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1. WO2010080495 - SLURRY COMPOSITION CONTAINING NON-IONIC POLYMER AND METHOD FOR USE

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CLAIMS

1. A wiresaw cutting fluid composition comprising 25 to 75 % by weight of a particulate abrasive suspended in an aqueous carrier containing a polymeric viscosity modifier; wherein the viscosity modifier comprises a polymer including a majority of non-ionic monomer units on a monomer mole basis, has a number average molecular weight (Mn) of at least 5 kiloDaltons (kDa), and is present in the aqueous carrier at a concentration sufficient to provide a Brookfield viscosity for the composition in the range of 50 to 1000 centiPoise (cP) at 25 0C at a spindle rotation rate of 60 revolutions-per-minute (rpm).

2. The composition of claim 1 wherein the viscosity modifier is a non-ionic polymer.

3. The composition of claim 2 wherein the non-ionic polymer is selected from the group consisting of (c) a polysaccharide that is optionally substituted with at least one alkyl group, hydroxyalkyl group, alkoxyalkyl group, or a combination of two or more such groups; (b) a polyvinylpyrrolidone, (c) a polyvinylalcohol, and (d) a combination of two or more of the foregoing.

4. The composition of claim 2 wherein the viscosity modifier comprises a polysaccharide that is optionally substituted with at least one substituent selected from the group consisting of an alkyl group, a hydroxyalkyl group, and an alkoxyalkyl group.

5. The composition of claim 4 wherein the polysaccharide is selected from the group consisting of a xanthan gum, a guar gum, a starch, a cellulose, and a combination of two or more of the foregoing.

6. The composition of claim 1 wherein the viscosity modifier comprises hydroxyethylcellulose .

7. The composition of claim 6 wherein the hydroxyethylcellulose has a weight average molecular weight (Mw) in the range of 20 to 100 kDa.

8. The composition of claim 1 wherein the viscosity modifier has an Mw in the range of 20 to 200 kDa.

9. The composition of claim 1 wherein the viscosity modifier has an Mn in the range of 20 to 70 kDa.

10. The composition of claim 1 wherein the viscosity modifier is present in the aqueous carrier at a concentration of about 0.01 to 15 % by weight.

11 The composition of claim 1 wherein the viscosity modifier is moderately shear thinning, providing a carrier viscosity measured at a moderate shear rate of 1000 s"1 that is not less than 55 % of the carrier viscosity measured at a low shear rate of 10 s"1.

12. The composition of claim 1 wherein the abrasive has a Mohs hardness of at least 7.5.

13. The composition of claim 1 wherein the abrasive comprises silicon carbide.

14. The composition of claim 1 wherein the abrasive has a mean particle size in the range of 1 to 500 micrometers.

15. The composition of claim 1 wherein the aqueous carrier has an acidic pH.

16. The composition of claim 1 wherein the aqueous carrier comprises at least 55 % by weight water.

17. The composition of claim 1 wherein the aqueous carrier contains a water soluble polyol anti-drying agent.

18. The composition of claim 17 wherein the anti-drying agent comprises a poly(alkylene glycol) having a number average molecular weight of less than 2 kDa.

19. The composition of claim 1 wherein the aqueous carrier contains a surfactant.

20. The composition of claim 19 wherein the surfactant comprises an acetylenic surfactant.

21. The composition of claim 1 wherein the aqueous carrier contains at least one additional polymer selected from a cationic polymer, an anionic polymer, a polysiloxane, a hydrophobically modified non-ionic polymer, and a polyether urea polyurethane.

22. The composition of claim 1 wherein the composition is free from clay materials.

23. The composition of claim 1 wherein the viscosity modifier comprises a non-ionic polymer having an Mw in the range of 20 to 200 kDa, and is present in the aqueous carrier at a concentration sufficient to provide a Brookfield viscosity for the composition in the range of 75 to 700 cP at 25 0C at a spindle rotation rate of 60 rpm.

24. The composition of claim 1 wherein the viscosity modifier comprises a copolymer comprising at least 60 mol % non-ionic monomer units.

25. A wiresaw cutting fluid composition comprising 25 to 75 % by weight of a particulate abrasive suspended in an aqueous carrier containing a viscosity modifier; wherein the viscosity modifier comprises a polymer including a majority of non-ionic monomer units, has an Mn or at least 5 kDa, and an Mw of at least 200 kDa, and is present in the aqueous carrier at a concentration sufficient to provide a Brookfϊeld viscosity for the composition in the range of 50 to 700 cP at 25 0C at a spindle rotation rate of 60 rpm.

26. The composition of claim 25 wherein the viscosity modifier comprises a non-ionic polymer.

27. The composition of claim 26 wherein the non-ionic polymer is selected from the group consisting of (c) a polysaccharide that is optionally substituted with at least one alkyl group, hydroxyalkyl group, alkoxyalkyl group, or a combination of two or more such groups;(b) a polyvinylpyrrolidone, (c) a polyvinylalcohol, and (d) a combination of two or more of the foregoing.

28. The composition of claim 26 wherein the viscosity modifier comprises a polysaccharide that is optionally substituted with at least one substituent selected from the group consisting of an alkyl group, a hydroxyalkyl group, and an alkoxyalkyl group.

29. The composition of claim 28 wherein the polysaccharide is selected from the group consisting of a xanthan gum, a guar gum, a starch, a cellulose, and a combination of two or more of the foregoing.

30. The composition of claim 25 wherein the viscosity modifier comprises hydroxy ethylcellulose .

31. The composition of claim 30 wherein the hydroxyethylcellulose has an Mw in the range of 300 to 1000 kDa.

32. The composition of claim 26 wherein the non-ionic polymer has an Mw in the range of 200 to 1200 kDa.

33. The composition of claim 25 wherein the viscosity modifier is moderately shear thinning, providing a viscosity measured at a moderate shear rate of 1000 s"1 that is not less than 55 % of the viscosity measured at a low shear rate of 10 s"1.

34. The composition of claim 25 wherein the abrasive has a Mohs hardness of at least 7.5, and has a mean particle size in the range of 1 to 500 micrometers.

35. The composition of claim 25 wherein the aqueous carrier has an acidic pH.

36. The composition of claim 25 wherein the aqueous carrier contains a surfactant, a water soluble polyol anti-drying agent, at least one additional polymer selected from a cationic polymer, an anionic polymer, a polysiloxane, a hydrophobically modified non-ionic polymer, and a polyether urea polyurethane; or a combination of two or more of the foregoing.

37. A wiresaw cutting process comprising cutting a workpiece with a wiresaw while applying a wiresaw cutting fluid composition of claim 25 to the wiresaw from a recirculating reservoir of cutting fluid, wherein the cutting fluid is circulated and applied by pumps and nozzles operating at a relatively low shear rate of not more than 104 s"1. 38. A wiresaw cutting process comprising cutting a workpiece with a wiresaw while applying a wiresaw cutting fluid composition of claim 1 to the wiresaw from a recirculating reservoir of cutting fluid.