Shaped abrasive particle and method of forming same

• US 10,428,255 B2
• Filed: 09/28/2016
• Issued: 10/01/2019
• Est. Priority Date: 12/30/2011
• 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: Braun, Paul, Yener, Doruk O., Czerepinski, Jennifer H., Bauer, Ralph, Subramanian, Krishnamoorthy, Bright, Robin M., Seth, Anuj, Lafond, Gregory G.
• Primary Examiner(s): Dunn, Colleen P
• Assistant Examiner(s): Christie, Ross J
• Application Number:
  US15/278,968
• Publication Number:
  US 20170015886A1
• Time in Patent Office: 1,098 Days
• Field of Search: None
• CPC Class Codes: B01J 2/22 by pressing in moulds or between rollers
• CPC Class Codes: B01J 2/26 on endless conveyor belts
• CPC Class Codes: C01P 2004/39 parallelepiped-like
• CPC Class Codes: C09C 1/24 Oxides of iron
• CPC Class Codes: C09C 1/407 Aluminium oxides or hydroxides
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25
• 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: C09K 3/1436 Composite particles, e.g. coated particles

Abstract

A method of forming a mixture including a ceramic material into a sheet, sectioning at least a portion of the sheet using a mechanical object and forming at least one shaped abrasive particle from the sheet, such that the at least one shaped abrasive particle can have a two-dimensional shape as viewed in a plane defined by a length and a width of the shaped abrasive particle selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.

Claims

1. A particulate material comprising:

a shaped abrasive particle having a body comprising a first major surface, a second major surface, and a side surface extending between the first major surface and second major surface, wherein the side surface comprises a fractured region located on a portion of the side surface, wherein the fractured region is spaced apart from an edge defining the first major surface and abutting an edge defining the second major surface, and wherein the fractured region has a height (h_fr) that is less than a height of the body (h_c) on the side surface.

2. The particulate material of claim 1, further comprising a boundary on the side surface extending between the fractured region and the first major surface and further defining a region between the boundary and the first major surface having a distinct surface appearance from the fractured region.

3. The particulate material of claim 1, wherein a majority of the fractured region has a surface roughness that is greater than a surface roughness of the first major surface and the region between the boundary and the first major surface.

4. The particulate material of claim 1, wherein a majority of the fractured region has a surface roughness that is greater than a surface roughness of the second major surface and the region between the boundary and the first major surface.

5. The particulate material of claim 1, wherein the fractured region extends for a minority of a width of the body on the side surface.

6. The particulate material of claim 2, and wherein the region between the boundary and the first major surface comprises a ripple feature.

7. The particulate material of claim 1, wherein the fractured region defines a serrated edge.

8. The particulate material of claim 1, wherein the fractured region extends along a majority of the side surface of the body.

9. The particulate material of claim 1, wherein the fractured region has a height (h_fr) extending for a minority of the height of the body (h_c) on the side surface.

10. The particulate material of claim 1, wherein the fractured region has a height (h_fr) extending for a majority of a height of the body (h_c) on the side surface.

11. The particulate material of claim 1, wherein the body comprises a length (l), a width (w), and a height (h), wherein the width>

length, length>

height, and the width>

height, and wherein the body comprises a primary aspect ratio defined by a ratio of width;

length of at least about 1.2;

1.

12. The particulate material of claim 1, wherein the body comprises a material selected from the group consisting of an oxide, a nitride, a carbide, a boride, an oxycarbide, oxynitride, and a combination thereof.

13. The particulate material of claim 1, wherein the particulate material is coupled to a substrate.

14. The particulate material of claim 13, wherein the substrate comprises a flexible material.

15. The particulate material of claim 1, wherein the body comprises a two-dimensional shape as viewed in a plane defined by a length (l) and a width (w) selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet letters, Latin alphabet letters, Russian alphabet characters, complex shapes including a combination of polygonal shapes, and a combination thereof.

16. The particulate material of claim 1, further comprising a fixed abrasive article containing the particulate material, wherein the particulate material is incorporated in the fixed abrasive article in a predetermined orientation.

17. The particulate material of claim 1, wherein the boundary has a substantially smooth surface.

18. The particulate material of claim 2, wherein the fractured region comprises a different surface roughness than the region between the boundary and the first major surface.