Abrasive article including a wear detection sensor

Abstract

An abrasive article can include a wear detection sensor embedded within the abrasive body or extending along an exterior surface of the abrasive body. The wear detection sensor can include at least one conductive lead and be designed to create one or more wear signals corresponding to the wear stage of the abrasive body. The at least one conductive lead can be coupled to a logic device, which may control the wear detection sensor and register the wear signal(s).

What is claimed is: 
     
         1 . An abrasive article comprising:
 an abrasive body including abrasive particles contained within a bond material; and   a wear detection sensor configured to detect a change in dimension of the abrasive body, wherein at least a portion of the wear detection sensor is coupled to and extending along at least a portion of the abrasive body.   
     
     
         2 . The abrasive article of  claim 1 , wherein the wear detection sensor comprises at least one electronic device including at least one antenna. 
     
     
         3 . The abrasive article of  claim 2 , wherein the antenna extends over a greater surface area of the abrasive body compared to an electronic element coupled to the antenna. 
     
     
         4 . The abrasive article of  claim 2 , wherein the antenna is arranged in a loop, in a serpentine shape, or a combination thereof. 
     
     
         5 . The abrasive article of  claim 2 , wherein the electronic device comprises an electronic element, wherein the electronic element is positioned within a non-abrasive portion of the abrasive body, and wherein at least a portion of the at least one antenna is positioned in an abrasive portion of the abrasive body. 
     
     
         6 . The abrasive article of  claim 5 , wherein the electronic element comprises a chip, an integrated circuit, a logic, a microcontroller, a transponder, a transceiver, a passive element, a resistor, a capacitor, a memory, or any combination thereof. 
     
     
         7 . The abrasive article of  claim 2 , wherein the antenna is at least partially embedded in the abrasive body. 
     
     
         8 . The abrasive article of  claim 1 , wherein the wear detection sensor comprises a plurality of antennas, wherein the plurality of antennas extend different lengths compared to each other toward a material removal surface of the abrasive body. 
     
     
         9 . The abrasive article of  claim 1 , wherein the wear detection sensor comprises an electronic device and a package encapsulating the electronic device. 
     
     
         10 . The abrasive article of  claim 1 , wherein the wear detection sensor comprises a plurality of antennas, wherein:
 at least one of the plurality of antennas is positioned within an exterior circumferential region of the abrasive body;   at least one of the plurality of the antennas comprises a flared body, wherein a width of the flared body increases as a length of the antenna extends;   at least one of the plurality of antennas extends in a radial direction, an axial direction, or a combination thereof, from a center region toward a material removal surface of the abrasive body;   at least one of the plurality of antennas comprises a terminal end aligned with the material removal surface; or   any combination thereof.   
     
     
         11 . The abrasive article of  claim 1 , wherein the wear detection sensor comprises at least one electronic device coupled to an electrical component, wherein the electrical component comprises a lead, a capacitor, a resistor, an inductor, a loop circuit, or a combination thereof, wherein the capacitor comprises a first capacitance plate positioned in an interior circumferential region of the abrasive body and a second capacitance plate positioned in an exterior circumferential region of the abrasive body. 
     
     
         12 . The abrasive article of  claim 1 , wherein the wear detection sensor comprises a first electronic device and a second electronic device extending in parallel along a portion of the abrasive body, wherein the first and second electronic devices are spaced apart from one another and staggered such that a first terminal end of the first electronic device is closer to a material removal surface compared to a second terminal end of the second electronic device, wherein the first terminal end is distal to a center region of the abrasive body compared to a third terminal end of the first electronic device, and the second terminal end is distal to the center region of the abrasive body compared to a fourth terminal end of the second electronic device. 
     
     
         13 . The abrasive article of  claim 1 , wherein the wear detection sensor comprises a plurality of components coupled to one another, wherein the plurality of components comprises a sensing circuit, a microcontroller, a transceiver, an antenna, or any combination thereof, wherein the sensing circuit comprises a magnetometer, such as a 3-axis magnetometer, a temperature and/or humidity sensor, 3-axis accelerometer, a capacitive input interface, or any combination thereof. 
     
     
         14 . A system for detecting wear in an abrasive article, comprising:
 the abrasive article of  claim 1 ; and   a data receiving unit configured to receive data generated by the wear detection sensor.   
     
     
         15 . The abrasive article of  claim 1 , wherein the wear detection sensor comprises a communication device for wireless communication with an external controller. 
     
     
         16 . An abrasive article comprising:
 an abrasive body comprising;
 abrasive particles contained within a bond material; 
 a wear detection sensor comprising at least one lead in contact with the abrasive body; and 
 at least one logic device in communication with the at least one conductive lead. 
   
     
     
         17 . The abrasive article of  claim 16 , wherein the at least one logic device is coupled to a hub, wherein the hub is coupled to the abrasive body, and wherein the wear sensor comprises a protection layer overlying the at least one logic device. 
     
     
         18 . The abrasive article of  claim 16 , wherein the protection layer comprises a material including polydimethylsiloxane (PDMS), polyethylene naphthalate (PEN), polyimide, polyether ether ketone (PEEK), or any combination thereof. 
     
     
         19 . The abrasive article of  claim 16 , wherein the wear sensor comprises a heat resistant coating overlying at least a portion of the at least one lead. 
     
     
         20 . The abrasive article of  claim 16 , wherein the wear detection sensor includes a plurality of conductive leads extending in parallel along a portion of an exterior surface of the abrasive body, wherein the plurality of leads have different lengths compared to each other.