Shaped abrasive particle including dopant material and method of forming same

Patent metadata

Field	Value
Publication number	US-9771507-B2
Application number	US-201514607308-A
Country	US
Kind code	B2
Filing date	Jan 28, 2015
Priority date	Jan 31, 2014
Publication date	Sep 26, 2017
Grant date	Sep 26, 2017

Abstract

A method of forming a shaped abrasive particle including extruding a mixture into a form, applying a dopant material to an exterior surface of the form, and forming a precursor shaped abrasive particle from the form.

First claim

What is claimed is:

1. A particulate material comprising:
a shaped abrasive particle having a body comprising a length, a width, and a thickness, wherein the body comprises a central region including the geometric center of the body having a first dopant material present in a center dopant amount (D Cc ), the body further comprising an upper surface defined by the dimensions of length and width, the upper surface having a second dopant material present in an upper surface dopant amount (D USc ), wherein the body comprises a dopant amount difference (ΔD c ) between the center dopant amount and the upper surface dopant amount, and wherein the dopant amount difference (ΔD c ) is at least about 0.2 wt % and not greater than about 30 wt %.

2. The particulate material of claim 1 , wherein the first dopant material and second dopant material are different from each other.

3. The particulate material of claim 1 , wherein the body comprises a two-dimensional shape as viewed in a plane defined by a length and a width of the shaped abrasive particle selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.

4. The particulate material of claim 1 , wherein the body comprises a material selected from the group consisting of an oxide, a nitride, a carbide, a boride, an oxycarbide, oxynitride, and a combination thereof.

5. The particulate material of claim 1 , wherein at least one of the first dopant material and the second dopant material comprises an element or compound including an element selected from the group consisting of alkali elements, alkaline earth elements, rare-earth elements, hafnium (Hf), zirconium (Zr), niobium (Nb), tantalum (Ta), molybdenum (Mo), vanadium (V), and a combination thereof.

6. The particulate material of claim 1 , wherein the body comprises not greater than about 12 wt % of the first dopant material for the total weight of the body and at least about 0.5 wt % of the first dopant material for the total weight of the body.

7. The particulate material of claim 1 , wherein the body comprises not greater than about 12 wt % of the second dopant material for the total weight of the body and at least about 0.5 wt % of the second dopant material for the total weight of the body.

8. The particulate material of claim 1 , wherein the upper surface has an upper surface contour significantly different than a contour of a bottom surface of the body as viewed in a cross-section of the body in a plane defined by the thickness and the length.

9. The particulate material of claim 1 , wherein the body comprises a corner-truncated triangle shape.

10. The particulate material of claim 1 , wherein the body comprises a pattern of features on at least one exterior surface, and wherein the features are selected from the group consisting of protrusions, grooves, ridges, scales, and a combination thereof.

11. A particulate material comprising:
a shaped abrasive particle having a body comprising a length, a width, and a thickness, wherein the body comprises a central region including the geometric center of the body having a first dopant material present in a center dopant amount (D Cc ), the body further comprising an upper surface defined by the dimensions of length and width, the upper surface having a second dopant material present in an upper surface dopant amount (D USc ), wherein the body comprises a dopant amount difference (ΔD c ) between the center dopant amount and the upper surface dopant amount, and wherein the body comprises not greater than about 12 wt % of the first dopant material for the total weight of the body and at least about 0.5 wt % of the first dopant material for the total weight of the body.

12. The particulate material of claim 11 , wherein the first dopant material and second dopant material are different from each other.

13. The particulate material of claim 1 , wherein the body comprises a two-dimensional shape as viewed in a plane defined by a length and a width of the shaped abrasive particle selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.

14. The particulate material of claim 11 , wherein at least one of the first dopant material and the second dopant material comprises an element or compound including an element selected from the group consisting of alkali elements, alkaline earth elements, rare-earth elements, hafnium (Hf), zirconium (Zr), niobium (Nb), tantalum (Ta), molybdenum (Mo), vanadium (V), and a combination thereof.

15. The particulate material of claim 11 , wherein the body comprises a corner-truncated triangle shape.

16. A particulate material comprising:
a shaped abrasive particle having a body comprising a length, a width, and a thickness, wherein the body comprises a central region including the geometric center of the body having a first dopant material present in a center dopant amount (D Cc ,), the body further comprising an upper surface defined by the dimensions of length and width, the upper surface having a second dopant material present in an upper surface dopant amount (D USc ), wherein the body comprises a dopant amount difference (ΔD c ) between the center dopant amount and the upper surface dopant amount, and wherein the body comprises not greater than about 12 wt % of the second dopant material for the total weight of the body and at least about 0.5 wt % of the second dopant material for the total weight of the body.

17. The particulate material of claim 16 , wherein the first dopant material and second dopant material are different from each other.

18. The particulate material of claim 16 , wherein the body comprises a two-dimensional shape as viewed in a plane defined by a length and a width of the shaped abrasive particle selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.

19. The particulate material of claim 16 , wherein at least one of the first dopant material and the second dopant material comprises an element or compound including an element selected from the group consisting of alkali elements, alkaline earth elements, rare-earth elements, hafnium (Hf), zirconium (Zr), niobium (Nb), tantalum (Ta), molybdenum (Mo), vanadium (V), and a combination thereof.

20. The particulate material of claim 16 , wherein the body comprises a corner-truncated triangle shape.

Assignees

• Saint-Gobain Ceram & Plastics Inc

Inventors

• Yener Doruk O
• Braun Paul

Classifications

• C04B35/1115

  Minute sintered entities, e.g. sintered abrasive grains or shaped particles such as platelets (abrasives C09K3/14) · CPC title

• C04B2235/3205

  Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide · CPC title

• C09K3/1436 Primary

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

• C04B35/01

  based on oxide ceramics · CPC title

• C04B2235/94

  Products characterised by their shape · CPC title