Abrasive tool making process – material – or composition – With inorganic material – Metal or metal oxide
Reexamination Certificate
2000-07-19
2003-06-24
Marcheschi, Michael (Department: 1755)
Abrasive tool making process, material, or composition
With inorganic material
Metal or metal oxide
C051S307000, C501S105000, C501S126000, C501S127000, C501S152000, C501S153000, C264S332000
Reexamination Certificate
active
06582488
ABSTRACT:
FIELD OF THE INVENTION
This invention pertains to fused material comprised of Al
2
O
3
-rare earth oxide-ZrO
2
eutectics. Examples of useful articles comprising fused Al
2
O
3
-rare earth oxide eutectic material include fibers and abrasive particles.
DESCRIPTION OF RELATED ART
A variety of fused eutectic metal oxide materials are known in the art, including binary and ternary eutectic materials. Fused eutectic metal oxide materials are typically made by charging a furnace with sources of the various metal oxides, as well as other desired additives, heating the material above its melting point, and cooling the melt to provide a solidified mass (see, e.g., U.S. Pat. No. 1,161,620 (Coulter), U.S. Pat. No. 1,192,709 (Tone), U.S. Pat. No. 1,247,337 (Saunders et al.), U.S. Pat. No. 1,268,533 (Allen), U.S. Pat. No. 2,424,645 (Baumann et al.) U.S. Pat. No. 3,891,408 (Rowse et al.), U.S. Pat. No. 3,781,172 (Pett et al.), U.S. Pat. No. 3,893,826 (Quinan et al.), U.S. Pat. No. 4,126,429 (Watson), U.S. Pat. No. 4,457,767 (Poon et al.), U.S. Pat. No. 5,143,522 (Gibson et al.),. U.S. Pat. No. 5,023,212 (Dubots et. al), and U.S. Pat. No. 5,336,280 (Dubots et. al).
There is, however, a continuing desire for new materials which may offer performance characteristics (including combinations of characteristics) that are different than conventional materials, are easier to make, and/or cheaper to make.
SUMMARY OF THE INVENTION
The present invention provides a fused, crystalline eutectic material comprising eutectic of at least (a) crystalline ZrO
2
and (b) at least two of (i) crystalline Al
2
O
3
, (ii) first crystalline complex Al
2
O
3
.rare earth oxide, or (iii) second, different (i.e., different from the first crystalline complex Al
2
O
3
.rare earth oxide), crystalline complex Al
2
O
3
.rare earth oxide material.
One preferred eutectic material according to the present invention comprises eutectic of at least (a) crystalline ZrO
2
(b) crystalline Al
2
O
3
, and crystalline complex Al
2
0
3
.rare earth oxide. Another preferred eutectic material according to the present invention comprises eutectic of at least (a) crystalline ZrO
2
, (b) first crystalline complex Al
2
O
3
.rare earth oxide, and (c) second, different, crystalline complex Al
2
O
3
.rare earth oxide.
In another aspect, the present invention provides a fused, crystalline eutectic material comprising eutectic of at least (a) crystalline complex Al
2
O
3
.rare earth oxide and (b) crystalline ZrO
2
.
In another aspect, a fused, crystalline material according to the present invention preferably comprises, on a theoretical oxide basis, at least 30 percent (or even at least 40, 50, 60, 70, or 80 percent) by weight Al
2
O
3
, based on the total metal oxide content the material.
In this application:
“simple metal oxide” refers to a metal oxide comprised of a one or more of the same metal element and oxygen (e.g., Al
2
O
3
, CeO
2
, MgO, SiO
2
, and Y
2
O
3
);
“complex metal oxide” refers to a metal oxide comprised of two or more different metal elements and oxygen (e.g., CeAl
11
O
18
, Dy
3
Al
5
O
12
, MgAl
2
O
4
, and Y
3
Al
5
O
12
);
“complex Al
2
O
3
.metal oxide” refers to a complex metal oxide comprised of, on a theoretical oxide basis, Al
2
O
3
and one or more metal elements other than Al (e.g., CeAl
11
O
18
, Dy
3
Al
5
O
12
, MgAl
2
O
4
, and Y
3
Al
5
O
12
);
“complex Al
2
O
3
.Y
2
O
3
” refers to a complex metal oxide comprised of, on a theoretical oxide basis, Al
2
O
3
and Y
3
O
3
(e.g., Y
3
Al
5
O
12
);
“complex Al
2
O
3
.rare earth oxide” or “complex Al
2
O
3
.REO” refers to a complex metal oxide comprised of, on a theoretical oxide basis, Al
2
O
3
and rare earth oxide (e.g., CeAl
11
O
18
and Dy
3
Al
5
O
12
);
“rare earth oxides” refer to, on a theoretical oxide basis, CeO
2
, Dy
2
O
3
, Er
2
O
3
, Eu
2
O
3
, Gd
2
O
3
, Ho
2
O
3
, La
2
O
3
, Lu
2
O
3
, Nd
2
O
3
, Pr
6
O
11
, Sm
2
O
3
, Th
4
O
7
, Tm
2
O
3
, and Yb
2
O
3
; and
“REO” means rare earth oxide.
In another aspect, the present invention provides a method for making fused, crystalline material according to the present invention, the method comprising:
melting at least one Al
2
O
3
source, at least one rare earth oxide source, and at least one ZrO
2
source to provide a melt; and
converting the melt to the fused, crystalline material.
Fused crystalline material according to the present invention can be made, formed as, or converted into fibers or abrasive particles.
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3M Innovative Properties Company
Allen Gregory D.
Marcheschi Michael
LandOfFree
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