Shaped abrasive particle fractions and method of forming same

• US 9,676,981 B2
• Filed: 12/24/2014
• Issued: 06/13/2017
• Est. Priority Date: 12/24/2014
• 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: Louapre, David, Marazano, Alexandra, Salvatore, James A.
• Primary Examiner(s): MCDONOUGH, JAMES E
• Application Number:
  US14/582,448
• Publication Number:
  US 20160186028A1
• Time in Patent Office: 902 Days
• Field of Search: 51309, 51293, 51307
• CPC Class Codes: B01J 2/22 by pressing in moulds or between rollers
• CPC Class Codes: B01J 2/26 on endless conveyor belts
• 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

A method of forming a shaped abrasive particle including forming a precursor shaped abrasive particle having a body including at least one predetermined stress concentration point and at least one predetermined stress concentration vector and processing the precursor shaped abrasive particle and fracturing the precursor shaped abrasive particle substantially along the predetermined stress concentration vector to form a fractured shaped abrasive particle.

Claims

1. A shaped abrasive particle fraction comprising a body including a bottom surface, an upper surface, and a side surface extending between the bottom surface and the upper surface, wherein the upper surface defines a shovel shape including a concave surface having a tip region including at least one tip corner and at least one rear region defining at least one rear corner, wherein the tip corner has a tip sharpness that is greater than a tip sharpness of the at least one rear corner, wherein the upper surface comprises a first upper edge and a second upper edge, wherein the first upper edge and second upper edge defining a portion of the shovel shape and intersect at the tip region, wherein the rear region defines at least one rear edge, and wherein the rear edge has an edge sharpness less than a sharpness of the first upper edge or second upper edge, and further wherein the at least one rear edge has a more rounded contour in comparison to the fist upper edge and the second upper edge.

2. The shaped abrasive particle fraction of claim 1, wherein the at least one tip corner has a tip sharpness that is at least about 50% sharper than the tip sharpness of the at least one rear corner.

3. The shaped abrasive particle fraction of claim 1, wherein the at least one tip corner has a tip sharpness that is at least about 90% sharper than the tip sharpness of the at least one rear corner.

4. The shaped abrasive particle fraction of claim 1, wherein the at least one tip corner has a tip sharpness that is not greater than about 50 microns.

5. The shaped abrasive particle fraction of claim 1, wherein the at least one tip corner has a tip sharpness that is not greater than about 15 microns.

6. The shaped abrasive particle fraction of claim 1, wherein the at least one rear corner has a tip sharpness of at least about 50 microns.

7. The shaped abrasive particle fraction of claim 1, wherein the first upper edge and the second upper edge define regions of the greatest height on the body as viewed from the side.

8. The shaped abrasive particle fraction of claim 1, wherein the at least one rear corner is located at a higher position on the concave surface relative to the at least one tip corner.

9. The shaped abrasive particle fraction of claim 1, wherein the at least one rear region comprises a second rear corner.

10. The shaped abrasive particle fraction of claim 9, wherein the at least one tip corner has a tip sharpness that is at least about 50% sharper than the tip sharpness of the second rear corner.

11. The shaped abrasive particle fraction of claim 9, wherein the second rear corner has a tip sharpness of at least about 50 microns.

12. The shaped abrasive particle fraction of claim 1, wherein the bottom surface comprises a rounded contour.

13. The shaped abrasive particle fraction of claim 1, wherein the first upper edge and the second upper edge each define a fractured edge.

14. The shaped abrasive particle fraction of claim 1, wherein the body comprises at least one of an oxide, a nitride, a carbide, a boride, an oxycarbide, an oxynitride, or any combination thereof.

15. The shaped abrasive particle fraction of claim 1, wherein the body comprises alumina.

16. The shaped abrasive particle fraction of claim 1, wherein the body comprises at least 90 wt % alumina for the total weight of the body.

17. The shaped abrasive particle fraction of claim 1, wherein the upper surface comprises an axis extending from the tip corner to a midpoint of the rear edge, wherein at least one point along the axis is lower in height than the first upper edge.

18. The shaped abrasive particle fraction of claim 17, wherein at least one point along the axis is lower in height than the second upper edge.

19. The shaped abrasive particle fraction of claim 1, wherein the at least one rear corner and the tip corner are located on the concave surface.

20. The shaped abrasive particle fraction of claim 19, wherein, relative to the tip corner, the at least one rear corner is located at a higher position on the body as viewed from the side.