Abrasive particles with vitrified bond and filler

Patent metadata

Field	Value
Publication number	US-11214718-B2
Application number	US-201715857041-A
Country	US
Kind code	B2
Filing date	Dec 28, 2017
Priority date	Dec 29, 2016
Publication date	Jan 4, 2022
Grant date	Jan 4, 2022

Abstract

An abrasive particle having a body and a coating overlying the body, the coating including an amorphous material and at least one filler contained within the amorphous material. The abrasive particle may be included in a fixed abrasive article.

First claim

What is claimed is:

1. An abrasive particle comprising:
a body, and
a coating overlying the body;
wherein the coating comprises
an amorphous material, and
at least one filler distinct from the amorphous material and contained within the amorphous material;

wherein the body has a median particle size of at least about 50 microns and not greater than about 4000 microns;
wherein the filler has a median particle size of at least 0.1 microns and not greater than 10 microns;
wherein the filler comprises a particulate material;
wherein the filler comprises at least one oxide compound comprising at least one element selected from the group consisting of Fe, Co, Ti, Ni, V, Vr, Sb, Mn, Zn, and combinations thereof;
wherein the weight of the coating is at least 0.1 wt. % and not greater than 10 wt. % of the total weight of the abrasive particle including the body and the coating; and
wherein the filler comprises a polycrystalline particulate material.

2. The abrasive particle of claim 1 , wherein the body comprises alumina and zirconia.

3. The abrasive particle of claim 1 , wherein the body consists essentially of alumina and zirconia.

4. The abrasive particle of claim 1 , wherein the body consists essentially of alumina.

5. The abrasive particle of claim 1 , wherein the body comprises at least 35 wt. % alumina and not greater than 75 wt. % alumina for the total weight of the body.

6. The abrasive particle of claim 1 , wherein the body comprises at least 20 wt. % zirconia and not greater than 60 wt. % zirconia for a total weight of the body.

7. The abrasive particle of claim 1 , the body is substantially free of nitrides, borides, or any combination thereof.

8. The abrasive particle of claim 1 , wherein the body is substantially free of metals, metal alloys, or any combination thereof.

9. The abrasive particle of claim 1 , wherein the coating covers at least 1% and not greater than 99% of the outer surface of the body.

10. The abrasive particle of claim 1 , wherein the coating has a softening point within a range of 400° C. to not greater than 700° C.

11. The abrasive particle of claim 1 , wherein the coating comprises silicon, boron, zinc, iron, sodium, potassium, lithium or combinations thereof.

12. The abrasive particle of claim 1 , wherein the coating comprises boron.

13. The abrasive particle of claim 1 , wherein the abrasive particle comprises chromium (Cr) from the coating in an amount of at least about 0.2 wt. % and not greater than about 20 wt. % for a total weight of the abrasive particle.

14. The abrasive particle of claim 1 , wherein the abrasive particle comprises sodium (Na) from the coating in an amount of at least about 0.01 wt. % and not greater than about 6.0 wt. % for a total weight of the abrasive particle.

15. The abrasive particle of claim 1 , wherein the abrasive particle comprises calcium (Ca) from the coating in an amount of at least about 0.05 wt. % and not greater than about 7.0 wt. % for a total weight of the abrasive particle.

16. The abrasive particle of claim 1 , wherein the abrasive particle comprises potassium (K) from the coating in an amount of at least about 0.01 wt. % and not greater than about 10 wt. % for a total weight of the abrasive particle.

Assignees

• Saint Gobain Ceramics

Inventors

• Nie Pinxu
• Liang Shuqiong

Classifications

• C04B35/628

  Coating the powders {or the macroscopic reinforcing agents} · CPC title

• C04B35/62886

  by wet chemical techniques · CPC title

• C01G25/02

  Oxides · CPC title

• C09K3/1445 Primary

  the coating consisting exclusively of metals · CPC title

• C04B35/62828

  Non-oxide ceramics · CPC title