Shaped abrasive particles and methods of forming same

• US 9,428,681 B2
• Filed: 10/28/2015
• Issued: 08/30/2016
• Est. Priority Date: 05/23/2012
• 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: Bauer, Ralph, Barnes, Martin, Demers, Rene G., Skowron, Margaret L.
• Primary Examiner(s): KILIMAN, LESZEK B
• Application Number:
  US14/925,191
• Publication Number:
  US 20160053151A1
• Time in Patent Office: 307 Days
• Field of Search: 428/402
• US Class Current: 1/1
• CPC Class Codes: B01J 2/20 by expressing the material, e.g. through sieves and fragmenting the extruded length
• CPC Class Codes: B01J 2/22 by pressing in moulds or between rollers
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 2235/6021 Extrusion moulding
• CPC Class Codes: C04B 35/10 based on aluminium oxide
• CPC Class Codes: C04B 35/624 Sol-gel processing
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25
• CPC Class Codes: C09K 3/1427 obtained by division of a mass agglomerated by melting, at least partially, e.g. with a binder
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]

Abstract

A method of forming a shaped abrasive particle includes applying a mixture into a shaping assembly within an application zone and directing an ejection material at the mixture in the shaping assembly under a predetermined force, removing the mixture from the shaping assembly and forming a precursor shaped abrasive particle.

Claims

1. A batch of shaped abrasive particles including a first portion comprising a shaped abrasive particle having a tortuous contour extending along at least a portion of a first major surface.

2. The batch of claim 1, wherein the tortuous contour comprises a first planar portion, a second planar portion, and a curved portion joining the first planar portion and the second planar portion.

3. The batch of claim 1, wherein the tortuous contour comprises a first curved portion, a second curved portion, and a planar portion joining the first curved portion and the second curved portion.

4. The batch of claim 3, wherein the first curved portion defines a substantially convex curvature and the second curved portion is spaced apart from the first curved portion and defines a substantially concave portion.

5. The batch of claim 3, wherein the first curved portion and the second curved portion define different radiuses of curvature compared to each other.

6. The batch of claim 1, wherein the shaped abrasive particle comprises a body, and wherein the tortuous contour defines a waviness having a first curved portion extending above a line that extends between a first corner and a second corner of the body, and further comprising a second curved portion extending below the line.

7. The batch of claim 6, wherein the first curved portion extends above the line for a peak height of at least about 5% of an average height of the particle and wherein the second curved portion extends below the line for a valley height of at least about 5% of an average height of the particle.

8. The batch of claim 1, wherein the shaped abrasive particle comprises the first major surface, a second major surface, and a side surface joining the first major surface and the second major surface.

9. The batch of claim 8, wherein the tortuous contour extends along at least a portion of the second major surface.

10. The batch of claim 8, wherein the tortuous contour extends along at least a portion of the side surface.

11. The batch of claim 8, wherein the tortuous contour extends along at least an edge joining the first major surface and the side surface.

12. The batch of claim 8, wherein the side surface extends at a generally orthogonal angle relative to at least one of the first major surface and the second major surface.

13. The batch of claim 1, wherein the shaped abrasive particle comprises a body having a percent flashing of not greater than about 10%.

14. The batch of claim 1, wherein the shaped abrasive particle comprises a body having a length (l), a width (w), and a height (hi), wherein the height (hi) is an interior height of the body, and wherein the width>

length, wherein the length>

height, wherein the width>

height.

15. The batch of claim 1, wherein the shaped abrasive particle comprises a body having 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 polygons, ellipsoids, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, triangles, quadrilaterals, rectangles, pentagons, hexagons, heptagons, octagons, nonagons, decagons, and a combination thereof.

16. The batch of claim 1, wherein the first portion comprises a minority of a total number of shaped abrasive particles of the batch.

17. The batch of claim 1, wherein the batch further comprises a second portion of shaped abrasive particles, wherein the second portion of shaped abrasive particles have a discrete shape feature different than the tortuous contour of the shaped abrasive particles of the first portion.

18. The batch of claim 1, wherein the batch is part of a fixed abrasive article selected from the group consisting of bonded abrasive articles, coated abrasive articles, and a combination thereof.

19. The batch of claim 18, wherein the fixed abrasive article comprises a coated abrasive article, and wherein the first portion of the batch includes a plurality of shaped abrasive particles, each of the shaped abrasive particles of the plurality of shaped abrasive particles being arranged in a controlled orientation relative to a backing, the controlled orientation including at least one of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation.

20. The batch of claim 19, wherein the shaped abrasive particle is coupled to the backing in a side orientation relative to the backing.