Resin Bonded Abrasive

Abstract

A superabrasive resin product includes a superabrasive grain component, an oxide component, and a continuous phase defining a network of interconnected pores. The oxide component consists of an oxide of a lanthanoid, and the continuous phase includes a thermoplastic polymer component. The superabrasive grain component and the oxide component are distributed in the continuous phase.

1 . A superabrasive resin product, comprising:
 a superabrasive grain component;   an oxide component consisting of an oxide of a lanthanoid; and   a continuous phase including a polymeric bond component, the continuous phase defines a network of interconnected pores, wherein the pores have a multimodal size distribution with at least two modes, wherein the superabrasive grain component and the oxide component are distributed in the continuous phase.   
     
     
         2 . The superabrasive resin product of  claim 1 , wherein the lanthanoid includes an element having an atomic number of at least 57 and at most 60. 
     
     
         3 . The superabrasive resin product of  claim 1 , wherein the lanthanoid is at least one member selected from the group consisting of lanthanum, cerium, praseodymium, and neodymium. 
     
     
         4 . The superabrasive resin product of  claim 1 , wherein the lanthanoid includes cerium. 
     
     
         5 . The superabrasive resin product of  claim 8 , wherein the lanthanoid consists essentially of cerium. 
     
     
         6 . The superabrasive resin product of  claim 1 , wherein the oxide component is present in an amount in a range of between about 0.05 and about 10.0 volume percent of the superabrasive product. 
     
     
         7 . The superabrasive resin product of  claim 1 , wherein the oxide component has an average particle size in a range of between about 0.1 and about 30 microns. 
     
     
         8 . The superabrasive resin product of  claim 1 , wherein the continuous includes a thermoset polymer component. 
     
     
         9 . The superabrasive resin product of  claim 8 , wherein the thermoset polymer component includes at least one member selected from the group consisting phenol-formaldehyde, polyamide, polyimide and epoxy-modified phenolformaldehyde. 
     
     
         10 . The superabrasive resin product of  claim 9 , wherein the thermoset polymer component includes polyphenol-formaldehyde. 
     
     
         11 . The superabrasive resin product of  claim 1 , wherein the continuous phase includes a thermoplastic polymer component and a thermoset resin component. 
     
     
         12 . The superabrasive resin product of  claim 11 , wherein the ratio of thermoset resin to thermoplastic polymer components in the continuous phase is in a range of between about 80:15 and about 80:10 by volume. 
     
     
         13 . The superabrasive resin product of  claim 1 , wherein the ratio of continuous phase to superabrasive component is in a range of between about 2:1 and about 1:2 by volume. 
     
     
         14 . The superabrasive resin product of  claim 1 , wherein the continuous phase is a substantially open continuous phase. 
     
     
         15 . The superabrasive resin product of  claim 1 , wherein the superabrasive includes at least one member selected from the group consisting of diamond, cubic boron nitride, zirconia and aluminum oxide. 
     
     
         16 . The superabrasive resin product of  claim 14 , wherein the superabrasive includes diamond. 
     
     
         17 . The superabrasive resin product of  claim 1 , wherein the superabrasive product has a porosity in a range of between about 30% and about 80% by volume. 
     
     
         18 . The superabrasive product of any of  claims 1  and  2 , wherein the product is a wheel. 
     
     
         19 . The superabrasive product of  claim 18 , wherein the superabrasive has a median particle size in a range of between about 0.25 μm and about 30 μm. 
     
     
         20 . The superabrasive resin product of  claim 11 , wherein the thermoplastic polymer component includes polyacrylonitrile.