Abrasive particles having particular shapes and methods of forming such particles

Patent metadata

Field	Value
Publication number	US-12122017-B2
Application number	US-202218147309-A
Country	US
Kind code	B2
Filing date	Dec 28, 2022
Priority date	Mar 29, 2013
Publication date	Oct 22, 2024
Grant date	Oct 22, 2024

Abstract

A coated abrasive article comprising a backing, an adhesive layer disposed in a discontinuous distribution on at least a portion of the backing, wherein the discontinuous distribution comprises a plurality of adhesive contact regions and at least one shaped abrasive particle is disposed on a majority of each of the discrete adhesive contact regions, wherein at least 50% of the shaped abrasive particles comprise a predetermined side orientation and have a tilt angle of at least 45 degrees, wherein the shaped abrasive particles comprise a polycrystalline material and are free of binder, wherein the first plurality of discrete adhesive contact regions comprise a predetermined two-dimensional shape as viewed from above, and wherein each of the discrete contact regions comprises a length, a width, or a combination thereof that substantially corresponds to a dimension of the at least one abrasive particle.

First claim

What is claimed is:

1. A coated abrasive article comprising:
a backing;
a make coat disposed on the backing in a predetermined distribution; and
a plurality of shaped abrasive particles having an average height (h),
wherein the predetermined distribution comprises a discontinuous pattern of a plurality of contact regions having an average width (w);
wherein at least one shaped abrasive particle of the plurality of shaped abrasive particles is disposed on each of the contact regions; and
wherein the w, is at least 0.1(h) and not greater than 0.99(h).

2. The coated abrasive article of claim 1 ,
wherein the plurality of particles comprises an average length ( 1 );
wherein the plurality of discrete contact regions comprises an average adjacent spacing of at least 0.5 ( 1 ).

3. The coated abrasive article of claim 2 , wherein the average adjacent spacing is not greater than 10 ( 1 ).

4. The coated abrasive article of claim 1 , wherein the plurality of discrete contact regions comprises an average adjacent spacing of at least 0.2 mm.

5. The coated abrasive article of claim 1 , wherein the plurality of discrete contact regions comprises an average adjacent spacing of not greater than 0.4 mm.

6. The coated abrasive article of claim 1 , wherein the abrasive particles have a tip, and wherein at least 55% of the abrasive particle tips are upright.

7. The coated abrasive article of claim 1 , wherein the predetermined distribution is a non-shadowing pattern, a controlled non-uniform pattern, a semi-random pattern, a random pattern, a regular pattern, an alternating pattern, or combinations thereof.

8. The coated abrasive article of claim 1 , wherein the number of discrete contact regions is in a range of 1000 to 40,000.

9. The coated abrasive article of claim 1 , wherein the shaped abrasive particles comprise a predetermined 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 nonagon, a decagon, and a combination thereof.

10. The coated abrasive article of claim 1 , wherein the make coat covers at least 1% to 95% of the backing.

11. A coated abrasive article comprising:
a backing;
a make coat disposed on the backing in a predetermined distribution; and
a plurality of shaped abrasive particles having an median height (h),
wherein the predetermined distribution comprises a discontinuous pattern of a plurality of discrete contact regions having an median width (w);
wherein at least one shaped abrasive particle of the plurality of shaped abrasive particles is disposed on each of the discrete contact regions; and
wherein the w, is at least 0.1(h) and not greater than 0.99(h).

12. The coated abrasive article of claim 11 , wherein the plurality of particles comprises an average length ( 1 );
wherein the plurality of discrete contact regions comprises an average adjacent spacing of at least 0.5 ( 1 ).

13. The coated abrasive article of claim 2 , wherein the average adjacent spacing is not greater than 10 ( 1 ).

14. The coated abrasive article of claim 11 , wherein the plurality of discrete contact regions comprises an average adjacent spacing of at least 0.2 mm.

15. The coated abrasive article of claim 11 , wherein the plurality of discrete contact regions comprises an average adjacent spacing of not greater than 0.4 mm.

16. The coated abrasive article of claim 11 , wherein the abrasive particles have a tip, and wherein at least 55% of the abrasive particle tips are upright.

17. The coated abrasive article of claim 11 , wherein the predetermined distribution is a non-shadowing pattern, a controlled non-uniform pattern, a semi-random pattern, a random pattern, a regular pattern, an alternating pattern, or combinations thereof.

18. The coated abrasive article of claim 11 , wherein the number of discrete contact regions is in a range of 1000 to 40,000.

19. The coated abrasive article of claim 11 , wherein the shaped abrasive particles comprise a predetermined 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 nonagon, a decagon, and a combination thereof.

20. The coated abrasive article of claim 11 , wherein the make coat covers at least 1% to 95% of the backing.

Assignees

• Saint Gobain Abrasives Inc
• Saint Gobain Abrasifs Sa

Inventors

• Seth Anuj
• Cheruvari Kottieth Raman Vivek
• Everts Darrell K

Classifications

• B24D3/00

  Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents · CPC title

• B24D2203/00

  Tool surfaces formed with a pattern · CPC title

• B24D11/04 Primary

  Zonally-graded surfaces · CPC title

• B24D18/0072

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

• B24D18/0054 Primary

  by impressing abrasive powder in a matrix · CPC title