Abrasive particles having complex shapes and methods of forming same

• US 10,364,383 B2
• Filed: 04/25/2018
• Issued: 07/30/2019
• Est. Priority Date: 01/10/2012
• Status: Active Grant

• Current Assignee: Saint-Gobain Ceramics & Plastics Incorporated (Compagnie De Saint-Gobain)
• Original Assignee: Saint-Gobain Ceramics & Plastics Incorporated (Compagnie De Saint-Gobain)
• Inventors: Yener, Doruk O., Czerepinski, Jennifer H., Iyengar, Sujatha, Kavanaugh, Michael D., Brandes, Alan J., Arcona, Christopher, Bauer, Ralph, Boussant-Roux, Yves, Panzarella, Tracy H.
• Primary Examiner(s): Kiliman, Leszek B
• Application Number:
  US15/962,838
• Publication Number:
  US 20180237675A1
• Time in Patent Office: 461 Days
• Field of Search: 428402
• CPC Class Codes: B01J 2/26 on endless conveyor belts
• CPC Class Codes: C01F 7/442 in presence of a calcination additive
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25
• CPC Class Codes: C09K 3/1418 obtained by division of a mass agglomerated by sintering
• CPC Class Codes: C09K 3/1427 obtained by division of a mass agglomerated by melting, at least partially, e.g. with a binder
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]

Abstract

An abrasive grain is disclosed and may include a body. The body may define a length (l), a height (h), and a width (w). In a particular aspect, the length is greater than or equal to the height and the height is greater than or equal to the width. Further, in a particular aspect, the body may include a primary aspect ratio defined by the ratio of length:height of at least about 2:1. The body may also include an upright orientation probability of at least about 50%.

Claims

1. A shaped abrasive particle comprising:

a generally prismatic body having a length, width, and thickness;

wherein the length is greater than the width and the length is greater than the thickness;

wherein the generally prismatic body with a first end face and a second end face have a polygonal shape; and

wherein the generally prismatic body comprises an odd number of major surfaces.

2. The shaped abrasive particle of claim 1, wherein the body comprises a twist along a longitudinal axis defining the length of the body.

3. The shaped abrasive particle of claim 2, wherein the twist angle is at least about 2 degrees.

4. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle is part of a fixed abrasive article.

5. The shaped abrasive particle of claim 1, wherein the body comprises a twist along a lateral axis defining the width of the body.

6. The shaped abrasive particle of claim 5, wherein the twist along the lateral axis defines a lateral twist angle between two ends of the body of at least about 1 degree.

7. The shaped abrasive particle of claim 1, wherein the polygonal shape is selected from the group consisting of a triangle, a rectangle, a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, a nonagon, a decagon, and a combination thereof.

8. The shaped abrasive particle of claim 1, wherein the body comprises a polycrystalline material.

9. The shaped abrasive particle of claim 1, wherein the body comprises a twist along a vertical axis defining the height of the body.

10. The shaped abrasive particle of claim 9, wherein the twist along the vertical axis defines a vertical twist angle between two ends of the body of at least about 1 degree.

11. The shaped abrasive particle of claim 1, wherein the first end face comprises a different polygonal shape compared to the second end face.

12. The shaped abrasive particle of claim 1, wherein the body consists essentially of alumina.

13. A shaped abrasive particle comprising:

a generally prismatic body having a length, width, and thickness;

wherein the length is greater than the width and the length is greater than the thickness;

wherein the generally prismatic body with a first end face and a second end face have a polygonal shape; and

wherein the generally prismatic body comprises a center of mass and a geometric midpoint and wherein the center of mass is displaced from the geometric midpoint by a distance selected from the group consisting of;

(Dh) of at least about 0.05(h) along a vertical axis of the body defining the height, (Dw) of at least about 0.05(w) along a lateral axis of the body defining the width, and (Dl) of at least about 0.05(l) along a longitudinal axis of the body defining the length.

14. The shaped abrasive particle of claim 13, wherein the center of mass is closer to a base surface of the body than the geometric midpoint.

15. The shaped abrasive particle of claim 13, wherein the first end face and the second end face have a polygonal shape.

16. The shaped abrasive particle of claim 13, wherein the body is overlying a backing and comprises an upright orientation probability of at least about 50%.

17. A shaped abrasive particle comprising:

a generally prismatic body having a length, width, and thickness;

wherein the length is greater than the width and the length is greater than the thickness;

wherein the generally prismatic body with a first end face and a second end face have a polygonal shape; and

wherein the body consists essentially of alumina.

18. The shaped abrasive particle of claim 17, wherein the body comprises a first side face extending between the first end face and the second end face and a second side face extending between the first end face and the second end face adjacent to the first side face.

19. The shaped abrasive particle of claim 18, wherein the body comprises a first V-shaped edge channel face between the first side face and the second side face.

20. The shaped abrasive particle of claim 17, where the shaped abrasive particle is part of a fixed abrasive article.