Abrasive particles having particular shapes and methods of forming such particles

• US 9,440,332 B2
• Filed: 10/15/2013
• Issued: 09/13/2016
• Est. Priority Date: 10/15/2012
• Status: Active Grant

• Current Assignee: Saint-Gobain Abrasives Incorporated (Compagnie De Saint-Gobain), Saint-Gobain Abrasifs (Compagnie de Saint-Gobain SA)
• Original Assignee: Saint-Gobain Abrasives Incorporated (Compagnie De Saint-Gobain), Saint-Gobain Abrasifs (Compagnie de Saint-Gobain SA)
• Inventors: Gaeta, Anthony C., Seth, Anuj, Arcona, Christopher, Yener, Doruk O., Czerepinski, Jennifer H., Iyengar, Sujatha, Csillag, Frank J., Rice, William C., Ramesh, Satyalakshmi K., Lafond, Gregory, Wijesooriya, Sidath S., Lior, Adam D., Brandes, Alan J., Parmar, Anil, Braun, Paul, Everts, Darrel K.
• Primary Examiner(s): VAN SELL, NATHAN L
• Application Number:
  US14/054,568
• Publication Number:
  US 20140106126A1
• Time in Patent Office: 1,064 Days
• Field of Search: 428/98, 428141-150, 428/195.1, 428/206, 428/210, 428323-340, 512/95, 512/97, 513/07
• US Class Current: 1/1
• CPC Class Codes: B24D 11/001 Manufacture of flexible abrasive materials
• CPC Class Codes: B24D 11/04 Zonally-graded surfaces
• CPC Class Codes: B24D 18/00 Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
• CPC Class Codes: B24D 18/0072 using adhesives for bonding abrasive particles or grinding elements to a support, e.g. by gluing
• CPC Class Codes: B24D 2203/00 Tool surfaces formed with a pattern
• CPC Class Codes: B24D 3/001 the constituent being used as supporting member
• CPC Class Codes: B24D 7/02 Wheels in one piece
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25
• CPC Class Codes: Y10T 428/24 Structurally defined web or sheet [e.g., overall dimension, etc.]
• CPC Class Codes: Y10T 428/24372 Particulate matter
• CPC Class Codes: Y10T 428/24893 including particulate material
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles

Abstract

An abrasive article comprising a first group including a plurality of shaped abrasive particles overlying a backing, wherein the plurality of shaped abrasive particles of the first group define a first non-shadowing distribution relative to each other.

Claims

1. An abrasive article comprising:

a first group including a plurality of shaped abrasive particles coupled to a backing, wherein each shaped abrasive particle of the first group of shaped abrasive particles shares at least one of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation, wherein each shaped abrasive particle of the first group of shaped abrasive particles includes a body having a first major surface, a second major surface, and a side surface extending between the first major surface and the second major surface, wherein the body is essentially free of a binder, wherein the body includes a length and a width defined by dimensions of the first or second major surfaces and the side surface defines a height of the body, wherein the height is less than the length and the width, and wherein each of the shaped abrasive particles of the first group is arranged in a side orientation with a side surface of the body closest to the backing and further is arranged in a frontal orientation relative to an axis of the backing, and wherein the first major surface or second major surface is substantially perpendicular to the axis of the backing, and wherein the first group comprises all of the shaped abrasive particles coupled to the backing that are arranged in the frontal orientation relative to the axis of the backing;

a second group comprising a plurality of shaped abrasive particles distinct from the first group and coupled to the backing, wherein each shaped abrasive particle of the second group of shaped abrasive particles shares at least one of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation, wherein each shaped abrasive particle of the second group of shaped abrasive particles includes a body having a first major surface, a second major surface, and a side surface extending between the first major surface and the second major surface, wherein the body is essentially free of a binder, wherein the body includes a length and a width defined by dimensions of the first or second major surfaces and the side surface defines a height of the body, wherein the height is less than the length and the width, and wherein each of the shaped abrasive particles of the second group is arranged in a side orientation with a side surface of the body closest to the backing and further is arranged in a sideways orientation relative to an axis of the backing, and wherein the first major surface or second major surface is substantially parallel to the axis of the backing, wherein the second group comprises all of the shaped abrasive particles coupled to the backing that are arranged in the sideways orientation relative to the axis of the backing;

wherein the first group defines a first region on the backing, the second group defines a second region on the backing, and wherein the first region and the second region are entirely separated from each other; and

wherein the plurality of shaped abrasive particles of the first group are arranged in a controlled, non-shadowing arrangement relative to each other, wherein the controlled, non-shadowing arrangement comprises a first shaped abrasive particle located at a first, predetermined position on the backing, a second shaped abrasive particle immediately adjacent to the first shaped abrasive particle and located at a second, predetermined position on the backing, and wherein the first and second, predetermined positions are staggered from each other relative to at least two axes defining a plane of the backing.

2. The abrasive article of claim 1, wherein each shaped abrasive particle of the first group of shaped abrasive particles comprises at least one feature different from a feature of at least one shaped abrasive particle of the second group, wherein the feature is selected from the group of features consisting of average particle size, two-dimensional particle shape, orientation relative to a grinding direction, average lateral space, average longitudinal space, side orientation, inverted orientation, flat orientation, composition, and predetermined distribution.

3. The abrasive article of claim 1, wherein the plurality of shaped abrasive particles of the first group are arranged in a first controlled, non-shadowing arrangement relative to each other, wherein the plurality of shaped abrasive particles of the second group are arranged in a second controlled, non-shadowing arrangement relative to each other, and wherein the first controlled, non-shadowing arrangement is different than the second controlled, non-shadowing arrangement.

4. The abrasive article of claim 3, wherein the first controlled, non-shadowing arrangement comprises a first pattern of shaped abrasive particles repeating a plurality of times within the first controlled, non-shadowing arrangement, wherein the second controlled, non-shadowing arrangement comprises a second pattern of shaped abrasive particles repeating a plurality of times within the second controlled, non-shadowing arrangement, and wherein the first pattern is different from the second pattern.

5. The abrasive article of claim 1, wherein a portion of the first shaped abrasive particle is abutting a portion of the second shaped abrasive particle.

6. The abrasive article of claim 1, wherein the first major surface of at least one shaped abrasive particle of the first group has a two-dimensional shape selected from a group consisting of:

a polygon, a triangle, a rectangle, a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, a decagon, an ellipsoid, a numeral, a Greek alphabet letter, a Latin alphabet letter, a Russian alphabet character, a Kanji character, a complex shape including a combination of polygonal and ellipsoid features defining linear and curved segments, or a combination thereof.

7. The abrasive article of claim 1, wherein the controlled, non-shadowing arrangement is a phyllotactic pattern.

8. The abrasive article of claim 1, wherein the backing has a circular geometry.

9. The abrasive article of claim 1, wherein at least an uppermost portion of each of the first shaped abrasive particle and the second shaped abrasive particle are visible in the plane of the backing when viewed from a grinding direction, and a degree of overlap of the first shaped abrasive particle and the second shaped abrasive particle during an initial phase of a material removal operation is not greater than about 25%.

10. The abrasive article of claim 1, wherein the first group is separated from the second group by a channel region.

11. The abrasive article of claim 10, wherein the channel region is free of shaped abrasive particles.

12. The abrasive article of claim 10, wherein the channel region extends along the backing and defines a patterned region that is free of shaped abrasive particles and separates the first group and the second group.

13. The abrasive article of claim 10, wherein the channel region comprises a width that is greater than a distance between any two immediately adjacent shaped abrasive particles within the first group.

14. The abrasive article of claim 1, wherein a majority of the shaped abrasive particles of the first group are arranged in the controlled, non-shadowing arrangement relative to each other.

15. The abrasive article of claim 14, wherein all of the shaped abrasive particles of the first group are arranged in the controlled, non-shadowing arrangement relative to each other.

16. The abrasive article of claim 1, wherein the plurality of shaped abrasive particles of the second group are arranged in a second controlled, non-shadowing arrangement relative to each other, wherein the second controlled, non-shadowing arrangement comprises a first shaped abrasive particle located at a first, predetermined position on the backing, a second shaped abrasive particle immediately adjacent to the first shaped abrasive particle and located at a second, predetermined position on the backing, and wherein the first and second, predetermined positions are staggered from each other relative to at least two axes defining a plane of the backing.

17. The abrasive article of claim 16, wherein a majority of the shaped abrasive particles of the second group are arranged in the second controlled, non-shadowing arrangement relative to each other.

18. The abrasive article of claim 17, wherein all of the shaped abrasive particles of the second group are arranged in the second controlled, non-shadowing arrangement relative to each other.

19. The abrasive article of claim 1, further comprising:

a third group comprising a plurality of shaped abrasive particles distinct from the first and second groups and coupled to the backing, wherein each shaped abrasive particle of the third group of shaped abrasive particles shares at least one of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation, wherein each shaped abrasive particle of the third group of shaped abrasive particles includes a body having a first major surface, a second major surface, and a side surface extending between the first major surface and the second major surface, wherein the body is essentially free of a binder, wherein the body includes a length and a width defined by dimensions of the first or second major surfaces and the side surface defines a height of the body, wherein the height is less than the length and the width, and wherein each of the shaped abrasive particles of the third group is arranged in a side orientation with a side surface of the body closest to the backing and further is arranged in a third rotational orientation relative to an axis of the backing that is different from a rotational orientation of the shaped abrasive particles within the first and second groups, and wherein the third group comprises all of the shaped abrasive particles coupled to the backing that are arranged in the third rotational orientation relative to the axis of the backing; and

wherein the plurality of shaped abrasive particles of the third group are arranged in a controlled, non-shadowing arrangement relative to each other, wherein the controlled, non-shadowing arrangement comprises a first shaped abrasive particle located at a first, predetermined position on the backing, a second shaped abrasive particle immediately adjacent to the first shaped abrasive particle and located at a second, predetermined position on the backing, and wherein the first and second, predetermined positions are staggered from each other relative to at least two axes defining a plane of the backing.

20. The abrasive article of claim 1, wherein the first region is continuous and the second region is continuous, and wherein the first region is non-overlapping with the second region.