Shaped abrasive particle and method of forming same

• US 9,765,249 B2
• Filed: 07/18/2014
• Issued: 09/19/2017
• Est. Priority Date: 12/30/2011
• 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: Braun, Paul, Yener, Doruk O., Czerepinski, Jennifer H., Bauer, Ralph, Subramanian, Krishnamoorthy, Bright, Robin M., Seth, Anuj, Lafond, Gregory G.
• Primary Examiner(s): Olsen, Kaj K
• Assistant Examiner(s): Christie, Ross J
• Application Number:
  US14/335,323
• Publication Number:
  US 20140325917A1
• Time in Patent Office: 1,159 Days
• Field of Search: None
• 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: C01P 2004/39 parallelepiped-like
• CPC Class Codes: C09C 1/24 Oxides of iron
• CPC Class Codes: C09C 1/407 Aluminium oxides or hydroxides
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25
• CPC Class Codes: C09K 3/1427 obtained by division of a mass agglomerated by melting, at least partially, e.g. with a binder
• CPC Class Codes: C09K 3/1436 Composite particles, e.g. coated particles

Abstract

A method of forming a mixture including a ceramic material into a sheet, sectioning at least a portion of the sheet using a mechanical object and forming at least one shaped abrasive particle from the sheet, such that the at least one shaped abrasive particle can have a two-dimensional shape as viewed in a plane defined by a length and a width of the shaped abrasive particle selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.

Claims

1. A particulate material comprising:

a shaped abrasive particle having a body comprising a corner-truncated polygonal shape including a first side, a second side, and a third side disposed between the first side and second side, wherein the third side has a width shorter than a width of the first side and shorter than a width of the second side, wherein the body has a first angle between the third side and the first side greater than 90°

, wherein the body is essentially free of a binder, and wherein the body comprises a corner truncated quadrilateral two-dimensional shape.

2. The particulate material of claim 1, wherein the third side comprises a width of not greater than about 60% and at least about 2% of the width of the first side.

3. The particulate material of claim 1, wherein the particulate material is part of a batch of particulate material and defines a first type of abrasive particle having a first polygonal shape, and wherein the batch includes a second type of abrasive particle having a different polygonal shape with respect to the first type of abrasive particle, and wherein the batch comprises:

a first type of shaped abrasive particle and a second type of shaped abrasive particle, and wherein the first type of shaped abrasive particle comprises the corner-truncated shaped abrasive particle having a length (l), the width of the first side (w), and a height (h), and wherein the first type of shaped abrasive particle comprises a first polygonal shape as viewed in a plane defined by the length and width; and

a second type of shaped abrasive particle comprising a length (l), a width (w), and a height (h), wherein the second type of shaped abrasive particle comprises a second polygonal shape as viewed in a plane defined by the length and width, the second polygonal shape being different than the first polygonal shape.

4. The particulate material of claim 1, wherein the body comprises the width of the first side (w), a length (l), and a height (h), wherein the width>

length, the width>

height, and the length>

height, and wherein a side surface defines a height of the body.

5. The particulate material of claim 1, further comprising a ripple feature extending along at least a portion of at least one side surface of the body.

6. The particulate material of claim 1, wherein the particulate material is incorporated in a fixed abrasive article.

7. The particulate material of claim 1, wherein the body comprises a ceramic material comprising an oxide, a nitride, a carbide, a boride, an oxycarbide, an oxynitride, or a combination thereof.

8. The particulate material of claim 1, wherein the width of the first side is at least equal to the width of the second side.

9. The particulate material of claim 1, further comprising a second angle between the third side and the second side greater than 90°

.

10. The particulate material of claim 9, wherein the first angle is the same as the second angle.

11. The particulate material of claim 9, wherein the first angle is different than the second angle.

12. The particulate material of claim 1, further comprising a fourth side, wherein the fourth side has a width that is at least equal to the width of the first side.

13. The particulate material of claim 12, further comprising a fifth side between the first side and the fourth side.

14. The particulate material of claim 1, wherein the body comprises an additive selected from the group consisting of alkali elements, alkaline earth elements, rare-earth elements, hafnium (Hf), zirconium (Zr), niobium (Nb), tantalum (Ta), molybdenum (Mo), and a combination thereof.

15. The particulate material of claim 1, wherein the body further comprises a first major surface, a second major surface, and a side surface extending between the first major surface and second major surface, wherein the side surface comprises a fractured region.

16. The particulate material of claim 15, wherein the fractured region intersects the second major surface of the body.

17. The particulate material of claim 15, wherein the fractured region has a height extending for a majority of a height of the body on at least one side surface.

18. The particulate material of claim 15, wherein the fractured region extends along a majority of the side surface of the body.

19. The particulate material of claim 15, wherein the fractured region abuts a truncated corner of the body.

20. The particulate material of claim 15, wherein the fractured region defines a serrated edge comprising protrusions and grooves.