Abrasive article having a core of an organic material and a bonded abrasive body comprising a bond material

Abstract

An abrasive article includes a core comprising an organic material and a first bonded abrasive body integrally bonded directly to the core, wherein the bonded abrasive body includes a bond material, and abrasive particles contained within the bond material.

What is claimed is: 
     
         1 . An abrasive article comprising:
 a core comprising an organic material; and   a first bonded abrasive body integrally bonded directly to the core, the bonded abrasive body comprising:
 a bond material comprising a hybrid material including an inorganic portion and an organic portion; and 
 abrasive particles contained within the bond material. 
   
     
     
         2 . The abrasive article of  claim 1 , wherein the first bonded abrasive body is integrally bonded to a peripheral surface of the core. 
     
     
         3 . The abrasive article of  claim 1 , wherein the core comprises a volume of at least about 75 in 3  (1229 cm 3 ). 
     
     
         4 . The abrasive article of  claim 1 , wherein the core has a monolithic body, wherein the core has a cylindrical shape defined by a diameter (d), a circumference (C), and a height (h), wherein the height is at least about 3 inches (7.6 cm). 
     
     
         5 . The abrasive article of  claim 4 , wherein the diameter is at least about 6 inches (15.2 cm). 
     
     
         6 . The abrasive article of  claim 1 , wherein the core comprises an opening defining an arbor hole, wherein the opening is configured to engage a spindle for a grinding operation, wherein the opening extends through a volume of the monolithic body, wherein the opening extends along a direction of the height, wherein the opening extends between a first major surface and a second major surface of the core. 
     
     
         7 . The abrasive article of  claim 6 , wherein the core comprises a liner overlying at least a portion of the surface defining the opening. 
     
     
         8 . The abrasive article of  claim 1 , wherein the core consists essentially of the organic material. 
     
     
         9 . The abrasive article of  claim 1 , wherein the organic portion and the inorganic portion are substantially uniformly distributed throughout the volume of the bond material of the first bonded abrasive body. 
     
     
         10 . The abrasive article of  claim 1 , wherein the inorganic portion of the bond material comprises a metal material. 
     
     
         11 . The abrasive article of  claim 10 , wherein the metal material of the bond material comprises a combination of copper and tin. 
     
     
         12 . The abrasive article of  claim 1 , wherein the organic portion of the bond material comprises a polymer. 
     
     
         13 . A method of forming an abrasive article, the method comprising:
 preparing a preform comprising an abrasive article;   forming a mixture comprising a thermoset;   pouring the mixture into the preform; and   curing the mixture to form the core on the abrasive article, wherein the curing comprises a phase change of a liquid phase to a solid phase, the core having a cylindrical shape defined by a diameter (d), a circumference (C), and a height (h), wherein the height is at least about 3 inches (7.6 cm).   
     
     
         14 . The method of  claim 13 , wherein the mixture includes a curing agent. 
     
     
         15 . The method of  claim 14 , wherein the curing agent is selected from the group consisting of an oligoamine, a diol, a dithiol, an amino alcohol, an amino thiol, a thioalcohol, and any combination thereof. 
     
     
         16 . The method of  claim 15 , wherein the oligoamine is selected from the group consisting of an aliphatic oligoamine, a cycloaliphatic oligoamine, and an aromatic oligoamine, and a combination thereof. 
     
     
         17 . The method of  claim 16 , wherein the aliphatic oligoamine is selected from the group consisting of ethylene diamine, 2-methyl-1,5-pentamethylenediamine, 1,6-hexamethylenediamine, 1,3-pentanediamine, (2-aminoethyl)-1,2-ethanediamine (DETA), N,N′-bis-(2-aminoethyl)-1,2-ethanediamine) (TETA), tris-(2-aminoethyl)amine) (TAEA), bis-(aminoethyl)ether, a polyether diamine, tetraethylenepentamine (TEPA), and a combination thereof. 
     
     
         18 . The method of  claim 13 , wherein the mixture includes an epoxy resin and the curing agent includes an oligoamine. 
     
     
         19 . The method of  claim 18 , wherein the epoxy resin includes a bisphenol-A diglycidyl ether and the curing agent includes a isophorone diamine. 
     
     
         20 . An abrasive article, comprising:
 a first bonded abrasive body comprising:
 a bond material comprising a hybrid material including an inorganic portion and an organic portion; and 
 abrasive particles contained within the bond material; and 
   a core comprising an organic material and bonded to the first bonded abrasive body, the core having a monolithic body including a cylindrical shaped defined by a diameter (d), a circumference (C), and a height (h), wherein the height is at least about 3 inches (7.6 cm);   wherein the core comprises at least one filler selected from the group consisting of oxides, carbides, borides, silicides, nitrides, fluorides, oxynitrides, oxycarbides, silicates, metal-hydrate compounds, hydrated oxide compounds, carbonates, phosphates, minerals, feldspar, nepheline syenite, chromites, magnesites, dolomites, pyrites, sulfides, carbon-based materials, graphite, sulfides, silicon, metal, metal alloys, inter-metallics, ceramics, hollow-ceramics, fused silica, glass, glass-ceramics, hollow glass spheres, glass fibers, polymers, polyimides, polyamides, resins, aramids, epoxies, polyesters, polyurethanes, acetates, celluloses, ethers, ethanol, wood flour, clay, talc, and a combination thereof.