Shaped abrasive particle including dopant material and method of forming same

• US 10,597,568 B2
• Filed: 08/25/2017
• Issued: 03/24/2020
• Est. Priority Date: 01/31/2014
• 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., Braun, Paul
• Primary Examiner(s): McDonough, James E
• Application Number:
  US15/686,674
• Publication Number:
  US 20170349797A1
• Time in Patent Office: 942 Days
• Field of Search: 51293, 51307, 51309
• CPC Class Codes: C04B 2235/3201 Alkali metal oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3205 Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
• CPC Class Codes: C04B 2235/3224 Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
• CPC Class Codes: C04B 2235/3239 Vanadium oxides, vanadates or oxide forming salts thereof, e.g. magnesium vanadate
• CPC Class Codes: C04B 2235/3244 Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3251 Niobium oxides, niobates, tantalum oxides, tantalates, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3256 Molybdenum oxides, molybdates or oxide forming salts thereof, e.g. cadmium molybdate
• CPC Class Codes: C04B 2235/6021 Extrusion moulding
• CPC Class Codes: C04B 2235/75 Products with a concentration gradient
• CPC Class Codes: C04B 2235/94 Products characterised by their shape
• CPC Class Codes: C04B 2235/95 Products characterised by their size, e.g. microceramics
• CPC Class Codes: C04B 35/01 based on oxide ceramics
• 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 35/62802 Powder coating materials
• CPC Class Codes: C09K 3/1436 Composite particles, e.g. coated particles

Abstract

A method of forming a shaped abrasive particle including extruding a mixture into a form, applying a dopant material to an exterior surface of the form, and forming a precursor shaped abrasive particle from the form.

Claims

1. A particulate material comprising:

a shaped abrasive particle having a body comprising a length (l), a width, (w), and a thickness (t), wherein the body comprises an upper surface, a bottom surface, and a side surface extending between the upper surface and the bottom surface;

wherein the body further comprises a first exterior surface having a first dopant amount (D1c) of a first dopant material;

a second exterior surface spaced apart from the first exterior surface by at least one edge, the second exterior surface having a second dopant amount (D2c) of a second dopant material;

a dopant amount difference (Δ

Dc) between the first dopant amount and the second dopant amount;

wherein a geometric center of the body is essentially free of a dopant material; and

at least one of the upper surface, bottom surface, or the side surface is essentially free of a dopant material.

2. The particulate material of claim 1, wherein the first dopant material and second dopant material are different from each other.

3. 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, an oxynitride, or any combination thereof.

4. The particulate material of claim 1, wherein the shaped abrasive particle comprises alpha alumina.

5. The particulate material of claim 4, wherein the shaped abrasive particle comprises at least about 90 wt % alpha alumina.

6. The particulate material of claim 4, wherein the alpha alumina has an average grain size of at least 0.01 microns and not greater than about 1 micron.

7. The particulate material of claim 1, wherein at least one of the first dopant material and the second dopant material comprises an element or compound including an element selected from the group consisting of alkali elements, alkaline earth elements, rare-earth elements, hafnium (Hf), zirconium (Zr), niobium (Nb), tantalum (Ta), molybdenum (Mo), vanadium (V), and a combination thereof.

8. The particulate material of claim 1, wherein the dopant amount difference (Δ

Dc) is at least about 0.2 wt % and not greater than about 30 wt %.

9. The particulate material of claim 1, wherein the dopant amount difference (Δ

Dc) is at least about 2 wt % and not greater than about 16 wt %.

10. The particulate material of claim 1, wherein the first dopant amount is present in an amount of at least about 0.2 wt % and not greater than about 12 wt % for the total weight of the body.

11. The particulate material of claim 1, wherein the second dopant amount is present in an amount of at least about 0.2 wt % and not greater than about 12 wt % for the total weight of the body.

12. The particulate material of claim 1, wherein the body comprises 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.

13. The particulate material of claim 1, wherein the first exterior surface comprises the upper surface defined by dimensions of the length and width.

14. The particulate material of claim 1, wherein the second exterior surface comprises the bottom surface opposite the upper surface and separated from the upper surface by at least one side surface.

15. The particulate material of claim 1, wherein the upper surface has an upper surface contour significantly different than a contour of a bottom surface of the body as viewed in a cross-section of the body in a plane defined by the thickness and the length.

16. The particulate material of claim 1, wherein the body comprises a triangular two-dimensional shape as viewed in a plane defined by the length and width.

17. The particulate material of claim 1, wherein the body comprises a pattern of features on at least one exterior surface, and wherein the features are selected from the group consisting of protrusions, grooves, ridges, scales, and a combination thereof.

18. The particulate material of claim 17, wherein the body comprises a side surface including a plurality of ridges.

19. The particulate material of claim 1, further comprising an edge extending between two of the exterior surfaces, the edge comprising a third dopant material present in a third dopant amount, wherein the third dopant amount is different than at least one of the first dopant amount and the second dopant amount.

20. The particulate material of claim 1, further comprising:

the upper surface defined by dimensions of the length and width, the upper surface having a first dopant material present in a first dopant amount;

the side surface extending from the upper surface and defining the thickness of the body, the side surface comprising a second dopant material present in the second dopant amount.