Note: Descriptions are shown in the official language in which they were submitted.
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
ABRASIVE ARTICLE INCLUDING A WEAR DETECTION SENSOR
TECHNICAL FIELD
The following is directed to an abrasive article, and particularly, to an
abrasive article
including a wear detection sensor.
BACKGROUND ART
Fixed abrasive articles can be used in various material removal operations and
are
often subjected to long time grinding processes, for example, during the
grinding of railroad
tracks. In order to optimize the grinding process and to determine a needed
replacement of
an abrasive article, it is important to observe the wear stage of the abrasive
body, which can
require time-consuming operation stops. For example, rail grinding can only be
conducted in
time periods when the trains are not running. These time periods can be of
short duration and
need to be efficiently used, such that a major part of the time is spend on
the grinding
operation and not on time-consuming replacement of abrasive wheels. The amount
of
abrasive material left on each wheel is typically manually measured prior to
the grinding to
identify the wheels that may be fully worn during the next run. These
measurements are also
time consuming and any needed replacement is handled conservatively by the
operator, to
avoid changing of the wheels during the open grinding time period.
There exists a demand to continuously observe the wear stage of an abrasive
article
without interrupting the grinding process.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure may be better understood, and its numerous features and
advantages made apparent to those skilled in the art by referencing the
accompanying
drawings.
FIG. 1 includes a side-view illustration of an abrasive article according to
one
embodiment.
FIG. 2 includes a cross-sectional illustration of an abrasive article
according to one
embodiment.
FIG. 3 includes a side view illustration of an abrasive article according to
one
embodiment.
FIG. 4A includes an illustration of a section of an abrasive body before use
including
portions of the wear detection sensor according to one embodiment.
- 1 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
FIG. 4B includes an illustration of a section of an abrasive body during a
material
removing operation including portions of the wear detection sensor according
to one
embodiment.
FIG. 5A includes an illustration of one lead of a wear detection sensor
according to
one embodiment.
FIG. 5B includes an illustration of one lead of a wear detection sensor
according to
another embodiment.
FIG. 6 includes an illustration of one lead helically wound around an abrasive
body
according to one embodiment.
FIG. 7 includes an illustration of a plan view of an abrasive article
including a wear
detection sensor according to an embodiment.
FIG. 8 includes an illustration of a plan view of an abrasive article
including a
detection sensor according to another embodiment.
FIG. 9A includes an illustration of a wear detection sensor according to an
embodiment.
FIG. 9B includes an illustration of a wear detection sensor according to
another
embodiment.
FIG. 9C includes an illustration of a portion of a wear sensor attached to a
mounting
plate according to an embodiment.
FIG. 9D includes an illustration of a plot of time vs. loop state for a wear
sensor.
FIG. 9E includes an illustration of another plot of time vs. loop state for a
wear
sensor.
Fig. 10 includes an illustration of a cross-sectional view of a portion of an
abrasive
article according to an embodiment.
FIG. 11 includes an illustration of a plan view of an abrasive article
including a
detection sensor according to another embodiment.
FIG. 12 includes an illustration of a plan view of an abrasive article
including a
detection sensor according to another embodiment.
FIG. 13 includes an illustration of a plan view of an abrasive article
including a
detection sensor according to another embodiment.
FIG. 14 includes an illustration of a plan view of an abrasive article
including a
detection sensor according to another embodiment.
FIG. 15 includes an illustration of a section of an abrasive body according to
an
embodiment.
- 2 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
FIG. 16A includes an illustration of a plan view of an abrasive article
including a
detection sensor according to another embodiment.
FIG. 16B includes a plot of diameter vs. reflected power.
FIG. 17A includes an illustration of a section of an abrasive body according
to an
embodiment.
FIG. 17B includes an illustration of a section of another abrasive body
according to an
embodiment.
FIG. 18 includes an illustration of a wear detection system according to an
embodiment.
FIG. 19A includes a plot of reflected power vs. time of an abrasive article
according
to an embodiment.
FIG. 19B includes a plot of reflected power vs. time of another abrasive
article
according to an embodiment.
FIG. 20 includes an illustration of an exemplary wear sensor.
FIG. 21 includes an illustration of components of an exemplary reader.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
The following description in combination with the figures is provided to
assist in
understanding the teachings provided herein. The following disclosure will
focus on specific
implementations and embodiments of the teachings. This focus is provided to
assist in
describing the teachings and should not be interpreted as a limitation on the
scope or
applicability of the teachings. However, other teachings can certainly be used
in this
application.
As used herein, the terms "comprises," "comprising," "includes," "including,"
"has,"
"having" or any other variation thereof, are intended to cover a non-exclusive
inclusion. For
example, a method, article, or apparatus that comprises a list of features is
not necessarily
limited only to those features but may include other features not expressly
listed or inherent
to such method, article, or apparatus. Further, unless expressly stated to the
contrary, "or"
refers to an inclusive-or and not to an exclusive-or. For example, a condition
A or B is
satisfied by any one of the following: A is true (or present) and B is false
(or not present), A
is false (or not present) and B is true (or present), and both A and B are
true (or present).
Also, the use of "a" or "an" is employed to describe elements and components
described herein. This is done merely for convenience and to give a general
sense of the
scope of the invention. This description should be read to include one or at
least one and the
singular also includes the plural, or vice versa, unless it is clear that it
is meant otherwise.
- 3 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
For example, when a single item is described herein, more than one item may be
used in
place of a single item. Similarly, where more than one item is described
herein, a single item
may be substituted for that more than one item.
Unless otherwise defined, all technical and scientific terms used herein have
the same
.. meaning as commonly understood by one of ordinary skill in the art to which
this invention
belongs. The materials, methods, and examples are illustrative only and not
intended to be
limiting. To the extent that certain details regarding specific materials and
processing acts
are not described, such details may include conventional approaches, which may
be found in
reference books and other sources within the manufacturing arts.
Embodiments disclosed herein are directed to an abrasive article including an
abrasive
body of abrasive particles within a bond material. The abrasive article can
include a wear
detection sensor configured for detecting a change in a 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. As used herein, the phrase "coupled to
and extending
along at least a portion of the abrasive body" means that at least a portion
of the wear
detection sensor can be contained at an exterior surface of the body, or being
partially
embedded in the abrasive body, or being totally embedded in the body of the
abrasive article.
In one embodiment, the wear detection sensor can include at least one lead.
The at
least one lead can include an electrically conductive structure.
In one aspect, the lead can include a pair of conductive wires connected
together at
their ends (i.e., terminal end or lead tip), which can create an electrically
conductive loop.
In another aspect, the lead can be a thin elongated conductive plate or wire
adapted to
change resistance corresponding to a length of the elongated plate or wire.
With increasing
wear of the abrasive body, the length of the lead becomes shorter, and the
measured change
in resistance of the lead with decreasing length of the lead may correspond to
the wear of the
abrasive body.
In yet another aspect, the lead can be an electric circuit including two wires
connected
by a plurality of resistors. The resistors are positioned in parallel to each
other at different
locations along a length direction of the two wires (i.e., a resistive
ladder). As resistors get
destroyed during the wear of the abrasive body, the equivalent resistance of
the circuit
increases and the measured increase in resistance of the circuit can
correspond to the state of
the wear of the abrasive body.
- 4 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
The at least one lead of the wear detection sensor can be partially embedded
in the
abrasive body, completely embedded in the abrasive body, or extend along an
exterior
surface of the abrasive body.
As used herein, the term at least one lead is also called plurality of leads
if the wear
detection sensor contains more than one lead.
In one aspect, the at least one lead of the wear detection sensor can extend
along a
portion of the exterior surface of the abrasive body. In another aspect, a
majority or the leads
of the plurality of leads can extend along a portion of the exterior surface
of the abrasive
body. In a particular aspect, each lead of the plurality of leads may extend
along a portion of
the exterior surface of the abrasive body.
In a further embodiment, at least one lead of the plurality of leads can be
embedded
within the abrasive body. In a particular embodiment, all of the leads of the
plurality of leads
may be embedded within the abrasive body.
In one aspect, the wear detection sensor can have a first portion, e.g., a
logic device,
and a second portion, e.g., a plurality of leads, wherein the first portion
can be coupled to a
hub and the second portion can be coupled to the abrasive body. In another
aspect, the first
portion of the wear detection sensor can be coupled to the abrasive body and
the second
portion may be coupled to the hub. In another aspect, both the plurality of
leads and the logic
device can be coupled to the abrasive body.
FIG.1 includes an illustration of an abrasive article 100 according to one
embodiment.
The abrasive article (100) can be an abrasive wheel, wherein the abrasive body
(102)
is coupled to a hub (103). The abrasive body can include a bonded abrasive
material,
including abrasive particles contained in a three-dimensional matrix of bond
material. The
abrasive body (102) may optionally include some porosity as a distinct phase
from the
abrasive particles and bond material. A wear detection sensor can be coupled
to the abrasive
article (100), such as the abrasive body (102) and/or hub (103) in form of a
plurality of leads
(104) and a logic device (105). The plurality of leads (104) of the wear
detection sensor can
be coupled to a portion of the exterior surface of the abrasive body (102).
The plurality of
leads 104 can extend from the logic device (105) in axial direction (x) of the
abrasive body
.. (102) towards the material removing surface (107).
In another embodiment of an abrasive article illustrated in FIG. 2, the
plurality of
leads (204) of the wear detection sensor can extend from the logic device
(205) in a radial
direction (z) of the abrasive body (202), the radial direction (z) being
orthogonal to the axial
direction (x). FIG. 2 shows a crosscut of an abrasive wheel including an
abrasive body (202)
- 5 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
attached to a hub (203), wherein all leads of the wear detection sensor (204)
can be
completely embedded in the abrasive body (202) and point towards the material
removal
surface (207). The logic device (205) can further optionally include a
communication device
(e.g., transceiver) (206) for communication with an external controller (not
shown).
FIG. 3 illustrates a side view of an abrasive wheel (300) of the present
disclosure. In
this embodiment, the plurality of leads of the wear detection sensor (304) can
extend along a
portion of the exterior surface (308) of the abrasive body. The plurality of
leads (304) may
be connected to a logic device (305), and the logic device (305) can be
coupled to a hub
(303). The plurality of leads (304) may extend in a radial direction (z) to
the outer material
removal surface (307).
The amount of leads of the wear detection sensor can be at least one lead and
may
have no specific upper limit. The amount of leads can depend on the thickness
of the
abrasive body subjected to a material removing process, such as grinding,
cutting, or
polishing, and in which increments of the wear of the abrasive body should be
observed. In
one embodiment, the wear detection sensor can include at least one lead, such
as at least two
leads, at least three leads or at least four leads, at least five leads, at
least seven leads, or at
least nine leads. In another embodiment, the wear detection sensor can include
not more than
100 leads, such as not more than 80 leads, not more than 60 leads, not more
than 50 leads, not
more than 30 leads, not more than 20 leads, not more than 15 leads, or not
more than 10
.. leads. The amount of leads in the wear detection sensor can be a value
within a range
including any of the minimum and maximum values noted above.
The plurality of leads of the wear detection sensor may have different lengths
compared to each other. In one embodiment, all the leads can extend parallel
to each other
from a logic device for different depths into the volume of the abrasive body.
In one aspect,
each of the leads of the plurality of leads can include a terminal end, and
each of the terminal
ends can be located at a different position relative to each other. For
example, each of the
terminal ends may be embedded at different depths within the abrasive body
relative to each
other.
In another embodiment, the plurality of leads may extend from the logic device
at an
angle to each other along the abrasive body. In a further embodiment, the
plurality of leads
may not be directly coupled to the logic device but can have a connective
structure between
the logic device and the plurality of leads.
In one embodiment, each lead can reach with its terminal end up to a defined
distance
ADT from the original material removing surface of the abrasive body, wherein
the terminal
- 6 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
ends of the leads can be embedded in the abrasive body or extend along an
exterior surface of
the abrasive body. FIG. 4A illustrates a section of an abrasive body, wherein
all leads of the
wear detection sensor (404) may be embedded in the abrasive body (402) and the
terminal
end of each lead can have a defined distance ADT1, ADT2, ADT3, and ADT4, from
the
original material removing surface of the abrasive body (407). Under original
material
removing surface of the abrasive body (407) should be understood herein the
exterior surface
of the abrasive body before it is subjected to grinding or cutting of a work
piece. In FIG. 4A,
the plurality of leads extends in axial direction (x) towards the original
material removal
surface (407).
During a material removing operation, the abrasive body of the present
disclosure can
be subjected to wear, such that portions of the abrasive body may be removed
from the
original material removing surface. FIG. 4B illustrates a stage of an abrasive
article 401
wherein a portion of the abrasive body has been removed from the original
outer material
removing surface during a material removing operation of a work piece (410),
and the
terminal end of the longest lead of the plurality of leads (404) has reached
the actual material
removing surface (409) of the abrasive body (402).
When the terminal end of a lead reaches the actual material removing surface
(409) of
the abrasive body (402), the connection between the two wires which conduct
current through
the lead can be destroyed, thereby opening the electric circuit, and the
current between the
pair of wires of the lead cannot flow anymore. The open circuit of the broken
wire loop can
be detected by the logic device and understood herein as a broken lead. From
the amount of
broken leads detected by the logic device, a calculation can be made about the
wear of the
abrasive body.
In another aspect, the plurality of leads can be connected together within one
electric
circuit, wherein a broken wire loop can cause a change of the total voltage
through the
complete electric circuit if the total amount of supplied current is remained
constant. The
amount of change in voltage can be measured as a wear signal by the logic
device connected
to the plurality of leads and can allow to make conclusions about the wear
stage of the
abrasive body, such as how much of the abrasive body has been removed from the
original
outer material removing surface (307) and the remaining life time.
By knowing the position of the terminal ends of the leads within the abrasive
body or
along the exterior surface of the abrasive body from the original material
removal surface of
the abrasive body, the wear stage of the abrasive body during working
operation can be
calculated by the logic device. In one embodiment, the distance ADT of a
terminal end of a
- 7 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
lead of the plurality of leads from the original removal surface of the
abrasive body can be at
least 100 microns, such as at least 150 microns, at least 200 microns, at
least 500 microns, at
least 1000 microns, at least 5000 microns, or at least 10000 microns. In
another aspect, the
distance ADT may be not be greater than 1.5 meters, such as not greater than
1.3 meters, or
not greater than 1.0 meter, or not greater than 0.8 meter, or not greater than
0.5 meter, or not
greater than 0.3 meter, or not greater than 0.1 meter, or not greater than
0.05 meter, or not
greater than 0.01 meter. The distance ADT can be a value within a range
including any of the
minimum and maximum values noted above.
In a further embodiment, a distance ADI between two terminal lead ends to each
other
in a direction orthogonal to the material removal surface of the abrasive body
can be at least
100 microns, such as at least 200 microns, at least 300 microns, or at least
500 microns, or at
least 1000 microns, or at least 5000 microns. In another aspect, the distance
between two
terminal lead ends may be not greater than 1.5 meters, such as not greater
than 1.2 meters, or
not greater than 1.0 meter, or not greater than 0.8 meter, or not greater than
0.5 meter, or not
greater than 0.3 meter, or not greater than 0.1 meter, or not greater than
0.05 meter. The
distance ADI can be a value within a range including any of the minimum and
maximum
values noted above.
In the embodiment wherein each lead of the wear detection sensor is a single
wire or
elongated plate, the wear detection sensor can be designed that the area of
the lead (e.g., the
length of the lead) correlates with a certain resistance, wherein the change
in resistance with
decreasing length of the lead (by increasing wear) can be converted to
information about the
wear of the abrasive body.
In one embodiment, the total length of the at least one lead of the wear
detection
sensor can be at least 100 microns, such as at least 200 microns, or at least
500 microns, or at
least 1000 microns, or at least 1 cm, or at least 5 cm. In another aspect, the
total length of the
at least one lead may be not greater than 10 meters, such as not greater than
8 meters, or not
greater than 5 meters, or not greater than 3 meters, or not greater than 2
meters, or not greater
than 1.5 meters, or not greater than 1.0 meter, or not greater than 0.8 meter,
or not greater
than 0.5 meter, or not greater than 0.3 meter, or not greater than 0.2 meter,
or not greater than
0.1 meter, or not greater than 0.05 meter, or not greater than 0.01 meter. The
total length of
the at least one lead can be a value within a range including any of the
minimum and
maximum values noted above.
The at least one conductive lead of the wear detection sensor can be in
communication with at least one logic device. In one embodiment, the logic
device can be a
- 8 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
microcontroller configured to detect a change in the states of the wear
detection sensor. The
logic device can optionally include a communication device, for example, a
transceiver, for
communication with an external controller.
In one aspect, the at least one lead of the wear detection sensor can be
detected by the
logic device being in an active state when a current is flowing through the
lead, and being in
an inactive state when no or a smaller amount of current is flowing through
the lead because
the lead is damaged. The interruption or reduction of the current flow in the
inactive stage of
the lead can create a wear signal. Accordingly, by detecting the wear signals
and controlling
and measuring the current flowing through the plurality of leads, the wear
stage of the
abrasive body can be analyzed without interrupting the material removing
process.
The wear signal created by the wear detection sensor can be transmitted by a
communication device to an external controller, e.g., a portable control unit
in the hand of an
operator, or a fixed unit implemented on the machine on which the wheels are
mounted. The
transmission of the wear signal can be via an electrical connection, for
example, to the
spindle on which the wheel is mounted, or as a wireless signal. In one aspect,
the logic
device can include a transceiver, e.g., an RFID transceiver, for sending the
wear signals to an
external controller which may oversee and control the grinding process. Other
options for
wireless sending the wear signal can be via Wi-Fi or Bluetooth or other
wireless protocols.
The wear signals can be stored as local data storage on a logic board (e.g.,
SD card or flash
memory). The external controller can be a part of the logic device or an
independent unit. In
a further aspect, light indicators can be used to signal that a wheel needs to
be replaced or still
has a long life time.
The electrical power needed for operating the wear detection sensor can be
provided
from a battery, or from a direct electrical connection from a machine or
train. The wear
detection sensor can also be remotely powered using RF energy or powered by an
energy
harvesting system, for instance a system producing electrical energy from
vibration.
The material of the at least one conductive lead can be a metal or metal
alloy. Non-
limiting examples of lead materials can be copper, aluminum, silver, or
stainless steel.
In one embodiment, particularly when the lead has the structure of a wire loop
or of a
resistive ladder, each lead may be further surrounded or embedded by a
protective material.
FIG. 5A illustrates an embodiment of one lead (500), which can include a pair
of wires (501)
connected together by forming a lead end (502) and forming a loop, wherein the
wire may be
surrounded by a lead protecting material (503).
- 9 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
FIG. 5B illustrates a lead having the structure of a resistive ladder, wherein
two wires
(504) are connected by a plurality of resistors (505) placed parallel to each
other at different
positions along a length direction of the two wires (504). The whole electric
circuit is
embedded in a protective material (503).
The lead protecting material can be a material which may protect the wire of
the lead
during manufacturing of the abrasive article, but can be easily destroyed by
the forces during
the material removal operation of the abrasive article when it reaches the
actual outer material
removing surface of the abrasive body. Non-limiting examples of lead-
protecting materials
can be, e.g., a polyimide, a polyurethane, or a polyolefin. The lead
protecting material can
also serve as an insulator preventing shorting of the electric circuit, for
example, in an
embodiment wherein the abrasive body is electrically conductive. In one
aspect, at least one
wire loop can be directly applied on the exterior surface of the abrasive body
and embedded
within a protective polymer, e.g., a polyimide. Similarly, if the lead is
designed for
measuring the change in resistance, the wire or elongated plate can be
directly applied on the
exterior surface of the abrasive body and embedded within a protective
polymeric material.
In another embodiment, the leads of the wear protection sensor may not include
a
wire protecting material.
In yet a further embodiment, the at least one lead can have a spiral form and
be wound
around an external surface of the abrasive body, as illustrated in FIG. 6.
This embodiment
may apply for a lead which can change resistance according to its size
reduction during wear
of the abrasive body. FIG. 6 shows an abrasive body in form of a wheel (602)
fixed on a hub
(603), wherein the lead (604) is in form of a wire and wound helically around
the abrasive
body (602) in axial direction (x). In one aspect, the abrasive body can be
covered by a
reinforcement fiber glass mat (not shown) and the lead can be weaved into the
mat or the lead
can directly replace some of the threads of the fiber glass mat.
In another embodiment, the wear detection sensor can include at least one
electronic
device. In an aspect, the electronic device can include an electronic element.
The electronic
element can include, for example, a chip, an integrated circuit, logic, a
transponder, a
transceiver, a passive element, such as a resistor, a capacitor, a memory, or
the like, or any
combination thereof. In another aspect, the electronic device can include an
antenna directly
coupled to the electronic element. In a particular aspect, the electronic
device can include a
chip, an integrated circuit, data transponder, a radio frequency based tag or
sensor with or
without chip, an electronic tag, electronic memory, a sensor, an analog to
digital converter, a
transmitter, a receiver, a transceiver, a modulator circuit, a multiplexer, an
antenna, a near-
- 10 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
field communication device, a power source, a display (e.g., LCD or OLED
screen), optical
devices (e.g., LEDs), global positioning system (GPS) or device, fixed or
programmable
logic, or any combination thereof. In some instances, the electronic device
may optionally
include a substrate, a power source, or both. In a further aspect, the
electronic device can be
wired or wireless.
A more particular example of the electronic device can include a tag or
sensor, such
as a radio-frequency identification (RFID) tag or sensor, a near field
communication tag or
sensor, or a combination thereof. In an aspect, the electronic device can
include a RFID tag.
In some instances, the RFID tag can be inactive, and may be powered by a
reader device for
the RFID tag. In another instance, the RFID tag can be active, including for
example, a
power supply, such as a battery or inductive capacitive tank circuit.
In another aspect, the electronic device can include a near-field
communication
device. A near field communication device can be any device capable of
transmitting
information via electromagnetic radiation within a certain defined radius of
the device,
typically less than 20 meters.
In a particular aspect, the electronic device can include a dual frequency
tag. A dual
frequency tag can facilitate readability in multiple frequencies. For
instance, the electronic
device can include a near-field communication device and an RFID tag. In a
further instance,
the electronic device can include a dual frequency chip attached to an RFID
antenna and an
NFC antenna.
In a further aspect, the electronic device can include a transceiver. A
transceiver can
be a device that can receive information and/or transmit information. Unlike
passive RFID
tags or passive near-field communication devices, which are generally read-
only devices that
store information for a read operation, a transceiver can actively transmit
information without
having to conduct an active read operation. Moreover, the transceiver may be
capable of
transmitting information over various select frequencies, which may improve
the
communication capabilities of the electronic device with a variety of systems
that are
intended for receiving and/or storing the information.
In an aspect, the electronic device can be attached to at least a portion of
the abrasive
body. For example, the electronic device can be attached to a portion of a
surface of the
abrasive body, such as to a major surface, a peripheral surface, or a
combination thereof. In a
further aspect, the electronic device can be in contact with the abrasive
body. In another
aspect, the electronic device can be partially embedded in the abrasive body.
In a further
aspect, the electronic device can be fully embedded within the abrasive body.
- 11-
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
In some implementations, the electronic device can be adapted to detect wear
of the
abrasive article, such as a dimension change of the abrasive body. In other
implementations,
the electronic device may be combined with another component to facilitate
wear detection.
FIG. 7 includes an illustration of a plan view of an abrasive article 700
including an
abrasive body 701 and a wear detection sensor 702. The body 701 can include a
center hole
713. In some instances, the abrasive body 701 can include an interior
circumferential region
704 that abuts the center hole 703 and an exterior circumferential region 705
that is outside of
the interior circumference region 705. The interior circumferential region can
include an
interior circumferential diameter DI, and the abrasive body can include an
outer diameter Do
that may also be referred to as an exterior circumferential region diameter in
this disclosure.
In an embodiment, wear of the abrasive article can include a dimension change
including reduction in the outer diameter Do. For instance, a peripheral
surface of the
abrasive body may be the material removing surface in contact with a work
piece. Material
loss on the material removing surface can cause a reduction in the outer
diameter Do. In
certain applications, when the outer diameter Do is reduced to approximately
the size of the
inner diameter DI, the abrasive article may not be suitable for further use.
In another
embodiment, a major surface of the abrasive body can be the material removing
surface.
The wear detection sensor 702 can include an electronic device 710 including
an
electronic element 712, such as an integrated circuit, coupled to an antenna
714. In some
implementations, the electronic device 710 can include an integrated circuit
and may not
include an antenna. The electronic device 710 can be placed within the
interior
circumferential region 704 or within the exterior circumferential region 705
or extending
along a portion of the interior circumferential region 704 and a portion of
the exterior
circumferential region 705. In a particular instance, the electronic device
710 can be placed
within the interior circumferential region 704, as illustrated.
The wear detections sensor 702 can further include an electrical component
coupled
to the electronic device 710. The electrical component can include a passive
element, such as
a capacitor, a resistor, an inductor, or combination thereof. In a particular
instance, the
electrical component can include a first capacitance plate 718 and a second
capacitance plate
720. The first and second capacitance plates 718 and 720 can be coupled to the
electronic
device 710, such as by wires 716.
The first capacitance plate 718 and the second capacitance plate 720 can be
spaced
apart and may be placed in parallel to each other. In some instances, the
first capacitance
- 12-
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
plate 718 can be placed in the interior circumferential region 704 and the
second capacitance
plate 720 can be placed in the exterior circumferential region 705.
In an exemplary material removing operation, wear of the abrasive article may
result
in removal of a portion of or the entire second capacitance plate 720, which
can cause the
.. electric field strength in the capacitor plates to change. The electronic
device 710 can detect
the change and generate a wear signal.
In other instances, the electrical component can include a resistor, inductor,
or a
combination thereof. In an exemplary material removing operation, a portion of
the resistor,
inductor, or both may be removed, which may cause the current or magnetic
filed to change,
which can lead to generation of a wear signal.
The wear signal can be received by a data-receiving device and the operator
may be
warned of the wear condition of the abrasive article.
In an embodiment, a data-receiving device can include a reader, an
interrogator, or
another device that can receive, read, store, and/or edit data. In some
instances, the data-
receiving device can read data stored in the electronic device, and the
electronic device may
not function to transmit data. In another embodiment, the data-receiving
device can transmit
data from the electronic device to another device, system, a database, or the
like. In
particular embodiment, the data-receiving device can include a RFID reader or
interrogator,
an NFC reader, a mobile phone, or a combination thereof.
As illustrated in FIG. 7, the wear detection sensor 702 can be positioned over
a major
surface of the abrasive body 701. In another embodiment, at least a portion of
the wear
detection sensor 702 can be attached to a portion of the major surface,
peripheral surface, or
both. For example, the electronic device, the electrical component, the wire,
or any
combination thereof, may be directly cold pressed, warm pressed, or hot
pressed onto a
.. surface of the abrasive body. In another example, at least a portion of the
wear detection
sensor may be disposed on a surface of the abrasive body during a forming
process of the
abrasive body, and co-cured with the abrasive body. In a further instance, at
least a portion of
the wear detection sensor may be attached to the surface by heat, radiation,
glues, adhesives,
in a mechanical manner, or any combination thereof.
In an embodiment, the wear detection sensor 702 can be in contact with a
portion of
the abrasive body 701. For example, the wear detection sensor 702 can be in
direct contact
with the bond material, abrasive particles, another component of the abrasive
body 701, or
the combination thereof. In another embodiment, the wear detection sensor 702
can be
partially embedded or entirely embedded within the abrasive body. In some
instances, a
- 13 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
portion of the abrasive body may be removed to create a space (e.g., a slot)
inside the
abrasive body to receive the wear detection sensor, and heat, pressure,
adhesives, glue, or any
combination thereof, may be used to attach the wear detection sensor to at
least a portion of
the body. In some other instance, the wear detection sensor may be embedded in
a mixture
for forming the abrasive body during the forming process. The mixture can
include the bond
material, abrasive articles, and optionally additives. In a particular
example, the mixture and
the wear detection sensor can be placed in a mold, wherein the wear detection
sensor can be
partially or fully embedded in the mixture. The abrasive body can then be
formed by
subjecting the mixture to pressure, heat, irradiation, other known processes
for forming an
abrasive body, or a combination thereof.
As illustrated, at least a portion of the electrical component, such as the
first and
second capacitance plates 718 and 720, can be placed on a major surface of the
abrasive body
701. In a particular instance, a portion of the electrical component, such as
at least one of the
capacitance plates 718 and 720, can be attached to a portion of the abrasive
body. In another
particular instance, the first and second capacitance plates 718 and 720 can
be attached to a
portion of a major surface, a peripheral surface, or both. In a more
particular instance, at
least one of the first and second capacitance plates 718 and 720 can be in
contact with a
portion of the abrasive body including the bond material, abrasive particles,
another
component, or any combination thereof.
In some implementations, at least one of the capacitance plates 718 and 720
can be
partially or fully embedded in the abrasive body 701. For instance, the first
capacitance plate
718 can be placed on a major surface or a peripheral surface, and the second
capacitance plate
can be partially or fully embedded in the abrasive body 701. In another
instance, the second
capacitance plate 720 can be placed on a major surface or a peripheral
surface, while the first
capacitance plate 718 can be partially or fully embedded in the abrasive body
701. In another
instance, both the first and second capacitance plates 718 and 720 can be
partially or fully
embedded in the abrasive body 701.
In another embodiment, the wear detection sensor can include a loop circuit
coupled
to the electronic device. FIG. 8 includes an illustration of a plan view of
another exemplary
abrasive wheel 800 including an abrasive body 801. The abrasive article 800
includes a wear
detection sensor 802 including an electronic device 810 placed on a major
surface 803. The
electronic device 810 can include an electronic element, and optionally, an
antenna 814
coupled to the electronic element 812. The wear detection sensor 802 can
include a loop
circuit. In some applications, the loop circuit can include a wire loop 820
coupled to the
- 14 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
electronic device 810. For instance, the wire can be resistive. The wire loop
can be directly
connected to the electronic element 812, such as an integrated circuit.
Alternatively, the wire
loop can be coupled to the electronic element 812 by the antenna 814.
In another application, the loop circuit can include a passive element, such
as a
capacitor, a resistor, an inductor, or a combination thereof. In a particular
application, the
loop circuit can include a capacitive loop circuit including at least one
capacitor. In another
particular application, the loop circuit can include at least one resistor. In
another particular
instance, the loop circuit can include a plurality of capacitive loop
circuits, where capacitors
are placed in parallel connected by a wire.
FIG. 9A includes an illustration of a wear detection sensor 900 including an
electronic
device 901 coupled to a loop circuit 902. The electronic device 901 can
include an electronic
element 905, such as a transponder, integrated circuit, or the like, and
antenna 903 coupled to
the electronic element 905. The loop circuit 902 can include a plurality of
capacitors 911,
912, and 913 placed in parallel. In another instance, at least one or all of
911, 912, and 913
.. can include a resistor.
In an embodiment, the wear detection sensor 802 or 900 may be placed on a
major
surface 803, a peripheral surface (not illustrated), or a combination thereof,
of the abrasive
body 801. In an aspect, the length LL of the loop circuit 820 or 902 can
extend along a
portion of the major surface, the peripheral surface, or both. In another
aspect, the length LL
of the loop circuit 820 or 902 can extend in a radial direction, an axial
direction, or a
combination thereof, of the abrasive body 801. In another instance, the length
LL of the loop
circuit 820 or 902 can extend toward the material removing surface to
facilitate wear
detection.
In a further embodiment, at least a portion of the wear detection sensor 802
or 900 can
be embedded in the abrasive body 801. In an aspect, the loop circuit 820 or
902, the
electronic device 810 or 901, or both can be partially embedded in the
abrasive body. In
another aspect, the loop circuit 820 or 902, the electronic device 810 or 901,
or both can be
fully embedded in the abrasive body.
In another embodiment, the wear detection sensor 802 or 900 can be placed in a
certain position that can facilitate determination of the wear level. For
example, in a material
removal operation, a first portion of the wear detection sensor can be removed
and a first
wear signal can be generated, when wear of the abrasive body reaches a first
level. The first
wear signal can be an indicator of a first wear level. The first wear level
may be a relatively
low wear level, such as 20%, 30%, or 40%. As the operation continues, a second
portion of
- 15 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
the wear detection sensor may be removed and a second wear signal is
generated, when a
second wear level is reached. The second wear signal can be an indicator of a
second wear
level. The second wear level may be a relatively higher wear level, such as
705, 80%, or
90%. The second wear signal can be interpreted as a warning of the upcoming
end-of-life of
the abrasive article.
Referring to FIG. 8, the loop circuit 820 can extend in the radial direction
toward the
peripheral surface. The peripheral surface can be the material removing
surface. The wear
detection sensor 810 may be positioned such that in a material removal
operation, a certain
length of the circuit loop 820 or 902 can be removed to cause the circuit loop
to break, as
wear of the abrasive body reaches a certain level. The electronic device can
sense the broken
circuit loop and generate a wear signal. A data-receiving device can receive
the wear signal
and interpret it as an indicator that the certain wear level, such as a
certain low level wear, is
reached. As the operation continues, a portion of the electronic device 810,
such as at least a
portion of the electronic element 812, antenna 814, or both, may be removed,
which may turn
the electronic device into an inactive state, and the data-receiving device
may receive a wear
signal indicating a higher level of wear is reached. A wear signal can include
a change in a
signal, such as a change in response time, signal strength, reflected energy,
disappearance of
existing signal, or any combination thereof. In certain instances, as the
electronic device
becomes inactive, the data-receiving device may stop receiving any signal or
response from
the electronic device.
In some instances, the electronic device 810 may be damaged gradually during
an
operation of the abrasive article 800, and the received signal strength
indicator on the data-
receiving device may be used to determine the level of wear, as the electronic
device 810
may send a progressively weaker signal until the electronic device 810 turns
inactive. The
value of the received signal strength indicator can be measured, calculated,
or both by the
data-receiving device to determine the level of wear.
FIG. 9B includes an illustration of another example of the wear detection
sensor 950
including a wire loop 951 coupled to an electronic device 952. In an
embodiment, the wire
loop 951 can include one or more wire loops, such as 1 loop, 2 loops, 3 loops,
5 loops, or
more. The electronic device 952 can include an integrated circuit 954 and an
antenna 953. In
a particular embodiment, the electronic device 952 can include an RFID chip or
integrated
circuit. The electronic device 952 may further include additional components
955, such as a
chip, another integrated circuit, a logic device, a transponder, a
transceiver, a passive
element, or the like, or any combination thereof. In some implementations, the
wear
- 16-
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
detection sensor 950 can be printed and include a substrate 956. The substrate
956 can
include a flexible material, such as an organic material, and more
particularly, a flexible
material. A more particular example of the substrate 956 can include PET,
polyimide, or
another material that can be used to make flexible electronics.
In certain implementations, the wear detection sensor 950 can be placed abut
an outer
surface, such as the peripheral surface, of the abrasive body of an abrasive
article. For
example, the wear detection sensor 950 can be placed around at least a portion
of the
peripheral surface of the abrasive body, and a non-abrasive portion, such as a
layer of fiber,
can be wound over the wear detection sensor 950 and at least a portion or the
entire outer
.. peripheral surface of the abrasive body.
FIG. 9C includes an illustration of a top view of a mounting plate (or a hub)
981
attached with an electronic assembly 982 including an electronic device 983
contained within
a package 985. The package 985 and the stool spokes 988 can help protect the
electronic
device 983 from sparks and heat generated during a grinding operation. In an
embodiment,
the package 985 can include a protecting material that can be resistant to
high temperatures
and function as a heat shield. In another embodiment, the package 985 can
include a
polymer. A particular example of the polymer can include a high performance
polymer, such
as polyether ether ketone (PEEK) or the like or a combination thereof.
Alternatively, the
electronics device 983 may be completely covered by a protecting material in
lieu of the
package and separated from the outer environment.
The electronic device 983 can be part of a wear sensor that further includes
wire loops
attached to the electronic device 983. In a particular embodiment, the
electronic device 983
can include a microcontroller, and the wire loops can be attached to the
microcontroller. The
wire loops can also be attached to a peripheral surface of the abrasive body
that is attached to
the mounting plate 981. The peripheral surface can be the inner or outer
peripheral surface.
In an implementation, a coating may be applied to the wire loops to facilitate
attachment of
the wire loops to the peripheral surface and provide protection against heat
and sparks. In an
embodiment, the coating can include an adhesive. In another embodiment, the
coating can be
heat resistant. In particular instances, the coating can include a heat
resistant adhesive, which
may facilitate improved performance of the wear sensor. An exemplary adhesive
can include
epoxy, acrylates, silicone rubber, or the like. In a particular embodiment,
the coating can
include steel epoxy.
In some instances, signal transmission from the electronic device 983 during a
grinding operation can be wireless. For example, wheel wear information can be
sent via Wi-
- 17 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Fi, Bluetooth, or a combination thereof, to a receiving device, such as a
mobile phone, a hand
held device, a computer, or the like. The transmitted data can include state
and change of
state of the wire loops. For instance, data may be in the format in which "0"
represents
closed loop (e.g., no detectable wear of the wire loop), and "1" represents
open loop (broken
loop). State and/or change of state of wear loops can be used to determine the
level of wear
of the abrasive tool. FIGs. 9D and 9E include graphs illustrating data
transmitted by a wear
sensor including wire loops attached to the electronic device 983, indicating
state of different
wire loops in a grinding operation. As illustrated, the wire loop #2 is closed
and has no state
change, while the state of the wire loop #4 changes from 0 to 1 indicating the
wire loop is
broken during the grinding operation and some level of wear of the grinding
tool. As
grinding continues, the wire loop#2 can be broken at a later time to indicate
a higher level of
wear of the grinding tool.
FIG. 10 includes an illustration of a cross section of a portion of an
abrasive article
1000 including a body 1001. The body 1001 can include a first major surface
1002 opposite
a second major surface 1003, and a peripheral surface 1004 extending between
the first and
second major surfaces 1002 and 1003. In some instances, the body 1001 can
include an
abrasive portion 1020 and a non-abrasive portion 1022. The peripheral surface
1004 can be
the material removing surface of the abrasive article 1000.
The wear detection sensor 1005 can be at least partially embedded in the body
1101,
including an electronic device including an electronic element 1008 and an
antenna 1006
coupled to the electronic element 1008. The electronic element 1008 may be
placed within
the non-abrasive portion 1022. In some instances, a portion of the electronic
element 1008
may be placed in the abrasive portion 1020. The antenna 1006 is placed in the
abrasive
portion 1020, and in some instances, a portion of the antenna may be placed in
the non-
abrasive portion. The terminal end 1014 of the antenna 1006 can be aligned
with the
peripheral surface 1004.
The antenna 1006 can extend toward the peripheral surface 1004. For instance,
the
antenna 1006 can extend in the radial direction along a portion of the body.
In another
instance, the antenna 1006 can extend over an entire radial distance of the
abrasive portion.
In some instances, the wear detection sensor can include a package that
contains at
least a portion of the electronic element 1008 and the antenna 1006. For
instance, the
package can separate the electronic element 1008 and/or the antenna 1006 from
a
surrounding environment. In another instance, the package can separate the
electronic
- 18 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
element 1008 and/or the antenna 1006 from the composition of the body 1001,
such as
abrasive particles, the bond material, and other components.
The package may include, such as a protective layer 1010, a substrate 1012, or
both.
A portion of the protective layer 1010 may extend above the major surface
1003.
Alternatively, the protective layer 1010 can be beneath the major surface 1003
or at the same
plane as the major surface 1003. In an aspect, the protective layer 1010 may
include a
material that can protect the electronic element 1008 and/or antenna 1006 from
an outer
environment condition, including such as moisture, coolant, or the like. An
exemplary
protective material can include polydimethylsiloxane (PDMS), polyethylene
naphthalate
.. (PEN), polyimide, polyether ether ketone (PEEK), or any combination
thereof.
In some instances, certain coolant is used in material removal operations, and
exposing an electronic device to the coolant can cause degradation of the
electronic device.
The protective layer 1010 or the entire package can be applied to protect the
electronic device
from the coolant and extend service life of the electronic device. The
protective layer can
.. also be applied to protect the electronic device from moisture, harsh
temperatures, or other
conditions that may damage the electronic device.
In an aspect, the substrate 1012 can include a similar or different material
as the
protective layer 1010. In a particular instance, the package may encapsulate
the electronic
device.
The wear detection sensor 1005 can survive multiple material removal
operations, and
serve as an indicator that high level of wear is reached when the abrasive
article 1000 is
retired. For instance, the remaining length of the electronic element 1008 can
be an indicator
that the interior circumference is reached at the time the abrasive article
1000 is replaced.
In an embodiment, the wear detection sensor can include an electronic device
including an antenna directly and electrically connected to an electronic
element. In another
embodiment, the wear detection sensor can include a plurality of electronic
devices, wherein
at least one of the electronic devices can include an antenna directly and
electrically
connected to an electronic element. In still another embodiment, the wear
detection sensor
can include a plurality of electronic devices, wherein at least some or each
of the electronic
devices can include an antenna directly and electrically connected to an
electronic element.
In some implementations, the antenna can include a thin film antenna.
In an aspect, the antenna can extend along a portion of the abrasive body. For
instance, the antenna can extend along a portion of a major surface, a
peripheral surface, or
both, toward a material removing surface of the abrasive body. In another
aspect, the antenna
- 19-
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
can extend in a radial direction, an axial direction, or combination thereof
of the abrasive
body. In a further aspect, the antenna may be partially or fully embedded in
the abrasive
body.
In an aspect, the electronic device can include at least 1 antenna, at least 2
antennas, at
least 3 antennas, or at least 4 antennas, wherein each antenna is directly and
electrically
connected to an electronic element. In an aspect, at least some of the
antennas may extend a
different distance along the abrasive body. In another aspect, each of the
antennas can extend
a different distance along the abrasive body.
FIG. 11 includes an illustration of a plan view of an abrasive article 1100
including a
body 1101 including an interior circumferential region 1103 and an exterior
circumferential
region 1102. The wear detection sensor 1104 can include an electronic device
including an
electronic element 1105 and a plurality of antennas 1106 to 1109 coupled to
the electronic
element 1105. The electronic element 1105 can be placed within the interior
circumferential
region 1103. In another instance, the electronic element 1105 may be placed in
the exterior
circumferential region 1102. In some particular implementations, the
electronic element
1105 can include an integrated circuit, a transponder, or a combination
thereof.
The antennas 1106 to 1109 can be spaced apart from one another. As
illustrated, the
antennas 1106 to 1109 can extend such that the lengths of the antennas are in
parallel to one
another. In another instance, at least some of the antennas 1106 to 1109 can
be placed such
that the lengths may extend at an angle to each other. For example, the angle
can include an
acute angle, an obtuse angle, a right angle, or a combination thereof.
The antennas 1106 to 1109 can extend along a portion toward a material
removing
surface (e.g., the peripheral surface) of the abrasive body. In an aspect, one
of the antennas
can extend a different distance compared to one of the other antennas. In
another aspect, all
the antennas can extend a different distance along the abrasive body.
In a further aspect, at least some of the antennas 1106 to 1109 can include
different
lengths compared to one another. In a particular aspect, each of the antennas
1106 to 1009
can include a different length. For example, a relative difference in length
between the
antennas can be at least 5%, at least 10%, at least 15%, at least 17%, at
least 20%, at least
30%, at least 40%, or at least 50%. In another aspect, a relative difference
in length between
the antennas can be at most 80%, at most 70%, at most 60%, at most 50%, at
most 45%, at
most 40%, at most 35%, or at most 30%. Moreover, the relative difference in
length between
the antennas can be in the range including any of the minimum and maximum
percentages
noted herein.
- 20 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
As illustrated, the antennas 1109 can be placed within the interior
circumferential
region 1103. The other antennas 1106 to 1108 can extend from a position within
the interior
circumferential region 1103 into the exterior circumferential region 1102 for
a different
distance.
The antennas 1106 to 1109 can be spaced apart from the centerline 1111 of the
abrasive body 1101 by a distance 6dc. As illustrated, 6dc is the vertical
distance from a
terminal end of the antenna (e.g., 1106) to the centerline 1111, wherein the
terminal end is the
one that is closer to the centerline 1111. For example, a relative difference
in distance 6dc
between at least some of or all of the antennas 1106 to 1109 can be at least
2%, at least 5%, at
least 10%, at least 15%, or at least 20%. In another instance, a relative
difference in distance
6dc can be at most 40%, at most 35%, at most 20%, at most 15%, or at most 10%.
Moreover,
the relative difference in 6dc can be in the range including any of the
minimum and
maximum percentages noted herein.
The other terminal end of each antenna can be spaced apart from the outer
circumference of the abrasive body 1101 by a distance 6d0. The distance is the
linear
extension from the terminal end of the antenna (e.g., 1106) to the outer
circumference. The
distance 6d0 between the antennas 1106 to 1109 may be different. For example,
a relative
difference in distance 6d0 between at least some of or all of the antennas
1106 to 1109 can be
at least 2%, at least 5%, at least 8%, at least 10%, or at least 15%. In
another instance, a
relative difference in distance 6d0 can be at most 45%, at most 40%, at most
35%, at most
30%, or at most 25%. Moreover, the relative difference in 6d0 can be in the
range including
any of the minimum and maximum percentages noted herein.
In an exemplary material removal operation of the abrasive article 1100, the
longest
antenna 1107 may come into contact with the actual material removing surface
(e.g., the
peripheral surface) and a portion of the antenna 1107 may be removed. As wear
of the
abrasive article progresses, portions of antennas 1108, 1106, and 1104 may be
removed. As
the sizes of the antennas reduce, the response energy from the electronic
device decreases.
The data-receiving device can sense the changes in received signals and the
operator can be
warned of wear. In some instances, the data-receiving device may calculate the
changes in
response energy and calculate to indicate the level of wear.
In an embodiment, the wear detection sensor can include an electronic device
including an electronic element and an antenna, wherein the antenna can
include a greater
surface area than the electronic element. For example, the electronic device
can include a
- 21 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
plurality of antennas coupled to an electronic element, wherein at least one,
some, or each of
the antennas can have a surface greater than a surface area of the electronic
element.
In another instance, the wear detection sensor can include a plurality of
electronic
devices, wherein at least one of the electronic devices can include an antenna
coupled to an
electronic element, wherein the antenna can have a surface area bigger than
the electronic
element. In a particular instance, some or each of the plurality of electronic
devices can
include an antenna coupled to an electronic element, wherein the antenna can
have a surface
area bigger than the electronic element. In another particular instance, one
or more of the
plurality of electronic devices can include a plurality of antennas coupled to
an electronic
element, wherein at least one or more of the plurality of antennas can have a
bigger surface
area than the electronic element. In a more particular instance, all of the
antennas can have a
surface arear greater than the electronic elements they are coupled to.
In an embodiment, the electronic device can be positioned at a non-abrasive
portion,
an abrasive portion, or both, of the body of the abrasive article. In some
instances, the
antenna can be coupled to an electronic element can be positioned at a non-
abrasive portion
of the body of the abrasive article. As used herein, non-abrasive portion is
intended to refer
to a portion of an abrasive article body that is essentially free of an
abrasive particle. The
non-abrasive portion may or may not include a bond material. Abrasive portion
is intended
to refer to a portion of an abrasive article body that includes a bond matrix
and abrasive
particles contained in the bond matrix. The abrasive body is intended to refer
to a bonded
body including a bond matrix and abrasive particles distributed through the
bond matrix,
wherein the bonded body is essentially free of a non-abrasive portion.
In an embodiment, the wear detection sensor can include an antenna including a
flared
body. In some instances, the wear detection sensor can include a plurality of
antennas,
wherein one or more of the antennas can include a flared body. FIG. 12
includes an
illustration of a plan view of an abrasive article 1200 including an abrasive
body 1201
including an interior circumferential region 1214 and an exterior
circumferential region 1215.
In some instances, the body can include a center region 1213. The center
region may include
a flange region or a hub.
A wear detection sensor 1203 can include the first electronic device 1204
including an
electronic element 1205 placed in the center region 1213 and an antenna 1207.
The second
electronic device 1208 includes an electronic element 1209 positioned in the
interior
circumferential region 1214 and an antenna 1211. In another instance, the
first and second
electronic elements 1205 and 1209 can be placed out side of the center region
1213. In still
- 22 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
another instance, both of the first and second electronic elements 1209 and
1205 can be
placed in the interior circumferential region 1214. In yet another instance,
one of the first and
second electronic elements 1205 and 1209 can be placed in the interior
circumferential region
1214 and the other can be placed in the exterior circumferential region 1215.
In a particular
instance, none of the electronic elements is placed in the exterior
circumferential region 1215.
In another particular instance, at most one of the electronic elements can be
placed in the
center region 1213. In a more particular instance, at least some of the
electronic elements are
placed in different regions including the center region 1213, the interior
circumferential
region 1214, and the exterior circumferential region 1215.
The antennas 1207 and 1211 can be spaced apart from one another in the
circumferential direction, in the radial direction, in the axial direction, or
any combination
thereof, of the abrasive body 1201. The antennas 1207 and 1211 can extend in
the radial
direction, axial direction, or a combination thereof along a portion of the
abrasive body. The
antennas 1207 can extend from a location in the center region 1213, across the
entire radial
distance of the interior circumferential region 1214, and into the exterior
circumferential
region 1215. The terminal end of the antenna 1207 can be spaced apart from or
aligned with
the outer circumference or the material removing surface (e.g., peripheral
surface) of the
abrasive body. As illustrated, one of the terminal ends of the secondary
antenna 1207 can
reach the outer circumference or the material removing surface.
The antenna 1211 can extend from a location in the interior circumferential
region
1214 into the exterior circumferential region 1215. At least one of the
antenna 1211 can have
a terminal end that can reach the outer circumference.
As illustrated, each of the secondary antennas 1207 and 1211 can include a
flared
body. The width of the body can increase as the secondary antennas 1207 and
1211 extend
.. toward the outer circumference or peripheral surface. For instance, the
width W at the
terminal end of the secondary antenna 1207 or 1211 that is closer to the outer
circumference
of the body 1201 can be greatest compared to a width of another portion of the
antenna.
In some instances, the antenna 1207 or 1211 or both can be attached to a major
surface of the abrasive body 1201. For instance, the antenna 1207 or 1211 or
both can extend
along a portion of a major surface of the abrasive body. In another instance,
a portion of the
antenna 1207 or 1211 or both can be exposed to an outer environment. For
instance, the
secondary antenna 1207 or 1211 or both can be partially embedded in the
abrasive body
1201. In another instance, the antenna 1207 or 1211 or both can include a
portion protruding
-23 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
outside of a surface portion of an interior circumferential region 1214 of the
abrasive body
1201.
In other instances, the antenna 1207 or 1211 can extend over a greater surface
area of
the abrasive body compared to the electronic device 1204 or 1205, while in a
shape other
.. than a flared body. For instance, the antenna 1207 and/or 1211 can be in a
shape including a
triangle, a rectangle, a square, or an irregular shape. The antenna 1207 and
1211 can be in
the same or different shape.
In another instance, any or each of the antennas 1207 and 1211 can extend over
a
certain surface area of the abrasive body that can facilitate improved data
transmission and/or
continuous powering the electronic devices 1204 and/or 1208. For instance, any
or each of
the antennas 1207 and 1211 can extend over at least 1/20 of the surface area
of a major
surface or a peripheral surface of the abrasive body 1201, such as at least
2/20, at least 3/20,
at least 4/20, or at least 5/20 of the surface area of a major surface or a
peripheral surface of
the abrasive body 1201. In another instance, any or each of the antennas 1207
and 1211 can
extend over at most 10/20 of the surface area of a major surface or a
peripheral surface of the
abrasive body 1201, such as at most 9/20, at most 8/20, at most 7/20, at most
6/20, at most
5/20, at most 4/20, or at most 3/20 of the surface area of a major surface or
a peripheral
surface of the abrasive body 1201. Moreover, any or each of the antennas 1207
and 1211 can
extend over a surface area including any of the minimum and maximum values
noted herein.
FIG. 13 includes an illustration of a plan view of an abrasive article 1300
including an
abrasive body 1301. The abrasive body 1301 can include an interior
circumferential region
1302 and an exterior circumferential region 1303. In some instances, the
abrasive body 1301
can include a center region 1310.
The wear detection sensor 1304 can include a first electronic device including
an
electronic element 1305 coupled to an antenna 1306, and a second electronic
device including
an electronic element 1307 coupled to an antenna 1308.
The antennas 1307 and 1308 can include a curved portion that can extend in the
circumferential direction of the abrasive body 1301. In a particular instance,
the antennas
1307 and 1308 can include a length that can extend in the circumferential
direction. In a
further instance, the antenna 1307, 1308, or both can extend in a
circumferential direction, an
axial direction, a radial direction, or any combination thereof. In another
instance, the
antenna 1307 and 1308 can have the same or different length.
In another instance, the antenna 1306, 1308, or both can extend for a certain
length
along a portion of the abrasive body 1301. In an aspect, the antenna 1307,
1308, or both can
- 24 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
extend along a portion of a major surface, peripheral surface, or a
combination thereof. In
another aspect, one or each of the antennas 1307 and 1308 can extend for a
certain length that
can facilitate improved data transmission and/or continuous powering. For
instance, one or
each of the antennas 1307 and 1308 can extend for at least 1/10 of the outer
circumference of
the abrasive body 1301, such as at least 2/10, at least 3/10, at least 4/10,
at least 5/10, at least
6/10, or at least 7/10 of the outer circumference of the abrasive body 1301.
In another
instance, one or each of the antennas 1307 and 1308 can extend for at most
9/10, of the outer
circumference of the abrasive body 1301, such as at most 8/10, at most 7/10,
at most 6/10, at
most 5/10, or at most 4/10 of the outer circumference of the abrasive body
1301. Moreover,
one or each of the antennas 1307 and 1308 can extend for a length in a range
including any of
the minimum and maximum values noted herein.
In another instance, any or each of the antennas 1306 and 1308 can extend over
a
certain surface area of the abrasive body that can facilitate improved data
transmission and/or
continuous powering the electronic devices 1305 and/or 1307. For instance, any
or each of
the antennas 1306 and 1308 can extend over at least 1/20 of the surface area
of a major
surface or a peripheral surface of the abrasive body 1301, such as at least
2/20, at least 3/20,
at least 4/20, or at least 5/20 of the surface area of a major surface or a
peripheral surface of
the abrasive body 1301. In another instance, any or each of the antennas 1306
and 1308 can
extend over at most 10/20 of the surface area of a major surface or a
peripheral surface of the
abrasive body 1201, such as at most 9/20, at most 8/20, at most 7/20, at most
6/20, at most
5/20, at most 4/20, or at most 3/20 of the surface area of a major surface or
a peripheral
surface of the abrasive body 1301. Moreover, any or each of the antennas 1306
and 1308 can
extend over a surface area including any of the minimum and maximum values
noted herein.
As illustrated, each of the antennas 1306 and 1308 can have an arc shape. The
antennas 1306 and 1308 can extend toward each other and be spaced apart in the
radial
direction, the axial direction, the circumferential direction, or a
combination thereof.
The antennas 1306 and 1308 can extend along a portion of the interior
circumferential
region 1302, a portion of the exterior circumferential region 1303, or both.
In some
instances, the antennas 1306 and 1308 and the electronic devices 1305 and 1306
may be
placed outside of the center region 1310. In another instance, one of the
electronic devices
1307 and 1305 may be placed in the center circumferential region 1310 or the
exterior
circumferential region 1303.
In some instances, one or each of the antennas 1306 and 1308 can extend along
a
portion of a major surface of the abrasive body. In a particular instance, one
or each of the
- 25 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
antennas 1306 and 1308 can be attached to a major surface of the abrasive
body. In another
instance, one or each of the antennas 1306 and 1308 is at least partially
embedded in the
abrasive body. In a further instance, at least one or each of the antennas
1306 and 1308 can
include a portion exposed to an outer environment. In a particular instance,
at least one or
each of the antennas 1306 and 1308 can include a portion protruding outside of
a surface
portion of the interior circumferential region 1302.
In another embodiment, the wear detection sensor can include a certain number
of an
electronic device that can facilitate improved response of the electronic
device to a data-
receiving device. For instance, the wear detection sensor can include at least
1 electronic
device, such as at least 2, at least 3, at least 5, at least 6, or at least 7
electronic devices. In a
further embodiment, the wear detection sensor can include at most 45
electronic devices, at
most 40, at most 35, at most 30, at most 25, at most 20, at most 15, at most
12, at most 10, at
most 9, or at most 8 electronic devices. Moreover, the number of the
electronic devices can
be in the range including any of the minimum and maximum values noted herein.
For
instance, the wear detection sensor can include 1 to 45 electronic devices.
In an aspect, the wear detection sensor can include a plurality of electronic
devices
that are spaced apart from one another in the radial direction, the axial
direction, the
circumferential direction, or a combination thereof. In another aspect, at
least some of the
plurality of electronic devices may be placed in an angle to one another. In
another aspect,
some of the electronic devices may be aligned in the radial direction. In
still another aspect,
some of the electronic devices may be in parallel. In a further aspect, the
plurality of
electronic devices can extend toward a material removing surface of the
abrasive body.
FIG. 14 includes an illustration of a plan view of an abrasive article 1400
including an
abrasive body 1401 and a wear detection sensor including a plurality of
electronic devices
1402 extending along a portion of the abrasive body 1401. The plurality of
electronic devices
1402 can include the same or different electronic devices including any of the
electronic
devices noted in embodiments of this disclosure. In a particular instance, the
plurality of
electronic devices 1402 can include a RFID tag or sensor, an NFID tag or
sensor, or any
combination thereof.
In some instances, one or more of the electronic devices 1402 can extend along
a
portion of major surface, a peripheral surface, or a combination thereof, of
the abrasive body
1401. In another instance, one or more or each of the electronic devices 1402
can be partially
embedded or fully embedded in the abrasive body.
- 26 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
The abrasive body 1401 can include an interior circumferential region 1404 and
an
exterior circumferential region 1403. The plurality of electronic devices 1402
can be placed
in the exterior circumferential region 1403. In some instances, one or more of
the electronic
devices 1402 may be placed in the interior circumferential region 1404. In a
further instance,
one or more of the electronic devices 1402 may extend along a portion of the
interior
circumferential region 1404 and a portion of the exterior circumferential
region 1403. In
another instance, one or more of the electronic devices 1402 can include a
terminal end that is
aligned with a material removal surface of the abrasive body 1401.
At least some of the electronic devices 1402 can include an electronic element
1410
and antenna 1411. The electronic element 1410 can be positioned within the
interior
circumferential region 1405.
During an operation of the abrasive 1400, one or more of the electronic
devices may
contact the material removing surface, and a portion of the electronic device
may be
removed. The damaged electronic device or devices may reflect reduced power in
response
to a data-receiving device or not respond when turn inactive. The reduction in
reflected
energy can be sensed and may be calculated by the data-receiving device such
that the
operator can be warned of the wear condition of the abrasive article 1400 and
determine
when the abrasive article 1400 must be replaced.
FIG. 15 includes an illustration of a plan view of a portion of an abrasive
body 1500
of another abrasive article. The abrasive body 1500 can include an inner
circumference 1501
defining a center hole of the abrasive body 1500 and an outer circumference
1502. In some
instances, the outer circumference can define the material removing surface.
In some
instances, the abrasive body can include a major surface 1503. In other
instances, the
abrasive body can include a peripheral surface 1503.
A wear detection sensor including a plurality of electronic devices can
include a first
electronic device 1504 and a second electronic device 1505. The first and
second electronic
devices 1504 and 1505 can be staggered and placed in parallel to each other.
The first and
second electronic devices 1504 and 1505 can extend along a portion of the
abrasive body
1500 and be spaced apart from one another in the radial direction, the axial
direction, the
circumferential direction, or a combination thereof. In some instances, the
first and second
electronic devices 1504 and 1505 can extend along the surface 1503. In another
instance, the
first and second electronic devices 1504 and 1505 can extend in the radial
direction, in the
axial direction, or a combination thereof, toward a material removing surface.
In a further
- 27 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
instance, one or each of the electronic devices 1504 and 1505 can be partially
or fully
embedded in the abrasive body 1500.
The first electronic device 1504 can include a first length L1 extending
between the
terminal ends 1510 and 1511, wherein the terminal end 1511 is closer to the
inner
circumference 1501 compared to the terminal end 1511, and the terminal end
1512 can be
closer to the outer circumference 1502 compared to the terminal end 1511.
The second electronic device 1505 can include a second length L2 extending
between
the terminal ends 1513 and 1514, wherein the terminal end 1513 is closer to
the inner
circumference 1501 compared to the terminal end 1514, and the terminal 1514
can be closer
to the outer circumference 1502 compared to the terminal end 1513. The
lengths, L1 and L2,
can the same or different.
In an aspect, the distance 6dI1 from the terminal end 1511 to the inner
circumference
1501 can be greater than the distance 6d12 between the terminal end 1513 to
the inner
circumference 1501. For instance, a relative difference between 6dI1 and 6d12
can be at least
at least 2%, at least 5%, at least 10%, at least 12%, at least 15%, at least
20%, at least 30%, at
least 40%, or at least 50%. In another instance, a relative difference between
6dI1 and 6d12
can be at most 80%, at most 70%, at most 60%, at most 50%, at most 45%, at
most 40%, at
most 35%, or at most 30%. Moreover, the relative difference 6dI1 and 6d12 can
be in the
range including any of the minimum and maximum percentages noted herein.
In another aspect, the distance 6d02 between the terminal end 1514 to the
outer
circumference 1502 can be greater than the distance 6d01 from the terminal end
1512 to the
outer circumference 1502. For instance, a relative difference between 6d01 and
6c102 can be at
least at least 2%, at least 5%, at least 10%, at least 12%, at least 15%, at
least 20%, at least
30%, at least 40%, or at least 50%. In another instance, a relative difference
between 6d01
.. and 6d02 can be at most 80%, at most 70%, at most 60%, at most 50%, at most
45%, at most
40%, at most 35%, or at most 30%. Moreover, the relative difference 6d01 and
6d02 can be in
the range including any of the minimum and maximum percentages noted herein.
In an exemplary operation of the abrasive article, the first electronic device
1504 may
be damaged sooner than the second abrasive device 1505, which may cause a
change of
signal received by a data-receiving device. For instance, when wear reaches
the position
1507 of the first electronic device 1504, the first electronic device 1504 may
be damaged and
turns inactive (e.g., not functional), while the second electronic device 1505
can remain
functional. The signal change, such as a change in strength or intensity of
the signal may be
measured and/or calculated by the data-receiving device, and the data-
receiving device can
- 28 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
send a wear warning to the operator. In a particular aspect, the electronic
devices 1504 and
1505 can be positioned such that when wear reaches a certain position, such as
1507, of the
first electronic device, the wear level can be determined. For instance, the
electronic devices
1504 and 1505 can be positioned such that when the position 1507 is reached,
the wear level
.. can be 50%. As the operation continues, the position 1506 may be reached
and the second
electronic device may be damaged. A further change to the signal received by
the data-
receiving device may be utilized to send another warning of the wear level,
such as 80%
wear, to warn the operator of the upcoming end-of-life of the abrasive
article.
In some exemplary forming processes, an abrasive body precursor may be
subjected
to a heating cycle of 20 to 30 hours to form a finally formed abrasive body.
In some
instances, the electronic devices, such as 1504 and 1505, may be subjected to
the same
heating cycle. In those instances, the electronic devices 1504 and 1505 may
include a
protection layer to facilitate improved heat resistance of the electronic
devices and/or
coupling of the electronic devices to the abrasive body. The protection layer
can cover at
least a portion of the electronic device, and in particular instances, the
protection layer can
encapsulate the entire electronic device. In an aspect, the protection layer
can include a heat
resistance material. In another aspect, the protection layer can include the
lead protecting
material described in embodiments of this disclosure. In a particular aspect,
the protection
layer can include a polyimide film.
In other instances, the electronic devices, such as 1504 and 1505, may be
coupled to
the abrasive body after the heating cycle is completed. In an exemplary
implement, an
opening may be formed in the wheel mounting plate and/or the abrasive body to
accommodate the electronic devices using, such as a snap-fit configuration.
The electronic
devices can be secured to the mounting plate and/or an outer surface of the
abrasive body. In
a particular instance, a coating can be applied over the electronic devices,
and may be also
over at least a portion of the mounting plate and/or a portion of the outer
surface of the
abrasive body. The coating may help to secure the electronic devices and/or
protect the
electronic devices from the outer environment. An exemplary coating can
include epoxy.
In another instance, the electronic devices, such as 1504 and 1505, may
include
.. components that can be attached to the abrasive body separately. For
example, the electronic
device can include a two-piece tag including antenna and integrated circuit,
such as an RFID
circuit. The antenna can be attached to the abrasive body prior to the heating
cycle, and the
integrated circuit can be attached after the heating cycle. In a particular
implement, an
opening can be formed on the mounting plate that is attached to an abrasive
body precursor,
- 29 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
and an antenna can be attached near the cutout of the mounting plate to an
outer surface of
the abrasive body precursor, such as the peripheral surface. In some
instances, a non-
abrasive portion, such as a layer of fiber, can be wound over the antenna and
at least a portion
of the peripheral surface. After the heating cycle, the antenna may be bonded
to the abrasive
body and/or the non-abrasive portion, and the integrated circuit can be placed
into the
opening in the mounting plate via snap-fit configuration and attached to the
antenna. In a
particular instance, the antenna can be a dipole antenna. In another
particular instance, the
dipole antenna can be formed using a conductive material, including for
example, a metal
wire, such as a copper wire, conductive ink. In another particular instance,
the dipole antenna
can include a thin film, such as a thin metal foil, and in a more particular
instance, the dipole
antenna can include a thin copper foil tape. In another particular instance,
the electronic
device can include a printed integrated circuit on a flexible substrate (e.g.,
a PCB), and the
antenna can be attached to the integrated circuit.
FIG. 16A includes an illustration of an abrasive article 1600 including a body
1601.
The wear detection sensor can include an electronic device including an
electronic element
1605 and an antenna 1606. The electronic element 1605 can be positioned within
the interior
circumferential region 1602 of the abrasive body, and the antenna 1606 can
extend along a
portion of the interior circumferential region 1602 and a portion of the
exterior
circumferential region 1603 toward the material removing surface, i.e., the
peripheral surface.
In a material removal operation utilizing the abrasive article 1600, as the
outer
diameter Do reduces, the size of the antenna 1606 may start to reduce. The
reduction of the
size of the antenna can cause energy reflected by the antenna to reduce.
Referring to FIG.
16B, as the wheel diameter Do decreases, reduction in reflected energy
increases. The outer
diameter Do is a function of the reduction in energy reflected by the antenna.
Wear of the
abrasive article can be determined based on the reduction of the reflected
energy.
FIG. 17A includes an illustration of a cross section of an abrasive article
1701
including a body 1702 and wear detection sensor 1703 fully embedded in the
abrasive body
1702. The body can include a center hole 1705, an interior circumferential
region 1706, and
an exterior circumferential region 1707. The boundary between the interior and
exterior
regions is indicated by a dotted line.
The wear detection sensor 1703 can include an electronic element 1709
positioned
within the interior circumferential region 1706, and an antenna 1708 extending
in a
serpentine shape toward the material removing surface 1704. In another
instance, the antenna
can be arranged in a shape of a loop or multiple loops. Such shapes of the
antenna or the like
-30-
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
may facilitate improved wear detection. For example, during a material removal
process,
multiple portions of the antenna may be removed at the same wear level of the
abrasive body,
which can increase the amount of data generated by the electronic device. In
certain
instances, data can be compared and used to verify wear level of the abrasive
body.
In some implementations, the antenna may be arranged such that a portion of
the
antenna can protrude outside of the major surface of the abrasive body. As
illustrated in FIG.
17B, the abrasive article 1710 can include a body 1712 and wear detection
sensor 1713
embedded in the abrasive body 1712. The wear detection sensor 1713 can include
an
electronic element 1719 and an antenna 1718, wherein a portion 1720 of the
antenna 1718 is
raised above the major surface 1714. The raised portion 1720 is abut the
interior
circumferential region 1716 and can be visible when viewed from the major
surface 1714,
which can allow visual observation of wear of the abrasive body and help to
confirm wear
level detected by a data-receiving device. For instance, that the size of the
raised portion
1720 starts to reduce can be an indicator of the upcoming end-of-life. In
another instance,
.. that the raised portion 1720 disappears can be an indicator that the
abrasive article 1710 must
be replaced.
The abrasive particles contained within the bond material of the abrasive
article can
include an oxide, a carbide, a nitride, a boride, an oxynitride, an oxyboride,
diamond, or any
combination thereof. In a certain aspect, the abrasive particles can include a
superabrasive
material, for example, cubic boron nitride or diamond.
In one embodiment, the average particles size of the abrasive particles (D50)
can be at
least 0.1 microns or at least 0.5 microns or at least 1 micron or at least 2
microns or at least 5
microns or at least 8 microns. In another embodiment, the average particle
size of the
abrasive particles may be not greater than 6000 microns, such as not greater
than 5000
microns, or not greater than 3000 microns, or not greater than 2000 microns,
or not greater
than 1500 microns, or not greater than 1000 microns, or not greater than 900
microns, or not
greater than 800 microns, or not greater than 500 microns, or not greater than
300 microns.
The average particles size of the abrasive particles can be a value within a
range including
any of the minimum and maximum values noted above.
The bond material of the abrasive article of the present disclosure may have a
particular bond chemistry that may facilitate improved manufacturing and
performance of the
abrasive article. The bond material can be an inorganic material, an organic
material, or a
combination thereof. The bond material can have a certain porosity or be free
porosity. In
one embodiment, the bond material can be an inorganic material, such as a
metal, a metal
-31 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
alloy, a ceramic, a glass, a ceramic, a cermet, or any combination thereof.
The bond material
may have at least one of a monocrystalline phase, a polycrystalline phase,
amorphous phase,
or any combination thereof. In yet a further aspect, the bond material can
include an oxide, a
boride, a nitride, a carbide, or any combination thereof.
In another embodiment, the bond material may be an organic material, such as a
natural material, a synthetic material, a polymer, a resin, an epoxy, a
thermoset, a
thermoplastic, an elastomer, or any combination thereof. In a certain
embodiment, the
organic material can include a phenolic resin, an epoxy resin, a polyester
resin, a
polyurethane, a polyester, a polyimide, a polybenzimidazole, an aromatic
polyamide, a
modified phenolic resin (such as: epoxy modified and rubber modified resin, or
phenolic
resin blended with plasticizers) or any combination thereof.
The present disclosure is further directed to a system for detecting wear in
an abrasive
article. The system can comprise an abrasive body including abrasive particles
within a bond
material and a wear detection system coupled to the abrasive body. The wear
detection
system can comprise a wear detection sensor including at least one lead
configured to change
states between an active state and an inactive state; and at least one logic
device coupled to
the wear detection sensor and configured to detect a change in states of the
at least one lead
and generate a wear signal based on the change in states. In one aspect, the
wear signal can
correspond to a voltage increase measured across an electric circuit of the at
least one lead.
In another embodiment, a system for detecting wear in an abrasive article can
include
any of the abrasive articles described in embodiments herein, and a data
receiving unit
configured to receive data, such as a wear signal, generated by the wear
detection sensor. In
an aspect, the data receiving unit can be further configured to transmit the
data, to provide
energy to the wear detection sensor, to send a signal to the wear detection
sensor and to
receive a response from the wear detection sensor, or a combination thereof.
In a particular
aspect, the electronic device, the antenna, or the electronic element can be
powered by the
data receiving unit in a wireless manner. In another aspect, the data
receiving unit can
include a data-receiving device, a data base, a system, or a combination
thereof. An
exemplary data-receiving device can include a reader, an interrogator, a cell
phone, a
computer, a data base, or a combination thereof.
In a further instance, the system can include an additional antenna, wherein
the
antenna may not be coupled to an electronic device. In a particular instance,
the antenna can
help to boost a signal generated by the wear detection sensor, the data
receiving unit, or both.
-32-
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
FIG. 18 includes an illustration of an exemplary system for detecting wear in
an
abrasive article 1803 including a wear detection sensor 1804. The abrasive
article 1803 is
installed in a grinding machine including a metallic cage 1801 and utilized in
a material
removal process. The metallic cage 1801 can include an opening, and a booster
antenna 1805
is placed in the opening. The system can further include a data receiving unit
including an
edge reception antenna 1806, an edge computing processor 1807, or a
combination thereof.
In some instances, the edge computing process may be connected to cloud or the
like.
The metallic cage can have an adverse effect on signal transmission. With the
aid of
the booster antenna 1805, signal generated by the wear detection sensor 1804,
such as wear
signal or reflected energy or another signal, may be amplified and/or
transmitted by the
booster antenna, and received by the edge reception antenna 1806 and the
processor 1807.
The present disclosure is further directed to a method of detecting the wear
of an
abrasive article. In one embodiment, the method of detecting the wear of an
abrasive article
can include conducting a material removing process with an abrasive article.
The abrasive
article can comprise an abrasive body having abrasive particles contained
within a bond
material, and may have a wear detection sensor embedded in at least a portion
of the abrasive
body or the wear detection sensor can extend along an exterior surface of the
abrasive body.
During the material removing process, the abrasive article can be worn and
material of the
abrasive body being removed, which can be detected by a wear signal generated
by the wear
detection sensor. The wear signal can be based on removing at least a portion
of the wear
detection sensor. As described above, the wear detection sensor can include at
least one lead,
and the wear signal may correspond to an inactive state of one lead of the at
least one lead by
interrupting a current flow through the lead.
In another embodiment, the method of detecting the wear of an abrasive article
can
include removing at least a portion of a wear detection sensor attached to at
least a portion of
the abrasive body and generating a wear signal based on removing at least a
portion of the
wear detection sensor. In an aspect, removing at least a portion of the wear
detection sensor
can include removing a portion of an antenna. In a further aspect, reduction
in the length or
surface area or a combination thereof of an antenna can result in generation
of a wear signal.
In a further aspect, the wear signal can be received and interpreted as an
indicator of a wear
level by a data-receiving device.
In another aspect, removing at least a portion of the wear detection sensor
can include
removing a first portion of a first electronic device and removing a second
portion of a
second electronic device. In a further aspect, a first wear signal can be
generated based on
- 33 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
removing the first portion, and a second wear signal can be generated based on
removing the
second portion. In still another aspect, the first and second wear signals may
be compared by
the data-receiving unit to determine wear level of the abrasive article. In
yet another aspect,
portions of additional electronic devices may be removed, such as a third
portion or more,
and additional wear signal can be generated and used for confirmation of the
wear level.
In another embodiment, the method of detecting the wear of an abrasive article
can
include improving response of a wear detection sensor. In certain
implementations, an
abrasive article can be installed on a grinding machine including a metallic
cage. Only a
portion of the abrasive article may be exposed to an outside environment in a
grinding
operation. As the metallic cage can have an adverse effect on signal
transmission of the wear
detection sensor, signal can only be transmitted when the wear detection
sensor is exposed to
the outside environment. For instance, a data-receiving device can only
receive energy
reflected by the electronic devices when the wear detection sensor is exposed,
which may
result in a low data output frequency by the data receiving device. As
illustrated in FIG. 19A,
when the wear detection sensor includes one electronic device, the reflected
energy can be
received at intervals. Increasing the number of electronic devices can help
shorten the
intervals, and in certain instances, allow the reflected energy to be received
continuously. In
a particular aspect, the wear detection sensor can include at least 2, at
least 4, or more
electronic devices to improve response of the wear detection sensor to the
data-receiving
device. In another aspect, the method of detecting the wear of an abrasive
article can include
improving frequency of data output by a data-receiving device. As illustrated
in FIG. 19B,
when the wear detection sensor includes 4 electronic devices, the reflected
energy can be
detected at much shorter intervals, compared to the wear detection sensor
having one
electronic device.
Further embodiments are drawn to methods of detecting vibration, acoustic,
rotation
per minute, cracks, and/or other operation conditions of the abrasive article.
The wear
detection sensor noted in the embodiments herein can be suitable for the
detection. For
instance, certain operation conditions, such as a crack, vibration, and
acoustic, can affect
resistance or impedance of an electrical field, which can be detected by the
wear detection
sensor and cause a signal change. In some instances, one or more additional
components,
such as another electronic device, logic element, passive element, lead,
antenna, or the like,
can be coupled to the wear detection sensor to facilitate detection of
operation conditions of
the abrasive article.
- 34-
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
FIG. 20 includes an illustration of a particular example of a wear sensor 2000
according to an embodiment. The wear sensor 2000 can include a sensing circuit
2001, a
microcontroller 2002, an RFID transceiver 2003, and an antenna 2004. In an
embodiment,
the sensing circuit 2001 can convert the magnetic field into equivalent
digital electric output
.. (current/ voltage). Alternatively, the wear sensor 2000 can include an
analog-to-digital
converter for converting the sensing signal. In another embodiment, the wear
sensor 2000
can include an additional component, such as a passive element. For instance,
the wear
sensor 2000 may include a memory for storage of data. In an embodiment, the
wear sensor
2000 may be contained in a package or printed or attached to a substrate.
The microcontroller 2002 can receive signals from the sensing circuit 2001 and
transmit related data to the RFID transceiver 2003 and/or an outside
communication unit.
The microcontroller 2002 may perform certain operations, such as determining
wear level
based on the sensing signal received from the sensing circuit, and/or sending
data related to
the wear level to the RFID transceiver 2003. In some instances, the data sent
from the
microcontroller 2002 may include sensing signals, the wear level, and/or
additional
information, such as instructions to adjust grinding/cutting parameters and/or
to terminate the
current grinding/cutting operation, indications of a proper grinding/cutting
operation, or the
like, or any combination thereof. The microcontroller may also store data on
the transceiver
2003 or a memory, and the data may be referenced for next operation using the
abrasive tool.
Additionally, or optionally, the microcontroller 2002 may receive data from
the RFID
transceiver 2003 and transmit the data to the sensing circuit 2001.
The antenna 2004 can be directional or non-directional. The antenna 2004 can
function to receive and/or transmit signal and/or data to an outside
communication unit. The
sensing circuit 2000 may be battery powered, powered by wires, or wirelessly
powered
through the antenna 2004, Wi-Fi, Bluetooth, or any combination thereof.
An exemplary sensing circuit can include a magnetometer, such as a 3-axis
magnetometer, a temperature and/or humidity sensor, 3-axis accelerometer, a
capacitive input
interface, or the like, or any combination thereof.
A magnetometer can sense the surrounding magnetic field and convert into
digital
electric output. In applications involving a ferrous workpiece, the inherent
magnetic field of
the workpiece can be a source of field variations for the magnetometer. The
magnetometer
can sense proximity of a workpiece to the abrasive tool. In some applications,
the
magnetometer may function as a counter indicating the number of grind that has
been
performed on a single workpiece as changes of the dimension of the workpiece
can cause
- 35 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
changes to the magnetic field. In other applications, wear of the abrasive
tool can be detected
and indicated by an abrupt change to magnetic field. In some instances,
interference with
grinding by a foreign object may be detected due to interference with magnetic
field.
Inappropriate tilting of the workpiece can cause shift of the magnetic field
and be sensed by
the magnetometer.
A temperature and/or humidity sensor can sense surrounding environmental
temperature and/or humidity and in some instances can convert the signal into
equivalent
digital electric output. In some instances, temperature and/or humidity sensor
can be based
on capacitive sensing and may not be affected by magnetic field of a ferrous
environment. In
some instances, temperature and/or humidity sensor can sense the presence of
coolant on a
workpiece, inappropriate applications of coolant, or any combination thereof
due to effect of
coolant on capacity.
3-axis accelerometer can be based on an MEMS accelerometer sensing
acceleration in
3 axes. A 3-axis accelerometer can sense vibrations and angular acceleration
of the abrasive
tool and may convert sensing signals into equivalent digital electric output.
In some
instances, acoustics data may be obtained by detecting surface acoustic waves.
In other
instances, 3-axis accelerometer may sense wheel rpm by calculating the number
of repeated
cycles of grinding.
In some instances, the wear sensor can further include capacitive plates or
wires when
a capacitive input interface is used as a sensing circuit. The capacitive
plates or wires may be
external to the components illustrated in FIG. 20. The capacitive plates or
wires can sense
variations in density of the abrasive body, such as material loss or a crack
of the abrasive
body. Changes in capacity may be sensed by the capacitive input interface and
converted
into equivalent digital electric output.
FIG. 21 includes an illustration of components of a radio frequency reader
2100
including a radio frequency unit (e.g., transceiver) 2106. The radio frequency
unit2106 can
generate radio frequency signals and receive reflected signals and data from a
wear sensor,
such as the wear sensor 2000. The up convertor 2107 and down convertor 2108
can adjust
and match frequencies between control unit 2102 and radio frequency signals.
The DAC unit
2104 and ADC unit 2105 are analog/digital convertors. Control unit 2102 can
control all the
data acquisition such that the same antenna may be used as a transmitter and
receiver. The
Wi-Fi/Blue tooth unit 2101 can facilitate communication with an external
server,
visualization device, cloud, or any combination thereof. The reader 2100 may
be powered by
- 36 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
the power unit 2103. In other implementations, the reader 2100 may include one
or more
additional component or fewer components than illustrated.
The abrasive article described in embodiments herein can be employed in
various
material removal operations wherein it is desirable to observe the wear stage
of the abrasive
body during the material removing process. Non-limiting examples can include,
but are not
limited to, bonded abrasives, which may come in various grades, structures,
and shapes. In
one particular embodiment, the abrasive article can include a bonded abrasive
grinding
wheel. More specifically, the abrasive article may be a grinding wheel
configured to be
attached to a portion of a railroad car or other object configured to grind
railroad tracks.
It will be appreciated that the abrasive article of the present disclosure may
have any
suitable size and shape as known in the art.
Many different aspects and embodiments are possible. Some of those aspects and
embodiments are described herein. After reading this specification, skilled
artisans will
appreciate that those aspects and embodiments are only illustrative and do not
limit the scope
of the present invention. Embodiments may be in accordance with any one or
more of the
embodiments as listed below.
EMBODIMENTS
Embodiment 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.
Embodiment 2. 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.
Embodiment 3. The abrasive article of Embodiments 1 or 2, wherein at least a
portion of the wear detection sensor extends along an exterior surface of the
abrasive body.
Embodiment 4. The abrasive article of any one of Embodiments 1 and 2, wherein
a
first portion of the wear detection sensor is coupled to a portion of the
abrasive body and a
second portion of the wear detection sensor is coupled to a hub, wherein the
hub is coupled to
the abrasive body.
Embodiment 5. The abrasive article of Embodiment 4, wherein the first portion
includes at least one lead and the second portion includes a logic device.
- 37 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Embodiment 6. The abrasive article of Embodiment 4, wherein the first portion
includes a logic device and the second portion includes at least one lead
extending from the
logic device.
Embodiment 7. The abrasive article of any one of Embodiments 1 and 2, wherein
at
least a portion of the wear detection sensor is embedded in the abrasive body.
Embodiment 8. The abrasive article of Embodiment 7, wherein the portion of the
wear detection sensor embedded in the abrasive body extends for a depth into a
volume of the
abrasive body towards a material removing surface of the abrasive body.
Embodiment 9. The abrasive article of Embodiment 8, wherein the portion of the
wear detection sensor embedded in the abrasive body includes at least one lead
extending
from a logic device.
Embodiment 10. The abrasive article of Embodiment 9, wherein the logic device
is
coupled to an exterior surface of the abrasive body.
Embodiment 11. The abrasive article of Embodiment 10, wherein the logic device
is
coupled to a hub, and the hub is coupled to the abrasive body.
Embodiment 12. The abrasive article of Embodiment 10, wherein the portion of
the
wear detection sensor includes a plurality of leads extending parallel to each
other for
different depths into the volume of the abrasive body.
Embodiment 13. The abrasive article of Embodiment 2, wherein the logic device
and
the wear detection sensor are coupled to an exterior surface of the abrasive
body.
Embodiment 14. The abrasive article of Embodiment 1, wherein the wear
detection
sensor comprises at least one lead in contact with the abrasive body.
Embodiment 15. The abrasive article of any one of Embodiments 2 and 14,
wherein
the wear detection sensor comprises a plurality of leads.
Embodiment 16. The abrasive article of Embodiment 15, wherein at least one
lead of
the plurality of leads extends along a portion of the exterior surface of the
abrasive body.
Embodiment 17. The abrasive article of Embodiment 15, wherein a majority of
the
leads of the plurality of leads extend along a portion of the exterior surface
of the abrasive
body.
Embodiment 18. The abrasive article of Embodiment 15, wherein each of the
leads of
the plurality of leads extend along a portion of the exterior surface of the
abrasive body.
Embodiment 19. The abrasive article of Embodiment 15, wherein the plurality of
leads have different lengths compared to each other.
- 38 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Embodiment 20. The abrasive article of Embodiment 14, wherein at least one of
the
leads of the plurality of leads is embedded within the abrasive body.
Embodiment 21. The abrasive article of Embodiment 20, wherein all of the leads
of
the plurality of leads are embedded within the abrasive body.
Embodiment 22. The abrasive article of Embodiment 20, wherein at least two of
the
leads of the plurality of leads have terminal ends spaced apart from each
other.
Embodiment 23. The abrasive article of Embodiment 22, wherein each of the
leads of
the plurality of leads comprise terminal ends, and wherein each of the
terminal ends are
spaced apart from each other.
Embodiment 24. The abrasive article of Embodiment 23, wherein each of the
terminal ends are located at different positions relative to each other.
Embodiment 25. The abrasive article of Embodiment 23, wherein each of the
terminal ends are embedded at different depths within the abrasive body
relative to each
other.
Embodiment 26. The abrasive article of any one of Embodiments 2 and 14,
wherein
the at least one lead is partially embedded within the abrasive body.
Embodiment 27. The abrasive article of any one of Embodiments 2 and 14,
wherein
the at least one lead is embedded within the abrasive body.
Embodiment 28. The abrasive article of Embodiments 2 or 14, wherein the at
least
one lead includes an elongated plate or wire adapted to change resistance
corresponding to a
length of the elongated plate or wire.
Embodiment 29. The abrasive article of Embodiments 2 or 14, wherein the at
least
one lead comprises an electric circuit including two wires connected by a
plurality of
resistors, wherein the resistors are positioned in parallel to each other at
different locations
along a length direction of the two wires.
Embodiment 30. The abrasive article of Embodiments 2 or 14, wherein the at
least
one lead comprises a metal or metal alloy.
Embodiment 31. The abrasive article of Embodiment 1, further comprising a
logic
device in communication with the wear detection sensor.
Embodiment 32. The abrasive article of any one of Embodiments 2, 14, or 31,
wherein the logic device comprises a microcontroller configured to detect a
change in states
of the wear detection sensor.
Embodiment 33. The abrasive article of any one of Embodiments 2, 14, or 31,
wherein the wear detection sensor comprises at least one lead configured to
change states
- 39 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
between an active state and an inactive state, and wherein the logic device
comprises a
microcontroller configured to detect a change in states of the at least one
lead.
Embodiment 34. The abrasive article of any one of Embodiments 2, 14, or 31,
wherein the wear detection sensor comprises a plurality of leads, each of the
leads of the
plurality of leads having terminal ends at different positions, and wherein
during use the
terminal ends of the leads are adapted to be worn and change states from an
active state to an
inactive state upon being worn.
Embodiment 35. The abrasive article of Embodiments 2, 14, or 31, wherein a
distance ADT orthogonal from an original outer material removing surface of
the abrasive
body to a terminal end of the at least one lead is at least 100 micron, such
as at least 200
microns, or at least 300 microns, or at least 500 microns, or at least 800
microns, or at least
900 microns, or at least 1000 microns, or at least 5000 microns, and not
greater than 1.5
meters, such as not greater than 1.3 meters, or not greater than 1.0 meter, or
not greater than
0.8 meter, or not greater than 0.5 meter or not greater than 0.3 meter, or not
greater than 0.1
meter, or not greater than 0.05 meter, or not greater than 0.01 meter.
Embodiment 36. The abrasive article of Embodiments 2, 14, or 31, wherein a
distance ADI between two terminal lead ends to each other in a thickness
direction of the
abrasive body is at least 50 microns, such as at least 100 microns, at least
250 microns, at
least 500 microns, or at least 1000 microns, and not greater than 1.5 meters,
such as not
greater than 1.2 meters, or not greater than 1 meter, or not greater than 0.8
meter, or not
greater than 0.5 meter, or not greater than 0.3 meter, or not greater than 0.2
meter, or not
greater than 0.1 meter, or not greater than 0.05 meter, or not greater than
0.01 meter.
Embodiment 37. The abrasive article of Embodiments 2, 14, or 31, wherein a
total
length of the at least one lead is at least 100 microns, such as at least 200
microns, or at least
500 microns, or at least 1000 microns, or at least 10,000 microns, or at least
50,000 microns,
and not greater than 10 meters, such as not greater than 8 meters, not greater
than 5 meters,
not greater than 3 meters, not greater than 2 meters, not greater than 1.5
meters, not greater
than 1.2 meters, not greater than 1.0 meter, not greater than 0.8 meter, not
greater than 0.5
meter, not greater than 0.3 meter, not greater than 0.2 meter, not greater
than 0.1 meter, not
greater than 0.05 meter, or not greater than 0.01 meter.
Embodiment 38. The abrasive article of Embodiments 2, 14, or 31, wherein each
of
the at least one lead comprises an electric circuit.
- 40 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Embodiment 39. The abrasive article of Embodiments 2, 14, or 31, wherein the
at
least lead is a plurality of leads, and the plurality of leads is combined
within one electric
circuit.
Embodiment 40. The abrasive article of Embodiments 2, 14, or 31, wherein the
at
least one lead comprises at least two leads, or at least 3 leads, at least 5
leads, at least 7 leads,
or at least 9 leads.
Embodiment 41. The abrasive article of Embodiments 2, 14, or 31, wherein the
at
least one lead comprises not more than 100 leads, such as not more than 80
leads, not more
than 60 leads, not more than 50 leads, not more than 30 leads, not more than
20 leads, not
more than 15 leads, or not more than 10 leads.
Embodiment 42. The abrasive article of Embodiments 2, 14, or 31, wherein the
logic
device further includes a communication device for wireless communication with
an external
controller.
Embodiment 43. The abrasive article of Embodiment 42, wherein the
communication
device is a transceiver.
Embodiment 44. The abrasive article of Embodiment 43, wherein the
communication
device is an RFID transceiver.
Embodiment 45. A system for detecting wear in an abrasive article comprising:
an
abrasive body comprising abrasive particles contained within a bond material;
a wear
detection system coupled to the abrasive body, wherein the wear detection
system comprises:
a wear detection sensor including at least one lead configured to change
states between an
active state and an inactive state; and at least one logic device coupled to
the wear detection
sensor and configured to detect a change in states of the at least one lead
and generate a wear
signal based on the change in states.
Embodiment 46. The system of Embodiment 45, wherein the wear signal
corresponds
to a voltage change measured across an electric circuit of the at least one
lead.
Embodiment 47. The system of Embodiment 45, wherein each lead of the at least
one
lead has an independent electric circuit, and the inactive state of the at
least one lead
corresponds to an interrupted electric circuit.
Embodiment 48. A system for detecting wear in an abrasive article comprising:
an
abrasive body comprising abrasive particles contained within a bond material;
a wear
detection system coupled to the abrasive body, wherein the wear detection
system comprises:
a wear detection sensor including at least one lead configured to change
resistance during
wear of the abrasive body; and at least one logic device coupled to the wear
detection sensor
- 41 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
and configured to measure the resistance of the at least one lead and to
generate a wear signal
based on a change of the measured resistance.
Embodiment 49. The system of Embodiment 48, wherein the at least one lead is
an
elongated plate or wire adapted to change resistance corresponding to a length
of the
elongated plate or wire.
Embodiment 50. The system of Embodiment 48, wherein the at least one lead
wherein the at least one lead comprises an electric circuit including two
wires connected by a
plurality of resistors, wherein the resistors are positioned in parallel to
each other at different
locations along a length distance of the two wires.
Embodiment 51. A method for detecting wear in an abrasive article comprising:
conducting a material removal process with an abrasive body comprising
abrasive particles
contained within a bond material; removing at least a portion of a wear
detection sensor
embedded in at least a portion of the abrasive body; and generating a wear
signal based on
removing at least a portion of the wear detection sensor.
Embodiment 52. The method of Embodiment 51, wherein the wear detection sensor
includes at least one lead configured to change states between an active state
and an inactive
state.
Embodiment 53. The method of Embodiment 51, wherein the wear signal is
generated by removing at least a portion of the at least one lead and changing
said lead states
from active state to inactive state.
Embodiment 54. The method of Embodiment 51, wherein the wear signal
corresponds to a voltage change measured across an electric circuit of the at
least one lead.
Embodiment 55. The method of Embodiment 51, wherein the wear signal
corresponds to a measured resistance change of the at least one lead.
Embodiment 56. The method of Embodiment 51, wherein the at least one lead is
an
elongated plate or wire and the resistance change corresponds to a decrease in
length of the
elongated plate or wire during wear of the abrasive body.
Embodiment 57. The method of Embodiment 51, wherein the at least one lead
comprises an electric circuit including two wires connected by a plurality of
resistors,
wherein the resistors are positioned in parallel to each other at different
locations along a
length direction of the two wires, and a change in total resistance of the
circuit corresponds to
an amount of destroyed resistors during wear of the abrasive body.
Embodiment 58. An abrasive article comprising:
an abrasive body including:
- 42 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
abrasive particles contained within a bond material; and
a wear detection sensor coupled to the abrasive body,
wherein the wear detection sensor is configured to detect a change in a
dimension of the abrasive body; and
wherein the wear detection sensor comprises at least one electronic device.
Embodiment 59. The abrasive article of 58, wherein at least a portion of the
wear
detection sensor is in direct contact with a portion of the abrasive body.
Embodiment 60. The abrasive article of Embodiment 58 or 59, wherein the at
least
one electronic device comprises an antenna.
Embodiment 61. The abrasive article of Embodiment any one of Embodiments 58 to
60, wherein the wear detection sensor comprises at least one, at least 2, at
least 4, or at least 6
antennas.
Embodiment 62. The abrasive article of any one of Embodiments 58 to 61,
wherein
the electronic device is attached to a major surface of the abrasive body, a
peripheral surface
of the abrasive body, or a combination thereof.
Embodiment 63. The abrasive article of any one of Embodiments 58 to 61,
wherein
the electronic device is at least partially embedded in the abrasive body.
Embodiment 64. The abrasive article of any one of Embodiments 58 to 61,
wherein
the electronic device is completely embedded within the abrasive body.
Embodiment 65. The abrasive article of any one of Embodiments 58 to 64,
wherein
the wear detection sensor comprises an electrical component coupled to the at
least one
electronic device, wherein the electrical component comprises a capacitor, a
resistor, an
inductor, or a combination thereof.
Embodiment 66. The abrasive article of Embodiment 65, wherein the electrical
component comprises a first capacitance plate, and a second capacitance plate
that is spaced
apart from the first capacitance plate.
Embodiment 67. The abrasive article of Embodiments 65 or 66, wherein the
abrasive
body comprises an interior circumferential region and an exterior
circumferential region,
wherein the first capacitance plate is positioned in the interior
circumferential region, and the
second capacitance plate is positioned in the exterior circumferential region.
Embodiment 68. The abrasive article of any one of Embodiments 65 to 67,
wherein
the electrical component is attached to a portion of the abrasive body or at
least partially
embedded in the abrasive body.
-43 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Embodiment 69. The abrasive article of any one of Embodiments 65 to 68,
wherein
at least one of the first and second capacitance plates is attached to a major
surface of the
abrasive body, a peripheral surface of the abrasive body, or a combination
thereof.
Embodiment 70. The abrasive article of any one of Embodiments 65 to 69,
wherein
.. both the first and second capacitance plates are attached to a major
surface or a peripheral
surface of the abrasive body.
Embodiment 71. The abrasive article of any one of Embodiments 65 to 69,
wherein
the first capacitance plate is attached to a major surface or peripheral
surface of the abrasive
body, and wherein the second capacitance plate is at least partially embedded
within the
abrasive body.
Embodiment 72. The abrasive article of any one of Embodiments 65 to 68,
wherein
both the first and second capacitance plates are at least partially embedded
in the abrasive
body.
Embodiment 73. The abrasive article of any one of Embodiments 65 to 68,
wherein
both the first and second capacitance plates are fully embedded within the
abrasive body.
Embodiment 74. The abrasive article of any one of Embodiments 58 to 73,
wherein
the wear detection sensor comprises a loop circuit.
Embodiment 75. The abrasive article of Embodiment 74, wherein the loop circuit
comprises a resistive wire loop coupled to the at least one electronic device.
Embodiment 76. The abrasive article of Embodiments 74 or 75, wherein the wear
detection sensor comprises a loop circuit comprising the electrical component.
Embodiment 77. The abrasive article of any one of Embodiments 74 to 76,
wherein
the loop circuit further comprises a resistive element.
Embodiment 78. The abrasive article of Embodiment 77, wherein the resistive
element comprises resistor, a resistive wire, or a combination thereof.
Embodiment 79. The abrasive article of any one of Embodiments 74 to 78,
wherein
the loop circuit comprises a plurality of capacitors, a plurality of
resistors, a plurality of
inductors, or a combination thereof.
Embodiment 80. The abrasive article of any one of Embodiments 58 to 64,
wherein
the at least one electronic device comprising an electronic element and an
antenna directly
and electrically connected to the electronic element, wherein the electronic
element
comprises a chip, an integrated circuit, logic, a transponder, a transceiver,
a memory, a
passive element, or any combination thereof.
- 44 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Embodiment 81. The abrasive article of Embodiment 80, wherein the wear
detection
sensor comprises a plurality of electronic devices including the at least one
the electronic
devices.
Embodiment 82. The abrasive article of Embodiments 80 or 81, wherein the wear
detection sensor comprises a plurality of electronic devices, wherein at least
some of the
electronic devices comprise an antenna.
Embodiment 83. The abrasive article of any one of Embodiments 80 to 82,
wherein
the wear detection sensor comprises a plurality of electronic devices, wherein
each one of the
electronic devices comprises an antenna.
Embodiment 84. The abrasive article of any one of Embodiments 80 to 83,
wherein
the wear detection sensor comprises an electronic device comprising at least
1, at least 2, at
least 3, or at least 4 antennas directly and electrically coupled to an
electronic element.
Embodiment 85. The abrasive article of any one of Embodiments 80 to 84,
wherein
the antenna comprises a thin film antenna.
Embodiment 86. The abrasive article of any one of Embodiments 80 to 85,
wherein
the antenna includes a surface area that is greater than a surface area of the
electronic
element.
Embodiment 87. The abrasive article of any one of Embodiments 80 to 87,
wherein
the antenna extends over a greater surface area of the abrasive body compared
to the
electronic element.
Embodiment 88. The abrasive article of any one of Embodiments 80 to 87,
wherein
the antenna is directly and electrically coupled to the integrated circuit.
Embodiment 89. The abrasive article of any one of Embodiments 86 to 88,
wherein
the electronic device including the antenna is coupled to a non-abrasive
portion of the
.. abrasive article.
Embodiment 90. The abrasive article of any one of Embodiments 80 to 89,
wherein
the antenna extends along a portion of a major surface, a peripheral surface,
or both, toward a
material removing surface of the abrasive body.
Embodiment 91. The abrasive article of any one of Embodiments 80 to 90,
wherein
the antenna is at least partially embedded or fully embedded in the abrasive
body.
Embodiment 92. The abrasive article of any one of Embodiments 80 to 91,
wherein
the antenna extends in a radial direction, an axial direction, a
circumferential direction, or
combination thereof of the abrasive body.
- 45 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Embodiment 93. The abrasive article of any one of Embodiments 80 to 92,
wherein
the antenna is arranged in a loop, in a serpentine shape, or a combination
thereof.
Embodiment 94. The abrasive article of any one of Embodiments 80 to 93,
wherein
the electronic element is positioned within an interior circumferential region
of the abrasive
body, wherein the electronic element includes an integrated element, wherein
the integrated
element is positioned within the interior circumferential region.
Embodiment 95. The abrasive article of any one of Embodiments 80 to 94,
wherein
the electronic element is positioned within a non-abrasive portion of the
abrasive body,
wherein the antenna is positioned in an abrasive portion of the abrasive body.
Embodiment 96. The abrasive article of any one of Embodiments 80 to 95,
wherein
the wear detection sensor comprises a package containing at least a portion of
the electronic
element, the antenna, or a combination thereof.
Embodiment 97. The abrasive article of Embodiment 96, wherein the package
comprises a protective layer.
Embodiment 98. The abrasive article of Embodiment 97, wherein the protective
layer
comprises a material including polydimethylsiloxane (PDMS), polyethylene
naphthalate
(PEN), polyimide, polyether ether ketone (PEEK), or any combination thereof.
Embodiment 99. The abrasive article of Embodiment 98 or 99, wherein the
protective
layer encapsulates the electronic element and the antenna.
Embodiment 100. The abrasive article of any one of Embodiments 80 to 99,
wherein
the wear detection sensor comprises a plurality of antennas, wherein the
plurality of antennas
have a different length compared to each other.
Embodiment 101. The abrasive article of Embodiment 100, wherein a relative
difference in length between the plurality of antennas can be at least 5%, at
least 10%, at least
15%, at least 17%, at least 20%, at least 30%, at least 40%, or at least 50%.
Embodiment 102. The abrasive article of Embodiment 100 or 101, wherein a
relative
difference in length between the plurality of antennas can be at most 80%, at
most 70%, at
most 60%, at most 50%, at most 45%, at most 40%, at most 35%, or at most 30%.
Embodiment 103. The abrasive article of Embodiment 102, wherein the plurality
of
antennas extend a different distance along the abrasive body toward a material
removing
surface.
Embodiment 104. The abrasive article of any one of Embodiments 100 to 103,
wherein at least one of the antennas is positioned within an interior
circumferential region of
the abrasive body.
- 46 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Embodiment 105. The abrasive article of any one of Embodiments 100 to 104,
wherein at least one of the antennas extends from an interior circumferential
region into an
exterior circumferential region.
Embodiment 106. The abrasive article of any one of Embodiments 100 to 105,
wherein at least one of the antennas is positioned within an exterior
circumferential region of
the abrasive body.
Embodiment 107. The abrasive article of any one of Embodiments 80 to 106,
wherein wear detection sensor comprises a plurality of antennas, wherein at
least one of the
antennas comprises a flared body.
Embodiment 108. The abrasive article of Embodiment 107, wherein each of the
plurality of antennas comprises a flared body.
Embodiment 109. The abrasive article of Embodiment 107 or 108, wherein 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 removing surface
of the abrasive
body, wherein a width of the flared body increases as the antenna extends from
the center
region to the material removal surface of the abrasive body.
Embodiment 110. The abrasive article of any one of Embodiments 107 to 108,
wherein at least one of the plurality of antennas extends in the radial
direction, an axial
direction, or a combination there, across at least a portion of the center
region and across at
least a portion of an interior circumferential region of the abrasive body.
Embodiment 111. The abrasive article of any one of Embodiments 107 to 110,
wherein at least one of the plurality of antennas extends from the center
region, across the
interior circumferential region, and into an exterior region of the abrasive
body.
Embodiment 112. The abrasive article of Embodiment 111, wherein the at least
one
of the plurality of secondary antennas comprises a terminal end aligned with
the material
removal surface.
Embodiment 113. The abrasive article of Embodiment 111 or 112, wherein each of
the plurality of antennas extends across a portion of the interior
circumferential region and
into an exterior region of the abrasive body.
Embodiment 114. The abrasive article of any one of Embodiments 111 to 113,
wherein at least one of the plurality of antennas comprises at least a portion
exposed to an
outer environment.
Embodiment 115. The abrasive article of any one of Embodiments 111 to 114,
wherein at least one of the plurality of antennas is partially embedded in the
abrasive body
- 47 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Embodiment 116. The abrasive article of any one of Embodiments 111 to 115,
wherein each of the antennas is partially embedded in the abrasive body.
Embodiment 117. The abrasive article of any one of Embodiments 111 to 116,
wherein at least one of the antennas comprises a portion protruding outside of
a surface
portion of an interior circumferential region of the abrasive body.
Embodiment 118. The abrasive article of any one of Embodiments 111 to 117,
wherein at least one of the antennas extends along a portion of a major
surface of the abrasive
body.
Embodiment 119. The abrasive article of any one of Embodiments 111 to 118,
wherein each of the antennas extends along a portion of a major surface of the
abrasive body.
Embodiment 120. The abrasive article of any one of Embodiments 80 to 118,
wherein the wear detection sensor comprises a plurality of antennas, wherein
one or more of
the plurality of antennas comprises a body including a curved portion.
Embodiment 121. The abrasive article of Embodiment 119 or 120, wherein at
least
one of the plurality of antennas has a curved body, wherein at least a portion
of the curved
body extends in a circumferential direction of the abrasive body.
Embodiment 122. The abrasive article of any one of Embodiments 119 to 120,
wherein at least one of the plurality of antennas has a length extending in a
circumferential
direction.
Embodiment 123. The abrasive article of any one of Embodiment 119 to 122,
wherein each one of the antennas has a length extending in a circumferential
direction of the
abrasive body.
Embodiment 124. The abrasive article of any one of Embodiments 119 to 122,
wherein one or more of the antennas extend in a radial direction,
circumferential direction,
axial direction, or a combination thereof.
Embodiment 125. The abrasive article of any one of Embodiments 119 to 124,
wherein the wear detection sensor can include a first and second antennas
extending from a
same electronic device in an opposite direction.
Embodiment 126. The abrasive article of any one of Embodiments 119 to 125,
wherein one or each of the antennas extend along a portion of the interior
circumferential
region, a portion of the exterior circumferential region, or combination
thereof.
Embodiment 127. The abrasive article of any one of Embodiments 119 to 126,
wherein each of the antennas is positioned outside of a center area of the
abrasive body.
- 48 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Embodiment 128. The abrasive article of any one of Embodiments 119 to 127,
wherein at least one of the electronic elements are positioned outside of a
center area of the
abrasive body.
Embodiment 129. The abrasive article of any one of Embodiments 119 to 128,
wherein each of the electronic elements is positioned outside of a center area
of the abrasive
body.
Embodiment 130. The abrasive article of any one of Embodiment 119 to 129,
wherein at least one of the antennas extends along a portion of a major
surface of the abrasive
body.
Embodiment 131. The abrasive article of any one of the Embodiments 119 to 130,
wherein the at least one of the antennas is attached to a major surface of the
abrasive body.
Embodiment 132. The abrasive article of any one of Embodiments 119 to 131,
wherein each one of the antennas extends along a portion of a major surface of
the abrasive
body
Embodiment 133. The abrasive article of any one of Embodiments 119 to 132,
wherein each one of the antennas is attached to a major surface of the
abrasive body.
Embodiment 134. The abrasive article of any one of Embodiments 119 to 133,
wherein at least one of the antennas is at least partially embedded in the
abrasive body.
Embodiment 135. The abrasive article of any one of Embodiments 119 to 134,
wherein each of the antennas is at least partially embedded in the abrasive
body.
Embodiment 136. The abrasive article of any one of Embodiments 119 to 135,
wherein at least one of the antennas comprises a portion exposed to an outer
environment.
Embodiment 137. The abrasive article of any one of Embodiments 119 to 136,
wherein at least one of the antennas comprises a portion protruding outside of
a surface
portion of an interior circumferential region.
Embodiment 138. The abrasive article of any one of Embodiments 119 to 137,
wherein each antenna comprises a portion protruding outside of a surface
portion of an
interior circumferential region.
Embodiment 139. The abrasive article of any one of Embodiments 119 to 138,
wherein the antennas have different lengths compared to each other.
Embodiment 140. The abrasive article of any one of Embodiments 58 to 60,
wherein
the wear detection sensor comprises a plurality of electronic devices.
Embodiment 141. The abrasive article of Embodiment 140, wherein the wear
detection sensor comprises at least 2 electronic devices, at least 3, at least
5, at least 6, or at
- 49 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
least 8 electronic devices, wherein each of the electronic devices extend
along a portion of the
abrasive body toward a material removing surface of the abrasive body.
Embodiment 142. The abrasive article of Embodiment 141, wherein at least one
of
the electronic devices extend in a radial direction, an axial direction, or a
combination thereof
of the abrasive body.
Embodiment 143. The abrasive article of Embodiments 141 or 142, wherein an
electronic element of at least one of the electronic devices is positioned in
the interior
circumferential region of the abrasive body.
Embodiment 144. The abrasive article of Embodiment 143, wherein the electronic
element includes an integrated circuit, wherein the integrated circuit is
positioned in the
interior circumferential region.
Embodiment 145. The abrasive article of Embodiments 141 to 144, wherein at
least
one of the electronic devices has a terminal end that is aligned with a
material removal
surface of the abrasive body.
Embodiment 146. The abrasive article of Embodiment 145, wherein the wear
detection sensor comprises a first electronic device and a second electronic
device, wherein
the first and second electronic devices are placed spaced apart from one
another and extend
along a portion of the abrasive body.
Embodiment 147. The abrasive article of Embodiment 146, wherein the first
electronic device is positioned closer to the material removing surface
compared to the
second electronic device.
Embodiment 148. The abrasive article of Embodiments 146 or 147, wherein the
second electronic device is positioned closer to an inner circumference of the
abrasive body
compared to the first electronic device.
Embodiment 149. The abrasive article of any one of Embodiments 146 to 148,
wherein the first electronic device comprises a first length extending from a
first terminal end
to a second terminal end of the first body toward an outer circumference, and
wherein the
second electronic device comprises a second length extending from a third
terminal end to a
fourth terminal end toward the outer circumference, wherein the first terminal
end is closer to
an inner circumference compared to the third terminal end, and the second
terminal end is
father away from the outer circumference compared to the fourth terminal end.
Embodiment 150. The abrasive article of Embodiment 149, wherein the first
length
and the second length extend in a radial or an axial direction of the abrasive
body.
- 50 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Embodiment 151. The abrasive article of Embodiments 149 or 150, wherein the
first
electronic device is in parallel to the second electronic device.
Embodiment 152. The abrasive article of any one of Embodiments 149 to 151,
wherein the first and second electronic devices are staggered.
Embodiment 153. The abrasive article of any one of Embodiments 149 to152,
wherein a distance 6dI1 between the first terminal end and the inner
circumference is greater
than a distance 6d12 between the third terminal end to the inner
circumference, wherein a
relative difference between 6dI1 and 6d12 is at least at least 2%, at least
5%, at least 10%, at
least 12%, at least 15%, at least 20%, at least 30%, at least 40%, or at least
50%.
Embodiment 154. The abrasive article of Embodiment 153, wherein the relative
difference between 6dI1 and 6d12 is most 80%, at most 70%, at most 60%, at
most 50%, at
most 45%, at most 40%, at most 35%, or at most 30%.
Embodiment 155. The abrasive article of any one of Embodiments 149 to 154,
wherein a distance 6d02 between the fourth terminal end and the outer
circumference is
greater than a distance 6d01 from the second terminal end to the outer
circumference, wherein
a relative difference between 6d01 and 6c102 is at least at least 2%, at least
5%, at least 10%, at
least 12%, at least 15%, at least 20%, at least 30%, at least 40%, or at least
50%.
Embodiment 156. The abrasive article of Embodiment 155, wherein the relative
difference between 6d01 and 6c102 is at most 80%, at most 70%, at most 60%, at
most 50%, at
most 45%, at most 40%, at most 35%, or at most 30%.
Embodiment 157. The abrasive article of any one of Embodiments 58 to 156,
wherein the wear detection sensor comprises an electronic device, wherein the
device
comprises a chip, an integrated circuit, data transponder, a radio frequency
based tag or
sensor with or without chip, an electronic tag, electronic memory, a sensor,
an analog to
digital converter, a transmitter, a receiver, a transceiver, a modulator
circuit, a multiplexer, an
antenna, a near-field communication device, a power source, a display (e.g.,
LCD or OLED
screen), optical devices (e.g., LEDs), global positioning system (GPS) or
device, fixed or
programmable logic, or any combination thereof.
Embodiment 158. The abrasive article of any one of Embodiments 58 to 157,
wherein the wear detection sensor comprises an electronic device comprising a
radio-
frequency identification tag or sensor, a near field communication tag or
sensor, or a
combination thereof.
Embodiment 159. The abrasive article of any one of Embodiments 58 to 158,
wherein the wear detection sensor comprises a plurality of electronic devices,
wherein at least
- 51 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
one of the electronic devices is placed in an interior circumferential region
of the abrasive
body.
Embodiment 160. The abrasive article of Embodiments 159, wherein each of the
electronic devices is placed outside of an exterior circumferential region of
the abrasive body.
Embodiment 161. The abrasive article of Embodiments 159 or 160, wherein each
of
the electronic devices is placed outside of a center area of the abrasive
body.
Embodiment 162. The abrasive article of Embodiments 160 or 161, wherein at
least
one of the electronic devices is placed in a center area of the abrasive body
Embodiment 163. The abrasive article of any one of Embodiments 58 to 162,
wherein the wear detection sensor comprises a plurality of electronic devices
comprising a
plurality of integrated circuits.
Embodiment 164. A system for detecting wear in an abrasive article,
comprising:
the abrasive article of any one of Embodiments 58 to 163; and
a data receiving unit configured to receive data generated by the wear
detection
sensor.
Embodiment 165. The system of Embodiment 164, wherein the data receiving unit
is
further configured to transmit the data.
Embodiment 166. The system of Embodiment 164 or 165, wherein the data
receiving
unit is configured to provide energy to the wear detection sensor.
Embodiment 167. The system of Embodiment 166, wherein the wear detection
sensor
comprises an antenna and an electronic element, wherein the antenna,
electronic element, or
both is powered by the data receiving unit in a wireless manner.
Embodiment 168. The system of any one of Embodiments 164 to 167, wherein the
data receiving unit is configured to send a signal to the wear detection
sensor and to receive a
response from the wear detection sensor.
Embodiment 169. The system of any one of Embodiments 164 to 168, further
comprising an antenna, wherein the antenna is not coupled to the wear
detection sensor.
Embodiment 170. The system of any one of Embodiments 164 to 169, wherein the
antenna is configured to boost a signal generated by the wear detection
sensor, the data
receiving unit, or both.
Embodiment 171. The system of any one of Embodiments 164 to 170, wherein the
data receiving unit comprises a reader, an interrogator, a cell phone, a
computer, a data base,
or a combination thereof.
- 52 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
Embodiment 172. The method of Embodiment 51, wherein removing at least a
portion of the wear detection sensor comprises removing a portion of an
antenna.
Embodiment 173. The method of Embodiments 51 or 172, wherein generating a wear
signal is based on reduction of a surface area, a length, or a combination
thereof, of an
antenna.
Embodiment 174. The method of any one of Embodiments 51 and 172 to 173,
generating wear signal comprises generating a first wear signal based on
removing at least a
first portion of the wear detection sensor, and generating a second wear
signal based on
removing at least a second portion of the wear detection sensor.
Embodiment 175. The method of Embodiment 174, further comprising comparing
the first wear signal and the second wear signal to determine wear of the
abrasive body.
Embodiment 176. The method of Embodiments 174 or 175, wherein the wear
detection sensor comprises a plurality of electronic devices, wherein the
first portion of the
wear detection sensor comprises a first portion of a first electronic device,
and the second
portion of the wear detection sensor comprises a second portion of a second
electronic
device.
Embodiment 177. The method of Embodiment 51, wherein the portion of the wear
detection sensor comprises a portion of an antenna.
Embodiment 178. The method of Embodiment 177, wherein the wear signal
comprises a reduction in energy reflected by the antenna, wherein a dimension
of the abrasive
body is a function of the reduction.
Embodiment 179. The method of Embodiment 178, further comprising determining a
first dimension of the abrasive body based on a first wear signal, and a
second dimension of
the abrasive body based on a second wear signal.
Embodiment 180. The method of Embodiment 179, further comprising comparing
the first and second dimension and determining wear of the abrasive body.
EXAMPLES
Example 1. Manufacturing an abrasive wheel for grinding railroad tracks
including a
wear detection sensor.
An abrasive body of a grinding wheel is formed and pressed. Before applying an
external fiber winding to the wheel, a plurality of five leads is attached to
the exterior surface
of the wheel by gluing such that the leads extend in axial direction x towards
the outer
grinding surface of the wheel, as also illustrated in FIG. 1. After an
exterior fiber winding
and a hub is applied to the wheel, a logic device in form of a microcontroller
is connected via
- 53 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
electric wiring to the leads and mounted on an inner diameter of the abrasive
body of wheel.
The logic device contains an RFID chip for wireless sending data related to
the wear stage of
the abrasive body to an external control device which is handled by an
operator.
Example 2. Wheel operation during rail grinding.
A plurality of abrasive wheels manufactured as described in Example 1 is
mounted on
a railtrack grinder. During the grinding operation, leads of the wear
detection sensor in each
wheel get broken according to the wear of the abrasive body. The exact wear of
each wheel
is measured by the amount of broken leads, which corresponds to the amount of
leads
changing from active stage to inactive stage (closed circuit to open circuit),
and is registered
by the logic device. Based on the amount of broken leads, the logic device of
each wheel is
calculating a single number of the remaining abrasive wheel life in % and
transmitting this
number with an RFID chip to the control device. The control device is
collecting the data of
each wheel attached to the rail grinder and is indicating during grinding
operation by blinking
of red colored light bulbs when a specific wheel needs to be replaced.
The foregoing embodiments are directed to bonded abrasive products, and
particularly
grinding wheels, which represent a departure from the state-of-the-art.
Benefits, other advantages, and solutions to problems have been described
above with
regard to specific embodiments. However, the benefits, advantages, solutions
to problems,
and any feature(s) that may cause any benefit, advantage, or solution to occur
or become
more pronounced are not to be construed as a critical, required, or essential
feature of any or
all the claims. Reference herein to a material including one or more
components may be
interpreted to include at least one embodiment wherein the material consists
essentially of the
one or more components identified. The term "consisting essentially" will be
interpreted to
include a composition including those materials identified and excluding all
other materials
except in minority contents (e.g., impurity contents), which do not
significantly alter the
properties of the material. Additionally, or in the alternative, in certain
non-limiting
embodiments, any of the compositions identified herein may be essentially free
of materials
that are not expressly disclosed. The embodiments herein include range of
contents for
certain components within a material, and it will be appreciated that the
contents of the
components within a given material total 100%. The specification and
illustrations of the
embodiments described herein are intended to provide a general understanding
of the
structure of the various embodiments. The specification and illustrations are
not intended to
serve as an exhaustive and comprehensive description of all of the elements
and features of
apparatus and systems that use the structures or methods described herein.
Separate
- 54 -
CA 03108094 2021-01-28
WO 2020/028855
PCT/US2019/044978
embodiments may also be provided in combination in a single embodiment, and
conversely,
various features that are, for brevity, described in the context of a single
embodiment, may
also be provided separately or in any subcombination. Further, reference to
values stated in
ranges includes each and every value within that range. Many other embodiments
may be
apparent to skilled artisans only after reading this specification. Other
embodiments may be
used and derived from the disclosure, such that a structural substitution,
logical substitution,
or another change may be made without departing from the scope of the
disclosure.
Accordingly, the disclosure is to be regarded as illustrative rather than
restrictive.
- 55 -
