Abrasive grain, abrasive articles, and methods of making and using the same
Assignee3M Innovative Properties Company
InventorsDarren T. Castro, Ahmet Celikkaya, Larry D. Monroe
Life of this patent
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Abstract
Alpha alumina-based abrasive grain. The abrasive grain can be incorporated into abrasive products such as coated abrasives, bonded abrasives, non-woven abrasives, and abrasive brushes.
Claims72
Sintered alpha alumina-based abrasive grain comprising at least 0.1 percent by weight SiO2 and in the range from 1 to 14 percent by weight ZrO2, based on the total metal oxide content of said abrasive grain, wheren the alpha alumina of said abrasive grain has an average crystallite size of less than 1 micrometer, wherein said ZrO2 includes crystalline zirconia, and wherein ZrO2 present as crystalline zirconia has an average crystallite size of less than 0.25 micrometer.
A method for making alpha alumina-based ceramic abrasive grain, said method comprising:
- preparing a dispersion by combining components comprising liquid medium, peptizing agent, zirconia source, silica source, and alumina source;
- converting said dispersion to particulate alpha alumina-based ceramic abrasive grain precursor material;
- and
- sintering said precursor material to provide sintered alpha alumina-based abrasive grain comprising at least 0.1 percent by weight SiO2 and in the range from 1 to 14 percent by weight ZrO2, based on the total metal oxide content of said abrasive grain, wherein the alpha alumina of said abrasive grain has an average crystallite size of less than 1 micrometer, wherein said ZrO2 includes crystalline zirconia, and wherein ZrO2 present as crystalline zirconia has an average crystallite size of less than 0.25 micrometer.
A method for making an abrasive article, said method comprising:
- preparing a dispersion by combining components comprising liquid medium, peptizing agent, zirconia source, silica source, and alumina source;
- converting said dispersion to particulate alpha alumina-based ceramic abrasive grain precursor material;
- sintering said precursor material to provide sintered alpha alumina-based abrasive grain comprising at least 0.1 percent by weight SiO2 and in the range from 1 to 14 percent by weight ZrO2, based on the total metal oxide content of said abrasive grain, wherein the alpha alumina of said abrasive grain has an average crystallite size of less than 1 micrometer, wherein said ZrO2 includes crystalline zirconia, and wherein ZrO2 present as crystalline zirconia has an average crystallite size of less than 0.25 micrometer;
- and
- combining at least a plurality of said alpha alumina-based ceramic abrasive grain with binder to provide an abrasive article.
A method for making alpha a lumina-based ceramic abrasive grain, said method comprising:
- preparing a dispersion by combining components comprising first liquid medium, peptizing agent, silica source, and alumina source;
- converting said dispersion to particulate alpha alumina-based ceramic abrasive grain precursor material;
- impregnating said precursor material with a composition comprising a mixture comprising a second liquid medium and a zirconia source;
- and
- sintering the impregnated precursor material to provide sintered alpha alumina-based abrasive grain comprising at least 0.1 percent by weight SiO2 and in the range from 1 to 14 percent by weight ZrO2, based on the total metal oxide content of said abrasive grain, wherein the alpha alumina of said abrasive grain has an average crystallite size of less than 1 micrometer, wherein said ZrO2 includes crystalline zirconia, and wherein ZrO2 present as crystalline zirconia has an average crystallite size of less than 0.25 micrometer.
A method for making an abrasive article, said method comprising:
- preparing a dispersion by combining components comprising first liquid medium, peptizing agent, silica source, and alumina source;
- converting said dispersion to particulate alpha alumina-based ceramic abrasive grain precursor material;
- impregnating said precursor material with a composition comprising a mixture comprising a second liquid medium and a zirconia source;
- sintering the impregnated precursor material to provide sintered alpha alumina-based abrasive grain comprising at least 0.1 percent by weight SiO2 and in the range from 1 to 14 percent by weight ZrO2, based on the total metal oxide content of said abrasive grain, wherein the alpha alumina of said abrasive grain has an average crystallite size of less than 1 micrometer, wherein said ZrO2 includes crystalline zirconia, and wherein ZrO2 present as crystalline zirconia has an average crystallite size of less than 0.25 micrometer;
- and
- combining at least a plurality of said alpha alumina-based ceramic abrasive grain with binder to provide an abrasive article.
A method of abrading a surface comprising:
- contacting a plurality of abrasive grain with a surface of a substrate at a contact pressure of at least 1 kg/cm2, wherein at least a portion of said abrasive grain is sintered alpha alumina-based abrasive grain comprising at least 0.1 percent by weight SiO2 and in the range from 1 to 14 percent by weight ZrO2, based on the total metal oxide content of said abrasive grain, wherein the alpha alumina of said abrasive grain has an average crystallite size of less than 1 micrometer, wherein said ZrO2 includes crystalline zirconia, and wherein ZrO2 present as crystalline zirconia has an average crystallite size of less than 0.25 micrometer;
- and
- moving at least of one said plurality of abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said abrasive grain.
Dependencies are inferred from the claim text.