# US 10,323,165 B2 · Agglomerate abrasive grain comprising incorporated hollow microspheres

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- Number: US 10,323,165 B2
- Document ID: US10323165B2
- Status: Granted
- Kind: B2
- Application number: 14/369,892
- Filed: 2013-09-11
- Published: 2015-02-26
- Granted: 2019-06-18
- Earliest claimed: 2012-09-12
- Assignees: ImerTech SAS
- Applicants: ImerTech SAS
- Inventors: Knuth Gebhardt; Georg Paul Zylka
- Web page: https://patentgrep.com/patent/US10323165B2

## CPC

- C09K 3/1436: {Composite particles, e.g. coated particles}
- C04B 18/02: Agglomerated materials {, e.g. artificial aggregates}
- C04B 28/006: {containing mineral polymers, e.g. geopolymers of the Davidovits type}
- C04B 28/26: Silicates of the alkali metals
- C04B 2111/00215: {Mortar or concrete mixtures defined by their oxide composition}
- Y02P 40/10: Production of cement, e.g. improving or optimising the production methods; Cement grinding
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

An agglomerate abrasive grain includes a mixture of individual abrasive grains and hollow bodies, wherein the abrasive grains and the hollow bodies are held together via a binding matrix of aluminosilicate and alkali silicate, and the agglomerate abrasive grain has an open porosity and a closed porosity in each case ranging from 5% by volume to 40% by volume, wherein the total porosity of the agglomerate abrasive grain is less than 50% by volume.

## Claims

### Claim 1

An agglomerate abrasive grain comprising a plurality of individual abrasive grains incorporated into a binding matrix, wherein:
the abrasive grains are selected from the group consisting of corundum, fused corundum, sintered corundum, alumina zirconia, silicon carbide, boron carbide, cubic boron nitride, diamond, and mixtures thereof;
the binding matrix is obtained from a mixture of an aluminosilicate, an alkali sodium silicate, and water;
the aluminosilicate and the alkali sodium silicate having a molar ratio of Al2O3 to SiO2 ranging from 1:2 to 1:20;
the binding matrix is hardened at temperatures below 500° C.;
the agglomerate abrasive grain has an open porosity ranging from 5% by volume to 25% by volume,
the agglomerate abrasive grain further comprising hollow bodies that are incorporated into the binding matrix and that provide the agglomerate abrasive grain with a closed porosity, wherein
the hollow bodies are 5% to 40% by volume of the agglomerate abrasive grain, and
the sum of closed and open porosity is less than 50% by volume of the agglomerate abrasive grain;
further wherein the abrasive grains and the hollow bodies have an average particle diameter ranging from 5 μm to 250 μm, and wherein the ratio of the average particle diameter of the abrasive grains to the average particle diameter of the hollow bodies ranges from 2:1 to 1:2.

### Claim 2 (depends on 1)

The agglomerate abrasive grain according to claim 1, characterized in that the percentage by volume of the abrasive grains to the percentage by volume of the hollow bodies has a ratio ranging from 9:1 to 1.5:1.

### Claim 3 (depends on 2)

The agglomerate abrasive grain according to claim 2, characterized in that the percentage by volume of the abrasive grains to the percentage by volume of the hollow bodies has a ratio ranging from 6:1 to 2:1.

### Claim 4 (depends on 1)

The agglomerate abrasive grain according to claim 1, characterized in that the agglomerate abrasive grain comprises from 10% by volume to 80% by volume of abrasive grains, from 5% by volume to 40% by volume of hollow bodies, from 5% by volume to 40% by volume of binding matrix, and from 5% by volume to 25% by volume of open pores.

### Claim 5 (depends on 1)

The agglomerate abrasive grain according to claim 1, characterized in that the hollow bodies are selected from the group consisting of hollow bodies on the basis of aluminum oxide, silicon oxide, zirconium oxide, titanium oxide, cerium oxide, and/or mixtures thereof.

### Claim 6 (depends on 5)

The agglomerate abrasive grain according to claim 5, characterized in that the hollow bodies are hollow spheres made of glass.

### Claim 7 (depends on 1)

The agglomerate abrasive grain according to claim 1, characterized in that the agglomerate abrasive grain comprises from 5% by weight to 30% by weight of binding matrix, from 60% by weight to 95% by weight of abrasive grains, and from 0.3% by weight to 20% by weight of hollow bodies.

### Claim 8 (depends on 1)

A method for producing agglomerate abrasive grains according to claim 1, wherein a mixture of individual abrasive grains and hollow bodies are incorporated into a binding matrix of aluminosilicate and alkali sodium silicate having a molar ratio of Al2O3 to SiO2 ranging from 1:2 to 1:20, the method comprising:
mixing the abrasive grains and hollow bodies with the binding agent of aluminosilicate, alkali sodium silicate, and water,
drying the agglomerate abrasive grain green bodies obtained in this manner at a temperature ranging from 80° to 150° C.;
classifying the dried agglomerate abrasive grain green bodies to a defined abrasive grit size; and
hardening the dried and classified agglomerate abrasive grains at a temperature below 500° C.