Polymer Bond Abrasive Articles Including Continuous Polymer Matrix, and Methods of Making Same

Patent metadata

Field	Value
Publication number	US-2022395961-A1
Application number	US-202017775639-A
Country	US
Kind code	A1
Filing date	Dec 4, 2020
Priority date	Dec 12, 2019
Publication date	Dec 15, 2022
Grant date	—

Abstract

The present disclosure provides a polymer bond abrasive article formed of a continuous photocured polymer matrix having abrasive particles retained therein. The photocured polymer matrix includes at least one of an optical brightener or a light absorber, and the polymer bond abrasive article has a three-dimensional shape. An abrasive tool is also provided, including the abrasive article affixed to a shaft or a pad. Further, a method of making the polymer bond abrasive article is provided, including a) obtaining a photocurable composition liquid dispersion; b) selectively curing a portion of the photocurable composition; and repeating steps a) and b) to form the polymer bond abrasive article. The dispersion contains at least one photocurable component; abrasive particles; a photoinitiator; and at least one of an optical brightener or a light absorber.

First claim

1 . A polymer bond abrasive article formed of a continuous photocured polymer matrix comprising abrasive particles retained therein, wherein the photocured polymer matrix comprises at least one of an optical brightener or a light absorber, and wherein the polymer bond abrasive article has a three-dimensional shape.

2 . The polymer bond abrasive article of claim 1 , wherein the at least one of the optical brightener or the light absorber is present in an amount of greater than 0.01 weight percent (wt. %), based on the total weight of the photocured polymer matrix.

3 . The polymer bond abrasive article of claim 1 , wherein the continuous photocured polymer matrix is formed of a plurality of layers having an average thickness of 10 micrometers or greater, 20 micrometers or greater, 30 micrometers or greater, 40 micrometers or greater, 50 micrometers or greater, 60 micrometers or greater, 70 micrometers or greater, 80 micrometers or greater, or 90 micrometers or greater; and an average thickness of 150 micrometers or less, 140 micrometers or less, 130 micrometers or less, 120 micrometers or less, 110 micrometers or less, or 100 micrometers or less.

4 . The polymer bond abrasive article of claim 1 , wherein the abrasive particles comprise ceramic abrasive agglomerates, wherein the ceramic abrasive agglomerates comprise individual abrasive particles dispersed in a porous ceramic matrix, and wherein at least a portion of the porous ceramic matrix comprises glassy ceramic material.

5 . The polymer bond abrasive article of claim 1 , wherein the abrasive particles comprise at least one of diamond particles, metal oxide ceramic particles, or non-oxide ceramic particles.

6 . The polymer bond abrasive article of claim 1 , wherein the abrasive particles comprise at least one of cubic boron nitride, silicon carbide, titanium diboride, titanium nitride, boron carbide, tungsten carbide, titanium carbide, aluminum nitride, aluminum oxide, diamond, fused alumina-zirconia, sol-gel derived abrasive particles, or silicon nitride particles.

7 . The polymer bond abrasive article of claim 1 , wherein the abrasive particles exhibit a Mohs hardness of 9-10.

8 . The polymer bond abrasive article of claim 1 , wherein the photocured polymer matrix comprises a reaction product of at least one monomer selected from vinyl monomers, oxirane monomers, oxetane monomers, cyclic olefin monomers, or thiol-ene monomers.

9 . The polymer bond abrasive article of claim 8 , wherein the photocured polymer matrix comprises a reaction product of the at least one monomer and at least one oligomer exhibiting a viscosity of 40 Pascal seconds (Pas) or greater.

10 . The polymer bond abrasive article of claim 1 , comprising 0.1 volume percent (vol. %) to 70 vol. % of the abrasive particles.

11 . The polymer bond abrasive article of claim 1 , comprising 0.5 weight percent (wt. %) to 80 wt. % of the abrasive particles.

12 . The polymer bond abrasive article claim 1 , comprising a cylindrical shape, a conical shape, a spherical shape, a disc shape, or a hemispherical shape.

13 . The polymer bond abrasive article of claim 1 , comprising a plurality of separated substructures each having a three-dimensional pattern disposed on an exterior surface thereof.

14 . The polymer bond abrasive article of claim 1 , wherein the continuous photocured polymer matrix defines one or more tortuous or arcuate channels, one or more architectural voids, one or more undercuts, one or more perforations, or combinations thereof.

15 . An abrasive tool comprising the article of claim 1 , wherein the article is affixed to a shaft or a pad.

16 . A method of making the polymer bond abrasive article of claim 1 , the method comprising:
a) obtaining a photocurable composition liquid dispersion comprising:
i) at least one photocurable monomer;
ii) abrasive particles;
iii) a photoinitiator; and
iv) at least one of an optical brightener or a light absorber;
b) selectively curing a portion of the photocurable composition; and c) repeating steps a) and b) to form the polymer bond abrasive article comprising a continuous photocured polymer matrix comprising abrasive particles retained therein and at least one of the optical brightener or the light absorber.

17 . The method of claim 16 , wherein the photocurable composition is cured using actinic radiation comprising UV radiation, e-beam radiation, visible radiation, or a combination thereof.

18 . A non-transitory machine readable medium comprising data representing a three-dimensional model of a polymer bond abrasive article, when accessed by one or more processors interfacing with a 3D printer, causes the 3D printer to create a polymer bond abrasive article formed of a continuous photocured polymer matrix comprising abrasive particles retained therein, wherein the polymer bond abrasive article has a three-dimensional shape.

19 . (canceled)

20 . A method comprising:
a) receiving, by a manufacturing device having one or more processors, a digital object comprising data specifying a polymer bond abrasive article; and b) generating, with the manufacturing device by an additive manufacturing process, the polymer bond abrasive article based on the digital object, the polymer bond abrasive article formed of a continuous photocured polymer matrix comprising abrasive particles retained therein, wherein the polymer bond abrasive article has a three-dimensional shape.

21 . (canceled)

22 . The polymer bond abrasive article of claim 1 , wherein the light absorber is present and comprises at least one of a visible light absorber or a hindered amine light stabilizer (HALS).

Assignees

• 3M Innovative Properties Company

Inventors

• Wu Tianyu
• Hughes Gareth A
• Sventek Bruce A
• Stolzenburg Fabian
• Chen Jing
• Kobussen Gregory A
• Smithson Robert L W

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29K2509/04

  Carbides; Nitrides · CPC title

• B24D18/0072

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

• B29C64/124

  using layers of liquid which are selectively solidified · CPC title

• B29K2105/16

  Fillers · CPC title