Patent Description:
Certain construction materials, such as clay bricks, can be formed with substantial dimensional variations from brick-to-brick. Modern techniques for assembly a plurality of bricks together typically require that such bricks conform to particular dimensional tolerances, which can be performed by a grinding operation. A typical grinding operation can include the passing of a brick through a grinding apparatus including two grinding rings on opposing sides of the brick for grinding two opposite faces of the brick at the same time. Such a grinding operation can introduce surface imperfections on the brick and can also cause wear on the grinding ring, particularly the abrasive segments of the grinding ring. Imperfections in the brick and wear on the abrasive segment can be manifested in the form of cracks or fractures. Improvements to abrasive segments of grinding rings are needed to reduce imperfections in construction materials having undergone a grinding operation and wear of abrasive segments performing the grinding operation. <CIT> describes a cup grinding wheel having a substantially circular main wheel and a plurality of grinding segments. The grinding segments each have a V shape that is open towards the outside in the radial direction. The V shape is formed in each case by two arms of the grinding segment. The arms can be arranged in an axially symmetric manner to a respective axis of symmetry extending in the radial direction, in particular the respective arms of a grinding segment are in contact towards the inside in the radial direction. Passages that narrow in a funnel-like manner in the radial direction are formed between the grinding segments by respective outer edges of the arms.

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 use of the same reference symbols in different drawings indicates similar or identical embodiments. The present invention refers to an abrasive article according to independent claim <NUM>. Further advantageous features of the abrasive article are described in the dependent claims.

The following is generally directed to abrasive articles, and more particularly, segmented grinding wheels and segmented grinding rings used to grind industrial materials such as ceramic, stone, concrete, and/or brick. In particular, the following abrasive articles disclosed herein may be useful for finishing of building materials.

<FIG> includes a perspective view illustration of a base of an abrasive article in accordance with the invention. As illustrated, an abrasive article <NUM> includes a grinding ring having a base <NUM>. The base <NUM> has a cylindrical, three-dimensional shape. More particularly, the base <NUM> has an annular shape defining a central opening <NUM> extending through the base <NUM>. The central opening <NUM> is suitable for attachment of the base <NUM> to a machine equipped for rotation of the base <NUM> for carrying out shaping operations. For example, a spindle of a machine may be engaged within the central opening <NUM> of the base <NUM>, which may be in turn connected to a rotor suitable for rotating the base <NUM>.

In accordance with an embodiment, the base <NUM> can be made from an inorganic material, such as a metal or metal alloy. In certain instances, the base can be formed of a metal alloy such as steel. For example, the base <NUM> can include heat treatable steel alloys, such as 30CrNiMo8, 25CrMo4, 75Cr1, C60, or simple construction steel like St <NUM>, St <NUM>, and St <NUM>. The base <NUM> can have a tensile strength of at least about <NUM> N/mm<NUM>. It will be appreciated that the base <NUM> can be formed by a variety of metallurgical techniques known in the art.

As generally illustrated in <FIG>, the base <NUM> has a receiving surface <NUM> for receiving an abrasive segment and a rear surface <NUM> opposite the receiving surface <NUM> extending generally perpendicular to the rotation axis <NUM> and extending through a center point in the central opening <NUM>. The base <NUM> has an outer annular surface <NUM> extending generally axially between the receiving surface <NUM> and the rear surface <NUM>. The outer annular surface <NUM> also extends circumferentially around the base <NUM> defining the outer peripheral surface of the base <NUM>. Further, the base <NUM> has an inner annular surface <NUM> opposite the outer annular surface <NUM> and extending generally axially between the receiving surface <NUM> and the rear surface <NUM>. The inner annular surface <NUM> also extends circumferentially around inner diameter of the body of the base <NUM> defining the inner peripheral surface of the base <NUM>. It will be appreciated that the inner annular surface <NUM> can define the central opening <NUM> of the base <NUM>.

<FIG> includes a top view illustration of an abrasive article in accordance with the invention. As illustrated, the abrasive article <NUM> includes a grinding ring having a base <NUM> as generally described in <FIG>. The central opening <NUM> has a diameter than defines an inner diameter (ID) of the base <NUM>. The body of the base <NUM> includes an outer diameter (OD) extending through the center point, or rotation axis <NUM>, of the central opening <NUM> and between the outer annular surface <NUM> of the base <NUM>.

The inner diameter (ID) of the base <NUM> is defined by an inner radius of curvature, and the outer diameter (OD) is defined by an outer radius of curvature. The outer diameter (OD) can be greater than the inner diameter (ID), and the outer radius of curvature can be greater than the inner radius of curvature. The outer diameter (OD) of the base <NUM> can be at least about <NUM>, such as at least <NUM>, at least <NUM>, <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM> at least about <NUM>, at least about <NUM>, at least about <NUM>, or at least <NUM>. In a non-limiting embodiment, the outer diameter (OD) of the base <NUM> can be not greater than <NUM>, such as not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, or not greater than <NUM>. It will be appreciated that the outer diameter (OD) of the base <NUM> can be within a range between any minimum or maximum value noted above. In an embodiment, the outer diameter of the base <NUM> can be within a range between <NUM> and <NUM>. In a certain embodiment, the outer diameter of the base <NUM> can be within a range of between <NUM> and <NUM>.

<FIG> includes a close up plan view of a portion of the abrasive article of <FIG>, taken at Circle <NUM> of <FIG> and illustrating abrasive segments in accordance with an embodiment. As illustrated, a plurality of abrasive segments <NUM> is attached to the base <NUM> of the abrasive article <NUM>. The abrasive segments <NUM> can be brazed, or otherwise welded, affixed, coupled or attached to the base <NUM>. In accordance with another embodiment, the abrasive segments <NUM> can be attached to a mounting assembly, which in turn can be attached to the base <NUM>, as will be discussed further herein.

The abrasive article <NUM> includes a plurality of abrasive segments <NUM> coupled to the base <NUM>. For instance, the abrasive article <NUM> can include at least <NUM> abrasive segments <NUM> coupled to the base <NUM>, such as 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 segments <NUM> coupled to the base <NUM>. In a non-limiting embodiment, the abrasive article <NUM> can include not greater than <NUM> abrasive segments <NUM> coupled to the base <NUM>, such as not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, or not greater than <NUM> abrasive segments <NUM> coupled to the base <NUM>. It will be appreciated that the number of abrasive segments <NUM> coupled to the base <NUM> can be within a range between and including any minimum and maximum value noted above.

Referring to <FIG>, details concerning an abrasive segment <NUM> according to the invnetion are illustrated. Specifically, <FIG> includes a perspective view of the abrasive segment <NUM>; <FIG> includes a top plan view of the abrasive segment <NUM>; <FIG> includes a side plan view illustrating a third side surface portion <NUM> of the abrasive segment <NUM>; and <FIG> includes a side plane view illustrating a first side surface portion <NUM> of the abrasive segment <NUM>. As illustrated in <FIG>, the abrasive segment <NUM> includes a body <NUM>. The body <NUM> of the abrasive segment <NUM> includes abrasive grains contained within a matrix material. Notably, the abrasive segment <NUM> can be a bonded abrasive article wherein the abrasive grains are contained within a three-dimensional matrix of material. The abrasive grains can include an abrasive particulate material having a Mohs hardness of at least <NUM>, such as at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or even at least <NUM>. In certain instances, the abrasive grains can include a superabrasive material, such as diamond, cubic boron nitride, or a combination thereof. In one embodiment, the abrasive grains consist essentially of diamond.

The abrasive particles can be selected to have a particle size of not less than about <NUM> mesh, such as not less than about <NUM> mesh, such as between about <NUM> and <NUM> mesh. Further, depending on the intended application of the abrasive article, the size of the abrasive grains can be between about <NUM> and <NUM> mesh.

The matrix material of the abrasive segment <NUM> can include an inorganic material, such as a vitreous bond, metal bond, metal alloy bond, and a combination thereof. In particular instances, the matrix material may include a metal or metal alloy, and particularly, can be formed from a transition metal element or even a combination of transition metal elements.

The abrasive segment <NUM> can be an infiltrated bonded abrasive article. In such instances, the abrasive segment <NUM> can include abrasive grains contained within a metal matrix, wherein the abrasive segment <NUM> further includes an interconnected network of pores, which can be filled with an infiltrant material. The metal matrix can include a metal element or metal alloy including a plurality of metal elements.

As noted above, the abrasive segment <NUM> can be formed such that an infiltrant is present within the interconnected network of pores within the body <NUM> of the abrasive segment <NUM>. The infiltrant can partially fill, substantially fill, or even completely fill the volume of the pores extending through the volume of the abrasive segment <NUM>. In accordance with one particular design, the infiltrant can be a metal or metal alloy material.

As illustrated in <FIG>, the body <NUM> of the abrasive segment <NUM> includes a top surface <NUM>, a bottom surface <NUM> opposite the top surface <NUM>, a first side surface portion <NUM> and a second side surface portion <NUM> opposite the first side surface portion <NUM>. In accordance with an embodiment, the abrasive segment <NUM> can be mounted on the base <NUM> of the grinding ring <NUM> such that the second side surface portion <NUM> faces the rotation axis <NUM> and the first side surface portion <NUM> faces away from the rotation axis <NUM>. The first side surface portion <NUM> and the second side surface portion <NUM> can each extend between the top surface <NUM> and the bottom surface <NUM>. The body <NUM> of the abrasive segment <NUM> can further include a third side surface portion <NUM> and a fourth side surface portion <NUM> opposite the third side surface portion <NUM>. The third side surface portion <NUM> and the fourth side surface portion <NUM> can also each extend between the top surface <NUM> and the bottom surface <NUM>. The body <NUM> of the abrasive segment <NUM> can also include bevel side surface portions <NUM> extending between top surface <NUM> and the bottom surface <NUM>.

The body <NUM> of the abrasive segment <NUM> also includes bevel side surface portions <NUM> extending between the first side surface portion <NUM> and the third side surface portion <NUM>, between the third side surface portion <NUM> and the second side surface portion <NUM>, between the second side surface portion <NUM> and the fourth side surface portion <NUM>, and between the fourth side surface portion <NUM> and the first side surface portion <NUM>. In accordance with an embodiment, the first side surface portion <NUM>, second side surface portion <NUM>, third side surface portion <NUM> and fourth side surface portion <NUM>, in combination with the bevel side surface portions <NUM> therebetween, can define an outer peripheral surface of the body <NUM> of the abrasive segment <NUM>.

In accordance with an embodiment, the body <NUM> of the abrasive segment <NUM> can have a certain width, length and height. In a certain aspect, the body <NUM> of the abrasive segment <NUM> can have an overall width, W, defined as the greatest distance as measured from the first side surface portion <NUM> and the second surface portion <NUM>. For instance, the overall width, W, can be at least <NUM>, such as at least <NUM>, at least about <NUM>, at least about <NUM>, or at least about <NUM>. In a non-limiting embodiment, the overall width, W, can be not greater than <NUM>, such as no greater than <NUM>, no greater than <NUM>, no greater than <NUM>, no greater than about <NUM>, no greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, or not greater than <NUM>. The overall width can be within a range between and including any of the minimum and maximum width values noted above.

A width of the abrasive segment <NUM> varies along its length, L. The first side surface portion <NUM> includes a non-linear shape, such that the width, W, varies along the length, L, of the body <NUM>. The abrasive segment 104includes a minimum width, Wm, defined as the minimum distance between the first side surface portion <NUM> and the second surface portion <NUM>. In a particular instance, the minimum width, Wm, can be located at center, C, of the length, L, of the body <NUM>, equidistant between the third side surface portion <NUM> and fourth side surface portion <NUM>, as illustrated in <FIG>. In an embodiment, the minimum width, Wm, can be at least <NUM>, such as at least <NUM>, at least about <NUM>, at least about <NUM>, or at least about <NUM>. In a non-limiting embodiment, the minimum width, Wm, can be not greater than <NUM>, such as not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than about <NUM>, or not greater than <NUM>. The minimum width, Wm, can be within a range between and including any of the minimum and maximum width values noted above.

As particularly illustrated in <FIG>, the body <NUM> of the abrasive segment 104has an overall height, H, defined as the greatest distance between the bottom surface <NUM> to the top surface <NUM>. In a certain aspect, the overall height, H, of the body can be at least <NUM>, such as at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>. The overall height, H, may be no greater than about <NUM>, no greater than about <NUM>, no greater than about <NUM>, no greater than about <NUM>, no greater than about <NUM>, no greater than about <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, such as not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than about <NUM>, or not greater than <NUM>. The overall height, H, can be within a range between and including any of the minimum and maximum overall height values noted above.

In one aspect, a height of the abrasive segment <NUM> can be the same as measured at different surfaces of the body <NUM>. In another aspect, a height of the abrasive segment <NUM> can be different at a certain surface of the body <NUM> than a different surface of the body <NUM>. For instance, the height as measured at the first side surface portion <NUM> can be different that the height as measured at the second side surface portion <NUM>. The difference between a height at the first side surface portion <NUM> and the second side surface portion <NUM> can be at least <NUM>%, such as at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or even at least <NUM>%. In a non-limiting embodiment, the difference between a height at the first side surface portion <NUM> and the second side surface portion <NUM> can be not greater than <NUM>%, such as not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, or even not greater than <NUM>%. It will be appreciated that the difference between a height at the first side surface portion <NUM> and the second side surface portion <NUM> can be within a range of any minimum or maximum value noted above.

As particularly illustrated in <FIG>, the body <NUM> of the abrasive segment <NUM> further has an overall length, L, defined as the greatest distance between the third side surface portion <NUM> and the fourth side surface portion <NUM>. In a certain aspect, the body <NUM> of the abrasive segment <NUM> can have an overall length, L, of at least <NUM>, 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>, or at least <NUM>. The overall length, L, can be not greater than about <NUM>, such as not greater than about <NUM>, not greater than about <NUM>, not greater than about <NUM>, not greater than about <NUM>, not greater than about <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, or not greater than <NUM>. The overall length, L, can be within a range between and including any of the minimum and maximum overall length values noted above.

In accordance with an embodiment, the first side surface portion <NUM> can extend between adjacent bevel side surface portions <NUM>, as illustrated in <FIG>. In a non-limiting embodiment, the first side surface portion <NUM> can have a length that extends between adjacent bevel side surface portions <NUM>.

The first side surface portion <NUM> of the abrasive segment <NUM> has a certain shape. In accordance with an embodiment, the shape of the first side surface portion 308is defined along a plane intersecting the width, W, of the abrasive segment <NUM> at a normal angle. The first side surface portion <NUM> has a non-linear shape, as briefly noted above. A non-linear shape can be defined by a changing slope between two different lines drawn tangent to two different points on the first side surface portion <NUM>. For example, the non-linear shape can be defined by a curve drawn between any two points on the first side surface portion <NUM>. Particularly, the non-linear shape of the first side surface portion <NUM> can define an arcuate portion. In another particular embodiment, the non-linear shape of the first side surface portion <NUM> can define a monotonic curve.

In accordance with an embodiment, the non-linear shape of the first side surface portion <NUM> can have a shape defined by a sinusoidal shape, an elliptical shape, a portion of a circle, a portion of an oval, a convex shape, a concave shape, or any combination thereof. The non-linear shape of the first side surface portion <NUM> is concave.

In an embodiment, the non-linear shape of the first side surface portion <NUM> can extend for a full length of the first side surface portion <NUM>. In a non-limiting embodiment, the non-linear shape can extend for not greater than the full length or <NUM>% of the length of the first side surface portion <NUM>, such as not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, or not greater than <NUM>% of the length of the first side surface portion <NUM>. In a non-limiting embodiment, the non-linear shape can extend for at least <NUM>% of the full length of the first side surface portion <NUM>, such as at least <NUM>%, at least <NUM>%, at least <NUM>%, or at least <NUM>% of the full length of the first side surface portion <NUM>. It will be appreciated that the non-linear shape can extend for a length of the first side surface portion <NUM> within a range of any minimum and maximum value noted above.

In accordance with an embodiment, the full length of the non-linear shape of the first side surface portion <NUM> can be defined by a certain radius of curvature. A radius of curvature is defined as both the inverse of a curve and the distance from the curve to the center of curvature of the curve. In accordance with an embodiment, the radius of curvature of the first side surface portion <NUM> can be smaller than the outer radius of curvature of the base <NUM>. In accordance with another embodiment, the radius of curvature of the first side surface portion <NUM> can be smaller than the outer diameter (OD) of the base <NUM>. In a non-limiting embodiment, the radius of curvature of the first side surface portion <NUM> can be smaller than an inner radius of curvature of the base <NUM>. In accordance with another embodiment, the radius of curvature of the first side surface portion <NUM> can be smaller than the inner diameter (ID) of the base <NUM>. In an embodiment, the radius of curvature of the non-linear shape of the first side surface portion <NUM> can be at least <NUM>, such as at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>. In a non-limiting embodiment, the radius of curvature of the non-linear shape of the first side surface portion <NUM> can be not greater than <NUM>, such as not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, or not greater than <NUM>. It will be appreciated that the radius of curvature of the non-linear shape of the first side surface portion <NUM> can be within any minimum and maximum value noted above. In a certain instance, the radius of curvature of the non-linear shape of the first side surface portion <NUM> can be within a range of at least <NUM> and not greater than <NUM>.

The second side surface portion <NUM> of the abrasive segment <NUM> includes features that are similar or different to those of the first side surface portion <NUM>. In particular embodiments, the second side surface portion <NUM> includes features that are similar or substantially identical to those of the first side surface portion <NUM> noted above. In an embodiment, the second side surface portion <NUM> extends between adjacent bevel side surface portions <NUM>, as illustrated in <FIG>. In a non-limiting embodiment, the second side surface portion <NUM> has a length that extends between adjacent bevel side surface portions <NUM>.

The second side surface portion <NUM> can have a certain shape. In accordance with an embodiment, the shape of the second side surface portion <NUM> is defined along a plane intersecting a width, W, of the abrasive segment <NUM> at a normal angle. The second side surface portion <NUM> has a non-linear shape as defined above with respect to the first side surface portion <NUM>. The non-linear shape of the second side surface portion <NUM> is a concave shape. Both the non-linear shape of the first side surface portion <NUM> and the non-linear shape of the second side surface portion <NUM> are concave shapes. The concave shapes of the first side surface portion <NUM> and the second side surface portion <NUM> can be different or similar, and in a particular embodiment, the concave shape of the first side surface portion <NUM> and the concave shape of the second side surface portion <NUM> can be substantially similar such that they are identical and mirror each other.

The abrasive segment <NUM> has a bi-concave shape defined by the first side surface portion <NUM> and the second side surface portion <NUM>, such that each of the first side surface portion <NUM> and the second side surface portion <NUM> have a concave shape and are substantially similar such that they are identical and mirror each other, as generally illustrated in <FIG>. As also illustrated, the bi-concave shape of the abrasive segment <NUM> can be further defined by an hourglass shape, such that each of the first side surface portion <NUM> and the second side surface portion <NUM> have a concave shape, and each of the third side surface portion <NUM> and the fourth side surface portion <NUM> have a linear shape. In an embodiment of the bi-concave shape, the linear shapes of the third side surface portion <NUM> can include a flat surface that is parallel and substantially identical to a flat surface of the fourth side surface portion <NUM>.

The shape of the abrasive segment <NUM> is defined by one or more shapes of the edges that join adjacent side surface portions or features of the abrasive segment <NUM>. The abrasive segment <NUM> has a first non-linear edge <NUM> joining the first side surface portion <NUM> and the top surface <NUM>, as generally illustrated in <FIG>. The first non-linear edge <NUM> has a shape defined by a a convex shape. The shape of the first non-linear edge <NUM> is a concave shape. The shape of the first non-linear edge can be defined by a changing slope between two different lines drawn tangent to two different points on the first non-linear edge <NUM>. In an embodiment, the shape of the first non-linear edge can be defined by a curve drawn between any two points on the first non-linear edge. In accordance with an embodiment, the shape of the first non-linear edge <NUM> can define an arcuate portion, and in a certain embodiment, the arcuate portion can define a monotonic curve.

In an embodiment, the first non-linear edge <NUM> can extend for a full length of the first side surface portion <NUM>. In another embodiment, the first non-linear edge <NUM> can extend for not greater than the full length of the first side surface portion <NUM>, such as not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, or not greater than <NUM>% of the length of the first side surface portion <NUM>. In a non-limiting embodiment, the first non-linear edge <NUM> can extend for at least <NUM>% of the full length of the first side surface portion <NUM>, such as at least <NUM>%, at least <NUM>%, at least <NUM>%, or at least <NUM>% of the full length of the first side surface portion <NUM>. It will be appreciated that the first non-linear edge <NUM> can extend for a length of the first side surface portion <NUM> within a range of any minimum and maximum value noted above. In accordance with an embodiment, the full length of the non-linear edge <NUM> can be defined by a certain radius of curvature. In an embodiment, the radius of curvature of the first non-linear edge <NUM> can be at least <NUM>, such as at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>. In a non-limiting embodiment, the radius of curvature of the first non-linear edge <NUM> can be not greater than <NUM>, such as not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, or not greater than <NUM>. It will be appreciated that the radius of curvature of the first non-linear edge <NUM> can be within any minimum and maximum value noted above. In a certain instance, the radius of curvature of the first non-linear edge <NUM> can be within a range of at least <NUM> and not greater than <NUM>.

In accordance with an embodiment, the abrasive segment <NUM> can have a second non-linear edge <NUM> joining the first side surface portion <NUM> and the bottom surface <NUM>, as generally illustrated in <FIG>. The second non-linear edge <NUM> can include features that are similar or different to those of the first non-linear edge <NUM>. In particular embodiments, the second non-linear edge <NUM> can include features that are similar or substantially identical to those of the first non-linear edge <NUM> noted above.

The abrasive segment <NUM> has a third non-linear edge <NUM> joining the second side surface portion <NUM> and the top surface <NUM>, as generally illustrated in <FIG>. The third non-linear edge <NUM> includes features that are similar or different to those of the first non-linear edge <NUM>. In particular embodiments, the third non-linear edge <NUM> can include features that are similar or substantially identical to those of the first non-linear edge <NUM> noted above.

The abrasive segment <NUM> has a fourth non-linear edge <NUM> joining the second side surface portion <NUM> and the bottom surface <NUM>. The fourth non-linear edge <NUM> includes features that are similar to those of the first non-linear edge <NUM>, or even the third non-linear edge <NUM>. The fourth non-linear edge <NUM> includes features that are similar or substantially identical to those of the third non-linear edge <NUM>.

A curvature of the first non-linear edge <NUM> and a curvature of the second non-linear edge <NUM> are the same. A curvature of the first non-linear edge <NUM> and a curvature of the third non-linear edge <NUM> are the same. The curvature of the first non-linear edge <NUM>, second non-linear edge <NUM>, third non-linear edge <NUM> and fourth non-linear edge <NUM> are the same, defining a bi-concave shape of the abrasive segment <NUM>.

As illustrated in <FIG>, the bevel side surface portions <NUM> can be formed at a bevel angle <NUM> with respect to a linear portion of the adjacent third side surface portion <NUM> or fourth side surface portion <NUM>, respectively. In a particular aspect, the bevel angle <NUM> can be at least <NUM>°, such as at least <NUM>°, at least about <NUM>°, at least <NUM>°, at least <NUM>°, or at least <NUM>°. In a non-limiting embodiment, the bevel angle <NUM> can be not greater than <NUM>°, not greater than <NUM>°, not greater than <NUM>°, not greater than <NUM>°, or not greater than <NUM>°. It will be appreciated that the bevel angle <NUM> may be within a range between and including any of minimum and maximum angle values described above.

In another aspect, the third side surface portion <NUM> can include a surface area defined with respect to a surface area of first side surface portion <NUM>. In accordance with an embodiment, the surface area of the third side surface portion <NUM> can be less than the surface area of the first side surface portion <NUM>. For example, the surface area of the third side surface portion <NUM> can be less than <NUM>% the surface area of the first side surface portion <NUM>, such as less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>% or less than <NUM>%. In a non-limiting embodiment, the surface area of the third side surface portion <NUM> can be at least <NUM>% the surface area of the first side surface portion <NUM>, such as at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or at least <NUM>%. It will be appreciated that the surface area of the third side surface portion <NUM> with respect to the surface area of the first side surface portion <NUM> can be within a range of any minimum and maximum value of noted above.

In another aspect, the surface area of the third side surface portion <NUM> can have the same relationship with a surface area of the second side surface portion <NUM> as noted above regarding the relationship of the surface area of the third side surface portion <NUM> to the surface area of the first side surface portion <NUM>. Similarly, it will also be appreciated that the surface area of the fourth side surface portion <NUM> with respect to the surface area of the first side surface portion <NUM> can have the same relationship as noted above with respect to the relationship of the surface area of the third side surface portion <NUM> with respect to the surface area of the first side surface portion <NUM>. Still further, it will also be appreciated that the surface area of the fourth side surface portion <NUM> with respect to the surface area of the second side surface portion <NUM> can have the same relationship as noted above with respect to the relationship of the surface area of the third side surface portion <NUM> with respect to the surface area of the first side surface portion <NUM>.

<FIG> illustrates a cross-section view of the grinding ring <NUM> taken along line <NUM>-<NUM> in <FIG>. As illustrated, the base <NUM> has an axial flange <NUM>. The axial flange <NUM> can be formed integrally with the base <NUM> or can be attached or mounted on the base <NUM> such that it forms a portion of the outer annular surface <NUM> of the base <NUM>. In another embodiment, the axial flange <NUM> can be part of a mounting assembly configured to be attached to the base <NUM>, as discussed further herein. As further illustrated in <FIG>, the abrasive segment <NUM> is mounted on the receiving surface <NUM> of the base <NUM> between the inner annular surface <NUM> and the outer annular surface <NUM>. In a particular embodiment, the abrasive segment <NUM> can be mounted on the receiving surface <NUM> in direct contact with the axial flange <NUM>.

As previously described, the grinding ring <NUM> may rotate around the rotation axis <NUM> (<FIG>). With respect to <FIG>, the grinding ring <NUM> can rotate such that the base <NUM> and the abrasive segment <NUM> would illustratively move into (or out of) the page. A workpiece <NUM> can move in a direction along a working axis <NUM> so that the workpiece <NUM> can be abraded by the grinding ring <NUM> as it rotates. In a particular aspect, the working axis <NUM> can be substantially perpendicular to the rotation axis <NUM>.

As depicted in <FIG>, the top surface <NUM> defines a working angle <NUM> with respect to the working axis <NUM>. During operation, the abrasive segment <NUM> can remove a portion of material <NUM> from the workpiece <NUM> at a particular grinding depth determined in part by a height of the abrasive segment. In particular, the height as measured at the first side surface portion <NUM> can be substantially the same as the height as measured at the second side surface portion <NUM>, thereby defining a certain working angle <NUM>. In another instance, the height as measured at the first side surface portion <NUM> can be different that the height as measured at the second side surface portion <NUM>, thereby defining a working angle <NUM> that may be different than the working angle <NUM> depicted in <FIG>. As depicted in <FIG>, the height as measured at the first side surface portion <NUM> can be less than that the height as measured at the second side surface portion <NUM>, thereby defining a working angle <NUM> that may be less than the working angle <NUM> depicted in <FIG>, that is, if the shape of the base <NUM> and the receiving surface <NUM> are the same. In any instance, the working angle <NUM> can be at least about <NUM>°, such as at least about <NUM>°, at least about <NUM>°, at least about <NUM>°, at least about <NUM>°, or at least about <NUM>°. In a non-limiting embodiment, the working angle <NUM> may be not greater than <NUM>°, not greater than <NUM>°, not greater than <NUM>°, not greater than <NUM>°, not greater than <NUM>°, or not greater than <NUM>°. The working angle <NUM> can be within a range between and including any of the minimum and maximum angle values described above.

In general, an overall size of a construction block, e.g., a brick can be changed by moving the construction block through a space established by a pair of opposing parallel grinding rings such that each grinding ring contacts a separate face of the construction block. A grinding system for such an operation can be configured using a first grinding ring and a second grinding ring parallel to the first grinding ring.

<FIG> includes a perspective view of a portion of an abrasive article <NUM> having abrasive segments <NUM> in accordance with the invention, and <FIG> includes a cross-sectional view of an abrasive article <NUM> of <FIG> as corresponding to a view taken at Line <NUM>-<NUM> of abrasive article <NUM> of <FIG>. As generally illustrated, the base <NUM> has an axial flange <NUM> at the outer annular surface <NUM> of the base <NUM>. As further illustrated, the axial flange <NUM> can be a portion of a mounting assembly <NUM> mounted on the base <NUM>. In accordance with an embodiment, the mounting assembly <NUM> can have a receiving surface <NUM> for receiving an abrasive segment <NUM> and a rear surface <NUM> opposite the receiving surface <NUM>, both of which can extend generally perpendicular to the rotation axis <NUM>. The mounting assembly <NUM> can have an outer annular surface <NUM> extending generally axially between the receiving surface <NUM> and rear surface <NUM>, and an inner annular surface <NUM> opposite the outer annular surface <NUM>. The outer annular surface <NUM> can also extend circumferentially around the body of the mounting assembly, and can define an outer peripheral surface of the abrasive article <NUM> (e.g., grinding ring). As further illustrated, the abrasive segment <NUM> can be mounted on the receiving surface <NUM> of the mounting assembly <NUM>. In a particular embodiment, the abrasive segment <NUM> can be mounted on the receiving surface <NUM> of the mounting assembly in direct contact with the axial flange <NUM>. The first side surface portion <NUM> of the abrasive segment <NUM> can be adjacent to the outer annular surface <NUM> of the base <NUM>. In a particular embodiment, the first side surface portion <NUM> can be adjacent to the outer annular surface <NUM> of the mounting assembly <NUM>.

<FIG> includes a plan view of a grinding ring in accordance with an embodiment. <FIG> illustrates a cross-section view of the grinding ring <NUM> taken along line <NUM>-<NUM> in <FIG>. As illustrated in <FIG>, the base <NUM> has an axial flange <NUM>. The axial flange <NUM> can be formed integrally with the base <NUM> or can be a discrete body mounted on the base <NUM>. In another embodiment, the axial flange <NUM> can be part of a mounting assembly that can be mounted to the base <NUM>, as discussed further herein. As further illustrated in <FIG>, the abrasive segment <NUM> is mounted on the receiving surface <NUM> of the base <NUM> between the inner annular surface <NUM> and the outer annular surface <NUM>. In a particular embodiment, the abrasive segment <NUM> can be mounted on the receiving surface <NUM> in direct contact with the axial flange <NUM>.

As depicted in <FIG>, the top surface <NUM> defines a working angle <NUM> with respect to the working axis <NUM>. During operation, the abrasive segment <NUM> can remove a portion of material <NUM> from the workpiece <NUM> at a particular grinding depth determined in part by the height of the abrasive segment. In particular, the height as measured at the first side surface portion <NUM> can be substantially the same as the height as measured at the second side surface portion <NUM>, thereby defining a certain working angle <NUM>. In another instance, as depicted in <FIG>, the height as measured at the first side surface portion <NUM> can be different that the height as measured at the second side surface portion <NUM>, thereby defining a working angle <NUM> that may be different or even less than the working angle <NUM> depicted in <FIG>. In any instance, the working angle <NUM> can be at least about <NUM>° in accordance with an embodiment, such as at least about <NUM>°, at least about <NUM>°, at least about <NUM>°, at least about <NUM>°, or at least about <NUM>°. In a non-limiting embodiment, the working angle <NUM> may be not greater than <NUM>°, not greater than <NUM>°, not greater than <NUM>°, not greater than <NUM>°, not greater than <NUM>°, or not greater than <NUM>°. The working angle <NUM> can be within a range between and including any of the minimum and maximum angle values described above.

<FIG> includes a perspective view of a portion of an abrasive article having abrasive segments in accordance with an embodiment, and <FIG> includes a cross-sectional view of an abrasive article taken at Line <NUM>-<NUM> of <FIG>. As generally illustrated, the base <NUM> has an axial flange <NUM> extending axially from grinding ring <NUM>. As further illustrated, the axial flange <NUM> can be a portion of a mounting assembly <NUM> mounted on the base <NUM>. The mounting assembly <NUM> has a receiving surface <NUM> for receiving an abrasive segment <NUM> and a rear surface <NUM> opposite the receiving surface <NUM>, both of which can extend generally perpendicular to the rotation axis <NUM>. The mounting assembly <NUM> has an outer annular surface <NUM> extending generally axially between the receiving surface <NUM> and rear surface <NUM>, and an inner radial surface <NUM> opposite the outer annular surface <NUM>. The outer annular surface <NUM> can also extend circumferentially around the body of the mounting assembly, and can define an outer peripheral surface of the grinding ring <NUM>. As further illustrated, the abrasive segment <NUM> is mounted on the receiving surface <NUM> of the mounting assembly <NUM>. In a particular embodiment, the abrasive segment <NUM> can be mounted on the receiving surface <NUM> of the mounting assembly <NUM> in direct contact with the axial flange <NUM>. The first side surface portion <NUM> of the abrasive segment <NUM> can be adjacent to the outer annular surface <NUM> of the base <NUM>. In a particular embodiment, the first side surface portion <NUM> can be adjacent to the outer annular surface <NUM> of the mounting assembly <NUM>.

<FIG> includes a cross-sectional view of a portion of a mounting assembly including an axial flange in accordance with an embodiment taken at Circle <NUM> of <FIG>. <FIG> includes a cross-sectional view of a portion of a mounting assembly including an axial flange in accordance with an embodiment taken at Circle <NUM> of <FIG>. As generally illustrated in <FIG> and <FIG>, the base <NUM> of the abrasive article <NUM> includes an inner annular surface <NUM>, an outer annular surface <NUM> opposite the inner annular surface <NUM>, and a receiving surface <NUM> extending between the inner annular surface <NUM> and the outer annular surface <NUM>. The base <NUM> includes a top annular surface <NUM> extending from the inner annular surface <NUM> to the outer annular surface <NUM>. As illustrated, the receiving surface <NUM> of the base <NUM> defines a channel region comprising an intermediate radial surface <NUM> and a radial flange <NUM> extending radially from the intermediate radial surface <NUM>. According to an embodiment, the receiving surface <NUM> of the base <NUM> can be configured to include a complementary shape for accepting a mounting assembly <NUM>. In a particular embodiment, the base <NUM> can be configured to receive a fastener for coupling the mounting assembly <NUM> to the receiving surface <NUM> of the base <NUM>. In a particular embodiment, the base <NUM> can be configured to receive a radial fastening member <NUM> In accordance with an embodiment, the base <NUM> can be configured to receive a plurality of mounting assemblies <NUM>.

In accordance with an embodiment, the mounting assembly <NUM> can have a complementary shape for inserting into the base <NUM> of the abrasive article <NUM>. In a particular aspect, the mounting assembly can have a complementary shape for inserting into the receiving surface <NUM> of the base <NUM>. In one aspect, the mounting assembly <NUM> can be coupled to the base <NUM>. In another aspect, the mounting assembly <NUM> can be coupled to the receiving surface <NUM> of the base <NUM>. In a particular aspect, the mounting assembly <NUM> can be removably attached to the base <NUM>. In another aspect, the mounting assembly <NUM> can be coupled to and in direct contact with the receiving surface <NUM> of the base <NUM>. In a particular aspect, a portion of the mounting assembly <NUM> can be under a compressive force with coupled to the base <NUM>. In a particular aspect, the mounting assembly <NUM> can be coupled to the receiving surface <NUM> by one or more fasteners. In accordance with an embodiment, the mounting assembly <NUM> can have a fastener receiving portion <NUM> configured to receive a fastener. In accordance with an embodiment, the fastener can be a radial fastening member <NUM>. In a particular aspect, the receiving portion <NUM> can be a countersunk portion such that, when installed, the radial fastening member1601 can be countersunk with respect to the outer annular surface <NUM> of the mounting assembly <NUM>. In a particular embodiment, the mounting assembly <NUM> can be engaged and fastened to the base <NUM>, and more particularly the channel region of the base <NUM> with at least one radial fastening member <NUM>.

The abrasive article <NUM> includes at least one abrasive segment <NUM> coupled to the base <NUM>. The abrasive segment <NUM> is coupled to the receiving surface <NUM> of the base <NUM>. In another aspect, the abrasive segment <NUM> can be attached to the mounting assembly <NUM>. In yet another aspect, the abrasive segment <NUM> can be coupled to the receiving surface <NUM> of the base <NUM> via the mounting assembly <NUM>.

According to an embodiment, the abrasive segment <NUM> can be attached to and in direct contact with a receiving surface <NUM> of the mounting assembly <NUM>. In particular embodiments, the abrasive segment <NUM> can be coupled to the receiving surface <NUM> of the base <NUM> via the mounting assembly <NUM>, which itself can be coupled to and in direct contact with the receiving surface <NUM> of the base <NUM>. In an embodiment, a plurality of abrasive segments <NUM> can be attached to a single mounting assembly <NUM>.

In accordance with an embodiment, the mounting assembly <NUM> can further include an axial flange <NUM>. The axial flange <NUM> can be disposed between the abrasive segment <NUM> and the central opening <NUM> of the base <NUM>. In another aspect, the axial flange <NUM> can be disposed between the abrasive segment <NUM> and the inner annular surface <NUM> of the base <NUM>.

In accordance with an embodiment, the axial flange <NUM> can include an inner radial surface <NUM>, an outer radial surface <NUM> opposite the inner radial surface <NUM>, and an upper surface <NUM> extending between the inner radial surface <NUM> and the outer radial surface <NUM> of the axial flange <NUM>. In an embodiment, the outer radial surface <NUM> of the axial flange <NUM> can be in direct contact with a side surface portion of the abrasive segment <NUM>. In a particular aspect, the outer radial surface <NUM> of the axial flange <NUM> can be in direct contact with the second side surface portion <NUM> of the abrasive segment <NUM>.

In accordance with an embodiment, the axial flange <NUM> can include a height, Haf, defined as a portion of the axial flange <NUM> extending above a receiving surface <NUM> of the mounting assembly <NUM>, and wherein Haf is at least <NUM>% the overall height, H, of the abrasive segment <NUM>, 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>%, or even at least <NUM>%. In a non-limiting embodiment, the height, Haf, of the axial flange <NUM> can be not greater than <NUM>% the overall height, H, of the abrasive segment <NUM>, such as not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, or even not greater than <NUM>%. It will be appreciated that the height, Haf, as a function of the overall height, H, of the abrasive segment <NUM> can be within any minimum or maximum value noted above. In a particular embodiment, the portion of the axial flange <NUM> extending above the receiving surface <NUM> of the mounting assembly <NUM> can include the outer radial surface <NUM> of the axial flange <NUM>.

In accordance with an embodiment, the axial flange includes <NUM> can include a thickness, Taf, defined as the distance between the outer radial surface <NUM> of the axial flange <NUM> and the inner radial surface <NUM> of the axial flange <NUM>. In an embodiment, the thickness, Taf, can include the top surface <NUM> of the axial flange <NUM>. In an embodiment, the thickness, Taf, can be at least <NUM>% the height, Haf, of the axial flange <NUM>, 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>%, or even at least <NUM>%. In a non-limiting embodiment, the thickness, Taf, can be not greater than <NUM>% the height, Haf, of the axial flange <NUM>, such as not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, or even not greater than <NUM>%. It will be appreciated that the thickness, Taf, as a function of the height, Haf, of the axial flange <NUM> can be within any minimum or maximum value noted above.

In accordance with an embodiment, the mounting assembly <NUM> can be formed of any material disclosed herein with respect to the abrasive article according to embodiments herein. In a particular aspect, the mounting assembly <NUM> can include a metal or metal alloy.

In accordance with an embodiment, the axial flange <NUM> can form a continuous member mounted along the top annular surface <NUM> of the base <NUM>. In another embodiment, the abrasive article <NUM> can include a plurality of axial flanges <NUM> separated from each other.

A sample grinding wheel SN1 was formed to include a plurality of abrasive segments with a biconcave shape according to an embodiment described herein, and as shown in <FIG>. A comparative sample grinding wheel CS1 was formed identical to sample SN1, but instead including abrasive segments without a non-linear shape. A grinding operation was performed on a clay brick using sample SN1, and on a substantially identical clay brick using sample CS1. The resulting brick of the grinding operation using sample SN1 is shown in <FIG>, while the resulting brick of the grinding operation using CS1 is shown in <FIG>. As illustrated, sample SN1 provided a brick with fewer cracks (see <FIG>) than was provided by sample CS1 (see <FIG>).

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 process, 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 other features that are inherent to such process, method, article, or apparatus.

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 embodiments of the disclosure. 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.

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 disclosure belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent not described herein, many details regarding specific materials and processing acts are conventional and may be found in textbooks and other sources within the scintillation and radiation detection arts.

An abrasive article including an abrasive segment as described herein can be used to perform a grinding operation while experiencing less wear than a comparative abrasive segment not having shape as described herein (e.g., non-linear, curved, or concave). Further, an abrasive article including an abrasive segment as described herein can be used to perform a grinding operation while providing a more desirable finish to a workpiece and reducing wear on the workpiece (e.g., cracks, fractures, etc.) as compared to a comparative abrasive segment not having shape as described herein (concave). The shape of the abrasive segment according to the embodiments herein provide increased longevity and effectiveness by reducing wear that can manifest during a grinding operation in the form of cracks or fractures in the workpiece or in the body of the abrasive segment or. As such, the need for replacing or repairing abrasive articles can be substantially reduced, and the process time for grinding bricks to an acceptable surface finish and dimensional tolerance can be substantially reduced.

The order in which activities are listed is not necessarily the order in which they are performed.

Claim 1:
An abrasive article (<NUM>; <NUM>), comprising:
a base (<NUM>) having a body comprising an annular shape including an inner annular surface (<NUM>), an outer annular surface (<NUM>), and a receiving surface (<NUM>) extending between the inner annular surface (<NUM>) and the outer annular surface (<NUM>);
an abrasive segment (<NUM>) comprising a body (<NUM>) and coupled to the receiving surface (<NUM>) of the base (<NUM>), wherein the abrasive segment (<NUM>) comprises a first side surface portion (<NUM>) having a non-linear shape, wherein the first side surface portion (<NUM>) is adjacent to the outer annular surface (<NUM>) of the base (<NUM>);
and wherein the first side surface portion (<NUM>) extends between adjacent bevel side portions (<NUM>), characterized in that the abrasive segment (<NUM>) comprises a biconcave shape.