Elongate abrasive article with orientationally aligned formed abrasive particles

Patent metadata

Field	Value
Publication number	US-2022016745-A1
Application number	US-201917309097-A
Country	US
Kind code	A1
Filing date	Oct 14, 2019
Priority date	Oct 25, 2018
Publication date	Jan 20, 2022
Grant date	—

Abstract

Abrasive articles are disclosed comprising at least one primary elongate abrasive element extending along an element axis. The primary elongate abrasive element comprises a plurality of formed abrasive particles, wherein at least 50% of the formed abrasive particles are orientationally aligned along the element axis.

First claim

1 . An abrasive article comprising at least one primary elongate abrasive element extending along an element axis, the primary elongate abrasive element comprising a plurality of formed abrasive particles, wherein at least 50% of the formed abrasive particles are orientationally aligned along the element axis.

2 . The abrasive article of claim 1 wherein the plurality of formed abrasive particles each comprise
a maximum dimension M;
a thickness T measured normally to the maximum dimension M;
a particle axis defined along the maximum dimension M; and
a particle plane containing the particle axis and defined normally to the thickness T;
wherein the formed abrasive particles that are orientationally aligned are generally orientationally aligned such that particle plane is oriented within 60 degrees of parallel to the element axis.

3 . The abrasive article of claim 2 wherein one of: at least 66%, at least 75%, at least 90%, at least 95%, or at least 96% of the formed abrasive particles are generally orientationally aligned.

4 . The abrasive article of claim 2 wherein at least a portion of the formed abrasive particles that are orientationally aligned are precisely orientationally aligned such that particle plane is oriented within 15 degrees of parallel to the element axis.

5 . (canceled)

6 . (canceled)

7 . The abrasive article of claim 1 wherein the plurality of formed abrasive particles each comprise
a maximum dimension M;
a thickness T measured normally to the maximum dimension M;
a particle axis defined along the maximum dimension M; and
a particle plane containing the particle axis and defined normally to the thickness T;
wherein the formed abrasive particles that are orientationally aligned are precisely orientationally aligned such that particle plane is oriented within 15 degrees of parallel to the element axis.

8 . The abrasive article of claim 7 wherein at least 66% of the formed abrasive particles are precisely orientationally aligned.

9 . The abrasive article of claim 2 wherein the orientationally aligned formed abrasive particles comprise first and second major faces separated by the thickness T, wherein the particle axis is defined along one of the first face or the second face, and the particle plane is substantially parallel to the first and second major faces.

10 . (canceled)

11 . (canceled)

12 . The abrasive article of claim 2 wherein a ratio R of the maximum dimension M to the thickness T of the orientationally aligned formed abrasive particles is 3 or greater.

13 . The abrasive article of claim 1 comprising a branch elongate abrasive element extending from the primary elongate abrasive element.

14 . The abrasive article of claim 1 wherein the first elongate abrasive element extends from a base.

15 - 22 . (canceled)

23 . The abrasive article of claim 1 wherein each primary elongate abrasive element comprises a binder retaining the formed abrasive particles.

24 . The abrasive article of claim 23 wherein each primary elongate abrasive elements is formed by flowing a mixture of the binder and the formed abrasive particles along the element axis.

25 . A method of forming an elongate abrasive element, the elongate abrasive element comprising a binder and a plurality of formed abrasive particles, the method comprising
flowing a mixture of the binder and the plurality of formed abrasive particles along a flow axis such that at least 50% of the plurality of shape abrasive particles orientationally align along the flow axis; allowing the mixture to set, thereby forming the elongate abrasive element comprising an element axis, wherein at least 50% of the plurality of formed abrasive particles are orientationally aligned along the element axis.

26 . The method of claim 25 wherein each of the orientationally aligned formed abrasive particles comprise
a maximum dimension M;
a thickness T measured normally to the maximum dimension M;
a particle axis defined along the maximum dimension M; and
a particle plane containing the particle axis and defined normally to the thickness T;
wherein orientationally aligning the formed abrasive particles results in generally orientationally aligning the formed abrasive particles such that the particle plane is oriented within 60 degrees of parallel to the element axis.

27 . (canceled)

28 . The method of claim 25 wherein at least a portion of the formed abrasive particles that are orientationally aligned are precisely orientationally aligned such that particle plane is oriented within 15 degrees of parallel to the element axis.

29 . (canceled)

30 . (canceled)

31 . The method of claim 25 wherein the plurality of formed abrasive particles each comprise
a maximum dimension M;
a thickness T measured normally to the maximum dimension M;
a particle axis defined along the maximum dimension M; and
a particle plane containing the particle axis and defined normally to the thickness T;
wherein the formed abrasive particles that are orientationally aligned are precisely orientationally aligned such that particle plane is oriented within 15 degrees of parallel to the element axis.

32 . (canceled)

33 . The method of claim 25 wherein the orientationally aligned formed abrasive particles comprise first and second major faces separated by the thickness T, wherein the particle axis is defined along one of the first face or the second face, and the particle plane is substantially parallel to the first and second major faces.

34 . The method of claim 25 wherein flowing the mixture comprises injection molding the mixture into a mold cavity comprising a shape corresponding to the elongate abrasive element.

35 . The method of claim 25 wherein flowing the mixture comprises extruding the mixture from a die opening.

36 . The method of claim 25 wherein prior to flowing the mixture, the binder is heated to a molten state, and wherein allowing the mixture to set comprises cooling the binder until it reaches a solidified state to retain the plurality of formed abrasive particles.

Assignees

• 3M Innovative Properties Co

Inventors

• Holmes Dean S

Classifications

• C09K3/1436

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

• B24D11/001

  Manufacture of flexible abrasive materials · CPC title

• B24D11/00 Primary

  Constructional features of flexible abrasive materials; Special features in the manufacture of such materials · CPC title

• B24D13/145

  having a brush-like working surface · CPC title

• B24D13/10

  comprising assemblies of brushes · CPC title