Abrasive articles and methods for forming same

Patent metadata

Field	Value
Publication number	US-12031083-B2
Application number	US-202217810335-A
Country	US
Kind code	B2
Filing date	Jun 30, 2022
Priority date	Jun 30, 2021
Publication date	Jul 9, 2024
Grant date	Jul 9, 2024

Abstract

An abrasive article can include a body including a first portion coupled to a second portion in a radial plane. The body can include a central opening extending in an axial direction of the body through the first portion and through the second portion. The central opening can include a circumferential surface defining an inner diameter of the body. The circumferential surface can be defined by at least a portion of the first portion and at least a portion of the second portion. The first portion can include first abrasive particles contained within a first bond material, including an inorganic material, and the second portion can include second abrasive particles contained within a second bond material, including an organic material. The organic material can include epoxy. In an embodiment, the second portion comprises an elongation-at-fracture of less than 2.7%, a Stiffness Value of at least 8.3, or a combination thereof.

First claim

What is claimed is:

1. An abrasive article comprising:
a body including:
a first portion comprising first abrasive particles contained within a first bond material including an inorganic material;
a second portion comprising second abrasive particles contained within a second bond material comprising an organic material comprising epoxy, wherein the second abrasive particles comprise an average particle size D 50AP2 of at least 2 microns and at most 20 microns; and D10 of at least 0.5 microns and at most 4 microns or D90 of at least 9 microns and at most 34 microns or both; and
a central opening extending in an axial direction of the body through the first portion and through the second portion,

wherein:
the central opening comprises a circumferential surface defining an inner diameter of the body, wherein the circumferential surface is defined by at least a portion of the first portion and at least a portion of the second portion;
the second portion is coupled to the first portion in a radial plane; and
the second portion comprises an elongation-at-fracture of less than 2.7%.

2. The abrasive article of claim 1 , wherein the first portion of the body comprises for a total volume of the first portion:
a porosity of at least 5 vol % and at most 75 vol %;
the bond material of at least 5 vol % and at most 60 vol %; and
the first abrasive particles of at least 10 vol % and at most 65 vol %.

3. The abrasive article of claim 1 , wherein the first portion comprises a central region and a peripheral region coaxial with the central region, wherein the central region has a greater hardness than the peripheral region, a smaller porosity than the peripheral region, or a combination thereof.

4. The abrasive article of claim 1 , wherein the second abrasive particles are in a content of at least 37 wt % and at most 60 wt % for the total weight of the second portion.

5. The abrasive article of claim 1 , wherein the second portion comprises a coefficient of thermal expansion of at least 38 ppm/° C. and at most 68 ppm/° C. in a temperature range of 30° C. to 50° C.

6. The abrasive article of claim 1 , wherein the second portion comprises the elongation-at-fracture of less than 2.7% and at least 1.9%.

7. The abrasive article of claim 1 , wherein the radial plane extends through the circumferential surface of the central opening and an outer peripheral surface of the body wherein a longitudinal axis extending in an axial direction of the body is perpendicular to the radial plane, and wherein the first portion and the second portion of the body are only coupled in the radial plane.

8. The abrasive article of claim 1 , wherein the first bond material comprises a vitrified material.

9. The abrasive article of claim 1 , wherein the first abrasive particles, the second abrasive particles, or both comprise alumina including seeded gel alumina, fused alumina, sol-gel alumina, sol-gel sintered alumina, shaped and sintered alumina, or any combination thereof.

10. An abrasive article comprising:
a body including:
a first portion comprising first abrasive particles contained within a first bond material including an inorganic material, wherein the first portion of the body comprises for a total volume of the first portion:
a porosity of at least 5 vol % and at most 75 vol %;
the bond material of at least 5 vol % and at most 60 vol %; and
the first abrasive particles of at least 10 vol % and at most 65 vol %;

a second portion comprising second abrasive particles contained within a second bond material comprising an organic material comprising epoxy; and
a central opening extending in an axial direction of the body through the first portion and through the second portion,

wherein:
the central opening comprises a circumferential surface defining an inner diameter of the body, wherein the circumferential surface is defined by at least a portion of the first portion and at least a portion of the second portion;
the second portion is coupled to the first portion in a radial plane; and
the second portion comprises a Stiffness Value of at least 8.3 wherein the second abrasive particles comprise an average particle size D 50AP2 of at least 2 microns and at most 30 microns.

11. The abrasive article of claim 10 , wherein the organic material comprises:
a storage modulus of greater than 3130 MPa at 25° C.;
a storage modulus of greater than 2875 MPa at 50° C.; or
any combination thereof.

12. The abrasive article of claim 10 , wherein the second abrasive particles comprise D10 of at least 0.5 microns and at most 4 microns, D90 of at least 9 microns and at most 34 microns, or both.

13. The abrasive article of claim 10 , wherein the second portion comprises at least one of the following:
a coefficient of thermal expansion of at least 38 ppm/° C. and at most 68 ppm/° C. in a temperature range of 30° C. to 50° C.;
elongation-at-fracture of less than 2.7% and at least 1.6%;
Stiffness Value of at least 8.3 and at most 20;
Modulus of Rupture of at least 11 MPa and at most 38 MPa; or
any combination thereof.

14. The abrasive article of claim 10 , wherein the second portion comprises:
a porosity of at least 3 vol % and at most 55 vol % for a total volume of the second portion;
the bond material of at least 29 wt % and at most 53 wt % for a total weight of the second portion; and
the second abrasive particles of at least 37 wt % and at most 60 wt % for the total weight of the second portion.

15. An abrasive article, comprising:
a body including:
a first portion comprising first abrasive particles contained within a first bond material including an inorganic material,
a second portion comprising second abrasive particles contained within a second bond material comprising an organic material comprising epoxy; and
a central opening extending in an axial direction of the body through the first portion and through the second portion,

wherein:
the first portion comprises a central region and a peripheral region coaxial with the central region, wherein the central region has a greater hardness than the peripheral region, a smaller porosity than the peripheral region, or a combination thereof; and
the central opening comprises a circumferential surface defining an inner diameter of the body, wherein the circumferential surface is defined by at least a portion of the first portion and at least a portion of the second portion,
the second portion is coupled to the first portion in a radial Mane, and
the second portion comprises a Stiffness Value of at least 8.3.

16. The abrasive article of claim 15 , wherein the peripheral region of the first portion comprises an abrasive portion comprising the first bond material and the first abrasive particles.

17. The abrasive article of claim 15 , wherein the body comprises an outer peripheral surface defining an outer diameter of the body, wherein a first portion of the outer peripheral surface of the body is defined by an outer surface of the peripheral region of the first portion.

18. The abrasive article of claim 15 , wherein a second portion of the circumferential surface of the central opening is defined by an inner surface of the second portion, wherein the second portion of the circumferential surface comprises the second bond material, the second abrasive particles, or a combination thereof.

19. The abrasive article of claim 15 , wherein the first portion of the body comprises for a total volume of the first portion:
a porosity of at least 5 vol % and at most 75 vol %;
the bond mater

Assignees

• Saint Gobain Abrasives Inc
• Saint Gobain Abrasifs Sa

Inventors

• Nashed Alexander
• Martin Amandine
• Janeczek Peter
• Schaefer Simone
• Sarangi Nilanjan
• Lin Guangyong
• Turkin Arthur

Classifications

• B24D3/18

  for porous or cellular structure · CPC title

• B24D5/14

  Zonally-graded wheels; Composite wheels comprising different abrasives · CPC title

• B24D5/06

  with inserted abrasive blocks, e.g. segmental · CPC title

• B24D3/32

  for porous or cellular structure · CPC title

• B24D3/34

  characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties · CPC title