Abrasive articles including abrasive particulate materials, coated abrasives using the abrasive particulate materials and methods of forming

Patent metadata

Field	Value
Publication number	US-9517546-B2
Application number	US-201213627923-A
Country	US
Kind code	B2
Filing date	Sep 26, 2012
Priority date	Sep 26, 2011
Publication date	Dec 13, 2016
Grant date	Dec 13, 2016

Abstract

An abrasive particulate material which is made of alumina crystals and a primary additive composition impregnated within the abrasive particulate material, the primary additive composition including a combination of Mg and Ca, wherein Mg and Ca are present in an additive ratio [Mg:Ca] within a range between about 1:1 and about 10:1, and a Ca amount is at least about 0.2 wt % Ca for the total weight of the abrasive particulate material.

First claim

What is claimed is:

1. An abrasive article comprising: an abrasive particulate material comprising alumina crystals and a primary additive composition impregnated within the abrasive particulate material, the primary additive composition comprising a combination of Mg and Ca, wherein Mg and Ca are present in an additive ratio [Mg:Ca] within a range between about 1:1 and about 10:1, wherein the abrasive particulate material comprises Mg in an amount of at least about 0.1 wt % and not greater than about 2 wt % based on the total weight of the abrasive particulate material and further comprising at least about 0.2 wt % Ca for the total weight of the abrasive particulate material, and wherein the abrasive particulate material is free of a rare earth oxide.

2. The abrasive article of claim 1 , wherein the alumina crystals comprise alpha alumina.

3. The abrasive article of claim 1 , wherein the abrasive particulate material comprises Ca in an amount of at least about 0.25 wt % and not greater than about 2 wt % based on the total weight of the abrasive particulate material.

4. The abrasive article of claim 1 , wherein the abrasive particulate material comprises Mg in an amount of at least about 0.1 wt % and not greater than about 1.5 wt % based on the total weight of the abrasive particulate material.

5. The abrasive article of claim 1 , wherein the abrasive particulate material comprises not greater than about 8 wt % of the primary additive composition.

6. The abrasive article of claim 1 , wherein the additive ratio [Mg:Ca] is within a range between about 1:1 and about 9:1.

7. The abrasive article of claim 1 , wherein the abrasive particulate material comprises a crystallinity content of at least about 90 wt %.

8. The abrasive article of claim 1 , wherein the abrasive particulate material comprises a contour, and wherein the contour comprises a polyhedral shape.

9. The abrasive article of claim 1 , wherein the abrasive particulate material is part of a fixed abrasive.

10. The abrasive article of claim 1 , wherein the additive ratio [Mg:Ca] is within a range between about 3:1 and about 10:1.

11. The abrasive article of claim 1 , wherein the abrasive particulate material comprises shaped abrasive particles selected from the group consisting of triangular, rectangular, pentagonal, hexagonal, conical, helical, elliptical, elongated shape, and any combination thereof.

12. The abrasive article of claim 11 , wherein the shaped abrasive particles have a triangular shape.

13. An abrasive article comprising: an abrasive particulate material consisting essentially of alumina crystals and a primary additive composition impregnated within the abrasive particulate material, the primary additive composition consisting essentially of a combination of Mg and Ca, wherein Mg and Ca are present in an additive ratio [Mg:Ca] within a range between about 1:1 and about 10:1, wherein the abrasive particulate material comprises Mg in an amount of at least about 0.1 wt % and not greater than about 2 wt % based on the total weight of the abrasive particulate material and further comprising at least about 0.2 wt % Ca for the total weight of the abrasive particulate material.

14. The abrasive article of claim 13 , wherein the alumina crystals comprise alpha alumina.

15. The abrasive article of claim 13 , wherein the abrasive particulate material comprises Ca in an amount of at least about 0.25 wt % and not greater than about 2 wt % Ca based on the total weight of the particulate material.

16. The abrasive article of claim 13 , wherein the abrasive particulate material comprises Mg in an amount of at least about 0.1 wt % and not greater than about 1.5 wt % based on the total weight of the abrasive particulate material.

17. The abrasive article of claim 13 , wherein the additive ratio [Mg:Ca] is within a range between about 1:1 and about 9:1.

18. The abrasive article of claim 13 , wherein the additive ratio [Mg:Ca] is within a range between about 3:1 and about 10:1.

19. The abrasive article of claim 13 , wherein the abrasive particulate material comprises shaped abrasive particles having a shape selected from the group consisting of triangular, rectangular, pentagonal, hexagonal, conical, helical, elliptical, elongated, and a combination thereof.

20. The abrasive article of claim 19 , wherein the shaped abrasive particles have a triangular shape.

21. The abrasive article of claim 13 , wherein the abrasive particulate material is part of a fixed abrasive.

Assignees

• Panzarella Tracy H
• Yener Doruk O
• Saint-Gobain Ceram & Plastics Inc

Inventors

• Panzarella Tracy H
• Yener Doruk O

Classifications

• C01P2004/50

  Agglomerated particles · CPC title

• B24D3/348 Primary

  utilised as impregnating agent for porous abrasive bodies · CPC title

• C09K3/1436

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

• C09K3/14

  Anti-slip materials; Abrasives {(products specifically intended for the fabrication of abrasive tools, blocks or papers, or for operations of the kind of sand-blasting and barrelling B24B31/14, B24C1/00; polishing compositions containing abrasive or grinding agents C09G1/02; friction compositions for brakes or clutches F16D69/02; polishing of semi-conductors H10P52/40)} · CPC title

• B24D3/34 Primary

  characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties · CPC title