting embodiment, the content of
bond material in the first abrasive region 202 can be not greater
than 90 wt % of the total weight of the first abrasive region 202,
such as not greater than 85 wt % or not greater than 83 wt % or not
greater than 80 wt % or not greater than 78 wt % or even not
greater than 75 wt %. In yet another non-limiting embodiment, the
content of bond material may be not greater than 60 wt %, such as
not greater than 50 wt % or not greater than 40 wt % or not greater
than 30 wt % or not greater than 20 wt % or not greater than 18 wt
% or not greater than 16 wt %. It will be appreciated that the
content of bond material can be within a range including any of the
minimum and maximum ratios noted above.
[0056] Among phenolic resins, resoles can be obtained by a one-step
reaction between aqueous formaldehyde and phenol in the presence of
an alkaline catalyst. Novolac resin, also known as a two-stage
phenolic resin, can be produced under acidic conditions and during
milling process blended with a cross-linking agent, such as
hexamethylenetetramine (often also referred to as "hexa").
Exemplary phenolic resins can include resole and novolac. Resole
phenolic resins can be alkaline catalyzed and have a ratio of
formaldehyde to phenol of greater than or equal to one, such as
from 1:1 to 3:1. Novolac phenolic resins can be acid catalyzed and
have a ratio of formaldehyde to phenol of less than one, such as
from 0.5:1 to 0.8:1.
[0057] The bond material can contain more than one phenolic resin,
including for example or at least one resole and at least
novolac-type phenolic resin. In many cases or at least one
phenol-based resin is in liquid form. Suitable combinations of
phenolic resins are described, for example, in U.S. Pat. No.
4,918,116 to Gardziella, et al., the entire contents of which are
incorporated herein by reference.
[0058] An epoxy resin can include an aromatic epoxy or an aliphatic
epoxy. Aromatic epoxies components include one or more epoxy groups
and one or more aromatic rings. An example aromatic epoxy includes
epoxy derived from a polyphenol, e.g., from bisphenols, such as
bisphenol A (4,4'-isopropylidenediphenol), bisphenol F
(bis[4-hydroxyphenyl]methane), bisphenol S (4,4'-sulfonyldiphenol),
4,4'-cyclohexylidenebisphenol, 4,4'-biphenol,
4,4'-(9-fluorenylidene)diphenol, or any combination thereof. The
bisphenol can be alkoxylated (e.g., ethoxylated or propoxylated) or
halogenated (e.g., brominated). Examples of bisphenol epoxies
include bisphenol diglycidyl ethers, such as diglycidyl ether of
Bisphenol A or Bisphenol F. A further example of an aromatic epoxy
includes triphenylolmethane triglycidyl ether,
1,1,1-tris(p-hydroxyphenyl)ethane triglycidyl ether, or an aromatic
epoxy derived from a monophenol, e.g., from resorcinol (for
example, resorcin diglycidyl ether) or hydroquinone (for example,
hydroquinone diglycidyl ether). Another example is nonylphenyl
glycidyl ether. In addition, an example of an aromatic epoxy
includes epoxy novolac, for example, phenol epoxy novolac and
cresol epoxy novolac. Aliphatic epoxy components have one or more
epoxy groups and are free of aromatic rings. The external phase can
include one or more aliphatic epoxies. An example of an aliphatic
epoxy includes glycidyl ether of C2-C30 alkyl; 1,2 epoxy of C3-C30
alkyl; mono or multiglycidyl ether of an aliphatic alcohol or
polyol such as 1,4-butanediol, neopentyl glycol, cyclohexane
dimethanol, dibromo neopentyl glycol, trimethylol propane,
polytetramethylene oxide, polyethylene oxide, polypropylene oxide,
glycerol, and alkoxylated aliphatic alcohols; or polyols. In one
embodiment, the aliphatic epoxy includes one or more cycloaliphatic
ring structures. For example, the aliphatic epoxy can have one or
more cyclohexene oxide structures, for example, two cyclohexene
oxide structures.
[0059] An example of an aliphatic epoxy comprising a ring structure
includes hydrogenated bisphenol A diglycidyl ether, hydrogenated
bisphenol F diglycidyl ether, hydrogenated bisphenol S diglycidyl
ether, bis(4-hydroxycyclohexyl)methane diglycidyl ether,
2,2-bis(4-hydroxycyclohexyl)propane diglycidyl ether,
3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexanecarboxylate,
3,4-epoxy-6-methylcyclohexylmethyl-3,4-epoxy-6-methylcyclohexanecarboxyla-
te, di(3,4-epoxycyclohexylmethyl)hexanedioate,
di(3,4-epoxy-6methylcyclohexylmethyl) hexanedioate,
ethylenebis(3,4-epoxycyclohexanecarboxylate),
ethanedioldi(3,4-epoxycyclohexylmethyl) ether, or
2-(3,4-epoxycyclohexyl-5,5-spiro-3,4-epoxy)cyclohexane-1,3-dioxane.
[0060] An exemplary multifunctional acrylic can include
trimethylolpropane triacrylate, glycerol triacrylate,
pentaerythritol triacrylate, methacrylate, dipentaerythritol
pentaacrylate, sorbitol triacrylate, sorbital hexacrylate, or any
combination thereof. In another example, an acrylic polymer can be
formed from a monomer having an alkyl group having from 1-4 carbon
atoms, a glycidyl group or a hydroxyalkyl group having from 1-4
carbon atoms. Representative acrylic polymers include polymethyl
methacrylate, polyethyl methacrylate, polybutyl methacrylate,
polyglycidyl methacrylate, polyhydroxyethyl methacrylate,
polymethyl acrylate, polyethyl acrylate, polybutyl acrylate,
polyglycidyl acrylate, polyhydroxyethyl acrylate and mixtures
thereof.
[0061] Curing or cross-linking agents that can be utilized depend
on the bonding material selected. For curing phenol novolac resins,
for instance, a typical curing agent is hexa. Other amines, e.g.,
ethylene diamine; ethylene triamine; methyl amines and precursors
of curing agents, e.g., ammonium hydroxide which reacts with
formaldehyde to form hexa, also can be employed. Suitable amounts
of curing agent can be within the range, for example, of from 5 to
20 parts, or 8 parts to 15 parts, by weight of curing agent per
hundred parts of total novolac resin. It will be appreciated that
the ratio can be adjusted based on various factors, including for
example the particular types of resins used, the degree of cure
needed, and the desired final properties for the articles, such as
strength, hardness, and grinding performance.
[0062] As noted herein and according to one embodiment, the bonded
abrasive can be reinforced with one or more reinforcing members,
which may be in the form of layers, partial layers, discrete
bundles of material distributed throughout the body, and a
combination thereof. As used herein, the term "reinforcing member"
can refer to a discrete component that can be made of a material
that is different from the bond material and abrasive particles
utilized to make the abrasive layers within the bonded abrasive
body. In an embodiment, the reinforcing member does not include
abrasive particles. With respect to the thickness of the bonded
abrasive, a reinforcing member can be embedded within the body of
the bonded abrasive and such bonded abrasives may be referred to as
"internally" reinforced. A reinforcing member also can be close to,
or attached to the front and/or back face of the body of the bonded
abrasive. Several reinforcing members can be disposed at various
depths through the thickness of the bonded abrasive.
[0063] Certain reinforcing members may have a circular geometry.
The outer periphery of the reinforcing member also can have a
square, hexagon or another polygonal geometry. An irregular outer
edge also can be used. Suitable non-circular shapes that can be
utilized are described in U.S. Pat. Nos. 6,749,496 and 6,942,561,
incorporated herein by reference in their entirety. In certain
instances wherein the bonded abrasive is in the form of a wheel or
disc, the reinforcing member can extend from the inner diameter
(edge of the central opening) to the outermost edge (i.e.,
peripheral surface) of the bonded abrasive body. Partial
reinforcing members can be employed and in such cases, the
reinforcing member may extend, for example, from the mounting hole
to at least 30% along the radius or, for non-circular shapes, along
the equivalent of the largest "radius" of the bonded abrasive body.
For example, a partial reinforcing member can extend for at least
60% or at least 70% or at least 75% or at least 80% or at least 85%
or at least 90% or at least 95%, or even at least 99% along the
radius or, for non-circular shapes, along the equivalent of the
largest "radius" of the body of the bonded abrasive. In another
non-limiting embodiment, the partial reinforcing member may extend
for not greater than 100%, such as not greater than 99% or not
greater than 97% or not greater than 95% or not greater than 90% or
not greater than 85% or not greater than 80% or not greater than
70%, or even not greater than 60% along the radius or the
equivalent of the largest "radius" of the bonded abrasive body. It
will be appreciated that the partial reinforcing member can extend
within a range including any of the minimum and maximum values
noted above. For instance, the partial reinforcing member can
extend within a range of 60% to 100%, such as, within a range of
70% to 99%, or within a range of 80% to 90% along the radius or the
equivalent of the largest "radius" of the bonded abrasive body
[0064] The reinforcing member can include various materials,
including a single material or more than one type of material, such
as a composite material. Moreover, the abrasive tool of the
embodiments herein can use a single type of reinforcing member or
may use different types of reinforcing members, which can employ
different materials with respect to each other. Some suitable
reinforcing member materials can include woven materials or
non-woven materials. In at least one embodiment, the reinforcing
member can include a glass material, including but not limited to a
fiberglass material. In yet other embodiments, the reinforcing
member can include, a fiber (e.g., Kevlar.RTM.), basalt, carbon,
fabric organic materials (e.g., elastomers, rubbers), combinations
of materials and so forth. An exemplary reinforcing member can
include a polymeric film (including primed films) including for
example, a polyolefin film (e.g., polypropylene including biaxially
oriented polypropylene), a polyester film (e.g., polyethylene
terephthalate), a polyamide film, a cellulose ester film, a metal
foil, a mesh, a foam (e.g., natural sponge material or polyurethane
foam), a cloth (e.g., cloth made from fibers or yams comprising
fiberglass, polyester, nylon, silk, cotton, poly-cotton, or rayon),
a paper, a vulcanized paper, a vulcanized rubber, a vulcanized
fiber, a nonwoven material, or any combination thereof, or treated
versions thereof. A cloth backing can be woven or stitch bonded. In
particular examples, the reinforcing member can be selected from a
group consisting of paper, polymer film, cloth, cotton,
poly-cotton, rayon, polyester, poly-nylon, vulcanized rubber,
vulcanized fiber, fiberglass fabric, metal foil or any combination
thereof. In other examples, the reinforcing member includes a woven
fiberglass fabric. In a particular example, the bonded abrasive can
include one more layers of fiberglass between which a blend
abrasive grains or particles are bound in a bond material such as a
polymer matrix. Using reinforcing members also can allow for shear
at the interface between the reinforcing member and adjacent
region(s) of the bonded abrasive (which contain abrasive grains or
particles distributed in a three dimensional bond material matrix).
It will be appreciated that a reinforcing member can consist
essentially of any of the foregoing materials or consists
essentially of two or more of the foregoing materials noted
above.
[0065] In specific examples, the body can include at least one or
more fiberglass reinforcing members, provided, for instance, in the
form of fiberglass web(s). Fiberglass webs can include fiberglass
woven from very fine fibers of glass. Fiberglass web can include
leno or plain woven. The fiberglass utilized can include E-glass
(alumino-borosilicate glass with less than 1 wt % alkali oxides).
Other types of fiberglass can include, for example, A-glass
(alkali-lime glass with little or no boron oxide), E-CR-glass
(alumino-lime silicate with less than 1 wt % alkali oxides, with
high acid resistance), C-glass (alkali-lime glass with high boron
oxide content, used for example for glass staple fibers), D-glass
(borosilicate glass with high dielectric constant), R-glass
(alumino silicate glass without MgO and CaO with high mechanical
requirements), or S-glass (alumino silicate glass without CaO but
with high MgO content with high tensile strength).
[0066] Fiberglass webs can be arranged in the bonded abrasive such
as a bonded abrasive wheel in any suitable manner. In certain
implementations, placement of a glass fiber web at the working face
of the wheel may be avoided. Any of the embodiments herein can be
reinforced with at least one fiberglass web having a hole
corresponding to the central opening or arbor hole of the wheel and
the same diameter as the wheel. Partial web reinforcing members
that extend from the mounting hole through some but not the total
radius of the wheel also can be used, as can be other web
reinforcement placements.
[0067] The abrasive tools of the embodiments herein, with or
without one or more reinforcing members, can be prepared by forming
a mixture of the components, including but not limited to abrasive
particles, a bond material, e.g., an organic material (resin) or an
inorganic material, and in many cases other ingredients, such as,
for instance, fillers, processing aids, lubricants, crosslinking
agents, antistatic agents and so forth.
[0068] The various ingredients can be added in any suitable order
and blended using known techniques. The resulting mixture can be
used to form a green body. As used herein, the term "green" refers
to a body which maintains its shape during the next process step,
but generally does not have enough strength to maintain its shape
permanently. Green may also refer to a body that is unfinished, or
that there are further processes yet to be completed before
transforming the green body to a finally-formed abrasive tool. For
example, a resin bond present in the green body is in an uncured or
unpolymerized state. The green body preferably is molded in the
shape of the desired article.
[0069] One or more reinforcing members can be incorporated in the
green body. For example, a first portion of a mixture can be placed
and distributed at the bottom of an appropriate mold cavity and
then covered with a first reinforcing member. A second portion of
the mixture can then be disposed and distributed over the first
reinforcing member. Additional reinforcing members and/or
bond/abrasive mixture layers can be provided, if so desired. The
amounts of mix added to form a particular layer thickness can be
modified as suitable for the intended purposes of the abrasive
article. Other suitable sequences and/or techniques can be employed
to shape the reinforced green body. For instance, a piece of paper
or a fiberglass mesh or web or a piece of paper with a fiber glass
mesh or web may be inserted in the mold cavity before the first
mixture.
[0070] As noted herein, the body can be formed of one or more
abrasive regions, which may be in the form of layers, which can
have the same or different characteristics, such as, layer
thickness, layer formulation (e.g., amounts and or types of
ingredients being employed, grit size, grit shape, porosity),
filler materials, bond composition, bond content, abrasive content,
abrasive particle composition, porosity, pore size, porosity
distribution, porosity type (i.e., closed and/or open porosity) and
the like.
[0071] The bonded abrasive body described herein can be fabricated
to have a certain porosity. The porosity can be set to provide a
particular performance of the abrasive tool, including parameters
such as hardness, strength, and initial stiffness, as well as chip
clearance and swarf removal. Porosity can be uniformly or
non-uniformly distributed throughout the body of the bonded
abrasive and can be intrinsic porosity, obtained by the arrangement
of grains within the bond matrix, shape of the abrasive grains
and/or bond precursors being utilized, pressing conditions, curing
conditions and so forth, or can be generated by the use of pore
inducers. Both types of porosity can be present.
[0072] The porosity can be closed and/or interconnected (open). In
"closed" type of porosity, the pores are generally discrete with
respect to each other and are not interconnected. In contrast,
"open" porosity presents pores that are interconnected to one
another creating an interconnected network of channels.
[0073] In one embodiment, an abrasive region of the abrasive tool
may contain porosity of at least 0.1 vol % for a total volume of
the abrasive region, such as at least 1 vol % or at least 2 vol %
or at least 3 vol % or even at least 5 vol %. In another
non-limiting embodiment, the porosity may be not greater than 40
vol %, such as not greater than 35 vol % or not greater than 30 vol
% or not greater than 25 vol %, or not greater than 20 vol % or not
greater than 15 vol % or not greater than 10 vol %, or even not
greater than 5 vol % for the total volume of abrasive layers within
the body of the bonded abrasive. It will be appreciated that the
porosity of the bonded abrasive can be within a range including any
of the minimum and maximum values noted above, such as within the
range of from 1 vol % to 40 vol %.
[0074] Various techniques can be used to produce the abrasive
tools, including for example cold pressing, warm pressing, or hot
pressing. In accordance with a particular embodiment the process of
forming the abrasive articles herein can include cold pressing. In
cold pressing, the materials in the mold are maintained at
approximately ambient temperature, such as less than 30.degree.
centigrade (C). Force can be applied to the materials in the mold.
For example, the applied force can be at least 40 tons. The applied
force may be not greater than 2000 tons. The applied force can be
within a range of 100 tons to 2000 tons. Alternatively, pressure
can be applied to the materials by suitable means, such as a
hydraulic press. The pressure applied can be, for example, in the
range of 4.2 kg/cm2 (60 psi or 0.03 tsi), 8.4 kg/cm2 (120 psi or
0.06 tsi) 70.3 kg/cm2 (0.5 tsi) to 2109.3 kg/cm2 (15 tsi), or in
the range of 140.6 kg/cm2 (1 tsi) to 843,6 kg/cm2 (6 tsi). The
holding time within the press can be, for example, within the range
of from less than 2.5 seconds to 1 minute.
[0075] Wheels may be molded individually or large "bats" can be
molded, from which individual wheels are later cored out. The
various abrasive mix layers, which comprise abrasive grain, resin
and fillers), fiberglass reinforcement and barrier layer material
are sequentially placed into a mold cavity in the appropriate
configuration. The barrier layer can serve as the outermost layers
of the stack. The full stack can be pressed using forces
commensurate with the pressures described above. The barrier layer
can adhere to the abrasive mixture, and thus ultimately be bonded
in-situ to the abrasive wheel as a result of the curing
process.
[0076] It will be appreciated however that warm pressing or hot
pressing may be utilized to form the abrasive articles. Warm
pressing and hot pressing are similar to cold pressing operations,
except that higher temperatures may be utilized during the
application of pressure.
[0077] In the embodiments employing an organic bond material, the
bonded abrasive can be formed by curing the organic bond material.
As used herein, the term "final cure temperature" is the
temperature at which the molded article is held to effect
polymerization, e.g., cross-linking, of the organic bond material,
thereby forming the final composition of the bond material,
although cross-linking can begin at lower temperatures. The curing
temperature may be utilized during other processes, such as during
the cold pressing operation. Alternatively, certain processes of
the embodiments herein, can utilize a separate curing step, which
can be separate from other processes such as the cold pressing
operation. In such instances, the pressing operation may be first
conducted, and the uncured abrasive article may be removed from the
press and placed in a temperature-controlled chamber to facilitate
curing. As used herein, "cross-linking" refers to the chemical
reaction(s) that take(s) place in the presence of heat and often in
the presence of a cross-linking agent, such as "hexa" or
hexamethylenetetramine, whereby the organic bond composition
hardens. Generally, the molded article can be held at a final cure
temperature for a period of time, such as between 6 hours and 48
hours, between 10 and 36 hours, or until the center of mass of the
molded article reaches the cross-linking temperature and desired
grinding performance (e.g., density of the cross-link).
[0078] Selection of a curing temperature depends, for instance, on
factors such as the type of bonding material employed, strength,
hardness, and grinding performance desired. According to certain
embodiments, the curing temperature can be in the range including
at least 100.degree. C. to not greater than 250.degree. C. In more
specific embodiments employing organic bonds, the curing
temperature can be in the range including at least 150.degree. C.
to not greater than 230.degree. C. Polymerization of novolac-based
resins may occur at a temperature in the range of including at
least 110.degree. C. and not greater than 225.degree. C. Resole
resins can polymerize at a temperature in a range of including at
least 100.degree. C. and not greater than 225.degree. C. Certain
novolac resins suitable for the embodiments herein can polymerize
at a temperature in a range including at least 110.degree. C. and
not greater than 250.degree. C.
Items
[0079] Item 1. An abrasive tool comprising a bonded abrasive
including a body comprising abrasive particles contained within a
three-dimensional matrix of bond material, the bond material
comprising an organic material; a first filler contained within the
three-dimensional matrix of bond material comprising a silicate in
a first content; and a second filler contained within the
three-dimensional matrix of bond material comprising a sulfate in a
second content; and wherein the first content is greater than the
second content.
[0080] Item 2. An abrasive tool comprising: a bonded abrasive
including a body comprising: a first abrasive region including
abrasive particles contained within a three-dimensional matrix of
bond material, the bond material comprising an organic material,
wherein the first abrasive region further comprises a first filler
comprising a silicate contained within the three-dimensional matrix
of bond material, wherein the first filler is substantially
uniformly radially distributed throughout the first abrasive
region; and a reinforcing member coupled to the first abrasive
region.
[0081] Item 3. An abrasive tool comprising: a bonded abrasive
including a body comprising: a diameter, a thickness, and a ratio
of diameter:thickness of at least about 10:1; and a first abrasive
region including abrasive particles contained within a
three-dimensional matrix of bond material comprising an organic
material, wherein the first abrasive region further comprises a
first filler contained within the three-dimensional matrix of bond
material comprising a silicate, wherein the first filler is
substantially uniformly radially distributed throughout the first
abrasive region.
[0082] Item 4. An abrasive tool comprising: a bonded abrasive
including a body comprising: a first abrasive region including
abrasive particles contained within a three-dimensional matrix of
bond material comprising an organic material, wherein the first
abrasive region further comprises a first filler contained within
the three-dimensional matrix of bond material comprising a
silicate, the first abrasive region comprising a ratio (Cff/Cb) of
at least 0.2 and not greater than 1, wherein Cff represents a
content of the first filler (wt %) for the first abrasive region
and Cb represents a content of the bond material (wt %) for the
first abrasive region; and a reinforcing member coupled to the
first abrasive region.
[0083] Item 5. An abrasive tool comprising: a bonded abrasive
including a body having a thickness not greater than 10 mm
comprising: a first abrasive region including abrasive particles
contained within a three-dimensional matrix of bond material, the
bond material comprising an organic material, wherein the first
abrasive region further comprises a first filler comprising a
silicate contained within the three-dimensional matrix of bond
material, wherein the first filler is substantially uniformly
radially distributed throughout the first abrasive region, and
wherein the first abrasive region comprises a content of
wollastonite within a range including at least 0.2 wt % and not
greater than 20 wt % for a total weight of the first abrasive
region.
[0084] Item 6. The abrasive tool of any of the items herein,
wherein the first filler comprises calcium.
[0085] Item 7. The abrasive tool of any of the items herein,
wherein the first filler comprises a calcium silicate compound.
[0086] Item 8. The abrasive tool of any of the items herein,
wherein the first filler comprises an inosilicate compound.
[0087] Item 9. The abrasive tool of any of the items herein,
wherein the first filler comprises wollastonite.
[0088] Item 10. The abrasive tool of any of the items herein,
wherein the first filler consists essentially of wollastonite
(CaSiO3).
[0089] Item 11. The abrasive tool of any of the items herein,
wherein the first filler comprises a median particle size (D50) of
at least 1 micron or at least 2 microns or at least 3 microns or at
least 4 microns or at least 5 microns or at least 6 microns or at
least 7 microns or at least 8 microns or at least 9 microns or at
least 10 microns or at least 11 microns or at least 12 microns or
at least 13 microns.
[0090] Item 12. The abrasive tool of any of the items herein,
wherein the first filler comprises a median particle size (D50) of
not greater than 100 microns or not greater than 95 microns or not
greater than 90 microns or not greater than 85 microns or not
greater than 80 microns or not greater than 75 microns or not
greater than 7+0 microns or not greater than 65 microns or not
greater than 60 microns or not greater than 55 microns or not
greater than 50 microns or not greater than 45 microns or not
greater than 40 microns or not greater than 35 microns or not
greater than 30 microns or not greater than 25 microns.
[0091] Item 13. The abrasive tool of any of the items herein,
wherein the first filler is a material distinct from the abrasive
particles.
[0092] Item 14. The abrasive tool of any of the items herein,
wherein the first filler is substantially uniformly distributed
throughout the entire volume of the bond material.
[0093] Item 15. The abrasive tool of any of the items herein,
wherein the first content of the first filler is substantially the
same in an outer annular region of the body as compared to a
content of the first filler in an inner annular region of the
body.
[0094] Item 16. The abrasive tool of any of the items herein,
wherein the first content of the first filler is substantially the
same at a peripheral edge of the body as compared to an inner
annular edge of the body.
[0095] Item 17. The abrasive tool of any of the items herein,
wherein the first filler is substantially uniformly radially
distributed throughout the first abrasive region;
[0096] Item 18. The abrasive tool of any of the items herein,
wherein the first abrasive region comprises an inner annular region
and an outer annular region, wherein the inner annular region has a
different content (wt %) of the first filler compared to a content
(wt %) of the first filler in the outer annular region.
[0097] Item 19. The abrasive tool of any of the items herein,
wherein the content of the first filler is greater in the outer
annular region compared to the inner annular region.
[0098] Item 20. The abrasive tool of any of the items herein,
wherein the content of the first filler is less in the outer
annular region compared to the inner annular region.
[0099] Item 21. The abrasive tool of any of the items herein,
wherein the first filler is a reinforcing agent configured to
reduce the wear of the bond during grinding operations.
[0100] Item 22. The abrasive tool of any of the items herein,
wherein the first filler is a particle having an aspect ratio of
length:width of at least 1.1:1.
[0101] Item 23. The abrasive tool of any of the items herein,
wherein the aspect ratio is at least 1.2:1 or at least 1.3:1 or at
least 1.4:1 or at least 1.5:1 or at least 1.6:1 or at least 1.7:1
or at least 1.8:1 or at least 1.9:1 or at least 2:1.
[0102] Item 24. The abrasive tool of any of the items herein,
wherein the aspect ratio is not greater than 100:1 or not greater
than 90:1 or not greater than 80:1 or not greater than 70:1 or not
greater than 60:1 or not greater than 60:1 or not greater than 50:1
or not greater than 40:1 or not greater than 30:1 or not greater
than 20:1 or not greater than 10:1.
[0103] Item 25. The abrasive tool of any of the items herein,
wherein the body comprises a first abrasive region including
abrasive particles contained within the three-dimensional matrix of
bond material and the first filler is present in a first content
within a range including at least 0.2 wt % and not greater than 20
wt % for a total weight of the first abrasive region.
[0104] Item 26. The abrasive tool of any of the items herein,
wherein the first content is at least 0.1 wt % of the first
abrasive region or at least 0.5 wt % or at least 0.8 wt % or at
least 1 wt % or at least 1.2 wt % or at least 1.4 wt % or at least
1.6 wt % or at least 1.8 wt % or at least 2 wt % or at least 2.2 wt
% or at least 2.4 wt % or at least 2.6 wt % or at least 2.8 wt % or
at least 3 wt % or at least 3.2 wt % or at least 3.4 wt % or at
least 3.6 wt % or at least 3.8 wt % or at least 4 wt % or at least
4.2 wt %.
[0105] Item 27. The abrasive tool of any of the items herein,
wherein the first content is not greater than 19 wt % of the first
abrasive region or not greater than 18 wt % or not greater than 17
wt % or not greater than 16 wt % or not greater than 15 wt % or not
greater than 14 wt % or not greater than 13 wt % or not greater
than 12 wt % or not greater than 11 wt % or not greater than 10 wt
% or not greater than 9 wt % or not greater than 8 wt % or not
greater than 7 wt % or not greater than 6 wt % or not greater than
5 wt %.
[0106] Item 28. The abrasive tool of any of the items herein,
further comprising a second filler contained within the
three-dimensional matrix of bond material comprising a sulfate in a
second content.
[0107] Item 29. The abrasive tool of any of the items herein,
wherein the first content of the first filler is greater than the
second content of the second filler.
[0108] Item 30. The abrasive tool of any of the items herein,
wherein the second filler comprises potassium.
[0109] Item 31. The abrasive tool of any of the items herein,
wherein the second filler comprises a potassium sulfate
compound.
[0110] Item 32. The abrasive tool of any of the items herein,
wherein the second filler consists essentially of potassium
sulfate.
[0111] Item 33. The abrasive tool of any of the items herein,
wherein the second filler comprises an average particle size of at
least 0.1 microns.
[0112] Item 34. The abrasive tool of any of the items herein,
wherein the second filler comprises an average particle size of not
greater than 500 microns.
[0113] Item 35. The abrasive tool of any of the items herein,
wherein the second filler is a particle having an aspect ratio of
length:width of at least 1.1:1.
[0114] Item 36. The abrasive tool of any of the items herein,
wherein the second filler has a different aspect ratio
(length:width) compared to an aspect ratio (length:width) of the
first filler.
[0115] Item 37. The abrasive tool of any of the items herein,
wherein the body comprises a first abrasive region including
abrasive particles contained within the three-dimensional matrix of
bond material and the second filler present in the second content
within a range including at least 0.01 wt % and not greater than 15
wt % for a total weight of the first abrasive region.
[0116] Item 38. The abrasive tool of any of the items herein,
wherein the second content is at least 0.1 wt % or at least 0.5 wt
% or at least 0.8 wt % or at least 1 wt % or at least 1.2 wt % or
at least 1.4 wt % or at least 1.6 wt % or at least 1.8 wt % or at
least 2 wt % or at least 2.2 wt %.
[0117] Item 39. The abrasive tool of any of the items herein,
wherein the second content is not greater than 14 wt % or not
greater than 13 wt % or not greater than 12 wt % or not greater
than 11 wt % or not greater than 10 wt % or not greater than 9 wt %
or not greater than 8 wt % or not greater than 7 wt % or not
greater than 6 wt % or not greater than 5 wt %.
[0118] Item 40. The abrasive tool of any of the items herein,
wherein the abrasive region comprises a ratio (C1:C2) of the first
content (C1) to the second content (C2) of at least 1.1:1 or at
least 1.2:1 or at least 1.3:1 or at least 1.4:1 or at least 1.5:1
or at least 1.6:1 or at least 1.7:1 or at least 1.8:1 or at least
1.9:1 or at least 2:1.
[0119] Item 41. The abrasive tool of any of the items herein,
wherein the abrasive region comprises a ratio (C1:C2) of the first
content (C1) to the second content (C2) of not greater than 100:1
or not greater than 90:1 or not greater than 80:1 or not greater
than 70:1 or not greater than 60:1 or not greater than 60:1 or not
greater than 50:1 or not greater than 40:1 or not greater than 30:1
or not greater than 20:1 or not greater than 10:1 or not greater
than 8:1 or not greater than 6:1 or not greater than 5:1 or not
greater than 4:1 or not greater than 3:1 or not greater than
2.5:1.
[0120] Item 42. The abrasive tool of any of the items herein,
further comprising a third filler contained within the
three-dimensional matrix of bond material comprising a
halide-containing compound in a third content.
[0121] Item 43. The abrasive tool of any of the items herein,
wherein the first content is greater than the third content.
[0122] Item 44. The abrasive tool of any of the items herein,
wherein the third filler comprises sodium.
[0123] Item 45. The abrasive tool of any of the items herein,
wherein the third filler comprises aluminum.
[0124] Item 46. The abrasive tool of any of the items herein,
wherein the third filler comprises sodium hexafluoroaluminate
(Na3AlF6).
[0125] Item 47. The abrasive tool of any of the items herein,
wherein the third filler consists essentially of sodium
hexafluoroaluminate (Na3AlF6).
[0126] Item 48. The abrasive tool of any of the items herein,
wherein the third filler comprises a median particle size (D50) of
at least 1 micron.
[0127] Item 49. The abrasive tool of any of the items herein,
wherein the third filler comprises an average particle size of not
greater than 50 microns.
[0128] Item 50. The abrasive tool of any of the items herein,
wherein the third filler is a particle having a substantially
equiaxed shape.
[0129] Item 51. The abrasive tool of any of the items herein,
wherein the third filler has a substantially elongated shape.
[0130] Item 52. The abrasive tool of any of the items herein,
wherein the third filler has a different aspect ratio
(length:width) compared to an aspect ratio (length:width) of the
first filler.
[0131] Item 53. The abrasive tool of any of the items herein,
wherein the third filler has a different aspect ratio
(length:width) compared to an aspect ratio (length:width) of a
second filler.
[0132] Item 54. The abrasive tool of any of the items herein,
wherein the third filler is present in a third content within a
range including at least 0.01 wt % and not greater than 18 wt % for
a total weight of the first abrasive region.
[0133] Item 55. The abrasive tool of any of the items herein,
wherein the third content is at least 0.1 wt % or at least 0.5 wt %
or at least 0.8 wt % or at least 1 wt % or at least 1.2 wt % or at
least 1.4 wt % or at least 1.6 wt % or at least 1.8 wt % or at
least 2 wt % or at least 2.2 wt % or at least or at least 2.4 wt %
or at least 2.6 wt % or at least 2.8 wt % or at least 3 wt % or at
least 3.2 wt %.
[0134] Item 56. The abrasive tool of any of the items herein,
wherein the third content is not greater than 17 wt % or not
greater than 16 wt % or not greater than 15 wt % or not greater
than 14 wt % or not greater than 13 wt % or not greater than 12 wt
% or not greater than 11 wt % or not greater than 10 wt % or not
greater than 9 wt % or not greater than 8 wt % or not greater than
7 wt % or not greater than 6 wt % or not greater than 5 wt % or not
greater than 4 wt %.
[0135] Item 57. The abrasive tool of any of the items herein,
wherein the abrasive region comprises a ratio (C1:C3) of the first
content (C1) to the third content (C3) of at least 1.1:1 or at
least 1.2:1 or at least 1.3:1 or at least 1.4:1 or at least 1.5:1
or at least 1.6:1 or at least 1.7:1 or at least 1.8:1 or at least
1.9:1 or at least 2:1.
[0136] Item 58. The abrasive tool of any of the items herein,
wherein the abrasive region comprises a ratio (C1:C3) of the first
content (C1) to the second content (C2) of not greater than 100:1
or not greater than 90:1 or not greater than 80:1 or not greater
than 70:1 or not greater than 60:1 or not greater than 50:1 or not
greater than 40:1 or not greater than 30:1 or not greater than 20:1
or not greater than 10:1 or not greater than 5:1 or not greater
than 3:1 or not greater than 2.5:1.
[0137] Item 59. The abrasive tool of any of the items herein,
wherein the first abrasive region further includes a second filler
contained within the three-dimensional matrix of bond material.
[0138] Item 60. The abrasive tool of any of the items herein,
wherein the second filler present in a second content within a
range including at least 0.01 wt % and not greater than 15 wt % for
a total weight of the first abrasive region.
[0139] Item 61. The abrasive tool of any of the items herein,
wherein the first abrasive region further comprises a third filler
in a third content, and wherein the first abrasive region comprises
a ratio (C3:C2) of the third content (C3) to the second content
(C2) of at least 1.1:1 or at least 1.2:1 or at least 1.3:1 or at
least 1.4:1 or at least 1.5:1 or at least 1.6:1 or at least 1.7:1
or at least 1.8:1 or at least 1.9:1 or at least 2:1.
[0140] Item 62. The abrasive tool of any of the items herein,
wherein the abrasive region comprises a ratio (C3:C2) of the third
content (C3) to the second content (C2) of not greater than 100:1
or not greater than 90:1 or not greater than 80:1 or not greater
than 70:1 or not greater than 60:1 or not greater than 60:1 or not
greater than 50:1 or not greater than 40:1 or not greater than 30:1
or not greater than 20:1 or not greater than 10:1 or not greater
than 5:1 or not greater than 3:1 or not greater than 2.5:1.
[0141] Item 63. The abrasive tool of any of the items herein,
wherein the abrasive particles include a material selected from the
group consisting of oxides, nitrides, carbides, carbon-based
materials, borides, oxynitrides, oxycarbides, oxyborides, naturally
occurring minerals, agglomerated particles, non-agglomerated
particles, and a combination thereof, and wherein the abrasive
particles comprise shaped abrasive particles, wherein the abrasive
particles comprise alumina.
[0142] Item 64. The abrasive tool of any of the items herein,
wherein the abrasive particles comprise a blend of different types
of abrasive particles, a first type including alumina and a second
type including silicon carbide.
[0143] Item 65. The abrasive tool of any of the items herein,
wherein the body comprises a first abrasive region including
abrasive particles contained within the three-dimensional matrix of
bond material, wherein the first abrasive region includes a content
of abrasive particles within a range including at least 30 wt % and
not greater than 90 wt % for a total weight of the first abrasive
region.
[0144] Item 66. The abrasive tool of any of the items herein,
wherein the body comprises at least one reinforcing member
extending radially through at least a portion of the body, wherein
the at least one reinforcing layer comprises a material selected
from the group consisting of 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, and a combination thereof.
[0145] Item 67. The abrasive tool of any of the items herein,
wherein the body includes a first reinforcing member extending
radially through at least a portion of the body at a first axial
position and a second reinforcing member extending radially through
at least a portion of the body at a second axial position different
than the first axial position.
[0146] Item 68. The abrasive tool of any of the items herein,
wherein the body comprises a diameter (D) extending radially across
the body and a thickness (t) extending axially across the body,
wherein the body comprises a ratio of diameter: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.
[0147] Item 69. The abrasive tool of any of the items herein,
wherein the three-dimensional matrix of bond material includes an
organic material selected from the group consisting of a resin, an
epoxy, a polymer, and a combination thereof, wherein the bond
material comprises a phenolic resin.
[0148] Item 70. The abrasive tool of any of the items herein,
wherein the body comprises a first abrasive region including
abrasive particles contained within the three-dimensional matrix of
bond material, wherein the first abrasive region includes a content
of the three-dimensional matrix of bond material within a range
including at least 1 wt % and not greater than 40 wt % for a total
weight of the first abrasive region.
[0149] Item 71. The abrasive tool of any of the items herein,
wherein the body comprises a first abrasive region and a second
abrasive region distinct from the first abrasive region, wherein
the first abrasive region and the second abrasive region comprise
at least one of: [0150] a. a first content of abrasive particles in
the first abrasive region different than a second content of
abrasive particles in the second abrasive region; [0151] b. a first
type of abrasive particles in the first abrasive region different
than a second type of abrasive particles in the second abrasive
region; [0152] c. a first content of the first filler in the first
abrasive region different than a first content of the first filler
in the second abrasive region; [0153] d. a first filler composition
in the first abrasive region different than a second filler
composition in the second abrasive region; [0154] e. a first
content of bond material in the first abrasive region different
than a second content of bond material in the second abrasive
region; [0155] f. a first type of bond material in the first
abrasive region different than a second type of bond material in
the second abrasive region; [0156] g. a second content of a second
filler in the first abrasive region different than a second content
of the second filler in the second abrasive region; [0157] h. a
third content of a third filler in the first abrasive region
different than a third content of the third filler in the second
abrasive region;
[0158] Item 72. The abrasive tool of any of the items herein,
wherein the first abrasive region and second abrasive region are
layers that are axially spaced apart from each other within the
body.
[0159] Item 73. The abrasive tool of any of the items herein,
wherein the first abrasive region and second abrasive region define
distinct annular regions within the body that are radially spaced
apart from each other within the body.
[0160] Item 74. The abrasive tool of any of the items herein,
wherein the body comprises a thickness not greater than 10 mm or
not greater than 9.5 mm or not greater than 9 mm or not greater
than 8.5 mm or not greater than 8 mm or not greater than 7.5 mm or
not greater than 7 mm or not greater than 6.5 mm or not greater
than 6 mm or not greater than 5.5. mm or not greater than 5 mm or
not greater than 4.5 mm or not greater than 4 mm, and wherein the
body comprises a thickness of at least 0.3 mm or at least 0.5 mm or
at least 0.8 mm or at least 1 mm.
[0161] Item 75. The abrasive tool of any of the items herein,
wherein the first filler comprises a coating overlying at least a
portion of the surface of the first filler, wherein the coating is
selected from the group consisting of an inorganic material, an
organic material, a resin, an epoxy, and a combination thereof.
[0162] Item 76. The abrasive tool of any of the items herein,
wherein the coating comprises silane.
[0163] Item 77. The abrasive tool of any of the items herein,
wherein the first filler is a particle having an aspect ratio of
length:width greater than 5:1.
[0164] Item 78. The abrasive tool of any of the items herein,
wherein the first filler is a particle having an aspect ratio of
length:width less than 15:1.
[0165] Item 79. The abrasive tool of any of the items herein,
wherein the first filler is a particle having an aspect ratio
within a range of greater than 5:1 to less than 15:1.
[0166] Item 80. The abrasive tool of any of the items herein,
wherein the first filler is a particle having an aspect ratio
within a range of at least 7:1 to 10:1.
[0167] Item 81. The abrasive tool of any of the items herein,
wherein the first filler is present in a first content within a
range including at least 0.2 wt % and not greater than 20 wt % for
a total weight of the first abrasive region.
[0168] Item 82. The abrasive tool of any of the items herein,
wherein the first filler is present in the first content within a
range including at least 2 wt % and not greater than 12 wt % for a
total weight of the first abrasive region.
[0169] Item 83. The abrasive tool of any of the items herein,
wherein the first filler is present in the first content within a
range including at least 2.8 wt % and not greater than 8 wt % for a
total weight of the first abrasive region.
[0170] Item 84. The abrasive tool of any of the items herein,
wherein the second content of the second filler is within a range
including 1 wt % and not greater than 4 wt % for a total weight of
the first abrasive region.
[0171] Item 85. The abrasive tool of any of the items herein,
wherein the abrasive region comprises a ratio (C1:C2) of the first
content (C1) to the second content (C2) of at least 1.5:1 and not
greater than 3.5:1.
[0172] Item 86. The abrasive tool of any of the items herein,
wherein the third filler is present in the third content within a
range including at least 2.6 wt % and not greater than 4 wt %.
[0173] Item 87. The abrasive tool of any of the items herein,
wherein the abrasive region comprises a ratio (C1:C3) of the first
content (C1) to the third content (C3) in a range including at
least 1.1:1 and not greater than 2.5:1.
EXAMPLE 1
[0174] A representative sample (S1) of an abrasive tool having a
depressed center shape with an outer diameter of 230 mm, an inner
diameter of approximately 22 mm, and an average thickness of
approximately 6.5-7.5 mm was made using the following procedure. A
mixture including the components provided in Table 1 was created
and provided in a mold. Sample S1 was created to have the
construction of a first reinforcing member of fiberglass
(approximately 260 gsm), a first layer of the mixture overlying the
first reinforcing member, a second reinforcing member of fiberglass
(approximately 320 gsm) overlying the first layer, a second layer
of the abrasive mixture overlying the second reinforcing member,
and a third reinforcing member overlying the second layer. The
sample (S1) was cold pressed including application of a pressure
within a range of 90-160 bars at approximately room temperature.
Then, the sample was cured in an oven at approximately
170-200.degree. C. for at least 8 hours.
TABLE-US-00001 TABLE 1 Sample S1 Weight % INGREDIENT in mix Brown
fused alumina 33.578 (approximate average particle size of 1190
microns) SiC (approximate 40.932 average particle size of 1035
microns) Resole 3.954 Novolac 10.690 Cryolite 3.565 Potassium
sulfate 2.403 Wollastonite 4.411 Castor Oil 0.199 Titania 0.269
EXAMPLE 2
[0175] Mixtures having a conventional composition W1 and
compositions representative of embodiments herein, W2 and W3, were
used to form abrasive tool samples in the same manner as described
for Sample 51 in Example 1. The compositions are disclosed in Table
2 below. W1 did not include wollastonite, the mixture W2 included
wollastonite, but had reduced contents of bond material, resole and
novolac, as compared to W1. W3 included wollastonite, had similar
contents of resin, but decreased contents of cryolite and potassium
sulfate, as compared to W1. All of the ingredients added up to 100
wt % for each composition. Three samples for each composition were
tested utilizing Bosch 9-inch Angle grinder on Grey Cast Iron
plates having thickness of 15 mm. Grinding was performed at an
angle of 30 to 45 degrees with 2.4 kW rated power (corresponding to
an average of 4 to 6 kg normal force) and controlled current within
8 to 9 Amps. Average G-Ratio and MRR (material removal rate) for
each of W2 and W3 compositions was used to compare to the average
G-Ratio and MRR of W1, respectively. The relative G-Ratio and MRR
of W1 is 1.00, respectively, and the relative G-Ratio and MRR of W2
and W3 samples are included in FIG. 5. MRR of W2 and W3 was similar
to that of W1. However, W2 demonstrated reduced G-Ratio with
relative G-Ratio of 0.59, while W3 demonstrated increased G-Ratio
with relative G-ratio of 1.36.
TABLE-US-00002 TABLE 2 W1 W2 W3 Weight Weight Weight Ingredient %
in mix % in mix % in mix Brown fused 33.639 32.821 33.578 alumina
SiC 41.006 40.008 40.932 Resole 3.961 3.729 3.954 Novolac 10.710
8.701 10.690 Cryolite 5.803 5.662 3.565 Potassium sulfate 4.413
4.305 2.403 Wollastonite 0.000 4.311 4.411 Castor oil 0.199 0.199
0.199 Titania 0.269 0.263 0.269
EXAMPLE 3
[0176] Mixtures having compositions W6, W9, W11, W 12, and W13, as
disclosed in Table 3 below, were used to form additional
representative abrasive tool samples. Samples of W1 were also
formed. W6, W9, W11, W 12, and W13 included Wollastonite having
aspect ratios of 7:1, 4:1, 5:1, 10:1, and 15:1, respectively. FIGS.
6A to 6C include images of wollastonite having aspect ratios of
4:1, 7:1, and 10:1, respectively.
TABLE-US-00003 TABLE 3 W6 W9 W11 W12 W13 Weight Weight Weight
Weight Weight Ingredient % in mix % in mix % in mix % in mix % in
mix Brown fused 33.566 33.566 33.566 33.566 33.566 alumina SiC
40.917 40.917 40.917 40.917 40.917 Resole 3.952 3.952 3.952 3.952
3.952 Novolac 10.686 10.686 10.686 10.686 10.686 Cryolite 3.118
3.118 3.118 3.118 3.118 Potassium 2.001 2.001 2.001 2.001 2.001
sulfate Wollastonite 5.291 5.291 5.291 5.291 5.291 Castor oil 0.199
0.199 0.199 0.199 0.199 Titania 0.269 0.269 0.269 0.269 0.269
[0177] Three samples for each of the compositions were formed, and
all of the samples were tested utilizing Bosch 9-inch Angle grinder
on Grey Cast Iron plates having thickness of 15 mm. Grinding was
performed at an angle of 30 to 45 degrees with 2.4 kW rated power
(corresponding to an average of 4 to 6 kg normal force) and
controlled current within 8 to 9 Amps. Average G-Ratio and MRR
(material removal rate) for each of compositions W6, W9, W11, W 12,
and W13 was compared to the corresponding average of W1 samples.
Relative G-Ratio and MRR of W1 is 1.00, respectively. Relative
performance of G-Ratio and MRR of samples of W6 and W9 is included
in FIG. 7, and FIG. 8 includes relative performance for samples W11
to W13. Samples of W1, W6, and W9 demonstrated similar MRR. Samples
of W9 had G-Ratio that was comparable to W1, while W6 demonstrated
improved G-Ratio over W1 and W9. As disclosed in FIG. 7, the
relative G-Ratio of W6 is 1.6, while the relative G-Ratio of W9 is
1.2. As disclosed in FIG. 8, MRR of samples of W1 and W11 to W13
were comparable, but G-ratio of W12 was improved over W1, W11, and
W13. Samples of W11 and W13 demonstrated similar G-ratio as
compared to W1. The relative G-ratio for W11 to W13 is 1.0, 1.5,
and 1.0, respectively.
[0178] 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.
[0179] 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.
[0180] 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. Certain features, that are for clarity, described herein in
the context of separate embodiments, may also be provided in
combination in a single embodiment. Conversely, various features
that are, for brevity, described in the context of a single
embodiment, may also be provided separately or in a sub
combination. Further, reference to values stated in ranges includes
each and every value within that range. Many other embodiments may
be apparent to skilled artisans only after reading this
specification. Other embodiments may be used and derived from the
disclosure, such that a structural substitution, logical
substitution, or another change may be made without departing from
the scope of the disclosure. Accordingly, the disclosure is to be
regarded as illustrative rather than restrictive.
[0181] The description in combination with the figures is provided
to assist in understanding the teachings disclosed herein, is
provided to assist in describing the teachings, and should not be
interpreted as a limitation on the scope or applicability of the
teachings. However, other teachings can certainly be used in this
application.
[0182] As used herein, the terms "comprises," "comprising,"
"includes," "including," "has," "having" or any other variation
thereof, are intended to cover a non-exclusive inclusion. For
example, a method, article, or apparatus that comprises a list of
features is not necessarily limited only to those features but may
include other features not expressly listed or inherent to such
method, article, or apparatus. Further, unless expressly stated to
the contrary, "or" refers to an inclusive-or and not to an
exclusive-or. For example, a condition A or B is satisfied by any
one of the following: A is true (or present) and B is false (or not
present), A is false (or not present) and B is true (or present),
and both A and B are true (or present).
[0183] Also, the use of "a" or "an" is employed to describe
elements and components described herein. This is done merely for
convenience and to give a general sense of the scope of the
invention. This description should be read to include one or at
least one and the singular also includes the plural, or vice versa,
unless it is clear that it is meant otherwise. For example, when a
single item is described herein, more than one item may be used in
place of a single item. Similarly, where more than one item is
described herein, a single item may be substituted for that more
than one item.
[0184] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
materials, methods, and examples are illustrative only and not
intended to be limiting. To the extent that certain details
regarding specific materials and processing acts are not described,
such details may include conventional approaches, which may be
found in reference books and other sources within the manufacturing
arts.
* * * * *