Acoustic driven toughened foam glass abrasive devices and a method for producing the same

Abstract

An abrasive tool having an elongated handle member, an ultrasonic vibration source operationally connected to the elongated handle member, and a toughened foamed glass ceramic portion operationally connected to the vibration source. The toughened foamed glass ceramic portion includes a first glassy phase and a second glassy phase, wherein the second glassy phase puts the first glassy phase into compression.

1 . A method of fabricating an abrasive tool with a toughened foamed glass ceramic abrasive surface, comprising the steps of:
 a) combining a first predetermined amount of a first frit and a second predetermined amount of a second frit to produce a batch;   b) adding a third predetermined amount of foaming agent to the batch;   c) mixing the batch;   d) placing a fourth predetermined amount of the batch into a mold;   e) heating the mold to a predetermined temperature;   f) cooling the mold;   g) removing a foamed glass abrasive body from the mold; and   h) operationally connecting the foamed glass abrasive body to a handle;   wherein the first frit is characterized by a first coefficient of thermal expansion;   wherein the second frit is characterized by a second coefficient of thermal expansion; and   wherein the first coefficient of thermal expansion is higher than the second coefficient of thermal expansion.   
     
     
         2 . The method of  claim 1  wherein the first and second frits substantially maintain their respective chemical identities when the mold is heated. 
     
     
         3 . The method of  claim 1  wherein the first frit is powdered window glass. 
     
     
         4 . The method of  claim 1  wherein the foaming agent is limestone. 
     
     
         5 . The method of  claim 1  wherein the foaming agent is a mixture of limestone and magnesite. 
     
     
         6 . The method of  claim 1  wherein the handle is connected to a vibratory source. 
     
     
         7 . The method of  claim 1  wherein the handle further comprises an ultrasonic acoustic source. 
     
     
         8 . A method of producing a toughened foamed glass body, comprising:
 a) combining a first predetermined amount of powdered window glass cullet with a second predetermined amount of powdered toughening glass cullet to define a batch;   b) adding a third predetermined amount of foaming agent to the batch;   c) mixing the batch;   d) apportioning the batch;   e) softening the glass;   f) releasing gas from the foaming agent to foam the softened glass;   g) cooling the foamed glass body;   wherein the window glass cullet is characterized by a higher coefficient of thermal expansion than the toughening glass cullet.   
     
     
         9 . The method of  claim 8  wherein the glass is softened and gas is released from the foaming agent as a result of firing the batch. 
     
     
         10 . The method of  claim 8  wherein the window glass and the toughening glass do not substantially chemically interact. 
     
     
         11 . The method of  claim 9  wherein the foaming agent is selected from the following compositions: CaCO 3 , MgCO 3  and SrCO 3 . 
     
     
         12 . The method of  claim 8  wherein batch is apportioned by at least partially filing a refractory vessel and wherein the glass is softened and gas is released from the foaming agent as a result of firing the refractory vessel. 
     
     
         13 . An abrasive tool, comprising in combination:
 an elongated handle member;   an ultrasonic vibration source operationally connected to the elongated handle member; and   a toughened foamed glass ceramic portion operationally connected to the vibration source;   wherein the toughened foamed glass ceramic portion includes a first glassy phase and a second glassy phase; and   wherein the second glassy phase puts the first glassy phase into compression.   
     
     
         14 . The system of  claim 13  wherein the first glassy phase is substantially soda-lime-silica glass characterized by a first coefficient of thermal expansion and wherein the second glassy phase is characterized by a second coefficient of thermal expansion that is substantially smaller than the first coefficient of thermal expansion.