US5037451A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Manufacture of abrasive products
Assignee: Individual
•
Filing: 1989-08-30
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Granted: 1991-08-06
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Expires: 2009-08-30
Abstract
Abstract The invention provides a method of making an abrasive product which comprises a layer of bonded ultra-hard abrasive particles bonded to a substrate. The abrasive product is typically a diamond or cubic boron nitride composite compact. The method includes the steps of: (a) providing a substrate which has a surface to which the layer of bonded ultra-hard abrasive particles is to be bonded; (b) providing a slurry of the components, in particulate form, necessary to make the layer of bonded ultra-hard abrasive particles in a liquid medium adapted to flow and to set to a green state under predetermined conditions; (c) applying a layer of the slurry to the surface of the substrate; (d) applying the predetermined conditions during step (c) or immediately thereafter to cause the liquid medium to set to a green state; (e) contacting the green state layer with a complemental surface provided on a pressure pad; (f) removing substantially all the liquid medium from the green state layer; (g) placing the substrate/pressure pad combination in the reaction zone of a high temperature/high pressure apparatus; and (h) applying conditions of elevated temperature and pressure to the combination to convert the green state layer into a layer of bonded ultra-hard abrasive particles which is bonded to the substrate.
Inventors
- 👤 Richard P. Burnand
- 👤 Raymond A. Chapman
- 👤 Trevor J. Martell
- 👤 Stephen A. Parsons
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 17:18
CPC Classifications
E; E21; E21B; E21B10/00; E21B10/46; E21B10/56; E21B10/567; E21B10/573; E21B10/5735; B; B24; B24D; B24D18/00; B24D18/0009
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
294 words
A method of making an abrasive product which comprises a layer of bonded ultra-hard abrasive particles bonded to a substrate, includes the steps of: (a) providing a substrate consisting essentially of cemented tungsten carbide, cemented tantalum carbide, cemented titanium carbide or mixtures thereof which has a surface to which the layer of bonded ultra-hard abrasive particles is to be bonded; (b) providing a slurry comprised of diamond or cubic boron nitride particles, organic binder and water in particulate form, necessary to make the layer of bonded ultra-hard abrasive particles in a liquid medium adapted to flow and subsequently gel upon application in layer form to a suitable heated substrate and set to a green state under heat and pressure; (c) applying a layer of slurry in a uniform thickness to the surface of the substrate to which the layer of bonded ultra-hard abrasive particles is to be bonded; (d) applying the heat and pressure during step (c) or immediately thereafter to said substrate which is suitably heated to cause the liquid medium to gel and to set to a green state; (e) contacting the green state layer with a surface provided on a pressure pad, which surface is complementary to the surface of the substrate with which the green state layer is in contact and having interposed therebetween a layer of material which substantially prevents bonding of the green state layer to the pressure pad; (f) removing substantially all the liquid medium from the green state layer; (g) placing the substrate/pressure pad combination in the reaction zone of a high temperature/high pressure apparatus; (h) applying conditions of elevated temperature and pressure to the combination to convert the green state layer into a layer of bonded ultra-hard abrasive particles which is bonded to the substrate.
Claim 2
Independent Claim
294 words
A method of making an abrasive product which comprises a layer of bonded ultra-hard abrasive particles bonded to a substrate, includes the steps of: (a) providing a substrate consisting essentially of cemented tungsten carbide, cemented tantalum carbide, cemented titanium carbide or mixtures thereof which has a surface to which the layer of bonded ultra-hard abrasive particles is to be bonded; (b) providing a slurry comprised of diamond or cubic boron nitride particles, organic binder and water in particulate form, necessary to make the layer of bonded ultra-hard abrasive particles in a liquid medium adapted to flow and subsequently gel upon application in layer form to a suitable heated substrate and set to a green state under heat and pressure; (c) applying a layer of slurry in a uniform thickness to the surface of the substrate to which the layer of bonded ultra-hard abrasive particles is to be bonded; (d) applying the heat and pressure during step (c) or immediately thereafter to said substrate which is suitably heated to cause the liquid medium to gel and to set to a green state; (e) contacting the green state layer with a surface provided on a pressure pad, which surface is complementary to the surface of the substrate with which the green state layer is in contact and having interposed therebetween a layer of material which substantially prevents bonding of the green state layer to the pressure pad; (f) removing substantially all the liquid medium from the green state layer; (g) placing the substrate/pressure pad combination in the reaction zone of a high temperature/high pressure apparatus; (h) applying conditions of elevated temperature and pressure to the combination to convert the green state layer into a layer of bonded ultra-hard abrasive particles which is bonded to the substrate.
Claim 3
Dependent Claim
20 words
A method according to claim 1 wherein the liquid medium is water containing a suitable binder dissolved or dispersed therein.
Claim 4
Dependent Claim
31 words
A method according to claim 2 wherein the binder is capable of decomposing or volatilising at a temperature of about 350° C. or lower and of forming a gel in water.
Claim 5
Dependent Claim
19 words
A method according to claim 3 wherein the binder is an organic binder selected from cellulose ethers and esters.
Claim 6
Dependent Claim
12 words
A method according to claim 4 wherein the binder is methyl cellulose.
Claim 7
Dependent Claim
15 words
A method according to claim 5 wherein the interposed material of step 1(e) is molybdenum.
Claim 8
Dependent Claim
17 words
A method according to claim 1 wherein the liquid medium is removed in step (f) by heating.
Claim 9
Dependent Claim
26 words
A method according to claim 1 wherein the surface of the substrate to which the slurry is applied has a corrugated, scalloped or other similar shape.
Claim 10
Dependent Claim
41 words
A method according to claim 1 wherein the conditions of elevated temperature and pressure which are used in step (h) are a pressure in the range 25 to 70 kilobars and the temperature in the range of 1400° to 1600° C.
Claim 11
Independent Claim
125 words
A method of making an abrasive product while preventing a slurry of particles from bonding to a pressure pad which comprises: (a) providing a substrate which has a surface to which the layer of bonded ultra-hard abrasive particles is to be bonded (b) providing a slurry of components in particulate form in a liquid medium adapted to flow and set to a green state upon application of heat (c) applying a layer of material to a pressure pad which prevents bonding of the slurry to the pressure pad (d) applying a uniform layer of slurry to the substrate to which the slurry shall be bonded; (e) applying heat and pressure to cause the liquid medium to gel and slurry to set to a green state.
Claim 12
Independent Claim
125 words
A method of making an abrasive product while preventing a slurry of particles from bonding to a pressure pad which comprises: (a) providing a substrate which has a surface to which the layer of bonded ultra-hard abrasive particles is to be bonded (b) providing a slurry of components in particulate form in a liquid medium adapted to flow and set to a green state upon application of heat (c) applying a layer of material to a pressure pad which prevents bonding of the slurry to the pressure pad (d) applying a uniform layer of slurry to the substrate to which the slurry shall be bonded; (e) applying heat and pressure to cause the liquid medium to gel and slurry to set to a green state.
Claim 13
Dependent Claim
13 words
The method of claim 10 where said material of step 14(c) is molybdenum.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1994-08-05 | 1995-02-04 | 1995-08-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-08-05 | 1999-02-04 | 1999-08-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-08-05 | 2003-02-04 | 2003-08-06 | $7700.00 | Window Closed / Lapsed |