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US 5,908,478 AGranted
Method for making abrasive grain using impregnation, and abrasive articles
AssigneeMinnesota Mining and Manufacturing Company
InventorWilliam P. Wood
Life of this patent
Estimating the term…
Abstract
Method for making alpha alumina-based abrasive grain from a dispersion comprising boehmite, wherein the method involves the impregnation of an alpha alumina-based ceramic precursor material. The abrasive grain can be incorporated into abrasive products such as coated abrasives, bonded abrasives, and non-woven abrasives.
Claims60
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising a first liquid medium, a peptizing agent, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion, said boehmite being present in an amount sufficient to provide, on an oxide basis, said dispersion with greater than 99.9 percent by weight Al.sub.2 O.sub.3, based on the total metal oxide content of said dispersion:
- (b) converting said dispersion to alpha alumina-based ceramic precursor material, wherein step (b) includes extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising a second liquid medium and at least one of a metal oxide or precursor thereof;
- and
- (d) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 90 percent of theoretical.
2 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising water, a peptizing agent, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion, said boehmite being present in an amount sufficient to provide, on an oxide basis, said dispersion with greater than 99.95 percent by weight Al.sub.2 O.sub.3, based on the total metal oxide content of said dispersion, said dispersion containing, on a metal oxide basis, less than 0.05 percent by weight of nucleating material, based on the total metal oxide content of said dispersion, and said peptizing agent being at least one acid;
- (b) converting said dispersion to alpha alumina-based ceramic precursor material, wherein step (b) includes (i) extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion, (ii) drying said dispersion, and (iii) calcining the dried dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising water and at least one of a metal oxide or precursor thereof;
- and
- (d) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 92 percent of theoretical,
- wherein said composition impregnated into said precursor material is sufficient to provide, on a metal oxide basis, greater than 0.1 percent metal oxide, based on the total metal oxide content of said abrasive grain.
3 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising water, a peptizing agent, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion, said boehmite being present in an amount sufficient to provide, on an oxide basis, said dispersion with greater than 99.95 percent by weight Al.sub.2 O.sub.3, based on the total metal oxide content of said dispersion, said dispersion containing, on a metal oxide basis, less than 0.05 percent by weight nucleating agent, based on the total metal oxide content of said dispersion, and said peptizing agent being at least one acid;
- (b) converting said dispersion to alpha alumina-based ceramic precursor material, wherein step (b) includes (i) extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion, (ii) drying said dispersion, and (iii) calcining the dried dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising water and at least one of a metal oxide or precursor thereof;
- and
- (d) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 92 percent of theoretical,
- wherein said composition impregnated into said precursor material is sufficient to provide, on a metal oxide basis, greater than 0.1 percent metal oxide, based on the total metal oxide content of said abrasive grain.
3 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising water, a peptizing agent, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion, said boehmite being present in an amount sufficient to provide, on an oxide basis, said dispersion with greater than 99.95 percent by weight Al.sub.2 O.sub.3, based on the total metal oxide content of said dispersion, said dispersion containing, on a metal oxide basis, less than 0.05 percent by weight alpha alumina seeds, based on the total metal oxide content of said dispersion, and said peptizing agent being at least one acid;
- (b) converting said dispersion to alpha alumina-based ceramic precursor material, wherein step (b) includes (i) extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion, (ii) drying said dispersion, and (iii) calcining the dried dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising water and at least one of a metal oxide or precursor thereof;
- and
- (d) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 92 percent of theoretical,
- wherein said composition impregnated into said precursor material is sufficient to provide, on a metal oxide basis, greater than 0.1 percent metal oxide, based on the total metal oxide content of said abrasive grain.
3 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a first dispersion by combining components comprising liquid medium, acid, and boehmite;
- (b) drying the first dispersion to provide first alpha alumina-based precursor material;
- (c) combining components comprising water and said first alpha alumina-based precursor material to provide a second dispersion comprising water, an acid, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion, said boehmite being present in an amount sufficient to provide, on an oxide basis, said dispersion with greater than 99.95 percent by weight Al.sub.2 O.sub.3, based on the total metal oxide content of said dispersion.
- (d) converting said second dispersion to second alpha alumina-based ceramic precursor material, wherein step (d) includes (i) extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion, (ii) doing said second dispersion, and (iii) calcining the dried dispersion;
- (e) impregnating the second precursor material with a composition comprising a mixture comprising water and at least one of a metal oxide or precursor thereof;
- and
- (f) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 92 percent of theoretical,
- wherein said composition impregnated into said precursor material is sufficient to provide, on a metal oxide basis, greater than 0.1 percent metal oxide, based on the total metal oxide content of said abrasive grain.
5 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a first dispersion by combining components comprising liquid medium, acid, and boehmite;
- (b) drying the first dispersion to provide first alpha alumina-based precursor material;
- (c) combining components comprising water, boehmite, and said first alpha alumina-based precursor material to provide a second dispersion comprising water, an acid, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion, said boehmite being present in an amount sufficient to provide, on an oxide basis, said dispersion with greater than 99.95 percent by weight Al.sub.2 O.sub.3, based on the total metal oxide content of said dispersion;
- (d) converting said second dispersion to second alpha alumina-based ceramic precursor material, wherein step (d) includes (i) extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion, (ii) drying said second dispersion, and (iii) calcining the dried dispersion;
- (e) impregnating the second precursor material with a composition comprising a mixture comprising water and at least one of a metal oxide or precursor thereof;
- and
- (f) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 92 percent of theoretical,
- wherein said composition impregnated into said precursor material is sufficient to provide, on a metal oxide basis, greater than 0.1 percent metal oxide, based on the total metal oxide content of said abrasive grain.
5 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising a first liquid medium, a peptizing agent, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion, said boehmite being present in an amount sufficient to provide, on an oxide basis, said dispersion with greater than 99.9 percent by weight Al.sub.2 O.sub.3, based on the total metal oxide content of said dispersion;
- (b) converting said dispersion to alpha alumina-based ceramic precursor material, wherein step (b) includes extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising a second liquid medium and at least one acidic metal oxide salt;
- (d) impregnating at least a portion of the impregnated precursor material from step (c) with a second composition comprising a mixture comprising a third liquid medium and at least one basic salt;
- and
- (e) converting the impregnated precursor material from step (d) to alpha alumina-based ceramic abrasive grain having a density of greater than 90 percent of theoretical.
3 more elements
A method for making an abrasive article, said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising a first liquid medium, a peptizing agent, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion, said boehmite being present in an amount sufficient to provide, on an oxide basis, said dispersion with greater than 99.9 percent by weight Al.sub.2 O.sub.3, based on the total metal oxide content of said dispersion;
- (b) converting said dispersion to alpha alumina-based ceramic precursor material, wherein step (b) includes extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising a second liquid medium and at least one of a metal oxide or precursor thereof;
- (d) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 90 percent of theoretical;
- and
- (e) combining at least a plurality of said alpha alumina-based ceramic abrasive grain with binder to provide an abrasive article.
3 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising a first liquid medium, a peptizing agent, at least one of a first metal oxide or precursor thereof, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion;
- (b) converting said dispersion to alpha alumina-based ceramic precursor material, wherein step (b) includes extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising a second liquid medium and at least one of a second metal oxide or precursor thereof;
- and
- (d) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 90 percent of theoretical,
- wherein said at least one of a first metal oxide or precursor thereof and said at least one of a second metal oxide or precursor thereof are present in a sufficient amount to provide said abrasive grain with, on a metal oxide basis, at least 0.1 percent by weight metal oxide, based on the total metal oxide content of said abrasive grain.
3 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising water, a peptizing agent, at least one of a first metal oxide or precursor thereof, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion, said dispersion containing, on a metal oxide basis, less than 0.05 percent by weight of nucleating material, based on the total metal oxide content of said dispersion, and said peptizing agent being at least one acid;
- (b) converting said dispersion to alpha alumina-based ceramic precursor material, wherein step (b) includes (i) extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion, (ii) drying said dispersion, and (iii) calcining the dried dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising water and at least one of a second metal oxide or precursor thereof;
- and
- (d) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 92 percent of theoretical,
- wherein said second metal oxide or precursor thereof is present in a sufficient amount to provide said abrasive grain with, on a metal oxide basis, at least 0.1 percent by weight metal oxide, based on the total metal oxide content of said abrasive grain.
3 more elements
A method for making alpha alumina-based ceramic abrasive grain said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising water, a peptizing agent, at least one of a first metal oxide or precursor thereof, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion, said dispersion containing, on a metal oxide basis, less than 0.05 percent by weight nucleating agent, based on the total metal oxide content of said dispersion, and said peptizing agent being at least one acid;
- (b) converting said dispersion to alpha alumina-based ceramic precursor material, wherein step (b) includes (i) extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion, (ii) drying said dispersion, and (iii) calcining the dried dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising water and at least one of a second metal oxide or precursor thereof;
- and
- (d) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 92 percent of theoretical,
- wherein said second metal oxide or precursor thereof is present in a sufficient amount to provide said abrasive grain with, on a metal oxide basis, at least 0.1 percent by weight metal oxide, based on the total metal oxide content of said abrasive grain.
3 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising water, a peptizing agent, at least one of a first metal oxide or precursor thereof, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion, said dispersion containing, on a metal oxide basis, less than 0.05 percent by weight alpha alumina seeds, based on the total metal oxide content of said dispersion, and said peptizing agent being at least one acid;
- (b) converting said dispersion to alpha alumina-based ceramic precursor material, wherein step (b) includes (i) extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion, (ii) drying said dispersion, and (iii) calcining the dried dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising water and at least one of a second metal oxide or precursor thereof;
- and
- (d) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 92 percent of theoretical,
- wherein said second metal oxide or precursor thereof is present in a sufficient amount to provide said abrasive grain with, on a metal oxide basis, at least 0.1 percent by weight metal oxide, based on the total metal oxide content of said abrasive grain.
3 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) providing a first dispersion by combining components comprising liquid medium, acid, and boehmite;
- (b) drying said first dispersion to provide first alpha alumina-based precursor material;
- (c) combining components comprising water and said first alpha alumina-based precursor material to provide a second dispersion comprising water, an acid, at least one of a first metal oxide or precursor thereof, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion;
- (d) converting said second dispersion to second alpha alumina-based ceramic precursor material, wherein step (d) includes (i) extruding said dispersion through a segmented screw extruder and wherein extruding includes compacting said dispersion, (ii) drying said dispersion, and (iii) calcining the dried dispersion;
- (e) impregnating said second precursor material with a composition comprising a mixture comprising a second liquid medium and at least one of a second metal oxide or precursor thereof;
- and
- (f) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 92 percent of theoretical,
- wherein said least one of a second metal oxide or precursor thereof is present in a sufficient amount to provide said abrasive grain with, on a metal oxide basis, at least 0.1 percent by weight metal oxide, based on the total metal oxide content of said abrasive grain.
5 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a first dispersion by combining components comprising liquid medium, acid, and boehmite;
- (b) drying said first dispersion to provide first alpha alumina-based precursor material;
- (c) combining components comprising water, boehmite, and said first alpha alumina-based precursor material to provide a second dispersion comprising water, an acid, at least one of a first metal oxide or precursor thereof, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion;
- (d) converting said second dispersion to second alpha alumina-based ceramic precursor material, wherein step (d) includes (i) extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion, (ii) drying said second dispersion, and (iii) calcining the dried dispersion,
- (e) impregnating said second precursor material with a composition comprising a mixture comprising a second liquid medium and at least one of a second metal oxide or precursor thereof;
- and
- (f) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 92 percent of theoretical,
- wherein said least one of a second metal oxide or precursor thereof is present in a sufficient amount to provide said abrasive grain with, on a metal oxide basis, at least 0.1 percent by weight metal oxide, based on the total metal oxide content of said abrasive grain.
5 more elements
A method for making alpha alumina-based ceramic abrasive grain, said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising a first liquid medium, a peptizing agent, at least one of a first metal oxide or precursor thereof, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion;
- (b) converting said dispersion to alpha alumina-based ceramic precursor material, wherein step (b) includes extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising a second liquid medium and at least one acidic metal oxide salt;
- (d) impregnating at least a portion of the impregnated precursor material from step (c) with a second composition comprising a mixture comprising a third liquid medium and at least one basic salt;
- (e) converting the impregnated precursor material from step (d) to alpha alumina-based ceramic abrasive grain having a density of greater than 90 percent of theoretical,
- wherein said at least one of a first metal oxide or precursor thereof, said at least one acidic salt, and said at least one basic salt are present in a sufficient amount to provide said abrasive grain with, on a metal oxide basis, at least 0.1 percent by weight metal oxide, based on the total metal oxide content of said abrasive grain.
3 more elements
A method for making an abrasive article, said method comprising the steps of:
- (a) preparing a dispersion by combining components comprising a first liquid medium, a peptizing agent, at least one of a first metal oxide or precursor thereof, and greater than 60 percent by weight boehmite, based on the total weight of said dispersion;
- (b) converting said dispersion to alpha alumina-based ceramic precursor, material, wherein step (b) includes extruding said dispersion through a segmented screw extruder, and wherein extruding includes compacting said dispersion;
- (c) impregnating the precursor material with a composition comprising a mixture comprising a second liquid medium and at least one of a second metal oxide or precursor thereof;
- (d) converting the impregnated precursor material to alpha alumina-based ceramic abrasive grain having a density of greater than 90 percent of theoretical;
- and
- (d) combining at least a plurality of said alpha alumina-based ceramic abrasive grain with binder to provide an abrasive article,
- wherein said at least one of a first metal oxide or precursor thereof and said at least one of a second metal oxide or precursor thereof are present in a sufficient amount to provide said abrasive grain with, on a metal oxide basis, at least 0.1 percent by weight metal oxide, based on the total metal oxide content of said abrasive grain.
4 more elements
Dependencies are inferred from the claim text.