U.S. patent application number 16/203328 was filed with the patent office on 2019-03-28 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 Lawrence J. Lavallee, JR., Michael K. Montgomery, Nan Y. Pacella, Katherine M. Sahlin.
Application Number | 20190091834 16/203328 |
Document ID | / |
Family ID | 56163172 |
Filed Date | 2019-03-28 |
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United States Patent
Application |
20190091834 |
Kind Code |
A1 |
Pacella; Nan Y. ; et
al. |
March 28, 2019 |
ABRASIVE TOOLS AND METHODS FOR FORMING SAME
Abstract
An abrasive tool can include a bonded abrasive including a body
and a barrier layer bonded to a major surface of the body. The body
can include abrasive particles contained within a bond material.
The barrier material can include a metal-containing film. In an
embodiment, the barrier layer may further include a
polymer-containing film. In another embodiment, the barrier layer
may include a biaxially oriented material. The abrasive tool may be
formed such that the barrier layer is formed in-situ with the
formation of the bonded abrasive.
Inventors: |
Pacella; Nan Y.; (San Jose,
CA) ; Lavallee, JR.; Lawrence J.; (Auburn, MA)
; Montgomery; Michael K.; (Marlborough, MA) ;
Sahlin; Katherine M.; (Old Orchard Beach, ME) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAINT-GOBAIN ABRASIVES, INC.
SAINT-GOBAIN ABRASIFS |
Worcester
Conflans-Sainte-Honorine |
MA |
US
FR |
|
|
Family ID: |
56163172 |
Appl. No.: |
16/203328 |
Filed: |
November 28, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15810410 |
Nov 13, 2017 |
10189146 |
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16203328 |
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14985041 |
Dec 30, 2015 |
9844853 |
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15810410 |
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62097783 |
Dec 30, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B24D 7/02 20130101; B24D
3/001 20130101; B24D 18/00 20130101; B24D 3/005 20130101; B24D 5/02
20130101; B24D 18/0009 20130101; B24D 5/12 20130101 |
International
Class: |
B24D 18/00 20060101
B24D018/00; B24D 7/02 20060101 B24D007/02; B24D 3/00 20060101
B24D003/00; B24D 5/02 20060101 B24D005/02; B24D 5/12 20060101
B24D005/12 |
Claims
1. An abrasive tool comprising: a bonded abrasive including a body
comprising abrasive particles contained within a bond material,
wherein the body comprises a first major surface and a second major
surface opposite the first major surface, and a peripheral surface
extending between the first major surface and the second major
surface; and a barrier layer directly bonded to the first major
surface and second major surface of the body, wherein the barrier
layer comprises a metal; and wherein the barrier layer does not
extend over the peripheral surface.
2. The abrasive tool of claim 1, wherein the barrier layer further
comprises a polymer.
3. The abrasive tool of claim 2, wherein the polymer is selected
from the group consisting of polyamides, polyesters, polyethlyenes,
polypropylene, polyvinyls, epoxies, resins, polyurethanes, rubbers,
polyimides, phenolics, polybenzimidazole, aromatic polyamide, and a
combination thereof.
4. The abrasive tool of claim 2, wherein the polymer comprises a
biaxially-oriented polymer.
5. The abrasive tool of claim 1, wherein the barrier layer
comprises a foil including the metal.
6. The abrasive tool of claim 1, wherein the barrier layer
comprises a metal-containing film including the metal.
7. The abrasive tool of claim 1, wherein the barrier layer
comprises a plurality of films, wherein an innermost layer of the
barrier layer comprises a polymer and is directly bonded to the
first and second major surfaces of the body.
8. The abrasive tool of claim 1, wherein the barrier layer
comprises a film including the metal, a first polymer-containing
film, and a second polymer-containing film, wherein the film
including the metal is disposed between the first and second
polymer-containing films.
9. The abrasive tool of claim 8, wherein the first
polymer-containing film comprises a first polymer, and the second
polymer-containing film comprises a second polymer different from
the first polymer.
10. The abrasive tool of claim 9, wherein the first polymer
comprises polyester, polypropylene, polyamide, nylon, or a
combination thereof.
11. The abrasive tool of claim 9, wherein the first polymer
comprises a biaxially-orientated polymer.
12. The abrasive tool of claim 11, wherein the first
polymer-containing film is an outermost layer of the barrier
layer.
13. The abrasive tool of claim 12, wherein the first polymer
comprises a biaxially-orientated nylon, biaxially-oriented
polyethylene terephthalate, biaxially-oriented polypropylene, or
any combination thereof.
14. The abrasive tool of claim 9, wherein the second polymer
comprises polyethylene.
15. The abrasive tool of claim 1, wherein the barrier layer is
co-cured with the first and second major surfaces.
16. An abrasive tool comprising: a bonded abrasive including a body
comprising abrasive particles contained within a bond material,
wherein the body comprises a first major surface and a second major
surface opposite the first major surface, and a peripheral surface
extending between the first major surface and the second major
surface; and a barrier layer directly bonded to at least the first
major surface and the second major surface of the body, wherein the
barrier layer does not extend over the peripheral surface; and
wherein the barrier layer comprises a plurality of layers including
a polymer-containing film overlying a foil and an innermost layer
comprising a polymer.
17. The abrasive tool of claim 16, wherein the barrier layer
further comprises another polymer-containing film, wherein the foil
is disposed between the polymer-containing films.
18. The abrasive tool of claim 16, wherein the polymer-containing
film is an outermost layer of the barrier layer and comprises a
biaxially-oriented polymer.
19. The abrasive tool of claim 18, wherein the biaxially-oriented
polymer comprises biaxially-oriented nylon, biaxially-oriented
polyethylene terephthalate, biaxially-oriented polypropylene, or
any combination thereof.
20. The abrasive tool of claim 16, wherein the innermost layer
comprises polyethylene.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation of and claims priority to
U.S. patent application Ser. No. 15/810,410, entitled "ABRASIVE
TOOLS AND METHODS FOR FORMING SAME," by Nan Y. PACELLA et al.,
filed Nov. 13, 2017, which is a continuation of and claims priority
to U.S. patent application Ser. No. 14/985,041, entitled "ABRASIVE
TOOLS AND METHODS FOR FORMING SAME," by Nan Y. PACELLA et al.,
filed Dec. 30, 2015, which claims priority under 35 U.S.C. .sctn.
119(e) to U.S. Patent Application No. 62/097,783, entitled
"ABRASIVE TOOLS AND METHODS FOR FORMING SAME," by Nan Y. PACELLA et
al., filed Dec. 30, 2014, all of which are assigned to the current
assignee hereof and incorporated herein by reference in their
entireties.
BACKGROUND OF THE INVENTION
Field of the Disclosure
[0002] The present invention relates in general to abrasive tools
and, in particular, to a bonded abrasive including a barrier
layer.
Description of the Related Art
[0003] 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. Some
resin-based bond matrix materials may be susceptible to water
absorption, which may degrade the performance of the abrasive
article. A need for improved abrasive articles continues to
exist.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Embodiments are illustrated by way of example and are not
limited in the accompanying figures.
[0005] FIG. 1 includes a cross-sectional view of an abrasive tool,
such as a bonded abrasive wheel bonded abrasive, in accordance with
an embodiment described herein.
[0006] FIG. 2A includes a cross-sectional view of a portion of an
abrasive tool including an abrasive layer and a barrier layer in
accordance with an embodiment.
[0007] FIG. 2B includes a cross-sectional view of a portion of an
abrasive tool including an abrasive layer and a barrier layer in
accordance with an embodiment.
[0008] FIG. 2C includes a cross-sectional view of a portion of an
abrasive tool including an abrasive layer and a barrier layer in
accordance with an embodiment.
[0009] FIG. 3A includes a cross-sectional view of a portion of an
abrasive tool including a barrier layer overlying an abrasive layer
in accordance with an embodiment.
[0010] FIG. 3B includes a cross-sectional view of a portion of an
abrasive tool including a barrier layer overlying an abrasive layer
in accordance with an embodiment.
[0011] FIG. 3C includes a cross-sectional view of a portion of an
abrasive tool including a barrier layer overlying an abrasive layer
in accordance with an embodiment.
[0012] FIG. 4A includes a cross-sectional view of a portion of a
barrier layer including a metal-containing film and a polymer
containing film in accordance with an embodiment.
[0013] FIG. 4B includes a cross-sectional view of a portion of a
barrier layer including more than one polymer-containing films and
a polymer-containing film in accordance with an embodiment.
[0014] FIG. 4C includes a cross-sectional view of a portion of a
barrier layer including more than one polymer-containing films and
a polymer-containing film in accordance with an embodiment.
[0015] FIG. 5 includes a plot of moisture uptake of bonded abrasive
wheel samples over a period of time.
[0016] FIG. 6 includes a plot of G-ratios of bonded abrasive wheel
samples.
[0017] FIG. 7 includes a plot of moisture uptake of bonded abrasive
wheel samples over a period of time.
[0018] FIG. 8 includes a plot of G-ratios of bonded abrasive wheel
samples.
[0019] 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
[0020] The following description in combination with the figures is
provided to assist in understanding the teachings disclosed herein.
The following discussion will focus on specific implementations and
embodiments of the teachings. This focus is provided to assist in
describing the teachings and should not be interpreted as a
limitation on the scope or applicability of the teachings. However,
other teachings can certainly be used in this application.
[0021] 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).
[0022] 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.
[0023] 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.
[0024] Embodiments disclosed herein are related to abrasive tools
including a bonded abrasive and a barrier layer. 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. The barrier layer may
facilitate reduced absorption of certain materials, including water
and/or water vapor during storage, shipment, and/or use to reduce
aging of the bond matrix material. The barrier layer may facilitate
improved life and performance of the abrasive article by reducing
the absorption of certain species of materials, such as water
vapor, which may reduce degradation of the bond matrix
material.
[0025] Some other embodiments are directed to a method of forming
the abrasive tool in which the barrier layer is formed in-situ with
the formation of the bonded abrasive. As used herein, in-situ is
intended to mean during the formation of the bonded abrasive.
Particularly, when an organic material is used to form the bond
material of the bonded abrasive, in-situ means during the curing of
the organic material.
[0026] The abrasive tool disclosed herein includes the bonded
abrasive. In specific implementations, the bonded abrasive can
include any suitable type of abrasive wheel as known in the art,
including thin disc shaped abrasive articles. For example, the
bonded abrasive wheel 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 bonded abrasive tool can
include Type 41 or Type 1 wheels, 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.
[0027] Shown in FIG. 1A, for instance, is a cross-sectional view of
depressed center of a bonded abrasive 10, which can include a body
including a rear (top) face 12 and a front (bottom) face 14. The
rear face 12 can 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 (which provides the
working surface of the wheel). 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 bonded
abrasive 10 can have central opening 32 for mounting the bonded
abrasive 10 on the rotating spindle of a tool, e.g., a hand-held
angle grinder. During operation, the bonded abrasive 10 can be
secured by mounting hardware (not shown in FIG. 1A) such as, for
instance, a suitable flange system. The bonded abrasive 10 can also
be part of an integrated arrangement that includes mounting
hardware.
[0028] The body of the bonded abrasive 10 can have a thickness "t"
that can be measured at various positions, including at the
periphery of the bonded abrasive body. The thickness of the body of
the bonded abrasive 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 bonded abrasive 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. For example, the body of the bonded abrasive 10 can
have a thickness "t" of at least 0.8 mm, such as, at least 0.9 mm,
at least 1 mm, at least 1.2 mm, at least 1.3 mm, at least 1.5 mm,
at least 1.8 mm, at least 2 mm, at least 2.2 mm, at least 2.5 mm,
at least 2.8 mm, at least 3 mm, at least 3.2 mm, at least 3.5 mm,
at least 3.8 mm, at least 4 mm, at least 4.2 mm, at least 4.5 mm,
at least 4.8 mm, or even at least 5 mm. In another non-limiting
embodiment, the thickness "t" of the body of the bonded abrasive 10
can be not greater than 20 mm, such as not greater than 18 mm, not
greater than 16 mm, not greater than 15 mm, not greater than 12 mm,
not greater than 10 mm, not greater than 9 mm, not greater than 8
mm, not greater than 7 mm, not greater than 6 mm, not greater than
5.8 mm, not greater than 5.5 mm, not greater than 5.2 mm, not
greater than 5 mm, not greater than 4.5 mm, not greater than 4 mm,
not greater than 3.5 mm, or even not greater than 3 mm. It will be
appreciated that the body of the bonded abrasive 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 0.8 mm to 20 mm, such as a range of 0.8 mm to 15 mm, or
even a range of 0.8 mm to 10 mm.
[0029] In certain alternative embodiments, the body of the bonded
abrasive may utilize a patterned working surface, wherein the
working surface is a major surface (e.g., a front (bottom) face 14)
of the abrasive tool intended to contact the workpiece and conduct
the material removal operation. Shown in FIG. 1B, for instance, is
a front view of a wheel 150, having mounting hole 155, center
region 151, and working surface 153, which can be patterned to have
an array of protrusions 157 that are separated by recesses (or
channels) 159. It will be appreciated that any arrangement,
distribution, or pattern may be utilized with any of the
embodiments herein.
[0030] In an alternative embodiment, the bonded abrasive can have a
working surface that is essentially free of patterned features.
FIG. 1C, for instance, shows a front view of a body of a bonded
abrasive 100, having center region 101, a mounting hole 105, and
working surface 103, which is substantially smooth (i.e., not
patterned). In other words, the working surface 103 does not have
protrusions or channels (recesses).
[0031] Furthermore, it will be appreciated that certain bonded
abrasives, which are in the form of bonded abrasive wheels having a
bonded abrasive body, can be used as cutting tools, wherein the
peripheral surface of the body is used for abrasive material
removal operations. In such instances, the major surfaces of the
body, such as the working surfaces 153 and 103 of FIGS. 1B and 1C,
respectively, are not necessarily used to conduct the material
removal operations. Instead, the outer peripheral surface (e.g.,
peripheral surface 161 of FIG. 1B or peripheral surface 107 of FIG.
1C) of the body can be configured to contact a surface of the
workpiece and conduct the material removal operations. Such
abrasive tools may be cut-off thin wheels and the like.
[0032] Further, the body of the bonded abrasive of the embodiments
herein can include a diameter, which defines the length of
extending between two points on the perimeter and through the
center of the circular body as viewed top down. In a non-limiting
embodiment, the diameter can be at least 50 mm, such as at least 55
mm, at least 60 mm, at least 65 mm, at least 70 mm, or even at
least 75 mm. In another non-limiting embodiment, the diameter may
be not greater than 400 mm, such as, not greater than 350 mm, not
greater than 300 mm, not greater than 275 mm, not greater than 230
mm, not greater than 200 mm, or even not greater than 150 mm. It
will be appreciated that the diameter 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 of 50 mm to 400 mm,
such as within a range of 50 mm to 230 mm, 75 mm to 230 mm, or even
within a range of 75 mm to 150 mm.
[0033] The body of the bonded abrasive 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, at least 15:1, at least 20:1, at
least 35:1, at least 50:1, at least 75:1, at least 100:1, or even
at least 125:1. In other instances, the body of the bonded abrasive
can have an aspect ratio (diameter:thickness) of not greater than
125:1, not greater than 100:1, not greater than 75:1, not greater
than 50:1, not greater than 35:1, not greater than 25:1, not
greater than 20:1, or not greater than 15:1. The ratio can be
within a range including any of the above minimum and maximum
values, such as within a range of 125:1 to 15:1, such as 100:1 to
30:1. However, the invention can be practiced with wheels having
different dimensions and different ratios between dimensions. For
example, the thin-wheel abrasive article also can have a desirable
aspect ratio within a range of 5 to 160, such as within a range of
15 to 160, within a range of 15 to 150, or even within a range of
20 to 125.
[0034] The bonded abrasive of the embodiments herein can have
certain constructions. It will be appreciated that the body of the
embodiments herein may be monolithic articles formed of a single
layer having a single construction, having a substantially uniform
grade and structure throughout the volume of the body of the bonded
abrasive. Alternatively, the body of the embodiments herein can be
composite bodies having one or more layers, wherein at least two of
the layers 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, filler materials,
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.
[0035] Abrasive Particles
[0036] Bonded abrasives such as bonded abrasive wheels with or
without a reinforcing layer, including depressed center wheels, can
be prepared by including one or more types of abrasive particles or
grains, a bond material (e.g., an organic material (resin) or an
inorganic material), and in many cases other ingredients, such as,
for instance, active or inactive fillers, processing aids,
lubricants, crosslinking agents, antistatic agents and so
forth.
[0037] Abrasive particles can include inorganic materials, organic
materials, naturally occurring materials (e.g., minerals),
superabrasive materials, synthesized materials (e.g.,
polycrystalline diamond compacts) and a combination thereof. Some
suitable exemplary abrasive particles can include oxides, carbides,
carbon-based materials, nitrides, borides, oxycarbides,
oxynitrides, oxyborides, and a combination thereof. A particular
example 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 which can be employed in the present
invention include white alundum grain, from Saint-Gobain Ceramics
& Plastics, Inc. or pink alundum, from Treibacher
Schleifmittel, AG, mono-crystal alumina, coated or non-coated brown
fused alumina, heat-treated alumina, silicon carbide, and a
combination thereof.
[0038] 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 for use in the
bonded abrasive can include silica, alumina (fused or sintered),
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.
[0039] The abrasive particles also can include various shapes,
structures, and/or configurations. For example, the abrasive
particle can be a shaped abrasive particle. 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. 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.
[0040] The shaped abrasive particles can be in the form of any
alphanumeric character, e.g., 1, 2, 3, etc., A, B, C. etc. Further,
the shaped abrasive particles can be in the form of a symbol,
trademark, a character selected from the Greek alphabet, the modern
Latin alphabet, the ancient Latin alphabet, the Russian alphabet,
any other alphabet (e.g., Kanji characters), and any combination
thereof.
[0041] 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.
[0042] 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, at least 20 microns, 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, not
greater than 800 microns, not greater than 600 microns, not greater
than 500 microns, not greater than 400 microns, not greater than
300 microns, not greater than 280 microns, not greater than 250
microns, 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.
[0043] Bond Material
[0044] The abrasive tool of the present invention, as well as the
methods of making and using the abrasive tool, can include various
bond materials and precursor bond materials. In specific
implementations of the present invention, at least one of the bond
material and the precursor bond material is an organic material,
also referred to as 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.
[0045] 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.
[0046] The bond material can contain more than one phenolic resin,
including for example, at least one resole and at least
novolac-type phenolic resin. In many cases, 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.
[0047] 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.
[0048] 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.
[0049] 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.
[0050] 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.
[0051] Reinforcing Layer
[0052] According to one embodiment, the bonded abrasive can be
reinforced with one or more, (e.g., two or three) reinforcing
layers, which may be in the form of layers, partial layers,
discrete bundles of material distributed throughout the bond
material, and a combination thereof. As used herein, the term
"reinforcing layer" 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 layer does
not include abrasive particles. With respect to the thickness of
the bonded abrasive, a reinforcing layer can be embedded within the
body of the bonded abrasive and such bonded abrasives may be
referred to as "internally" reinforced. A reinforcing layer also
can be close to, or attached to the front and/or back face of the
body of the bonded abrasive. Several reinforcing layers can be
disposed at various depths through the thickness of the bonded
abrasive.
[0053] Certain reinforcing layers may have a circular geometry. The
outer periphery of the reinforcing layer 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 layer 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 layers can be
employed and in such cases, the reinforcing layer 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 layer can extend for at least 60%, at least 70%, at
least 75%, at least 80%, at least 85%, at least 90%, 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 layer may extend for not greater than 100%, such as not
greater than 99%, not greater than 97%, not greater than 95%, not
greater than 90%, not greater than 85%, not greater than 80%, 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 layer can
extend within a range including any of the minimum and maximum
values noted above. For instance, the partial reinforcing layer 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
[0054] The reinforcing layer can include various materials,
including a single material or more than one type of material, such
as a composite material. Moreover, a bonded abrasive of the
embodiments herein can use a single type of reinforcing layer or
may use different types of reinforcing layers, which can employ
different materials with respect to each other. Some suitable
reinforcing layer materials can include woven materials or
non-woven materials. In at least one embodiment, the reinforcing
layer can include a glass material, including but not limited to a
fiberglass material. In yet other embodiments, the reinforcing
layer 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 layer 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 layer is 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 layer 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 layers also can allow for shear at the interface
between the reinforcing layer 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 layer can consist essentially of any of the
foregoing materials or consists essentially of two or more of the
foregoing materials noted above.
[0055] In specific examples, the body of the bonded abrasive can
include at least one or more fiberglass reinforcing layers,
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).
[0056] 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 mounting hole of the wheel and the same
diameter as the wheel. Partial web reinforcing layers 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.
[0057] The reinforcing layer can be characterized by one or more of
the following physical parameters: weight (g/m.sup.2), thickness
(mm), openings per cm and tensile strength (MPa), which can be
further delineated with respect to the tensile strength of the warp
(the long web components that run continuously for the length of
the roll) and the tensile strength of the fill (the short
components that run crosswise to the roll direction). In certain
instances, one or more of the fiberglass webs employed has a
minimum tensile strength of at least 200 MPa. Other factors include
filament diameter, amount of coating, for instance, the coverage of
the web with coating and others, as known in the art.
[0058] Chemical parameters can relate to the chemistry of the
coating provided on the fiberglass web. Generally, there are two
types of chemical "coatings." A first coating, referred to as
"sizing," can be applied to the glass fiber strands immediately
after they exit the bushing and include ingredients such as film
formers, lubricants, silanes, which for example, can be dispersed
in water. The sizing can provide protection of the filaments from
processing-related degradation (such as abrasion). It can also
provide abrasion protection during secondary processing such as
weaving into a web. Strategic manipulation of properties associated
with the first coating (sizing) can affect the compatibility of the
glass fibers with the second coating, which, in turn, can affect
compatibility of the coating with the resin bond. The second
coating can be applied to the glass web and traditionally includes
wax, used primarily to prevent "blocking" of the webs during
shipping and storage. In many cases, the second coating can be
compatible with both the sizing (first coating) and the matrix
resin for which the reinforcement is intended.
[0059] Bonded abrasives such as bonded abrasive wheel tools with or
without one or more reinforcing layers can be prepared by combining
abrasive grains or 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.
[0060] The various ingredients can be added in any suitable order
and blended using known techniques and equipment such as, for
instance, Eirich mixers, e.g., Model RV02, Littleford, bowl-type
mixers and others. 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 bonded abrasive. 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, including for example, a bonded
abrasive wheel (cold, warm or hot molding).
[0061] One or more reinforcing layers can be incorporated in the
green body. For example, a first portion of a mixture containing
one or more types of abrasive grains or particles and a bond
material can be placed and distributed at the bottom of an
appropriate mold cavity and then covered with a first reinforcing
layer. A second portion of the bond/abrasive mixture can then be
disposed and distributed over the first reinforcing layer.
Additional reinforcing layers 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.
[0062] In some arrangements, the layers containing one or more
types of abrasive particles and bond material (also referred herein
as "abrasive layers") can differ from one another with respect to
one or more characteristics such as, for instance, 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.
[0063] To form the bonded abrasive, such as a bonded abrasive
wheel, a first abrasive layer, a.sub.1 (containing abrasive
particles and bond material), is laid in the mold. A first
reinforcing layer V.sub.1 is disposed on the first abrasive layer
a.sub.1, followed by a second abrasive layer, a.sub.2, which can be
the same or different from the first abrasive layer, a.sub.1. A
second reinforcing layer, V.sub.2 (which can be the same or
different from V.sub.1), can be disposed over the second abrasive
layer, a.sub.2. If desired, a third abrasive layer, a.sub.3, that
includes abrasive particles and bond material can be used to cover
the second reinforcing layer, V.sub.2. The third abrasive layer
a.sub.3 can be the same or different with respect to one or more of
the abrasive layers a.sub.1 and/or a.sub.2. Additional reinforcing
layers and abrasive layers can be added, essentially as described,
to obtain the desired number of abrasive layers and reinforcing
layers. In another approach, a first reinforcing layer V.sub.1 is
placed at the bottom of the mold and covered by a first abrasive
layer a.sub.1, with additional abrasive layers and reinforcing
layers being disposed as described above. Arrangements in which
adjacent abrasive layers a.sub.n and a.sub.n+1 are not separated by
a reinforcing layer also are possible, as are those in which two or
more reinforcing layers, e.g., V.sub.n and V.sub.n+1, are not
separated by an abrasive layer. Labels made of paper or polymer may
also be affixed to major faces of the wheel. These labels may be
used to identify the wheels. They may be affixed to the wheel
during the abrasive wheel formation process or applied after
curing.
[0064] The individual thickness of the mix layers can be
substantially the same. In certain instances, the thickness of the
mix layers can be different. The difference in thickness between
any two of the mix layers may be calculated by using formula
[(tab1-tab2)/tab1].times.100%, wherein tab1 is the greater
thickness of the thicknesses of the two mix layers and tab2 is the
smaller thickness with respect to tab1. For example, the difference
in thickness between two abrasive layers can be at least 5%
different, at least 10% different, at least 20% different, at least
25% different, at least 30% different, or even at least 50%
different. Engineered differences in the thicknesses between two
abrasive layers can promote certain mechanical properties and
advantages in grinding performance. In addition or alternatively to
thickness variations, abrasive layers and/or reinforcing layers may
differ with respect to formulation, materials employed and/or other
properties.
[0065] Filler
[0066] Any of the abrasive layers of the embodiments herein may
include one or more fillers, which can be contained within the
bond. According to an embodiment, the filler can include powders,
granules, spheres, fibers, or a combination thereof. In another
embodiment, the filler can include an inorganic material, an
organic material, or a combination thereof. For example, suitable
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, CaF.sub.2, KBF.sub.4, Cryolite (Na.sub.3AlF.sub.6),
potassium cryolite (K.sub.3AlF.sub.6), pyrites, ZnS, copper
sulfide, mineral oil, fluorides, carbonates, calcium carbonate, or
a combination thereof. In a further embodiment, the 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.
[0067] Note that fillers may be functional, such as, grinding aids,
lubricants, and porosity inducers. In alternative instances, the
fillers can be used for functional and/or aesthetics, such as a
coloring agent. According to an embodiment, the filler can be
distinct from the abrasive particles. In yet another embodiment,
the filler can include secondary abrasive grains.
[0068] In an embodiment, the amount of filler can be at least 1
part per weight of the entire weight of the entire composition,
such as at least 2 parts, at least 3 parts, at least 4 parts, or
even at least 5 parts. In another embodiment, the amount of the
filler may be not greater than 30 parts, such as not greater than
28 parts, not greater than 27 parts, or event not greater than 25
parts by weight, based on the weight of the entire composition. It
will be appreciated that the amount of the filler can be within a
range including any of the minimum to maximum values noted above.
For example, the amount of the filler can be within a range of 1
and 30 parts, such as 2 parts to 28 parts, or 5 to 25 parts by
weight, based on the weight of the entire composition.
[0069] The bonded abrasive or mix layer(s) thereof, can be formed
to include at least 20 vol % bond material of the total volume of
the bonded abrasive (or a specific mix layer). A greater content of
bond material, such as at least 30 vol % at least 40 vol %, at
least 50 vol %, or even at least 60 vol % can be utilized. With
respect to abrasive grains, the bonded abrasive (or a given mix
layer thereof) contains at least 20 vol % abrasive grains, such as
at least 35 vol %, at least 45 vol %, at least 55 vol %, at least
60 vol %, or at least 65 vol %.
[0070] 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 bonded abrasive, 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.
[0071] 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.
[0072] The finally-formed bonded abrasives may contain porosity of
at least 0.1 vol %, such as at least 1 vol %, at least 2 vol %, at
least 3 vol %, or even at least 5 vol % based on the total volume
of the abrasive layers in the body of the bonded abrasive. In
another non-limiting embodiment, the porosity may be not greater
than 40 vol %, such as not greater than 35 vol %, not greater than
30 vol %, not greater than 25 vol %, or not greater than 20 vol %,
not greater than 15 vol %, 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 0 vol % to 40 vol %. For instances, the porosity of
the bonded abrasives described herein (or of a mix layer thereof)
can be within a range of from 0 vol % to 30 vol %, e.g., within a
range between 1 vol % and 25 vol %, or between 5 vol % and 25 vol
%.
[0073] Techniques that can be used to produce the bonded abrasive,
including for example a bonded abrasive wheel with or without a
reinforcing layer, can include, 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/cm.sup.2 (60 psi or 0.03 tsi), 8.4
kg/cm.sup.2 (120 psi or 0.06 tsi) 70.3 kg/cm.sup.2 (0.5 tsi) to
2109.3 kg/cm.sup.2 (15 tsi), or in the range of 140.6 kg/cm.sup.2
(1 tsi) to 843.6 kg/cm.sup.2 (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.
[0074] 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.
[0075] 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.
[0076] 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).
[0077] 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.
[0078] Barrier Layer
[0079] One or more barrier layers may be employed on the body of
the bonded abrasive to facilitate improved performance of the
abrasive tool. For example, the one or more barrier layers can be
applied to particular surfaces of the body of the bonded abrasive
to limit absorption of certain species (e.g., water) by the body,
including for example, the bond material, which may facilitate
improved performance of the abrasive tool.
[0080] According to an embodiment, the body of the bonded abrasive
can be in close proximity with the barrier layer for construction
of the abrasive tool disclosed herein. In particular embodiments,
the barrier layer can be in direct contact with (i.e., abutting) at
least one major surface of the bonded abrasive body. In an even
more particular embodiment, the barrier layer can be directly
bonded to at least one major surface of the bonded abrasive body,
such that the barrier layer would not be separated from the bonded
abrasive during operation of the abrasive tool.
[0081] FIG. 2A includes a cross-sectional view of a portion of an
abrasive tool according to an embodiment. The abrasive tool 200
includes the barrier layer 202 overlying the body 206 of the bonded
abrasive. The body 206 includes major surfaces 208 and 210, among
which barrier layer 202 abuts the major surface 208. In FIG. 2B,
the body 206 can be on top of the barrier layer 202, and the major
surface 210 is in direct contact with the barrier layer 202.
Alternatively, the abrasive tool 200 can include more than one
barrier layers. Furthermore, the barrier layer can be in direct
contact with one or more major surfaces of the body of the bonded
abrasive. FIG. 2C includes a cross-sectional view of a portion of a
body of a bonded abrasive including a barrier layer according to an
embodiment. As illustrated, the body 206 of the bonded abrasive can
be disposed between a first barrier layer 202 and a second barrier
layer 204. For example, the barrier layer 202 can be in direct
contact with the major surface 208 and the barrier layer 204 can be
in direct contact with the major surface 210.
[0082] Although the barrier layers 202 and 204 are illustrated to
be single layers, it will be appreciated that the barrier layers
202 and 204 can include more than one layer (i.e., films) as
described in embodiments herein.
[0083] According to one embodiment, the barrier layer can overlie
the entire surface area of the major surface of the body. In a
further embodiment, the barrier layer may not extend over the
peripheral surface that extends between the major surfaces of the
body. In FIG. 3A, the barrier layer 302 can overly the major
surface 306 of the bonded abrasive body 312 without extending over
the peripheral surface of 310. In FIG. 3B, the barrier layer 302
can overlie the major surface 306 of the body 312 and extend over
to at least a portion of the peripheral surface 310. Alternatively,
the barrier layer 302 can overlie the major surface 306 and extend
to overlie the entire surface areas of the peripheral surface 310
of the body 312. In accordance with these embodiments, it may not
be necessary for the barrier layer to be removed prior to use of
the abrasive tool. For example, the barrier layer can be removed
during operation of the abrasive tool, such as grinding or cutting,
without interfering with the process of operation. For another
instance, the barrier layer can be formed such that forces
encountered during applications of the abrasive tool can be
sufficient to selectively remove at least a portion of the barrier
layer to expose at least a portion of the work surface of the
bonded abrasive. Removal of the barrier layer may occur without
affecting the abrasive capabilities of the bonded abrasive.
[0084] According to an embodiment, the barrier layer can include a
single layer or include more than one layer, wherein each discrete
layer may be referred to as a film. According to an embodiment, the
barrier layer can include a metal-containing film. The
metal-containing film can include a metal or a metal alloy.
Particularly, the metal can be selected from the group consisting
of aluminum, iron, tin, copper, scandium, titanium, vanadium,
chromium, manganese, nickel, zinc, yttrium, zirconium, niobium,
molybdenum, silver, palladium cadmium, tantalum, tungsten,
platinum, gold, and a combination thereof. The metal alloy can
include an alloy including one or more of the metals disclosed
herein. Moreover, the metal-containing film can consist essentially
of any one of the metals noted above. Furthermore, the
metal-containing film can consist essentially of a metal alloy made
of two or more of the metals noted above.
[0085] According to another embodiment, the barrier layer can
include a polymer-containing film. The polymer-containing film can
include a polymer. In a particular embodiment, the
polymer-containing film can consist essentially of a polymer.
Examples of the polymer can include a thermoplastic, a thermoset,
or the like. In a particular embodiment, the polymer can be
selected from the group consisting of a thermoplastic and a
thermoset. Examples of a thermoplastic can include poly(methyl
methacrylate) (PMMA), polybenzimidazole, polyethylene,
polypropylene, polystyrene, polyvinyl chloride,
polytetrfluoroethylene, a thermoplastic elastomer, or any
combination thereof. Examples of a thermoset can include polyester,
polyurethanes, phenol-formaldehyde resin, an epoxy resin,
polyimide, or any combination thereof. In a more particular
embodiment, the polymer is selected from the group consisting of
polyamide, polyester, polypropylene, polyvinyl, an epoxy, a resin,
polyurethanes, a rubber, polyimide, phenolic, polybenzimidazole,
aromatic polyamide, and a combination thereof. In a more particular
embodiment, the polymer consists essentially of polyethylene
terephthalate.
[0086] According to another embodiment, the barrier layer can
include a biaxially-oriented material. Exemplary biaxially-oriented
material can include polyester, such as polyethylene terephthalate.
It will be appreciated that the barrier layer can consist
essentially of any of the foregoing materials or consists
essentially of two or more of the foregoing materials noted above.
In a particular embodiment, the barrier layer can be essentially
free of epoxy. In another particular embodiment, the barrier layer
can be essentially free of paraffin. In still another particular
embodiment, the barrier layer can be essentially free of a wax.
[0087] In some instances, the barrier layer can include more than
one layer, such as a combination of the films in the embodiments
herein. As shown in FIG. 4A, the barrier layer 410 can include the
polymer-containing film 402 overlying the metal-containing film
404. Particularly, the polymer-containing film may be bonded
directly to the metal-containing film, which may help to enhance
structure stability of the barrier layer. The barrier layer may
also include more than one metal-containing film,
polymer-containing film, or a combination of multiple layers of
these films. FIG. 4B to 4D include some exemplary configurations of
the barrier layer 410. FIG. 4B depicts the metal-containing film
304 disposed between two polymer-containing films 402 and 406. In
FIG. 4C, the polymer-containing film 402 is disposed between the
polymer-containing film 406 and the metal-containing film 404, as
shown in FIG. 4C. It will be appreciated that various combinations
of one or more metal-containing films or polymer-containing films
is within the scope of the present embodiments, and many other
configurations of the barrier layer including one than one layer of
the metal-containing films and the polymer-containing films would
be possible and within the scope of the embodiments herein.
[0088] In accordance with a particular embodiment, the barrier
layer can include a polymer-containing film disposed between a
plurality of metal-containing layers, including for example, two
metal-containing films. The two metal-containing films may include
the same metal material, such as aluminum, however this is not
always necessary. The polymer can include any of the polymers noted
herein, including for example, polyethylene. Particularly, the
barrier layer can be a double-sided reflective aluminum with
polyethylene woven reinforcement disposed between the two layers of
aluminum.
[0089] In accordance with another particular embodiment, the
barrier layer can include a metal-containing film and a
polymer-containing film. The polymer-containing film can be placed
between the bonded abrasive body and the metal-containing film. In
a more particular embodiment, the polymer-containing film can be in
direct contact with the metal-containing film. In another more
particular embodiment, the metal-containing film can be the
outermost layer of the barrier layer.
[0090] In another particular embodiment, the barrier layer can
include a plurality of films. The barrier layer can include a first
polymer-containing film, a second polymer-containing film, a
metal-containing film, a third polymer-containing film, and a
fourth polymer-containing film. The first polymer-containing film
can include biaxially-oriented nylon. The second polymer-containing
film can include polyethylene. The metal-containing film can be
foil. The third polymer-containing film can include polyethylene.
The fourth polymer-containing film can include polyethylene, such
as co-extruded polyethylene. In an even more particular embodiment,
the fourth polymer-containing film can be the outermost layer of
the barrier layer that is facing away from the bonded abrasive
body. In another more particular body, the metal-containing film
can be the outermost layer of the barrier layer. It will be
appreciated that any of the foregoing films and the respective
materials include films that consist essentially of the
corresponding materials as noted above. For example, the fourth
polymer-containing film can consist essentially of co-extruded
polyethylene.
[0091] In the embodiments employing barrier layer including the
metal-containing film and the polymer-containing film, the average
thickness of these films can be similar or different. In some
embodiments, the average thickness of the polymer-containing film
can be greater than the average thickness of the metal-containing
film. In other embodiments, the average thickness of the
metal-containing film may be greater than the average thickness of
the polymer-containing film.
[0092] According to an embodiment, the metal-containing film can be
bonded to the major surface of the body, such that the
metal-containing film can be in direct contact with the major
surface of the body. In such an embodiment, the metal-containing
film can be disposed between the major surface of the body and
another film overlying the metal-containing film (e.g., a
polymer-containing film). According to another embodiment, the
polymer-containing film can be bonded to the major surface of the
body, such that the polymer-containing film can be in direct
contact with the major surface of the body. In such an embodiment,
the polymer-containing film can be disposed between the major
surface of the body and another film overlying the
polymer-containing film (e.g., a metal-containing film). In a
particular embodiment of the barrier layer including both
metal-containing and polymer-containing films, the
polymer-containing film can be directly bonded to the major surface
of the body.
[0093] It has been noted that given the particular forming process
of the embodiments herein, the barrier layer may be susceptible to
damage, such as the formation of perforations that can extend
through the thickness of the barrier layer (e.g., partially through
the thickness or entirely through the thickness). During the
process of forming the abrasive tool, perforations may be formed in
the barrier layer. In addition, perforations may be formed during
routine handling and shipping. The perforations can have similar or
different sizes. For example, the perforations can have various
sizes of diameters. In an embodiment, the perforation diameter can
be at least 2 .mu.m, such as 8 .mu.m, at least 13 .mu.m, at least
25 .mu.m, at least 50 .mu.m, at least 75 .mu.m, at least 105 .mu.m,
at least 145 .mu.m, at least 220 .mu.m, or even at least 280 .mu.m.
In another embodiment, the perforation diameter of the perforations
may not be greater than 1000 .mu.m, such as not greater than 950
.mu.m, not greater than 890 .mu.m, not greater than 810 .mu.m, not
greater than 750 .mu.m, not greater than 680 .mu.m, not greater
than 610 .mu.m, not greater than 520 .mu.m, or even not greater
than 420 .mu.m. It will be appreciated that the diameter of the
perforations can be within a range including any of the minimum
values and maximum values disclosed herein. For example, the can
have the diameters of the perforations within a range of 2 .mu.m to
1000 .mu.m, such as within a range of 50 inn to 890 .mu.m.
[0094] The perforations can have an average size, such as an
average diameter. In an embodiment, the average diameter of the
perforations can be at least 200 .mu.m, at least 240 .mu.m, at
least 260 .mu.m, at least 285 .mu.m, or even at least 310 .mu.m. In
another embodiment, the average diameter may be not greater than
580 .mu.m, such as not greater than 520 .mu.m, not greater than 480
.mu.m, not greater than 430 .mu.m, or even not greater than 380
.mu.m. It will be appreciated that the average diameter of the
perforations can be within a range including any of the minimum
values and maximum values noted above. For example, the
perforations can have an average diameter within a range of 200
.mu.m to 580 .mu.m, such as within a range of 285 .mu.m to 430
.mu.m.
[0095] Density of perforation may be determined by counting the
number of the perforations within randomly selected areas of a
surface of the barrier layer that is facing away from the bonded
abrasive body. At least 4 areas can be selected. Magnifiers or
microscopes with backside illumination can be used to aid
identifying the perforations. Perforation density can be the total
number of perforations normalized by the total areas examined.
[0096] According to another embodiment, the perforation density may
be not greater than not greater than 200 perforations/cm.sup.2,
such as not greater than 180 perforations/cm.sup.2, not greater
than 160 perforations/cm.sup.2, not greater than 140
perforations/cm.sup.2, not greater than 120 perforations/cm.sup.2,
not greater than 100 perforations/cm.sup.2, not greater than 90
perforations/cm.sup.2, not greater than 80 perforations/cm.sup.2,
not greater than 70 perforations/cm.sup.2, not greater than 60
perforations/cm.sup.2, not greater than 50 perforations/cm.sup.2,
not greater than 40 perforations/cm.sup.2, not greater than 30
perforations/cm.sup.2, not greater than 20 perforations/cm.sup.2,
not greater than 15 perforations/cm.sup.2, not greater than 10
perforations/cm.sup.2, not greater than 9 perforations/cm.sup.2,
not greater than 8 perforations/cm.sup.2, not greater than 7
perforations/cm.sup.2, not greater than 6 perforations/cm.sup.2, or
not greater than 5 perforations/cm.sup.2, not greater than 4
perforations/cm.sup.2, not greater than 3 perforations/cm.sup.2,
not greater than 2 perforations/cm.sup.2, not greater than 1
perforation/cm.sup.2. For at least one embodiment, the barrier
layer can be essentially free of perforations. Still, in at least
one non-limiting embodiment, some minor content of perforations can
exist, such that the perforation density can be at least 0.1
perforations/cm.sup.2, such as at least 0.5 perforations/cm.sup.2,
at least 1 perforation/cm.sup.2, at least 1.5
perforations/cm.sup.2, at least 1.8 perforations/cm.sup.2, at least
2 perforations/cm.sup.2, at least 2.3 perforations/cm.sup.2, at
least 2.5 perforations/cm.sup.2, at least 3 perforations/cm.sup.2,
at least 3.5 perforations/cm.sup.2, at least 4
perforations/cm.sup.2, at least 4.5 perforations/cm.sup.2, at least
5 perforations/cm.sup.2, at least 5.6 perforations/cm.sup.2, at
least 6 perforations/cm.sup.2, at least 6.5 perforations/cm.sup.2,
at least 7.2 perforations/cm.sup.2, at least 8
perforations/cm.sup.2, at least 9 perforations/cm.sup.2, or even at
least 10 perforations/cm.sup.2. It will be appreciated that the
perforation density can be within a range including any of the
minimum values to maximum values noted above. For example, the
perforation density can be within a range of 0.1
perforations/cm.sup.2 to 200 perforations/cm.sup.2, such as within
a range of 0.5 perforations/cm.sup.2 to 180 perforations/cm.sup.2,
within a range of 1 perforations/cm.sup.2 to 160
perforations/cm.sup.2, within a range of 2 perforations/cm.sup.2 to
140 perforations/cm.sup.2, within a range of 5
perforations/cm.sup.2 to 120 perforations/cm.sup.2, or within a
range of 10 perforations/cm.sup.2 to 100 perforations/cm.sup.2.
[0097] In certain embodiments, orientation of the films of the
barrier layer may affect the density of the perforation. It may be
desired to have the polymer-containing film as the outermost layer
for the barrier layer, as in some instances, depending upon the
polymer-containing film material, during processing the material
may exhibit a self-sealing capability configured to seal some
perforations formed in the barrier layer. Notably, certain
polymer-containing films may exhibit flow behaviors during
processing that facilitate flowing and sealing of perforations
formed during processing. For example, the polymer-containing film
that includes co-extruded polyethylene may be disposed as the
outmost layer in some embodiments to reduce perforation density of
the barrier layer can be obtained.
[0098] In at least one other application, the polymer-containing
film can be placed between the metal-containing film and the bonded
abrasive body, which may help to reduce formation of perforation in
the metal-containing film during the process of forming the
abrasive tool. For instance, during curing, the material of the
polymer-containing film may flow and seal at least some of the
perforations formed in the metal-containing film. Additionally or
alternatively, during processing, the material may facilitate
flowing and sealing of perforations in the metal-containing film.
The metal-containing film may be used as the outermost layer for
the barrier layer.
[0099] Formation of the barrier layer can be carried out in-situ
with the formation of the bonded abrasive (e.g. the abrasive
wheel). Notably, the barrier layer can be selected such that it can
withstand the forming process of forming the bonded abrasive.
Moreover, the barrier layer may undergo some modification during
the forming process, including for example, some physical or
chemical changes that facilitate bonding of the barrier layer to
one or more surfaces of the bonded abrasive body.
[0100] According to one particular forming process, the barrier
layer can be disposed within the mold, on top of which an abrasive
layer including abrasive particles contained in the bond material
can be added in the manner in accordance with the embodiments
herein. The abrasive layer can be in the form of the green body,
mixture, various layers, or any other form described above. In
certain instances, another barrier layer may be laid on top of the
abrasive body. In some other embodiments, the barrier layer may be
placed only adjacent to the bottom or top of the abrasive body.
Moreover, a barrier layer may be placed in the mold such that it is
adjacent the peripheral surface of the abrasive layer, such that
the barrier layer can be formed on the peripheral surface of the
bonded abrasive body.
[0101] In the embodiments of utilizing an organic bonding material
to form the bond material, during curing of the organic bonding
material, the barrier layer can adhere to one or more major
surfaces of the body and/or a peripheral surface of the body.
[0102] In some embodiments, hot pressing can be used to form the
bonded abrasive may be utilized for the barrier layer to directly
bond to the major surface. The hot pressing operation can include
parameters as detailed in the embodiments herein.
[0103] Certain temperature ranges may be particularly suitable to
treat the barrier layer. For instance, the temperature can be at
least 50.degree. C., at least 100.degree. C., or at least
150.degree. C. In another instance, the temperature may be not
greater than 250.degree. C., not greater than 225.degree. C., or
not greater than 200.degree. C. The temperature can be within any
of the minimum and maximum values disclosed herein. For example,
the temperature can be within a similar range of curing the
abrasive wheel.
[0104] Embodiments disclosed herein represent a departure from
state of the art abrasive articles. The barrier layer in accordance
with the embodiments herein may be substantially impermeable, such
as entirely impermeable, to moisture. Utilizing the barrier layers
to reduce moisture absorption of the bonded abrasive may improve
the performance of the abrasive tool over time and mitigate
aging.
[0105] Many different aspects and embodiments are possible. Some of
those aspects and embodiments are described herein. After reading
this specification, skilled artisans will appreciate that those
aspects and embodiments are only illustrative and do not limit the
scope of the present invention. Embodiments may be in accordance
with any one or more of the items as listed below.
Embodiment 1
[0106] An abrasive tool comprising:
a bonded abrasive including a body comprising abrasive particles
contained within a bond material; and a barrier layer bonded to at
least a major surface of the body, the barrier layer comprising a
metal-containing film.
Embodiment 2
[0107] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a polymer-containing film overlying the metal-containing
film.
Embodiment 3
[0108] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a polymer-containing film bonded directly to the
metal-containing film.
Embodiment 4
[0109] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a polymer-containing film consisting essentially of a
polymer.
Embodiment 5
[0110] The abrasive tool of embodiment 1, wherein the polymer is
selected from the group consisting of a thermoplastic and a
thermoset.
Embodiment 6
[0111] The abrasive tool of embodiment 1, wherein the polymer is
selected from the group consisting of polyamides, polyesters,
polyethlyenes, polypropylene, polyvinyls, epoxies, resins,
polyurethanes, rubbers, polyimides, phenolics, polybenzimidazole,
aromatic polyamide, and a combination thereof.
Embodiment 7
[0112] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a biaxially-oriented material.
Embodiment 8
[0113] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a polymer including a biaxially-oriented material.
Embodiment 9
[0114] The abrasive tool of embodiment 8, wherein the polymer
comprises polyethylene terephthalate or wherein the polymer
consists essentially of polyethylene terephthalate.
Embodiment 10
[0115] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a polymer-containing film and wherein the
polymer-containing film comprises an average thickness greater than
an average thickness of the metal-containing film.
Embodiment 11
[0116] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a polymer-containing film and wherein the
polymer-containing film comprises an average thickness less than an
average thickness of the metal-containing film.
Embodiment 12
[0117] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a polymer-containing film and wherein the
polymer-containing film is bonded directly to the major surface of
the body.
Embodiment 13
[0118] The abrasive tool of embodiment 1, wherein the body
comprises a first major surface and a second major surface opposite
the first major surface, and a peripheral surface extending between
the first major surface and the second major surface, and wherein
the barrier layer is bonded directly to the first major surface and
second major surface.
Embodiment 14
[0119] The abrasive tool of embodiment 13, wherein the barrier
layer overlies at least a portion of the peripheral surface.
Embodiment 15
[0120] The abrasive tool of embodiment 13, wherein the barrier
layer overlies the entire surface area of the first major surface
and the second major surface.
Embodiment 16
[0121] The abrasive tool of embodiment 1, wherein the
metal-containing film is in direct contact with the major surface
of the body.
Embodiment 17
[0122] The abrasive tool of embodiment 1, wherein the
metal-containing film comprises a metal or metal alloy.
Embodiment 18
[0123] The abrasive tool of embodiment 1, wherein the barrier layer
consists essentially of the metal-containing film, wherein the
barrier layer consists essentially of a single layer of the
metal-containing film.
Embodiment 19
[0124] The abrasive tool of embodiment 1, wherein the
metal-containing film comprises at least one metal selected from
the group consisting of aluminum, iron, tin, copper, scandium,
titanium, vanadium, chromium, manganese, nickel, zinc, yttrium,
zirconium, niobium, molybdenum, silver, palladium cadmium,
tantalum, tungsten, platinum, gold, and a combination thereof.
Embodiment 20
[0125] The abrasive tool of embodiment 1, 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,
and a combination thereof, and wherein the abrasive particles
comprise shaped abrasive particles, wherein the abrasive particles
comprise alumina.
Embodiment 21
[0126] The abrasive tool of embodiment 1, wherein the body
comprises a filler contained within the bond, wherein the filler is
selected from the group consisting of powders, granules, spheres,
fibers, and a combination thereof, wherein the filler is selected
from the group consisting of an inorganic material, an organic
material, and a combination thereof, wherein the filler is selected
from the group consisting of sand, 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 spheres, glass
fibers, CaF2, KBF4, Cryolite (Na3AlF6), potassium Cryolite
(K3AlF6), pyrites, ZnS, copper sulfide, mineral oil, fluorides,
carbonates, calcium carbonate, and a combination thereof, wherein
the filler is selected from the group consisting of an antistatic
agent, a metal oxide, a lubricant, a porosity inducer, coloring
agent, and a combination thereof, wherein the filler is distinct
from the abrasive particles.
Embodiment 22
[0127] The abrasive tool of embodiment 1, wherein the body
comprises at least one reinforcing layer 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.
Embodiment 23
[0128] The abrasive tool of embodiment 1, 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.
Embodiment 24
[0129] A method of forming an abrasive article comprising: forming
a barrier layer in-situ with the formation of a bonded abrasive
including a body comprising abrasive particles contained within a
bond material comprising an organic material.
Embodiment 25
[0130] The method of embodiment 24, wherein the barrier layer is
adhered to a major surface of the body while the bond material is
curing.
Embodiment 26
[0131] The method of embodiment 24, wherein the barrier layer is
bonded directly to a major surface of the body using a hot pressing
operation used to form the bonded abrasive body.
Embodiment 27
[0132] The method of embodiment 24, wherein the barrier layer is
configured to be applied at a temperature within a range including
at least 20.degree. C. and not greater than 50.degree. C., wherein
the barrier layer is integrally bonded to the major surface,
wherein the barrier layer is integrally bonded to the major surface
during a cold pressing operation, wherein the barrier layer is
integrally bonded to the major surface during curing of the bond
material of the bonded abrasive.
Embodiment 28
[0133] The method of embodiment 24, wherein the barrier layer is
applied during a hot pressing operation applying a force within a
range between 40 tons and 2000 tons.
Embodiment 29
[0134] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a first metal-containing film, a second metal-containing
film, and polymer-containing film, wherein the polymer-containing
film is disposed between the first metal-containing film and the
second metal containing film.
Embodiment 30
[0135] The abrasive tool of embodiment 29, wherein the first
metal-containing film and the second metal-containing film comprise
a same metal including aluminum and the polymer-containing film
includes polyethylene woven reinforcement.
Embodiment 31
[0136] The abrasive tool of embodiment 1, further comprising a
first polymer-containing biaxially-oriented nylon, a second
polymer-containing film including polyethylene, a third
polymer-containing film including polyethylene, and a fourth
polymer-containing film including co-extruded polyethylene, wherein
the metal-containing film includes foil.
Embodiment 32
[0137] The abrasive tool of embodiment 31, wherein the metal
containing-film is an outermost film of the barrier layer.
Embodiment 33
[0138] The abrasive tool of embodiment 31, wherein the fourth
polymer-containing film is an outermost layer of the barrier
layer.
Embodiment 34
[0139] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a perforation density across a surface of the barrier
layer, the perforation density being at least 0.1
perforations/cm.sup.2, or at least 0.5 perforations/cm.sup.2, or at
least 1 perforations/cm.sup.2, or at least 2/cm.sup.2, or at least
5 perforations/cm.sup.2, or at least 10 perforations/cm.sup.2.
Embodiment 35
[0140] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a perforation density of not greater than 200
perforations/cm.sup.2, or not greater than 180
perforations/cm.sup.2, not greater than 160 perforations/cm.sup.2,
or not greater than 140 perforations/cm.sup.2, or not greater than
120 perforations/cm.sup.2, or not greater than 100
perforations/cm.sup.2.
Embodiment 36
[0141] The abrasive tool of embodiment 1, wherein the barrier layer
comprises a perforation density across a surface of the barrier
layer within a range of 0.1 perforations/cm.sup.2 to 200
perforations/cm.sup.2, or within a range of 0.5
perforations/cm.sup.2 to 180 perforations/cm.sup.2, or within a
range of 1 perforation/cm.sup.2 to 160 perforations/cm.sup.2, or
within a range of 2 perforations/cm.sup.2 to 140
perforations/cm.sup.2, or within a range of 5 perforations/cm.sup.2
to 120 perforations/cm.sup.2, or within a range of 10
perforations/cm.sup.2 to 100 perforations/cm.sup.2.
Example 1
[0142] A conventional abrasive bonded abrasive wheel A and abrasive
wheels representative of the embodiments herein with different
barrier layers (wheels B to F) were tested to determine the effect
of moisture on the performance. Wheels A to F were formed by the
method of cold pressing including application of a pressure within
a range of 90-120 bar at approximately room temperature. Then, all
wheels were stacked and cured in an oven at approximately
200.degree. C. Wheels A to F were Type 41 wheels having a structure
of barrier layer/fiberglass reinforcement/abrasive mix/fiberglass
reinforcement/barrier layer. The abrasive mix contained 40 vol % 46
grit ceramic-coated brown fused alumina, 34.5 vol % resin (resole
and novolac), 5.75 vol % each of potassium aluminum fluoride and
potassium sulfate and 14% porosity. The barrier layers of wheels B
to F included different combinations of the polymer-containing
films and metal-containing films described in embodiments herein.
The orientation of the films for each barrier layer is provided
herein in the order from the outmost layer to the innermost layer.
The barrier layer of wheel B included a biaxially-oriented nylon
film, a polyethylene film, a foil, another polyethylene film, and a
film of co-extruded polyethylene. The barrier layer of wheel C
included an oriented polypropylene film, a polyethylene film, a
foil, and another polyethylene film. Wheel D included a barrier
layer including double sided reflective aluminum with polyethylene
woven reinforcement disposed between the aluminum films. The
barrier layer of wheel E included aluminum foil. The barrier layer
of wheel F included a low density polyethylene film. Further
Information of the barrier layers of wheels B to F are provided in
Table 1 below.
TABLE-US-00001 TABLE 1 Moisture Vapor Transmission Rate at 25 C.
90% RH Perforation Samples (WVTR g/m.sup.2/day) Density (/cm.sup.2)
B <0.00775 19.6 C <0.31 101 D <0.01 8.7 E NA very high F
<22.1 not measured
[0143] All the abrasive wheels were 125.times.1.6.times.22.3 mm and
exposed to the same aging conditions of 90% relative humidity. The
abrasive wheels A, B, and D were exposed to the aging condition for
33 days, and the abrasive wheels C, E, and F were exposed for 20
days. Moisture uptake of each wheel was measured on different days
and illustrated in FIG. 5. At day 5, moisture uptake in the
conventional abrasive wheel A was measured to be 0.75% by weight,
while wheels B to F only had approximately 0.10%, 0.25%, 0.30%,
0.40%, and 0.50% of moisture uptake, respectively. At day 10,
moisture uptake of the conventional wheel A increased to greater
than approximately 0.90%, and reached approximately 1.00% at day
20. Wheels B to F had approximately 0.10%, 0.30%, 0.40%, 0.50%, and
0.70% of moisture uptake, respectively, at day 10, and
approximately 0.20%, 0.55%, 0.55%, .about.0.70%, and 0.80%,
respectively at day 20. At day 33, wheel A had 1.10% of moisture
uptake, but wheel B and D only had approximately 0.25% and 0.65% of
moisture uptake, respectively.
[0144] Wheel aging and performance degradation was observed in
association with moisture uptake. Before and after the aging test,
wheels A and D were subjected to G-ratio tests. As illustrated in
FIG. 6, wheel A had a G-ratio decrease of 39% after the aging test
compared to before the aging test, while G-ratio of wheel D only
dropped 25% after the aging test compared to before the aging test.
Thus wheel D and its particular barrier layer demonstrated a 14%
increase in G-ratio compared to the standard wheel (wheel A) with
no barrier layer.
Example 2
[0145] Wheels G and H were formed in accordance with the
embodiments herein. The barrier layers of wheels G and H both
included a film of biaxially-oriented nylon, a polyethylene film, a
film of foil, another polyethylene film, and a film of co-extruded
polyethylene. In wheel G, the biaxially-oriented nylon was the
outmost layer (facing away from the bonded abrasive body) of the
barrier layer, while in wheel H, the film of co-extruded
polyethylene, covered with an additional black paper were the
outermost layers. Wheels G and H were exposed to the same aging
conditions of 90% relative humidity for 7 days. As shown in FIG. 7
and Table 2 below, orientation of the films of the barrier layer
had an impact on moisture uptake of the wheels. FIG. 8 includes a
plot of G-ratio tests of wheels G and H conducted before and after
the aging test. The G-ratio of aged wheel G decreased 27% compared
to that before the aging test. The G-ratio of aged wheel H
decreased 50% compared to that before the aging test. Therefore, as
indicated by the data, the orientation of the barrier layer as well
as the type of material can have an effect on limiting the ageing
of the wheels.
TABLE-US-00002 TABLE 2 Wheel G Wheel H Day 3 0.06% 0.28% Day 4
0.07% 0.33% Day 5 0.06% 0.38% Day 6 0.08% 0.40% Day 7 0.10%
0.43%
Example 3
[0146] A conventional bonded abrasive wheel MMB1 and abrasive
wheels representative of the embodiments herein with different
barrier layers (wheels MMB2, MMB3, MMB4, MMB5, MMB6, MMB17, and
MMB20) were tested to determine the effect of compositions of the
barrier layer on moisture uptake into the bonded abrasive wheel.
All the wheels were formed by the method of cold pressing utilizing
a cold pressing machine (e.g., 350 Ton Press manufactured by Poggi
Pasqualino) and the pressure in the press was kept within a range
of 90-120 bar (corresponding to 9 MPa to 12 MPa) at approximately
room temperature. Then, the barrier layers were place around the
wheels to make the wheel samples noted in Table 3. No barrier layer
was applied to wheel MMB1. The wheels were then cured in an oven at
approximately 200.degree. C. 10 perforations were formed in the
barrier layer of each side of wheel MMB6 by puncturing the aluminum
film with a pin. The compositions and thickness of the barrier
layers are included in Table 3. All the abrasive wheels were
125.times.1.6.times.22.3 mm and exposed to aging conditions as
indicated in Table 3. The weight change from prior to moisture
exposure to after being exposed to 90% relative humidity at
25.degree. C. for 7 days was measured and compared to the original
weight for each wheel.
TABLE-US-00003 TABLE 3 Barrier Thickness Moisture Vapor Moisture
Wheels Barrier Composition (mil) Transmission Rate Uptake MMB1 None
N/A Not Measured 0.83% MMB2 Biaxially Orientated 7.3 0.00775
g/m.sup.2/day (90% 0.09% Nylon/PE/Foil/PE/Heavy relative humidity
at 40.degree. C.) Duty Coextruded Polyethylene MMB3 Biaxially 10.3
0.00775 g/m.sup.2/day (90% 0.04% Nylon/PE/Cross relative humidity
at 40.degree. C.) Laminated PE/PE/Foil/ Heavy Duty Coextruded
Polyethylene MMB4 Aluminum/ 4.5 0.013 g/m.sup.2/day (100% 0.14%
Polyethylene Woven relative humidity at 25.degree. C.)
Reinforcement/ Aluminum MMB5 Aluminum (no visible 0.64 <0.005
g/m.sup.2/day (100% 0.24% perforations) relative humidity at
37.8.degree. C.) MMB6 Aluminum (10 0.64 Not Measured 0.3%
perforations/film) MMB17 Silane Treated Black 4.2 1.91
g/m.sup.2/day (100% relative 0.17% PTFE humidity at 37.8.degree.
C.) MMB20 Silane Treated Clear 1 8.9 g/m.sup.2/day (100% relative
0.45% PTFE humidity at 37.8.degree. C.)
[0147] As disclosed in Table 3, wheel MMB2 had the barrier layer
including a biaxially-orientated nylon film, polyethylene (PE)
film, foil, PE film, and heavy duty coextruded polyethylene film
with the biaxially orientated Nylon film as the outermost layer.
The barrier layer of MMB2 had reduced moisture uptake, 0.09% as
compared to 0.83% of the conventional sample, MMB1. The barrier
layer of wheel MMB3 included a biaxially-orientated nylon film, PE
film, cross-laminated PE film, PE film, Foil, and heavy duty
coextruded polyethylene with the biaxially orientated nylon film as
the outermost layer. Wheel MMB3 had similarly low moisture uptake
as MMB2. The barrier layer of wheel MMB4 included a double sided
reflective aluminum film, polyethylene woven reinforcement and a
second double sided reflective aluminum film. Wheel MMB4
demonstrated reduced moisture uptake as compared to wheel MMB1
(0.14% vs. 0.83%). The barrier layer of MMB5 included an aluminum
film without pinholes, and wheel MMB5 had a moisture uptake of
0.24%. The aluminum film on each side of the abrasive body of wheel
MMB6 had 10 pinholes, and the MMB6 wheel had moisture uptake of
0.3%. Wheel MMB 17 had the barrier layer of a silane treated black
PTFE film and moisture uptake of 0.17%. Wheel MMB9 had the barrier
layer of a silane treated clear PTFE film and moisture uptake of
0.45%.
[0148] Certain attempts have been made to reduce the effects of
ageing, including placing bonded abrasive articles in bags or
coating the surfaces of the bonded abrasives with wax or resinous
materials to seal the surfaces. However, the embodiments herein
represent a departure from these techniques, and in particular, the
embodiments herein facilitate efficient and large-scale
manufacturing of bonded abrasive articles. Notably, in-situ
formation of a barrier layer was found to be a non-trivial
investigation and that one or more features of the barrier layer in
combination with the bonded abrasive were found remarkable and/or
unexpected, including features such as the material of the barrier
layer, the water vapor transmission rate of the barrier layer, the
structure and grade of the bonded abrasive, the orientation of the
barrier layer relative to the bonded abrasive, the puncture
density, and the like.
[0149] 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.
[0150] 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.
[0151] 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 subcombination.
Further, reference to values stated in ranges includes each and
every value within that range. Many other embodiments may be
apparent to skilled artisans only after reading this specification.
Other embodiments may be used and derived from the disclosure, such
that a structural substitution, logical substitution, or another
change may be made without departing from the scope of the
disclosure. Accordingly, the disclosure is to be regarded as
illustrative rather than restrictive.
* * * * *