Shaped abrasive particles and methods of forming same

Patent metadata

Field	Value
Publication number	US-10000676-B2
Application number	US-201715592430-A
Country	US
Kind code	B2
Filing date	May 11, 2017
Priority date	May 23, 2012
Publication date	Jun 19, 2018
Grant date	Jun 19, 2018

Abstract

A method of forming a shaped abrasive particle includes applying a mixture into a shaping assembly within an application zone and directing an ejection material at the mixture in the shaping assembly under a predetermined force, removing the mixture from the shaping assembly and forming a precursor shaped abrasive particle.

First claim

What is claimed is:

1. A system for forming precursor shaped abrasive particles having a batch productivity of at least about 0.1 kg/min/m 2 of shaping surface.

2. The system of claim 1 , wherein the system comprises an application zone comprising a shaping assembly including:
a first portion having an opening and configured to be filled with a mixture; and
a second portion abutting the first portion.

3. The system of claim 2 , wherein the mixture comprises a gel comprising a ceramic powder material as an integrated network of discrete particles.

4. The system of claim 2 , wherein the mixture comprises not greater than about 30 wt % organic materials for the total weight of the mixture.

5. The system of claim 2 , wherein the mixture comprises a storage modulus of at least about 1×10 4 Pa.

6. The system of claim 2 , wherein the mixture comprises a viscosity of at least about 4×10 3 Pa s.

7. The system of claim 2 , wherein the first portion comprises a screen and the second portion comprises a backing plate, wherein the first portion and the second portion are adjacent to each other in the application zone.

8. The system of claim 7 , wherein a surface of the backing plate is configured to contact the mixture in the opening of the screen.

9. The system of claim 2 , wherein at least a portion of the shaping assembly is translated through the application zone.

10. The system of claim 2 , further comprising an extruder configured to extrude the mixture through a die opening and into the opening in the shaping assembly.

11. The system of claim 2 , wherein the mixture comprises a change in weight of less than about 5% for a total weight of the mixture for a duration that the mixture is in the opening of the shaping assembly.

12. The system of claim 2 , further comprising a translator configured to translate at least a portion of the shaping assembly from the application zone to an ejection zone.

13. The system of claim 2 , wherein the mixture comprises a change in volume of less than about 5% for a total volume of the mixture for a duration that the mixture is in the opening of the shaping assembly.

14. The system of claim 2 , wherein an average residence time of the mixture in the opening of the shaping assembly is less than about 18 minutes.

15. The system of claim 2 , wherein an average residence time of the mixture in the opening of the shaping assembly is less than about 20 seconds.

16. The system of claim 2 , wherein the system comprises an ejection zone comprising an ejection assembly configured to direct an ejection material toward the opening in the first portion of the shaping assembly and wherein the ejection material is directed at the mixture in the shaping assembly under a predetermined force of at least about 0.1 N.

17. The system of claim 16 , wherein the ejection assembly comprises an ejection material opening defining an ejection material opening width, and wherein the opening in the shaping assembly comprises a shaping assembly opening width, wherein the ejection material opening width is different than the shaping assembly opening width.

18. The system of claim 16 , wherein the application zone and ejection zone are configured to be operated at a temperature differential of not greater than about 10° C.

19. The system of claim 2 , wherein the mixture comprises a coil value of at least about 1800 N.

20. The system of claim 2 , wherein the system comprises a batch efficiency of at least about 0.05 kg/min.

Assignees

• Saint Gobain Ceramics

Inventors

• Bauer Ralph
• Barnes Martin
• Demers Rene G
• Skowron Margaret L

Classifications

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title

• B01J2/20

  by expressing the material, e.g. through sieves and fragmenting the extruded length · CPC title

• C04B35/10

  based on aluminium oxide · CPC title

• C04B35/624

  Sol-gel processing · CPC title

• C04B2235/6021

  Extrusion moulding · CPC title