Fixed-abrasive nano-grinding plates, related articles, and related methods
AssigneeEngis Corporation
InventorsClement N. Onyenemezu, Benjamin Reynolds Rosczyk, Hyeseung Rachel Bae, Ion C. Benea
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Abstract
The disclosure relates to fixed-abrasive grinding plates, fixed-abrasive grinding tools formed therefrom, and related methods. The grinding plate generally has a composite structure with abrasive beads (e.g., beads with diamond abrasives), a porosity additive, and an inorganic filler and/or flux agent distributed throughout a binder matrix formed from a polymeric resin (e.g., a cured, thermoset resin) or a vitreous material (e.g., a fired, vitrified glass frit matrix).
Claims37
A fixed-abrasive grinding plate comprising:
- a) a plurality of micron-sized composite abrasive beads in an amount of 30 wt. % to 95 wt. % on a dry weight basis of the grinding plate;
- b) at least one porosity additive in an amount of 1 wt. % to 40 wt. % on a dry weight basis of the grinding plate;
- c) one or more inorganic fillers in an amount of 1 wt. % to 40 wt. % on a dry weight basis of the grinding plate;
- and
- d) at least one polymeric resin in an amount of 3 wt. % to 40 wt. % on a dry weight basis of the grinding plate, wherein the polymeric resin bonds the abrasive beads;
- wherein:
- the grinding plate has a hardness value in a range of 20 to 120 on the Rockwell Hardness L scale, and
- the grinding plate has a calculated density in a range 0.8 g/cm3 to 1.8 g/cm3.
A fixed-abrasive grinding plate comprising:
- a) a plurality of micron-sized composite abrasive beads in an amount of 30 wt. % to 95 wt. % on a dry weight basis of the grinding plate;
- b) at least one porosity additive in an amount of 1 wt. % to 40 wt. % on a dry weight basis of the grinding plate;
- c) one or more flux agents in an amount of 1 wt. % to 40 wt. % on a dry weight basis of the grinding plate;
- and
- d) a vitreous matrix in an amount of 3 wt. % to 40 wt. % on a dry weight basis of the grinding plate, wherein the vitreous matrix bonds the abrasive beads.
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A fixed-abrasive grinding kit comprising:
- a plurality of fixed-abrasive grinding tools comprising:
- (i) at least one polymeric fixed-abrasive grinding tool comprising a first base plate, and a plurality of first fixed-abrasive grinding segments mounted to the first base plate, the first fixed-abrasive grinding segments comprising a) a plurality of micron-sized composite abrasive beads in an amount of 30 wt. % to 95 wt. % on a dry weight basis of the grinding segments, b) at least one porosity additive in an amount of 1 wt. % to 40 wt. % on a dry weight basis of the grinding segments, c) one or more inorganic fillers in an amount of 1 wt. % to 40 wt. % on a dry weight basis of the grinding plate, and d) at least one polymeric resin in an amount of 3 wt. % to 40 wt. % on a dry weight basis of the grinding segments, wherein the polymeric resin bonds the abrasive beads, wherein the grinding segments have a hardness value in a range of 20 to 120 on the Rockwell Hardness L scale, and the grinding segments have a calculated density in a range 0.8 q/cm3 to 1.8 q/cm3;
- and
- (ii) at least one vitreous fixed-abrasive grinding tool comprising a second base plate, and a plurality of second fixed-abrasive grinding segments mounted to the second base plate, the second fixed-abrasive grinding segments comprising a) a plurality of micron-sized composite abrasive beads in an amount of 30 wt. % to 95 wt. % on a dry weight basis of the grinding segments, b) at least one porosity additive in an amount of 1 wt. % to 40 wt. % on a dry weight basis of the grinding segments, c) one or more flux agents in an amount of 1 wt. % to 40 wt. % on a dry weight basis of the grinding segments, and d) a vitreous matrix in an amount of 3 wt. % to 40 wt. % on a dry weight basis of the grinding segments, wherein the vitreous matrix bonds the abrasive beads.
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Dependencies are inferred from the claim text.