Abrasive agglomerate coated raised island articles
First Claim
1. A process of making spherical beads comprising:
- a) using a cell sheet wherein the cell sheet has a array of cell sheet through holes;
b) the cell sheet through holes each have a cross sectional area;
c) the cell sheet having a nominal thickness;
d) the cell sheet holes form cell sheet volumes wherein a cell sheet volume is equal to the cell sheet through hole cross sectional area multiplied by the cell sheet thickness;
e) mixing materials into a liquid solution, the mixture solution comprising an inorganic oxide or a combination of inorganic oxides, and water, solvents or a combination thereof;
f) filling the cell sheet holes with the liquid mixture solution to form mixture volumes wherein the volume of mixture solution contained in each mixture volume is equal to the cell sheet volume;
g) ejecting the liquid mixture volumes from the cell sheet by subjecting the liquid mixture solution contained in each cell to an impinging jet of fluid wherein the impact of the impinging jet of fluid dislocates the liquid mixture volumes from the cell sheet thereby forming independent mixture solution lump entities;
h) wherein the ejected independent liquid mixture solution lump entities are shaped into independent spherical entities by force comprising liquid mixture solution surface tension forces;
i) the independent spherical entities are introduced into and subjected to a solidification environment wherein the independent spherical entities become solidified to form loose, green, spherical beads; and
j) firing the loose, green, spherical beads at high temperatures to produce beads.
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Accused Products
Abstract
Abrasive disk sheet articles having raised islands coated with spherical abrasive agglomerates that can provide both precision flat and smooth workpiece surfaces by high speed lapping are described. These disks also provide high material removal rates and low surface pick-out of soft metallic or non-metallic materials embedded in hard workpieces. A method of producing equal-sized spherical shaped composite abrasive agglomerate beads containing small diamond abrasive particles is described. These beads can be bonded directly on the flat surface of a flexible backing or bonded onto raised island surfaces. Simple and inexpensive apparatus devices and process techniques are described that allow efficient low-volume batch or continuous web manufacturing of precision thickness, large diameter abrasive disk or rectangular sheet abrasive articles.
200 Citations
20 Claims
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1. A process of making spherical beads comprising:
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a) using a cell sheet wherein the cell sheet has a array of cell sheet through holes; b) the cell sheet through holes each have a cross sectional area; c) the cell sheet having a nominal thickness; d) the cell sheet holes form cell sheet volumes wherein a cell sheet volume is equal to the cell sheet through hole cross sectional area multiplied by the cell sheet thickness; e) mixing materials into a liquid solution, the mixture solution comprising an inorganic oxide or a combination of inorganic oxides, and water, solvents or a combination thereof; f) filling the cell sheet holes with the liquid mixture solution to form mixture volumes wherein the volume of mixture solution contained in each mixture volume is equal to the cell sheet volume; g) ejecting the liquid mixture volumes from the cell sheet by subjecting the liquid mixture solution contained in each cell to an impinging jet of fluid wherein the impact of the impinging jet of fluid dislocates the liquid mixture volumes from the cell sheet thereby forming independent mixture solution lump entities; h) wherein the ejected independent liquid mixture solution lump entities are shaped into independent spherical entities by force comprising liquid mixture solution surface tension forces; i) the independent spherical entities are introduced into and subjected to a solidification environment wherein the independent spherical entities become solidified to form loose, green, spherical beads; and j) firing the loose, green, spherical beads at high temperatures to produce beads. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A process of making spherical abrasive agglomerates comprising:
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a) using a cell sheet wherein the cell sheet has a array of cell sheet through holes; b) the cell sheet through holes each have a cross sectional area; c) the cell sheet having a nominal thickness; d) the cell sheet holes form cell sheet volumes wherein a cell sheet volume is equal to the cell sheet through hole cross sectional area multiplied by the cell sheet thickness; e) mixing materials into a liquid solution, the liquid mixture solution comprising abrasive particles, an inorganic vitrifiable oxide or a combination of inorganic vitrifiable oxides, and water or solvents or a combination thereof; f) filling the cell sheet holes with the liquid mixture solution to form mixture volumes wherein the volume of mixture solution contained in each mixture volume is equal to the cell sheet volume;
i) ejecting the liquid mixture volumes from the cell sheet by subjecting the mixture solution contained in each cell to an impinging jet of fluid wherein the impact of the impinging jet of fluid dislocates the liquid mixture volumes from the cell sheet thereby forming independent liquid mixture solution lump entities;g) wherein the ejected independent liquid mixture solution lump entities are shaped into independent spherical entities by at least mixture solution surface tension forces; h) the independent spherical entities are introduced into and subjected to a solidification environment wherein the independent spherical entities become solidified to form loose green agglomerates; and i) firing the green agglomerates at high temperatures to produce spherical abrasive agglomerates. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification