Abrasive particles having particular shapes and methods of forming such particles

• US 8,840,696 B2
• Filed: 01/10/2013
• Issued: 09/23/2014
• Est. Priority Date: 01/10/2012
• 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: Kavanaugh, Michael D., Yener, Doruk O., Czerepinski, Jennifer H.
• Primary Examiner(s): Olsen, Kaj K
• Assistant Examiner(s): Christie, Ross J
• Application Number:
  US13/738,913
• Publication Number:
  US 20130186006A1
• Time in Patent Office: 621 Days
• Field of Search: None
• US Class Current: 51/307
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25

Abstract

A method of forming an abrasive article includes depositing a mixture into an opening of a substrate, contacting an exposed surface of the mixture in the opening to a texturing form to form a textured preform, and removing the mixture from the opening and forming an abrasive particle having a textured surface.

Claims

1. A method of forming an abrasive article comprising:

providing a mixture on a substrate;

texturing a first major surface and a second major surface opposite the first major surface of the mixture to form a textured preform, wherein texturing comprises imparting at least one recessed-protrusion surface feature;

treating the textured preform; and

forming an abrasive particle having a first major surface comprising a first texture and a second major surface comprising a second texture.

2. The method of claim 1, wherein texturing comprises contacting the first major surface of the mixture with a first texturing form.

3. The method of claim 1, wherein providing further comprises forming the mixture using a process selected from the group consisting of casting, tape casting, printing, molding, extruding, sectioning, pressing, and a combination thereof.

4. The method of claim 3, wherein providing comprises printing the mixture into an opening of a screen.

5. The method of claim 4, wherein the mixture in the opening contacts a surface of a belt underlying the screen, and wherein the belt comprises a texture, and further wherein at least a portion of the texture of the belt forms the at least one recessed-protrusion surface feature on the first major surface of the textured preform.

6. The method of claim 1, further comprising

removing the mixture from the substrate to form the abrasive particle.

7. The method of claim 6, wherein the substrate comprises a screen.

8. The method of claim 6, wherein removing comprises separating the substrate from an underlying belt.

9. The method of claim 1, wherein the at least one recessed-protrusion surface feature comprises a discrete recess and a protrusion contained entirely within the discrete recess.

10. The method of claim 9, wherein the discrete recess comprises a bottom surface and the protrusion extends away from the bottom surface, and wherein a boundary of the protrusion is spaced apart from an edge of the discrete recess defining the bottom surface.

11. The method of claim 9, wherein the protrusion has a length different than a length of the discrete recess.

12. The method of claim 11, wherein the length of the protrusion is not greater than about 95% of the length of the discrete recess.

13. The method of claim 9, wherein the protrusion has a width different than a width of the discrete recess.

14. The method of claim 9, wherein the protrusion has a height that is different than a depth of the discrete recess.

15. The method of claim 14, wherein the height of the protrusion is greater than the depth of the discrete recess.

16. The method of claim 9, wherein the discrete recess extends in a substantially linear direction along a first axis.

17. The method of claim 16, wherein the protrusion extends in a substantially linear direction along a second axis, and wherein the first axis is parallel to the second axis.

18. The method of claim 9, wherein the discrete recess has a two-dimensional shape defining three arms.

19. The method of claim 9, wherein the protrusion comprises an upper surface having a substantially triangular two-dimensional shape.

20. The method of claim 1, wherein treating further comprises subjecting the textured preform to a surface treatment process.