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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
First Claim
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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.

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