Fused AL2O3-rare earth oxide-ZrO2 eutectic abrasive particles, abrasive articles, and methods of making and using the same
Assignee3M Innovative Properties Company
InventorAnatoly Z. Rosenflanz
Life of this patent
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Abstract
Fused abrasive particles comprising eutectic material. The fused abrasive particles can be incorporated into abrasive products such as coated abrasives, bonded abrasives, non-woven abrasives, and abrasive brushes.
Claims73
Fused, crystalline abrasive particle comprising at least 20 percent by volume, based on the total metal oxide volume of said particle, eutectic material, wherein said eutectic material comprises eutectic of at least:
- (a) crystalline ZrO2 and
- (b) at least two of:
- (i) crystalline Al2O3,
- (ii) first crystalline complex Al2O3.rare earth oxide, or
- (iii) second, different, crystalline complex Al2O3.rare earth oxide.
Fused, crystalline abrasive particle comprising at least 20 percent by volume, based on the total metal oxide volume of said particle, eutectic material, wherein said eutectic material comprises eutectic of at least:
- (a) crystalline complex Al2O3.rare earth oxide and
- (b) crystalline ZrO2.
A plurality of particles having a particle size distribution ranging from fine to coarse, wherein at least a portion of said plurality of particles are fused, crystalline abrasive particles comprising at least 20 percent by volume, based on the total metal oxide volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least:
- (a) crystalline ZrO2 and
- (b) at least two of:
- (i) crystalline Al2O3,
- (ii) first crystalline complex Al2O3.rare earth oxide, or
- (iii) second, different, crystalline complex Al2O3.rare earth oxide.
A plurality of particles having a particle size distribution ranging from fine to coarse, wherein at least a portion of said plurality of particles are fused, crystalline abrasive particles comprising at least 20 percent by volume, based on the total metal oxide volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least:
- (a) crystalline complex Al2O3.rare earth oxide and
- (b) crystalline ZrO2.
A plurality of abrasive particles having a specified nominal grade, said plurality of abrasive particle having a particle size distribution ranging from fine to coarse, wherein at least a portion of said abrasive particles is a plurality of fused, crystalline abrasive particles, said fused abrasive particles comprising at least 20 percent by volume, based on the total metal oxide volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least:
- (a) crystalline ZrO2 and
- (b) at least two of:
- (i) crystalline Al2O3,
- (ii) first crystalline complex Al2O3.rare earth oxide, or
- (iii) second, different, crystalline complex Al2O3.rare earth oxide.
A plurality of abrasive particles having a specified nominal grade, said plurality of abrasive particle having a particle size distribution ranging from fine to coarse, wherein at least a portion of said abrasive particles is a plurality of fused, crystalline abrasive particles, said fused abrasive particles comprising at least 20 percent by volume, based on the total metal oxide volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least:
- (a) crystalline complex Al2O3.rare earth oxide and
- (b) crystalline ZrO2.
A method for making fused, crystalline abrasive particles comprising at least 20 percent by volume, based on the total volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least (a) crystalline ZrO2 and (b) at least two of (i) crystalline Al2O3, (ii) first crystalline complex Al2O3.rare earth oxide, or (iii) second, different, crystalline complex Al2O3.rare earth oxide, said method comprising:
- melting at least one Al2O3 source, at least one rare earth oxide source, and at least one ZrO2 source to provide a melt;
- and
- converting the melt to said fused, crystalline abrasive particles.
A method for making fused, crystalline abrasive particles comprising at least 20 percent by volume, based on the total volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least (a) crystalline complex Al2O3.rare earth oxide and (b) crystalline ZrO2, said method comprising:
- melting at least one Al2O3 source, at least one rare earth oxide source, and at least one ZrO2 source to provide a melt;
- and
- converting the melt to said fused, crystalline abrasive particles.
An abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of said abrasive particles are fused, crystalline abrasive particles comprising at least 20 percent by volume, based on the total volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least:
- (a) crystalline ZrO2 and
- (b) at least two of:
- (i) crystalline Al2O3,
- (ii) first crystalline complex Al2O3.rare earth oxide;
- or
- (iii) second, different, crystalline complex Al2O3.rare earth oxide.
An abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of said abrasive particles are fused, crystalline abrasive particles comprising at least 20 percent by volume, based on the total volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least:
- (a) crystalline complex Al2O3.rare earth oxide and
- (b) crystalline ZrO2.
A vitrified bonded abrasive article comprising a plurality of abrasive particles bonded together via vitrified bonding material, wherein at least a portion of said plurality of abrasive particles are fused, crystalline abrasive particles comprising at least 20 percent by volume, based on the total volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least:
- (a) crystalline ZrO2 and
- (b) at least two of:
- (i) crystalline Al2O3,
- (ii) first crystalline complex Al2O3.rare earth oxide, or
- (iii) second, different, crystalline complex Al2O3.rare earth oxide.
A vitrified bonded abrasive article comprising a plurality of abrasive particles bonded together via vitrified bonding material, wherein at least a portion of said plurality of abrasive particles are fused, crystalline abrasive particles comprising at least 20 percent by volume, based on the total volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least:
- (a) crystalline complex Al2O3.rare earth oxide and
- (b) crystalline ZrO2.
A method of abrading a surface, said method comprising:
- contacting at least one fused, crystalline abrasive particle comprising at least percent by volume, based oil the total volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least (a) crystalline ZrO2 and (b) at least two of (i) crystalline Al2O3, (ii) first crystalline complex Al2O3, rare earth oxide, or (iii) second, different, crystalline complex Al2O3.REO, with a surface of a workpiece;
- and
- moving at least of one said fused abrasive particle or said surface relative to the other to abrade at least a portion of said surface with said fused abrasive particle.
A method of abrading a surface, said method comprising:
- contacting at least one fused, crystalline abrasive particle comprising at least 20 percent by volume, based on the total volume of the respective particle, eutectic material, wherein said eutectic material comprises eutectic of at least (a) crystalline complex Al2O3.rare earth oxide and (b) crystalline ZrO2, with a surface of a workpiece;
- and
- moving at least of one said fused abrasive particle or said surface relative to the other to abrade at least a portion of said surface with said fused abrasive particle.
Dependencies are inferred from the claim text.