# US 11,999,029 B2 · Abrasive articles and methods for forming same

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- Number: US 11,999,029 B2
- Document ID: US11999029B2
- Status: Granted
- Kind: B2
- Application number: 16/457,542
- Filed: 2019-06-28
- Published: 2020-01-02
- Granted: 2024-06-04
- Earliest claimed: 2018-06-29
- Assignees: Saint-Gobain Abrasives, Inc.; Saint-Gobain Abrasifs
- Applicants: Saint-Gobain Abrasives, Inc.; Saint-Gobain Abrasifs
- Inventors: Srikanth Rapaka; Stephen E. Fox; Nilanjan Sarangi
- Web page: https://patentgrep.com/patent/US11999029B2

## CPC

- B24D 3/04: and being essentially inorganic
- B24D 3/10: for porous or cellular structure, e.g. for use with diamonds as abrasives
- B24D 3/18: for porous or cellular structure
- B24D 18/00: Manufacture of grinding tools {or other grinding devices}, e.g. wheels, not otherwise provided for
- C09K 3/1436: {Composite particles, e.g. coated particles}
- B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11)
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE

## Abstract

An abrasive article including a bonded abrasive body having a bond material including an inorganic material, abrasive particles contained within the bond material of the bonded abrasive body, porosity within a range of at least 55 vol % to not greater than 90 vol % for a total volume of the bonded abrasive body, and a Solid Phase Variation of not greater than 45%.

## Claims

### Claim 1

A method of making an abrasive article comprising:
forming a mixture comprising abrasive particles having an average size of at least 200 microns, a bond precursor material, and a foaming agent;
adding a foaming catalyst to the mixture, wherein the foaming catalyst interacts with the foaming agent to create bubbles in the mixture; and
forming a bonded abrasive body from the mixture, wherein the bonded abrasive body comprises a bond material comprising an inorganic material and further comprising a permeability as defined by Darcy's number of at least 350.

### Claim 2 (depends on 1)

The method of claim 1, wherein the foaming agent comprises hydrogen peroxide.

### Claim 3 (depends on 1)

The method of claim 1, wherein the foaming agent is in an amount of at least 0.5 wt % and not greater than 50 wt % for a total weight of the mixture.

### Claim 4 (depends on 1)

The method of claim 1, wherein the foaming catalyst comprises a salt including potassium iodide, iron oxide, magnesium oxide, copper oxide, or any combination thereof.

### Claim 5 (depends on 1)

The method of claim 1, further comprising adding a gelling agent to the mixture, wherein the gelling agent is selected from the group consisting of agar, agarose, xanthan gum, carboxy methyl cellulose, gellan gum, carrageenan gum, guar gum, tara gum, cellulose gum, locust bean gum, or any combination thereof.

### Claim 6 (depends on 5)

The method of claim 5, further comprising adding a cationic agent to the mixture and forming a gel.

### Claim 7 (depends on 1)

The method of claim 1, comprising forming a gel by heating the mixture to a gelling temperature.

### Claim 8 (depends on 7)

The method of claim 7, wherein the mixture is mixed while heating the mixture to the gelling temperature.

### Claim 9 (depends on 1)

The method of claim 1, further comprising:
forming a gel from the mixture;
foaming the gel to create a foamed gel; and
forming a green body from the foamed gel.

### Claim 10 (depends on 1)

The method of claim 1, wherein the abrasive particles are unagglomerated.

### Claim 11 (depends on 1)

The method of claim 1, wherein the bonded abrasive body comprises:
a diameter of at least 5 mm and not greater than 800 mm;
a volume of at least 1 cm3 and not greater than 1000 cm3;
a thickness of at least 2 mm and not greater than 400 mm; or
any combination thereof.

### Claim 12 (depends on 1)

The method of claim 1, wherein the mixture includes a cationic agent including a compound including sulfates, chlorides, chromates, nitrates, carbonates, hydrates or any combination thereof.

### Claim 13 (depends on 12)

The method of claim 12, wherein the mixture includes at least 0.1 wt % and not greater than 6 wt % of the cationic agent for a total weight of the mixture.

### Claim 14 (depends on 1)

The method of claim 1, forming the mixture includes adding a dispersant to the mixture, wherein the dispersant is selected from the group consisting of sodium polyacrylate, copolymer with pigment affinic group, ammonium polymeta acrylate, ammonium polyacrylate, polyacrylic acid, ammonium salt in an acrylic polymer in water, citric acid, sodium dodecylbenzenesulfonate, and cetyltrimethyl ammonium bromide.

### Claim 15

A method of making an abrasive article comprising:
forming a mixture comprising abrasive particles having an average size of at least 200 microns, a bond precursor material, and a foaming agent, wherein the foaming agent is a reactant to a foaming process, wherein forming the mixture includes adding a surfactant to the mixture, wherein the surfactant is selected from the group consisting of sodium lauroyl sarcosinate, sodium laurel sulfate, sodium laurate, sodium stearate, sodium alkyl sulfate, sodium dodecyl sulfate, sorbitan, polyethylene glycol, polysorbate, glycerol monosterate, egg lecithin; and
forming a bonded abrasive body from the mixture, wherein the bonded abrasive body comprises a bond material comprising an inorganic material and further comprising a permeability as defined by Darcy's number of at least 350.

### Claim 16 (depends on 15)

The method of claim 15, further comprising adding a foaming catalyst to the mixture, wherein the foaming catalyst interacts with the foaming agent to create bubbles in the mixture.

### Claim 17

A method of making an abrasive article comprising:
forming a mixture comprising abrasive particles, a bond precursor material, a foaming agent, and a gelling agent, wherein the bond precursor material comprises an inorganic material, and wherein the gelling agent is selected from the group consisting of agar, agarose, xanthan gum, carboxy methyl cellulose, gellan gum, carrageenan gum, guar gum, tara gum, cellulose gum, locust bean gum, or any combination thereof;
adding a foaming catalyst to the mixture, wherein the foaming catalyst interacts with the foaming agent to create bubbles in the mixture;
forming a bonded abrasive body from the mixture, wherein the bonded abrasive body comprises a porosity within a range of at least 55 vol % to not greater than 90 vol % for a total volume of the bonded abrasive body, a permeability as defined by Darcy's number of at least 350, or a combination thereof.

### Claim 18 (depends on 17)

The method of claim 17, further comprising forming a gel by heating the mixture to a gelling temperature.

### Claim 19 (depends on 17)

The method of claim 17, wherein the foaming agent comprises hydrogen peroxide.

### Claim 20 (depends on 17)

The method of claim 17, wherein the foaming catalyst comprises a salt including potassium iodide, iron oxide, magnesium oxide, copper oxide, or any combination thereof.