Abrasive articles including abrasive particles bonded to an elongated body, and methods of forming thereof

Patent metadata

Field	Value
Publication number	US-9028948-B2
Application number	US-85737410-A
Country	US
Kind code	B2
Filing date	Aug 16, 2010
Priority date	Aug 14, 2009
Publication date	May 12, 2015
Grant date	May 12, 2015

Abstract

An abrasive article includes an elongated body, a bonding layer including a metal overlying a surface of the elongated body, and a coating layer including a polymer material overlying the boding layer. The abrasive article further includes abrasive grains contained within the bonding layer and coating layer, and wherein the bonding layer comprises an average thickness (t bl ) at least about 40% of the average grit size of the abrasive grains.

First claim

What is claimed is:

1. An abrasive article comprising:
an elongated body;
a bonding layer comprising a metal overlying a surface of the elongated body;
a coating layer comprising a polymer material overlying the boding layer, wherein the coating layer comprises an average thickness (t c ) less than an average thickness of the bonding layer (t bl ); and
abrasive grains contained within the bonding layer and coating layer, wherein a minor amount of the total amount of abrasive grains are contained within the bonding layer and spaced away from the surface of the elongated body.

2. The abrasive article of claim in the currently application 1 , wherein the elongated body comprises a thickness:width ratio of at least about 1:2.

3. The abrasive article of claim 1 , wherein the metal of the bonding layer comprises a transition metal element.

4. The abrasive article of claim 1 , wherein the surface of the elongated body is essentially covered by the bonding layer.

5. The abrasive article of claim 1 , wherein the bonding layer comprises an average thickness (t bl ) at least about 40% of the average grit size of the abrasive grains.

6. The abrasive article of claim 1 , wherein the elongated body is a wire.

7. The abrasive article of claim 1 , wherein the bonding layer comprises a filler.

8. The abrasive article of claim 7 , wherein the filler comprises a particulate.

9. The abrasive article of claim 8 , wherein the particulate comprises an average grain size substantially less than an average grit size of the abrasive grains.

10. The abrasive article of claim 8 , wherein the particulate comprises a different material than a material of the abrasive grains.

11. The abrasive article of claim 1 , wherein the coating layer comprises an average thickness (t c ) of not greater than about 50% of an average grit size of the abrasive grains.

12. The abrasive article of claim 1 , wherein the coating layer comprises a coating filler material.

13. The abrasive article of claim 1 , wherein the abrasive grains comprise a superabrasive material.

14. The abrasive article of claim 1 , wherein the abrasive grains consist essentially of diamond.

15. The abrasive article of claim 1 , wherein the abrasive grains comprise and average grit size of less than about 200 microns.

16. The abrasive article of claim 1 , wherein the abrasive grains are spaced away from the surface of the elongated body at a spacing distance of at least about 2% of the average thickness of the bonding layer (t bl ).

17. The abrasive article of claim 1 , wherein the abrasive grains are embedded within the bonding layer at an average indentation depth (d i ) of at least about 40% of an average grit size of the abrasive grains.

18. The abrasive article of claim 1 , wherein a portion of the coating includes wetted regions selectively surrounding a portion of the abrasive grains and unwetted regions between a portion of the abrasive grains, the wetted regions having an average thickness of the coating layer that is greater than an average thickness of the coating layer in the unwetted regions.

19. The abrasive article of claim 18 , wherein each wetted region is defined by a substantially circular region surrounding an abrasive grain, the substantially circular region having a wetted region radius equal to not greater than about twice the average grit size.

Assignees

• Tian Yinggang
• Ding Ran
• Liebelt Susanne
• Subramanian Krishnamoorthy
• Saint Gobain Abrasives Inc
• Saint Gobain Abrasifs Sa

Inventors

• Tian Yinggang
• Ding Ran
• Liebelt Susanne
• Subramanian Krishnamoorthy

Classifications

• B24D3/06

  metallic {or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements} · CPC title

• B23D61/185 Primary

  Saw wires; Saw cables; Twisted saw strips · CPC title

• B23D65/00

  Making tools for sawing machines or sawing devices for use in cutting any kind of material · CPC title

• Y10T428/2944

  Free metal in coating · CPC title

• Y10T428/2927

  including structurally defined particulate matter · CPC title