Abrasive particles having particular shapes and methods of forming such particles

• US 8,758,461 B2
• Filed: 12/30/2011
• Issued: 06/24/2014
• Est. Priority Date: 12/31/2010
• 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.
• Primary Examiner(s): MCDONOUGH, JAMES E
• Application Number:
  US13/341,588
• Publication Number:
  US 20120167481A1
• Time in Patent Office: 907 Days
• Field of Search: 513/07, 512/93, 513/08, 513/09
• US Class Current: 51/293
• CPC Class Codes: B24D 3/20 and being essentially organic
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25

Abstract

An abrasive article includes a shaped abrasive particle including a body having a first height (h1) at a first end of the body defining a corner between an upper surface, a first side surface, and a second side surface, and a second height (h2) at a second end of the body opposite the first end defining an edge between the upper surface and a third side surface, wherein the average difference in height between the first height and the second height is at least about 50 microns. The body also includes a bottom surface defining a bottom area (A_b) and a cross-sectional midpoint area (A_m) defining an area of a plane perpendicular to the bottom area and extending through a midpoint of the particle, the body has an area ratio of bottom area to midpoint area (A_b/A_m) of not greater than about 6.

Claims

1. An abrasive article comprising:

a shaped abrasive particle comprising a body having a first height (h1) at a first end of the body defining a corner between an upper surface, a first side surface, and a second side surface, and a second height (h2) at a second end of the body opposite the first end defining an edge between the upper surface and a third side surface, wherein h1 is different from h2, and wherein the upper surface comprises a trench region extending in an arc around a midpoint of the upper surface.

2. The abrasive article of claim 1, wherein the body comprises a profile ratio of at least about 0.04, wherein profile ratio is defined as a ratio between the average difference in height and a profile length [(h1−

h2)/(lp)].

3. The abrasive article 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 body selected from the group consisting of ellipsoids, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, triangles, pentagons, hexagons, heptagons, octagons, nonagons, decagons, and a combination thereof.

7. The abrasive article of claim 1, wherein the body comprises at least four sides.

8. The abrasive article of claim 1, wherein the body further comprises a third side surface, and wherein the first side surface, second side surface, and third side surface define a generally triangular shape.

9. The abrasive article of claim 1, wherein the trench region extends entirely around the midpoint of the upper surface.

10. The abrasive article of claim 1, wherein the trench region defines an ellipsoidal region encompassing the midpoint.

11. The abrasive article of claim 10, wherein the ellipsoidal region defines a plateau in the upper surface having a generally planar shape and extending above a bottom surface of the trench region.

12. The abrasive article of claim 1, further comprising a plateau region in the upper surface wherein the plateau region includes the midpoint and defines a raised portion of the upper surface.

4. An abrasive article comprising:

a shaped abrasive particle comprising a body having a first height (h1) at a first end of the body and a second height (h2) at a second end of the body opposite the first end wherein h1 is greater than h2, and wherein the upper surface comprises an ellipsoidal region defining a portion of the upper surface having a raised surface relative to the periphery of the ellipsoidal region.

5. The abrasive article of claim 4, wherein the body comprises a profile ratio of at least about 0.04, wherein profile ratio is defined as a ratio between the average difference in height and a profile length [(h1−

h2)/(lp)].

13. The abrasive article of claim 4, wherein a trench region extends around at least a portion of the periphery of the ellipsoidal region.

14. The abrasive article of claim 13, wherein the ellipsoidal region defines a plateau in the upper surface having a generally planar shape and extending above a bottom surface of the trench region.

6. An abrasive article comprising:

a sample of shaped abrasive particle comprising a plurality of individual shaped abrasive particles, each shaped abrasive particle having a body having a first height (h1) at a first end of the body and a second height (h2) at a second end of the body opposite the first end, wherein h1 and h2 are significantly different relative to each other, and wherein the upper surface comprises a midpoint defining a midpoint height and a trench region extending through at least a portion of the upper surface and defining a trench height, wherein the trench height is less than the midpoint height.

15. The abrasive article of claim 6, wherein the body comprises at least four sides.

16. The abrasive article of claim 6, wherein the body further comprises a first side surface, a second side surface, and a third side surface that define a generally triangular shape.

17. The abrasive article of claim 6, wherein the trench region extends around at least a portion of an ellipsoidal region, and wherein the ellipsoidal region encompasses the midpoint.

18. The abrasive article of claim 17, wherein the trench region extends around the entire periphery of the ellipsoidal region.

19. The abrasive article of claim 17, wherein the trench region defines the ellipsoidal region encompassing the midpoint.

20. The abrasive article of claim 6, wherein the midpoint is disposed on a plateau region of the upper surface defining a raised portion of the upper surface relative to the trench region.