# US 8,771,390 B2 · High porosity vitrified superabrasive products and method of preparation

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- Number: US 8,771,390 B2
- Document ID: US8771390B2
- Status: Granted
- Kind: B2
- Application number: 13/544,800
- Filed: 2012-07-09
- Published: 2013-01-10
- Granted: 2014-07-08
- Earliest claimed: 2008-06-23
- Assignees: Saint-Gobain Abrasives, Inc.; Saint-Gobain Abrasifs
- Applicants: Rachana D. Upadhyay; Gilles Querel; Pradyumna Gupta; Richard W. J. Hall
- Inventors: Rachana D. Upadhyay; Gilles Querel; Pradyumna Gupta; Richard W. J. Hall
- Web page: https://patentgrep.com/patent/US8771390B2

## CPC

- B24D 3/18: for porous or cellular structure
- C09K 3/1409: {Abrasive particles per se (preparation of diamond C01B32/25)}
- B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11)
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE

## Abstract

A vitrified superabrasive product includes a superabrasive component and a vitrified bond component in which the superabrasive component is dispersed, wherein the vitrified bond component defines pores occupying greater than about 50% of the total volume of the vitrified superabrasive product. The vitrified superabrasive product can be in the form of a grinding tool, such as a grinding wheel. A superabrasive mixture includes a glass powder, a superabrasive grit, a binder and a silicon carbide. The mixture can be in the form of a green body, which is fired under an atmosphere and pressure, and at a temperature sufficient to form a porous vitrified superabrasive product.

## Claims

### Claim 1

A method of forming a vitrified superabrasive product, the method comprising:
providing a mixture including a glass powder, a suberabrasive grit, and silicon carbide; and
heating the mixture such that the silicon carbide is oxidized and acts as a foaming agent to form pores of the vitrified superabrasive product.

### Claim 2 (depends on 1)

The method of claim 1, further comprising forming a green body that includes the glass powder, the superabrasive grit, and the silicon carbide.

### Claim 3 (depends on 2)

The method of claim 2, wherein the green body includes a binder.

### Claim 4 (depends on 1)

The method of claim 1, wherein the mixture is heated at a temperature in a range of between about 600° C. to 820° C.

### Claim 5 (depends on 1)

The method of claim 1, wherein the mixture is heated for a period of time in a range of about one-half hour to about 10 hours.

### Claim 6 (depends on 1)

The method of claim 1, wherein heating the mixture produces a fired product and the method further comprises cooling the fired product to form the vitrified superabrasive product.

### Claim 7 (depends on 1)

The method of claim 1, wherein the superabrasive grit includes a diamond particulate.

### Claim 8 (depends on 1)

The method of claim 1, wherein the superabrasive grit has an average particle size in a range of between about 0.5 μm and about 60 μm.

### Claim 9 (depends on 1)

The method of claim 1, wherein a volume ratio of superabrasive grit to glass powder is in a range of between about 3:2 and about 1:99.

### Claim 10 (depends on 1)

The method of claim 1, wherein the silicon carbide is present in the form of particles having a number average particle size in a range of between about 0.1 microns and about 20 microns.

### Claim 11 (depends on 3)

The method of claim 3, wherein the silicon carbide is present in the mixture in an amount in a range of between about 0.1 and about 5 volume percent of the total amount of glass powder, abrasive grit, binder and silicon carbide components of the mixture.

### Claim 12 (depends on 1)

The method of claim 1, wherein the glass powder includes at least one member selected from the group consisting of silicon dioxide (SiO2), boron oxide (B2O3), aluminum oxide (Al2O3), alkali oxides (Li2O, Na2O, K2O) and alkaline earth oxides (CaO, MgO, BaO).

### Claim 13 (depends on 3)

The method of claim 3, wherein the binder includes at least one member selected from the group consisting of polyethylene glycol, water, a mixture of polyethylene glycol and water and colloidal silica.