Metal bond diamond tools that contain uniform or patterned distribution of diamond grits and method of manufacture thereof

US 6,286,498 B1
Filed: 09/20/1999
Issued: 09/11/2001
Est. Priority Date: 04/04/1997
Status: Expired due to Term

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First Claim

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1. A superabrasive tool having a superabrasive impregnated segment comprising:

a metal matrix configured for bonding a superabrasive grit; and

a plurality of the superabrasive grits each positively planted in the metal matrix and held at specific positions according to a predetermined pattern.

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Abstract

The present invention describes a novel metal bond superabrasive tool that contains a superabrasive such as diamond or CBN grits distributed in a predetermined or an uniform pattern. Such a pattern is produced by fabricating plurality layers of metal matrix with superabrasive grits distributed therein in a predetermined pattern and concentration and subsequently assembling and consolidating the layers into a tool segment. Superabrasive particles may be incorporated during the process of making these layers, or they may be planted afterwards into these layers that contains the metal matrix powder. In the latter case, the planting may be guided by a template with apertures laid in a specific pattern.

173 Citations

44 Claims

1. A superabrasive tool having a superabrasive impregnated segment comprising:
- a metal matrix configured for bonding a superabrasive grit; and
  
  a plurality of the superabrasive grits each positively planted in the metal matrix and held at specific positions according to a predetermined pattern.
- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31)
- - 2. A superabrasive tool according to claim 1, wherein the superabrasive grits are selected from the group consisting of diamond and cubic boron nitride(CBN).
  - 3. A superabrasive tool according to claim 2, wherein the superabrasive impregnated segment is formed from a plurality of the metal matrix layers, each layer being impregnated with superabrasive grits, and wherein the plurality of the layers are disposed adjacent one another to form the segment.
  - 4. A superabrasive tool according to claim 3, wherein at least one of the metal matrix layers is thinner than 1 mm.
  - 5. A superabrasive tool according to claim 3, wherein the superabrasive grits in one of the layers are larger than the superabrasive grits in at least one of the other layers.
  - 6. A superabrasive tool according to claim 5, wherein the plurality of layers includes at least one outer layer and at least one inner layer, and wherein the superabrasive grits of the at least one inner layer are larger than the abrasive particles of the at least one outer layer.
  - 7. A superabrasive tool according to claim 6, wherein the superabrasive segment is configured with two outer layers and at least one inner layer disposed between the outer layers, wherein each of the outer layers and the at least one inner layer has superabrasive grits disposed therein, and wherein the superabrasive grits disposed in the at least one inner layer are larger than those disposed in the outer layers.
  - 8. A superabrasive tool according to claim 3, wherein at least one of the layers has a greater concentration of superabrasive grits than at least one of the other layers.
  - 9. A superabrasive tool according to claim 8, wherein the plurality of layers includes at least one outer layer and at least one inner layer, and wherein the at least one outer layer has a greater concentration of superabrasive grits than the at least one inner layer.
  - 10. A superabrasive tool according to claim 9, wherein the abrasive segment is configured with two outer layers and at least one inner layer disposed between the outer layers, wherein each of the outer layers and the at least one inner layer have the superabrasive grits disposed therein, and wherein the superabrasive grits disposed in the outer layers are disposed in greater concentration than the superabrasive grits in the at least one inner layer.
  - 11. A superabrasive tool according to claim 8, wherein the plurality of layers includes at least one first layer having a first concentration of superabrasive grits, at least one second layer having a second concentration of superabrasive grits less than the first concentration, and at least one third layer having a third concentration of superabrasive grits less than the second concentration.
  - 12. A superabrasive tool according to claim 8, wherein the superabrasive grits impregnated segment has a leading edge configured to initially impact a surface to be cut, wherein the segment is formed by a plurality of layers, some of said layers being adjacent to the leading edge and some of the layers being remote from the leading edge and wherein the layers adjacent the leading edge have a higher concentration of superabrasive grits than layers remote from the leading edge.
  - 13. A superabrasive tool according to claim 2, wherein the segment is made by only one layer of superabrasive impregnated layer.
  - 14. A superabrasive tool according to claim 1, wherein the superabrasive grits are distributed in a uniform pattern throughout the impregnated segment.
  - 15. A superabrasive tool according to claim 1, wherein the superabrasive grits are uniformly distributed throughout the tool.
  - 16. A superabrasive tool according to claim 1, wherein the tool has superabrasive grits distributed therethrough, and wherein the tool has an outer portion having a higher concentration of superabrasive grits disposed therein.
  - 17. A superabrasive tool according to claim 1, wherein the segment has an impacting surface formed thereon and wherein the superabrasive grits are distributed in higher concentration adjacent to the impacting surface.
  - 18. A superabrasive tool according to claim 1, wherein the segment is formed by a plurality of the metal matrix layers having a certain patterned distribution of superabrasive grits, said plurality of the metal matrix layers being assembled together to form a segment having a desired three-dimensional distribution of superabrasive grits.
  - 22. A superabrasive tool of claim 1 or 19, wherein the layers have been consolidated together by a method selected from the group consisting of electroplating, brazing, sintering and infiltration.
  - 23. The superabrasive tool of claim 22, wherein the superabrasive grits are distributed within the layers in predetermined patterns.
  - 24. The superabrasive tool of claim 23, wherein the distribution of the superabrasive grits is uniform in at least one of the layers.
  - 25. The abrasive tool according to claim 1 or 19, wherein the superabrasive grits impregnated segment is formed by at least one layer of the metal matrix.
  - 26. The abrasive tool according to claim 25, wherein at least one layer of the metal matrix contains at least one layer of superabrasive grits.
  - 27. The abrasive tool according to claim 25, wherein the tool is a member selected from the group consisting of diamond drill bit, diamond dresser, diamond saw, diamond pad conditioner, and diamond profile wheel.
  - 28. The abrasive tool according to claim 27, wherein the diamond saw is a circular saw, frame saw, wire saw or chain saw.
  - 29. The abrasive tool according to claim 28, wherein the tool is a wire saw that is at least partially surrounded by the metal matrix containing the superabrasive grits.
  - 30. The abrasive tool according to claim 29, wherein the tool is a wire saw that contains diamond beads overcoated with diamond.
  - 31. The abrasive tool according to claim 25, wherein the metal matrix is consolidated by a method selected from the group consisting of electroplating, brazing, sintering and infiltration.

19. A superabrasive tool comprising a plurality of layers formed from a metal matrix for holding superabrasive grits, and a plurality of superabrasive grits each positively planted in the layers of metal matrix, and held at specific locations therein according to a predetermined pattern, wherein the layers are attached to one another to form a three-dimensional tool abrasive segment.
- View Dependent Claims (20, 21)
- - 20. A superabrasive tool of claim 19, wherein the superabrasive grit is diamond or CBN grit.
  - 21. A superabrasive tool of claim 19, wherein at least one of the layers is 1 millimeter thick or less.

32. A superabrasive tool comprising at least one layer of metal matrix with superabrasive grits formed therein, the layer being 1 millimeter or less in thickness and formed by rolling the metal matrix and the superabrasive grits between rollers to improve uniformity in the distribution of the abrasive particles.

33. A method for forning a superabrasive tool body with superabrasive grits distributed in a predetermined pattern in a metal matrix, comprising:
- (a) forming a layer of a metal matrix configured for bonding to superabrasive grits; and
  
  (b) positively planting a plurality of superabrasive grits at specific positions to be held in the layer of matrix material according to a predetermined pattern.
- View Dependent Claims (34, 35, 36, 37, 38, 39, 40, 42)
- - 34. The method according to claim 33 wherein the superabrasive grit is diamond or CBN grit.
  - 35. The method according to claim 34 comprises further steps of placing a template with a plurality of apertures formed therein on the layer of the metal matrix prior to disposition of the plurality of the superabrasive grits so that placement of the superabrasive grits is controlled by the position of the apertures, thereby selectively limiting placement of the superabrasive grits in the layer of the metal matrix to the positions of the apertures.
  - 36. The method according to claim 35 further comprises a step of using a template formed from a sieve.
  - 37. The method according to claim 35, wherein the template is formed by a plate having a plurality of apertures formed therein, the apertures being configured in a predetermined pattern.
  - 38. The method according to claim 37 wherein each aperture has a diameter which is greater than a diameter of the superabrasive grits to be positioned thereby, but less than twice the diameter of the superabrasive grits.
  - 39. The method according to claim 33 wherein the method comprises, forming the layer of the metal matrix by tape casting.
  - 40. The method according to claim 33 wherein the method comprises, forming the layer of the metal matrix by rolling.
  - 42. The method according to claim 33 wherein the method further comprises, the steps of forming a plurality of layers of metal matrix having the super abrasive grits disposed in a predetermined pattern therein, and attaching the layers together to form a superabrasive segment.

41. The method according to matrix 33 wherein the method comprises, forming the layer of the metal matrix by extrusion.

43. A method for forming a layer of superabrasive grits impregnated metal matrix having improved superabrasive grits distribution, comprising the steps of:
- (a) forming a layer having a mixture of metal matrix having a plurality of superabrasive grits each positively planted at specific locations therein according to a predetermined pattern; and
  
  (b) rolling the layer to form a layer no greater than 1 millimeter thick.
- View Dependent Claims (44)
- - 44. The method according to claim 43, wherein the superabrasive grit is diamond or CBN grit.

Specification

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Litigation Data

Current Assignee
Chien-Min Sung, Kinik Company
Original Assignee
Kinik Company
Inventors
Sung, Chien-Min
Primary Examiner(s)
Eley, Timothy V.

Application Number

US09/399,573
Time in Patent Office

722 Days
Field of Search

512/97, 125/16.02, 125/21.12, 125/22, 451/527, 451/529, 451/533, 451/544
US Class Current

125/12
CPC Class Codes

B01J 2203/061   Graphite

B01J 2203/062   Diamond

B01J 2203/0645   Boronitrides

B01J 2203/0655   Diamond

B01J 2203/066   Boronitrides

B01J 2203/068   Crystal growth

B01J 2203/0685   Crystal sintering

B01J 3/062   characterised by the compos...

B22F 1/05   Metallic powder characteris...

B22F 2003/1046   with separating means for a...

B22F 2005/001   Cutting tools, earth boring...

B22F 2207/03   of the metallic binder phas...

B22F 2999/00   Aspects linked to processes...

B22F 3/004   Filling molds with powder f...

B23P 15/28   cutting tools sawing tools ...

B24D 3/08   for close-grained structure...

B24D 7/066   Grinding blocks; their moun...

B24D 99/005   Segments of abrasive wheels

C04B 35/52   based on carbon, e.g. graphite

C22C 1/051   Making hard metals based on...

C22C 2204/00 : End product comprising diff...

C22C 26/00 : Alloys containing diamond o...

E21B 10/5676 : having a cutting face with ...

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Metal bond diamond tools that contain uniform or patterned distribution of diamond grits and method of manufacture thereof

First Claim

3 Assignments

Litigations

0 Petitions

Reexamination

Accused Products

Abstract

173 Citations

44 Claims

Specification

Solutions

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Metal bond diamond tools that contain uniform or patterned distribution of diamond grits and method of manufacture thereof

First Claim

3 Assignments

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Litigations

0 Petitions

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Reexamination

Accused Products

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Abstract

173 Citations

44 Claims

Specification

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Solutions

Use Cases

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