Methods of bonding superabrasive particles in an organic matrix
Superabrasive tools and their methods of manufacture are disclosed. In one aspect, a method of improving retention of superabrasive particles held in a solidified organic material layer of an abrading tool, a portion of each of said superabrasive particles protruding out of the solidified organic material layer is provided. Such a method may include securing the plurality of superabrasive particles in the solidified organic material layer such that the organic material layer wicks up the protruding portions of the superabrasive particles. In addition to the wicking of the organic material layer around the superabrasive particles, various additional parameters may be utilized to improve retention. For example, in another aspect the plurality of superabrasive particles may be secured in an arrangement that minimizes mechanical stress impinging on protruding portions of any individual superabrasive particle when used to abrade a work piece. As an example, the arrangement of the plurality of superabrasive particles may be configured to uniformly distribute drag forces across substantially each superabrasive particle.
1 . A method of improving retention of superabrasive particles held in a solidified organic material layer of an abrading tool, a portion of each of said superabrasive particles protruding out of the solidified organic material layer, comprising:
securing the plurality of superabrasive particles in the solidified organic material layer such that the organic material layer wicks up the protruding portions of the superabrasive particles, and wherein the organic material layer is substantially seamless.
2 . The method of claim 1 , wherein the plurality of superabrasive particles are secured in an arrangement that minimizes mechanical stress impinging on the protruding portion of any individual superabrasive particle when used to abrade a work piece.
3 . The method of claim 2 , wherein the arrangement of the plurality of superabrasive particles is configured to uniformly distribute drag forces across substantially each superabrasive particle.
4 . The method of claim 1 , wherein substantially all of the plurality of superabrasive particles protrude to a predetermined height above the solidified organic material layer.
5 . The method of claim 4 , wherein the superabrasive particles protruding to a predetermined height produce a cutting depth of less than about 20 microns when used to abrade a work piece.
6 . The method of claim 4 , wherein substantially all of the superabrasive particles protrude to a predetermined height that is along a designated profile.
7 . The method of claim 6 , wherein substantially all of the plurality of superabrasive particles are arranged such that their tips vary from the designated profile to less than about 10% of the average size of the superabrasive particles.
8 . The method of claim 4 , wherein substantially all of the plurality of superabrasive particles are arranged such that their tips protrude to less than about 40 microns.
9 . The method of claim 4 , wherein substantially all of the plurality of superabrasive particles are arranged such that their tips protrude to less than about 30 microns.
10 . The method of claim 4 , wherein substantially all of the plurality of superabrasive particles are arranged such that their tips protrude to about 20 microns.
11 . A method of making an abrading tool, comprising:
providing an adhesive layer having a stiffness that resists mounding around an object pressed therein;
pressing a plurality of superabrasive particles into the adhesive layer such that mounding of the adhesive layer around the plurality of superabrasive particles does not occur;
covering the plurality of superabrasive particles with a layer of an uncured organic material;
curing the uncured organic material to form a layer of solidified organic material; and
removing the adhesive layer from the solidified organic material to expose a portion of each of the plurality of superabrasive particles, wherein the solidified organic material layer either wicks up the exposed portions of the superabrasive particles or is perpendicular to the exposed portions of the superabrasive particles.
12 . The method of claim 11 , wherein pressing the plurality of superabrasive particles into the adhesive layer further includes pressing the plurality of superabrasive particles into the adhesive layer such that the plurality of superabrasive particles deflect the adhesive layer to form a plurality of dimples in the adhesive layer.
13 . The method of claim 12 , wherein covering the plurality of superabrasive particles further comprises covering the plurality of superabrasive particles with the layer of the uncured organic material such that the uncured organic material fills at least a portion of each of the plurality of dimples.
14 . The method of claim 12 , wherein the adhesive layer further comprises a first adhesive layer and a second adhesive layer disposed on the first adhesive layer, the second adhesive layer having increased stiffness as compared to the first adhesive layer.
15 . The method of claim 14 , wherein pressing the plurality of superabrasive particles further comprises pressing the plurality of superabrasive particles into the second adhesive layer such that the plurality of superabrasive particles deflect the second adhesive layer towards the first adhesive layer to form a plurality of dimples in the second adhesive layer.
16 . The method of claim 15 , wherein pressing the plurality of superabrasive particles into the second adhesive layer further comprises pressing the plurality of superabrasive particles into the second adhesive layer such that the plurality of superabrasive particles penetrate the second adhesive layer to contact the first adhesive layer.
17 . A superabrasive tool having improved superabrasive particle retention, comprising:
a solidified organic material layer; and
a plurality of superabrasive particles secured in the solidified organic material layer such that the organic material layer wicks up protruding portions of the superabrasive, and wherein the organic material layer is substantially seamless.
18 . The tool of claim 17 , wherein substantially all of the plurality of superabrasive particles protrude to a predetermined height is along a designated profile.
19 . The tool of claim 17 , wherein substantially all of the plurality of superabrasive particles are arranged such that their tips protrude to about 10% of the average size of the superabrasive particles.
20 . The tool of claim 17 , wherein the plurality of superabrasive particles include a member selected from the group consisting of diamond, polycrystalline diamond, cubic boron nitride, polycrystalline cubic boron nitride, and combinations thereof.
21 . The tool of claim 20 , wherein the plurality of superabrasive particles includes diamond.
22 . The tool of claim 20 , wherein the plurality of superabrasive particles includes polycrystalline cubic boron nitride.
23 . The tool of claim 17 , wherein the plurality of superabrasive particles are from about 30 microns to about 500 microns in size.
24 . The tool of claim 17 , wherein the plurality of superabrasive particles are from about 100 microns to about 200 microns in size.
25 . The tool of claim 17 , wherein the plurality of superabrasive particles are from about 40 microns to about 100 microns in size.
26 . The tool of claim 17 , wherein the solidified organic material layer comprises a member selected from the group consisting of amino resins, acrylate resins, alkyd resins, polyester resins, polyamide resins, polyimide resins, polyurethane resins, phenolic resins, phenolic/latex resins, epoxy resins, isocyanate resins, isocyanurate resins, polysiloxane resins, reactive vinyl resins, polyethylene resins, polypropylene resins, polystyrene resins, phenoxy resins, perylene resins, polysulfone resins, acrylonitrile-butadiene-styrene resins, acrylic resins, polycarbonate resins, polyimide resins, and mixtures thereof.
27 . The tool of claim 26 , wherein the solidified organic material layer is an epoxy resin.
28 . The tool of claim 26 , wherein the solidified organic material layer is a polyurethane resin.
29 . The tool of claim 26 , wherein the solidified organic material layer is a polyimide resin.
30 . The tool of claim 17 , wherein the tool is a polishing or grinding pad.
31 . The tool of claim 17 , wherein the tool is a CMP pad dresser.
32 . The tool of claim 17 , wherein the tool is for shaping dental materials.