Abrasive particles having particular shapes and methods of forming such particles

Patent metadata

Field	Value
Publication number	US-9457453-B2
Application number	US-201414231019-A
Country	US
Kind code	B2
Filing date	Mar 31, 2014
Priority date	Mar 29, 2013
Publication date	Oct 4, 2016
Grant date	Oct 4, 2016

Abstract

A coated abrasive article comprising a backing, an adhesive layer disposed in a discontinuous distribution on at least a portion of the backing, wherein the discontinuous distribution comprises a plurality of adhesive contact regions having at least one of a lateral spacing or a longitudinal spacing between each of the adhesive contact regions; and at least one abrasive particle disposed on each adhesive contact region, the abrasive particle having a tip, and there being at least one of a lateral spacing or a longitudinal spacing between each of the abrasive particles, and wherein at least 65% of the at least one of a lateral spacing and a longitudinal spacing between the tips of the abrasive particles is within 2.5 standard deviations of the mean.

First claim

What is claimed is:

1. A coated abrasive article comprising:
a backing;
a make coat layer disposed in a discontinuous distribution on at least a portion of the backing, wherein the discontinuous distribution comprises a plurality of discrete adhesive contact regions having at least one of a lateral spacing or a longitudinal spacing between each of the discrete adhesive contact regions; and
at least one shaped abrasive particle disposed on a majority of the discrete adhesive contact regions, wherein the shaped abrasive particles are arranged in a controlled, non-shadowing arrangement relative to each other, wherein the controlled, non-shadowing arrangement comprises at least one of a lateral spacing or a longitudinal spacing between each of the shaped abrasive particles, and wherein the shaped abrasive particles have at least two of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation,
wherein the plurality of discrete adhesive contact regions comprises an asymmetric pattern,
wherein the shaped abrasive particles have a tip and a predetermined two-dimensional shape selected from a group consisting of a polygon, a triangle, a rectangle, a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, a nonagon, a decagon, and a combination thereof,
wherein at least 65% of the at least one of a lateral spacing and a longitudinal spacing between the tips of the abrasive particles is within 2.5 standard deviations of the mean, and
wherein at least 80% of the shaped abrasive particle tips are upright.

2. The coated abrasive article of claim 1 , wherein the discontinuous distribution of discrete adhesive contact regions is a non-shadowing pattern, a controlled non-uniform pattern, a semi-random pattern, a random pattern, an alternating pattern, or combinations thereof.

3. The coated abrasive article of claim 1 , wherein at least 65% of the at least one of the lateral spacing and the longitudinal spacing between the discrete adhesive contact regions is within 2.5 standard deviations of the mean.

4. The coated abrasive article of claim 1 , wherein the discrete contact regions each have a uniform thickness that is less than the d 50 height of the at least one abrasive particle.

5. The coated abrasive article of claim 4 , wherein the width of each of the discrete adhesive contact regions is equal to the d 50 width of the at least one abrasive particle.

6. The coated abrasive article of claim 1 further comprising:
a size coat layer disposed in a discontinuous distribution over the make coat layer,
wherein the size coat layer covers a smaller surface area than the make coat layer and does not extend beyond the make coat layer.

7. The coated abrasive article of claim 1 , wherein at least one abrasive particle is disposed on each discrete adhesive contact region.

8. A method of making a coated abrasive article comprising:
applying a make coat to a backing using a continuous screen printing process, wherein the make coat is applied as a discontinuous distribution comprising a plurality of discrete adhesive contact regions having at least one of a lateral spacing and a longitudinal spacing between each of the discrete adhesive contact regions,
disposing at least one shaped abrasive particle onto each of the discrete adhesive contact regions, the shaped abrasive particle having a tip and a predetermined two-dimensional shape selected from a group consisting of a polygon, a triangle, a rectangle, a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, a nonagon, a decagon, and a combination thereof, and there being at least one of a lateral spacing or a longitudinal spacing between each of the shaped abrasive particles and
curing the make coat,
wherein the plurality of discrete adhesive contact regions comprises an asymmetric pattern,
wherein disposing the at least one shaped abrasive particle onto each of the discrete adhesive contact regions comprises a first shaped abrasive particle coupled to a first discrete adhesive contact region in a first position and a second shaped abrasive particle coupled to a second discrete adhesive contact region, and
wherein the first shaped abrasive particle and second shaped abrasive particle are arranged in a controlled, non-shadowing arrangement relative to each other, the controlled, non-shadowing arrangement comprising at least two of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation, and
wherein the make coat discontinuous distribution of the plurality of discrete adhesive contact regions comprises an asymmetric pattern, and
wherein at least 80% of the shaped abrasive particle tips are upright.

9. The method of claim 8 , wherein at least 65% of the at least one of a lateral spacing and a longitudinal spacing between the tips of the abrasive particles is within 2.5 standard deviations of the mean.

10. The coated abrasive article of claim 1 , wherein the discrete contact regions have an adjacent spacing in a range of 0.5 to 3 times the average length of the shaped abrasive particle.

11. The coated abrasive article of claim 1 , wherein the discrete contact regions have an adjacent spacing in a range of 0.2 mm to 2.2 mm.

12. The coated abrasive article of claim 1 , wherein the discontinuous make coat covers at least 1% to 95% of the backing.

13. The coated abrasive article of claim 1 , wherein the discrete contact regions have an average diameter in a range of 0.3 mm to 20 mm.

14. The coated abrasive article of claim 1 , wherein 4% to 85% of the backing is bare.

Assignees

• Saint Gobain Abrasives Inc
• Saint Gobain Abrasifs Sa
• Saint-Gobain Abrasives Inc /Saint-Gobain Abrasifs

Inventors

• Seth Anuj
• Everts Darrell K
• Raman Vivek Cheruvari Kottieth

Classifications

• B24D11/04 Primary

  Zonally-graded surfaces · CPC title

• B24D3/00

  Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents · CPC title

• B24D18/0054 Primary

  by impressing abrasive powder in a matrix · CPC title

• B24D18/0072

  using adhesives for bonding abrasive particles or grinding elements to a support, e.g. by gluing · CPC title

• B24D2203/00

  Tool surfaces formed with a pattern · CPC title