Composite shaped abrasive particles and method of forming same

Patent metadata

Field	Value
Publication number	US-2016177153-A1
Application number	US-201414581220-A
Country	US
Kind code	A1
Filing date	Dec 23, 2014
Priority date	Dec 23, 2014
Publication date	Jun 23, 2016
Grant date	—

Abstract

An abrasive particle including a shaped abrasive particle having a body and a plurality of abrasive particles bonded to at least one surface of the body of the shaped abrasive particle.

First claim

What is claimed is:

1 . An abrasive particle comprising:
a shaped abrasive particle comprising a body; and a plurality of abrasive particles bonded to at least one surface of the body of the shaped abrasive particle.

2 . The abrasive particle of claim 1 , wherein the body of the shaped abrasive particle comprises a two-dimensional shape as viewed in a plane defined by a length and a width of the body selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.

3 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles is bonded to a major surface of the body.

4 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles is bonded to at least two surfaces of the body.

5 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles is bonded to at least two major surfaces of the body.

6 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles cover at least about 50% of the total surface area of the body or at least about 60% or at least about 70% or at least about 80% or at least about 90% or at least about 95%.

7 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles are selected from the group consisting of oxides, carbides, nitrides, borides, oxycarbides, oxynitrides, oxyborides, natural minerals, synthetic materials, carbon-based materials, and a combination thereof.

8 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles are selected from the group consisting of crushed grains, irregularly shaped grains, elongated grains, agglomerates, aggregates, and a combination thereof.

9 . The abrasive particle of claim 1 , wherein the body of the shaped abrasive particle comprises a length>width>height, and the plurality of abrasive particles comprise a median particle size (D50), and wherein the median particle size (D50) is not greater than the length of the body of the shaped abrasive particle or wherein the median particle size (D50) is not greater than the width of the body of the shaped abrasive particle or wherein the median particle size (D50) is not greater than the height of the body of the shaped abrasive particle.

10 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles comprise at least about 10 wt % of a total weight of the abrasive particle or at least about 20 wt % or at least about 30 wt % or at least about 40 wt % or at least about 50 wt %.

11 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles comprise not greater than about 80 wt % of a total weight of the abrasive particle or not greater than about 60 wt % or not greater than about 40 wt % or not greater than about 30 wt % or not greater than about 20 wt %.

12 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles is embedded in the at least one surface the body of the shaped abrasive particle.

13 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles is directly bonded to at least one surface of the body of the shaped abrasive particle.

14 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles are sinter-bonded to the at least one surface of the body of the shaped abrasive particle.

15 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles include a material having a CTE that is not greater than about 50% different than a CTE of the body of the shaped abrasive particle.

16 . A method of forming an abrasive particle comprising:
forming a shaped abrasive particle having a body; attaching a plurality of abrasive particles to at least one surface of the body to form a composite abrasive particle including the shaped abrasive particle and the plurality of abrasive particles.

17 . The method of claim 16 , wherein forming a shaped abrasive particle includes forming a precursor shaped abrasive particle and attaching the plurality of abrasive particles to at least one surface of the precursor shaped abrasive particle, wherein the process further comprises drying the precursor shaped abrasive particle and plurality of abrasive particles, wherein the process further comprises calcining the precursor shaped abrasive particle and plurality of abrasive particles, wherein the process comprises sintering the precursor shaped abrasive particle and plurality of abrasive particles to form a composite shaped abrasive particle.

18 . The method of claim 16 , wherein the plurality of abrasive particles is attached the body of the shaped abrasive particle prior to substantial drying of the body.

19 . The method of claim 16 , wherein attaching the plurality of abrasive particles includes depositing the plurality of abrasive particles on a surface of the body, wherein depositing includes a process selected from the group consisting of blasting, projecting, pressing, gravity coating, molding, stamping, and a combination thereof.

20 . The method of claim 16 , wherein the body of the shaped abrasive particle is formed on a production tool including a layer of abrasive particles including the plurality of abrasive particles.

Assignees

• Saint Gobain Ceramics

Inventors

• Josseaux Frederic

Classifications

• B24D11/001

  Manufacture of flexible abrasive materials · CPC title

• B01J2/26 Primary

  on endless conveyor belts · CPC title

• B24D18/0063

  by extrusion · CPC title

• C09K3/1409

  Abrasive particles per se (preparation of diamond C01B32/25) · CPC title

• C09K3/1436 Primary

  Composite particles, e.g. coated particles · CPC title