Abrasive particles having particular shapes and methods of forming such particles

Patent metadata

Field	Value
Publication number	US-11148254-B2
Application number	US-201916359370-A
Country	US
Kind code	B2
Filing date	Mar 20, 2019
Priority date	Oct 15, 2012
Publication date	Oct 19, 2021
Grant date	Oct 19, 2021

Abstract

An abrasive article comprising a first group including a plurality of shaped abrasive particles overlying a backing, wherein the plurality of shaped abrasive particles of the first group define a first non-shadowing distribution relative to each other.

First claim

What is claimed is:

1. An abrasive article comprising:
a backing; and
a first group comprising a plurality of shaped abrasive particles coupled to the backing, wherein each shaped abrasive particle of the first group of shaped abrasive particles includes a body having a first major surface, a second major surface, and a side surface extending between the first major surface and the second major surface, wherein the body is essentially free of a binder, wherein the body includes a length and a width defined by dimensions of the first or second major surfaces and the side surface defines a height of the body, wherein the height is less than the length and the width;
wherein the plurality of shaped abrasive particles of the first group are arranged in a controlled, non-shadowing arrangement relative to each other, wherein the controlled, non-shadowing arrangement comprises a first shaped abrasive particle located at a first, predetermined position on the backing, a second shaped abrasive particle immediately adjacent to the first shaped abrasive particle and located at a second, predetermined position on the backing, and wherein the first and second, predetermined positions are staggered from each other relative to at least two axes defining a plane of the backing; and
wherein the total content of the plurality of shaped abrasive particles comprises a coating density of not greater than about 70 particles/cm 2 .

2. The abrasive article of claim 1 , further comprising an adhesive layer disposed in a discontinuous distribution on at least a portion of the backing, wherein the discontinuous distribution comprises a plurality of discrete adhesive contact regions having a gap between each of the adhesive contact regions.

3. The abrasive article of claim 1 , wherein the total content of the plurality of shaped abrasive particles define an open coat.

4. The abrasive article of claim 1 , wherein the coating density is at least 5 particles/cm 2 .

5. The abrasive article of claim 1 , wherein each shaped abrasive particle of the first group of shaped abrasive particles shares at least one of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation.

6. The abrasive article of claim 1 , wherein the first major surface of at least one shaped abrasive particle of the first group of shaped abrasive particles has a two-dimensional shape selected from a group consisting of: a polygon, a triangle, a rectangle, a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, a decagon, an ellipsoid, a numeral, a Greek alphabet letter, a Latin alphabet letter, a Russian alphabet character, a Kanji character, a complex shape including a combination of polygonal and ellipsoid features defining linear and curved segments, or a combination thereof.

7. The abrasive article of claim 1 , wherein the backing has a circular geometry.

8. The abrasive article of claim 1 , further comprising a second group comprising a plurality of shaped abrasive particles overlying the backing, wherein the second group of shaped abrasive particles is different than the first group of abrasive particles.

9. The abrasive article of claim 8 , wherein each shaped abrasive particle of the second group of shaped abrasive particles shares at least one of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation.

10. The abrasive article of claim 8 , wherein each of the shaped abrasive particles of the second group of abrasive particles comprises a body essentially free of binder.

11. The abrasive article of claim 8 , wherein each of the shaped abrasive particles of the second group is arranged in a side orientation with a side surface of the body closest to the backing and further is arranged in a sideways orientation relative to an axis of the backing, and wherein the first major surface or second major surface is substantially parallel to the axis of the backing.

12. The abrasive article of claim 8 , wherein the first group defines a first region on the backing, the second group defines a second region on the backing, and wherein the first region and the second region are entirely separated from each other.

13. The abrasive article of claim 8 , wherein each shaped abrasive particle of the first group of shaped abrasive particles comprises at least one feature different from a feature of at least one shaped abrasive particle of the second group, wherein the feature is selected from the group of features consisting of average particle size, two-dimensional particle shape, orientation relative to a grinding direction, average lateral space, average longitudinal space, side orientation, inverted orientation, flat orientation, composition, and predetermined distribution.

14. The abrasive article of claim 2 , wherein the gap defines a gap distance and is a non-contact region, wherein no adhesive material is provided on the backing.

15. The abrasive article of claim 14 , wherein the gap distance can be at least about 0.5(w) to not greater than 100(w), wherein (w) corresponds to a width of the at least one shaped abrasive particle.

16. The abrasive article of claim 2 , wherein each of the discrete contact regions have a two-dimensional shape selected from the group consisting of polygons, ellipsoids, numerals, crosses, multi-armed polygons, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, Arabic alphabet characters, rectangle, quadrilateral, pentagon, hexagon, heptagon, octagon, nonagon, decagon, and a combination thereof.

17. The abrasive article of claim 1 , further comprising a normalized weight of the plurality of abrasive particles per length of the backing of at least about 10 lb./ream (148 grams/m 2 ).

18. The abrasive article of claim 1 , further having a percentage coating of the abrasive particles relative to the total area of the entire backing of at least about 5%.

19. The abrasive article of claim 1 , wherein the degree of overlap of the abrasive particles during an initial phase of material removal operation is not greater than about 25%.

20. The abrasive article of claim 1 , wherein the non-shadowing arrangement comprises a radial pattern, a spiral pattern, a phyllotactic pattern, an asymmetric pattern, a self-avoiding random distribution, and a combination thereof.

Assignees

• Saint Gobain Abrasives Inc
• Saint Gobain Abrasifs Sa

Inventors

• Gaeta Anthony C
• Seth Anuj
• Arcona Christopher
• Yener Doruk O
• Czerepinski Jennifer H
• Iyengar Sujatha K
• Csillag Frank J
• Rice William C
• Ramesh Satyalakshmi K
• Lafond Gregory G
• Wijesooriya Sidath S
• Lior Adam D
• Brandes Alan J
• Parmar Anil
• Braun Paul
• Everts Darrell K

Classifications

• B24D7/02

  Wheels in one piece · CPC title

• Y10T428/25

  Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles · CPC title

• B24D18/0072

  using adhesives for bonding abrasive particles or grinding elements to a support, e.g. by gluing · CPC title

• B24D11/001

  Manufacture of flexible abrasive materials · CPC title

• Y10T428/24

  Structurally defined web or sheet [e.g., overall dimension, etc.] · CPC title