Abrasive article including shaped abrasive particles

• US 10,563,105 B2
• Filed: 01/31/2017
• Issued: 02/18/2020
• Est. Priority Date: 01/31/2017
• 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: Cotter, Todd M., Wijesooriya, Sidath S., Motta, Ronald Christopher, Guertin, Gary A., Kavanaugh, Michael D., Yener, Doruk O., Czerepinski, Jennifer H., Jia, Jun, Josseaux, Frederic, Bauer, Ralph, Csillag, Frank J., Wagner, Francois, Zhong, Yang, Stewart, James P., Dombrowski, Mark P., Jayaraman Rukmani, Sandhya, Martin, Amandine, Fox, Stephen E., Sarangi, Nilanjan, Matsumoto, Dean S., Demers, Rene G., Klok, Richard J., Marazano, Alexandra, Lior, Adam D., Salvatore, James A., Iyengar, Sujatha, Louapre, David F.
• Primary Examiner(s): Le, Hoa (Holly)
• Application Number:
  US15/420,701
• Publication Number:
  US 20180215976A1
• Time in Patent Office: 1,113 Days
• Field of Search: 428402
• CPC Class Codes: B01J 2/26 on endless conveyor belts
• CPC Class Codes: B24D 3/14 ceramic, i.e. vitrified bondings
• CPC Class Codes: B24D 99/00 Subject matter not provided for in other groups of this subclass
• CPC Class Codes: C04B 2235/3206 Magnesium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/5427 millimeter or submillimeter sized, i.e. larger than 0,1 mm
• CPC Class Codes: C04B 2235/6021 Extrusion moulding
• CPC Class Codes: C04B 2235/6023 Gel casting
• CPC Class Codes: C04B 2235/785 Submicron sized grains, i.e. from 0,1 to 1 micron
• CPC Class Codes: C04B 2235/786 Micrometer sized grains, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/94 Products characterised by their shape
• CPC Class Codes: C04B 35/1115 Minute sintered entities, e.g. sintered abrasive grains or shaped particles such as platelets abrasives C09K3/14
• CPC Class Codes: C04B 35/56 based on carbides or oxycarbides containing free metal binder C22C29/00
• CPC Class Codes: C04B 35/58 based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides containing free binder metal C22C29/00
• CPC Class Codes: C04B 35/624 Sol-gel processing
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25

Abstract

Various shaped abrasive particles are disclosed. Each shaped abrasive particle includes a body having at least one major surface and a side surface extending from the major surface.

Claims

1. A shaped abrasive particle comprising a body including a first surface, a second surface, a side surface extending between the first surface and second surface, a flange portion extending from the side surface and the first surface;

and wherein the body comprises a narrow end, a wide end, and a convex portion wherein the flange extends from the narrow end and the convex portion of the body.

2. The shaped abrasive particle of claim 1, wherein the flange comprises a rounded shape.

3. The shaped abrasive particle of claim 1, wherein the flange comprises a length that is less than a length of the body.

4. The shaped abrasive particle of claim 1, wherein the flange has a height that is not greater than a thickness of the body.

5. The shaped abrasive particle of claim 1, wherein the body comprises a single flange and wherein the single flange extends from the body and extends for a distance of not greater than 50% of a total peripheral length of the body.

6. The shaped abrasive particle of claim 5, wherein the single flange extends around at least 1 exterior corner and not greater than 3 exterior corners.

7. The shaped abrasive particle of claim 1, wherein the body comprises at least about 95 wt % alumina for a total weight of the particle.

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

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

10. The shaped abrasive particle of claim 1, wherein the body is essentially free of a binder.

11. The shaped abrasive particle of claim 1, wherein the body has an average grain size not greater than 100 microns.

12. The shaped abrasive particle of claim 1, wherein the body has an average particle size of at least bout 100 microns.

13. The shaped abrasive particle of claim 1, wherein the body comprises a dopant material selected from the group of hafnium, zirconium, niobium, tantalum, molybdenum, vanadium, lithium, sodium, potassium, magnesium, calcium, strontium, barium, scandium, yttrium, lanthanum, cesium, praseodymium, chromium, cobalt, iron, germanium, manganese, nickel, titanium, zinc, and a combination thereof.

14. The shaped abrasive particle of claim 13, wherein the dopant material comprises a magnesium-containing species.

15. The shaped abrasive particle of claim 14, wherein the magnesium-containing species is a distinct phase of material formed in the body of the shaped abrasive particle.

16. The shaped abrasive particle of claim 14, wherein the body comprises a content of magensium-containing species of at least about 0.5 wt % for the total weight of the body.

17. The shaped abrasive particle of claim 1, wherein the abrasive particle is incorporated into a fixed abrasive article.

18. The shaped abrasive particle of claim 1, wherein the flange extends around a corner of the body.

19. A shaped abrasive particle comprising a body including a first surface, a second surface, a side surface extending between the first surface and second surface, a flange portion extending from the side surface and the first surface;

and wherein the body comprises a narrow end and a wide end and wherein the flange extends from the wide end of the body.

20. The shaped abrasive particle of claim 19, wherein the abrasive particle is incorporated into a fixed abrasive article.