Abrasive particles having particular shapes and methods of forming such particles

• US 10,106,714 B2
• Filed: 06/28/2013
• Issued: 10/23/2018
• Est. Priority Date: 06/29/2012
• 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: Yener, Doruk O., Czerepinski, Jennifer H., Kavanaugh, Michael D., Marlin, Samuel S., Breder, Kristin K., Iyengar, Sujatha
• Primary Examiner(s): Dunn, Colleen P
• Assistant Examiner(s): Christie, Ross J
• Application Number:
  US13/931,573
• Publication Number:
  US 20140007518A1
• Time in Patent Office: 1,943 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: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]

Abstract

A shaped abrasive particle including a body having a length (l), a width (w), and a height (hi), wherein the height is at least about 28% of the width, and a percent flashing (f) of at least about 10% and not greater than about 45% for a total side area of the body.

Claims

1. A shaped abrasive particle comprising:

a body including;

a bottom surface, an upper surface, a side surface extending between the bottom surface and the upper surface, wherein the side surface is at least partially concave;

a percent flashing (f) of at least about 16% and not greater than about 45% of the area of the body as viewed from the side; and

a length (l), a width (w), and a height (hi), wherein the height (hi) is an interior height of the body and at least about 35% of the width, wherein the width (w) is ≥

the height (hi), and wherein the height (hi) extends between the bottom surface and the upper surface.

2. The shaped abrasive particle of claim 1, wherein the height (hi) is at least about 43% of the width.

3. The shaped abrasive particle of claim 1, wherein the percent flashing is at least about 20% and not greater than about 40%.

4. The shaped abrasive particle of claim 1, wherein the body comprises a shape selected from the group consisting of triangular, quadrilateral, rectangular, trapezoidal, pentagonal, hexagonal, heptagonal, octagonal, and a combination thereof.

5. The shaped abrasive particle of claim 1, wherein the side surface is tapered relative to a vertical axis extending in a direction of the height of the body.

6. The shaped abrasive particle of claim 1, wherein the body comprises a polycrystalline material selected from the group of materials consisting of nitrides, oxides, carbides, borides, oxynitrides, diamond, and a combination thereof.

7. The shaped abrasive particle of claim 1, wherein the body comprises a normalized height difference defined by the absolute value of the equation [(hc−

hm)/(hi)] of not greater than about 0.3.

8. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle is one of a batch of the shaped abrasive particles, the batch comprising a width variation (Vw) of not greater than about 0.9 mm.

9. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle is one of a batch of shaped abrasive particles, the shaped abrasive particles of the batch of shaped abrasive particles comprising an interior height variation (Vhi) of not greater than about 70 microns.

10. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle is one of a batch of shaped abrasive particles, the shaped abrasive particles of the batch of shaped abrasive particles comprising a height and flashing multiplier value (hiF) variation (VhiF) of not greater than about 380 micron %.

11. The shaped abrasive particle of claim 1, wherein the body comprises a profile ratio of at least about 0.0001, wherein the profile ratio is defined as a ratio between an average difference in height and a profile length [(hc−

hm)/(Lmiddle)].

12. The shaped abrasive particle of claim 1, wherein the body is essentially free of a binder.

13. The shaped abrasive particle of claim 1, wherein the body has a normalized height difference defined by the absolute value of the equation [(hc−

hm)/(hi)] of at least about 0.04.

14. The shaped abrasive particle of claim 1, wherein an innermost point of the side surface is disposed between the bottom surface and the upper surface.

15. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle is one of a batch of shaped abrasive particles, the shaped abrasive particles of the batch of shaped abrasive particles having a half-life change in specific grinding energy of not greater than about 8% for a material removal rate of at least about 1 in³/min/in (6.45 cm³/min/cm).

16. The shaped abrasive particle of claim 1, wherein the shaped abrasive particle is one of a batch of shaped abrasive particles, and wherein a majority of the shaped abrasive particles of the batch of shaped abrasive particles are oriented in a predetermined orientation relative to a backing of an abrasive article.

17. The shaped abrasive particle of claim 1, wherein the body can have a first height at a first corner and a second height at a second corner, and wherein the first height is greater than the second height.

18. The shaped abrasive particle of claim 1, wherein the body comprises a normalized height difference of at least about 0.06.

19. The shaped abrasive particle of claim 1, wherein the percent flashing (f) is at least 16% and not greater than 40% of the area of the body as viewed from the side;

and wherein the interior height (hi) of the body is at least 40% of the width.

20. The shaped abrasive particle of claim 1, wherein the percent flashing (f) is at least 16% and not greater than 36% of the area of the body as viewed from the side;

and wherein the interior height of the body is at least 43% of the width.