Abrasive particles having particular shapes and methods of forming such particles

• US 10,286,523 B2
• Filed: 07/29/2016
• Issued: 05/14/2019
• Est. Priority Date: 10/15/2012
• Status: Active Grant

• Current Assignee: Saint-Gobain Abrasives Incorporated (Compagnie De Saint-Gobain), Saint-Gobain Abrasifs (Compagnie de Saint-Gobain SA)
• Original Assignee: Saint-Gobain Abrasives Incorporated (Compagnie De Saint-Gobain), Saint-Gobain Abrasifs (Compagnie de Saint-Gobain SA)
• Inventors: Gaeta, Anthony C., Seth, Anuj, Arcona, Christopher, Yener, Doruk O., Czerepinski, Jennifer H., Iyengar, Sujatha, Csillag, Frank J., Rice, William C., Ramesh, Satyalakshmi K., Lafond, Gregory G., Wijesooriya, Sidath S., Lior, Adam D., Brandes, Alan J., Parmar, Anil, Braun, Paul, Everts, Darrell K.
• Primary Examiner(s): Van Sell, Nathan L
• Application Number:
  US15/223,701
• Publication Number:
  US 20170028531A1
• Time in Patent Office: 1,019 Days
• CPC Class Codes: B24D 11/001 Manufacture of flexible abrasive materials
• CPC Class Codes: B24D 11/04 Zonally-graded surfaces
• CPC Class Codes: B24D 18/00 Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
• CPC Class Codes: B24D 18/0072 using adhesives for bonding abrasive particles or grinding elements to a support, e.g. by gluing
• CPC Class Codes: B24D 2203/00 Tool surfaces formed with a pattern
• CPC Class Codes: B24D 3/001 the constituent being used as supporting member
• CPC Class Codes: B24D 7/02 Wheels in one piece
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25
• CPC Class Codes: Y10T 428/24 Structurally defined web or sheet [e.g., overall dimension, etc.]
• CPC Class Codes: Y10T 428/24372 Particulate matter
• CPC Class Codes: Y10T 428/24893 including particulate material
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles

Abstract

An abrasive article comprising a first group including a plurality of shaped abrasive particles overlying a backing, wherein the plurality of shaped abrasive particles of the first group define a first non-shadowing distribution relative to each other.

Claims

1. An abrasive article comprising:

a backing;

an adhesive layer disposed in a discontinuous distribution on at least a portion of the backing, wherein the discontinuous distribution comprises a first group of discrete adhesive contact regions having a gap between each of the adhesive contact regions;

a first group of abrasive particles overlying the backing, wherein the first group of abrasive particles comprises shaped abrasive particles,

wherein a single discrete adhesive contact region of the first group of discrete adhesive contact regions is coupled only to a single shaped abrasive particle of the first group of abrasive particles, wherein the single shaped abrasive particle has a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation, and

wherein the gap defines a gap distance that is a non-contact region having no adhesive material provided on the backing.

2. The abrasive article of claim 1, further comprising a second group of abrasive particles overlying the backing, wherein the second group of abrasive particles is different than the first group of abrasive particles.

3. The abrasive article of claim 2, wherein the second group of abrasive particles comprises at least one shaped abrasive particle disposed on a second group of discrete adhesive contact regions having a gap between each of the adhesive contact regions.

4. The abrasive article of claim 3, wherein the at least one shaped abrasive particle of the second group of abrasive particles is coupled only to a single discrete adhesive contact region of the second group of discrete adhesive contact regions, and wherein the at least one shaped abrasive particle of the second group of abrasive particles has at least one of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation.

5. The abrasive article of claim 4, wherein at least one of the predetermined rotational orientation, the predetermined lateral orientation, or the predetermined longitudinal orientation differs from the first group of abrasive particles.

6. The abrasive article of claim 1, wherein the shaped abrasive particles of the first group comprise a body essentially free of binder.

7. The abrasive article of claim 3, wherein the at least one shaped abrasive particle of the second group of abrasive particles comprises a body essentially free of binder.

8. The abrasive article of claim 3, wherein the at least one shaped abrasive particle of the second group of abrasive particles has at least two of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation.

9. The abrasive article of claim 1, wherein the gap distance is at least about 1(w) to not greater than 100(w), wherein (w) correspond to a width of the shaped abrasive particle.

10. The abrasive article of claim 1, wherein each of the discrete contact regions of the first group of discrete adhesive contact regions have a two-dimensional shape selected from the group consisting of polygons, ellipsoids, numerals, crosses, multi-armed polygons, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, Arabic alphabet characters, rectangle, quadrilateral, pentagon, hexagon, heptagon, octagon, nonagon, decagon, and a combination thereof.

11. The abrasive article of claim 1, wherein each of the discrete contact regions of the first group of discrete adhesive contact regions have a width at least about 0.5(h) to not greater than 50(h), wherein (h) is a height of the single shaped abrasive particle.

12. The abrasive article of claim 1, wherein the first group of abrasive particles defines a coating density of at least about 5 particles/cm² to not greater than about 70 particles/cm².

13. The abrasive article of claim 1, further comprising a normalized weight of the shaped abrasive particles per length of the backing of at least about 10 lb./ream (148 grams/m²).

14. The abrasive article of claim 1, further having a percentage coating of the abrasive particles relative to the total area of the entire backing of at least about 5%.

15. The abrasive article of claim 1, wherein the abrasive particles of the first group are arranged in a controlled, non-shadowing arrangement relative to each other.

16. The abrasive article of claim 1, wherein at least 85% of the abrasive particles of the first group are in a side orientation.

17. The abrasive article of claim 1, wherein the abrasive article has a continuous size coat layer disposed over the first group of discrete adhesive contact regions, shaped abrasive particles, and the gap between each of the discrete adhesive contact regions.

18. The abrasive article of claim 1, wherein the single discrete adhesive contact region of the first group of discrete contact regions is shaped and sized to accommodate a single shaped abrasive particle and controls a predetermined rotational orientation of the single shaped abrasive particle.

19. The abrasive article of claim 1, wherein each of the adhesive contact regions of the first group of discrete adhesive contact regions is coupled only to a single shaped abrasive particle from the first group of abrasive particles.

20. The abrasive article of claim 1, further comprising a second group of discrete adhesive contact regions disposed on the backing, wherein the second group of discrete adhesive contact regions is different than the first group of discrete adhesive contact regions.