Method of making ceramic shaped abrasive particles, sol-gel composition, and ceramic shaped abrasive particles

Patent metadata

Field	Value
Publication number	US-9790410-B2
Application number	US-201214127853-A
Country	US
Kind code	B2
Filing date	Jun 28, 2012
Priority date	Jul 12, 2011
Publication date	Oct 17, 2017
Grant date	Oct 17, 2017

Abstract

A method includes: providing a mold having a plurality of mold cavities, wherein each mold cavity is bounded by a plurality of faces joined along common edges; filling at least some of the mold cavities with a sol-gel composition that includes a release agent dispersed therein; at least partially drying the sol-gel composition thereby forming shaped ceramic precursor particles; calcining at least a portion of the shaped ceramic precursor particles to provide calcined shaped ceramic precursor particles; and sintering at least a portion of the calcined shaped ceramic precursor particles to provide ceramic shaped abrasive particles. A sol-gel composition, shaped ceramic precursor particles, and ceramic shaped abrasive particles associated with practice of the method are also disclosed.

First claim

What is claimed is:

1. A method of making shaped ceramic precursor particles, the method comprising:
providing a mold having a plurality of mold cavities, wherein each mold cavity is bounded by a plurality of faces joined along common edges;
filling at least some of the mold cavities with a sol-gel composition, the sol-gel composition comprising a liquid vehicle and a ceramic precursor comprising an alpha alumina precursor, the liquid vehicle comprising a volatile component and a release agent dispersed throughout the volatile component, wherein the release agent comprises an oil; and
removing at least a portion of the volatile component from the sol-gel composition while the sol-gel composition resides in the mold cavities thereby providing the shaped ceramic precursor particles.

2. The method of claim 1 , further comprising separating the shaped ceramic precursor particles from the mold.

3. A method of making ceramic shaped abrasive particles, the method comprising:
making shaped ceramic precursor particles according to the method of claim 1 ; and
sintering at least a portion of the shaped ceramic precursor particles to provide the ceramic shaped abrasive particles.

4. A method of making ceramic shaped abrasive particles, the method comprising:
making shaped ceramic precursor particles according to the method of claim 1 ;
calcining at least a portion of the shaped ceramic precursor particles to provide calcined shaped ceramic precursor particles; and
sintering at least a portion of the calcined shaped ceramic precursor particles to provide the ceramic shaped abrasive particles.

5. The method of claim 4 , wherein the ceramic shaped abrasive particles have an abrasives industry specified nominal grade.

6. The method of claim 4 , wherein the release agent is included in the sol-gel composition in an amount of from 0.08 to 4.25 percent of the theoretical oxide weight of the ceramic precursor.

Assignees

• Boden John T
• Culler Scott R
• 3M Innovative Properties Co

Inventors

• Boden John T
• Culler Scott R

Classifications

• 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

• C04B2235/6027

  Slip casting · CPC title

• C04B35/10

  based on aluminium oxide · CPC title

• B28B1/004

  Devices for shaping artificial aggregates from ceramic mixtures or from mixtures containing hydraulic binder (from slag C04B5/00; composition of artificial aggregates C04B18/02) · CPC title

• C04B2235/602

  Making the green bodies or pre-forms by moulding · CPC title