Patent Description:
Abrasive articles are used in various industries to machine work pieces by cutting, lapping, grinding, or polishing. Abrasive articles are often shipped from one location to another and stored for an amount of time prior to use. As some bonded abrasive articles have bond matrix materials that are susceptible to water vapor adsorption, humid environment can adversely affect performance and cause performance degradation of such bonded abrasive articles. Performance degradation can include, for example, an increase in wear rate of the abrasive article, a reduction in grind rate on a work piece, or a reduction in the amount of cutting before the abrasive article wears out. A need for improved abrasive article packaging exists.

<CIT> discloses an article, comprising a package including a packaging material defining an enclosed volume containing an abrasive article and a desiccant.

The above given problems are solved by the article according to claim <NUM>.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the invention.

The following description in combination with the figures is provided to assist in understanding the teachings disclosed herein. The following discussion 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.

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.

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 are drawn to an article including a package including a packaging material defining an enclosed volume, and an abrasive article and a desiccant contained within the enclosed volume. The package can be suited for shipping or storing abrasive articles including a hygroscopic bond material, such as a resin-based bond material or a hygroscopic inorganic material. The package can help to significantly reduce moisture uptake (i.e., water vapor adsorption) of abrasive articles contained therein, particularly when the package is exposed to a humid condition, and thus, can allow improved packaging and extended storage, reducing the likelihood of performance degradation of the abrasive article.

<FIG> includes an illustration of an exemplary embodiment of a package <NUM>. The package <NUM> includes at least one self-supporting wall <NUM> defining an edge of an enclosed volume <NUM> in which abrasive articles <NUM> are contained. The package <NUM> can also include a bottom <NUM> and a top <NUM>. In an example, the bottom <NUM> can be formed of the same material as the wall <NUM>. Alternatively, the bottom <NUM> can be formed of a different material than the wall <NUM>. The bottom <NUM> can be friction fit with the wall <NUM>. In another example, the wall <NUM> can have a screw configuration. In a further example, the bottom <NUM> can be integrally formed with the wall <NUM> or can be adhered to the wall <NUM>, such as by using an adhesive. As illustrated, the package <NUM> is in the form of a bucket. A skilled artisan would understand that the package <NUM> can take any other forms to contain the abrasive articles, e.g., for shipping and storage of the abrasive articles, such as in the form of a box.

As illustrated in the cross section, the wall <NUM> is formed of a packaging material <NUM>. In an embodiment, the packaging material <NUM> can be rigid such that the packaging material <NUM> can be self-supporting. A self-supporting packaging material <NUM> is a material that can stand on its own absent additional support. For example, the self-supporting packaging material <NUM> can stand on its own (e.g., under its own weight without external forces) without deviating more than <NUM>% in either direction from a longitudinal dimension extending from top to bottom of the self-supporting material <NUM> when viewed in cross-section.

In an embodiment, the packaging material <NUM> can have a particular water vapor transmission rate that can facilitate improved packaging and storage of abrasive articles. For instance, the packaging material <NUM> can have a water vapor transfer rate (WVTR) of at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, or at most <NUM>/m<NUM>-day. In another instance, the WVTR can be <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, or at least <NUM>/m<NUM>-day. Moreover, the WVTR of the packaging material can be in a range including any of the minimum and maximum values noted herein. For instance, the WVTR of the packaging material <NUM> can be in a range from <NUM>/m<NUM>-day to <NUM>/m<NUM>-day or in a range from <NUM>/m<NUM>-day to <NUM>/m<NUM>-day. As used herein, the WVTR can be determined using ASTM F1249 (Standard Test Method for Water Vapor Transmission Rate Through Plastic Film and Sheeting Using a Modulated Infrared Sensor) at <NUM> and <NUM>% relative humidity (RH). Alternatively, the water vapor transfer rate (WVTR) can be approximated using the material properties of the packaging material.

In an embodiment, the packaging material <NUM> can include an organic material, an inorganic material, or any combination thereof. In another embodiment, the packaging material <NUM> can consist essentially of an organic material. An exemplary organic material can include a thermoset or thermoplastic material. In a particular embodiment, the packaging material <NUM> can include a natural or a synthetic plastics material. For instance, the packaging material <NUM> can consist essentially of a plastics material. In still another embodiment, the packaging material <NUM> can include a polymer, or consist essentially of a polymer. An exemplary polymer can include polypropylene, polyethylene, polyvinyl chloride, or any combination thereof. An exemplary polyethylene can include linear low density polyethylene (LLDPE), low density polyethylene (LDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), ultra high density polyethylene (UHDPE), or any combination thereof. In another example, the polymer can include polyester, such as a polyethylene terephthalate, liquid crystal polymer (e.g., aromatic polyester polymers), or any combination thereof. In a particular embodiment, the packaging material <NUM> can include polypropylene, and more particularly, the packaging material <NUM> can consist essentially of polypropylene. In another particular embodiment, the packaging material can consist essentially of polyethylene, such as any of the polyethylene noted herein or a combination thereof.

In another example, the packaging material <NUM> can include an inorganic material, such as an elemental metal, an alloy, or a combination thereof. For example, the packaging material <NUM> can include iron, nickel, chromium, aluminum, tin, copper, or any combination thereof. In another instance, the packaging material <NUM> can include steel, stainless steel, tin-coated steel, plastic-coated steel, or the like.

In a particular embodiment, the packaging material <NUM> can have a multilayer construction. <FIG> includes an illustration of an example of the packaging material <NUM> including a self-supporting material <NUM>. As illustrated, the self-supporting material <NUM> includes a support material <NUM> and a barrier material <NUM>. In an example, the barrier material <NUM> can include a material similar to the packaging material <NUM>. In another instance, the barrier material <NUM> can include a barrier film, such as a polymer-containing film, a metal-containing film, a metal foil, a metal coated in a polymer film, or any combination thereof. Metal and polymer can include any of the metal or polymers noted above, respectively. An exemplary polymer-containing film can include a polyethylene film, PET film, polypropylene film, or the like. A metal-containing film can include a metalized polymer film, such as a metalized PET film. An exemplary metal foil can include an aluminum foil. In a further embodiment, the barrier film can have a thickness of at least <NUM> microns. For example, the thickness can be at least <NUM> microns, such as at least <NUM> microns, at least <NUM> microns, or even at least <NUM> microns. In another instance, the thickness can be at most <NUM>, such as at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM>. Moreover, the thickness of the barrier material <NUM> can have a thickness in a range including any of the minimum and maximum values noted herein. For instance, an aluminum foil can have a thickness of at least <NUM> microns. A typical metallized polymeric film differs from a metal foil, as a metalized film typically includes metal layer thickness on the order of less than <NUM> nanometers. While a single layer of the barrier material <NUM> is illustrated, the barrier material <NUM> can include more than one layer, such as including a plurality of films. In at least one embodiment, the packaging material <NUM> forms a single layer.

In an embodiment, the barrier material <NUM> can be secured to the support material <NUM> through lamination or with an adhesive (not shown). An exemplary support material <NUM> can include a thermoplastic material, a cured elastomer, a fibrous material, or any combination thereof. An exemplary fibrous material can include an impregnated glass fiber material. In another example, a fibrous material includes a pulp material, such as a paper product, a cardboard, or any combination thereof. In another example, the support material includes a thermoplastic material in a thickness to provide desirable self-supporting characteristics of the support material <NUM>. In an example, the thermoplastic material includes polyolefin, polyvinylchloride, polyester, ethylene vinyl acetate copolymer, polyvinylidene chloride, polystyrene, acrylic polymer, vinyl acetate, polyamide, polycarbonate, a copolymer thereof, or any combination thereof. For example, the thermoplastic material can be a polyolefin material, such as polyethylene, polypropylene, ethylene propylene copolymer, ethylene butene copolymer, ethylene octene copolymer, olefinic block copolymers, polyvinyl butyral, or any combination thereof. An exemplary polyethylene can include linear low density polyethylene (LLDPE), low density polyethylene (LDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), ultra high density polyethylene (UHDPE), or any combination thereof. In a further example, the support material <NUM> includes a cured elastomer. An exemplary cured elastomer includes a diene elastomer such as an ethylene propylene diene monomer (EPDM) elastomer. In an embodiment, the barrier material can form the interior surface of the package and support material can form the exterior surface of the package. In another embodiment, the barrier material can form the exterior surface and the support material can form the interior surface.

The top <NUM> can be secured to the wall <NUM> by for example, a friction fit or press fit. In another example, the top <NUM> can be secured to the wall <NUM> using a screw top configuration. Alternatively, the top <NUM> can include a peel tab to reveal an opening to allow an abrasive article to be taken out of the package, and in some particular instances, the peel tab may be pressed on to reclose the package. In an example, the top <NUM> can be formed of a material similar to the wall <NUM>. In an alternative example, the top <NUM> can be formed of a material different from the wall <NUM>.

The wall <NUM>, the top <NUM>, and the bottom <NUM> form an enclosed volume <NUM> within which the abrasive articles <NUM> and a desiccant <NUM> are contained. In an embodiment, the desiccant <NUM> can include a silicate, such as silicate minerals including metal ions. Exemplary metal ions can include aluminum, magnesium, iron, or any combination thereof. A further exemplary silicate can include aluminosilicate.

In another embodiment, the desiccant <NUM> can include a crystalline material, such as a polycrystalline or monocrystalline material. In another embodiment, the desiccant <NUM> can include a polycrystalline material having a layered crystalline structure. For instance, the desiccant <NUM> can include alternating crystal sheets formed of anions, cations, or any combination thereof. The alternating crystal sheets can include sheets having different structures, such as tetrahedral sheets alternating with octahedral sheets. In a particular example, the layered crystalline structure can include a plurality of units, wherein each unit can include at least one tetrahedral sheet and at least one octahedral sheet. In a further example, each unit can include a ratio of tetrahedral to octahedral crystal sheets, such as <NUM>: <NUM> or <NUM>:<NUM>. In another particular example, the desiccant <NUM> can include a <NUM>:<NUM> ratio of tetrahedral to octahedral crystal sheets. In another instance, the desiccant <NUM> can include an interlayer between adjacent units, wherein the interlayer can include H<NUM>O, cations, or any combination thereof. An exemplary cation can include calcium ions, sodium ions, potassium ions, or any combination thereof. In a particular instance, the desiccant <NUM> can include an interlayer including calcium ions. More particularly, calcium ions can make up most of the cations in the interlayer, and even more particularly, the cations in the interlayer can consist essentially of calcium ions.

<FIG> includes an illustration of a portion of a layered crystalline structure of an example of the desiccant <NUM>. The crystalline structure can include a unit <NUM> including tetrahedral sheets <NUM> and <NUM> alternating with an octahedral sheet <NUM>. An interlayer <NUM> is between the unit <NUM> and an adjacent unit in which only a tetrahedral sheet <NUM> is illustrated. The tetrahedral sheet, <NUM>, <NUM>, and <NUM>, can include oxygens <NUM> and silicon <NUM>. Some silicon may be substituted by aluminum <NUM>. The octahedral sheet <NUM> can include hydroxyl <NUM> and metal cations <NUM>, such as aluminum, iron, magnesium, or any combination thereof.

In a further embodiment, the desiccant <NUM> can include molecular sieves, clay, or any combination thereof. Exemplary clay can include a smectite, such as a bentonite or a montmorillonite, a sepiolite, or any combination thereof. In a particular example, clay can include a <NUM>:<NUM> ratio of tetrahedral to octahedral crystal sheets. In another example, the desiccant <NUM> can include bentonite, montmorillonite, sepiolite, or any combination thereof. In another particular example, the desiccant <NUM> can consist essentially of at least one of bentonite, montmorillonite, and sepiolite. For instance, the desiccant <NUM> can consist essentially of bentonite. In another instance, the desiccant <NUM> can consist essentially of montmorillonite. In still another instance, the desiccant <NUM> can consist essentially of sepiolite.

In an embodiment, the desiccant <NUM> can include a particular amount of calcium ions that can facilitate reduced water vapor adsorption and improved storage of the abrasive article. According to the invention the calcium ions are in a content of at least <NUM> ppm of the total weight of the desiccant, such as at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, at least <NUM> ppm, or at least <NUM> ppm for the total weight of the desiccant. Further, according to the invention the calcium ions are at most <NUM> ppm of a total weight of the desiccant, such as at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, at most <NUM> ppm, or at most <NUM> ppm. Moreover, the content of calcium ions can be within a range including any of the minimum and maximum values noted herein. The content of calcium ions is in a range from <NUM> ppm to <NUM> ppm. In a particular example, the desiccant <NUM> can include clay having calcium ions in a content noted herein, or more particularly, the desiccant <NUM> can include bentonite having calcium ions in a content noted herein.

In at least one embodiment, the package <NUM> can optionally include an additional desiccant. The additional desiccant can be similar to the desiccant <NUM>. Alternatively, the additional desiccant can include a metal oxide or hydroxide scavenger, a metal sulfate scavenger, a metal halide scavenger, a metal silicate, other inorganic scavengers, an organometallic scavenger, a metal ligand, organic scavengers, or any combination thereof. In an instance, a metal includes an alkali metal, such as lithium; an alkaline earth metal, such as beryllium, calcium, magnesium, or barium; a transition metal, such as iron, manganese, palladium, zirconium, cobalt, copper, zinc, titanium, or chromium; other metals, such as aluminum; alloys thereof, or any combination thereof. An exemplary metal oxide scavenger includes dehydrated or partially dehydrated oxides of the above metals, such as calcium oxide, barium oxide, cobalt oxide, magnesium oxide, alumina, titanium oxide, zirconia, zinc oxide, or any combination thereof. An exemplary metal halide can include a halide or perchlorate of a metal listed above, or an exemplary metal sulfate can include a sulfate of a metal listed above, such as sodium sulfate, calcium sulfate, barium sulfate, copper sulfate, or any combination thereof. Another inorganic scavenger can include a montmorillonite clay, a zeolite, activated carbon, silica gel, alumina gel, bauxite, or any combination thereof.

In a further embodiment, the package <NUM> can include a certain amount of desiccant that can facilitate reduced water vapor adsorption and improved storage of the abrasive article. In an aspect, the package <NUM> can include desiccant in desiccant units relative to a weight of the abrasive articles contained within the package <NUM>. For instance, the package <NUM> can include at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles. As used herein, the units of desiccant is determined in accordance with Standard NFH <NUM>. In another instance, the package <NUM> can include at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, or at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles. Additionally, or alternatively, the package <NUM> can include at most <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, such as at most <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at most <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, at most <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles, or at most <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles. Moreover, the package <NUM> can include desiccant in an amount including any of the minimum and maximum values noted herein. For instance, the package <NUM> can include desiccant in a range including at least <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles and at most <NUM>/<NUM> UD NFH per <NUM> grams of abrasive articles.

In another aspect, the package <NUM> can include a particular weight of desiccant relative to a weight of the abrasive articles contained within the package <NUM>. For example, the package <NUM> can include at least <NUM> grams of desiccant per gram of abrasive articles, such as at least <NUM> grams of desiccant per gram of abrasive articles, at least <NUM> grams of desiccant per gram of abrasive articles, at least <NUM> grams of desiccant per gram of abrasive articles, at least <NUM> grams of desiccant per gram of abrasive articles, at least <NUM> grams of desiccant per gram of abrasive articles, at least <NUM> grams of desiccant per gram of abrasive articles, at least <NUM> grams of desiccant per gram of abrasive articles, or at least <NUM> grams of desiccant per gram of abrasive articles. Alternatively or additionally, the package <NUM> can include at most <NUM> grams of desiccant per gram of abrasive articles, such as at most <NUM> grams of desiccant per gram of abrasive articles, at most <NUM> grams of desiccant per gram of abrasive articles, at most <NUM> grams of desiccant per gram of abrasive articles, at most <NUM> grams of desiccant per gram of abrasive articles, at most <NUM> grams of desiccant per gram of abrasive articles, at most <NUM> grams of desiccant per gram of abrasive articles, at most <NUM> grams of desiccant per gram of abrasive articles, at most <NUM> grams of desiccant per gram of abrasive articles, or at most <NUM> grams of desiccant per gram of abrasive articles. Moreover, the package <NUM> can include desiccant in an amount including any of the minimum and maximum values noted herein.

In an embodiment, the package <NUM> can include at least one abrasive article, such as at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM> abrasive articles. In another instance, the package <NUM> can include at most <NUM> abrasive articles, such as at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM> abrasive articles. Moreover, the number of abrasive articles contained in the package <NUM> can be in a range including any of the minimum and maximum values noted herein.

In an embodiment, the package <NUM> can include a certain weight of abrasive articles, such as at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, at least <NUM> grams, or at least <NUM> grams of abrasive articles. In another instance, the package <NUM> can include at most <NUM> grams of abrasive articles, such as at most <NUM> grams, at most <NUM> grams, at most <NUM> grams, or at most <NUM> grams. Moreover, in some instances, the package <NUM> can contain abrasive articles having a weight in a range including any of the minimum and maximum values noted herein.

In some instances, the number or weight of the abrasive articles contained in the package may be higher or lower than values noted in embodiments herein. It is to be understood that the weight and number of abrasive articles contained within the package can vary to suit the need of particular applications, and desiccant included in the package can be adjusted taking into consideration, for example, the weight of the abrasive articles, characteristics of the packaging material, and/or the environment the package is to be exposed to.

In an embodiment, the abrasive articles <NUM> can include a bonded abrasive article. An exemplary bonded abrasive article can include an ultra-thin wheel, a grinding wheel, a combination wheel, a cutoff wheel, a cutting wheel, or any combination thereof. As illustrated, the package <NUM> includes a plurality of abrasive articles <NUM> that are stacked on top of one another.

In an embodiment, the abrasive article <NUM> can have a thickness, defined parallel to an axis of the abrasive article <NUM> and orthogonal to a radial dimension. The thickness can be in a range of <NUM> to <NUM>, such as a range of <NUM> to <NUM>, or even a range of <NUM> to <NUM>. In another embodiment, the abrasive article can have a diameter in a range of <NUM> to <NUM>, such as a diameter in a range of <NUM> to <NUM>, or even a range of <NUM> to <NUM>. In still another embodiment, the abrasive article can have an aspect ratio, defined as the ratio of the diameter to the thickness, in a range of <NUM> to <NUM>, such as a range of <NUM> to <NUM>, a range of <NUM> to <NUM>, or even a range of <NUM> to <NUM>.

<FIG> includes an illustration of a cross section of a cutting wheel, an example of the abrasive articles <NUM>. The abrasive article includes a body <NUM> and a mounting hole <NUM>. As illustrated, the body <NUM> includes a first major surface <NUM>, a second major surface <NUM> opposite the first major surface <NUM>, and a peripheral surface <NUM> extending between the first and second major surfaces <NUM> and <NUM>.

In an embodiment, the body <NUM> can include a bond material and abrasive particles contained within the bond material. In an example, the bond material can include an organic material, such as a resin-based material. A non-limiting example of resin can include phenolic resin, boron-modified resin, nano-particle-modified resin, urea-formaldehyde resin, acrylic resin, epoxy resin, polybenzoxazine, polyester resin, isocyanurate resin, melamine-formaldehyde resin, polyimide resin, other suitable thermosetting or thermoplastic resins, or any combination thereof. An exemplary phenolic resin can include resole and novolac. In another instance, the bond material can include an inorganic material including a hygroscopic material. Such hygroscopic material can absorb water over time as it traverses the packaging material <NUM>. It is believed that after moisture in the product exceeds certain level, the grinding performance such as, grinding and cutting can be degraded.

The abrasive articles <NUM> can be formed utilizing techniques known in the art. For instance, the body <NUM> can include abrasive particles known in the art, such as abrasive particles including silica, alumina (fused or sintered), zirconia, zirconialalumina oxides, silicon carbide, garnet, diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide, titanium diboride, boron carbide, tin oxide, tungsten carbide, titanium carbide, iron oxide, chromia, flint, emery, dolomite, or any combination thereof. The body <NUM> can optionally include an additive including such as a filler material, secondary abrasive particles, or the like. The fillers can include active and/or inactive fillers. A non-exhaustive list of active fillers can include Cryolite, PAF (a mixture of K<NUM>AlF<NUM> and KAlF<NUM>), KBF<NUM>, K<NUM>SO<NUM>, barium sulfate, sulfides (FeS<NUM>, ZnS), NaCl/KCl, low melting metal oxides, or combinations thereof. A non-exhaustive list of inactive fillers can include CaO, CaCO<NUM>, Ca(OH)<NUM>, CaSiO<NUM>, Kyanite (a mixture of Al<NUM>O<NUM>-SiO<NUM>), Saran (Polyvinylidene chloride), Nephenline (Na, K) AlSiO<NUM>, wood powder, coconut shell flour, stone dust, feldspar, kaolin, quartz, other forms of silica, short glass fibers, asbestos fibers, balotini, surface-treated fine grain (silicon carbide, corundum etc.), pumice stone, cork powder and combinations thereof. The secondary abrasive grains can include, for example, ceramic oxides (e.g., coated or non-coated fused Al<NUM>O<NUM>, monocrystal Al<NUM>O<NUM>), minerals (e.g., garnet and emery), nitrides (e.g., Si<NUM>N<NUM>, AlN) and carbides (e.g., SiC).

Further, the abrasive article <NUM> can include one or more reinforcement layers. A reinforcement layer can be made of any number of various materials. An exemplary reinforcement layer can include a polymeric film (including primed films), such as a polyolefin film (e.g., polypropylene including biaxially oriented polypropylene), a polyester film (e.g., polyethylene terephthalate), or a polyamide film; a cellulose ester film; a metal foil; a mesh; a foam (e.g., natural sponge material or polyurethane foam); a cloth (e.g., cloth made from fibers or yams comprising fiberglass, polyester, nylon, silk, cotton, poly-cotton or rayon); a paper; a vulcanized paper; a vulcanized rubber; a vulcanized fiber; a nonwoven material; or any combination thereof, or treated versions thereof. A cloth backing can be woven or stitch bonded. In particular examples, the reinforcement layer can be selected from a group consisting of paper, polymer film, cloth, cotton, poly-cotton, rayon, polyester, poly-nylon, vulcanized rubber, vulcanized fiber, fiberglass fabric, metal foil or any combination thereof. In other examples, the reinforcement layer includes a woven fiberglass fabric.

<FIG> includes an illustration of another exemplary package <NUM> including a packaging material <NUM> defining an enclosed volume <NUM> in which abrasive articles <NUM> and desiccant <NUM> are disposed. As illustrated, the package is in the form of a bag, such as a pouch. In an embodiment, the pouch can be vacuum sealable. In another embodiment, an insert, such as a cardboard insert or a stiff polymeric insert, can be provided in the pouch or can be formed to one side of the pouch. In a particular example, the package <NUM> can be configured to reseal after opening, for example, using fastening structures <NUM>.

In at least one embodiment, at least one desiccant <NUM> can be contained within the enclosed volume <NUM>. The desiccant <NUM> can be similar to the desiccant <NUM>. The abrasive articles <NUM> can be similar to the abrasive articles <NUM>. In <FIG>, the abrasive articles <NUM> are illustrated as thin cutting wheels.

In an embodiment, the packaging material <NUM> can include a material that is similar to the packaging material <NUM>. In another embodiment, the packaging material <NUM> can include at least one barrier film. For instance, the packaging material <NUM> can include a metalized PET film. In another instance, the packaging material can include a PE film, such as a co-extruded PE film. In a particular example, the packaging material <NUM> can include a metalized PET film and a co-extruded PE film. In another embodiment, the packaging material <NUM> can include a plurality of layers. <FIG> includes an illustration of an example of the packaging material <NUM> including a barrier material <NUM> and optionally a support material <NUM>. The barrier material can be similar to the barrier material <NUM>, such as including barrier films noted herein.

In an embodiment, the support layer <NUM> can provide structural integrity to the barrier layer <NUM> or can enhance mechanical properties of the packaging material <NUM>. In another embodiment, the support layer <NUM> can act to bond to itself to form a seal. In an example, the support layer <NUM> can include a thermoplastic material such as acrylic, vinyl acetate, ethylene vinyl acetate copolymer, polyester, polyolefin, polyamide, polycarbonate, polyvinylchloride, polyvinylidene chloride, polystyrene, or any copolymer, blend or combination thereof. An exemplary polyolefin includes polyethylene, polypropylene, ethylene propylene copolymer, ethylene butene copolymer, ethylene octene copolymer, olefinic block copolymers, polyvinyl butyral, or any combination thereof. An exemplary polyethylene includes linear low density polyethylene (LLDPE), low density polyethylene (LDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), or any combination thereof. In particular, the thermoplastic material can be a melt adhesive that can be melted in locations and bonded to an opposing sheet material to form a seal around an enclosed volume. Alternatively, a melt adhesive can be placed proximal to locations at which a seal is to be formed, such as along an edge of the packaging material <NUM>.

In another embodiment, the packaging material <NUM> can have a WVTR similar to the WVTR of the packaging material <NUM>. In still another embodiment, the packaging material <NUM> can have a WVTR of at most <NUM>/m<NUM>-day, such as at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, at most <NUM>/m<NUM>-day, or at most <NUM>/m<NUM>-day. Alternatively or additionally, the WVTR of the packaging material can be at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, at least <NUM>/m<NUM>-day, or at least <NUM>/m<NUM>-day. Moreover, the WVTR of the packaging material can be in a range of <NUM>/m<NUM>-day to <NUM>/m<NUM>-day or in a range of <NUM>/m<NUM>-day to at most <NUM>/m<NUM>-day.

The package described in embodiments herein can notably reduce moisture (e.g., water vapor) uptake of the bonded abrasive articles contained therein, which can help to reduce the likelihood of degradation of performance, such as G-ratio, of the abrasive articles. In an example, the package allows the abrasive articles contained therein to have a Relative G-Ratio of at least <NUM> after exposing the package in the condition of <NUM> and <NUM>% relative humidity (RH) for at least <NUM> days, such as at least <NUM> days, or at least <NUM> days. In another instance, the Relative G-Ratio can be at least <NUM>, such as at least <NUM>, at least <NUM>, at least <NUM>, or even at least <NUM>, such as approximately <NUM> for any of the exposure time period noted herein. The Relative G-Ratio is determined by dividing the G-Ratio of the abrasive article after exposure by the G-Ratio of the dry abrasive article prior to exposure. As used herein, a dry abrasive article refers to the abrasive article that has been dried at <NUM> for <NUM> hours.

Moisture uptake of the abrasive articles contained in the package can be determined as follows. The package can be exposed to the condition of <NUM> and <NUM>% RH over at least <NUM> days, such as <NUM> days, <NUM> days, <NUM> days, or an even longer period of time. The percentage of the weight change of the abrasive article is used as moisture uptake, Wu, in this disclosure, and determined by the formula Wu=[(Wa-Wo)/Wo]×<NUM>%, where Wo is the weight of the abrasive article prior to exposure and Wa is the weight after the exposure. In an embodiment, the abrasive article can have a moisture uptake of at most <NUM>% or at most <NUM>% or at most <NUM>% when the package is exposed to <NUM>% relative humidity at <NUM> for <NUM> days. In another embodiment, the bonded abrasive article can have a moisture uptake of at most <NUM>% or at most <NUM>% or at most <NUM>% when the package is exposed to <NUM>% relative humidity at <NUM> for <NUM> days. In still another embodiment, the bonded abrasive article can have a moisture uptake of at most <NUM>% or at most <NUM>% or at most <NUM>% when the package is exposed to <NUM>% relative humidity at <NUM> for <NUM> days.

In a further embodiment, the abrasive article can have a moisture uptake of at most <NUM>% when the package is exposed to air at <NUM> to <NUM> for a certain period of time, such as at least <NUM> month, at least <NUM> months, at least <NUM> months, at least <NUM> months, at least <NUM> months, at least <NUM> months, or at least <NUM> months. In an aspect, the abrasive article can have a moisture uptake of at most <NUM>% or at most <NUM>% or at most <NUM>% or at most <NUM> or at most <NUM>% or at most <NUM>% when the package is exposed to air at <NUM> to <NUM> for at least <NUM> month, such as at least <NUM> months, at least <NUM> months, at least <NUM> months, at least <NUM> months, at least <NUM> months, or at least <NUM> months. For example, the bonded abrasive article can have a moisture uptake of at most <NUM>% or at most <NUM>% when the package is exposed to air at <NUM> to <NUM> for least <NUM> month. In another example, the bonded abrasive article can have a moisture uptake of at most <NUM>% when exposed to air at <NUM> to <NUM> for least <NUM> month, at least <NUM> months, or at least <NUM> months.

In an embodiment, the package can include a plurality of abrasive articles, such as at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM> abrasive articles. In accordance with these embodiments, the abrasive articles in the package can have an average moisture uptake including any values of moisture uptake described in embodiments herein. The term, average moisture uptake, is intended to refer to an average of moisture uptake of all the abrasive articles contained in the same package.

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. The scope of the invention is limited by the appended claims.

Commercially available Gemini Right Cut cutoff wheels and different desiccants were placed into plastic buckets made of polypropylene. Each bucket contained <NUM> of bentonite clay including different contents of calcium ions and <NUM> cutoff wheels. The contents of calcium ions are included in Table <NUM>. The buckets were closed with lids made of polypropylene. All the buckets were exposed to <NUM>% RH and <NUM> for <NUM> days, and moisture uptake of the abrasive articles were determined as noted in this disclosure. <FIG> includes a bar graph of moisture uptake of samples S1 and S2.

As illustrated in <FIG>, the critical moisture uptake is <NUM>% and indicated by the dotted line. When the moisture uptake is beyond the critical level, <NUM>%, performance degradation of abrasive articles is expected. S1 demonstrated the average moisture uptake of <NUM>%, while S2 had <NUM>%.

Samples S3 to S7 were formed by placing commercially available Gemini Right Cut cutoff wheels and different desiccants into plastic buckets made of polypropylene that had the WVTR of <NUM>/m<NUM>-day determined by ASTM F1249 as disclosed in embodiments herein. Table <NUM> includes package information of the samples. Each bucket of samples S3 to S7 contained <NUM> of desiccant and <NUM> cutoff wheels. A set of <NUM> wheels were not packaged, and another set were placed into the bucket without desiccant. The buckets were closed with lids made of polypropylene that had the WVTR of <NUM> to <NUM>/m<NUM>-day determined by ASTM F1249 as disclosed in embodiments herein. All the buckets and unpacked wheels were exposed to <NUM>% RH and <NUM> and moisture uptake of the abrasive articles over <NUM> days, <NUM> days, <NUM> days, <NUM> days were determined, respectively.

<FIG> includes a bar graph of moisture uptake of samples C1, C2, and S3 to S7, and the average moisture uptake of the wheels are included in Table <NUM>.

Samples C1, C2, and S7 had moisture uptake above the critical level, <NUM>%, over the <NUM>-day exposure. Over the prolonged exposure time, e.g., <NUM> days and <NUM> days, samples S3 and S5 demonstrated moisture uptake less than the critical level. For the shorter exposure time, <NUM> days and <NUM> days, samples S4 and S6 had moisture uptake less than the critical level, but moisture uptake increased over time to higher than the critical level at day <NUM> and <NUM>.

Commercially available Gemini Right Cut cutoff wheels and different desiccants were sealed in bags to form samples S8 to S15 as disclosed in Table <NUM>. The bags were formed using laminated films including a metalized PET film and coextruded PE film. The laminated films had the WVTR of <NUM>/m<NUM>-day. Each bag of samples S8 to S15 contained <NUM> of desiccant and <NUM> cutoff wheels. A set of <NUM> wheels were not packaged, and another set were sealed in the bag without desiccant. All the samples were exposed to <NUM>% RH and <NUM> and moisture uptake of the abrasive articles over <NUM> days were determined and illustrated in <FIG>.

<FIG> includes a bar graph of moisture uptake of samples C3, C4, and S8 to S15. As illustrated, samples S8, S9, and S15 had moisture uptake less than the critical level, <NUM>% (dotted line in <FIG>), while the others had higher moisture uptake.

Cutoff wheels having an average weight of about <NUM> grams and different amounts of bentonite including <NUM> ppm of calcium ions were placed in buckets formed with polypropylene to form different package Samples S19 to S23. Each package included <NUM> wheels. Package Samples S19 to C23 were exposed to the aging condition of <NUM>% RH and <NUM> for <NUM> days, <NUM> days, or <NUM> days. After exposure, average G-ratio and average material removal rate of each of Samples S19 to S23 was determined by performing a grinding test of the wheels on stainless steel workpieces. At least <NUM> wheels that were not exposed but were refreshed by drying at <NUM> for <NUM> hours (referred to as CS16 hereinafter) were tested in the same grinding condition for determining average G-ratio and average material removal rate of CS16.

Twenty-five wheels were packed in a carton box without desiccant to form Sample CS17. Another <NUM> wheels were packed in the same type of polypropylene bucket as Samples S19 to S23 without desiccant to form Sample CS18. Samples CS17 and CS18 were exposed to the same aging condition and tested in the same grinding conditions as Samples S19 to S23 for determining their respective average G-ratio and material removal rate.

The average G-ratio and average material removal rate of all Samples were divided by the average G-ratio and average material removal rate of CS16, respectively, and the resulted relative G-ratio and relative material removal rate of all the samples are disclosed in Table <NUM> below. Relative G-ratio of Sample S19 is comparable to that of Sample CS16 after the <NUM>-day, <NUM>-day, and <NUM>-day exposure to the aging condition.

SB4® wheels (available from Saint-Gobain Abrasives) having the dimension of 125X1. <NUM> were refreshed at <NUM> for <NUM> hours and weighed (Wo). Two refreshed wheels, referred to as CS24, were subjected to a grinding operation performed on a stainless steel workpiece for evaluation of G-Ratio and Material Removal Rate (MRR). Every <NUM> wheels were packed in a carton box without a desiccant to form Samples CS25 or in a polypropylene bucket containing <NUM>/<NUM> UD NFH of bentonite including <NUM> ppm of calcium ions to form Samples S <NUM>, respectively. All the CS25 and S26 Samples were stored in air at <NUM> to <NUM> for up to <NUM> months to allow the wheels to age naturally. Aged Samples were weighed (Wa) to determine moisture uptake according to embodiments described herein, and G-Ratio and MRR of aged Samples was tested in the same manner as described with respect to CS24.

<FIG> includes a plot illustrating moisture uptake of Samples CS25 and S26 after aging for <NUM> month, <NUM> months, <NUM> months, <NUM> months, and <NUM> months. Sample S26 demonstrated significantly reduced moisture uptake compared to Sample CS25 for all tested aging times. For up to <NUM> months, moisture uptake of Sample S26 was below the critical level <NUM>%, while moisture uptake of Sample CS25 exceeded the critical level when stored over <NUM> months.

<FIG> includes a plot of G-Ratio and MMR of all the Samples. As illustrated, Sample S26 had similar G-Ratio and MMR for each tested time period compared to refreshed Sample CS24, while Sample CS25 demonstrated increased loss in both G-Ratio and MRR over time.

The present embodiments represent a departure from the state of the art. It was unexpectedly and surprisingly discovered that packages including certain desiccant can facilitate significantly improved and extended protection of abrasive articles from moisture uptake, which can be expected to improve performance of the abrasive tool over time and mitigate aging. In particularly instances, the use of certain desiccant in combination with packaging materials that have a relatively higher water vapor transmission rate can unexpectedly improve water vapor uptake of abrasive tools after extended exposure to humidity. Certain characteristics of desiccant (e.g., particular calcium ion contents and/or crystalline structures) in combination with packaging materials are considered to contribute to improved moisture resistance function of the packages.

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 <NUM>%.

Claim 1:
An article, comprising a package (<NUM>, <NUM>) including:
a packaging material (<NUM>, <NUM>) defining an enclosed volume (<NUM>, <NUM>); and
a desiccant (<NUM>, <NUM>) contained within the enclosed volume (<NUM>, <NUM>); and
a bonded abrasive article (<NUM>, <NUM>) contained within the enclosed volume (<NUM>, <NUM>),
wherein the desiccant (<NUM>, <NUM>) comprises a layered crystalline structure and calcium ions,
characterized in that the calcium ions are present in an amount of at least <NUM> ppm and at most <NUM> ppm of a total weight of the desiccant (<NUM>, <NUM>).