Shaped abrasive particles and methods of forming same
First Claim
Patent Images
1. A method of forming a shaped abrasive particle having a body, the method comprising:
- depositing a print material from a nozzle to a target using an additive manufacturing process to form the body of the shaped abrasive particle, wherein the print material comprises a viscosity of at least about 4×
103 Pa s; and
controlling a dispense gap defining a distance between the nozzle and the target, wherein the dispense gap is not greater than about 10 W, wherein “
W”
represents the width of the nozzle, and wherein controlling the dispense gap includes varying a Z-directional distance between the nozzle and the target based upon at least one of the nozzle tip length, the nozzle width, the deposition pressure, the deposition rate, the deposition volume, the deposition position, the filling pattern of the print material, the dynamic yield stress (σ
d) of the print material, the static yield stress (σ
s) of the print material, the yield stress ratio (σ
d/σ
s) of the print material, and the viscosity of the print material.
1 Assignment
0 Petitions
Accused Products
Abstract
A method of forming a shaped abrasive particle having a body formed by an additive manufacturing process.
528 Citations
19 Claims
-
1. A method of forming a shaped abrasive particle having a body, the method comprising:
-
depositing a print material from a nozzle to a target using an additive manufacturing process to form the body of the shaped abrasive particle, wherein the print material comprises a viscosity of at least about 4×
103 Pa s; andcontrolling a dispense gap defining a distance between the nozzle and the target, wherein the dispense gap is not greater than about 10 W, wherein “
W”
represents the width of the nozzle, and wherein controlling the dispense gap includes varying a Z-directional distance between the nozzle and the target based upon at least one of the nozzle tip length, the nozzle width, the deposition pressure, the deposition rate, the deposition volume, the deposition position, the filling pattern of the print material, the dynamic yield stress (σ
d) of the print material, the static yield stress (σ
s) of the print material, the yield stress ratio (σ
d/σ
s) of the print material, and the viscosity of the print material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
-
-
10. A method of forming a shaped abrasive particle having a body, wherein forming the body comprises:
-
depositing a print material from a nozzle to a target using an additive manufacturing process, wherein the additive manufacturing process includes depositing a plurality of discrete portions of print material in a controlled, non-random manner relative to each other in a filling pattern, and wherein the print material comprises a viscosity of at least about 4×
10−
3 Pa·
s; andcontrolling a dispense gap defining a distance between the nozzle and the target wherein the dispense gap is not greater than about 10 W, wherein “
W”
represents the width of the nozzle,wherein depositing the print material comprises depositing a first print material as a first portion of the body at a first time; and
depositing a second print material as a second portion of the body distinct from the first portion at a second time; andwherein depositing the print material comprises using an outside-in filling process, an inside-out filling process, a side-to-side filling process, a bottom-up filling process, or a combination thereof. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18)
-
-
19. A method of forming a shaped abrasive particle having a body, the method comprising:
-
depositing a print material from a nozzle to a target using an additive manufacturing process to form the body of the shaped abrasive particle, wherein depositing the print material comprises depositing a plurality of discrete portions of the print material in a controlled, non-random manner relative to each other, and wherein the print material comprises a viscosity of at least about 4×
103 Pa s; andcontrolling a dispense gap defining a distance between the nozzle and the target, wherein the dispense gap is not greater than about 10 W, wherein “
W”
represents the width of the nozzle;wherein the nozzle comprises a nozzle width not greater than about 100 microns, a tip length of not greater than about 10 mm, and an aspect ratio value (width/tip length) of not greater than about 0.8; and wherein the body comprises a corner roundness of not greater than about 100 microns.
-
Specification