Abrasive articles including abrasive particles of silicon nitride

• US 9,598,620 B2
• Filed: 01/16/2015
• Issued: 03/21/2017
• Est. Priority Date: 06/30/2011
• Status: Active Grant

• Current Assignee: Fiven Norge As (Compagnie De Saint-Gobain S.A.)
• Original Assignee: Saint-Gobain Ceramics & Plastics Incorporated (Compagnie De Saint-Gobain S.A.)
• Inventors: Wang, Guan, Pujari, Vimal K., Boussant-Roux, Yves
• Primary Examiner(s): Parvini, Pegah
• Application Number:
  US14/598,860
• Publication Number:
  US 20150128505A1
• Time in Patent Office: 795 Days
• Field of Search: 501/97.1, 501/132, 501/152
• US Class Current: 1/1
• CPC Class Codes: B24D 11/001 Manufacture of flexible abrasive materials
• CPC Class Codes: B24D 3/14 ceramic, i.e. vitrified bondings
• 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

Abstract

An abrasive article includes a body having abrasive particles contained within a bond material. The abrasive particles can include a majority content of silicon nitride and a minority content of sintering material including at least two rare-earth oxide materials. In an embodiment, the rare-earth oxide materials can include Nd₂O₃ and Y₂O₃. In a particular embodiment, the abrasive particles comprise a content (wt %) of Nd₂O₃ that is greater than a content of Y₂O₃ (wt %).

Claims

1. A shaped abrasive particle comprising:

a body having (i) a majority content of silicon nitride; and

(ii) a minority content of sintering material including Nd₂O₃ and Y₂O₃, wherein the shaped abrasive particle comprises a content (wt %) of Nd₂O₃ greater than a content (wt %) of Y₂O₃;

wherein the body of the shaped abrasive particle has a two-dimensional shape as viewed in a plane defined by a length and a width of the body; and

wherein the two-dimensional shape is selected from the group consisting of a polygonal shape, an ellipsoidal shape, a numeral, a Greek alphabet character, a Latin alphabet character, a Russian alphabet character, and a complex shape utilizing a combination of polygonal shapes.

2. The shaped abrasive particle of claim 1, wherein the body of the shaped abrasive particle is part of a coated abrasive article or a bonded abrasive article.

3. The shaped abrasive particle of claim 1, wherein the body of the shaped abrasive particle comprises no greater than 5 vol % porosity.

4. The shaped abrasive particle of claim 1, wherein a side face of the shaped abrasive particle is convex or concave.

5. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle comprises a total content of rare earth oxide greater than a content of alumina.

6. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle comprises no greater than 10 wt % of a dopant material.

7. The shaped abrasive particle of claim 6, wherein the dopant material is selected from the group consisting of an alkali element, an alkaline earth element, a rare earth element, hafnium, zirconium, niobium, tantalum, molybdenum, vanadium, or a combination thereof.

8. The shaped abrasive particle of claim 1, wherein the body of the shaped abrasive particle has 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, and wherein h₁ is different than h₂.

9. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle comprises a majority content (>

50 wt %) of beta-phase silicon nitride.

10. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle has a base surface and an upper surface, and wherein the base surface has a planar shape different than a planar shape of the upper surface.

11. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle has a center of mass and a geometric midpoint, and wherein the center of mass is disposed at a different location than the geometric midpoint.

12. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle has a twist angle rotatably offsetting opposing end faces of the shaped abrasive particle, the twist angle being less than 360°

.

13. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle has:

an aspect ratio of length;

width of at least 1;

1,

an aspect ratio of height;

width of at least 0.5;

1,

an aspect ratio of length;

height of at least 1;

1, or

a combination thereof.

14. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle further comprises a sintering aid.

15. The shaped abrasive particle of claim 14, wherein the sintering aid comprises an oxide selected from the group consisting of Al₂O₃, MgO, TiO₂, AlN, or a combination thereof.

16. The shaped abrasive particle of claim 14, wherein the sintering aid comprises no greater than 13.2 wt % of the shaped abrasive particle.

17. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle comprises a polyhedron.

18. A batch of shaped abrasive particles comprising:

a plurality of shaped abrasive particles, wherein each shaped abrasive particle of the plurality of shaped abrasive particles comprises;

a body having (i) a majority content of silicon nitride; and

(ii) a minority content of sintering material including Nd₂O₃ and Y₂O₃, wherein the shaped abrasive particle comprises a content (wt %) of Nd₂O₃ greater than a content (wt %) of Y₂O₃;

wherein the body of the shaped abrasive particle has a two-dimensional shape as viewed in a plane defined by a length and a width of the body; and

wherein the two-dimensional shape is selected from the group consisting of a polygonal shape, an ellipsoidal shape, a numeral, a Greek alphabet character, a Latin alphabet character, a Russian alphabet character, and a complex shape utilizing a combination of polygonal shapes.