US5474583A
Expired / Lapsed
US
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Abrasive grain with metal oxide coating, method of making same and abrasive products
Assignee: 3M Co
•
Filing: 1994-03-11
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Granted: 1995-12-12
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Expires: 2014-03-11
Abstract
Abstract A method of preparing preferred abrasive grain material is provided. The method involves steps of coating a non-sintered aluminum base particles with a metal alkoxide containing coating; heating to convert the coating to a metal oxide coating; and then sinter the base particles to provide sintered particles having an alpha-alumina-based core with an autogenously bonded metal oxide coating. The invention also concerns improved abrasive grain materials and abrasive products including the improved abrasive grain materials therein.
Inventors
- 👤 Ahmet Celikkaya
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 06:30
CPC Classifications
C; C09; C09K; C09K3/00; C09K3/14; C09K3/1436; C09K3/1445; C04; C04B; C04B35/00; C04B35/01; C04B35/10; C04B35/111; C04B35/1115; C04B35/117; C04B35/119; C04B35/622; C04B35/624; C04B35/626; C04B35/62605; C04B35/62625; C04B35/6264; C04B35/62645; C04B35/62655; C04B35/628; C04B35/62802; C04B35/62805; C04B35/62807; C04B35/6281; C04B35/62813; C04B35/62815; C04B35/62818; C04B35/62821; C04B35/62823; C04B35/62826; C04B35/62886; C04B35/62889; C04B35/62897; C04B2235/00; C04B2235/02; C04B2235/30; C04B2235/32; C04B2235/3205; C04B2235/3206; C04B2235/3217; C04B2235/3218; C04B2235/327; C04B2235/3272; C04B2235/44; C04B2235/441; C04B2235/50; C04B2235/54; C04B2235/5409; C04B2235/70; C04B2235/74; C04B2235/77
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
104 words
A method of making ceramic abrasive grain, said method comprising the steps of: (a) providing a mass of particles comprising alpha-alumina precursor material each particle of which is sinterable to an alpha-alumina-based abrasive particle of said abrasive grain; (b) coating said particles with a coating composition comprising metal alkoxide to provide coated particles, said coating being capable of converting to a metal oxide coating which is autogenously bonded to the surface of each of said particles upon heating; and (c) heating said coated particles under conditions which convert said coating to a metal oxide coating and sinter said particles to provide alpha alumina-based particles.
Claim 2
Independent Claim
104 words
A method of making ceramic abrasive grain, said method comprising the steps of: (a) providing a mass of particles comprising alpha-alumina precursor material each particle of which is sinterable to an alpha-alumina-based abrasive particle of said abrasive grain; (b) coating said particles with a coating composition comprising metal alkoxide to provide coated particles, said coating being capable of converting to a metal oxide coating which is autogenously bonded to the surface of each of said particles upon heating; and (c) heating said coated particles under conditions which convert said coating to a metal oxide coating and sinter said particles to provide alpha alumina-based particles.
Claim 3
Dependent Claim
16 words
A method according to claim 1 wherein said coating composition also includes metal oxide modifier precursor.
Claim 4
Dependent Claim
49 words
A method according to claim 2 wherein said metal oxide modifier precursor is selected from the group consisting of salts of: magnesium; zinc; cobalt; iron; nickel; zirconium; manganese; silicon; hafnium; chromium; yttrium; praseodymium; samarium; ytterbium; neodymium; lanthanum; gadolinium; cerium; dysprosium; erbium; titanium; and mixtures of two or more thereof.
Claim 5
Dependent Claim
51 words
The method according to claim 1 wherein said metal alkoxide is selected from the group consisting of one or more alkoxides of: zirconium; titanium; aluminum; magnesium; zinc; cobalt; nickel; silicon; hafnium; iron; manganese; chromium; yttrium; praseodymium; samarium; ytterbium; neodymium; lanthanum; gadolinium; cerium; dysprosium; erbium; and mixtures of two or more thereof.
Claim 6
Dependent Claim
74 words
The method according to claim 1 wherein said metal alkoxide has a general Formula I as follows: Formula I Z.sub.x M(OR).sub.n-x wherein: M is a multivalent metal cation; n is the oxidation state of M; x is an integer having a value of 0 to n-1; OR is an alkoxy group, wherein O is oxygen; each R group is an alkyl group; and, each Z group is independently an organic group or inorganic group.
Claim 7
Dependent Claim
20 words
A method according to claim 5 wherein said metal alkoxide comprises material wherein n-x is within the range of 2-6.
Claim 8
Dependent Claim
24 words
A method according to claim 5 wherein each R group is independently a linear or branched organic group of 1 to 20 carbon atoms.
Claim 9
Dependent Claim
51 words
A method according to claim 5 wherein M is a metal cation selected from cations of metals in the group consisting of: zirconium; titanium; aluminum; magnesium; zinc; cobalt; nickel; silicon; hafnium; iron; manganese; chromium; yttrium; praseodymium; samarium; ytterbium; neodymium; lanthanum; gadolinium; cerium; dysprosium; erbium; and mixtures of two or more thereof.
Claim 10
Dependent Claim
20 words
A method according to claim 1 wherein said step of coating comprises spraying the metal alkoxide-containing coating onto said particles.
Claim 11
Independent Claim
37 words
A method according to claim wherein step (c) includes: (i) hydrolyzing said metal alkoxide coating to a coating of metal hydroxide; and (ii) heating said coating of metal hydroxide to a temperature of at least 400° C.
Claim 12
Dependent Claim
40 words
A method according to claim 1 wherein each of said particles has an outer surface, and said steps of coating and heating provides sintered coated particle particles with metal oxide coating covering at least 50% of said outer surface area.
Claim 13
Dependent Claim
16 words
A method according to claim 1 wherein said coating composition further comprises a non-polar organic solvent.
Claim 14
Dependent Claim
11 words
Ceramic abrasive grain made according to the process of claim 1.
Claim 15
Dependent Claim
58 words
Ceramic abrasive grain comprising a plurality of sintered particles, each particle comprising: (i) an alpha-alumina-based core; and, (ii) a metal oxide coating autogenously bonded to said alpha-alumina-based core; said metal oxide coating comprising randomly shaped metal oxide islands each island of which being at least about 10 micrometers in length and less than about 5 micrometers in thickness.
Claim 16
Dependent Claim
58 words
Ceramic abrasive grain comprising a plurality of sintered particles, each particle comprising: (i) an alpha-alumina-based core; and, (ii) a metal oxide coating autogenously bonded to said alpha-alumina-based core; said metal oxide coating comprising randomly shaped metal oxide islands each island of which being at least about 10 micrometers in length and less than about 5 micrometers in thickness.
Claim 17
Dependent Claim
20 words
Ceramic abrasive grain according to claim 14 including a plurality of metal oxide spheres autogenously bonded to said alpha-alumina-based core.
Claim 18
Dependent Claim
20 words
Ceramic abrasive grain according to claim 14 including a plurality of metal oxide spheres bonded to said metal oxide islands.
Claim 19
Dependent Claim
15 words
An abrasive product comprising: (a) a binder; and (b) the abrasive grain of claim 14.
Claim 20
Dependent Claim
20 words
An abrasive product according to claim 17 including a substrate to which said abrasive grain is bound by said binder.
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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) | 1998-12-11 | 1999-06-12 | 1999-12-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-12-11 | 2003-06-12 | 2003-12-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2006-12-11 | 2007-06-12 | 2007-12-12 | $7700.00 | Window Closed / Lapsed |