Polycrystalline Grits and Associated Methods

a technology of polycrystalline grits and associated methods, which is applied in the field of methods, can solve the problems of requiring extraordinary processing conditions, relying on expensive materials, and consuming a lot of time and resources to create grits

Inactive Publication Date: 2009-05-14
SUNG CHIEN MIN
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Creation of grits can be very time and resource intensive.
It can rely on expensive materials, and can require extraordinary processing conditions, such as high pressure high temperature (HPHT) conditions.
Furthermore, the grits created are generally non-uniform and require sorting for size and quality.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0054]Diamond powder of 2-4 μm is etch cleaned with molten fused salt such as NaOH, or eutectic mixture of NaCl—KCl—CaC12. The diamond powder is then thoroughly rinsed with DI water. The cleaned diamond powder is used in a mixture, along with 5 wt % silicon powder having an average particle size of 10 μm and 10 wt % wax binder. The mixture is thoroughly mixed to produce a dough. The dough is compacted repeatedly between two steel rollers to form a pull sheet of about 1 mm thick. The pull sheet is transferred to a tray having a sheet of Mylar that is sprinkled with fine graphite powder having an average particle size of about 20 μm. The graphite is natural graphite and has a high degree of graphitization and is soft to the touch. A set of parallel roller knives are used in perpendicular directions to slit the pull sheet into a plurality of cubic abrasive precursors. The Mylar is pulled in the directions perpendicular to the slits to reveal separations among the cubic abrasive precurs...

example 2

[0057]Same as Example 1, except cobalt powder is used in place of silicon powder. The sintered polycrystalline grits are not as thermally stable, but the overall diamond volume percent can be higher due to the higher sintering efficiency of molten cobalt liquid.

example 3

[0058]Same as Example 1, except a core of about 90 mm in diameter and 40 mm in thickness is fabricated and the ultrahigh pressure used for sintering is a belt apparatus instead of a cubic press.

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Abstract

A method for forming polycrystalline grits can include forming an abrasive dough, including a plurality of abrasive particles, into a sheet. The sheet can be divided into a plurality of abrasive precursors. By placing the sheet on a stretchable surface, separations among the plurality of abrasive precursors can be revealed by stretching the stretchable surface. The stretchable surface can include a particulate separating agent, and additional particulate separating agent can be distributed in the separations. The abrasive precursors can be sintered to form polycrystalline grits.

Description

PRIORITY DATA[0001]This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60 / 986,532, filed on Nov. 8, 2007, which is incorporated herein by reference.FIELD OF THE INVENTION[0002]The present invention relates to methods for use in producing abrasive grits, and the associated grits, particularly polycrystalline grits. Accordingly, the present invention involves the fields of chemical engineering, chemistry, metallurgy, and materials science.BACKGROUND OF THE INVENTION[0003]Abrasive particles can be used in a variety of applications such as cutting, sawing, grinding, lapping, drilling, and polishing of materials. Selection of abrasive particles depends on the anticipated use for the particles. As such, abrasive particles come in a variety of materials. For applications requiring extraordinarily hard abrasive particles, superabrasive particles, such as diamond and cubic boron nitride (cBN), can be used. In some cases, they may be single crystal grits, or po...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B24D3/00
CPCC09K3/1409C01B31/065C01B32/28
Inventor SUNG, CHIEN-MIN
Owner SUNG CHIEN MIN
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