CN116460755A

CN116460755A - Abrasive article including a package

Info

Publication number: CN116460755A
Application number: CN202310406893.9A
Authority: CN
Inventors: 迈林·让诺; 施泽华
Original assignee: Saint Gobain Abrasifs SA; Saint Gobain Abrasives Inc
Current assignee: Saint Gobain Abrasifs SA; Saint Gobain Abrasives Inc
Priority date: 2016-03-28
Filing date: 2016-03-28
Publication date: 2023-07-21
Also published as: CN107234549A

Abstract

The present disclosure relates to abrasive articles including packages. An abrasive article comprising a body comprising abrasive particles contained within a bond material; and a package extending around the peripheral surface of the body, the package having fibers and a coating covering the fibers, wherein the coating comprises a matrix resin and at least one of water, furfuryl alcohol, or a combination thereof.

Description

Abrasive article including a package

Information about the divisional application

The present application is a divisional application of chinese patent application with application number 201610184655.8, application date 2016, 3, 28, and the name "comprising packaged abrasive articles".

Technical Field

The following generally relates to abrasive articles, and more particularly to bonded abrasive articles including a package extending around a peripheral surface of a body of the bonded abrasive article.

Background

Grinding tools such as grinding wheels are typically used for grinding, cutting, lapping and shaping a variety of materials such as stone, metal, glass, plastic, among others. In general, the abrasive article can have materials of various phases, including abrasive grains, binder, and some air voids. The abrasive article can have a variety of designs, shapes, and configurations depending on the intended application. For example, for applications involving grinding of railway tracks, some grinding wheels are profiled such that they have contours for grinding railway track welded areas or particular surfaces of railway tracks (such as heads, lateral edges, and/or webs).

The abrasive tools used to grind railroad tracks are generally formed with abrasive grains contained within a bonding material. Various types of abrasive particles may be contained within the bond material, including, for example, superabrasive grains (e.g., diamond or cubic boron nitride) or alumina abrasive grains. The adhesive material may be an organic material such as a resin; or an inorganic material such as glass or vitrified material.

However, given the application of such wheels, the abrasive article experiences fatigue and failure, which can pose a safety risk. Accordingly, there is a continuing need in the industry for grinding wheels that can improve performance and safety.

Disclosure of Invention

According to a first aspect, an abrasive article comprises a body having abrasive particles contained within a bond material; and a package extending around the peripheral surface of the body, wherein the package comprises fibers and a coating covering the fibers, and wherein the coating comprises a resin and at least one of water, furfuryl alcohol, or a combination thereof.

According to another aspect, a method of making an abrasive article includes forming a bonded abrasive body, applying a coating to a fiber to form a coated fiber; and wrapping the coated fibers around a peripheral surface of a body to form a package, wherein the body comprises abrasive particles contained within a binding material, and the coating comprises a resin and at least one of water, furfuryl alcohol, or a combination thereof.

Drawings

The present invention may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

FIG. 1 includes a flow chart illustrating a process of forming an abrasive article according to one embodiment

Fig. 2 includes an illustration of a perspective view of an abrasive article in accordance with an embodiment.

Detailed Description

The following relates to abrasive articles, including bonded abrasive articles suitable for grinding various targets and types of workpieces. The abrasive article is a bonded abrasive tool comprising abrasive particles contained within a three-dimensional matrix of a bonding material for surface treating, shaping, and/or conditioning a workpiece. Certain embodiments herein relate to bonded grinding wheels. However, features of embodiments herein may be applicable to other grinding techniques.

Fig. 1 includes a flow chart illustrating a process of forming an abrasive article according to an embodiment. As illustrated, the process may include forming a bonded abrasive body at step 101. The process of forming the bonded abrasive body may begin with forming a mixture that may include components or precursor components that are part of the final formed bonded abrasive body. For example, the mixture may include abrasive particles, binding materials or one or more precursors of binding materials, fillers, additives, reinforcing materials, and the like.

In one embodiment, the abrasive particles may include materials such as: oxides, carbides, nitrides, borides, carbon-based materials (e.g., diamond), oxycarbides, oxynitrides, borooxides, and combinations thereof. According to one embodiment, the abrasive particles may comprise superabrasive material. The abrasive particles may comprise a material selected from the group of: silica, silicon carbide, alumina, zirconia, flint, garnet, carborundum, rare earth oxides, rare earth-containing materials, ceria, sol-gel derived particles, gypsum, iron oxide, glass-containing particles, and combinations thereof. In another instance, the abrasive particles can also include silicon carbide (e.g., green 39C and Black 37C), brown fused alumina (57A), seeding gel abrasives, sintered alumina with additives, shaped and sintered alumina, pink alumina, ruby alumina (e.g., 25A and 86A), fused monocrystalline alumina 32A, MA88, alumina zirconia abrasives (e.g., NZ, NV, ZF brands from Saint-goban company (Saint-Gobain Corporation)), extruded bauxite, sintered bauxite, cubic boron nitride, diamond, aluminum oxynitride, sintered alumina (e.g., ccsk of the balch (Treibacher)), extruded alumina (e.g., SR1, TG, and TGII available from Saint-goban company), or any combination thereof. The abrasive particles may have a Mohs hardness (Mohs hardness) or at least 7, such as at least 8, or even at least 9.

According to one aspect of embodiments herein, the mixture and resulting fixed abrasive article may include a blend of abrasive particles. The blend of abrasive particles may include a first type of abrasive particles and a second type of abrasive particles that differ from the first type of abrasive particles in at least one aspect, such as particle size, grain size, composition, shape, hardness, brittleness, toughness, and the like. For example, in one embodiment, the first type of abrasive particles may include premium abrasive particles (e.g., fused alumina, alumina-zirconia, seeded sol gel alumina, shaped abrasive particles, etc.), and the second type of abrasive particles may include diluent abrasive particles. According to a particular embodiment, the abrasive particles may comprise brown alumina. In another particular embodiment, the abrasive particles can include an alumina/zirconia blend.

In one embodiment, the mixture and resulting fixed abrasive article may include a first portion including a first type of shaped abrasive particle; and a second portion comprising shaped abrasive particles of a second type. The content of the first portion and the second portion in the mixture and the resulting fixed abrasive article may be controlled based at least in part on certain process parameters. Providing a mixture having a first portion and a second portion and the resulting fixed abrasive article may facilitate replacement or improved placement of particles in the abrasive article and may further facilitate improved performance or use of the abrasive article.

The first portion can include a plurality of shaped abrasive particles, wherein each of the particles of the first portion can have substantially the same characteristics, such as the same two-dimensional shape, the same configuration (e.g., the same number or orientation of layers) of portions of the substantially similar composite body, and the like. The mixture and resulting fixed abrasive article may include various levels of the first portion. For example, the first portion may be present in a minority or majority amount. In particular instances, the first portion can be present in an amount of at least about 1%, such as at least about 5%, at least about 10%, at least about 20%, at least about 30%, at least about 40%, at least about 50%, at least about 60%, or even at least about 70%, for the total content of the mixture and the resulting inner portion of the fixed abrasive article. Additionally, in another embodiment, the mixture and resulting fixed abrasive article may include no more than about 99%, such as no more than about 90%, no more than about 80%, no more than about 70%, no more than about 60%, no more than about 50%, no more than about 40%, no more than about 30%, no more than about 20%, no more than about 10%, no more than about 8%, no more than about 6%, or even no more than about 4% of the total portion of the mixture and resulting fixed abrasive article. The mixture and resulting fixed abrasive article may include a first portion at a level within a range between any of the minimum and maximum percentages noted above.

The second portion may include a plurality of shaped abrasive particles, wherein each of the shaped abrasive particles of the second portion may have a two-dimensional shape of substantially the same type. The second portion may have one or more features of the embodiments herein, which may be different as compared to the plurality of shaped abrasive particles of the first portion. In some cases, the mixture and the resulting fixed abrasive article may include a smaller amount of the second portion relative to the first portion, and more specifically, may include a smaller amount of the second portion relative to the total amount of particles in the mixture and the resulting fixed abrasive article. For example, the mixture and resulting fixed abrasive article may contain a particular amount of the second portion, including, for example, no more than about 40%, such as no more than about 30%, no more than about 20%, no more than about 10%, no more than about 8%, no more than about 6%, or even no more than about 4%. Additionally, in at least one non-limiting embodiment, the mixture and resulting fixed abrasive article may contain at least about 0.5%, such as at least about 1%, at least about 2%, at least about 3%, at least about 4%, at least about 10%, at least about 15%, or even at least about 20% of the second portion, for the total content of the mixture and the inner portion of the resulting fixed abrasive article. It will be appreciated that the mixture and resulting fixed abrasive article may contain a second portion at a level within a range between any of the minimum and maximum percentages noted above.

Additionally, in alternative embodiments, the mixture and resulting fixed abrasive article may include a greater content of the second portion relative to the first portion, and more specifically, may include a majority content of the second portion, with respect to the total content of particles in the mixture and resulting fixed abrasive article. For example, in at least one embodiment, the mixture and the resulting fixed abrasive article may contain at least about 55%, such as at least about 60%, of the second portion for the total portion of the mixture and the resulting fixed abrasive article.

In one particular embodiment, the mixture and resulting fixed abrasive article can include a first portion including a plurality of shaped abrasive particles, wherein each of the particles has a body including a first layer and a second layer overlying the first layer. The mixture and resulting fixed abrasive article may include a second portion including a plurality of shaped abrasive particles, wherein each of the particles has a body including a first layer, a second layer overlying the first layer, and an intermediate layer disposed between the first layer and the second layer. It should be appreciated that the foregoing embodiments are one of a variety of exemplary mixtures and resulting fixed abrasive articles that may include at least a first portion and a second portion, wherein each of the portions includes a plurality of shaped abrasive particles and each of the particles of the different portions has at least one characteristic that is different from one another.

It should be appreciated that the mixture and resulting fixed abrasive article may include other portions, including, for example, a third portion comprising a plurality of shaped abrasive particles having a third characteristic that may be different from the characteristics of the particles of the first and second portions. The mixture and resulting fixed abrasive article may include various levels of the third portion relative to the second portion and the first portion. The third portion may be present in a small number or a large number. In certain instances, the third portion can be present in an amount of no more than about 40%, such as no more than about 30%, no more than about 20%, no more than about 10%, no more than about 8%, no more than about 6%, or even no more than about 4% of the total portion within the mixture and resulting fixed abrasive article. Additionally, in other embodiments, the mixture and resulting fixed abrasive article may include a minimum amount of third portion, such as at least about 1%, such as at least about 5%, at least about 10%, at least about 20%, at least about 30%, at least about 40%, or even at least about 50%. The mixture and resulting fixed abrasive article may include a third portion at a level within a range between any of the minimum and maximum percentages noted above. Further, the mixture and resulting fixed abrasive article may include a diluent, a component of the randomly shaped abrasive particles, which may be present in the same amount as any of the portions of the embodiments herein.

In one aspect, the abrasive particles can include a particular average particle size. For example, the abrasive particles can include an average particle size of at least 0.25mm, at least 0.3mm, at least 0.355mm, at least 0.425mm, at least 0.5mm, at least 0.6mm, at least 0.710mm, at least 0.85mm, at least 1mm, at least 1.18mm, at least 1.4mm, at least 1.7mm, at least 2mm, at least 2.36mm, or at least 2.8 mm. In one non-limiting embodiment, the abrasive particles can include an average particle size of no more than 3.35mm, no more than 2.8mm, no more than 2.36mm, no more than 2mm, no more than 1.7mm, no more than 1.4mm, no more than 1.18mm, no more than 1mm, no more than 0.85mm, no more than 0.710mm, no more than 0.6mm, no more than 0.5mm, no more than 0.425mm, no more than 0.355mm, or no more than 0.3 mm. The abrasive particles can include average particle sizes within any of the minimum or maximum ranges mentioned above.

In addition to the abrasive particles, the mixture may include other components or precursors to facilitate the formation of the abrasive article. For example, the mixture may include a binder material or a precursor of a binder material. According to one embodiment, the adhesive material may comprise a material selected from the group consisting of: an organic material, an organic precursor material, an inorganic precursor material, a natural material, a synthetic material, or any combination thereof. In particular cases, the bonding material may comprise a metal or metal alloy, such as a powder metal material or a metal material precursor, which is suitable for forming a metal bonding matrix material during further processing.

According to another embodiment, the mixture may include a vitreous material or a precursor of a vitreous material (e.g., a frit) suitable for forming a vitreous bond material during further processing. For example, the mixture may include a vitreous material in powder form, including, for example, an oxygen-containing material, an oxide compound or complex, a frit, or any combination thereof.

In yet another embodiment, the mixture may include a ceramic material or a precursor of a ceramic material suitable for forming a ceramic bonding material during further processing. For example, the mixture may include a ceramic material in powder form, including, for example, an oxygen-containing material, an oxide compound or complex, and any combination thereof. In some cases, the bond material may not necessarily include a ceramic material in the mixture, but the final formed bond material of the abrasive article may include a ceramic material, based on certain process parameters. Such processing parameters may include controlled cooling and/or recrystallization of the vitreous material during the forming process. The ceramic material may be monocrystalline or polycrystalline.

According to another embodiment, the mixture may comprise an organic material or a precursor of an organic material, which is suitable for forming an organic binding material during further processing. Such organic materials may include one or more natural organic materials, synthetic organic materials, and combinations thereof. In some cases, the organic material may be made of resins, which may include thermosetting resins, thermoplastic resins, and combinations thereof. For example, some suitable resins may include phenolic resins, epoxy resins, polyesters, cyanate esters, shellac, polyurethanes, polybenzoxazines, polydimaleimides, polyimides, rubbers, and combinations thereof. In one particular embodiment, the mixture includes an uncured resin material configured to form a phenolic resin binder material via further processing.

The phenolic resin may be modified with a curing agent or a crosslinking agent (e.g., hexamethylenetetramine). Some examples of hexamethylenetetramine may form crosslinks at temperatures exceeding about 90 ℃ to form methylene and dimethylamino bridges that help cure the resin. Hexamethylenetetramine can be uniformly dispersed in the resin. More specifically, hexamethylenetetramine may be uniformly dispersed in the resin region. Even more precisely, the phenolic resin may contain resin regions having cross-linked domains of submicron average size.

Other materials, such as one or more fillers, may be included in the mixture. In at least one embodiment, the filler may comprise a material selected from the group consisting of: antistatic agents, lubricants, pore inducers, colorants, or any combination thereof. In particular cases where the filler is a particulate material, it may be different from the abrasive particles. The filler may be different based on composition, average particle size, density, or any combination thereof.

One or more fillers may or may not be present in the final formed abrasive article. Typically, if present, one or more fillers are contained within the adhesive material. The filler may comprise a material selected from the group consisting of: powders, granules, spheres, fibers, and combinations thereof. Further, in particular instances, the filler may include inorganic materials, organic materials, fibers, woven materials, non-woven materials, particles, minerals, nuts, shells, oxides, alumina, carbides, nitrides, borides, polymeric materials, naturally occurring materials, and combinations thereof. In one embodiment, the filler may comprise the following materials: sand, foamed alumina, chromite, magnesite, dolomite, foam Mullite, boride, titanium dioxide, carbon products (e.g., carbon black, coke, or graphite), silicon carbide, wood flour, clay, talc, hexagonal boron nitride, molybdenum disulfide, feldspar, nepheline syenite, glass spheres, glass fibers, caF ₂ 、KBF ₄ Cryolite (Na) ₃ AlF ₆ ) Elpasolite (K) ₃ AlF ₆ ) Iron sulfide, znS, copper sulfide, mineral oil, fluoride, carbonate, calcium carbonate, wollastonite, mullite, steel, iron, copper, brass, bronze, tin, aluminum, kyanite, andalusite, garnet, quartz, fluoride, mica, nepheline syenite, sulfate (e.g., potassium sulfate or barium sulfate), carbonate (e.g., calcium carbonate), titanate (e.g., potassium titanate fiber), rock wool, clay, sepiolite, iron sulfide (e.g., fe) ₂ S ₃ 、FeS ₂ Or a combination thereof), potassium fluoroborate (KBF) ₄ ) Zinc borate, borax, boric acid, fine corundum powder, P15A, cork, glass spheres, silica microspheres (Z-light), silver, saran resin, paradichlorobenzene, oxalic acid, alkali halides, organic halides, attapulgite, or any combination thereof. In a particular embodiment, the binding material may comprise phenolic resin and fillers of pyrite, potassium sulfate, and lime.

After forming the mixture, the process of forming the abrasive article may further include forming a green body including abrasive particles contained in the bond material. A green body is a body that is unprocessed and can undergo further processing prior to formation of the finally formed abrasive article. Green forming may include techniques such as pressing, molding, casting, printing, spraying, and combinations thereof. In one particular embodiment, the forming of the green body may include depositing the mixture in a form or mold and pressing the mixture into a particular shape, including, for example, performing a pressing operation to form the green body in the form of a grinding wheel. In one particular embodiment the process may include binding the ingredients, mixing the abrasive particles with a binder or binder precursor material, filling the mold, and pressing the mixture to form a green body.

After forming the mixture with the desired components and applying the mixture in the desired processing equipment, the process may continue with processing the mixture to form the finally-formed abrasive article. Some suitable examples of the treatment may include curing, heating, sintering, crystallization, polymerization, pressing, and combinations thereof.

In one embodiment, the treatment may include a pressing step to form the finally-formed abrasive article. Referring briefly to fig. 2, which includes a perspective view of an abrasive article 200 according to one embodiment, the abrasive article 200 may include a backing plate 211 disposed on a surface of a body 202. In one embodiment, the abrasive article can include a backing plate 211 disposed on the second major surface 209 of the body 202. In a particular embodiment, the back plate 211 may comprise metal. In one embodiment, the pressing step may include pressing the back plate 211 against the body, followed by a heating step to cure the body 202. For example, the pressing step may include forming the body 202 in a shape that is specific to the finally-formed abrasive article while pressing the backing plate 211 onto the body 202. In an alternative embodiment, the backing plate 211 may be pressed onto the body 202 after it has been heated or subjected to a sintering step.

In one embodiment, the processing may include heating or sintering the body 202 for a particular length of time. In one embodiment, the length of time may be at least 20 hours, such as at least 24 hours, at least 28 hours, at least 32 hours, at least 36 hours, or at least 40 hours. In one non-limiting embodiment, the length of time may be no more than 40 hours, such as no more than 36 hours, no more than 32 hours, no more than 28 hours, no more than 24 hours, or no more than 20 hours. It should be appreciated that the length of time may be within any of the shortest or longest times mentioned above. For example, the length of time may be in the range of 20 hours to 40 hours.

In one embodiment, the treatment may include heating or sintering the body 202 to reach a particular maximum temperature. In a particular embodiment, the maximum temperature may be at least 160 ℃, such as at least 180 ℃, at least 200 ℃, at least 220 ℃, or at least 240 ℃. In one non-limiting embodiment, the maximum temperature may be no more than 250 ℃, such as no more than 240 ℃, no more than 220 ℃, no more than 200 ℃, or no more than 180 ℃. It should be appreciated that the maximum temperature may be within any of the minimum or maximum temperature ranges mentioned above. For example, the maximum temperature may be in the range of at least 160 ℃ to no more than 250 ℃.

In one embodiment, the process may include heating or sintering the body 202 for a particular number of heating steps, and each heating step may be at a particular maximum temperature for a particular length of time. In some embodiments, the length of time and the maximum temperature of each heating step may be different. In some embodiments, the length of time and the maximum temperature of the one or more heating steps may be the same, but not immediately before or after the step having the same length of time and maximum temperature. In one embodiment, the number of heating steps may be at least 1, such as at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, or at least 8. In one non-limiting embodiment, the number of heating steps may be no more than 8, such as no more than 7, no more than 6, no more than 5, no more than 4, no more than 3, or no more than 2. It should be appreciated that the number of heating steps may be within any of the minimum or maximum number of steps mentioned above. For example, the number of heating steps may be in the range of 2 to 8.

After the treatment process is completed, an abrasive article is formed that includes abrasive particles and any other additives contained within the three-dimensional matrix of bond material. Fig. 2 includes a perspective illustration of an abrasive article 200 according to an embodiment. As illustrated, the abrasive article 200 can include a body 202 having abrasive particles contained within a bond material. It should be appreciated that the body 202 may have any shape, which may represent a wheel or disc shape with a central opening 206, such that it is a ring. According to one embodiment, the body 202 may be configured to have a shape suitable for grinding a railway track surface. For example, the body 202 may be configured to have a shape suitable for grinding a surface of a railway rail head, lateral edge, web, or a combination thereof. It is to be appreciated that the abrasive article of embodiments herein can have a body 202 that can be in the form of a grindstone, cone, cup, flange shape, cylinder, wheel (with or without a central opening), ring, and combinations thereof.

The body 202 may have a generally circular shape when viewed from the top down. It should be appreciated that in three dimensions, the body 202 may have a thickness (t) such that the body 202 has a disk-like or cylindrical shape. As illustrated, the body 202 may have an outer diameter (d) that extends through the center of the body 202. The central opening 206 may extend through the entire thickness (t) of the body 202 such that the abrasive article 200 may be mounted on a shaft or other machine to rotate the abrasive article 200 during operation.

According to one embodiment, the body of the abrasive article can have an average thickness (t) and an average diameter (d). The average thickness of the body may be at least 15mm, such as at least 25mm, at least 50mm, or at least 75mm. The average thickness may be no more than 120mm, such as no more than 100mm, no more than 80mm, or no more than 75mm. The average thickness may be in any of the minimum or maximum ranges mentioned above. In one embodiment, the average thickness may be in the range of 50mm and 100 mm.

The average diameter of the body may be at least 100mm, such as or at least 200mm, or at least 250mm. The average diameter of the body may be no more than 300mm, such as no more than 250mm. The average diameter may be in any of the minimum or maximum ranges mentioned above. In one embodiment, the average diameter may be in the range of 200mm and 300 mm.

In one aspect, the body may have a particular relationship between the average thickness (t) and the average diameter (d), defined as a particular aspect ratio d/t. In one embodiment, the aspect ratio d/t may be at least 0.8, such as at least 1, at least 2, at least 3, at least 4, at least 5, at least 10, or at least 15. In one non-limiting embodiment, the aspect ratio d/t may be no more than 20, such as no more than 15, no more than 10, no more than 5, or no more than 4. The aspect ratio d/t may be in any of the minimum or maximum ranges mentioned above. For example, the aspect ratio d/t may be in the range of 3 and 4.

According to one embodiment, the central opening 206 of the body 202 may have a particular diameter. For example, the central opening 206 may have a diameter of at least 75mm, such as at least 100mm, or at least 150mm. In one non-limiting embodiment, the diameter of the central opening 206 may be no more than 250mm, such as no more than 200mm, or no more than 150mm. The diameter of the central opening 206 may be within any of the minimum or maximum values mentioned above. For example, the diameter of the central opening 206 may be in the range of 100mm and 200 mm.

In one embodiment, the body of the abrasive article may have a specific content of bonding material. For example, the binder material may be present in an amount of at least 20wt%, such as at least 25wt%, at least 30wt%, at least 40wt%, or at least 50wt%, for the total weight of the body. In one non-limiting embodiment, the binding material may be present in an amount of no more than 75wt%, such as no more than 70wt%, no more than 65wt%, no more than 60wt%, no more than 55wt%, no more than 50wt%, no more than 45wt%, or no more than 40wt%, for the total weight of the body. The content of the binding material may be in any of the minimum or maximum percentages mentioned above.

In one embodiment, the body may have a specific content of pores. For example, the pore content may be at least 2vol%, such as at least 4vol%, at least 6vol%, at least 8vol%, at least 10vol%, at least 12vol%, at least 15vol%, at least 20vol%, or at least 25vol% for the total volume of the body. In one non-limiting embodiment, the pore content may be no more than 50vol%, such as no more than 45vol%, no more than 40vol%, no more than 35vol%, no more than 30vol%, no more than 25vol%, no more than 20vol%, no more than 15vol%, no more than 14vol%, no more than 12vol%, no more than 10vol%, no more than 8vol%, no more than 6vol%, or no more than 4vol% for the total volume of the body. The pore content may be in any of the minimum or maximum ranges mentioned above.

In one embodiment, the body may have a specific content of abrasive particles. For example, the abrasive particles can be present in an amount of at least 25wt%, such as at least 30wt%, at least 35wt%, at least 40wt%, at least 42wt%, at least 45wt%, at least 50wt%, or at least 55wt%, for the total weight of the body. The abrasive particles may be present in an amount of no more than 75wt%, such as no more than 70wt%, no more than 65wt%, no more than 60wt%, no more than 56wt%, no more than 55wt%, no more than 50wt%, or no more than 45wt%, based on the total weight of the body. The content of the abrasive particles may be within any of the minimum or maximum values mentioned above.

Referring again to fig. 1, after forming the bonded abrasive, the process can continue at step 102, which can include forming a coating over at least a portion of the one or more fibers to form one or more coated fibers. Some processes suitable for forming the coating may include deposition, dip coating, printing, pressing, spray coating, heating, curing, and combinations thereof.

According to one embodiment, forming the coating may include dip coating. In one embodiment, dip coating may include unwinding the fiber from a spool and directing it through a bath of coating solution. In one particular embodiment, unwinding the fibers and directing them through a bath of coating solution may be performed in a continuous process.

In one embodiment, the coating solution may include a coating solution of a particular depth. In one embodiment, the depth of the coating solution may be at least 1cm, such as at least 2cm, at least 3cm, at least 4cm, or at least 5cm. In one non-limiting embodiment, the depth of the coating solution may be no more than 10cm, such as no more than 9cm, no more than 8cm, no more than 7cm, no more than 6cm, or no more than 5cm. It should be appreciated that the depth of the coating solution may be within any of the minimum or maximum depth ranges mentioned above. For example, the depth of the coating solution may be in the range of 4cm to 6 cm.

Referring again to fig. 1, after coating the fibers, the process may continue at step 103, which may include wrapping one or more coated fibers around at least a portion of the body. According to a particular embodiment, the package may be wrapped around the peripheral surface of the body. For example, referring to fig. 2, the body 202 can include a first major surface 208, a second major surface 209 opposite the first major surface and spaced apart from the first major surface 208 by a peripheral surface 207. As illustrated in the embodiment of fig. 2, the abrasive article 200 can include a package 204 of coated fibers surrounding or covering a first major surface 208. As also illustrated, the abrasive article 200 can include an inner side surface 210 generally defining the central opening 206.

According to one embodiment, an abrasive article including a body and a package may be treated with a curing step. In one particular embodiment, treating an abrasive article comprising a body and a package can comprise treating an uncured package on an uncured body. For example, the package may be wrapped around the peripheral surface of the uncured body prior to processing the body through curing. In this particular embodiment, the package may be treated by curing while the body as disclosed above is being treated.

According to another embodiment, processing an abrasive article including a body and a package may include processing an uncured package on a cured body. For example, after the body has been treated by curing, the package may be wrapped around the peripheral surface of the cured body. In this particular embodiment, the package may be packaged by curing treatment on a body that has been treated or cured as disclosed below.

In one embodiment, processing the abrasive article including the body and the package may include curing for a particular length of time. In one embodiment, the length of time may be at least 2 hours, such as at least 4 hours, at least 8 hours, at least 10 hours, or at least 12 hours. In one non-limiting embodiment, the length of time may be no more than 20 hours, such as no more than 18 hours, no more than 16 hours, no more than 14 hours, no more than 12 hours, no more than 10 hours, no more than 8 hours, no more than 6 hours, or no more than 4 hours. It should be appreciated that the length of time may be within any of the shortest or longest times mentioned above. For example, the length of time may be in the range of 10 hours to 14 hours.

In one embodiment, processing an abrasive article including a body and a package may include achieving a particular maximum temperature. In a particular embodiment, the maximum temperature may be at least 80 ℃, such as at least 100 ℃, or at least 120 ℃. In one non-limiting embodiment, the maximum temperature may be no more than 180 ℃, such as no more than 160 ℃, no more than 140 ℃, no more than 120 ℃. It should be appreciated that the maximum temperature may be within any of the minimum or maximum temperature ranges mentioned above. For example, the maximum temperature may be in the range of at least 100 ℃ to no more than 140 ℃.

In one embodiment, processing the abrasive article including the body and the package may include heating steps that may include a particular number of times, and each heating step may be at a particular maximum temperature for a particular length of time. In some embodiments, the length of time and the maximum temperature of each heating step may be different. In some embodiments, the length of time and the maximum temperature of the one or more heating steps may be the same, but not immediately before or after the step having the same length of time and maximum temperature. In one embodiment, the number of heating steps may be at least 1, such as at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, or at least 8. In one non-limiting embodiment, the number of heating steps may be no more than 8, such as no more than 7, no more than 6, no more than 5, no more than 4, no more than 3, or no more than 2. It should be appreciated that the number of heating steps may be within any of the minimum or maximum number of steps mentioned above. For example, the number of heating steps may be in the range of 3 to 5.

The package 204 may include at least one monolayer of fibers wrapped around the peripheral surface 207 of the body 202. In other embodiments, the package 204 may include a greater number of layers including, for example, at least 2 layers, at least 4 layers, at least 6 layers, at least 8 layers, at least 10 layers, or at least 12 layers of fibers wrapped around the peripheral surface 207 of the body 202. It should be appreciated that the plurality of layers will include a layer overlying an underlying layer. The package 204 may include no more than 20 layers, such as no more than 18 layers, no more than 16 layers, or no more than 12 layers of fibers wrapped around the peripheral surface 207 of the body 202. The package 204 may include a number of layers within any of the minimum or maximum values noted above. In one particular embodiment, the package 204 may include between 10 and 14 layers of fibers wrapped around the peripheral surface 207 of the body 202.

In one embodiment, the package may include one or more fiber strands. In a particular embodiment, the package may comprise a single fiber strand. For example, a single fiber wire may consist essentially of a single wire unit from one distal end of the wire to the opposite distal end of the wire. In a particular embodiment, the package may contain no more than one fiber strand.

According to one embodiment, the fibers may be formed from a particular material. For example, the fibers may include glass fibers, such as fiberglass. In a more particular embodiment, the glass fibers may be a single layer of glass fibers. In other particular embodiments, the glass fibers may be multi-layer glass fibers.

According to one embodiment, the coating may include a matrix resin. In particular embodiments, the matrix resin may include a phenolic resin. It should be appreciated that the coating may include other components in addition to the matrix resin. In certain cases, the coating may include a certain amount of matrix resin and a certain amount of water. In another particular case, the coating may include a content of a matrix resin and a content of furfuryl alcohol. It should be appreciated that the matrix resin may include water in a different content than the total content of water in the coating. It should also be appreciated that the matrix resin may include furfuryl alcohol in a content different from the total content of furfuryl alcohol in the coating.

In one embodiment, the matrix resin may include a specific amount of water, which may promote improved formation, handling, and/or performance of the abrasive article. For example, the matrix resin may include no more than 3wt% water, such as no more than 2wt% water, or no more than 1wt% water, for the total weight of the phenolic resin. In one non-limiting embodiment, the matrix resin may include at least 1wt% water, such as at least 2wt% water, for the total weight of the phenolic resin. The matrix resin may include a water content within any of the minimum or maximum percentage ranges mentioned above. In a particular embodiment, the matrix resin may be substantially free of water, for the total weight of the phenolic resin.

In other embodiments, the matrix resin may include a level of furfuryl alcohol, which may promote improved formation and/or improved properties of the abrasive article. For example, in at least one embodiment, the matrix resin may include at least 6wt% furfuryl alcohol, such as at least 8wt% furfuryl alcohol, at least 10wt% furfuryl alcohol, at least 12wt% furfuryl alcohol, at least 14wt% furfuryl alcohol, or at least 16wt% furfuryl alcohol, for the total weight of the matrix resin. In one non-limiting embodiment, the matrix resin may include no more than 18wt% furfuryl alcohol, such as no more than 16wt% furfuryl alcohol, no more than 14wt% furfuryl alcohol, no more than 12wt% furfuryl alcohol, no more than 10wt% furfuryl alcohol, or no more than 8wt% furfuryl alcohol, based on the total weight of the matrix resin. The matrix resin may include furfuryl alcohol in an amount within any of the minimum or maximum percentages noted above. For example, the matrix resin may include furfuryl alcohol in an amount ranging between 6wt% and 18 wt%. In certain other cases, the matrix resin may include furfuryl alcohol in an amount of no more than 3wt%, such as no more than 2wt% or no more than 1wt%, based on the total weight of the phenolic resin. In a particular embodiment, the matrix resin may be substantially free of furfuryl alcohol.

According to one embodiment, the coating may include a particular amount of matrix resin for the total weight of the coating, which may promote improved formation and/or improved performance of the abrasive article. For example, the matrix resin content may be at least 50wt%, such as at least 60wt%, such as at least 70wt% or at least 80wt%, based on the total weight of the coating. In one non-limiting embodiment, the coating may include a base resin in an amount of no more than 99wt%, such as no more than 90wt%, no more than 80wt%, or no more than 70wt%, for the total weight of the coating. The content of the matrix resin may be in any of the minimum or maximum percentage ranges mentioned above. For example, the content of the matrix resin may be in the range of 60wt% to 80wt% with respect to the total weight of the coating. In some particular embodiments, the matrix resin may be present in an amount of 60wt% based on the total weight of the coating. In other particular embodiments, the resin content may be 80wt% with respect to the total weight of the coating.

According to one embodiment, the coating may include a specific amount of furfuryl alcohol for the total content of the coating, which may promote improved formation and/or improved performance of the abrasive article. For example, the coating may include furfuryl alcohol in an amount of at least 30wt%, such as at least 35wt% or at least 40wt%, based on the total weight of the coating. In one non-limiting embodiment, the coating may include furfuryl alcohol in an amount of no more than 50wt%, such as no more than 45wt% or no more than 40wt%, for the total weight of the coating. The furfuryl alcohol content may be in any of the minimum or maximum percentage ranges mentioned above. In a particular embodiment, the furfuryl alcohol may be present in an amount in the range of 35wt% and 45wt% based on the total weight of the coating.

In one aspect, the coating may include a specific ratio of the matrix resin content (R) in wt% to the furfuryl alcohol content (FA) in wt% [ R/FA ]. For example, the coating may include a ratio [ R/FA ] of matrix resin content (R) in wt% to furfuryl alcohol content (FA) in wt%, of at least 1, such as at least 1.25 or at least 1.50. In one non-limiting embodiment, the coating may include a ratio [ R/FA ] of matrix resin content (R) in wt% to furfuryl alcohol content (FA) in wt% of not more than 2.3, such as not more than 2. The coating may comprise a ratio [ R/FA ] of the matrix resin content (R) in wt% to the furfuryl alcohol content (FA) in wt% within any of the minimum or maximum values mentioned above. In a particular embodiment, the coating may include a ratio [ R/FA ] of matrix resin content (R) in wt% to furfuryl alcohol content (FA) in wt% of 1.5.

According to one embodiment, the coating may comprise a specific content of water for the total content of the coating. For example, the coating may include water in an amount of at least 18wt%, such as at least 20wt%, at least 22wt%, at least 25wt%, at least 30wt%, or at least 40wt%, for the total weight of the coating. In one non-limiting embodiment, the coating may include water in an amount of no more than 50wt%, such as no more than 40wt%, no more than 30wt%, no more than 25wt%, or no more than 22wt%, for the total weight of the coating. The content for the total content of the coating may be in any of the minimum or maximum percentage ranges mentioned above.

In one aspect, the coating may include a matrix resin content (R) in wt% and a water content (H ₂ Specific ratio of O) [ R/H ] ₂ O]. For example, the coating may comprise a matrix resin content (R) in wt% and a water content (H) in wt% ₂ Ratio of O) [ R/H ] ₂ O]. In one non-limiting embodiment, the coating may include no more than 5, such as no more than 4, no more than 3, or no more than 2In wt% of matrix resin content (R) and in wt% of water content (H ₂ Ratio of O) [ R/H ] ₂ O]. The coating may comprise a matrix resin content (R) in wt% and a water content (H) in wt% within any of the minimum or maximum ranges mentioned above ₂ Ratio of O) [ R/H ] ₂ O]. In a particular embodiment, the coating may include a base resin content (R) in wt% of 4 and a water content (H ₂ Ratio of O) [ R/H ] ₂ O]。

The description and illustrations of embodiments described herein are intended to provide a general understanding of the structure of various embodiments. The description and illustrations are not intended to serve as an exhaustive and complete description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Individual embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Furthermore, references to values stated in ranges include each value within the range. Many other embodiments will be apparent to those of skill in the art upon reading this specification only. Other embodiments may be utilized and derived from the invention, such that structural, logical, or other changes may be made without departing from the scope of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. The benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as a critical, required, or essential feature of any or all the claims.

The description in conjunction with the figures is provided to aid in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and examples of the teachings. This focus is used to help describe the teaching content and should not be interpreted as a limitation on the scope or applicability of the teaching content. However, other teachings may of course be used in this application.

As used herein, the terms "comprise," "include," "have," or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited to only those features, but may include other features not expressly listed or inherent to such method, article, or apparatus. Furthermore, unless expressly stated to the contrary, "or" means an inclusive or rather than an exclusive or. For example, condition a or B is satisfied by any one of the following: a is true (or present) and B is false (or absent), a is false (or absent) and B is true (or present) and both a and B are true (or present).

Furthermore, the use of "a/an" is used to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. Unless clearly indicated otherwise, this description should be understood to include one or at least one, and the singular also includes the plural, or vice versa. For example, when a single article is described herein, more than one article may be used in place of a single article. Similarly, where more than one article is described herein, a single article may be substituted for more than one article.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. In aspects not described herein, many details regarding specific materials and processing acts are conventional and may be found in reference books and other sources within the structural arts and the corresponding manufacturing arts.

The subject matter disclosed above is to be regarded as illustrative rather than restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true scope of the present invention. Accordingly, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing embodiments.

The Abstract of the invention is provided to comply with the patent statutes, and it is to be understood that it is not intended to interpret or limit the scope or meaning of the claims. In addition, in the foregoing detailed description of the drawings, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. The invention should not be construed as reflecting the following intent: the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may lie in less than all features of any of the disclosed embodiments. Accordingly, the following claims are incorporated into the detailed description of the drawings, with each claim standing on its own as defining separately claimed subject matter.

Claims

1. An abrasive article, comprising:

a main body having abrasive particles contained in a binder material; and

a package extending directly around a peripheral surface of the body, wherein the package comprises fibers and a coating covering the fibers, wherein the coating comprises a matrix resin and at least one of water, furfuryl alcohol, or any combination thereof.

2. The abrasive article of claim 1, wherein the body comprises the bonding material at a content of at least 30wt% and not more than 60 wt%.

3. The abrasive article of claim 1, wherein the body comprises pores at a content of at least 2vol% and not more than 14 vol%.

4. The abrasive article of claim 1, wherein the body comprises abrasive particles at a content of at least 42wt% and not more than 56 wt%.

5. The abrasive article of claim 1, wherein the bonding material comprises a phenolic resin, pyrite, potassium sulfate, lime, or any combination thereof.

6. The abrasive article of claim 1, wherein the fibers comprise glass fibers.

7. The abrasive article of claim 1, wherein the coating comprises a matrix resin at a level of at least 50wt% and not more than 99 wt%.

8. The abrasive article of claim 1, wherein the coating comprises a matrix resin at a content of at least 55wt% and not more than 65 wt%.

9. The abrasive article of claim 1, wherein the coating comprises a matrix resin at a level of at least 75wt and not more than 85 wt.

10. The abrasive article of claim 1, wherein the coating comprises furfuryl alcohol in an amount of at least 30wt% and not more than 50 wt%.