Particulate materials and methods of forming same

• US 9,074,119 B2
• Filed: 12/30/2013
• Issued: 07/07/2015
• Est. Priority Date: 12/31/2012
• 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: Panzarella, Tracy H., Yener, Doruk O., Kavanaugh, Michael D., Brandes, Alan J.
• Primary Examiner(s): Parvini, Pegah
• Application Number:
  US14/143,656
• Publication Number:
  US 20140182216A1
• Time in Patent Office: 554 Days
• Field of Search: 513/07, 513/09
• US Class Current: 1/1
• CPC Class Codes: C01F 7/021 After-treatment of oxides or hydroxides
• CPC Class Codes: C01F 7/16 Preparation of alkaline-earth metal aluminates or magnesium aluminates; Aluminium oxide or hydroxide therefrom C01F7/028 takes precedence
• CPC Class Codes: C01G 17/00 Compounds of germanium
• CPC Class Codes: C01P 2004/03 obtained by SEM
• CPC Class Codes: C01P 2004/82 two phases having the same anion, e.g. both oxidic phases
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 35/62802 Powder coating materials
• CPC Class Codes: C04B 35/62813 Alumina or aluminates
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25
• CPC Class Codes: C09K 3/1418 obtained by division of a mass agglomerated by sintering
• CPC Class Codes: C09K 3/1436 Composite particles, e.g. coated particles

Abstract

A particulate material having a body including a first phase having at least about 70 wt % alumina for a total weight of the first phase, and a second phase comprising phosphorus, wherein the body includes at least about 0.1 wt % of the second phase for the total weight of the body, and wherein the second phase has an average grain size of not greater than about 1 micron.

Claims

1. A particulate material having a body including a first phase comprising alumina and a second phase comprising phosphorus and a rare earth element, wherein the second phase is substantially uniformly dispersed throughout the body, wherein the second phase comprises grains and the first phase comprises grains, and wherein the grains of the second phase have an average grain size less than an average grain size of the grains of the first phase.

2. The particulate material of claim 1, wherein the first phase comprises at least about 71 wt % alumina for the total weight of the first phase.

3. The particulate material of claim 1, wherein the body comprises at least about 0.2 wt % of the second phase for the total weight of the body.

4. The particulate material of claim 1, wherein the body comprises not greater than about 30 wt % of the second phase for the total weight of the body.

5. The particulate material of claim 1, wherein the second phase comprises monazite (LaPO₄).

6. The particulate material of claim 1, wherein the first phase comprises grains having an average grain size of not greater than about 1 micron.

7. The particulate material of claim 1, wherein the body is a shaped abrasive particle.

8. The particulate material of claim 1, wherein the body comprises a shape selected from the group consisting of triangular, quadrilateral, rectangular, trapezoidal, pentagonal, heptagonal, hexagonal, octagonal, and a combination thereof.

9. The particulate material of claim 1, wherein the body comprises a ratio [W1/W2], wherein W1 represents a weight percent of the first phase within the body and W2 represents a weight percent of the second phase within the body, and wherein the ratio [W1/W2] is at least about 1.5.

10. The particulate material of claim 1, wherein the body comprises a ratio [W1/W2], wherein W1 represents a weight percentage of the first phrase within the body and W2 represents the weight percent of the second phase within the body, and wherein the ratio [W1/W2] is not greater than about 100.

11. The particulate material of claim 1, wherein the first phase comprises grains and the second phase is primarily disposed at grain boundaries between the grains of the first phase.

12. The particulate material of claim 1, wherein the body comprises a third phase comprising lanthanum aluminate (LaAl₁₁O₁₈).

13. The particulate material of claim 1, wherein the particulate material is part of a fixed abrasive article selected from the group consisting of a coated abrasive article and a bonded abrasive article.

14. A particulate material having a body including a first phase comprising alumina and a second phase comprising phosphorus and a rare earth element, wherein the second phase is non-uniformly dispersed throughout the body, and wherein the first phase has an average grain size of not greater than about 10 microns.

15. The particulate material of claim 14, wherein the first phase comprises at least about 71 wt % alumina for the total weight of the first phase.

16. The particulate material of claim 14, wherein the body comprises at least about 0.2 wt % of the second phase for the total weight of the body.

17. The particulate material of claim 14, wherein the body comprises not greater than about 30 wt % of the second phase for the total weight of the body.

18. The particulate material of claim 14, wherein the second phase comprises monazite (LaPO₄).

19. The particulate material of claim 14, wherein the body is a shaped abrasive particle.

20. The particular material of claim 14, wherein the body comprises a third phase comprising lanthanum aluminate (LaAl₁₁O₁₈).