Bonded abrasive articles and methods

Abstract

A bonded abrasive article having a matrix formed from matrix abrasive particles and a matrix binder; and a grinding layer having erectly-oriented abrasive particles and a grinding layer binder. The grinding layer is disposed on an exterior surface of the bonded abrasive article or is disposed at least partly within the interior of the bonded abrasive article.

What is claimed is: 
     
         1 . A bonded abrasive article comprising:
 a matrix comprising matrix abrasive particles and a matrix binder;   a grinding layer comprising erectly-oriented abrasive particles and a grinding layer binder;   wherein the grinding layer is disposed on an exterior surface of the bonded abrasive article or is disposed at least partly within the interior of the bonded abrasive article.   
     
     
         2 . The bonded abrasive article of  claim 1 ,
 the grinding layer further comprising a grinding face and a back face;   wherein the grinding layer is disposed on a first major surface of the matrix; and   wherein the back face is proximal to the matrix and the grinding face is distal to the matrix.   
     
     
         3 . The bonded abrasive article of  claim 1 ,
 the grinding layer further comprising a grinding face and a back face,   wherein the grinding layer is disposed at least partly within the interior of the bodned abrasive articles; and   wherein the back face is distal to the matrix and the grinding face is proximal to the matrix.   
     
     
         4 . The bonded abrasive article of  claim 1 , wherein the erectly-oriented abrasive particles comprise electrostatically erectly-oriented abrasive particles. 
     
     
         5 . The bonded abrasive article of  claim 1 , wherein either or both of the matrix abrasive particles and the erectly-oriented abrasive particles comprise precision-shaped abrasive particles. 
     
     
         6 . A grinding wheel comprising the bonded abrasive article of  claim 1 , wherein the grinding wheel has a mounting hole. 
     
     
         7 . The bonded abrasive article of  claim 1 , wherein
 the grinding layer further comprises a backing; and   wherein the grinding layer binder binds the erectly-oriented abrasive particles to the backing.   
     
     
         8 . The bonded abrasive article of  claim 1 , wherein the grinding layer is attached to the bonded abrasive article by an adhesive layer. 
     
     
         9 . The bonded abrasive article of  claim 1 , the grinding layer further comprising a sizing layer. 
     
     
         10 . The bonded abrasive article of  claim 1 , wherein the grinding layer is disposed completely within the interior of the matrix. 
     
     
         11 . The bonded abrasive article of  claim 1 , further comprising a second grinding layer; the second grinding layer further comprising a grinding face and a back face,
 wherein the second grinding layer is disposed on a first major surface of the matrix, wherein the back face is distal to the matrix and the grinding face is proximal to the matrix.   
     
     
         12 . A method of forming a bonded abrasive article, the method comprising:
 applying a matrix mixture to a grinding layer,   the matrix mixture comprising a curable matrix binder and matrix abrasive particles,   the grinding layer comprising erectly-oriented grinding abrasive particles; and   curing the matrix binder.   
     
     
         13 . The method of  claim 12 , wherein the grinding layer further comprises a backing and a grinding layer binder. 
     
     
         14 . The method of  claim 12 , wherein the grinding layer comprises a grinding face, wherein the applying further comprises contacting the matrix mixture with the grinding face. 
     
     
         15 . The method of  claim 12 , wherein the grinding layer comprises a back face, wherein the applying further comprises contacting the matrix mixture with the back face. 
     
     
         16 . The method of  claim 12 , wherein the grinding layer comprises a back face and a grinding face, wherein the applying further comprises contacting the matrix mixture with the back face and the grinding face. 
     
     
         17 . A method of forming a bonded abrasive article, the method comprising:
 applying a grinding layer precursor to a first major surface of a matrix,   depositing erectly-oriented particles on the grinding layer precursor,   applying a sizing layer on the erectly-oriented particles, and   curing the grinding layer precursor to form a grinding layer attached to the first major surface.   
     
     
         18 . The method of  claim 17 , wherein the depositing comprises: electrostatically erectly-orienting abrasive particles on the grinding layer.