High porosity abrasive articles and methods of manufacturing same

Abstract

An abrasive article includes a polymer matrix and abrasive grains dispersed in the polymer matrix, wherein the abrasive article has a void volume of at least 50%. The polymer matrix is polymerized from a monomer including at least one double bond.

What is claimed is: 
     
         1 . A method of forming an abrasive article, the method comprising:
 combining polymeric precursors including a monomer having at least one double bond, and abrasive grains to form a first liquid component;   forming an emulsion from the first liquid component and a second liquid component, the second liquid component substantially immiscible with the first liquid component; and   curing the polymeric precursors of the first liquid component, thereby forming a polymer matrix polymerized from the monomer.   
     
     
         2 . The method of  claim 1 , further comprising treating the abrasive grains with a coupling agent. 
     
     
         3 . The method of  claim 2 , wherein the coupling agent is hydrophobic. 
     
     
         4 . The method of  claim 1 , wherein the polymer precursors are thermally curable. 
     
     
         5 . The method of  claim 1 , wherein the polymer precursors are polymerizable through free radical polymerization. 
     
     
         6 . The method of  claim 1 , wherein the first liquid component is hydrophobic. 
     
     
         7 . The method of  claim 1 , wherein combining the polymer precursors and the abrasive grains includes combining at least 10 wt % of the abrasive grains. 
     
     
         8 . The method of  claim 1 , wherein the abrasive grains have an average particle size of 0.5 μm to 6 μm. 
     
     
         9 . The method of  claim 1 , wherein combining the polymer precursors and the abrasive grains includes combining an emulsifier with the polymer precursors and the abrasive grains. 
     
     
         10 . The method of  claim 1 , wherein combining the polymer precursors and the abrasive grains includes combining a stabilizing agent with the polymer precursors and the abrasive grains. 
     
     
         11 . The method of  claim 1 , wherein curing comprises exposing the emulsion to actinic radiation or thermal energy. 
     
     
         12 . The method of  claim 1 , wherein forming the emulsion includes forming the emulsion with at least 65 vol % of the second liquid component. 
     
     
         13 . The method of  claim 1 , wherein the monomer is selected from the group consisting of vinyl, acrylate, methacrylate, conjugated diolefin, allene, and olefin halide monomers. 
     
     
         14 . The method of  claim 1 , wherein the polymer matrix polymerized from the monomer has an open cell structure exhibiting a pore and throat configuration. 
     
     
         15 . A method of polishing an article, the method comprising:
 applying an abrasive article to the surface of the article, the abrasive article comprising a polymer matrix polymerized from a monomer including at least one double bond and abrasive grains dispersed in the polymer matrix, the abrasive article having a void volume of at least 50 vol %; and   abrading the surface of the article.   
     
     
         16 . The method of  claim 15 , wherein the abrasive article has a void volume of at least 65 vol %. 
     
     
         17 . The method of  claim 15 , wherein the abrasive article includes greater than 10 wt % of the abrasive grains. 
     
     
         18 . The method of  claim 15 , wherein the monomer is selected from the group consisting of vinyl, acrylate, methacrylate, conjugated diolefin, allene, and olefin halide monomers. 
     
     
         19 . The method of  claim 15 , wherein the polymer matrix has an open cell structure exhibiting a pore and throat configuration. 
     
     
         20 . The method of  claim 15 , wherein the abrasive grains have an average particle size of 0.5 μm to 6 μm.