• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    FORMATTED ABRASIVE PARTICLES The present invention relates to formatted abrasive particles which comprise a ceramic and which comprise a first plate integrally joined to a second plate at a predetermined (Beta) angle.
    公开号:BR112013001831B1
    申请号:R112013001831-3
    申请日:2011-08-03
    公开日:2020-10-27
    发明作者:Negus B. Adefris
    申请人:3M Innovative Properties Company；
    IPC主号:
    专利说明:

    Background
    [001] Abrasive particles and abrasive articles produced from abrasive particles are useful for abrasion, finishing or crushing a wide variety of materials and surfaces in the manufacture of goods. As such, there remains a need to improve the cost, performance or life of the abrasive particle and / or the abrasive article.
    [002] Triangular shaped abrasive particles and abrasive articles using triangular shaped abrasive particles are disclosed in US patents 5,201,916 to Berg; 5,366,523 to Rowenhorst (Re 35,570); and 5,984,988 to Berg. In one embodiment, the shape of the abrasive particles comprises an equilateral triangle. Abrasive particles with triangular shape are useful in the manufacture of abrasive articles that have high cutting rates. summary
    [003] Formatted abrasive particles can, in general, outperform randomly crushed abrasive particles. By controlling the abrasive particle shape, it is possible to control the performance resulting from the abrasive article. The inventors have discovered that by making formatted abrasive particles comprising a first plate and a second plate that intersect at a predetermined angle, the angle of inclination of one of the plates in relation to the workpiece can be controlled precisely in a once-coated abrasive article that one plate can act as a base to anchor the shaped abrasive particle to the support while the other plate comes into contact with the workpiece at the predetermined angle of inclination.
    [004] Other advantages may include: 1. Using the size of the bottom plate adhered to the base coating to control the spacing and density of abrasive points in contact with the workpiece. This technique can control the degree of openness of the abrasive layer, which can be adjusted for abrasion of different materials. 2. Formation of channels for removal of iron filings. Since the abrasive points can be spaced in a controllable way by the size and shape of the base, channels in the abrasive layer can be formed to conduct cooling fluid or to remove iron filings. 3. Creation of formatted abrasive particles that have more points and less flat surfaces. The abrasive particles in the triangular shape of RE 35.570 have two opposite flat surfaces and three vertices that could come into contact with the workpiece. The plate-shaped particles that intersect in Figure 3 have only a flat surface and 5 vertices that could come into contact with the workpiece significantly increasing the chances that a vertex will come into contact with the workpiece instead of one. flat surface. This can be a particular advantage in a nonwoven construction where controlling the orientation of the shaped abrasive particle is more difficult than in a coated abrasive article.
    [005] Therefore, in one embodiment, the invention relates to formatted abrasive particles that comprise a ceramic and that comprise a first plate integrally joined to the second plate at a predetermined angle β. Brief description of the drawings
    [006] It should be understood by those skilled in the art that the present discussion is a description of exemplary modalities only, and is not intended to limit the broader aspects of the present description, whose broad aspects are incorporated into the exemplary construction.
    [007] Figures 1A and 1B illustrate a modality of the intersecting plate-shaped abrasive particles comprising a first plate and a second plate.
    [008] Figures 2A and 2B illustrate another embodiment of the intersecting plate-shaped abrasive particles comprising a first plate and a second plate.
    [009] Figures 3A and 3B illustrate another embodiment of the intersecting plate-shaped abrasive particles comprising a first plate and a second plate.
    [0010] Figures 4A and 4B illustrate another embodiment of the intersecting plate-shaped abrasive particles comprising a first plate and a second plate.
    [0011] Figure 5 illustrates a coated abrasive article containing the intersecting plate-shaped abrasive particles comprising a first plate and a second plate.
    [0012] Figure 6 illustrates another coated abrasive article containing the intersecting plate-shaped abrasive particles comprising a first plate and a second plate.
    [0013] Figure 7 illustrates a nonwoven abrasive article containing the intersecting plate-shaped abrasive particles comprising a first plate and a second plate.
    [0014] Figure 8 illustrates another abrasive particle in the form of intersecting plates comprising a first plate and a second plate.
    [0015] Figures 9A-9C illustrate the dimensions of the mold used to make the abrasive particle in the shape of plates that intersect with figure 8.
    [0016] Figure 10 shows abrasive particles in the shape of intersecting plates produced by example 1.
    [0017] Figure 11 shows an abrasive nonwoven article made by example 2.
    [0018] The repeated use of reference characters in the specification and drawings is intended to represent the same or analogous characteristics or elements of the disclosure. Definitions
    [0019] For use in the present invention, the forms of the words "understand", "have" and "include" are legally equivalent and are not limiting. Therefore, the additional elements, functions, steps or limitations not mentioned may be present in addition to the elements, functions, steps, or limitations mentioned.
    [0020] For use in the present invention, the term "abrasive dispersion" means a precursor to alpha alumina that can be converted to alpha alumina, which is introduced into a mold cavity. The composition is called an abrasive dispersion until sufficient volatile components are removed to cause the abrasive dispersion to solidify.
    [0021] For use in the present invention, the term "integrally joined" means that the same material that forms the first and second plates joins the two plates. A separate binder that has a different chemical composition is not used to fix the two plates.
    [0022] For use in the present invention, the term "precursor shaped abrasive particle" means the unsintered particle produced by removing a sufficient amount of the volatile component from the abrasive dispersion, when it is in the mold cavity, to form a body solidified material that can be removed from the mold cavity and substantially retains its molded shape in subsequent processing operations.
    [0023] For use in the present invention, the term "shaped abrasive particle" means a ceramic abrasive particle with at least a portion of the abrasive particle having a predetermined shape that is replicated from a mold cavity used to form the particle formatted precursor abrasive. Except in the case of abrasive fragments (for example, as described in provisional application US 61 / 016.965), the formatted abrasive particle will, in general, have a predetermined geometric shape that substantially reproduces the mold cavity that was used to form the abrasive particle Formated. The formatted abrasive particle, for use in the present invention, excludes abrasive particles obtained by a mechanical crushing operation. Detailed Description Abrasive particles in the shape of intersecting plates
    [0024] With reference to figures 1 to 4, abrasive particles are illustrated in the form of plates that cross 20 examples. In one embodiment, the material from which the shaped abrasive particle 20 is produced comprises alpha alumina. Alpha alumina particles can be produced from a dispersion of aluminum oxide hydroxide or aluminum monohydrate that is gelled, molded to a shape, dried to retain the shape, calcined, and then sintered, as discussed later in this document. The geometry of the intersecting plate-shaped abrasive particle is retained without the need for a binder to form an agglomerate comprising abrasive particles held together by a binder.
    [0025] In general, the shaped abrasive particles 20 comprise at least two intersecting plates that have a first plate 21 integrally joined (in one embodiment, when the shaped abrasive particle is molded) to a second plate 23 at a predetermined angle β measured between the central plane (dashed line) of each plate. Each plate comprises a first main surface and a second main surface opposite the first main surface. One or both plates can be tapered, flat-concave (a flat surface with a concave surface), flat-convex (a flat surface with a convex surface), both convex surfaces, both concave surfaces, curved with parallel surfaces or tapered or have two substantially flat and parallel surfaces. In some embodiments, the main surfaces are joined by plates that form on the side wall with a thickness along the perimeter and, in other embodiments, the first and / or second main surface (s) may taper forming a thin border or line, where they are joined as the intersection between two convex surfaces. The plates can cross abruptly forming a distinct line, or a radius can be used at the intersection to form a more gradual transition between the plates. In other embodiments, three, four, five or more plates can intersect to form the formatted abrasive particle.
    [0026] In some embodiments, the first plate 21 acts as a base for attaching the shaped abrasive particle to a support 56 in a coated abrasive article 54 while the second plate 23 acts as the grinding element to erode a workpiece 64 as can be seen better in figure 5. Because the first plate and the second plate intersect at a predetermined angle β, the angle of inclination of the second plate 23 in relation to the workpiece can be precisely controlled thereby improving the rate cutting, finishing or both of the coated abrasive article. The first large, flat plate that acts as a base also helps to securely attach the formatted abrasive particles to the support compared to just using one edge of one of the plates.
    [0027] The first and second plates (21, 23) can comprise thin bodies that have a first main surface 24, and a second main surface 26 and which have a thickness T. In some embodiments, the thickness T varies between about 5 micrometers to about 1 mm. The plates may comprise a uniform thickness or the thickness of the plates may taper or vary. In some embodiments, the first main surface 24 and the second main surface 26 are connected to each other by at least one side wall 28, which can be an inclined side wall, as shown in figure 1 which has an outlet angle α between the second main surface 26 and side wall 28 of more than 90 degrees. In some embodiments, more than one inclined sidewall 28 may be present and the slope or angle for each inclined sidewall 28 may be the same or different as more fully described in US pending patent application serial number 12 / 337,075 filed in December 17, 2008 entitled “Shaped Abrasive Particles With A Sloping Sidewall.” In other embodiments, the side wall 28 can cross the first main surface 24 and the second main surface 26 at a 90 degree angle.
    [0028] In one embodiment, the first and second main surfaces (24, 26) of the first and second plates (21, 23) comprise a geometric shape selected as a circle, an oval shape, a triangle, a quadrilateral (rectangle , square, trapezoid, rhombus, rhomboid, kite, superelipse), or other geometric shape with several borders (pentagon, hexagon, octagon, etc.). Alternatively, the first and second main surfaces (24, 26) can comprise an irregular repeatable shape (replicated by the mold cavity) or a shape that combines line segments and arcuate segments to form the contour or perimeter. Depending on the angle of departure α, the areas of the first and second main surfaces of each plate can be the same or different. In many embodiments, the first plate and the second plate comprise a prism (90 degree exit angle) or a truncated pyramid (exit angle not equal to 90 degrees) such as a triangular prism, a truncated triangular pyramid, a rhomboid prism , or a truncated rhomboid pyramid, to name a few possibilities.
    [0029] In an embodiment shown in figure 1, the first plate 21 comprised a truncated triangular pyramid and the second plate 23 comprised a truncated triangular pyramid crossing the first plate at a predetermined β angle. In other embodiments, both plates may be prisms or one plate may be a prism while the other plate is a truncated pyramid. In one embodiment, the main surfaces of each plate comprised equilateral triangles with a second plate having a slightly smaller size so that its edge fits within the second main surface 26 of the first plate 21, as shown in figure 1. The second plate 23 can be located on the second main surface 26 of the first plate 21 with one of its edges (side wall) being cut by an imaginary line on the second main surface 26 of the first plate 21 which intersects the perimeter of the second main surface at an angle of 90 degrees and that cuts through one of the vertices of the second main surface. In a specific modality, the predetermined angle β was 82 degrees and the exit angle α for each plate was 98 degrees.
    [0030] In another embodiment shown in figure 2, the first plate 21 comprised a truncated triangular pyramid (alternatively, a prism) and the second plate 23 comprised a rectangular prism (trapezoid) (alternatively, a truncated pyramid) crossing the first plate in a predetermined β angle. In other embodiments, both plates may be prisms or both plates may be pyramids. The second plate 23 can be located on the second main surface 26 of the first plate 21 with one of its edges (side wall) being cut by an imaginary line on the second main surface 26 of the first plate 21 which intersects with the perimeter of the second main surface at a 90 degree angle and that cuts through one of the vertices of the second main surface. In a specific embodiment, the predetermined angle β was 90 degrees and the exit angle α for the first plate was 98 degrees and for the second plate it was 90 degrees.
    [0031] In another embodiment shown in figure 3, the first plate 21 comprised a rhomboid (diamond) prism and the second plate 23 comprised a triangular prism. In other embodiments, both plates may be truncated pyramids or one plate may be a prism while the other plate is a truncated pyramid. The second plate 23 can be located on the second main surface 26 of the first plate 21 with one of its edges (side wall) being cut by an imaginary line on the second main surface 26 of the first plate 21 that connects two of its opposite vertices. In a specific modality, the triangular prism comprised an equilateral triangle and the diamond was cut by the second plate into two triangles of size and shape similar to the equilateral triangle of the second plate and seen in figure 3. In a specific modality, the predetermined angle β was 90 degrees and the exit angle α for the first plate was 90 degrees and for the second plate it was 90 degrees.
    [0032] In another embodiment shown in figure 4, the first plate 21 comprised a rhomboid prism (diamond) and the second plate 23 comprised a rectangular prism (trapezoid). In other embodiments, both plates may be truncated pyramids or one plate may be a prism while the other plate is a truncated pyramid. The second plate 23 can be located on the second main surface 26 of the first plate 21 with one of its edges (side wall) being cut by an imaginary line on the second main surface 26 of the first plate 21 that connects two of its opposite vertices. In a specific embodiment, the predetermined angle β was 90 degrees and the exit angle α for the first plate was 90 degrees and for the second plate it was 90 degrees.
    [0033] In various embodiments of the invention, the second plate 23 (smaller plate) can be dimensioned so that the intersecting edge of the second plate is entirely contained within the perimeter of the first or second main surface on the first plate 21 that it cuts. Alternatively, the second plate 23 can be sized or located so that the intersecting edge of the second plate extends past the perimeter of the first or second main surface on the first plate 21 which it crosses. The extension can be done by making the plates the same size and shape and simply displacing their intersection, or a plate can be made larger (longer) than the plate it crosses to emphasize the perimeter of the surface over one or more edges.
    [0034] In various embodiments of the invention, the angle of departure α may be between approximately 90 degrees to approximately 135 degrees, or between approximately 95 degrees to approximately 130 degrees, or between about 95 degrees to about 125 degrees or between about 95 degrees to about 120 degrees or between about 95 degrees to about 115 degrees or between about 95 degrees to about 110 degrees or between about 95 degrees to about 105 degrees or between about 95 degrees to about 100 degrees. As discussed in US Patent Application Serial No. 12 / 337,075 entitled “Shaped Abrasive Particles With A Sloping Sidewall” filed on December 17, 2008, specific variations for the α departure angle were revealed to produce surprising increases in crushing performance of coated abrasive articles produced from abrasive particles shaped with a sloping sidewall. In particular, the 98-degree, 120-degree or 135-degree exit angles were revealed to have improved crushing performance over a 90-degree exit angle. The improvement in shredding performance is particularly pronounced at the exit angles of 98 degrees or 120 degrees as seen in Figures 6 and 7 of US Patent Application Serial No. 12 / 337,075. Different angles or the same angle for the departure angle α can be used with any of the plates that form the shaped abrasive particle. When intersecting plate-shaped abrasive particles are incorporated or otherwise attached to the abrasive article by one of the angled side walls instead of the first main surface 24 of the first plate 21, the angles in the intervals above can increase the performance of crushing in a similar way.
    [0035] Similarly, it is believed that a predetermined β angle other than 90 degrees results in enhanced cutting performance of intersecting plate-shaped abrasive particles; however, a 90 degree angle can also be used. In various embodiments of the invention, the predetermined β angle can be between about 20 degrees and about 85 degrees, or between about 55 degrees and about 85 degrees, or between about 60 degrees and about 85 degrees, or between about 65 degrees and about 85 degrees, or between about 70 degrees and about 85 degrees, or between about 75 degrees and about 85 degrees, or between about 80 degrees and about 85 degrees. The control of the predetermined β angle can control the angle of inclination of the second plate in relation to the workpiece in a coated abrasive article, as can be seen better in Figure 5.
    [0036] In various embodiments of the invention, the first and second plates (21, 23) may include additional features. In some embodiments, the first main surface 24 is substantially flat, the second main surface 26 is substantially flat, or both are substantially flat. Alternatively, one side could be concave or recessed, as discussed in more detail in copending patent application serial number US 12 / 336,961 entitled “Dish-Shaped Abrasive Particles With A Recessed Surface”, filed on December 17, 2008. A surface concave or recessed 50 can be created by selecting drying conditions for the sol-gel, while remaining in the cavity of the mold that forms a meniscus in the sol-gel that tends to shift the edges of the sol-gel up the sides of the mold as discussed in US Patent Application Serial No. 12 / 336,961. A concave surface can help increase cutting performance in some applications similar to a hollow ground chisel blade.
    [0037] Additionally, one or more openings that pass through the first main surface 24 and the second main surface 26 could be present in the plates, as discussed in more detail in US copending patent application serial number 12 / 337,112 entitled “Shaped Abrasive Particles With An Opening ”, deposited on December 17, 2008. An opening through the plate (s) can reduce the apparent density of the formatted abrasive particles, thus increasing the porosity of the resulting abrasive article in some applications, such as a grinding wheel, where increased porosity is often desired. Alternatively, the opening can reduce bombardment by anchoring the particle in the sizing coating more firmly or the opening can act as a reservoir for a crushing aid. An opening can be formed within the formatted abrasive particle by selecting drying conditions that exaggerate the meniscus phenomenon discussed above, or by producing a mold that has one or more posts extending from the mold surface. Methods of preparing abrasive particles formed with an aperture are discussed in US Patent Application Serial No. 12 / 337,112.
    [0038] In addition, the formatted abrasive particles may have a plurality of grooves on the first or second main surface, as described in US provisional application No. Serial 61 / 138.268 entitled “Shaped Abrasive Particles With Grooves” deposited on December 17 from 2008. The grooves are formed by a plurality of ridges on the surface of the mold cavity that have been shown to facilitate the removal of the precursor-shaped abrasive particles from the mold. A crest that has a triangular-shaped cross section is believed to act as a wedge that lifts the precursor-shaped abrasive particle off the bottom surface of the mold under drying conditions that promote sun-gel shrinkage while remaining in the cavity of the mold.
    [0039] The formatted abrasive particles 20 produced in accordance with the present description can be incorporated into an abrasive article or used in the loose form. Abrasive particles are, in general, classified for a given particle size distribution before use. Such distributions typically have a range of particle sizes, from rough particles to fine particles. In abrasive technique, this band is sometimes called "rough", "control" and "thin" fractions. Abrasive particles classified according to the classification standards accepted by the abrasives industry specify the particle size distribution for each nominal classification within numerical limits. Such industry-accepted classification standards (that is, nominal rating specified by the abrasives industry) include those known as the American National Standards Institute, Inc. (ANSI) standards, standards of the Federation of European Producers of Abrasive Products (FEPA) and Japanese Industrial Standard (JIS) standards.
    [0040] ANSI classification designations (ie specified nominal classifications) include: ANSI 4, ANSI 6, ANSI 8, ANSI 16, ANSI 24, ANSI 36, ANSI 40, ANSI 50, ANSI 60, ANSI 80, ANSI 100, ANSI 120, ANSI 150, ANSI 180, ANSI 220, ANSI 240, ANSI 280, ANSI 320, ANSI 360, ANSI 400 and ANSI 600. FEPA classification designations include P8, P12, P16, P24, P36, P40 , P50, P60, P80, P100, P120, P150, P180, P220, P320, P400, P500, P600, P800, P1000 and P1200. JIS classification designations include JIS8, JIS12, JIS16, JIS24, JIS36, JIS46, JIS54, JIS60, JIS80, JIS100, JIS150, JIS180, JIS220, JIS240, JIS280, JIS320, JIS360, JIS400, JIS600, JIS800, JIS800, JIS800 , JIS2500, JIS4000, JIS6000, JIS8000 and JIS10,000.
    [0041] Alternatively, formatted abrasive particles 20 can be classified by a nominal screening classification using U.S.A. Standard Test Sieves in accordance with ASTM E-11 "Standard Specification for Wire Cloth and Sieves for Testing Purposes". ASTM E-11 outlines requirements for the design and construction of test sieves using a woven wire cloth medium mounted on a frame for the classification of materials according to a designated particle size. A typical designation can be represented as -18 + 20, which means that the formatted abrasive particles pass through a test sieve that meets ASTM E-11 specifications for the number 18 sieve and are retained on a test sieve that meets ASTM E-11 specifications for the number 20 sieve. In one embodiment, the formatted abrasive particles 20 have a particle size such that most particles pass through a network test sieve 18 and are retained in a 20, 25, 30, 35, 40, 45 or 50 mesh test sieve. In various embodiments of the invention, the shaped abrasive particles 20 may have a nominal screened rating comprising: -18 + 20, -20 / + 25 , -25 + 30, -30 + 35, -35 + 40, - 40 + 45, -45 + 50, -50 + 60, -60 + 70, -70 / + 80, -80 + 100, -100+ 120, -120 + 140, -140 + 170, - 170 + 200, -200 + 230, -230 + 270, -270 + 325, -325 + 400, -400 + 450, -450 + 500, or -500 +635. Alternatively, an adapted network size could be used as -90 + 100.
    [0042] In one aspect, the present description features a plurality of formatted abrasive particles that have a nominal rating specified by the abrasive industry or nominal screened classification, with at least a portion of the plurality of abrasive particles being formatted abrasive particles 20. In In another aspect, the description features a method comprising classifying the formatted abrasive particles 20 produced in accordance with the present description to provide a plurality of formatted abrasive particles 20 that have a nominal rating specified by the abrasive industry or a nominal screening rating .
    [0043] If desired, formatted abrasive particles 20 that have a nominal rating specified by the abrasive industry or a nominal screening rating can be mixed with other known abrasive or non-abrasive particles. In some embodiments, at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or even 100 percent, by weight, of the plurality of abrasive particles, which have a nominal rating specified by the abrasive industry or a nominal screening classification, is shaped abrasive particles 20 produced in accordance with the present description, based on the total weight of the plurality of abrasive particles .
    [0044] Particles suitable for mixing with the formatted abrasive particles 20 include conventional abrasive grains, diluting grains or agglomerates susceptible to erosion, such as those described in US Patent Nos. 4,799,939 and 5,078,753. Representative examples of conventional abrasive grains include molten aluminum oxide, silicon carbide, boron carbide grenade, fused alumina zirconia, cubic boron nitride, diamond and the like. Representative examples of diluent grains include marble, natural plaster and glass. Blends of different geometrically formatted abrasive particles 20 or blends of 20 formatted abrasive particles with angled side walls having different exit angles or different predetermined β angles can be used in the articles of this invention.
    [0045] For some applications, mixtures of formatted abrasive particles and conventional abrasive grains have been revealed to work satisfactorily. In these applications, even a small amount of the formatted abrasive particles, such as 10% by weight, significantly enhances performance. In blends of abrasive particles formatted with conventional abrasive grains or thinner grains, the weight of the abrasive particles formatted in the blend can be less than or equal to 50, 40, 30, 25, 20, 15 or 10% and still provide a significant performance increase .
    [0046] Shaped abrasive particles 20 may also have a surface coating. Surface coatings are known to optimize the adhesion between abrasive grains and the binder in abrasive articles, or they can be used to assist in the electrostatic deposition of shaped abrasive particles 20. In one embodiment, surface coatings as described in US Patent No. 5,352 .254 in an amount of 0.1% to 2% inorganic products for the weight of the formatted abrasive particle were used. Such surface coatings are described in US Patent Nos. 5,213,591; 5,011,508; 1,910,444; 3,041,156; 5,009,675; 5,085,671; 4,997,461; and 5,042,991. Additionally, the surface coating can prevent welding or adhesion of the abrasive particle formed on the top of the abrasive grain (capping). “Capping” is the term used to describe the phenomenon where metal particles from the workpiece being ground are welded to the tops of the shaped abrasive particles. Surface coatings for performing the above functions are known to those skilled in the art. Abrasive articles that have intersecting plate-shaped abrasive particles
    [0047] With reference to figure 5, a coated abrasive article 54 comprises a support 56 that has a first binder layer, from this point on in this document called the basic coating 58, applied on a first main surface 60 of the support 56 Attached or partially incorporated into the base coating 58 is a plurality of shaped abrasive particles 20 that form an abrasive layer. On the formatted abrasive particles 20 is a second binder layer, later in this document called sealing coating 62. The purpose of the basic coating 58 is to trap the formatted abrasive particles 20 on the substrate 56 and the purpose of the sealing coating 62 is to reinforce the shaped abrasive particles 20. An optional superglue coating, as is known to those skilled in the art, can also be applied.
    [0048] As can be seen, the shaped abrasive particles 20 can be connected to support 56 by the first plate 21. Since the second plate 23 is joined to the first plate 21 at a predetermined angle β, the angle of inclination of the second plate 23 to a workpiece 64 while abrasing the workpiece can be precisely controlled. The ability to control the tilt angle can increase the cutting performance of the abrasive article or the finish of the abrasive article.
    [0049] In another embodiment shown in figure 6, the abrasive particles in the shape of intersecting plates (figure 1) are coated by immersion to form the coated abrasive particle. Even when dip coating is used, unlike electrostatic coating, intersecting plate-shaped abrasive particles tend to orient themselves so that a vertex of one of the triangular plates is present to come into contact with the workpiece during crushing. The result is especially pronounced if an open layer of abrasive coating is used and excessly shaped abrasive particles are not added so as to fall on the previously applied formatted abrasive particles.
    [0050] To optimize the orientation, the intersecting plate-shaped abrasive particles can be applied to the support in an open layer of abrasive coating in figures 5 and 6. An open layer of abrasive coating will result in less than 100% coverage of the basic coating with abrasive particles, thus leaving open areas and a visible resin layer between the abrasive particles. In various embodiments of the invention, the percentage of open area in the abrasive layer can be from 10% to about 90% or from about 30% to about 80%.
    [0051] The basic coating 58 and the sizing coating 62 comprise a resinous adhesive. The resinous adhesive of the basic coating 58 can be the same or different from that of the sizing coating 62. Examples of resinous adhesives that are suitable for these coatings include phenolic resins, epoxy resins, urea-formaldehyde resins, acrylate resins, aminoplastic resins, melamine resins, acrylated epoxy resins, urethane resins and combinations thereof. In addition to the resinous adhesive, the basic coating 58 or the sizing coating 62, or both coatings, may also comprise additives that are known in the art, such as fillers, crushing aids, wetting agents, surfactants, dyes, pigments, binding agents, adhesion promoters, and combinations thereof. Examples of fillers include calcium carbonate, silica, talc, clay, calcium metasilicate, dolomite, aluminum sulfate and combinations thereof.
    [0052] A crushing aid can be applied to the coated abrasive article. A crushing aid is defined as particulate material, the addition of which has a significant effect on the chemical and physical processes of abrasion, thus resulting in improved performance. Crushing aids cover a wide variety of different materials and can be inorganic or organic. Examples of chemical grinding aid groups include waxes, organic halide compounds, halide salts, and metals and their alloys. Organic halide compounds will typically decompose during abrasion and release a halogen acid or a gaseous halide compound. Examples of such materials include chlorinated waxes, such as tetrachloronaphthalene, pentachloronaphthalene; and polyvinyl chloride. Examples of halide salts include sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluorides, potassium chloride, and magnesium chloride. Examples of metals include tin, lead, bismuth, cobalt, antimony, cadmium, iron, and titanium. Other crushing aids include sulfur, organic sulfur compounds, graphite, and metal sulfides. Also included in the scope of this invention is the use of a combination of different crushing aids; in some cases, this can produce a synergistic effect. In some embodiments, the crushing aid is preferably cryolite or potassium tetrafluorborate. The amount of such additives can be adjusted according to the desired properties. It is also within the scope of this invention to use a supercoating coating. The supercoiling coating typically contains a binder and a crushing aid. Binders can be formed from materials such as phenolic resins, acrylate resins, epoxy resins, urea-formaldehyde resins, melamine resins, urethane resins and combinations thereof. In some embodiments, a supercoating coating comprising a heat-hardened epoxy resin, a dressing, a thermoplastic hydrocarbon resin, a grinding aid, a dispersing agent, and a pigment is used as disclosed in US Patent No. 5,441,549 (Helmin).
    [0053] It is also included in the scope of this invention that the shaped abrasive particles 20 can be used in a bonded abrasive article, a nonwoven abrasive article or abrasive brushes. A bonded abrasive comprises a plurality of shaped abrasive particles 20 connected by means of a binder to form a shaped mass. The binder for a bonded abrasive can be metallic, organic, ceramic or glassy. A nonwoven abrasive comprises a plurality of formatted abrasive particles 20 attached to a fibrous nonwoven web by means of an organic binder.
    [0054] With specific reference to figure 7, a nonwoven abrasive article comprises a fibrous web 100 formed by interwoven filaments 110 held together by a binder 120 as a polyurethane binder. The intersecting plate-shaped abrasive particles 20 are dispersed throughout the fibrous mat 100 on the exposed surfaces of filaments 110. Binder 120 covers at least a portion of filaments 110 and the abrasive particles formed on the non-woven mat are adhered . For some of the intersecting plate-shaped abrasive particles, at least a portion of filament 110 comes into contact with the first plate 21 and the second plate 23 simultaneously. Since a larger area of intersecting plate-shaped abrasive particles can come in contact with the filaments, better adhesion of the formatted abrasive particles to the filaments can occur. Production method of intersecting plate-shaped abrasive particles
    [0055] Materials that can be produced as ceramic objects formatted using the process of the invention include physical precursors, such as finely divided particles of ceramic materials known as alpha alumina, silicon carbide, alumina / zirconia and boron carbide. Also included are chemical and / or morphological precursors, such as aluminum trihydrate, boehmite, alumina range and other transition alumines and bauxite. The most useful of the above are typically based on alumina and its physical or chemical precursors. It should be understood, however, that the invention is not limited to this, but can be adapted for use with a plurality of different precursor materials.
    [0056] Other components that are desirable in certain circumstances for the production of alumina-based particles include nucleating agents such as finely divided alpha alumina, ferric oxide, chromium oxide and other materials capable of nuclear transformation of precursor forms to form alpha alumina; magnesia; titanium oxide; zirconia; yttria; and rare earth metal oxides. Such additives often act as crystal growth limiters or limit phase modifiers. The amount of such additives in the precursor is generally less than about 10% and often less than 5% by weight (based on solids).
    [0057] It is also possible to use, instead of a chemical or morphological precursor of alpha alumina, a strip of finely divided alpha alumina together with an organic compound that will keep it in suspension and act as a temporary binder while the particle is being heated to essentially complete densification. In these cases, it is often possible to include in the suspension materials that will form a separate phase upon heating or that can act as an aid in maintaining the structural integrity of the shaped particles during drying and heating or after heating. Such materials can be present as impurities. If, for example, the precursor is finely divided bauxite, there will be a small proportion of glassy material present that will form a second phase after the powder grains are sintered together to form the shaped particle.
    [0058] The dispersion that is employed in the process of the invention can be any dispersion of a ceramic precursor, such as a finely dispersed material that, after being subjected to the process of the invention, is in the form of a formatted ceramic article. The dispersion can be chemically a precursor, for example, bohemite is a chemical precursor to alpha alumina; a morphological precursor such as gamma alumina is a morphological precursor to alpha alumina; as well as (or alternatively), physically a precursor in the sense that a finely divided form of alpha alumina can be formed into a shape and sintered to retain this shape.
    [0059] When the dispersion comprises a physical or morphological precursor according to the term used in this document, the precursor is in the form of finely divided grains of powder which, when sintered, form a ceramic article, as an abrasive particle useful in conventional coated and bonded abrasive applications. Such materials generally comprise powder grains with an average size of less than about 20 microns, preferably less than about 10 microns and, most preferably, less than about 1 micron.
    [0060] The dispersion used in a preferred process is most conveniently a bohemian sol-gel. The sol-gel can be a seeded sol-gel that comprises finely dispersed seed particles capable of nuclear converting alumina precursors to alpha alumina or an unseeded sol-gel that transforms to alpha alumina when sintered.
    [0061] The solids content of the dispersion of a physical or morphological precursor is preferably about 40 to 65% although solids content greater than about 80% can be used. An organic compound is often used in conjunction with finely divided grains in such dispersions as a suspending agent or perhaps a temporary binder until the formed particle has been sufficiently dry to maintain its shape. This can be any of those commonly known for such purposes, such as polyethylene glycol, sorbitan esters and the like.
    [0062] The solids content of a precursor that changes to the final stable ceramic form upon heating may need to take into account the water that can be released from the precursor during drying and heating to sinter the abrasive particles. In these cases, the solids content is typically slightly less, such as about 75% or less or even between about 30% and about 50%. With a bohemian sol gel, a maximum solids content of about 60% or even 40% can be used and a sol gel with a minimum peptized solids content of about 20% can also be used.
    [0063] Abrasive particles produced from physical precursors will typically need to be heated to higher temperatures than those formed from a seeded chemical precursor. For example, while particles in a seeded bohemian sol-gel form an essential and fully densified alpha alumina at temperatures below about 1250 degrees C, particles produced from unsown bohemian sol-gels may require a temperature firing above 1400 degrees C for complete densification.
    [0064] In a modality of making the abrasive particles in the shape of intersecting plates, seven process steps can be used. The first step in the process involves providing both a seeded and unseeded abrasive dispersion that can be converted to alpha alumina. The precursor composition of alpha alumina often comprises a liquid that is a volatile component. In one embodiment, the volatile component is water. The abrasive dispersion must comprise a sufficient amount of liquid so that the viscosity of the abrasive dispersion is sufficiently low, allowing to fill the mold cavities and replicate the mold surfaces, but not so much liquid as to cause the subsequent removal of the liquid from the mold cavity, becoming prohibitively expensive. In one embodiment, the abrasive dispersion comprises from 2 percent to 90 percent by weight of particles that can be converted to alpha alumina, such as particles of aluminum oxide monohydrate (bohemite), and at least 10 percent, in weight, or 50 percent to 70 percent, or 50 percent to 60 percent, by weight, of a volatile component such as water. Adversely, the abrasive dispersion, in some embodiments, contains 30 percent to 50 percent, or 40 percent to 50 percent, by weight, of solids.
    [0065] Aluminum oxide hydrates in addition to bohemian can also be used. Bohemite can be prepared by known techniques or it can be commercially obtained. Examples of commercially available bohemians include products bearing the trademarks "DISPERAL" and "DISPAL", both of which are available from Sasol North America, Inc. or "HiQ-40" available from BASF Corporation. These aluminum oxide monohydrates are relatively pure, that is, they include relatively few, if any, hydrate phases, in addition to monohydrates and have a high surface area. The physical properties of the resulting shaped abrasive particles 20 will, in general, depend on the type of material used in the abrasive dispersion.
    [0066] In one embodiment, the abrasive dispersion is in a gel state. For use in the present invention, a "gel" is a three-dimensional network of solids dispersed in a liquid. The abrasive dispersion may contain a modifying additive or precursor to a modifying additive. The modifying additive can work to improve some desirable properties of the abrasive particles or to increase the effectiveness of the subsequent sintering step. Modification additives or modification additive precursors can be in the form of soluble salts, typically water-soluble salts. They typically consist of a metal-containing compound and can be a precursor to magnesium oxide, zinc, iron, silicon, cobalt, nickel, zirconium, hafnium, chromium, yttrium, praseodymium, samarium, ytterbium, neodymium, lanthan, gadolinium, cerium, dysprosium, erbium, titanium and mixtures thereof. The particular concentrations of these additives that may be present in the abrasive dispersion can be varied based on those skilled in the art. Typically, the introduction of a modifying additive or precursor to a modifying additive will induce abrasive dispersion to gel. Abrasive dispersion can also be induced to gel through the application of heat over a period of time.
    [0067] The abrasive dispersion may also contain a nucleating agent (seeding) to accentuate the transformation from calcined or hydrated aluminum oxide to alpha alumina. Nucleating agents suitable for this description include fine particles of alpha alumina, ferric oxide alpha or its precursor, titanium and titanate oxides, chromium oxides or any other material that will nuclear the transformation. The amount of nucleating agent, if used, must be sufficient to effect the transformation of alpha alumina. Nucleation as abrasive dispersions is disclosed in US Patent No. 4,744,802 to Schwabel.
    [0068] A peptizing agent can be added to the abrasive dispersion to produce a more stable hydrosol or colloidal abrasive dispersion. Suitable peptizing agents are monoprotic acids or acid compounds such as acetic acid, hydrochloric acid, formic acid and nitric acid. Multiprotic acids can also be used, but they can quickly make the dispersion abrasive in gel, making it difficult to handle or introduce additional components into it. Some commercial bohemian sources contain an acidic titration (such as absorbed formic acid or nitric acid) that will assist in the formation of a stable abrasive dispersion.
    [0069] The abrasive dispersion can be formed by any suitable means, such as, for example, simply by mixing aluminum oxide monohydrate with water containing a peptizing agent or by forming an aqueous paste of aluminum oxide monohydrate. aluminum to which the peptizing agent is added. Foam eliminators or other suitable chemicals can be added to reduce the tendency for bubbles or air to enter under mixing. Additional chemicals such as wetting agents, alcohols or binding agents can be added if desired. The abrasive grain of alpha alumina may contain silica and iron oxide, as shown in US patent No. 5,645,619 to Erickson et al. on July 8, 1997. The alpha alumina abrasive grain may contain zirconia as disclosed in US Patent No. 5,551,963 to Larmie on September 3, 1996. Alternatively, the alpha alumina abrasive grain has a microstructure or additives as shown in US Patent No. 6,277,161 to Castro on August 21, 2001.
    [0070] The second step of the process involves providing a mold that has at least one mold cavity, and preferably a plurality of cavities. The cavity has a specific three-dimensional shape to produce the formatted abrasive particles illustrated in figures 1 to 4. The mold can have a first mold cavity that corresponds to the shape of the first plate 2 and a second mold cavity that corresponds to the shape of the second plate 23 that intersect at a predetermined angle with the first mold cavity. In general, the first mold cavity will be adjacent to the top surface of the mold with the perimeter of the cavity on the top surface forming the perimeter of the first main surface 24 of the first plate 21. The second mold cavity will cross and extend into the thickness of the mold from the bottom of the first mold cavity forming the second main surface 26 of the first plate 21.
    [0071] The plurality of cavities can be formed in a production tool. The production tool can be a belt, a blade, a continuous mat, a coating cylinder such as a gravure cylinder, a glove mounted on a coating cylinder or matrix. In one embodiment, the production tool comprises polymeric material. Examples of suitable polymeric materials include thermoplastics such as polyesters, polycarbonates, poly (sulfone ether), poly (methyl methacrylate), polyurethanes, polyvinyl chloride, polyolefin, polystyrene, polypropylene, polyethylene or combinations thereof, or heat-cured materials. In one embodiment, the entire tool is made of a polymeric or thermoplastic material. In another embodiment, the surfaces of the tool in contact with the sol-gel under drying, such as the surfaces of the plurality of cavities, comprise polymeric or thermoplastic materials and other portions of the tool can be produced from other materials. A suitable polymeric coating can be applied to metal tooling to change its surface tension properties as an example.
    [0072] A polymeric or thermoplastic tool can be replicated from a metallic master tool. The master tool will have a pattern opposite to that desired for the production tool. The master tool can be produced in the same way as the production tool. In one embodiment, the master tool is made of metal, for example, nickel and is turned by diamond. The polymeric blade material can be heated together with the master tool such that the polymeric material is embossed with the standard master tool by pressing both. A polymeric or thermoplastic material can also be extruded or molded on the master tool and then pressed. The thermoplastic material is cooled to solidify and produce the production tool. If a thermoplastic production tool is used, then care must be taken not to generate excessive heat that could distort the thermoplastic production tool, limiting its life. More information regarding the design and manufacture of production tools or master tools can be found in US patents No. 5,152,917 (Pieper et al.); 5,435,816 (Spurgeon et al.); 5,672,097 (Hoopman et al.); 5,946,991 (Hoopman et al.); 5,975,987 (Hoopman et al.); and 6,129,540 (Hoopman et al.).
    [0073] Access to the cavities can be from an opening in the top surface. In one embodiment, the top surface is substantially parallel to the bottom surface of the mold, with the cavities having a substantially uniform depth. One side of the mold, that is, the side on which the cavity is formed, can remain exposed to the surrounding atmosphere during the step in which the volatile component is removed.
    [0074] The third step of the process involves filling the cavities in the mold with the abrasive dispersion using any conventional technique. In some embodiments, a knife cylinder coating application device or vacuum slit die coating application device may be used. A mold release can be used to assist in removing particles from the mold, if desired. Typical mold release agents include oils such as peanut oil or mineral oil, fish oil, silicones, polytetrafluoro ethylene, zinc stearate, and graphite. In general, between about 0.1% to about 5%, by weight of mold release agent, such as peanut oil, in a liquid, such as water or alcohol, is applied to the surfaces of production tools in contact with the sol-gel in such a way that between about 0.015 mg / cm2 (0.1 mg / inches2) to about 0.46 mg / cm2 (3.0 mg / inches2), or between about 0.015 mg / cm2 ( 0.1 mg / inches2) to about 0.78 mg / cm2 (5.0 mg / inches2) of the mold release agent is present per unit area of the mold when mold release is desired. In one embodiment, the top surface of the mold is coated with the abrasive dispersion. The abrasive dispersion can be pumped or applied to the top surface. Then, a scraper or leveling bar can be used to force the abrasive dispersion fully into the mold cavity. The remaining portion of abrasive dispersion that does not enter the cavity can be removed from the top surface of the mold and recycled. In some embodiments, a small portion of the abrasive dispersion may remain on the surface of, and in other embodiments, the top surface is substantially free of the dispersion. The pressure applied by the scraper or leveling bar is typically less than 0.69 MPa (100 psi) or less than 0.34 MPa (50 psi) or less than 0.06 MPa (10 psi). In some embodiments, no exposed surface of the abrasive dispersion extends substantially beyond the top surface to ensure uniformity in the thickness of the resulting shaped abrasive particles.
    [0075] The fourth step of the process involves removing the volatile component to dry the dispersion. Desirably, the volatile component is removed by rapid evaporation rates. In some embodiments, the removal of the volatile component through evaporation occurs at temperatures above the boiling point of the volatile component. An upper limit for the drying temperature often depends on the material from which the mold is made. For polypropylene tooling, the temperature must be lower than the melting point of the plastic.
    [0076] In one embodiment, for a water dispersion of between about 40 to 50 percent solids and a polypropylene mold, drying temperatures can be between about 90 degrees Celsius to about 165 degrees Celsius, or between about from 105 degrees Celsius to about 150 degrees Celsius, or between about 105 degrees Celsius to about 120 degrees Celsius. Higher temperatures can lead to improved production speeds, but it can also lead to degradation of the polypropylene tooling that limits its useful life as a mold.
    [0077] The fifth processing step involves removing the precursor-formatted abrasive particles from the mold cavities. The formatted precursor abrasive particles can be removed from the cavities using the following processes, alone or in combination in the mold: gravity, vibration, ultrasonic vibration, vacuum, or pressurized air to remove particles from the mold cavities.
    [0078] The abrasive precursor particles can be additionally dried out of the mold. If the abrasive dispersion is dried to the desired level in the mold, this additional drying step is not necessary. However, in some cases, it may be more economical to employ this additional drying step in order to minimize the time that the abrasive dispersion remains in the mold. Typically, the precursor-formatted abrasive particles will be dried between 10 to 480 minutes, or between 120 to 400 minutes, at a temperature of 50 degrees C to 160 degrees C, or 120 degrees C to 150 degrees C.
    [0079] The sixth stage of the process involves the calcination of precursor-formatted abrasive particles. During calcination, essentially all the volatile material is removed and the various components that are present in the abrasive dispersion are transformed into metal oxides. Precursor-formatted abrasive particles are generally heated to a temperature of 400 degrees C to 800 degrees C, and kept within this temperature range until free water and more than 90 weight percent of any bound volatile material removed. In an additional step, it may be desirable to introduce the modifying additive through an impregnation process. A water-soluble salt can be introduced by impregnating the pores of the calcined precursor-formatted abrasive particles into the pores. The precursor-formatted abrasive particles are then calcined again. This option is further described in European patent application No. 293,163.
    [0080] The seventh stage of the process involves sintering the abrasive particles shaped as calcined precursors, to form alpha alumina particles. Before sintering, the calcined precursor-formatted abrasive particles are not completely densified and therefore do not contain the desired hardness content to be used as formatted abrasive particles. Sintering occurs by heating the abrasive particles shaped as calcined precursors to a temperature of 1,000 degrees C to 1,650 degrees C and keeping them within this temperature range, until substantially all of the alpha alumina monohydrate (or equivalent) is converted to alpha alumina and the porosity is reduced to less than 15% by volume. The amount of time that the calcined precursor-formatted abrasive particles must be exposed to the sintering temperature to achieve this level of conversion depends on several factors, but is typically from five seconds to 48 hours. In another mode, the duration of the sintering step is in the range of one minute to 90 minutes. After sintering, the formatted abrasive particles can have a Vickers hardness content of 10 GPa, 16 GPa, 18 GPa, 20 GPa, or more.
    [0081] Other steps can be used to modify the described process, such as rapidly heating the material from the calcination temperature to the sintering temperature, centrifuging the abrasive dispersion to remove sludge, scrap, etc. In addition, the process can be modified by combining two or more of the process steps if desired. The conventional process steps that can be used to modify the process of that description are more fully described in US Patent No. 4,314,827 to Leitheiser.
    [0082] Further information regarding the methods for producing the formatted abrasive particles is presented in US copending patent application serial number 12 / 337,001 entitled “Method Of Making Abrasive Shards, Shaped Abrasive Particles With An Opening, Or Dish-Shaped Abrasive Particles ”, filed on December 17, 2008. Examples Example 1 and comparative example A
    [0083] Example 1 and comparative example A have been prepared to demonstrate the enhanced attributes of intersecting plate-shaped abrasive particles. The new abrasive particles in example 1 are formatted to have a specific geometry, as shown in figure 8 to provide them with the necessary sharpening for a desired abrasive application. Such abrasive particles have the shape of a triangular base plate with a flat plate protruding from one of the triangular surfaces. This abrasive is designed to have multiple very sharp edges. Example 1
    [0084] An alumina sol was prepared by combining 2316 grams of deionized water and 66 grams of nitric acid in a high-shear mixer (Scott Turbon mixer, Adelanto, California, USA) operating at 1601 RPM. 1600 grams of aluminum oxide monohydrate (“Disperal”, Sasol North America, Houston, Texas, USA) were added over the course of one minute. After 5 minutes, another 6 grams of nitric acid were added and after seven minutes of mixing, 12 grams of peanut oil (“peanut oil, nf”, Alnor Oil Company, Valley Stream, New York, USA) (0.75 % based on Disperal content) were added to the mix and incorporated for 2 minutes. The batch size was 4000 grams. The sun was allowed to gel and age for 24 hours before use.
    [0085] The sol gel was forced into the micro-replicate tool cavities using a 12.7 cm (5 inch) wide stainless steel spatula. The sol gel was forced into a 23 cm x 33 cm (9 in x 13 in) piece of production tools having cavities with the dimensions shown in figures 9A to 9C. The excess sol gel was carefully removed from the tool with the spatula. The coated tool was then placed in an air convection oven at 45 degrees C for 1.5 hours to remove water and dry the sun gel on shaped particles. The particles were removed from the tool with the aid of an ultrasonic horn. The precursor-formatted abrasive particles with 0.75% peanut oil were calcined at approximately 650 degrees Celsius (15 minutes) and then saturated with a mixed nitrate solution with the following concentration (reported as oxides): 1, 0% MgO, 1.2% Y2O3, 4.0% La2Ü3 and 0.05% CoO. The excess nitrate solution was removed and the cross-shaped, saturated precursor-shaped abrasive particles were left to dry and after that they were again calcined at 650 degrees C and sintered (15 minutes) at approximately 1,400 degrees C (5 minutes). Both calcination and sintering were performed using rotary tube calcination. The abrasive particles produced using the above processes are shown in figure 10. Due to air trapping, the projected triangle tip tended to be truncated resulting in the three-dimensional intersecting plate-shaped abrasive particles shown. Comparative example A
    [0086] Comparative example A was prepared in the same way as example 1 with the exception that a mold that has a flat triangular mold cavity with each side of the largest face of the triangle with 2,794 mm in length, a mold depth of 0.711 mm, and an exit angle of 97 degrees has been replaced by the intersecting plate mold used in example 1. The formatted abrasive particles produced were the same or similar to the formatted abrasive particles disclosed in US patent publication 2010/0151196. Example 2 and comparative example B
    [0087] The nonwoven abrasives of example 2 and comparative example B were prepared with the abrasive particles of example 1 and comparative example A, respectively. Example 2
    [0088] Example 2 was prepared by cylinder coating of a conventionally prepared non-woven fabric of 126 g / m2 of 6.6 nylon textile fibers with 70 denier (78dtex) x 38 mm (1.5 inch) which was lightly bonded with a polyurethane-based resin with the plate-shaped abrasive particles that cross from example 1. To a 10.2 x 15.2 cm (4 x 6 inch) piece of pre-woven non-woven fabric, a basic resin of 49.15% phenolic resin, 10.19% water, 40.56% calcium carbonate charge, 0.10% EMUUXN A emulsifier (BASF, Florham Park, New Jersey, USA) , and a trace amount of cryolite was applied to obtain a wet increase of 200 g / square meter. 323 grams per square meter of the abrasive particles of example 1 were dipped over the basic coating. The composite was then heated to 90 degrees C and maintained at that temperature for 90 minutes. A sizing coating of 50.56% DOCANOL PMA 484431 (Sigma Aldrich, St. Louis, Missouri, USA), 36.2% ADEPRINE BL-16 (Chemutra Group, Middlebury, CT, USA) polyurethane resin and 13.24% of LAPOX K450 dressing (42.33% in PMA) (Royce International, East Rutherford, CT, USA) was applied by roller coating to obtain a wet increase of 96 grams per square meter. The resulting composite was then heated to 330 degrees C and maintained at that temperature for 5 minutes. The resulting abrasive article is shown in figure 11. Comparative example B
    [0089] Comparative example B was prepared in the same way as example 2 with the exception that the abrasive particles of comparative example A were replaced by the abrasive particles of example 1. Non-woven abrasive article testing
    [0090] Nonwoven abrasive discs were cut from example 2 and comparative example B and were attached to 3M Blue Vinyl Foam reserve blocks no. 02345 (obtained from the 3M Company of Maplewood, Minnesota, USA) and mounted on a random orbital sander. The random orbital sander was activated to operate at 3450 rpm and propelled against a steel cutting mold (45 Rockwell) under a load of 2.72 kg (6 lb) over a 25.4 cm (10 inch) cross at 0 , 61 m / min (2 feet / min).
    [0091] The initial cut rate (the cut during the first cross section) of the sample in example 2 was three times higher than that of the sample in comparative example B. The total cut after three cycles was about 0.09 grams of steel for the sample of example 2 and 0.04 grams for the sample of comparative example B. The sample of example 2 was judged to have significantly improved crushing performance compared to comparative example B.
    权利要求:
    Claims (9)
    [0001]
    1. Formatted abrasive particles, CHARACTERIZED by the fact that they comprise a ceramic and comprise a first plate integrally joined to a second plate at a predetermined β angle, where the predetermined β angle is between 20 degrees to 90 degrees including 90 degrees, where the first plate or the second plate comprises a first main surface and a second main surface connected by at least one side wall, and in which an outlet angle α between the second main surface and at least one side wall is between 95 degrees a 135 degrees.
    [0002]
    2. Shaped abrasive particles, according to claim 1, CHARACTERIZED by the fact that the exit angle α between the second main surface and the side wall is between 95 degrees to 120 degrees.
    [0003]
    3. Abrasive particles shaped according to claim 1, CHARACTERIZED by the fact that the first plate comprises a truncated triangular pyramid and the second plate comprises a truncated triangular pyramid.
    [0004]
    4. Shaped abrasive particles according to claim 1, CHARACTERIZED by the fact that the first plate comprises a triangular prism and the second plate comprises a triangular prism.
    [0005]
    5. Abrasive particles shaped according to claim 1, CHARACTERIZED by the fact that the first plate comprises a rhomboid prism and the second plate comprises a triangular prism.
    [0006]
    6. Abrasive particles formatted according to claim 1, CHARACTERIZED by the fact that the first plate comprises a truncated rhomboid pyramid and the second plate comprises a truncated triangular pyramid.
    [0007]
    7. Shaped abrasive particles according to any one of claims 1 to 6, CHARACTERIZED by the fact that the predetermined angle β is 90 degrees.
    [0008]
    8. Shaped abrasive particles according to any one of claims 1 to 6, CHARACTERIZED by the fact that the predetermined angle β is between 20 degrees to 85 degrees.
    [0009]
    9. Shaped abrasive particles according to any one of claims 1 to 6, CHARACTERIZED by the fact that the shaped abrasive particles comprise alpha alumina and are formed by molding a bohemian alumina sol.
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    同族专利:
    公开号 | 公开日
    CN103025490B|2016-05-11|
    BR112013001831B8|2021-05-04|
    JP2013533128A|2013-08-22|
    KR20130105816A|2013-09-26|
    EP2601014A2|2013-06-12|
    WO2012018903A2|2012-02-09|
    BR112013001831A2|2016-05-31|
    WO2012018903A3|2012-03-29|
    EP2601014B1|2019-09-25|
    CN103025490A|2013-04-03|
    US8728185B2|2014-05-20|
    EP2601014A4|2017-07-26|
    JP5774105B2|2015-09-02|
    KR101879884B1|2018-07-18|
    US20130125477A1|2013-05-23|
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    法律状态:
    2018-04-03| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-04-24| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|
    2019-12-03| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2020-04-07| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-10-27| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 03/08/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    2021-05-04| B16C| Correction of notification of the grant [chapter 16.3 patent gazette]|Free format text: REF. RPI 2599 DE 27/10/2020 QUANTO AO ENDERECO. |
    优先权:
    申请号 | 申请日 | 专利标题
    US37049710P| true| 2010-08-04|2010-08-04|
    US61/370,497|2010-08-04|
    PCT/US2011/046408|WO2012018903A2|2010-08-04|2011-08-03|Intersecting plate shaped abrasive particles|
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