Composite shaped abrasive particles and method of forming same

• US 8,764,863 B2
• Filed: 12/31/2012
• Issued: 07/01/2014
• 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: Yener, Doruk O., Braun, Paul
• Primary Examiner(s): Olsen, Kaj K
• Assistant Examiner(s): Christie, Ross J
• Application Number:
  US13/731,793
• Publication Number:
  US 20130180180A1
• Time in Patent Office: 547 Days
• Field of Search: None
• US Class Current: 51/293
• CPC Class Codes: C04B 2235/3244 Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/94 Products characterised by their shape
• CPC Class Codes: C04B 2235/96 Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• 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 35/64 Burning or sintering processes C04B33/32 takes precedence ; powder metallurgy B22F
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25
• CPC Class Codes: C09K 3/1436 Composite particles, e.g. coated particles

Abstract

A method of forming a shaped abrasive particle includes forming a first mixture and a second mixture in a single forming process into an integral precursor shaped abrasive particle, wherein the first mixture has a different composition than a composition of the second mixture.

Claims

1. A particulate material comprising:

a shaped abrasive particle having a body comprising;

a first layer;

a second layer overlying the first layer and comprising a second dopant; and

wherein the first layer and the second layer are arranged in a stepped configuration with respect to each other, and wherein the stepped configuration is defined by a lateral shift of the first layer with respect to the second layer.

2. The particulate material of claim 1, wherein the lateral shift comprises a lateral distance of at least about 1% of the total length of the body.

3. The particulate material of claim 1, wherein the first layer comprises a first thickness and the second layer comprises a second thickness, and wherein the first thickness and the second thickness are different by at least about 5%.

4. The particulate material of claim 1, wherein the first layer comprises a first thickness of at least about 5% of an average thickness of the body, and wherein the second layer comprises a second thickness of at least about 5% of an average thickness of the body.

5. The particulate material of claim 1, wherein the second dopant is selected from the group consisting of alkali elements, alkaline earth elements, rare-earth elements, hafnium (Hf), zirconium (Zr), niobium (Nb), tantalum (Ta), molybdenum (Mo), and a combination thereof.

6. The particulate material of claim 1, wherein the second dopant comprises zirconium.

7. The particulate material of claim 1, wherein the second dopant comprises zirconia, and wherein the second layer comprises a greater content of zirconia than a content of zirconia in the first layer.

8. The particulate material of claim 1, wherein the first layer defines a first two-dimensional shape as viewed in a plane defined by a length and a width of the body 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.

9. The particulate material of claim 8, wherein the second layer defines a second two-dimensional shape as viewed in a plane defined by a length and a width of the body 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.

10. The particulate material of claim 9, wherein the second two-dimensional shape is different than the first two-dimensional shape.

19. The particulate material of claim 1, wherein the body comprises an oxide.

11. A particulate material comprising:

a shaped abrasive particle having a body comprising;

a first layer;

a second layer overlying the first layer and comprising a second dopant, wherein the second dopant comprises zirconia, and wherein the second layer comprises a greater content of zirconia than a content of zirconia in the first layer; and

wherein the first layer and the second layer are arranged in a stepped configuration with respect to each other.

12. The particulate material of claim 11, wherein the stepped configuration is defined by a lateral shift of the first layer with respect to the second layer.

13. The particulate material of claim 12, wherein the lateral shift comprises a lateral distance of at least about 1% of the total length of the body.

14. The particulate material of claim 11, wherein the first layer comprises a first thickness and the second layer comprises a second thickness, and wherein the first thickness and the second thickness are different by at least about 5%.

15. The particulate material of claim 11, wherein the first layer comprises a first thickness of at least about 5% of an average thickness of the body, and wherein the second layer comprises a second thickness of at least about 5% of an average thickness of the body.

16. The particulate material of claim 11, wherein the first layer defines a first two-dimensional shape as viewed in a plane defined by a length and a width of the body 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.

17. The particulate material of claim 16, wherein the second layer defines a second two-dimensional shape as viewed in a plane defined by a length and a width of the body 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.

18. The particulate material of claim 17, wherein the second two-dimensional shape is different than the first two-dimensional shape.

20. The particulate material of claim 11, wherein the body comprises an oxide.