Particulate materials and methods of forming same

• US 9,676,982 B2
• Filed: 06/02/2015
• Issued: 06/13/2017
• Est. Priority Date: 12/31/2012
• 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: Kavanaugh, Michael D., Yener, Doruk O., Panzarella, Tracy H., Brandes, Alan J.
• Primary Examiner(s): Parvini, Pegah
• Application Number:
  US14/728,628
• Publication Number:
  US 20150267099A1
• Time in Patent Office: 742 Days
• CPC Class Codes: C01F 7/021 After-treatment of oxides or hydroxides
• CPC Class Codes: C01F 7/16 Preparation of alkaline-earth metal aluminates or magnesium aluminates; Aluminium oxide or hydroxide therefrom C01F7/028 takes precedence
• CPC Class Codes: C01G 17/00 Compounds of germanium
• CPC Class Codes: C01P 2004/03 obtained by SEM
• CPC Class Codes: C01P 2004/82 two phases having the same anion, e.g. both oxidic phases
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 35/62802 Powder coating materials
• CPC Class Codes: C04B 35/62813 Alumina or aluminates
• 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
• CPC Class Codes: C09K 3/1436 Composite particles, e.g. coated particles

Abstract

A particulate material having a body including a first phase having at least about 70 wt % alumina for a total weight of the first phase, and a second phase comprising phosphorus, wherein the body includes at least about 0.1 wt % of the second phase for the total weight of the body, and wherein the second phase has an average grain size of not greater than about 1 micron.

Claims

1. A particulate material having a body including a first phase comprising alumina and a second phase comprising an oxide compound, wherein the oxide compound comprises phosphorus and a rare earth element, wherein the body comprises a greater content of the second phase within a peripheral region of the body as compared to a content of the second phase within a central region of the body wherein the body is a shaped abrasive particle.

8. The particulate material according to claim 1, wherein the body includes at least 0.5 to 30 wt % of the second phase for the total weight of the body.

9. The particulate material according to claim 1, wherein the second phase comprises LaPO₄.

10. The particulate material according to claim 1, wherein the particulate material is part of a fixed abrasive article selected from the group consisting of a coated abrasive article and a bonded abrasive article.

11. The particulate material according to claim 1, wherein the body comprises a two-dimensional shape selected from the group consisting of triangular, quadrilateral, rectangular, trapezoidal, pentagonal, heptagonal, hexagonal, and octagonal.

13. The particulate material according to claim 1, wherein the first phase has an average grain size of not greater than about 500 μ

m and the second phase has an average grain size of not greater than about 1 micron.

16. The particulate material according to claim 1, wherein the content of the second phase in the peripheral region is greater than half of the total amount of second phase in the body based on the weight of the second phase.

17. The particulate material according to claim 1, wherein the first phase includes at least 70 to 99.5 wt % alumina for the total weight of the first phase.

2. A particulate material having a body including a first phase comprising alumina and a second phase comprising phosphorus and a rare earth element, wherein the body comprises a greater content of the second phase within a peripheral region of the body as compared to a content of the second phase within a central region of the body, and wherein the body further comprises a third phase, and wherein the third phase comprises lanthanum aluminate.

3. The particulate material according to claim 2, wherein the body includes at least 0.5 to 30 wt % of the third phase for the total weight of the body.

4. The particulate material according to claim 2, wherein the second phase comprises monazite.

5. The particulate material according to claim 2, wherein the body comprises a ratio [W3/W2], wherein W3 represents a weight percent of the third phase within the body and W2 represents a weight percent of the second phase within the body, and wherein the ratio [W3/W2] is at least about 1.5.

6. The particulate material according to claim 2, wherein the body comprises a ratio [G1/G3], wherein G1 represents an average grain size of the first phase and G3 represents an average grain size of the third phase, and wherein the ratio [G1/G3 ] is in a range between about 0.2 and 5.

7. The particulate material according to claim 2, wherein the third phase is disposed within grains of the first or second phases.

12. The particulate material according to claim 2, wherein the body is a shaped abrasive particle.

14. The particulate material according to claim 2, wherein the body comprises a greater content of the third phase within a peripheral region of the body as compared to a content of the third phase within a central region of the body.

15. The particulate material according to claim 2, wherein the content of the third phase is uniformly dispersed in the body.

18. A particulate material having a body including a first phase comprising alumina and a second phase comprising phosphorus and a rare earth element, wherein the body comprises a greater content of the second phase within a peripheral region of the body as compared to a content of the second phase within a central region of the body, and wherein the body is a shaped abrasive particle.

19. The particulate material according to claim 18, wherein the second phase comprises LaPO₄.

20. The particulate material according to claim 18, wherein the particulate material is part of a fixed abrasive article selected from the group consisting of a coated abrasive article and a bonded abrasive article.