Bonded abrasive article including a coating

Patent metadata

Field	Value
Publication number	US-10933508-B2
Application number	US-201916370284-A
Country	US
Kind code	B2
Filing date	Mar 29, 2019
Priority date	Mar 30, 2018
Publication date	Mar 2, 2021
Grant date	Mar 2, 2021

Abstract

A bonded abrasive article can include a body including a bond material, abrasive particles contained within the bond material, and pores contained within the body. At least a portion of the pores of the body can include a coating. In one aspect, the coating can be a poly(p-xylylene) polymer applied via vapor deposition. The coated abrasive body can maintain a high permeability and pore volume after coating, and the coating can provide an increase in flexural strength and corrosion resistance to the abrasive article, thereby greatly enhancing its life time.

First claim

What is claimed is:

1. A bonded abrasive article comprising:
a body including:
a bond material;
abrasive particles contained within the bond material; and
pores contained within the body, wherein at least a portion of the pores have a coating comprising a polymer, wherein the polymer comprises a composition different than the composition of the bond material; and

wherein the body comprises a permeability of at least 100 mD, and the body comprises an average pore size (D50) of at least 5 microns and not greater than 300 microns.

2. The bonded abrasive article of claim 1 , wherein the coating comprises a poly(p-xylylene) polymer including fluorine.

3. The bonded abrasive article of claim 2 , wherein the coating comprises parylene HT.

4. The bonded abrasive article of claim 1 , wherein the body comprises a permeability of at least 800 mD and not greater than 15,000 mD.

5. The bonded abrasive article of claim 1 , wherein the pores comprise an open porosity defining an interconnected network of voids extending through the body, and wherein the open porosity is at least 5 vol % and not greater than 90 vol % based on a total volume of the body.

6. The bonded abrasive article of claim 1 , wherein a ratio of total porosity to open porosity of the body is not greater than 1:0.5.

7. The bonded abrasive article of claim 1 , wherein an average thickness of the coating is less than 50% of an average pore diameter of the pores contained within the body.

8. The bonded abrasive article of claim 1 , wherein the coating comprises an average thickness of at least 0.5 microns and not greater than 10 microns.

9. The bonded abrasive article of claim 1 , wherein the coating has a melting point of at least 350° C. and not greater than 600° C.

10. The bonded abrasive article of claim 1 , wherein the coating is overlying at least 50% of an exterior surface of the body including the pores contained within the body.

11. The bonded abrasive article of claim 1 , wherein the abrasive particles comprise a material selected from oxides, carbides, nitrides, borides, oxynitrides, oxyborides, diamond, or any combination thereof.

12. The bonded abrasive article of claim 1 , wherein the abrasive particles comprise an average particle size of at least 0.1 microns and not greater than about 500 microns.

13. The bonded abrasive article of claim 1 , wherein the bond material comprises an oxide-based vitreous material.

14. The bonded abrasive article of claim 1 , wherein the body comprises a flexural strength of at least 35 MPa.

15. The bonded abrasive article of claim 1 , wherein a loss of flexural strength of the body after a corrosion treatment is not greater than 10%, the corrosion treatment being an exposure of the body for 24 hours in a water bath having a temperature of 99° C.

16. A method of forming a bonded abrasive body comprising:
providing a bonded abrasive having a body, the body comprising:
a bond material;
abrasive particles contained within the bond material;
pores contained within the body; and

coating at least a portion of the body with a coating comprising a poly(p-xylylene) polymer by conducting a vapor deposition process,
wherein the permeability of the body after coating is at least 100 mD, and a ratio of total porosity to open porosity of the body after coating is not greater than 1:0.5.

17. The method of claim 16 , wherein the coating comprises parylene HT.

18. The method of claim 16 , wherein an increase of a flexural strength of the body after coating is at least 5% in comparison to a flexural strength of the body before coating.

19. The bonded abrasive article of claim 1 , wherein the coating comprises parylene HT, the bond material comprises an oxide-based vitreous material, and the permeability of the body is at least 800 mD.

20. A bonded abrasive article comprising:
a body including:
a bond material;
abrasive particles contained within the bond material; and
pores contained within the body, wherein at least a portion of the pores have a coating comprising a polymer, wherein the polymer comprises a composition different than the composition of the bond material; and

wherein the body comprises a permeability of at least 100 mD, and the coating comprises an average thickness of at least 0.5 microns and not greater than 10 microns.

21. The bonded abrasive article of claim 20 , wherein the coating comprises a poly(p-xylylene) polymer including fluorine.

22. The bonded abrasive article of claim 21 , wherein the coating comprises parylene HT.

23. The bonded abrasive article of claim 20 , wherein the pores comprise an open porosity defining an interconnected network of voids extending through the body, and wherein the open porosity is at least 5 vol % and not greater than 90 vol % based on a total volume of the body.

24. The bonded abrasive article of claim 20 , wherein a ratio of total porosity to open porosity of the body is not greater than 1:0.5.

25. The bonded abrasive article of claim 20 , wherein an average thickness of the coating is less than 50% of an average pore diameter of the pores contained within the body.

26. The bonded abrasive article of claim 20 , wherein the coating has a melting point of at least 350° C. and not greater than 600° C.

27. The bonded abrasive article of claim 20 , wherein the coating is overlying at least 50% of an exterior surface of the body including the pores contained within the body.

28. The bonded abrasive article of claim 20 , wherein the abrasive particles comprise a material selected from oxides, carbides, nitrides, borides, oxynitrides, oxyborides, diamond, or any combination thereof.

29. The bonded abrasive article of claim 20 , wherein the abrasive particles comprise an average particle size of at least 0.1 microns and not greater than about 500 microns.

30. The bonded abrasive article of claim 20 , wherein the bond material comprises an oxide-based vitreous material.

31. The bonded abrasive article of claim 20 , wherein the coating comprises parylene HT, the bond material comprises an oxide-based vitreous material, and the permeability of the body is at least 800 mD.

32. The bonded abrasive article of claim 20 , wherein the body comprises a flexural strength of at least 35 MPa.

33. The bonded abrasive article of claim 20 , wherein a loss of flexural strength of the body after a corrosion treatment is not greater than 10%, the corrosion treatment being an exposure of the body for 24 hours in a water bath having a temperature of 99° C.

Assignees

• Saint Gobain Abrasives Inc
• Saint Gobain Abrasifs Sa
• Saint Gobain Abrasives Inc /Saint Gobain Abrasifs

Inventors

• Gasdaska Charles J
• Temperelli Alexandre
• Dubovick Kenneth
• Upadhyay Rachana
• Lane William H
• Bright Robin M

Classifications

• C09K3/1436 Primary

  Composite particles, e.g. coated particles · CPC title

• C09K3/1409

  Abrasive particles per se (preparation of diamond C01B32/25) · CPC title

• B24D3/18 Primary

  for porous or cellular structure · CPC title

• B24D3/348

  utilised as impregnating agent for porous abrasive bodies · CPC title

• B24D18/0072

  using adhesives for bonding abrasive particles or grinding elements to a support, e.g. by gluing · CPC title