Abrasive articles and methods for forming same

Abstract

An abrasive article can include a body including a bond material and abrasive particles contained within the bond material. The bond material can include a siloxane functional group covalently bonded to a plurality of benzene rings. In an embodiment, the bond material can include at least one siloxane functional group covalently bonded to a phenoxy. In a particular embodiment, the bond material can include polydimethylsiloxane covalently bonded to a phenoxy. The body can include an improved wet strength, which may be represented by wet flexure stress retention. In an embodiment, the body includes a wet flexure stress retention of at least 52%.

What is claimed is: 
     
         1 . A bonded abrasive article, comprising:
 a body including abrasive particles contained within a bond material,   wherein the bond material comprises a polymer including a plurality of benzene rings that are covalently bonded to one another and at least one siloxane functional group covalently bonded to the plurality of benzene rings.   
     
     
         2 . The bonded abrasive article of  claim 1 , wherein the bond material has a FTIR signature peak at a wavelength from 1258 cm −1  to 1275 cm −1 . 
     
     
         3 . The bonded abrasive article of  claim 1 , wherein the body comprises a wet flexural stress retention of at least 52%. 
     
     
         4 . The bonded abrasive article of  claim 1 , wherein the bond material comprises siloxane covalently bonded to the plurality of benzene rings, wherein the siloxane is represented by a formula I: 
       
         
           
           
               
               
           
         
       
       wherein R includes a methyl or phenyl group, X and Y independently represents hydrogen atoms, a hydrocarbyl group, or an alkoxy group, and n is at least one. 
     
     
         5 . The bonded abrasive article of  claim 4 , wherein the siloxane is covalently bonded to an oxygen atom, wherein the oxygen atom is directly and covalently bonded to one of the plurality of benzene rings. 
     
     
         6 . The abrasive article of  claim 4 , wherein the bond material comprises a content of the siloxane in a range from at least 1 wt. % to at most 30 wt. % for a total weight of the bond material. 
     
     
         7 . The abrasive article of  claim 4 , wherein the siloxane consist essentially of polymethylsiloxane. 
     
     
         8 . The bonded abrasive article of  claim 1 , wherein the plurality of benzene rings are covalently bonded to one another by a methylene bridge. 
     
     
         9 . The bonded abrasive article of  claim 1 , wherein each of the plurality of benzene rings is covalently bonded to an oxygen atom that is covalently bonded to at least one siloxane functional group. 
     
     
         10 . The abrasive article of  claim 1 , wherein the bond material comprises a polymethylsiloxane including the at least one siloxane functional group. 
     
     
         11 . The abrasive article of  claim 10 , wherein the polymethylsiloxane is present in the bond material in a content from at least 1 wt. % to at most 30 wt. % for the total weight of the bond material. 
     
     
         12 . The abrasive article of  claim 1 , wherein the body comprises a filler including barium sulfate, cryolite, or any combination thereof. 
     
     
         13 . The bonded abrasive article of  claim 1 , wherein the body comprises:
 the bond material in a content from at least 5 vol % to at most 55 vol % for a total volume of the body;   the abrasive particles in a content from at least 8 vol % to at most 65 vol % for the total volume of the body; and   a porosity in a content from at least 3 vol % to at most 60 vol % for the total volume of the body.   
     
     
         14 . A bonded abrasive article, comprising:
 a body including abrasive particles contained within a bond material,   wherein the bond material comprises a polymer including a plurality of benzene rings that are covalently bonded to one another and siloxane covalently bonded to the plurality of benzene rings, wherein the siloxane is represented by a formula I:   
       
         
           
           
               
               
           
         
         wherein R includes a methyl or phenyl group, X and Y independently represents hydrogen atoms, a hydrocarbyl group, or an alkoxy group, and n is at least one. 
       
     
     
         15 . The bonded abrasive article of  claim 14 , wherein the siloxane comprises polydimethylsiloxane covalently bonded to an oxygen atom that is covalently bonded to the plurality of the benzene rings, and wherein the siloxane is presented in the bond material in a content from at least 3 wt. % to at most 25 wt. %. 
     
     
         16 . A process of forming an abrasive article, comprising:
 forming a green body with a mixture comprising abrasive particles and a bond precursor material,   wherein the bond precursor material comprises a phenolic resin covalently bonded to at least one siloxane functional group.   
     
     
         17 . The process of  claim 16 , wherein the resin has a FTIR signature peak at a wavelength from 1257 cm −1  to 1261 cm −1 . 
     
     
         18 . The process of  claim 16 , wherein the phenolic resin is covalently bonded to siloxane represented by a formula I: 
       
         
           
           
               
               
           
         
       
       wherein R includes a methyl or phenyl group, X and Y independently represents hydrogen atoms, a hydrocarbyl group, or an alkoxy group, and n is at least one. 
     
     
         19 . The process of  claim 18 , wherein the siloxane comprises polydimethylsiloxane, wherein the polydimethylsiloxane is directly and covalently bonded to an oxygen atom of the phenolic resin. 
     
     
         20 . The process of  claim 18 , wherein the bond precursor material comprises the siloxane in a content from at least 1 wt. % to at most 30 wt. % for a total weight of the bond precursor material.