Abrasive articles and methods of forming same

Patent metadata

Field	Value
Publication number	US-12338384-B2
Application number	US-202017132302-A
Country	US
Kind code	B2
Filing date	Dec 23, 2020
Priority date	Dec 27, 2019
Publication date	Jun 24, 2025
Grant date	Jun 24, 2025

Abstract

A coated abrasive article includes a substrate and a plurality of abrasive particles overlying the substrate, wherein at least 5% of the plurality of abrasive particles is tooth-shaped abrasive particles.

First claim

What is claimed is:

1. A coated abrasive article comprising:
a substrate; and
a plurality of abrasive particles overlying the substrate, wherein at least 5% of the plurality of abrasive particles are tooth-shaped abrasive particles,
wherein each of the tooth-shaped abrasive particles comprises a body having a length, a width, and a thickness, wherein length>width≥thickness, and wherein the tooth-shaped abrasive particles comprises a body including a tip region including a tip of the body and a base region including a base of the body, wherein the tip region is defined by a taper including a reduction in the thickness of the body over a tip region length; and wherein a greater content of the tooth-shaped abrasive particles have their tip regions oriented closer to the substrate compared to a content of the tooth-shaped abrasive particles having their base regions oriented closer to the substrate.

2. The coated abrasive article of claim 1 , wherein the base region is at an opposite end of the body from the tip region along a length of the body.

3. The coated abrasive article of claim 1 , wherein the tip region is defined by a taper including a reduction in the width of the body over a tip region length.

4. The coated abrasive article of claim 2 , wherein the tip region comprises an asymmetric taper including a first surface and a second surface, wherein the first surface has a different contour as compared to the second surface.

5. The coated abrasive article of claim 4 , wherein the first surface has a greater curvature compared to the second surface.

6. The coated abrasive article of claim 2 , wherein the base comprises a projection extending from the body, wherein the projection extends at a base angle relative to a longitudinal axis of the body, wherein the base angle is at least 91 degrees and not greater than 180 degrees.

7. The coated abrasive article of claim 6 , wherein the projection has a base surface including an upper corner and a lower corner spaced apart from the upper corner across the length of the base surface.

8. The coated abrasive article of claim 7 , wherein the upper corner or the lower corner comprises a corner radius less than a corner radius of the tip.

9. The coated abrasive article of claim 2 , wherein the base region comprises a base including a base surface, wherein the base surface is angled at an acute angle relative to the longitudinal axis of the body.

10. The coated abrasive article of claim 2 , wherein the base comprises a base surface having a plurality of peaks, wherein at least one peak of the plurality of peaks has a tip radius less than a tip radius of the tip of the body.

11. The coated abrasive article of claim 2 , wherein the base includes a first peak and a second peak separated from each other by a first valley as viewed in two-dimensions by a plane defined by the length and thickness of the body or in two-dimensions by a plane defined by the length and width of the body.

12. The coated abrasive article of claim 10 , wherein the base comprises a primary peak as viewed in two dimensions defined by the length and the width, wherein the primary peak comprises a tip sharpness that is greater than a tip sharpness of the tip of the body.

13. The coated abrasive article of claim 2 , further comprising an elongated region extending between the tip region and the base region wherein the elongated region defines a region having a change in width or thickness of not greater than 10% over the length of the elongated region.

14. The coated abrasive article of claim 1 , wherein the base region comprises a greater volume of material than the tip region based on the cross-sectional area of the base region as compared to the tip region.

15. The coated abrasive article of claim 1 , wherein at least 60% of the tooth-shaped abrasive particles have their tip regions oriented closer to the substrate than their base regions.

16. The coated abrasive article of claim 1 , wherein the body comprises striations on at least one surface.

17. The coated abrasive of claim 16 , wherein the striations extend in a direction of the length of the body.

Assignees

• Saint Gobain Ceramics

Inventors

• Marlin Samuel S
• Bauer Ralph
• Vujcic Stefan
• Rehrig Paul W
• Auscher Marie-Camille
• Everts Darrell K
• Fan Hua
• Iyengar Sujatha K
• Arcona Christopher
• Martone Anthony
• Tanikella Brahmanandam V

Classifications

• C09C1/407

  Aluminium oxides or hydroxides · CPC title

• C08K3/22

  of metals · CPC title

• C08K2003/2227

  of aluminium · CPC title

• B24D3/10

  for porous or cellular structure, e.g. for use with diamonds as abrasives · CPC title

• C09K3/1427

  obtained by division of a mass agglomerated by melting, at least partially, e.g. with a binder · CPC title