Abrasive particles and methods of forming same

Patent metadata

Field	Value
Publication number	US-2017335156-A1
Application number	US-201715591964-A
Country	US
Kind code	A1
Filing date	May 10, 2017
Priority date	May 10, 2016
Publication date	Nov 23, 2017
Grant date	—

Abstract

An abrasive particle having a body including a first major surface, a second major surface opposite the first major surface, and a side surface extending between the first major surface and the second major surface, such that a majority of the side surface comprises a plurality of microridges.

First claim

What is claimed is:

1 . A method for making abrasive particles comprising:
forming a mixture into a body, wherein the mixture comprises a ceramic; deforming at least a portion of the body to create at least one crack initiation point; and drying the body under controlled cracking conditions to fracture the body into a plurality of precursor abrasive particles, wherein controlled cracking conditions include controlled crack propagation from the at least one crack initiation point.

2 . The method of claim 1 , wherein drying the body comprises forming microridges on at least a portion of a side surface of at least one of the abrasive particles.

3 . The method of claim 1 , wherein forming is conducted without the use of a production tool.

4 . The method of claim 1 , wherein deforming at least a portion of the body includes forming a controlled distribution of features in at least a portion of the body.

5 . The method of claim 4 , wherein the controlled distribution of features includes a random distribution of features.

6 . The method of claim 4 , wherein the controlled distribution of features includes an interconnected network of depressions formed in at least a portion of the body.

7 . The method of claim 1 , wherein drying includes creating controlled cracking conditions in the body by controlling at least one of:
a drying temperature within a range of at least 20° C. and not greater than 250° C.; a relative humidity within a range of at least 10% and not greater than 90%; a flow rate within a range of at least 0.1 m/s and not greater than 5 m/s; or any combination thereof.

8 . The method of claim 1 , wherein the body is in the form of a layer having a first major surface, a second major surface, and a side surface, and wherein the first major surface defines a width (w), the side surface defines a height (h), and wherein the layer has an aspect ratio (w:h) of at least 10:1, and wherein the first major surface has a surface area of at least 10 cm 2 .

9 . The method of claim 1 , wherein the plurality of precursor abrasive particle is formed without comminution of the body or intentional vibration of the body to induce cracking of the body.

10 . The method of claim 1 , wherein the body of the first abrasive particle includes a side surface portion having an irregular contour.

11 . The method of claim 1 , further comprising sintering the precursor abrasive particles to form an abrasive particle with a body having a first major surface, a second major surface opposite the first major surface, and a side surface extending between the first major surface and the second major surface, wherein the side surface comprises a Mean Anisotropy Factor of at least 1.25.

12 . The method of claim 11 , wherein the Mean Anisotropy Factor is at least 1.30 and not greater than 20.

13 . The method of claim 11 , wherein the side surface comprises an Anisotropy Factor Standard Deviation of at least 0.75 and not greater than 10.

14 . The method of claim 11 , wherein the side surface comprises a first region extending from the first major surface and a second region extending from the second major surface, and wherein the first region and second region abut on the side surface, and wherein the second region comprises a Mean Anisotropy Factor that is greater than the first region.

15 . The method of claim 14 , wherein the second region extends for a greater percentage of the height as compared to the first region.

16 . The method of claim 14 , wherein the first region has an average height of not greater than 90% of the height of the body.

17 . The method of claim 14 , wherein the second region comprises an average height of not greater than 90% of the height of the body or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10% or not greater than 5%.

18 . The method of claim 14 , wherein the first region comprises a Mean Anisotropy Factor of not greater than 1.20.

19 . The method of claim 14 , wherein the Mean Anisotropy Factor of the second region is at least 1.30.

20 . The method of claim 14 , wherein the second region comprises a plurality of microridges defined by a conchoidal fracturing feature, and which are formed during controlled cracking of the side surface.

Assignees

• Saint-Gobain Ceram & Plastics Inc

Inventors

• Bauer Ralph
• MOCH Eric
• Czerepinski Jennifer H
• Boussant-Roux Yves
• Fremy Flavien

Classifications

• C04B2235/5292

  Flakes, platelets or plates · CPC title

• C09K3/1436

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

• C01F7/441

  by calcination · CPC title

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title

• C04B35/6261

  Milling · CPC title