Shaped abrasive particles and method of forming same

Patent metadata

Field	Value
Publication number	US-2016177154-A1
Application number	US-201514757688-A
Country	US
Kind code	A1
Filing date	Dec 23, 2015
Priority date	Dec 23, 2014
Publication date	Jun 23, 2016
Grant date	—

Abstract

An abrasive particle including a shaped abrasive particle including a body having 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.

4 . 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 first group consisting of regular polygons, irregular polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, a shape with linear and curved portions, and a combination thereof.

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

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

7 . The abrasive particle of claim 1 , wherein the body includes 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 plurality of abrasive particles is bonded to the first major surface and the side surface is essentially free of abrasive particles of the plurality of abrasive particles.

6 . The abrasive particle of claim 1 , wherein a portion of the abrasive particles of the plurality of abrasive particles is embedded within the at least one surface of the body.

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

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

9 . 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.

10 . 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 at least 0.1% and not greater than about 20% of the length of the body, at least 0.1% and not greater than about 20% of the width of the body, and at least 0.1% and not greater than about 20% of the height of the body.

11 . The abrasive particle of claim 1 , wherein the plurality of abrasive particles comprise a median particle size (D50) of at 0.1 microns and not greater than 80 microns.

12 . The abrasive particle of claim 1 , wherein the surface of the body including the plurality of abrasive particle comprises a random arrangement of the plurality of abrasive particles on a major surface of the body, and wherein a side surface of the body is essentially free of the plurality of abrasive particles.

13 . The abrasive particle of claim 1 , wherein the abrasive particle is incorporated into a fixed abrasive article.

14 . A method of forming an abrasive particle comprising:
forming a mixture; attaching a plurality of abrasive particles to at least one surface of the mixture and forming a shaped abrasive particle having a body and the plurality of abrasive particles bonded to at least one surface of the body.

15 . The method claim 14 , wherein forming the mixture includes forming a precursor shaped abrasive particle and attaching a plurality of abrasive particles to at least one surface of the precursor shaped abrasive particle.

16 . The method claim 14 , wherein forming the mixture includes depositing the mixture into an opening of a production tool and attaching a plurality of abrasive particles to at least one surface of the mixture in the opening of the production tool.

17 . The method claim 14 , wherein attaching the plurality of abrasive particles includes forcibly projecting the plurality of abrasive particles at the at least one surface.

18 . The method claim 14 , wherein attaching the plurality of abrasive particles includes directing an deposition material at the at least one surface, wherein the deposition material includes the plurality of abrasive particles and a carrier gas, wherein the carrier gas can include water vapor, steam, an inert gas element, and a combination thereof.

19 . The method claim 14 , wherein the process further comprising applying moisture to at least one surface of the mixture prior to attaching the plurality of abrasive particles.

20 . The method claim 19 , wherein applying moisture includes wetting the at least one surface of the mixture for a sufficient time to change a viscosity of an exterior region of the at least one surface relative to a viscosity of the mixture at an interior region spaced apart from the exterior region.

Assignees

• Saint Gobain Ceramics

Inventors

• Josseaux Frederic
• Louapre David F

Classifications

• C09K3/1409 Primary

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

• B01J2/26

  on endless conveyor belts · CPC title

• B01J2/20

  by expressing the material, e.g. through sieves and fragmenting the extruded length · CPC title

• C09K3/1436 Primary

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