Abrasive particles having particular shapes and methods of forming such particles

• US 9,017,439 B2
• Filed: 05/07/2014
• Issued: 04/28/2015
• 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:
  US14/272,400
• Publication Number:
  US 20140325916A1
• Time in Patent Office: 356 Days
• Field of Search: 512/93, 513/07, 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 the body comprises a normalized height difference defined by the equation [(h1−

h2)/(h1/h2)] of at least about 40 microns, wherein h1 is greater than h2;

wherein at least a portion of the upper surface has a curvilinear contour; and

wherein the body comprises a bottom surface opposite the upper surface and having a substantially planar contour, wherein the bottom surface has a greater surface area relative to the upper surface.

2. The abrasive article of claim 1, wherein the bottom surface comprises a surface area defined as a bottom area (Ab) and the body has a cross-sectional midpoint area (Am) defining an area of a plane perpendicular to the bottom area and extending through a midpoint of the shaped abrasive particle, and wherein the body comprises an area ratio of bottom area to midpoint area (Ab/Am) of not greater than about 6.

3. The abrasive article of claim 1, wherein the body comprises a normalized height difference of at least about 43 microns.

4. The abrasive article of claim 1, wherein the body comprises a normalized height difference of not greater than about 200 microns.

5. The abrasive article of claim 1, wherein an average difference in height between the first height and the second height is at least about 50 microns.

6. The abrasive article of claim 5, wherein the average difference in height is not greater than about 300 microns.

7. The abrasive article of claim 1, wherein the body comprises a length and a width, and wherein the body comprises a primary aspect ratio of length:

width of at least about 1;

1 and not greater than about 10;

1.

8. The abrasive article of claim 7, wherein the body comprises a height, and wherein the body comprises a secondary aspect ratio defined by a ratio of width:

height within a range between about 5;

1 and about 1;

3.

9. The abrasive article of claim 8, wherein the body comprises a tertiary aspect ratio defined by a ratio of length:

height within a range between about 6;

1 and about 1.5;

1.

10. The abrasive article of claim 1, wherein the shaped abrasive particle comprises an average difference in height [h1−

h2] and a profile length (l_p), and wherein the shaped abrasive particle comprises a profile ratio defined by the equation [(h1−

h2)/(l_p)] of not greater than about 0.3.

11. The abrasive article of claim 1, wherein the shaped abrasive particle is part of a sample of shaped abrasive particles comprising a plurality of individual shaped abrasive particles, each individual 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 sample comprises a height variation of at least about 20 microns.

12. The abrasive article of claim 11, wherein the sample comprises at least about 5 randomly-selected shaped abrasive particles made in a single forming process.

13. The abrasive article of claim 11, wherein the height variation is not greater than about 180 microns, not greater than about 150 microns, not greater than about 130 microns.

14. The abrasive article of claim 1, wherein the body comprises a rake angle defined as the angle between the first side surface and the bottom surface and wherein the rake angle comprises a value within a range between about 1°

and about 80°

.

15. The abrasive article of claim 1, wherein the body comprises a substantially trapezoidal two-dimensional shape as viewed in a plane defined by a length and a width of the body.

16. The abrasive article of claim 1, wherein the body comprises a polycrystalline material.

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

18. The abrasive article of claim 1, wherein the body comprises abrasive grains selected from the group of materials consisting of nitrides, oxides, carbides, borides, oxynitrides, diamond, and a combination thereof.

19. The abrasive article of claim 1, wherein the shaped abrasive particle is incorporated into a coated abrasive article or a bonded abrasive article.

20. The abrasive article of claim 19, wherein the shaped abrasive particle is applied to a substrate of the coated abrasive article.

21. The abrasive article of claim 1, wherein the upper surface comprises at least one depression.