Agglomerate abrasive grain and a method of making the same
Assignee3M Innovative Properties Company
InventorsWilliam P. Wood, James L. McArdle
Life of this patent
Estimating the term…
Abstract
Agglomerate abrasive grain is disclosed. The agglomerate abrasive grain can be incorporated into abrasive products such as coated abrasives, bonded abrasives, nonwoven abrasives, and abrasive brushes. A method of making agglomerate abrasive grain is also disclosed.
Claims210
Agglomerate abrasive grain comprising a plurality of abrasive particles bonded together with a sintered, crystalline ceramic bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on a total metal oxide content of the bonding material, and wherein the abrasive particles have an average particle size of at least 5 micrometers.
Agglomerate abrasive grain comprising a plurality of polycrystalline abrasive particles bonded together with a sintered, crystalline ceramic bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on a total metal oxide content of the bonding material, the abrasive particles have a density of at least 85% of theoretical density, and the agglomerate abrasive grain has a porosity value of at least 10 percent.
A method for making agglomerate abrasive grain comprising:
- contacting a plurality of at least one of abrasive particles or precursor abrasive particles with a precursor bonding material such that the particles agglomerate together;
- and
- heating the agglomerated particles at at least one temperature for a time sufficient to convert the agglomerated particles, into agglomerate abrasive grain comprising a plurality of abrasive particles bonded together with a sintered bonding material;
- wherein the sintered bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on the total metal oxide content of the bonding material;
- and wherein the abrasive particles of the agglomerate abrasive grain have an average particle size of at least 5 micrometers.
A method for making agglomerate abrasive grain comprising:
- contacting a plurality of at least one of abrasive particles or precursor abrasive particles with a precursor bonding material such that the particles agglomerate together;
- and
- heating the agglomerated particles at at least one temperature for a time sufficient to convert the agglomerated particles into agglomerate abrasive grain comprising a plurality of abrasive particles bonded together with a sintered bonding material;
- wherein the sintered bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on the total metal oxide content of the bonding material;
- and wherein the heat-treated abrasive particles have a density of at least 85% of theoretical density, and the agglomerate abrasive grain has a porosity value of at least 10 percent.
Agglomerate abrasive grain comprising a plurality of sintered polycrystalline abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, wherein the crystalline abrasive particles are comprised of crystals having an average size less than 10 micrometers, and wherein at least three of the largest abrasive particles have substantially the same volume.
Agglomerate abrasive grain comprising a plurality of sintered, crystalline abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, wherein the crystalline abrasive particles are comprised of crystals having an average size less than 10 micrometers, and wherein at least three of the largest abrasive particles are greater than 20 micrometers in size.
Agglomerate abrasive grain comprising a plurality of sintered, crystalline abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein said agglomerate abrasive grain comprises, on a theoretical oxide basis, at least 85% by weight Al2O3, based on the total metal oxide content of the agglomerate abrasive grain, and wherein at least three of the largest abrasive particles are greater than 20 micrometers in size.
Agglomerate abrasive grain comprising a plurality of sintered, polycrystalline abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, and wherein the agglomerate abrasive grain has a porosity value in the range from 10 to about 60 percent.
A method for making agglomerate abrasive grain comprising a plurality of sintered, crystalline, alpha alumina-based abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, and wherein at least three of the largest abrasive particles have substantially the same volume, said method comprising:
- contacting dried, boehmite-based precursor particles in the presence of liquid such that a plurality of said precursor particles agglomerate together;
- and
- heating the agglomerated particles at at least one temperature for a time sufficient to provide said agglomerate abrasive grain.
A method for making agglomerate abrasive grain comprising a plurality of sintered, crystalline, alpha alumina-based abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, and wherein at least three of the largest abrasive particles have substantially the same volume, said method comprising:
- contacting dried, boehmite-based precursor particles in the presence of liquid such that a plurality of said precursor particles agglomerate together;
- drying the agglomerated precursor particles;
- calcining the dried agglomerated precursor particles to provide porous agglomerated precursor particles;
- impregnating the porous agglomerated precursor particles with a composition comprising liquid and at least one of metal oxide or metal oxide precursor;
- and
- heating the impregnated, agglomerated precursor particles at at least one temperature for a time sufficient to provide said agglomerate abrasive grain.
A method for making agglomerate abrasive grain comprising a plurality of sintered, crystalline, alpha alumina-based abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, and wherein at least three of the largest abrasive particles are greater than 20 micrometers in size, said method comprising:
- contacting dried, boehmite-based precursor particles in the presence of liquid such that a plurality of said precursor particles agglomerate together;
- and
- heating the agglomerated particles at at least one temperature for a time sufficient to provide said agglomerate abrasive grain.
A method for making agglomerate abrasive grain comprising a plurality of sintered, crystalline, alpha alumina-based abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, and wherein at least three of the largest abrasive particles are greater than 20 micrometers in size, said method comprising:
- contacting dried, boehmite-based precursor particles in the presence of liquid such that a plurality of said precursor particles agglomerate together;
- drying the agglomerated precursor particles;
- calcining the dried agglomerated precursor particles to provide porous agglomerated precursor particles;
- impregnating the porous agglomerated precursor particles with a composition comprising liquid and at least one of metal oxide or metal oxide precursor;
- and
- heating the impregnated, agglomerated precursor particles at at least one temperature for a time sufficient to provide said agglomerate abrasive grain.
A method for making agglomerate abrasive grain comprising a plurality of sintered, crystalline, alpha alumina-based abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein said agglomerate abrasive grain comprises, on a theoretical oxide basis, at least 85% by weight alumina, based on the total metal oxide content of the agglomerate abrasive grain, and wherein at least three of the largest abrasive particles are greater than 20 micrometers in size, said method comprising:
- contacting dried, boehmite-based precursor particles in the presence of liquid such that a plurality of said precursor particles agglomerate together;
- and
- heating the agglomerated particles at at least one temperature for a time sufficient to provide the agglomerate abrasive grain.
A method for making agglomerate abrasive grain comprising a plurality of sintered, crystalline, alpha alumina-based abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein said agglomerate abrasive grain comprises, on a theoretical oxide basis, at least 85% by weight alumina, based on the total metal oxide content of the agglomerate abrasive grain, and wherein at least three of the largest abrasive particles are greater than 20 micrometers in size, said method comprising:
- contacting dried, boehmite-based precursor particles in the presence of liquid such that a plurality of said precursor particles agglomerate together;
- drying the agglomerated precursor particles;
- calcining the dried agglomerated precursor particles to provide porous agglomerated precursor particles;
- impregnating the porous agglomerated precursor particles with a composition comprising liquid and at least one of metal oxide or metal oxide precursor;
- and
- heating the impregnated, agglomerated precursor particles at at least one temperature for a time sufficient to provide said agglomerate abrasive grain.
A method for making agglomerate abrasive grain comprising a plurality of sintered, crystalline, alpha alumina-based abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, and wherein said agglomerate abrasive grain has a porosity value in the range from 10 to 60 percent, said method comprising:
- contacting dried, boehmite-based precursor particles in the presence of liquid such that a plurality of said precursor particles agglomerate together;
- and
- heating the agglomerated particles at at least one temperature for a time sufficient to provide said agglomerate abrasive grain.
A method for making agglomerate abrasive grain comprising a plurality of sintered, crystalline, alpha alumina-based abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, and wherein said agglomerate abrasive grain has a porosity value in the range from 10 to 60 percent, said method comprising:
- contacting dried, boehmite-based precursor particles in the presence of liquid such that a plurality of said precursor particles agglomerate together;
- drying the agglomerated precursor particles;
- calcining the dried agglomerated precursor particles to provide porous agglomerated precursor particles;
- impregnating the porous agglomerated precursor particles with a composition comprising liquid and at least one of metal oxide or metal oxide precursor;
- and
- heating the impregnated, agglomerated precursor particles at at least one temperature for a time sufficient to provide said agglomerate abrasive grain.
A method of abrading a surface, said method comprising:
- contacting at least agglomerate abrasive grain comprising a plurality of abrasive particles bonded together with a sintered, crystalline ceramic bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on a total metal oxide content of the bonding material, and wherein the abrasive particles have an average particle size of at least 5 micrometers, with a surface of a workpiece;
- and
- moving at least of one said agglomerate abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said agglomerate abrasive grain.
A method of abrading a surface, said method comprising:
- contacting at least agglomerate abrasive grain comprising a plurality of polycrystalline abrasive particles bonded together with a sintered, crystalline ceramic bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on a total metal oxide content of the bonding material, the abrasive particles have a density of at least 85% of theoretical density, and the agglomerate abrasive grain has a porosity value of at least 10 percent, with a surface of a workpiece;
- and
- moving at least of one said agglomerate abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said agglomerate abrasive grain.
A method of abrading a surface, said method comprising:
- contacting at least agglomerate abrasive grain comprising a, plurality of sintered polycrystalline abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, wherein the crystalline abrasive particles are comprised of crystals having an average size less than 10 micrometers, and wherein at least three of the largest abrasive particles have substantially the same volume, with a surface of a workpiece;
- and
- moving at least of one said agglomerate abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said agglomerate abrasive grain.
A method of abrading a surface, said method comprising:
- contacting at least agglomerate abrasive grain comprising a plurality of sintered, crystalline abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, wherein the crystalline abrasive particles are comprised of crystals having an average size less than 10 micrometers, and wherein at least three of the largest abrasive particles are greater than 20 micrometers in size, with a surface of a workpiece;
- and
- moving at least of one said agglomerate abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said agglomerate abrasive grain.
A method of abrading a surface, said method comprising:
- contacting at least agglomerate abrasive grain comprising a plurality of sintered, crystalline abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein said agglomerate abrasive grain comprises, on a theoretical oxide basis, at least 85% by weight Al2O3, based on the total metal oxide content of the agglomerate abrasive grain, and wherein at least three of the largest abrasive particles are greater than 20 micrometers in size, with a surface of a workpiece;
- and
- moving at least of one said agglomerate abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said agglomerate abrasive grain.
A method of abrading a surface, said method comprising:
- contacting at least agglomerate abrasive grain comprising a plurality of sintered, polycrystalline abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, and wherein the agglomerate abrasive grain has a porosity value in the range from 10 to about 60 percent, with a surface of a workpiece;
- and
- moving at least of one said agglomerate abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said agglomerate abrasive grain.
A method of abrading a surface, said method comprising:
- contacting at least agglomerate abrasive grain comprising a plurality of abrasive particles bonded together with a sintered, crystalline ceramic bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on a total metal oxide content of the bonding material, and wherein the abrasive particles have an average particle size of at least 5 micrometers, with a surface of a workpiece;
- and
- moving at least of one said agglomerate abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said agglomerate abrasive grain.
Agglomerate abrasive grain comprising a plurality of sintered, crystalline alpha alumina-based abrasive particles bonded together with a sintered, crystalline ceramic bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on a total metal oxide content of the bonding material, the abrasive particles have a density of at least 85% of theoretical density, and the agglomerate abrasive grain has a porosity value of at least 10 percent.
A method for making agglomerate abrasive grain comprising:
- contacting a plurality of abrasive particles with a precursor bonding material such that the particles agglomerate together;
- and
- heating the agglomerated particles at at least one temperature for a time sufficient to convert the agglomerated particles, into agglomerate abrasive grain comprising a plurality of sintered, crystalline alpha alumina-based abrasive particles bonded together with a sintered bonding material;
- wherein the sintered bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on the total metal oxide content of the bonding material;
- and wherein the abrasive particles of the agglomerate abrasive grain have an average particle size of at least 5 micrometers.
A method for making agglomerate abrasive grain comprising:
- contacting a plurality of abrasive particles with a precursor bonding material such that the particles agglomerate together;
- and
- heating the agglomerated particles at at least one temperature for a time sufficient to convert the agglomerated particles into agglomerate abrasive grain comprising a plurality of sintered, crystalline alpha alumina-based abrasive particles bonded together with a sintered bonding material;
- wherein the sintered bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on the total metal oxide content of the bonding material;
- and wherein the heat-treated abrasive particles have a density of at least 85% of theoretical density, and the agglomerate abrasive grain has a porosity value of at least 10 percent.
Agglomerate abrasive grain comprising a plurality of sintered crystalline abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, wherein the crystalline abrasive particles are comprised of crystals having an average size less than 10 micrometers, and wherein at least three of the largest abrasive particles have substantially the same volume.
Agglomerate abrasive grain comprising a plurality of sintered, crystalline abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, wherein the crystalline abrasive particles are comprised of crystals having an average size less than 10 micrometers, and wherein at least three of the largest abrasive particles are greater than 20 micrometers in size.
Agglomerate abrasive grain comprising a plurality of sintered, crystalline abrasive particles bonded together via crystalline ceramic, metal oxide bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight Al2O3, based on the total metal oxide content of the bonding material, and wherein the agglomerate abrasive grain has a porosity value in the range from 10 to about 60 percent.
A method of abrading a surface, said method comprising:
- contacting at least agglomerate abrasive grain comprising a plurality of abrasive particles bonded together with a sintered, crystalline ceramic bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on a total metal oxide content of the bonding material, wherein the abrasive particles have an average particle size of at least 5 micrometers, and wherein the abrasive particles comprises at least one of fused aluminum oxide abrasive particles, silicon carbide abrasive particles, boron carbide abrasive particles, titanium carbide abrasive particles, diamond abrasive particles, cubic boron nitride abrasive particles, garnet, or fused alumina-zirconia abrasive particles, with a surface of a workpiece;
- and
- moving at least of one said agglomerate abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said agglomerate abrasive grain.
A method of abrading a surface, said method comprising:
- contacting at least agglomerate abrasive grain comprising a plurality of fused abrasive particles bonded together with a sintered, crystalline ceramic bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on a total metal oxide content of the bonding material, and wherein the abrasive particles have an average particle size of at least 5 micrometers, with a surface of a workpiece;
- and
- moving at least of one said agglomerate abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said agglomerate abrasive grain.
A method of abrading a surface, said method comprising:
- contacting at least agglomerate abrasive grain abrasive grain comprising a plurality of sintered, crystalline abrasive particles bonded together with a sintered, crystalline ceramic bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on a total metal oxide content of the bonding material, the abrasive particles have a density of at least 85% of theoretical density, and the agglomerate abrasive grain has a porosity value of at least 10 percent, with a surface of a workpiece;
- and
- moving at least of one said agglomerate abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said agglomerate abrasive grain.
A method of abrading a surface, said method comprising:
- contacting at least agglomerate abrasive grain abrasive grain comprising a plurality of fused, polycrystalline abrasive particles bonded together with a sintered, crystalline ceramic bonding material, wherein the bonding material comprises, on a theoretical oxide basis, at least 50 percent by weight crystalline Al2O3, based on a total metal oxide content of the bonding material, the abrasive particles have a density of at least 85% of theoretical density, and the agglomerate abrasive grain has a porosity value of at least 10 percent, with a surface of a workpiece;
- and
- moving at least of one said agglomerate abrasive grain or said surface relative to the other to abrade at least a portion of said surface with said agglomerate abrasive grain.
Dependencies are inferred from the claim text.