molded abrasive particle

专利摘要:
ABRASIVE PARTICLES HAVING COMPLEX SHAPES AND METHODS OF FORMING THEM An abrasive grain is disclosed and may include a body. The body can define a length (l), a height (h) and a width (w). In a particular aspect, the length is greater than or equal to the height and the height is greater than or equal to the width. In addition, in a particular aspect, the body may include a primary aspect ratio defined by a length:height ratio of at least about 2:1. The body can also include a probability of vertical orientation of at least about 50%.
公开号:BR112014017050B1
申请号:R112014017050-9
申请日:2013-01-10
公开日:2021-05-11
发明作者:Tracy H. Panzarella；Michael D. Kavanaugh；Doruk O. Yener；Jennifer H. Czerepinski；Sujatha Iyengar；Alan J. Brandes；Christopher Arcona；Ralph Bauer；Yves Boussant-Roux
申请人:Saint-Gobain Ceramics & Plastics, Inc.；
IPC主号:

专利说明:

DISCLOSURE FIELD
[0001] This disclosure, in general, refers to the methods and systems for forming structured abrasive articles. More particularly, this disclosure relates to the form of abrasive grains. FUNDAMENTALS OF THE INVENTION
[0002] Abrasive articles, such as coated abrasives and bonded abrasives, are used in various machine parts industries, such as by lapping, grinding or polishing. Machining using abrasive articles covers a broad industrial scope from the optical industries, automotive paint repair industries, to metal fabrication industries. In each of these examples, manufacturing facilities use abrasives to remove bulk material or affect surface characteristics of products.
[0003] Surface characteristics include uniformity, texture and gloss. For example, metal component manufacturers use fine abrasive articles and polished surfaces and often desire an evenly smooth surface. Likewise, optics manufacturers want abrasive articles that produce defect-free surfaces to prevent light diffraction and scattering.
[0004] Manufacturers also want abrasive articles that have a high stock removal rate for certain applications. However, there is often a trade-off between removal rate and surface quality. Finer grit abrasive articles typically produce smoother surfaces, yet have lower stock removal rates. Lower stock removal rates lead to slower production and increased costs.
[0005] Particularly in the context of coated abrasive articles, abrasive article manufacturers have introduced surface structures for Petition 870190127113, dated 12/02/2019, p. 16/25 improve stock removal rate while maintaining surface quality. Coated abrasive articles having surface structures or patterns of raised abrasive layers, often called engineered or structured abrasives, typically have a longer service life.
[0006] However, typical techniques of structured formation of abrasive articles are unreliable and suffer from performance limitations. A typical process for forming a structured abrasive article includes coating a backing with a viscous binder, coating the viscous binder with a functional powder, and stamping or laminating patterns of structure for the viscous binder. Functional powder prevents binder from sticking to patterning tools. The binder is later cured.
[0007] Imperfect coating of the viscous binder with functional powder leads to the binder adherence in tool standardization. Binder adhesion produces poor structures, leading to poor product performance and wasted product.
[0008] The selection of suitable binders for typical structured abrasive formation techniques is limited by the process. Typical binders include traditional high loadings that increase binder viscosity. Such traditional loads affect the mechanical characteristics of the binder. For example, high load of traditional fillers can adversely affect tensile strength, modulus of elasticity and elongation on the binder's breaking characteristics. Poor mechanical characteristics of the binder allow the loss of abrasive grains, leading to scratching and turbidity on surfaces and reducing the life of the abrasive article.
[0009] Grain loss also degrades the performance of abrasive articles, leading to frequent replacement. Frequent replacement of the abrasive article is costly for manufacturers. As such, improved abrasive articles and methods for manufacturing abrasive articles would be desirable. SUMMARY
[0010] An abrasive grain is disclosed and may include a body. The body can define a length (l), a height (h) and a width (w). In a particular aspect, the length is greater than or equal to the height and the height is greater than or equal to the width. In addition, in a given aspect, the body may include a primary aspect ratio, defined by a length:height ratio of at least about 1:1. The body may also include a vertical orientation probability of at least about 50 %.
[0011] In another aspect, an abrasive grain is disclosed and may include a body having a length (l), width (w) and height (h). The length, width and height can correspond to a longitudinal axis, a lateral axis and a vertical axis, respectively, and the longitudinal axis, lateral axis and vertical axis can define three perpendicular planes. In this aspect, the body can include geometry asymmetrical with respect to any of the three perpendicular planes.
[0012] In yet another aspect, an abrasive grain is disclosed and may include a body having a complex three-dimensional geometry including 3 symmetrical folds in three perpendicular planes, defined by a longitudinal axis, a lateral axis and a vertical axis. In addition, the body may include an opening that extends throughout the interior of the body along a longitudinal axis, lateral axis, or vertical axis.
[0013] In yet another aspect, an abrasive grain is disclosed and may include a body having a complex three-dimensional geometry defined by a length (l), width (w) and height (h). The body can also include a center of mass and a geometric midpoint. The center of mass can be displaced from the geometric midpoint by a distance (Dh) of at least about 0.05 (h) along a vertical axis of the body that defines height.
[0014] In another aspect, an abrasive grain is disclosed and may include a body that defines a length (l), width (w) and height (h). The body can include a base surface and a top surface. Furthermore, the base surface comprises a different transverse shape than a transverse shape of the upper surface.
[0015] In yet another aspect, an abrasive grain is disclosed and may include a body having a generally flat bottom and a ridge-shaped dome extending from the generally flat underside.
[0016] In another aspect, the abrasive grain is disclosed and may include a body comprising a length (l), a width (W), and a height (h). The length, width and height can correspond to a longitudinal axis, a lateral axis and a vertical axis, respectively. In addition, the body may include a twist along a longitudinal axis defining the length of the body such that a base surface is rotated relative to an upper surface to establish a twist angle.
[0017] In yet another aspect, an abrasive grain is disclosed and may include a body having a first end face and a second end face, at least three sides of adjacent faces extending between the first end face and the second end face, and an edge structure established between each pair of adjacent side faces.
[0018] In another aspect, an abrasive grain is disclosed and may include a body having a central portion and at least three radial arms, extending from the central portion along the entire length of the outer central portion.
[0019] In another aspect, an abrasive grain includes a body having a length (l), width (w) and height (h), wherein the body has an ultimate surface base and a top surface, and in which the surface base includes a transverse shape other than a cross shape of the top surface.
[0020] In another aspect, an abrasive grain includes a body having a central portion and at least three radial arms, extending from the central portion along the entire length of the central portion outwardly, in which each radial arm includes an arrow in the form of a distal end.
[0021] According to another aspect, an abrasive particle shape includes a body having a length (l), width (w) and height (h), in which the body is composed of a final surface base, an upper surface. and a side surface, extending between the base surface and the top surface, and in which the base surface has a transverse shape other than a cross shape of the top surface.
[0022] In one aspect, an abrasive particle shape includes a body having a length (l), width (w) and height (h), wherein the body has a three-pointed star, including a first arm defining an arm. first, a second arm defining a second arm and a third arm defining a second arm, and in which the first arm, second arm, and third arm define a total angle of less than about 180 degrees, and wherein the body has a ripple factor not exceeding about 10.
[0023] In another aspect, an abrasive particle shape includes a body having a length (l), width (w) and height (h), in which the body defines a four-pointed star, having a first arm, second arm , third arm and fourth arm extending from a central part, and in which the body has a swell factor of not more than about 10.
[0024] According to another aspect, an abrasive particle shape includes a body having a length (l), width (w) and height (h), in which the body is defined by a base surface, an upper surface and a lateral surface, extending between the base surface and the top surface, in which the base surface is composed of a two-dimensionally shaped cross and the top surface is composed of a rounded quadrilateral two-dimensional shape.
[0025] In yet another aspect, an abrasive particle shape includes a body having a first layer having a length of the first and a second layer overlying the first layer, where the second layer has a length that is within a range of about 50 % and about 90% of the length of the first layer. BRIEF DESCRIPTION OF THE FIGURES
[0026] The disclosure of the gift can be better understood, and its numerous features and advantages placed apparent to those skilled in the art by referencing the accompanying drawings.
[0027] FIG. 1 is a diagram of an exemplary process;
[0028] FIG. 2 is a perspective view of a structured abrasive article;
[0029] FIG. 3 is a perspective view of a first embodiment in the form of an abrasive grain;
[0030] FIG. 4 is a perspective view of a first embodiment in the form of an abrasive grain;
[0031] FIG. 5 is a perspective view of a second embodiment in the form of an abrasive grain;
[0032] FIG. 6 is a plan view of a second end face of the second embodiment in the form of abrasive grain;
[0033] FIG. 7 is a perspective view of a third embodiment in the form of an abrasive grain;
[0034] FIG. 8 is a plan view of a second end face of the first embodiment in the form of abrasive grain;
[0035] FIG. 9 is a perspective view of a fourth embodiment in the form of an abrasive grain;
[0036] FIG. 10 is a plan view of a second end face of the fourth embodiment in the form of an abrasive grain;
[0037] FIG. 11 is a perspective view of a fifth embodiment in the form of abrasive grain;
[0038] FIG. 12 is a bottom plan view of the fifth embodiment in the form of an abrasive grain;
[0039] FIG. 13 is a perspective view of a sixth embodiment in the form of abrasive grain;
[0040] FIG. 14 is a plan view of a second end face of the fourth embodiment in the form of an abrasive grain;
[0041] FIG. 15 is a top plan view of a seventh embodiment in the form of abrasive grain;
[0042] FIG. 16 is a plan view of a bottom of the seventh embodiment in the form of an abrasive grain;
[0043] FIG. 17 is a top plan view of an eighth modality in the form of abrasive grain;
[0044] FIG. 18 is a bottom plan view of the eighth modality in the form of an abrasive grain;
[0045] FIG. 19 is a perspective view of a ninth embodiment in the form of an abrasive grain;
[0046] FIG. 20 is a plan view of a second end face of the ninth embodiment in the form of an abrasive grain;
[0047] FIG. 21 is a perspective view of a tenth embodiment in the form of an abrasive grain;
[0048] FIG. 22 is a plan view of a first end face of the tenth embodiment in the form of an abrasive grain;
[0049] FIG. 23 is a plan view of a second end face of the tenth embodiment in the form of an abrasive grain;
[0050] FIG. 24 is a perspective view of an eleventh embodiment in the form of an abrasive grain;
[0051] FIG. 25 is a plan view of a second end face of the eleventh abrasive shaped embodiment.
[0052] FIG. 26 is a perspective view of a twelfth embodiment in the form of an abrasive grain;
[0053] FIG. 27 is a plan view of a second end face of the twelfth embodiment in the form of abrasive grain;
[0054] FIG. 28 is a perspective view of a thirteenth embodiment in the form of an abrasive grain;
[0055] FIG. 29 is a plan view of a second end face of the thirteenth abrasive shaped embodiment.
[0056] FIG. 30 is a perspective view of a fourteenth embodiment in the form of an abrasive grain;
[0057] FIG. 31 is a plan view of a second end face of the fourteenth abrasive shaped embodiment.
[0058] FIG. 32 is a perspective view of a fifteenth embodiment in the form of an abrasive grain;
[0059] FIG. 33 is a plan view of a second face of the fifteenth end of the abrasive shaped embodiment.
[0060] FIG. 34 is a perspective view of a sixteenth embodiment in the form of an abrasive grain;
[0061] FIG. 35 is a plan view of a second end face of the sixteenth embodiment in the form of abrasive grain;
[0062] FIG. 36 is a perspective view of a seventeenth embodiment in the form of an abrasive grain;
[0063] FIG. 37 is a plan view of a second end face of the seventeenth abrasive grain shaped embodiment;
[0064] FIG. 38 is a perspective view of an eighteenth embodiment in the form of an abrasive grain;
[0065] FIG. 39 is a plan view of a second end face of the eighteenth embodiment in the form of an abrasive grain;
[0066] FIG. 40 is a perspective view of a nineteenth embodiment in the form of an abrasive grain;
[0067] FIG. 41 is a plan view of a second end face of the nineteenth embodiment of the abrasive grain embodiment;
[0068] FIG. 42 is a perspective view of a twentieth embodiment in the form of an abrasive grain;
[0069] FIG. 43 is a plan view of a second end face of the twentieth embodiment in the form of abrasive grain;
[0070] FIG. 44 is a perspective view of a twenty-first embodiment in the form of an abrasive grain;
[0071] FIG. 45 is a plan view of a first end face of the twenty-first embodiment in the form of an abrasive grain;
[0072] FIG. 46 is a plan view of a second end face of the twenty-first embodiment in the form of an abrasive grain;
[0073] FIG. 47 is a perspective view of a twenty-second embodiment in the form of an abrasive grain;
[0074] FIG. 48 is a plan view of a first end face of the twenty-second embodiment in the form of an abrasive grain;
[0075] FIG. 49 is a plan view of a second end face of the twenty-second embodiment in the form of an abrasive grain;
[0076] FIG. 50 is a perspective view of a twenty-third embodiment in the form of an abrasive grain;
[0077] FIG. 51 is a plan view of a first end face of the twenty-third embodiment in the form of an abrasive grain;
[0078] FIG. 52 is a plan view of a second end face of the twenty-third embodiment in the form of an abrasive grain;
[0079] FIG. 53 is a perspective view of a twenty-fourth embodiment in the form of an abrasive grain;
[0080] FIG. 54 is a plan view of a first end face of the twenty-fourth embodiment in the form of an abrasive grain;
[0081] FIG. 55 is a plan view of a second end face of the twenty-fourth embodiment in the form of an abrasive grain;
[0082] FIG. 56 is a perspective view of a twenty-fifth embodiment in the form of an abrasive grain;
[0083] FIG. 57 is a plan view of a first end face of the twenty-fifth embodiment in the form of abrasive grain;
[0084] FIG. 58 is a plan view of a second end face of the twenty-fifth embodiment in the form of abrasive grain;
[0085] FIG. 59 is a perspective view of the twenty-sixth embodiment in the form of an abrasive grain;
[0086] FIG. 60 is a plan view of a first face of the twenty-sixth embodiment in the form of abrasive grain; and
[0087] FIG. 61 is a plan view of a second end face of the twenty-sixth embodiment in the form of abrasive grain.
[0088] FIGs. 62A and B include illustrations of an abrasive particulate forming system in accordance with an embodiment.
[0089] FIG. 63 includes an illustration of an abrasive particulate forming system in accordance with an embodiment.
[0090] FIG. 64A includes an illustration of a portion of an abrasive particulate forming system in accordance with an embodiment.
[0091] FIG. 65A includes an image of an abrasive particle shaped in accordance with an embodiment.
[0092] FIG. 65B includes an illustration of a side view of the abrasive particle in the form of FIG. 65 A.
[0093] FIG. 65C includes an image of an abrasive particle shaped according to an embodiment.
[0094] FIG. 66A includes an image in the form of abrasive particles, in accordance with an embodiment.
[0095] FIG. 66B includes an illustration of a side view of the abrasive particle in the form of FIG. 66A.
[0096] The use of the same reference symbols in different drawings indicates similar or identical items. DETAILED DESCRIPTION
[0097] The following is also directed to methods of forming abrasive particles in shape and the characteristics of such formed abrasive particles. The formed abrasive particles can be used in various abrasive articles, including bonded abrasive articles for example, coated abrasive articles and the like. Alternatively, abrasive particles in the form of embodiments herein can be used in abrasive-free technologies, including, for example, grinding and/or polishing pastes.
[0098] Referring initially to FIG. 1, an exemplary process is shown and is generally designated 100. As shown, a backing 102 may be paid from a roll of 104. The backing 102 may be coated with a form of binder 106 dispensed from a coating apparatus 108 An exemplary coating apparatus includes die drop applicator, a knife applicator, a coating curtain, a vacuum coating matrix or a coating matrix. Coating methodologies can include contact or non-contact methods. Such methods include 2 roll, 3 reverse roll, knife over roll, slot die, engraving, extrusion or spray coating applications.
[0099] In a particular embodiment, the binder formulation 106 can be provided in a slurry that includes the binder formulation and abrasive grains. In an alternative embodiment, binder formulation 106 can be dispensed to separate the abrasive grains. Thereafter, the abrasive grains can be supplied following coating the backing 102 with the binder formulation 106, after partially curing the binder formulation 106, after standardizing the binder formulation 106, or after fully curing the binder formulation 108. Abrasive grains can, for example, be applied by a technique such as electrostatic coating, drop coating or mechanical spraying. In a particular aspect, the abrasive grains can be any combination of one or more of the shaped abrasive grains described herein.
[0100] The binder formulation 106 can be cured after passing under an energy source 110. The selection of the energy source 110 may depend in part on the chemistry of the binder formulation 106. For example, the energy source 110 may be a source of thermal energy or actinic radiation energy, such as the electron beam, ultraviolet light or visible light. The amount of energy used will depend on the chemical nature of the reactive groups of the precursor polymer components, as well as the thickness and density of the binder formulation 106. For thermal energy, an oven temperature from about 75 degrees C to about 150 degrees C, and lasting from about 5 minutes to about 60 minutes can usually be sufficient. Electron beam radiation or ionizing radiation can be used at an energy level of about 0.1 MRad to about 100 MRad, particularly at an energy level of about 1 MRad to about 10 MRad. Ultraviolet radiation includes radiation having a wavelength within a range of about 200 nanometers to about 400 nanometers, particularly within a range of about 250 nanometers to 400 nanometers. Visible radiation includes radiation having a wavelength within a range of about 400 nanometers to about 800 nanometers, in particular in a range of about 400 nanometers to about 550 nanometers. Cure parameters, such as exposure, are generally dependent and can be adjusted via lamp energy and belt speed.
[0101] In an exemplary embodiment, the energy source 110 can provide actinic radiation to the coated protective coating, partially curing the binder formulation 106. In another embodiment, the binder formulation 106 is thermally curable and the energy source 110 can provide heat for heat treatment. In another embodiment, the binder formulation 106 can include thermally curable components and curable actinic radiation. As such, the binder formulation can be partially cured through one of thermal radiation and actinic cure and cured to complete cure through one second of thermal radiation and actinic cure. For example, an epoxy glue constituent of the binder formulation can be partially cured using ultraviolet radiation and an acrylic component of the binder formulation can be further cured through thermal curing.
[0102] Once the binder formulation 106 is cured, a structured abrasive article 112 is formed. Alternatively, an overlying coating can be applied over the shaped abrasive structures. In a particular embodiment, the structured abrasive article 112 may be rolled on a roller 114. In other embodiments, curing may be performed fully after laminating a partially cured abrasive from the article 112.
[0103] In one or more alternative embodiments, an overlying coating may be applied over the binder formulation 106 and abrasive grains. For example, the overlying coating may be applied before partially curing the binder formulation 106, then partially curing the binder formulation 106 or after post curing the binder formulation 106. The overlying coating may be applied, for example, by coating roller or spray coating. Depending on the composition of the overcoat and when it is applied, the overcoat can be cured together with the binder formulation 106 or cured separately. An overlying coating including grinding apparatus can be applied over the overlying coating and cured with binder formulation 106, cured with overlying coating or cured separately.
[0104] With reference to FIG. 2, a structured abrasive article is shown and is generally designated 200. As illustrated, the structured abrasive article 200 may include a protective coating 202 and a plurality of shaped abrasive grains 204 deposited thereon. In a particular aspect, the structured abrasive article 200 may be manufactured using the process described in conjunction with FIG. 1.
[0105] In a particular aspect, the shaped abrasive grains 204 may be one or more of the shaped abrasive grains described herein. Additionally, the abrasive grains can be any combination of one or more of the shaped abrasive grains described herein. In addition, one or more of the shaped abrasive grains described herein may include a probability of vertical orientation. The vertical orientation can be considered an orientation that corresponds to a favorable abrasive/cut position for each abrasive grain in shape and the probability is a simple mathematical probability that the grain lands in the vertical orientation.
[0106] In a particular aspect, the vertical orientation is at least fifty percent (50%). In another aspect, the vertical orientation is at least fifty-five percent (55%). In another aspect, the vertical orientation is at least sixty percent (60%). In another aspect, the vertical orientation is at least sixty-five percent (65%). In another aspect, the vertical orientation is at least seventy percent (70%). In another aspect, the vertical orientation is at least seventy-five percent (75%). In another aspect, the vertical orientation is at least eighty percent (80%). In another aspect, the vertical orientation is at least eighty-five percent (85%). In another aspect, the vertical orientation is at least ninety percent (90%). In another aspect, the vertical orientation is at least ninety-five percent (95%). In another aspect, the vertical orientation is one hundred percent (100%).
[0107] The body of each of the molded abrasive grains described herein may include a polycrystalline material. Polycrystalline material can include abrasive grains. Abrasive grains can include nitrides, oxides, carbides, borides, oxynitrides, diamond or a combination thereof. Furthermore, the abrasive grains can include an oxide selected from the group of oxides consisting of aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide and a combination thereof.
[0108] In another aspect, abrasive grains can include alumina. In another aspect, the abrasive grains consist essentially of alumina. In addition, abrasive grains can have an average grain size of no more than about 500 microns. Alternatively, the average grain size is no larger than about 250 microns. In another aspect, the average grain size is no larger than about 100 microns. In another aspect, the average grain size is no larger than about 50 microns. In another aspect, the average grain size is no larger than about 30 microns. In another aspect, the average grain size is no larger than about 20 microns. In another aspect, the average grain size is no larger than about 100 microns. In another aspect, the average grain size is no larger than about 1 micron.
[0109] In another aspect, the average grain size is at least 0.01 micron. In another aspect, the average grain size is at least about 0.05 microns. In another aspect, the average grain size is at least about 0.08 microns. In another aspect, the average grain size is at least about 0.1 micron.
[0110] In another aspect, the body of each of the shaped abrasive grains described herein may be a composite that includes at least two different types of abrasive grains.
[0111] FIG. 3 and FIG. 4 illustrate a first embodiment in the form of abrasive grain 300. As shown in FIG. 4, shaped abrasive grain 300 may include a body 301 that is generally prismatic with a first end 302 and an opposing second end 304. In addition, the shaped abrasive grain 300 may include a first side face 310 extending between the first end face 302, second end face and 304. A second side surface 312 may extend between first end surface 302 and second end surface 304 adjacent first side surface 310. As shown, the molded abrasive particle 300 may include a third opposing surface 314 extending between the first opposing end 302 and the second opposing end 304 adjacent to the second side surface 312 and the first side surface 310.
[0112] As shown in FIG. 3 and FIG. 4, in the form of abrasive grain 300 may also include a first edge 320 between first side 310 and second side face 312. Molded abrasive particle 300 may also include a second edge 322 between second side surface 312 and third side surface 314 In addition, the shaped abrasive grain 300 may include a third edge 324 between the third side 314 and the first side face 312.
[0113] As shown, each end surface 302, 304 of molded abrasive grain 300 may be generally triangular in shape. Each side surface 310, 312, 314 may be generally rectangular in shape. Furthermore, the cross section of the shaped abrasive grain 300 in a plane parallel to the end faces 302, 304 is generally triangular. It may be appreciated that the shaped abrasive grain 300 may include more than three faces 310, 312, 314 and three side edges 320, 322, 324. It may be more appreciated that depending on the number of sides 310, 312, 314, the end surfaces 302, 304 and abrasive grain cross section shaped 300 through a plane parallel to the end surfaces 302, 304 may be shaped like a polygon, eg a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, an enneagon, a decagon, etc. Also, the polygon can be convex, non-convex, concave or non-concave.
[0114] FIG. 5 and FIG. 6 illustrate a first embodiment in the form of abrasive grain 500. As shown in FIG. 5, in the form of abrasive grain 500 may include a body 501 that is generally prismatic with a first end 502 and an opposing second end 504. In addition, molded abrasive particle 500 may include a first side surface 510 extending between the first end. end surface 502 and second end surface 504. A second side surface 512 may extend between first end surface 502 and second end surface 504 adjacent to first side surface 510. As shown, the abrasive grain is shaped 500 may also include a third side end 514 that extends between the first end surface 502 and the second end surface 504 adjacent the second side surface 512 and the first side face 510.
[0115] As shown in FIG. 5 and FIG. 6, shaped abrasive grain 500 may also include a first edge surface 520 between first side surface 510 and second side surface 512. Molded abrasive grain 500 may also include a second edge surface 522 between second side surface 512 and the third side surface 514. In addition, the molded abrasive grain 500 may include a third edge edge 524 between the third surface 514 and the first side surface 512.
[0116] As shown, each end surface 502, 504 of the molded abrasive grain 500 may be generally triangular in shape. Each side surface 510, 512, 514 may be generally rectangular in shape. In addition, the cross section of the molded abrasive grain 500 in a plane parallel to the end surfaces 502, 504 is generally triangular.
[0117] FIG. 7 and FIG. 8 illustrate a third embodiment in the form of abrasive grain 700. As shown in FIG. 7, in the form of abrasive grain 700 may include a body 701 that is generally prismatic with a first end 702 and a second end surface 704. In addition, molded abrasive particle 700 may include a first side surface 710 extending therebetween. first end surface 702 and second end surface 704. A second side surface 712 may extend between first end surface 702 and second end surface 704 adjacent to first side surface 710. As shown, the abrasive grain at shape 700 may also include a third surface 714 that extends between the first end surface 702 and the second end surface 704 adjacent the second side surface 712 and the first side surface 710.
[0118] As shown in FIG. 7 and FIG. 8, the molded abrasive grain 700 may also include a first concave edge channel 720 between the first side surface 710 and the second side surface 712. The molded abrasive grain 700 may also include a second concave edge channel 722 between the second side surface 712 and third side surface 714. Additionally, molded abrasive grain 700 may include a third concave edge channel 724 between third side surface 714 and first side surface 712.
[0119] As shown, each end surface 702, 704 of the molded abrasive grain 700 may be generally triangular in shape. Each side surface 710, 712, 714 may be generally rectangular in shape. In addition, the cross section of the molded abrasive grain 700 in a plane parallel to the end surfaces 702, 704 is generally triangular.
[0120] FIG. 9 and FIG. 10 illustrate a fourth embodiment of molded abrasive grain 900. As shown in FIG. 9, the molded abrasive grain 900 may include a body 901 that is generally prismatic with a first end surface 902 and a second end surface 904. In addition, the molded abrasive particle 900 may include a first side surface 910 extending between the first end surface 902 and the second end surface 904. A second side surface 912 may extend between the first end surface 902 and the second end surface 904 adjacent to the first side surface 910. As shown, the abrasive grain molding 900 may also include a third side surface 914 extending between the first end surface 902 and the second end surface 904 adjacent to the second side surface 912 and the first side surface 910.
[0121] As shown in FIG. 9 and FIG. 10, molded abrasive grain 900 may also include a V-shaped first edge channel surface 920 between the first side surface 910 and the second side surface 912. The molded abrasive grain 900 may also include a second side edge surface. 922 between the second side surface 912 and the third side surface 914. In addition, the molded abrasive grain 900 may include a third V-shaped edge channel surface 924 between the third side surface 914 and the first side surface 912.
[0122] As shown, each end surface 902, 904 of the molded abrasive grain 900 may be generally triangular in shape. Each side surface 910, 912, 914 can be generally rectangular in shape. In addition, the cross section of the molded abrasive grain 900 in a parallel plane at the end surfaces 902, 904 is generally triangular.
[0123] As shown in the exemplary embodiment in FIG. 3 to FIG. 10, it can be appreciated that edges 320, 322, 324; edge surfaces 520, 522, 524; concave edge channels 720, 722, 724; and V-shaped edge channels 920, 922, 924 can be considered edge structures. In addition, edge structures certify that when molded abrasive grains 300, 500, 700, 900 are deposited, or yielded, in a protective coating, a side surface over the support and an edge structure will face up, or outward, from the support. Additionally, the edge structures provide sharp edges that provide substantially greater grinding performance.
[0124] Furthermore, it can be appreciated that in each of the exemplary embodiments shown in FIG. 3 to FIG. 10, the face of the molded abrasive grain 300, 500, 700, 900, i.e. the base, which touches a bearing has an area substantially greater than the area of the portion of the molded abrasive grain 300, 500, 700, 900 that is pointed out out, or up, for example, the edge structure.
[0125] In particular, the base may comprise at least about thirty percent (30%) of the total surface area of the particle. In another aspect, the base can comprise at least about forty percent (40%) of the total surface area of the particle. In another aspect, the base can comprise at least about fifty percent (50%) of the total surface area of the particle. In another aspect, the base can comprise at least about sixty percent (60%) of the total surface area of the particle. In another aspect, the base may comprise no more than ninety-nine percent (99%) of the particle's total surface area. In another aspect, the base may comprise no more than ninety-five percent (95%) of the particle's total surface area. In another aspect, the base may comprise no more than ninety percent (90%) of the particle's total surface area. In another aspect, the base may comprise no more than eighty percent (80%) of the particle's total surface area. In another aspect, the base may comprise no more than seventy-five percent (75%) of the particle's total surface area.
[0126] With reference to FIG. 11 and Figure 12, a fifth embodiment of a molded abrasive grain is shown and is generally designated 1100. As shown, the molded abrasive grain 1100 may include a body 1101 that is generally pyramid-shaped with a generally triangular-shaped bottom face. 1102. In addition, the molded abrasive grain 1100 can be formed with a hole 1104, i.e., an opening, in it.
[0127] In a particular aspect, hole 1104 may define a central axis 1106 that passes through a center of hole 1104. In addition, molded abrasive grain 1100 may also define central axis 1108 that passes through a center of the grain. molded abrasive grain 1100. It will be appreciated that bore 1104 can be formed in molded abrasive grain 1100 such that central axis 1106 of bore 1104 is spaced a distance 1100 above central axis 1108 of molded abrasive grain 1100. As such , a center of mass of the molded abrasive grain 1100 can be moved below the geometric midpoint of the molded abrasive grain 1100. Moving the center of mass below the geometric midpoint of the molded abrasive grain can ensure that the molded abrasive grain 1100 lands on it face, for example, the bottom face 1102, when dropped, or otherwise laid, on a support, so that the molded abrasive grain has a vertical orientation.
[0128] In a given modality, the center of mass is displaced from the geometric mean point by a distance that is equal to 0.05 in height (h) along a vertical axis of the body 1102 defining a height. In another aspect, the center of mass can be shifted a distance of at least about 0.1 (h). In another aspect, the center of mass can be shifted a distance of at least about 0.15 (h). In another aspect, the center of mass can be shifted a distance of at least about 0.18(h). In another aspect, the center of mass can be shifted a distance of at least about 0.2(h). In another aspect, the center of mass can be shifted a distance of at least about 0.22(h). In another aspect, the center of mass can be shifted a distance of at least about 0.25(h). In another aspect, the center of mass can be shifted a distance of at least about 0.27(h). In another aspect, the center of mass can be shifted a distance of at least about 0.3(h). In another aspect, the center of mass can be shifted a distance of at least about 0.32(h). In another aspect, the center of mass can be shifted a distance of at least about 0.35(h). In another aspect, the center of mass can be shifted a distance of at least about 0.38(h).
[0129] In another aspect, the center of mass is shifted a distance not greater than 0.5(h). In another aspect, the center of mass is shifted no more than 0.49 (h). In yet another aspect, the center of mass is shifted a distance no greater than 0.48(h). In another aspect, the center of mass is shifted a distance no greater than 0.45(h). In yet another aspect, the center of mass is shifted a distance no greater than 0.43(h). In yet another aspect, the center of mass is shifted a distance no greater than 0.40(h). In another aspect, the center of mass is shifted a distance no greater than 0.39(h). In another aspect, the center of mass is shifted a distance no greater than 0.38(h).
[0130] Additionally, the center of mass can be shifted so that the center of mass is closer to the base, for example, to the bottom face 1102 of the body 1101, than to a top of the body 1101 when the abrasive grain is molded 1100 is in the vertical position as shown in FIG. 11.
[0131] In another embodiment, the center of mass may be displaced from the geometric mean point by a distance 1110 that is equal to 0.05 width (w) along a horizontal axis of the body 1102 defining the width. In another aspect, the center of mass can be shifted a distance of at least about 0.1(w). In another aspect, the center of mass can be shifted a distance of at least about 0.15(w). In another aspect, the center of mass can be shifted a distance of at least about 0.18(w). In another aspect, the center of mass can be shifted a distance of at least about 0.2(w). In another aspect, the center of mass can be shifted a distance of at least about 0.22(w). In another aspect, the center of mass can be shifted a distance of at least about 0.25(w). In another aspect, the center of mass can be shifted a distance of at least about 0.27(w). In another aspect, the center of mass can be shifted a distance of at least about 0.3(w). In another aspect, the center of mass can be shifted a distance of at least about 0.32(w). In another aspect, the center of mass can be shifted a distance of at least about 0.35(w). In another aspect, the center of mass can be shifted a distance of at least about 0.38(w).
[0132] In another aspect, the center of mass is shifted a distance not greater than 0.5(w). In another aspect, the center of mass is shifted by a distance no greater than 0.49 (w). In yet another aspect, the center of mass is shifted a distance no greater than 0.48(w). In another aspect, the center of mass is shifted a distance no greater than 0.45(w). In yet another aspect, the center of mass is shifted a distance no greater than 0.43(w). In yet another aspect, the center of mass is shifted a distance no greater than 0.40(w). In another aspect, the center of mass is shifted a distance no greater than 0.39(w). In another aspect, the center of mass is shifted a distance no greater than 0.38(w).
[0133] In another embodiment, the center of mass can be displaced from the geometric mean point by a distance equal to 0.05 of the length (l) along the longitudinal axis of the body 1102, defining a length. In another aspect, the center of mass can be shifted a distance of at least about 0.1(1). In another aspect, the center of mass can be shifted a distance of at least about 0.15(1). In another aspect, the center of mass can be shifted by a distance of at least about 0.18(1). In another aspect, the center of mass can be shifted a distance of at least about 0.2(1). In another aspect, the center of mass can be shifted a distance of at least about 0.22 (1). In another aspect, the center of mass can be shifted a distance of at least about 0.25 (l). In another aspect, the center of mass can be shifted a distance of at least about 0.27(1). In another aspect, the center of mass can be shifted a distance of at least about 0.3(1). In another aspect, the center of mass can be shifted a distance of at least about 0.32(1). In another aspect, the center of mass can be shifted a distance of at least about 0.35(1). In another aspect, the center of mass can be shifted a distance of at least about 0.38 (l).
[0134] In another aspect, the center of mass is shifted a distance not greater than 0.5(l). In yet another aspect, the center of mass is shifted no more than 0.49(1). In yet another aspect, the center of mass is shifted a distance no greater than 0.48(1). In another aspect, the center of mass is shifted a distance no greater than 0.45(l). In yet another aspect, the center of mass is shifted a distance no greater than 0.43(l). In yet another aspect, the center of mass is shifted a distance no greater than 0.40(1). In another aspect, the center of mass is shifted by a distance no greater than 0.39(l). In another aspect, the center of mass is shifted a distance no greater than 0.38(l).
[0135] FIG. 13 and FIG. 14 illustrate a sixth embodiment of a molded abrasive grain that is generally designated 1300. As described, the molded abrasive grain 1300 can include a body 1301 that can include a central portion 1302 that extends along a longitudinal axis 1304. A first radial arm 1306 may extend outwardly from the central portion 1302 along the length of the central portion 1302. A second radial arm 1308 may extend outwardly from the central portion 1302 along the length of the central portion 1302. A third radial arm 1310 may extend outwardly from central portion 1302 along the length of central portion 1302. In addition, a fourth radial arm 1312 may extend outwardly from central portion 1302 along the length of central portion 1302. Radial arms 1306, 1308, 1310, 1312 may be equally spaced around the central portion 1302 of the molded abrasive particle 1300.
[0136] As shown in FIG. 13, the first radial arm 1306 may generally include an arrow-shaped distal end 1320. The second radial arm 1308 may generally include an arrow-shaped distal end 1322. The third radial arm 1310 may include a generally arrow-shaped distal end. arrow 1324. Additionally, fourth radial arm 1312 may include a generally arrow-shaped distal end 1326.
[0137] FIG. 13 also indicates that molded abrasive grains 1300 can be formed with a first void 1330 between the first radial arm 1306 and the second radial arm 1308. A second void 1332 can be formed between the second radial arm 1308 and the third radial arm 1310. A third void 1334 may also be formed between the third radial arm 1310 and the fourth radial arm 1312. In addition, a fourth void 1336 may be formed between the fourth radial arm 1312 and the first radial arm 1306.
[0138] As shown in FIG. 13, the molded abrasive grain 1300 may include a length 1340, a height 1342 and a width 1344. In a particular aspect, the length 1340 is greater than the height 1342 and the height 1342 is greater than the width 1344. In a particular aspect, , molded abrasive grain 1300 can define a main aspect ratio which is the ratio of length 1340 to height 1342 (length:height). In addition, molded abrasive grain 1300 can define a secondary aspect ratio which is the ratio of height 1342 to width 1344 (height:width). Finally, molded abrasive grain 1300 can define a tertiary aspect ratio which is the ratio of length 1340 to width 1342 (length:width).
[0139] In a particular aspect, the primary aspect ratio is at least 1:1. In another aspect, the primary aspect ratio is at least 2: 1. In another aspect, the primary aspect ratio is at least 2, 5: 1. In another aspect, the primary aspect ratio is at least 3: 1. In another aspect, the primary aspect ratio is at least 3.5: 1. In another aspect, the primary aspect ratio is at least 4: 1. In another aspect, the primary aspect ratio is at least 4.5: 1. In another aspect, the primary aspect ratio is at least 5:1. In another aspect, the primary aspect ratio is at least 5.5: 1. In another aspect, the primary aspect ratio is at least 6: 1. In another aspect, the primary aspect ratio is at least 6.5: 1. In another aspect, the primary aspect ratio is at least 7: 1. In another aspect, the primary aspect ratio is at least 7.5: 1. In another aspect, the primary aspect ratio is at least 8: 1. In another aspect, the aspect ratio primary is at least s 8.5: 1. In another aspect, the primary aspect ratio is at least 9:1. In another aspect, the primary aspect ratio is at least 9.5: 1. In another aspect, the primary aspect ratio is at least 10:1.
[0140] In a particular aspect, the minor aspect ratio is at least 1:1. In another aspect, the minor aspect ratio is at least 1.5: 1. In another aspect, the minor aspect ratio is 2: 1. In another aspect, the secondary aspect ratio is 2.5: 1. In another aspect, the secondary aspect ratio is at least 3: 1. In another aspect, the secondary aspect ratio is at least 3.5: 1. In another aspect, the minor aspect ratio is at least 4: 1. In another aspect, the minor aspect ratio is at least 4.5: 1. In another aspect, the minor aspect ratio is at least 5: 1. In another aspect, the minor aspect ratio is at least 5.5: 1. In another aspect, the minor aspect ratio is at least 6: 1. In another aspect, the minor aspect ratio is at least 6, 5: 1. In another aspect, the minor aspect ratio is at least 7: 1. In another aspect, the minor aspect ratio is at least 7.5: 1. In another aspect, the minor aspect ratio is by minus 8: 1. In another aspect, the minor aspect ratio is at least 8.5: 1. In another aspect, the minor aspect ratio is at least 9: 1. In another aspect, the minor aspect ratio is by minus 9.5:1. In another aspect, the secondary aspect ratio is at least 10:1.
[0141] In one particular aspect, the tertiary aspect ratio is at least 1:1. In another aspect, the tertiary aspect ratio is at least 1.5: 1. In another aspect, the tertiary aspect ratio is 2: 1. In another aspect, the tertiary aspect ratio is at least 2.5: 1. In another aspect, the tertiary aspect ratio is at least 3: 1. In another aspect, the tertiary aspect ratio is at least 3, 5: 1. In another aspect, the tertiary aspect ratio is at least 4: 1. In another aspect, the tertiary aspect ratio is at least 4.5: 1. In another aspect, the tertiary aspect ratio is at least 5: 1. In another aspect the tertiary aspect ratio is at least 5.5: 1. In another aspect the tertiary aspect ratio is at least 6: 1. In another aspect the tertiary aspect ratio is at least 6.5: 1. In another aspect, the tertiary aspect ratio is at least 7: 1. In another aspect, the tertiary aspect ratio is at least 7.5: 1. In another aspect, the tertiary aspect ratio is at least s 8: 1. In another aspect the tertiary aspect ratio is at least 8.5: 1. In another aspect the tertiary aspect ratio is at least 9: 1. In another aspect the tertiary aspect ratio is by the minus 9.5:1. In another aspect, the tertiary aspect ratio is at least 10:1.
[0142] In a particular aspect, the shape of the molded abrasive grain 1300 with respect to the primary aspect ratio is generally rectangular, eg flat or curved. Furthermore, the shape of the molded abrasive grain 1300 with respect to the secondary aspect ratio can be any polyhedral shape, e.g., a triangle, a square, a rectangle, a pentagon, etc. The shape of the molded abrasive particle 1300 with respect to the secondary aspect ratio can also be the shape of any alphanumeric character, e.g., 1, 2, 3, etc., A, B, C, etc. In addition, the shape of the 1300 molded abrasive grain with respect to the secondary aspect ratio can be a character selected from the Greek alphabet, the modern Latin alphabet, the ancient Latin alphabet, the Russian alphabet, any other alphabet or any combination of these. In addition, the shape of the 1300 molded abrasive grain with respect to the secondary aspect ratio may be a Kanji character.
[0143] In another aspect of the molded abrasive grain 1300, the width 1344 is greater than the height 1342 and the height 1342 is greater than the length 1340. In this regard, the molded abrasive grain 1300 can define a primary aspect ratio which is the ratio between width 1344 and height 1342 (width: height). In addition, molded abrasive grain 1300 can define a secondary aspect ratio which is the ratio of height 1342 to length 1340 (height:length). Finally, molded abrasive grain 1300 can define a tertiary aspect ratio which is the ratio of width 1342 to length 1340 (width:length).
[0144] In a particular aspect, the primary aspect ratio is at least 2: 1. In another aspect, the primary aspect ratio is at least 2.5: 1. In another aspect, the primary aspect ratio is at least 3: 1. In another aspect, the primary aspect ratio is at least 3.5: 1. In another aspect, the primary aspect ratio is at least 4: 1. In another aspect, the primary aspect ratio is at least 4.5: 1. In another aspect, the primary aspect ratio is at least 5:1. In another aspect, the primary aspect ratio is at least 5.5: 1. In another aspect, the primary aspect ratio is at least 6: 1. In another aspect, the primary aspect ratio is at least 6.5: 1. In another aspect, the primary aspect ratio is at least 7: 1. In another aspect, the primary aspect ratio is of at least 7.5: 1. In another aspect, the primary aspect ratio is at least 8: 1. In another aspect, the primary aspect ratio is at least 8.5: 1. In another aspect, the ratio of primary aspect is at least in 9: 1. In another aspect, the primary aspect ratio is at least 9.5: 1. In another aspect, the primary aspect ratio is at least 10:1.
[0145] In a particular aspect, the minor aspect ratio is at least 1.5: 1. In another aspect, the minor aspect ratio is 2: 1. In another aspect, the minor aspect ratio is 2.5: 1. In another aspect, the minor aspect ratio is at least 3: 1. In another aspect, the minor aspect ratio is at least 3.5: 1. In another aspect, the minor aspect ratio is at least 4: 1. In another aspect, the minor aspect ratio is at least 4.5: 1. In another aspect, the minor aspect ratio is at least 5: 1. In another aspect, the minor aspect ratio is at least 5, 5: 1. In another aspect, the minor aspect ratio is at least 6: 1. In another aspect, the minor aspect ratio is at least 6.5: 1. In another aspect, the minor aspect ratio is at least 7: 1. In another aspect, the minor aspect ratio is at least 7.5: 1. In another aspect, the minor aspect ratio is at least 8: 1. In another aspect, the minor aspect ratio is by minus 8.5: 1. In another aspect, the minor aspect ratio is at least 9:1. In another aspect, the minor aspect ratio is at least 9.5: 1. In another aspect, the minor aspect ratio is at least 10:1.
[0146] In one particular aspect the tertiary aspect ratio is at least 1.5: 1. In another aspect the tertiary aspect ratio is 2: 1. In another aspect the tertiary aspect ratio is at least 2, 5: 1. In another aspect the tertiary aspect ratio is at least 3: 1. In another aspect the tertiary aspect ratio is at least 3.5: 1. In another aspect the tertiary aspect ratio is at least 4: 1. In another aspect, the tertiary aspect ratio is at least 4.5: 1. In another aspect, the tertiary aspect ratio is at least 5: 1. In another aspect, the tertiary aspect ratio is at least 5.5: 1. In another aspect the tertiary aspect ratio is at least 6: 1. In another aspect the tertiary aspect ratio is at least 6.5: 1. In another aspect the tertiary aspect ratio is at least 7: 1. In another aspect the tertiary aspect ratio is at least 7.5: 1. In another aspect the tertiary aspect ratio is at least 8: 1. In another aspect the tertiary aspect ratio is at least s 8.5: 1. In another aspect, the tertiary aspect ratio is at least 9: 1. In another aspect, the tertiary aspect ratio is at least 9.5: 1. In another aspect, the tertiary aspect ratio is at least 10:1.
[0147] In a particular aspect, the shape of the molded abrasive grain 1300 with respect to the secondary aspect ratio is generally rectangular, eg flat or curved. Furthermore, the shape of the molded abrasive grain 1300 with respect to the primary aspect ratio can be any polyhedral shape, e.g., a triangle, a square, a rectangle, a pentagon, etc. The shape of the molded abrasive grain 1300 with respect to the primary aspect ratio can also be the shape of any alphanumeric character, eg 1, 2, 3, etc., A, B, C, etc. In addition, the shape of the molded abrasive grain 1300 with respect to the primary aspect ratio can be a character selected from the Greek alphabet, the modern Latin alphabet, the ancient Latin alphabet, the Russian alphabet, any other alphabet or any combination of these. In addition, the shape of the 1300 molded abrasive grain with respect to the primary aspect ratio may be a Kanji character.
[0148] Referring now to FIG. 15 and FIG. 16, a seventh embodiment of a molded abrasive grain is shown and is generally designated 1500. As shown, the molded abrasive grain 1500 can include a body 1501 that includes a flat bottom 1502 and a generally dome-shaped top 1504. Dome shape 1504 may be formed with a first edge 1506, a second edge 1508, a third edge 1510, a fourth edge 1512 and a fifth edge 1514. It will be appreciated that the molded abrasive grain 1500 may include more or less than five edges 1506, 1508, 1510, 1512, 1514. In addition, the edges 1506, 1508, 1510, 1512, 1514 may be evenly spaced radially around a center of the dome-shaped top 1504.
[0149] In one aspect, the edges 1506, 1508, 1510, 1512, 1514 at the dome-shaped top 1504 can be formed by injecting the material, comprising the molded abrasive grain 1500 through a generally dome-shaped nozzle. star. It can be appreciated that the shape of the molded abrasive grain 1500 can facilitate the orientation of the molded abrasive grain 1500 as it falls, or otherwise is deposited, on a support. Specifically, the dome-shaped top 1504 will allow the molded abrasive grain 1500 to roll over the flat bottom 1502, ensuring that the edges face outward, or from, the backing.
[0150] FIG. 17 and FIG. 18 illustrate an eighth embodiment of a molded abrasive grain, designated 1700. As shown, the molded abrasive grain 1700 may include a body 1701 that includes a flat bottom 1702 and a generally dome-shaped top 1704. The dome-shaped top 1704 can be formed with a peak 1706. In one aspect, the peak 1706 at the top dome 1704 can be formed by injecting the material comprising the molded abrasive grain 1700 through a generally small round nozzle. It can be appreciated that the shape of the molded abrasive grain 1700 can facilitate the orientation of the molded abrasive grain 1700 as it falls, or otherwise is deposited, on a support. Specifically, the dome top 1704 and peak 1706 will allow the molded abrasive grain 1700 to roll over the flat bottom 1702, ensuring that the peak 1706 and the dome top 1704 face outward, or up, from the support.
[0151] Referring now to FIG. 19 and Figure 20, a ninth embodiment of a molded abrasive grain is shown and is generally designated 1900. As shown, molded abrasive grain 1900 can include a body 1,901 which is generally the molded case with six outer faces 1,902 and twelve edges 1904. In addition, molded abrasive grain 1900 can be formed with a generally X shaped hole 1906, that is, an opening, through the molded abrasive grain 1900 parallel to a longitudinal axis 1908 that passes through a center 1910 of the molded abrasive grain. In addition, a 1912 center of X-shaped hole 1906 can be spaced a distance 1914 from the longitudinal axis 1908. As such, a center of mass 1916 of the molded abrasive grain 1900 can be moved below the geometric mean point 1910 of the abrasive grain 1900 molded. Moving the center of mass below the geometric midpoint of the molded abrasive grain can ensure that the 1900 molded abrasive grain lands on the same face when dropped, or if otherwise deposited, on a support.
[0152] It can be appreciated that the X-shaped hole 1906 can be formed along the longitudinal axis 1908 through the geometric midpoint 1910 of the molded abrasive grain 1900. Furthermore, it can be appreciated that the X-shaped hole 1,906 can be rotated forty-five degrees (45°) and in this case the 1906 hole would appear to be generally + shaped. It can be appreciated that the 1906 hole formed 1900 molded abrasive grain can have any shape: polygonal or otherwise.
[0153] FIG. 21 to FIG. 23 illustrate a tenth embodiment of a molded abrasive grain which is generally designated 2100. As shown, the molded abrasive grain 2100 may include a body 2101 which may have a first end face 2102 and a second end face 2104. In a particular aspect depending on the orientation, first end face 2102 may be a base face and second end face 2104 may be a top surface. In addition, molded abrasive grain 2100 may include a first side face 2106 that extends between the first end face 2102 and the second end face 2104. A second side face 2108 may extend between the first end face 2102 and the second end face 2104. Additionally, a third side face 2110 may extend between the first end face 2102 and the second end face 2104. A fourth side face 2112 may also extend between the first end face 2102 and the second end face 2104.
[0154] As shown, the first end face 2102 and the second end face 2104 are parallel to each other. However, in a particular aspect, the first end face 2102 is rotated relative to the second end face 2104 to establish a twist angle 2114. In one aspect, the twist angle 2114 is at least about one degree. In another aspect, the torsional angle 2114 is at least about two degrees. In another aspect, the torsional angle 2114 is at least five degrees. In another aspect, the torsional angle 2114 is at least about eight degrees. In another aspect, the torsional angle 2114 is at least about ten degrees. In another aspect, the torsional angle 2114 is at least about twelve degrees. In another aspect, the torsional angle 2114 is at least about fifteen degrees. In another aspect, the torsional angle 2114 is at least about eighteen degrees. In another aspect, the torsional angle 2114 is at least about twenty degrees. In another aspect, the torsional angle 2114 is at least about twenty-five degrees. In another aspect, the torsional angle 2114 is at least about thirty degrees. In another aspect, the torsional angle 2114 is at least about forty degrees. In another aspect, the torsional angle 2114 is at least about 50 degrees. In another aspect, the torsional angle 2114 is at least about sixty degrees. In another aspect, the torsional angle 2114 is at least about seventy degrees. In another aspect, the torsional angle 2114 is at least about eighty degrees. In another aspect, the torsional angle 2114 is at least about ninety degrees.
[0155] It can be appreciated that the torsional angle 2100 of the molded abrasive grain may be a horizontal torsional angle, ie along a longitudinal axis of the body 2101 defining a length. In another aspect, the torsional angle 2100 of the molded abrasive grain may be a vertical torsional angle, that is, along a vertical axis defining the height of the body 2101.
[0156] With reference to FIG. 24 and FIG. 25, a ninth embodiment of a molded abrasive grain is shown and is generally designated 2400. As illustrated, the molded abrasive grain 2400 can include a body 2401 that can include a central portion 2402 that extends along a longitudinal axis 2404. first radial arm 2406 may extend outwardly from central portion 2402 along the length of central portion 2402. A second radial arm 2408 may extend outwardly from central portion 2402 along the length of central portion 2402. A third radial arm 2410 may extend outwardly from central portion 2402 along the length of central portion 2402. In addition, a fourth radial arm 2412 may extend outwardly from central portion 2402 along the length of central portion 2402. Radial arms 2406, 2408 , 2410, 2412 may be equally spaced around the center portion 2402 of the molded abrasive grain 2400.
[0157] As shown in FIG. 24, first radial arm 2406 may include a generally box-shaped distal end 2420. Second radial arm 2408 may include a generally box-shaped distal end 2422. Third radial arm 2410 may include a generally box-shaped distal end 2420. box 2424. In addition, fourth radial arm 2412 may include a generally box-shaped distal end 2426.
[0158] FIG. 24 and FIG. 25 further show that molded abrasive grain 2400 can be formed with a hole 2428 through molded abrasive grain 2400 along longitudinal axis 2404. As shown, hole 2428 can be generally triangular in shape. It can be appreciated that, in other aspects, the hole 2428 formed in the molded abrasive grain 2400 can have any shape: polygonal or otherwise.
[0159] FIG. 26 and FIG. 27 illustrate a twelfth embodiment of a molded abrasive grain that is generally designated 2600. As described, the molded abrasive grain 2600 can include a body 2601 that can include a central portion 2602 that extends along a longitudinal axis 2604. first radial arm 2606 may extend outwardly of central portion 2602 along the length of central portion 2602. A second radial arm 2608 may extend outwardly of central portion 2602 along the length of central portion 2602. A third radial arm 2610 may extend outwardly from central portion 2602 along the length of central portion 2602. In addition, a fourth radial arm 2612 may extend outwardly from central portion 2602 along the length of central portion 2602. Radial arms 2606, 2608 , 2610, 2612 may be equally spaced around the center portion 2602 of the molded abrasive grain 2600.
[0160] As shown in FIG. 26 and FIG. 27, the first radial arm 2606 may include a generally box-shaped distal end 2620 with a V-shaped channel 2622. The second radial arm 2608 may include a generally box-shaped distal end 2624 formed with a V-shaped channel. V 2626. The third radial arm 2610 may also include a generally box-shaped distal end 2628 formed with a V-shaped channel 2630. In addition, the fourth radial arm 2612 may also include a generally box-shaped distal end 2632 that it is also formed with a 2634 V-shaped channel.
[0161] FIG. 28 and FIG. 29 illustrate a thirteenth embodiment of a molded abrasive grain that is generally designated 2800. As described, the molded abrasive grain 2800 can include a body 2801 that can include a central portion 2802 that extends along a longitudinal axis 2804. first radial arm 2806 may extend outwardly from central portion 2802 along the length of central portion 2802. A second radial arm 2808 may extend outwardly from central portion 2802 along the length of central portion 2802. A third radial arm 2810 may extend outwardly from central portion 2802 along the length of central portion 2802. In addition, a fourth radial arm 2812 may extend outwardly from central portion 2802 along the length of central portion 2802. Radial arms 2806, 2,808 , 2810, 2812 may be equally spaced around the center portion 2802 of the molded abrasive grain 2800.
[0162] As shown in FIG. 28 and FIG. 29, first radial arm 2806 may include a generally box-shaped distal end 2820 with a concave channel 2822. Second radial arm 2808 may include a generally box-shaped distal end 2824 formed with a concave channel 2826. The radial arm 2810 may also include a generally box-shaped distal end 2828 with a concave channel 2830. In addition, the fourth radial arm 2812 may include a generally box-shaped distal end 2832 that is also formed with a concave channel 2834.
[0163] FIG. 30 and FIG. 31 illustrate a fourteenth embodiment of a molded abrasive grain that is generally designated 3000. As described, the molded abrasive grain 3000 may include a body 3001 having a central portion 3002 that extends along a longitudinal axis 3004. A first arm radial arm 3006 may extend outwardly from central portion 3002 along the length of central portion 3002. A second radial arm 3008 may extend outwardly from central portion 3002 along the length of central portion 3002. A third radial arm 3010 may extend extends outwardly from the central portion 3002 along the length of the central portion 3002. In addition, a fourth radial arm 3012 may extend outwardly from the central portion 3002 along the length of the central portion 3002. The radial arms 3006, 3008, 3010 , 3012 can be evenly spaced around the center portion 3002 of the molded abrasive grain 3000.
[0164] As shown in FIG. 30, first radial arm 3006 may include a generally T-shaped distal end 3020. Second radial arm 3008 may include a generally T-shaped distal end 3022. Third radial arm 3010 may include a T-shaped distal end. 3024. In addition, fourth radial arm 3012 may include a generally T-shaped distal end 3026.
[0165] FIG. 30 also indicates that molded abrasive grains 3000 can be formed with a first void 3030 between the first radial arm 3006 and the second radial arm 3008. A second void 3032 can be formed between the second radial arm 3,008 and the third radial arm 3010. A third void 3034 may also be formed between the third radial arm 3010 and the fourth radial arm 3012. In addition, a fourth void 3036 may be formed between the fourth radial arm 3012 and the first radial arm 3006.
[0166] FIG. 32 and FIG. 33 illustrate a fifteenth embodiment of a molded abrasive grain that is generally designated 3200. As described, the molded abrasive grain 3200 can include a body 3201 that can include a central portion 3202 that extends along a longitudinal axis 3204. first radial arm 3206 may extend outwardly from central portion 3202 along the length of central portion 3202. A second radial arm 3208 may extend outwardly from central portion 3202 along the length of central portion 3202. A third radial arm 3210 may extend outwardly from central portion 3202 along the length of central portion 3202. In addition, a fourth radial arm 3212 may extend outwardly from central portion 3202 along the length of central portion 3202. Radial arms 3206, 3208 , 3210, 3212 may be equally spaced around the center portion 3202 of the molded abrasive grain 3200.
[0167] As shown in FIG. 32, first radial arm 3206 may include a generally rounded T-shaped distal end 3220. Second radial arm 3208 may include a generally rounded T-shaped distal end 3222. Third radial arm 3210 may include a generally rounded distal end. Rounded T-shape 3224. In addition, the fourth radial arm 3212 may include a generally rounded T-shaped distal end 3226.
[0168] FIG. 32 also indicates that molded abrasive grains 3200 can be formed with a first void 3230 between the first radial arm 3206 and the second radial arm 3208. A second void 3232 can be formed between the second radial arm 3208 and the third radial arm 3210. A third void 3234 may also be formed between the third radial arm 3210 and the fourth radial arm 3212. In addition, a fourth void 3236 can be formed between the fourth radial arm 3212 and the first radial arm 3206.
[0169] FIG. 34 and FIG. 35 illustrate a sixteenth embodiment of a molded abrasive grain that is generally designated 3400. As described, the molded abrasive grain 3400 may include a body 3401 having a central portion 3402 that extends along a longitudinal axis 3404. 3402 can be formed with a hole 3406 along the longitudinal axis 3404 along the entire length of the central portion 3,402 of the molded abrasive grain 3400.
[0170] A generally triangular first radial arm 3410 may extend outwardly from the central portion 3402 of the molded abrasive grain 3400 along the length of the central portion 3402. A generally triangular second radial arm 3412 may extend outwardly from the central portion 3402 of the molded abrasive grain 3,400 along the length of the central portion 3402. A third generally triangular radial arm 3414 may extend outwardly from the central portion 3402 of the molded abrasive grain 3400 along the length of the central portion 3402. A fourth generally triangular radial arm 3416 may extend outwardly from central portion 3402 of molded abrasive grain 3400 along the length of central portion 3402. In addition, a generally triangular fifth radial arm 3418 may extend outwardly from central portion 3402 of molded abrasive grain 3400 along the length of length of the central part 3402.
[0171] As further described in FIG. 34 and FIG. 35, a generally triangular sixth radial arm 3420 may extend outwardly from the central portion 3402 of the molded abrasive grain 3400 along the length of the central portion 3402. A generally triangular seventh radial arm 3422 may extend outwardly from the central portion 3402 of the grit molded abrasive 3,400 along the length of the central portion 3402. An eighth generally triangular radial arm 3424 may extend outwardly from the central portion 3402 of the molded abrasive grain 3400 along the length of the central portion 3402. A ninth generally triangular radial arm 3426 may extending outwardly from the center portion 3402 of the shaped abrasive grain 3400 along the length of the center portion 3402. In addition, a generally triangular tenth radial arm 3428 may extend outwardly from the center portion 3.402 of the shaped abrasive grain 3400 along the length of the central part 3402.
[0172] In a particular aspect, the radial arms 3410, 3412, 3414, 3416, 3418, 3420, 3422, 3424, 3426, 3428 may be equally spaced around the central part 3402 of the shaped abrasive grain to form a first face of the generally star-shaped end 3430, a generally star-shaped second end face 3432 and a generally star-shaped cross section taken parallel to end faces 3430, 3432.
[0173] Referring now to FIG. 36 and FIG. 37, a seventeenth embodiment of a molded abrasive grain is shown and is generally designated 3600. As shown, the molded abrasive grain 3600 may include a body 3601 having a first end face 3602 and a second end face 3604. In particular, depending on the orientation, first end face 3602 may be a base surface and second end face 3604 may be a top surface. In addition, molded abrasive grain 3600 can be formed with a hole 3606 along a longitudinal axis 3608. As shown, hole 3606 can be generally box-shaped.
[0174] FIG. 36 and FIG. 37 show that molded abrasive grain 3600 may include a K-shaped first side face 3610 that extends between first end face 3602 and second end face 3604. Molded abrasive grain 3600 may also include a second end face at K-shaped 3612 extending between the first end face 3602 and the second end face 3604 opposite the first K-shaped side face 3610.
[0175] As illustrated, the molded abrasive grain 3600 may include a generally flat third side face 3614 extending between the first K-shaped side face 3610 and the second K-shaped side face 3612 and between the first end face 3602 and second end face 3604. Molded abrasive grain 3600 may also include a flat generally flat fourth face 3616 extending between the first K-shaped side face 3610 and the second K-shaped side face 3612 opposite the third side face generally flat 3614.
[0176] FIG. 38 and FIG 39 illustrate an eighteenth embodiment of a molded abrasive grain which is generally designated 3800. As shown, the molded abrasive grain 3800 may include a body 3801 having a first end face 3802 and a second end face 3804. In a particular aspect, depending on the orientation, the first end face 3802 may be a base surface and the second end face 3804 may be a top surface. The molded abrasive grain 3800 may include a generally K-shaped side face 3806 that extends between the first end face 3802 and the second end face 3804. Additionally, the molded abrasive grain 3800 may include a second generally planar side face 3808 opposite the K-shaped first side face 3806 and extends between the first end face 3802 and the second end face 3804.
[0177] As shown, the molded abrasive grain 3800 may also include a third side face 3810 that extends between the first end surface 3802 and the second end face 3804 and between the first side face 3806 and the second side face 3808. In addition, molded abrasive grain 3800 may include a fourth side face 3812 that extends between the first end face 3802 and the second end face 3804 opposite the third side face 3810.
[0178] FIG. 40 and FIG. 41 show a nineteenth embodiment of a molded abrasive grain 4000. As shown in FIG. 40 and in FIG. 41, the molded abrasive grain 4000 may include a body 4001 which is generally prismatic with a first end face 4002 and a second end face 4004. In a particular aspect, depending on the orientation, the first end face 4002 may be a surface of base and the second end face 4004 may be a top surface. In addition, molded abrasive grain 4000 can include a first side face 4,010 that extends between first end face 4002 and second end face 4004. A second side face 4,012 can extend between first end face 4002 and the second end face 4004 adjacent to the first side face 4.010. As shown, molded abrasive grain 4000 may also include a third lateral face 4,014 extending between first end face 4002 and second end face 4004 adjacent to second lateral face 4012. In addition, molded abrasive grain 4000 may include a fourth side face 4016 extending between the first end face 4002 and the second end face 4004 adjacent to the third side face 4014 and the first side face 4010.
[0179] As shown in FIG. 40 and in FIG. 41, the molded abrasive grain 4000 may also include a first edge 4020 between the first side face 4010 and the second side face 4012. The molded abrasive grain 4000 may also include a second edge 4022 between the second side face 4012 and the third side face 4014. The molded abrasive grain 4000 may include a third edge 4024 between the third side face 4014 and the fourth side face 4016. In addition, the molded abrasive grain 4000 may include a fourth edge 4026 between the fourth side face 4016 and the first face side 4010.
[0180] As shown, each end face 4002, 4004 of the molded abrasive grain 4000 may be generally diamond shaped. Each side face 4010, 4012, 4014, 4016 can be generally rectangular in shape. In addition, the cross section of the molded abrasive grain 4000 in a plane parallel to the end faces 4002, 4004 is generally diamond shaped. As shown, molded abrasive grain 4000 may also include a hole 4030 formed along a central longitudinal axis 4032. Hole 4030 may pass through the center of molded abrasive grain 4000. Alternatively, hole 4030 may be displaced in the center of the grain 4000 molded abrasive in any direction.
[0181] FIG. 42 and FIG. 43 illustrate a twentieth embodiment of a molded abrasive grain that is generally designated 4200. As shown, the molded abrasive grain 4200 may include a body 4201 having a generally circular first end face 4202 and a generally circular second end face 4204. In particular, depending on the orientation, the first end face 4202 may be a base surface and the second end face 4204 may be a top surface. In a particular aspect, a diameter of the second end face 4204 may be greater than a diameter of the first end face 4202.
[0182] As shown, the molded abrasive grain 4200 may include a continuous side face 4206 between the first end face 4202 and the second end face 4204. In that sense, the molded abrasive grain 4200 is generally frusto-conical in shape. FIG. 42 and FIG. 43 further indicate that the molded abrasive grain 4200 may include a generally cylindrical bore 4208 formed along a central longitudinal axis 4210.
[0183] Referring now to FIG. 44 to FIG. 46, a twenty-first embodiment of a molded abrasive grain is shown and is generally designated 4400. The molded abrasive grain 4400 can include a body 4401 that can include a generally circular first end face 4402 and a generally circular second end face 4404 In a particular aspect, depending on the orientation, the first end face 4402 may be a top surface and the second end face 4404 may be a base surface.
[0184] In addition, the molded abrasive particle 4400 may include a first side face 4410 extending between the first end face 4402 and the second end face 4404. A second side face 4412 may extend between the first end face of end 4402 and second end face 4404 adjacent to first side face 4410. As shown, molded abrasive grain 4400 may also include a third side face 4414 extending between first end face 4402 and adjacent second end face 4404 to the second side face 4412 and to the first side face 4410.
[0185] As shown in FIG. 44 and in FIG. 45, the molded abrasive grain 4400 may also include a first edge 4420 between the first side face 4410 and the second side face 4412. The molded abrasive grain 4400 may also include a second edge 4422 between the second side face 4412 and the third side face 4414. In addition, molded abrasive grain 4400 may include a third edge 4424 between third side face 4414 and first side face 4412.
[0186] Referring now to FIG. 47 to FIG. 49, a twenty-second embodiment of a molded abrasive grain is shown and is generally designated 4700. The molded abrasive grain 4700 may include a body 4701 having a generally square first end face 4702 and a generally circular second end face 4704. In a particular aspect, depending on the orientation, first end face 4702 may be a top surface and second end face 4704 may be a base surface.
[0187] In addition, the molded abrasive grain 4700 may include a first side face 4710 extending between the first end face 4702 and the second end face 4704. A second side surface 4712 may extend between the first end face of end 4702 and second end face 4704 adjacent to first side face 4710. As shown, molded abrasive grain 4700 may also include a third side face 4714 extending between first end face 4702 and adjacent second end face 4704. to second side face 4712. Molded abrasive grain 4700 may include a fourth side face 4716 adjacent to third side face 4714 and first side face 4710.
[0188] As shown in FIG. 47 and in FIG. 48, the molded abrasive grain 4700 may also include a first edge 4720 between the first side face 4710 and the second side face 4712. The molded abrasive grain 4700 may also include a second edge 4722 between the second side face 4712 and the third side face 4714. In addition, molded abrasive grain 4700 may include a third edge 4724 between third side face 4714 and fourth side face 4716. Additionally, molded abrasive grain 4700 may include a fourth edge 4726 between fourth side face 4716 and the first side face 4710.
[0189] FIG. 50 to FIG. 52 illustrate a twenty-third embodiment of a molded abrasive grain which is generally designated 5000. The molded abrasive grain 5000 may include a body 5001 having a generally plus (+) shaped first end face 5002 and a generally plus (+) second end face 5002 circular 5004. In a particular aspect, depending on the orientation, the first end face 5002 may be a top surface and the second end face 5004 may be a base surface.
[0190] Additionally, molded abrasive grain 5000 may include a first side face 5010 that extends between the first end face 5002 and the second end face 5004. A second side surface 5012 may extend between the first end surface 5002 and second end surface 5004 adjacent to first side surface 5010. As shown, molded abrasive grain 5000 may also include a third side face 5014 that extends between first end face 5002 and second end face 5004 adjacent the second side face 5012. Molded abrasive grain 5000 may also include a fourth side face 5016 adjacent to third side face 5014 and first side face 5010.
[0191] As shown in FIG. 50 and in FIG. 51, the molded abrasive grain 5000 may also include a first void 5020 between the first side face 5010 and the second side face 5012. The molded abrasive grain 5000 may also include a second void 5022 between the second side face 5012 and the third side face 5014. In addition, molded abrasive grain 5000 may include a third void 5024 between third side face 5014 and fourth side face 5016. Additionally, molded abrasive grain 5000 may include a fourth void 5026 between fourth side face 5016 and the first side face 5010.
[0192] FIG. 53 to FIG. 55 illustrate a twenty-fourth embodiment of a molded abrasive grain which is generally designated 5300. The molded abrasive grain 5300 may include a body 5301 having a generally plus (+) shaped first end face 5302 and a generally plus (+) shaped end face 5302. rounded plus (+) shape 5304. In a particular aspect, depending on the orientation, the first end face 5302 may be a top surface and the second end face 5304 may be a base surface.
[0193] As shown, molded abrasive grain 5300 may include a first side face 5310 extending between the first end face 5302 and the second end face 5304. A second side face 5312 may extend between the first end face of end 5302 and second end face 5304 adjacent to first side face 5310. As shown, molded abrasive grain 5300 may also include a third side face 5314 that extends between first end face 5302 and adjacent second end face 5304 to second side face 5312. Molded abrasive grain 5300 may also include a fourth side face 5316 adjacent to third side face 5314 and first side face 5310.
[0194] As shown in FIG. 53 to FIG. 55, the molded abrasive grain 5300 may also include a first void 5320 between the first side face 5310 and the second side face 5312. The molded abrasive grain 5300 may also include a second void 5322 between the second side face 5312 and the third side face 5314. In addition, molded abrasive grain 5300 may include a third void 5324 between the third side face 5314 and the fourth side face 5316. Also, the molded abrasive grain 5300 may include a fourth void 5326 between the fourth side face 5316 and the first side face 5.310.
[0195] Referring now to FIG. 56 through FIG. 58, a twenty-fifth embodiment of a molded abrasive grain is shown and is generally designated 5600. The molded abrasive grain 5600 may include a body 5601 having a generally circular first end face 5602 and a generally triangular second end face 5604. second end face 5604 is relatively larger than first end face 5602. In a particular aspect, depending on the orientation, first end face 5602 may be a top surface and second end face 5604 may be a base surface .
[0196] As described, abrasive grain 5600 may include a first side face 5610 that extends between the first end face 5602 and the second end face 5604. A second side face 5612 may extend between the first end face 5602 and second end face 5604 adjacent to first side face 5610. As shown, molded abrasive grain 5600 may also include a third side face 5614 extending between first side face 5602 and second end face 5604 adjacent to second side face 5612 and the first side face 5610.
[0197] As shown in FIG. 56 through FIG. 58, the molded abrasive grain 5600 may also include a first edge 5620 between the first side face 5610 and the second side face 5612. The molded abrasive grain 5600 may also include a second edge 5622 between the second side face 5612 and the third side face 5614. In addition, molded abrasive grain 5600 may include a third edge 5624 between third side face 5614 and first side face 5612.
[0198] With reference to FIG. 59 to FIG. 61, a twenty-sixth embodiment of a molded abrasive grain is shown and is generally designated 5900. The molded abrasive grain 5900 may include a body 5901 having a generally circular first end face 5902 and a generally square second end face 5904. In a particular aspect, the second end face 5904 is relatively larger than the first end face 5902. In a particular aspect, depending on the orientation, the first end face 5902 may be a top surface and the second end face 5904 may be a base surface.
[0199] Additionally, the molded abrasive grain 5900 may include a first side face 5910 that extends between the first end face 5902 and the second end face 5.904. A second side face 5912 may extend between the first end face 5902 and the second end face 5904 adjacent to the first side face 5910. As shown, the molded abrasive grain 5900 may also include a third side face 5914 that extends between first end face 5902 and second end face 5904 adjacent to second side face 5912. Molded abrasive grain 5900 may also include a fourth side face 5916 adjacent to third side face 5914 and first side face 5910.
[0200] As shown in FIG. 59 to FIG. 61, the molded abrasive grain 5900 may also include a first edge 5920 between the first side face 5910 and the second side face 5912. The molded abrasive grain 5900 may also include a second edge 5922 between the second side face 5912 and the third side face 5914. In addition, molded abrasive grain 5900 may include a third edge 5924 between third side face 5914 and fourth side face 5916. In addition, molded abrasive grain 5900 may include a fourth edge 5926 between fourth side face 5916 and the first side face 5910.
[0201] One or more of the molded abrasive grains described herein are configured to land in a vertical orientation when deposited on a support. In addition, one or more of the embodiments described herein may provide a relatively high aspect ratio associated with a length:height ratio, height:width ratio, length:width ratio, width:height ratio, height:length ratio, width:length ratio particulars or a combination thereof. A high aspect ratio allows the manufacture of a coated abrasive structure having an open coating, i.e. the distance between adjacent molded abrasive grains can be increased. In addition, the open coating provides greater splinter distance and can reduce energy consumption, making for better cutting or grinding.
[0202] Furthermore, in fine wheel applications and bonded abrasives molded abrasive grains having high aspect ratios with sharp edges allow the fabrication of grinding wheels having greater porosity. Greater porosity provides more chip space and chip clearance and can allow more coolant to flow through the grinding wheel for greater efficiency.
[0203] FIGs. 62A and B include illustrations of an abrasive particulate forming system in accordance with an embodiment. The process of forming the molded abrasive particles can be initiated by forming a 6201 mixture including a ceramic material and a liquid. In particular, the 6201 mixture can be a gel formed from a ceramic powder material and a liquid, wherein the gel can be characterized as a form-stable material having the ability to maintain a certain shape even in the green state (i.e. , not exposed to flame). In one embodiment, the gel can include a powder material that is an integrated network of discrete particles.
[0204] The 6201 mixture can be formed to have a specific content of solid materials, such as the ceramic powder material. For example, in one embodiment, the 6201 blend may have a solids content of at least about 25% by weight, such as at least about 35% by weight, at least about 38% by weight, or even at least about 42% by weight to the total weight of the 6201 blend. Still, in at least one non-limiting embodiment, the solids content of the 6201 blend may not be greater than about 75% by weight, such as no greater than about 70% by weight, not more than about 65% by weight, or even not more than about 55% by weight. It will be appreciated that the solid materials content in the 6201 blend can be within a range between any of the minimum and maximum percentages mentioned above.
[0205] According to an embodiment, the ceramic powder material may include an oxide, a nitride, a carbide, a boride, an oxycarbonate, an oxynitride and a combination thereof. In particular cases, the ceramic material can include alumina. More specifically, the ceramic material can include a boehmite material, which can be an alpha alumina precursor. The term "boehmite" is generally used in this document to denote hydrates of alumina, including mineral boehmite, typically being Al2O3^H2O and having a water content of the order of 15%, as well as pseudoboehmite, having a water content greater than 15% , such as 20-38% by weight. Note that boehmite (including pseudoboehmite) has a specific and identifiable crystal structure and unique x-ray diffraction pattern accordingly and as such is distinct from other aluminous materials including other hydrated aluminas such as ATH (aluminum trihydroxide) a common precursor material used in this document for the manufacture of boehmite particulate materials.
[0206] Furthermore, the 6201 mixture can be formed to have a specific content of liquid material. Some suitable liquids can include organic materials such as water. In accordance with one embodiment, blend 6201 may be formed to have a liquid content less than the solids content of blend 6201. In more particular cases, blend 6201 may have a net content of at least about 25% by weight for the total weight of the mixture 6201. In other cases, the amount of liquid within the mixture 6201 may be greater, such as at least about 35% by weight, at least about 45% by weight, at least about 50% by weight or even at least about 58% by weight. Further, in at least one non-limiting embodiment, the liquid content of the mixture may be no greater than about 75% by weight, such as no greater than about 70% by weight, no greater than about 65% by weight. weight, not more than about 60% by weight or even not more than about 55% by weight. It will be appreciated that the content of the liquid in the 6201 blend can be within a range between any of the minimum and maximum percentages mentioned above.
[0207] In addition, to facilitate the processing and formation of the molded abrasive particles, according to the modalities in this document, the 6201 mixture can have a particular storage module. For example, the 6201 blend can have a storage modulus of at least about 1x104 Pa, such as at least about 4x104 Pa, or even at least about 5x104 Pa. However, in at least one non-limiting embodiment, blend 6201 may have a storage modulus of no greater than about 1x107 Pa, such as no greater than about 1x106 Pa. It will be appreciated that the storage modulus of blend 6201 may be within a range between any of the minimum and maximum values. noted above. The storage module can be measured via a parallel plate system using ARES or AR-G2 rotational rheometers with Peltier plate temperature control systems. For testing, the 6201 blend can be extruded into a gap between two plates that are positioned to be approximately 8 mm apart from each other. After extruding the gel into the opening, the distance between the two plates defining the gap is reduced to 2 mm, until the 6201 mixture completely fills the gap between the plates. After removing the excess mixture, the gap is reduced by 0.1 mm and the test is started. The test is an oscillation deformation sweep test performed with instrument adjustments of a deformation range from 0.1% to 100%, at 6.28 rad/s (1 Hz), using the 25mm parallel plate and recording 10 points per decade. Within 1 hour after completion of the test, decrease the gap again by 0.1 mm and repeat the test. The test can be repeated at least 6 times. The first test may differ from the second and third tests. Only the results of the second and third tests for each specimen should be reported.
[0208] In addition, to facilitate the processing and formation of the molded abrasive particles, according to the modalities in this document, the 6201 mixture can have a particular viscosity. For example, the 6.201 blend can have a viscosity of at least about 4x103 Pa s, at least about 5x103 Pa s, at least about 6x103 Pa s, at least about 8x103 Pa s, at least about 10x103 Pa s , at least about 20x103 Pa s, at least about 30x103 Pa s, at least about 40x103 Pa s, at least about 50x103 Pa s, at least about 60x103 Pa s, or even at least about 65x103 Pa s . In at least one non-limiting embodiment, the 6201 blend may have a viscosity no greater than about 1x106 Pa s, no greater than about 5x105 Pa s, no greater than about 3x105 Pa s, or even no greater than about 2x105 Pa s Country It will be appreciated that the viscosity of the 6.201 blend may be within a range between any of the minimum and maximum values noted above. Viscosity can be calculated by dividing the storage modulus value by 6.28 s-1.
[0209] In addition, the 6201 mixture can be formed to have a specific content of organic materials, including for example, organic additives that may be distinct from the liquid, to facilitate the processing and formation of the molded abrasive particles, according to the modalities in this document. Some suitable organic additives can include stabilizers, binders such as fructose, sucrose, lactose, glucose, UV curing resins and the like.
[0210] Namely, the embodiments in this document may use a 6201 blend that is different from the slurries used in conventional tape sizing operations. For example, the content of organic materials within blend 6201, particularly any of the organic additives mentioned above may be in a smaller amount compared to other components within blend 6201. In at least one embodiment, blend 6201 may be formed to not have more than about 30% by weight organic material for the total weight of the 6201 mixture. In other instances, the amount of organic materials may be less, such as no more than about 15% by weight, no more than about 10% by weight, or even no more than about 5% by weight. Further, in at least one non-limiting embodiment, the amount of organic materials within the 6201 mixture can be at least about 0.1% by weight, such as at least about 0.5% by weight to the total weight of the 6201 blend. It will be appreciated that the amount of organic materials of the 6201 blend may be within a range between any of the minimum and maximum values noted above.
[0211] In addition, the 6201 mixture can be formed to have a specific content of acid or base distinct from the liquid, to facilitate the processing and formation of the molded abrasive particles, according to the modalities in this document. Some suitable acids or bases may include nitric acid, sulfuric acid, citric acid, chloric acid, tartaric acid, phosphoric acid, ammonium nitrate, ammonium citrate. In one embodiment, the 6201 blend may have a pH of less than about 5 and more particularly within a range of between about 2 and about 4, using a nitric acid additive.
[0212] With reference to FIG. 62, system 6200 may include a hub 6203. As illustrated, blend 6.201 may be supplied within hub 6203 and configured to be extruded through an opening of hub 6205 positioned at one end of hub 6203. As further illustrated, Formation may include applying a force 6280 (which can be translated into a pressure) on the 6201 mixture to facilitate movement of the 6201 mixture through the opening of the 6205 hub. According to an embodiment, a particular pressure may be used during extrusion . For example, the pressure can be at least about 10 kPa, such as at least about 500 kPa. Furthermore, in at least one non-limiting modality, the pressure used during extrusion may not be greater than about 4 MPa. It will be appreciated that the pressure used to extrude the 6201 blend can be within a range between any of the minimum and maximum values noted above.
[0213] In some systems, hub 6203 may include a hub opening 6205 having a specific shape. It will be appreciated that the opening of hub 6205 can be molded to give a specific shape to the mix 6201 during extrusion. In accordance with an embodiment, the opening of the hub 6205 may have a rectangular shape. In addition, the blend 6201 extruded through the hub opening 6205 may have essentially the same cross-sectional shape as the hub aperture 6205. As further illustrated, the blend 6201 may be extruded as a sheet 6211 and onto an underlying mat 6209. cube 6203. In specific cases, the 6201 mixture can be extruded as a 6211 sheet directly onto the 6209 belt, which can facilitate continuous processing.
[0214] According to a certain modality, the mat can be formed to have a film covering a substrate, where the film can be a discrete and separate layer from the material configured to facilitate the processing and the formation of molded abrasive particles. The process may include feeding the blend 6201 directly onto the mat film to form sheet 6211. In certain cases, the film may include a polymer material such as polyester. In at least one embodiment, the film can consist essentially of polyester.
[0215] In some embodiments, the mat 6209 can be translated by moving the mixture 6201 through the opening of the hub 6205. As illustrated in system 6200, the mixture 6201 can be extruded in a direction 6291. The direction of translation 6210 of the mat 6209 it can be angled relative to the extrusion direction 6291 of the mixture. While the angle between the translation direction 6210 and the extrusion direction 6291 is illustrated as substantially orthogonal in system 6200, other angles are contemplated, including, for example, an acute angle or an obtuse angle. Belt 6209 can be moved at a special rate to facilitate processing. For example, mat 6209 can be translated at a rate of at least about 3 cm/s, such as at least about 4 cm/s, at least about 6 cm/s, at least about 8 cm/s, or even at least about 10 cm/s. Still, in at least one non-limiting modality, the mat 6209 can be translated in a direction 6210, at a rate not exceeding about 5 m/s, such as not exceeding about 1 m/s, or even not exceeding at about 0.5 m/s. It will be appreciated that the mat 6209 can be translated at a rate within a range between any of the minimum and maximum values noted above.
[0216] For certain processes, according to embodiments in this document, the translation rate of the belt 6209 compared to the extrusion rate of the mixture 6201 in the 6291 direction can be controlled to facilitate proper processing. For example, the conversion rate of mat 6209 can be essentially the same as the extrusion rate, to ensure proper sheet formation 6211.
[0217] After the 6201 blend is extruded through the opening of the 6205 hub, the 6201 blend can be translated along the mat 6209 under a knife edge 6207 attached to a surface of the hub 6203. The knife edge 6207 can facilitate formation of a sheet 6211 More particularly, the opening defined between the surface of the knife edge 6207 and the mat 6209 can define particular dimensions of the extruded mixture 6201. For certain embodiments, the mixture 6201 can be extruded in the form of a sheet 6211 having a generally rectangular cross shape, as seen in a plane defined by a height and width of sheet 6211. While the extrudate is illustrated as a sheet, other shapes can be extruded, including, for example, cylindrical shapes and the like.
[0218] The process of forming sheet 6211 of the mixture 6201 may include control of particular characteristics and process parameters to facilitate the proper formation of molded abrasive particles having one or more characteristics as provided in the embodiments herein. For example, in certain instances, the process of forming a sheet 6211 of the mixture 6201 may include forming a sheet 6211 having a particular height 6281 controlled in part by a distance between the edge of knife 6207 and a surface of mat 6209.
[0219] In addition, note that the height 6281 of sheet 6211 can be controlled by varying the distance between the edge of knife 6207 and the surface of belt 6209. In addition, forming the mixture 6201 into sheet 6211 can include controlling the dimensions of sheet 6211 based in part on the viscosity of the mixture 6201. In particular, forming the sheet 6211 may include adjusting the height 6281 of the sheet 6211 based on the viscosity of the mixture 6201.
[0220] The sheet 6211 can have specific dimensions, including, for example, a length (l), a width (w) and a height (h). In accordance with an embodiment, sheet 6211 may have a length extending in the direction of translating belt 6209, which may be greater than the width, wherein the width of sheet 6211 is a dimension extending in a direction perpendicular to the belt length 6209 and sheet length. Sheet 6211 may have a height 6281, in which the length and width are greater than the height 6281 of sheet 6211.
[0221] Namely, the height 6281 of the sheet 6211 may be the dimension extending vertically from the surface of the belt 6209. In accordance with an embodiment, the sheet 6211 may be formed to have a particular dimension of the height 6281, wherein the height can be an average height of sheet 6211 derived from various measurements. For example, the height 6281 of sheet 6211 can be at least about 0.1 mm, such as at least about 0.5 mm. In other cases, the height 6281 of sheet 6211 may be greater, such as at least about 0.8 mm, at least about 1 mm, at least about 1.2 mm, at least about 1.6 mm, or even even at least about 2 mm. Further, in a non-limiting embodiment, the height 6281 of sheet 6211 cannot be greater than about 10 mm, not greater than about 5 mm, or even not greater than about 2 mm. It will be appreciated that sheet 6211 may have an average height in the range between any of the maximum and minimum values noted above.
[0222] According to an embodiment, the sheet 6211 can have a length (l), width (w) and height (h), where the length > width > height. In addition, sheet 6211 can have a secondary length:height aspect ratio of at least about 10, such as at least about 100, at least about 1000, or even at least about 1000.
[0223] After extrusion of the mixture 6201 from die 6203, the sheet 6211 can be translated in a direction 6212 along the surface of the belt 6209. The translation of the sheet 6211 along the belt 6209 can facilitate the transformation to form abrasive particles in the form of the precursor. For example, sheet 6211 may undergo a shaping process within shaping zone 6213, which in particular instances may include shaping a surface of sheet 6211, including, for example, an upper main surface. 6217 of sheet 6211, which may be completed using an article shaping 6215. In other embodiments, other large surfaces of the sheet may be formed, including, for example, the bottom surface or side surfaces. For certain processes, modeling may include altering a sheet contour through one or more processes such as engraving, rolling, cutting, etching, patterning, stretching, twisting and a combination of these.
[0224] In accordance with an embodiment, the process of forming an abrasive particulate form includes further translation of the sheet along the belt 6209 through a shape zone 6221. In accordance with an embodiment, the process of forming a particulate abrasive shape precursor sheet 6211 may include particulate abrasive cut shape precursor sheet 6223. For example, in certain cases, forming may include perforating a portion of sheet 6211. In other cases, the forming process includes patterning sheet 6211 to form a patterned sheet and extract patterned sheet shapes.
[0225] Particular forming processes include cutting, pressing, punching, crushing, rolling, twisting, bending, drying and a combination thereof. In one embodiment, the forming process may include sectioning sheet 6211. Cutting sheet 6211 may include using at least one mechanical object, which may be in the form of a gas, liquid, or solid material. The sectioning process can include at least one or a combination of cutting, pressing, punching, crushing, rolling, twisting, bending and drying. In addition, it will be appreciated that the sectioning may include perforators or creating a partial opening through a portion of sheet 6211 that may not extend through the entire height of sheet 6211. In one embodiment, cutting sheet 6211 may include the use of a mechanical object, including one or a plurality of a blade, a wire, a disk and a combination thereof.
[0226] The sectioning process can create different types of abrasive particle shapes in a single cutting process. Different types of shaped abrasive particles can be formed from the modalities processes at this point. Different types of shaped abrasive particles include a first type of shaped abrasive particles having a first two-dimensional shape and a second type of shaped abrasive particles having a different two-dimensional shape relative to the first two-dimensional shape. Also, different types of abrasive particles in shape may differ from each other in size. For example, different types of shaped abrasive particles can have different volumes compared to each other. A unique process that is capable of forming different types of shaped abrasive particles may be particularly suitable for producing certain types of abrasive articles.
[0227] Sectioning may include moving the mechanical object through a portion of a sheet 6211 and creating an opening within the sheet 6211. In particular, the sheet may be formed to have an opening extending into the volume of the sheet and defined by certain surfaces. The opening can define a cut extending through at least a fraction of the entire height of the sheet. It will be appreciated that the opening need not necessarily extend across the full height of the sheet. In certain cases, the sectioning method may include maintaining the opening in the sheet. Keeping the opening after cutting the sheet that has been cut by a mechanical object can facilitate the proper formation of abrasive shaped particles and characteristics of shaped abrasive particles and characteristics of a batch of shaped abrasive particles. Maintaining the opening may include at least partially drying at least one surface of the sheet defining the opening. The drying process, at least partially, may include directing material drying at the opening. A drying material can include a liquid, solid or even a gas. According to a certain modality, the drying material can include air. Controlled drying can facilitate the formation of abrasive particles in shape according to modalities at this point.
[0228] In certain cases, the cutting process can be carried out before sufficient drying of the sheet. For example, cutting can be performed prior to volatilizing no more than about 20% of the liquid in the sheet compared to the original liquid content of the sheet during initial forming of the sheet. In other embodiments, the amount of volatilization may occur before or during cutting may be less, such as, no more than about 15%, no more than about 12%, no more than about 10%, no more than about 8%, or even not more than about 4% of the original net content of the sheet.
[0229] Referring again to FIGs. 62A and 62B, after formation of the abrasive particulate precursor 6223, the particles can be converted through a post-forming zone 6225. Various processes can be performed in the post-forming zone 6225, including, for example, heating , healing, vibration, impregnation, doping and a combination thereof.
[0230] In one embodiment, the post-forming zone 6225 includes a heating process, where the abrasive particulate precursor 6223 can be dried. Drying can include the removal of a specific content of material, including volatile compounds such as water. According to an embodiment, the drying process can be conducted at a drying temperature of not more than 300°C, such as not more than 280°C or even not more than about 250°C. Still, in a non-limited modality, the drying process can be carried out at a drying temperature of at least 50°C. It will be appreciated that the drying temperature can be within a range between any of the minimum and maximum temperatures mentioned above.
[0231] In addition, the abrasive particulate precursor 6223 can be translated through a post-forming zone at a particular rate, such as at least approximately 0.2 ft/min and not greater than about 8 ft/min. min. Furthermore, the drying process can be carried out for a specified period. For example, the drying process may not be longer than six hours.
[0232] After the abrasive particulate precursor 6223 is translated by the post-forming zone 6225, the particles can be removed from the belt 6209. The abrasive particulate precursor 6223 can be collected in a bin 6227 for further processing.
[0233] According to a modality, the formation process in the form of abrasive particles can further include a sintering process. The sintering process can be performed after collecting the particulate abrasive precursors 6223 from the belt 6209. Sintering the particulate abrasive precursor 6223 can be used to densify the particles, which are generally in a green state. In a specific instance, the sintering process can facilitate the formation of a high temperature phase of the ceramic material. For example, in one embodiment, the abrasive particulate precursor 6223 can be sintered such that a high temperature phase of alumina such as alpha alumina is formed. In one example, a shaped abrasive particle can include at least about 90% by weight alpha-alumina to the total particle weight. In other cases, the alpha alumina content may be greater, such that the abrasive particulate form may consist essentially of alpha alumina.
[0234] FIG. 63 includes an illustration of an abrasive particulate forming system in accordance with an embodiment. In particular, the 6300 system generally includes a forming screen printing process in the form of abrasive particles. However, as noted here, certain parts of the system can be modified to conduct a molding process. As illustrated, system 6300 may include a screen 6351 configured to be translated between rollers 6370 and 6371. It will be appreciated that screen 6351 can be translated by a greater number of rollers or other devices, if desired. As illustrated, the 6300 system may include a belt 6309 configured to be translated in a direction 6316 on rollers 6372 and 6373. It will be appreciated that the belt 6309 can be translated along a greater number of rollers or other devices, if desired. .
[0235] As illustrated, the 6300 system may further include a 6303 die configured to perform the extrusion of a mixture 6301 contained in a reservoir 6302 of the 6303 die. The process of forming abrasive particles into shape can be initiated by forming a mixture 6301, including a ceramic material and a liquid as described herein.
[0236] Mix 6301 may be provided within die 6303 and configured to be extruded through an opening of die 6305 positioned at one end of die 6303. As further illustrated, extrusion can include the application of force (or pressure ) over the 6301 blend to facilitate extrusion of the 6301 blend through die opening 6305. According to one embodiment, a particular pressure may be utilized during extrusion. For example, the pressure can be at least about 10 kPa, such as at least about 500 kPa. Furthermore, in at least one non-limiting modality, the pressure used during extrusion may not be greater than about 4 MPa. It will be appreciated that the pressure used to extrude the 6301 blend can be within a range between any of the maximum and minimum values noted above.
[0237] In particular cases, the 6301 mixture can be extruded through an opening of the 6305 die, at the end of the 6303 die in the vicinity of the 6351 screen. The 6351 screen can be translated into a 6353 direction at a special rate to facilitate the proper processing. Notably, screen 6351 can be translated by application zone 6383 including matrix 6305 to facilitate formation of the aperture precursor in the form of abrasive particles. Screen 6351 can be translated through the application zone at a rate of at least about 3 cm/sec, such as at least about 4 cm/sec, at least about 6 cm/sec, at least about 8 cm/sec. s, or even at least about 10 cm/s. Still, in at least one non-limiting modality, the 6351 screen can be translated into a 6353 sense at a rate no greater than about 5 m/s, such as no more than about 1 m/s, or even less than or equal to about 0.5 m/s. It will be appreciated that screen 6351 can be converted at a rate in the range between any of the maximum and minimum values noted above.
[0238] In addition, the 6309 belt can be translated into a 6316 sense at a special rate to facilitate proper processing. For example, belt 6309 can be translated into a rate of at least about 3 cm/s, such as at least about 4 cm/s, at least about 6 cm/s, at least about 8 cm/s, or even at least about 10 cm/s. Further, in at least one non-limiting modality, belt 6309 can be translated in a 6316 direction, at a rate of not more than about 5 m/s, such as no more than about 1 m/s, or even no more at about 0.5 m/s. It will be appreciated that belt 6309 can be translated at a rate within a range between any of the minimum and maximum values noted above.
[0239] In accordance with a certain embodiment, the 6351 screen can be translated into a specific rate compared to the conversion rate of the 6309 belt. For example, within the application zone 6383, the 6351 screen can be translated into substantially the same translation rate as the 6309 belt. That is, the translation rate difference between the screen and the belt can be no more than about 5%, such as no more than about 3%, or even no greater than about 1% based on the 6351 screen translation rate.
[0240] As illustrated, the system 6300 can include an application zone 6383, including the given opening 6305. Within the application zone 6383, the mixture 6301 can be expelled from the matrix 6303 and directly onto the screen 6351. More particularly, a part of the mixture of 6301 can be extruded from the opening of die 6305, and further extruded through one or more openings in the screen of 6351 and onto the underlying belt 6309.
[0241] Referring briefly to FIG. 64, a portion of a screen 6451 is illustrated. As shown, screen 6451 may include an opening 6452 and more particularly, a plurality of openings 6452. The openings may extend through the volume of screen 6451, to facilitate passable mixing 6301 through the openings and over belt 6309. In one embodiment, the apertures 6452 may be one-dimensional in shape as seen in a plane defined by the length (1) and width (w) of the screen. While apertures 6452 are illustrated as having a two-dimensional three-pointed star shape, other shapes are contemplated. For example, openings 6452 can have a two-dimensional shape such as polygons, ellipsoids, numerals, Greek alphabet letters, Latin alphabet letters, Russian alphabet characters, including a combination of polygonal shapes and a combination of complex shapes. In particular cases, the openings 6452 may have their two-dimensional polygonal shapes, such as a triangle, a rectangle, a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, an enneagon, a decagon, and a combination. In addition, a screen 6451 may be formed to include a combination of apertures 6452 having a plurality of different two-dimensional shapes.
[0242] Certain processing aspects have been found to facilitate the formation of abrasive particles in shape according to modalities at this point. Namely, the orientation of the openings relative to the matrix has been found to have an effect on the shape of the abrasive particles in shape. In particular, it has been observed that when the openings are aligned as illustrated in FIG. 64, wherein an opening point 6455 is first filled with the mixture of 6301, the shaped abrasive particles are conveniently formed with the characteristics described herein. In other orientations, where, for example, one side of opening 6456 would be filled first, as opposed to a point (eg, 6455) of opening 6452, it was observed that shaped abrasive particles had lesser characteristics. appropriate.
[0243] Referring again to FIG. 63, after forcing the mixture of 6301 through the aperture of die 6305 and a portion of the mixture of 6301 through openings 6352 in the screen 6351, precursors in the form of abrasive particles 6353 can be printed onto a belt 6309 disposed under the screen of 6351 In accordance with a particular embodiment, the abrasive particulate precursor 6353 may be shaped substantially replicating the shape of apertures 6352.
[0244] After extrusion of the mixture of 6301 in the openings 6352 of the screen 6351, the belt 6309 and screen 6351 can be translated to a release zone 6385, in which the belt 6309 and 6351 of the screen can be separated to facilitate the formation of the abrasive form precursor of the particles. In accordance with an embodiment, the fabric 6351 and the belt 6309 may be separated from each other within the release zone 6385 at a particular release angle 6355. According to the specific embodiment, the release angle 6355 may be a measure of the angle between the lower surface 6354 of the screen 6351 and an upper surface 6356 of the belt 6309.
[0245] In particular, the mixture 6301 can be forced through the screen 6351 quickly, such that the average residence time of the mixture 6301 within the openings 152 can be less than about 2 minutes, less than about 1 minute, less than about 40 seconds, or even less than about 20 seconds. In particular non-limiting embodiments, the blend 6301 may be substantially unchanged during printing as it travels through the screen openings 6352, thus experiencing no change in the amount of components and may experience no appreciable drying at the screen openings 6352 of the screen 6351.
[0246] In an alternative embodiment, the forming process may include a molding process. The molding process can use some of the same components as the 6300 system, however, the screen can be replaced with a blank frame having openings within a substrate material to mold the 6301 mixture. The blank of the mold may have openings that extend partially through the entire blank thickness, such that the openings are not openings, extending from a large surface to the main opposite surface of the blank. Instead, the mold openings may have a lower surface within the interior volume, designed to form a larger surface of the abrasive particulate precursor formed therein. Also, a molding system may not necessarily use a belt underlying the blank mold.
[0247] The formation process can also use a special drying process, to facilitate the formation of abrasive particles in shape having characteristics of the embodiments of the present invention. In particular, the drying process may include drying under conditions including humidity, temperature and atmospheric pressure and suitable composition to limit distortions in the form of abrasive particles.
[0248] It was found that, unlike the formation of abrasive particles molded with typical polygonal shapes, the process of forming complex shapes, namely the use of replication processes, required the control of one or more process parameters, including the drying conditions, the amount and type of lubricant, the pressure applied to the mixture during extrusion, the material of the blank or belt, and the like. In particular instances it has been found that a stainless steel or polycarbonate polymer belt or blank could be used. In addition, it has been found that using a natural oil material (eg canola oil) as a lubricant over blank or belt openings can facilitate improving abrasive particle forming in shape.
[0249] The body of the shaped abrasive particles may include additives such as contaminants, which may be in the form of elements or compounds (eg oxides). Certain suitable additives can include alkali elements, alkaline earth elements, the rare earth elements, hafnium (Hf), zirconium (Zr), niobium (Nb), tantalum (Ta), molybdenum (Mo), and a combination thereof. In particular instances, the additive may include an element such as lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), strontium (Sr), barium (Ba), scandium ( Sc), yttrium (Y), lanthanum (La), cesium (Ce), praseodymium (Pr), niobium (Nb), hafnium (Hf), zirconium (Zr), tantalum (Ta), molybdenum (Mo), vanadium ( V), chromium (Cr), cobalt (Co), iron (Fe), germanium (Ge), manganese (Mn), nickel (Ni), titanium (Ti), zinc (Zn) and a combination thereof.
[0250] The body of a shaped abrasive article may include specific additive content (eg dopant). For example, the body of an abrasive particle form can include no more than about 12% by weight of additive to total body weight. In still other embodiments, the amount of additive can be less, such as no more than about 11% by weight, no more than about 10% by weight, no more than about 9% by weight, no more than about 8% by weight, not greater than about 7% by weight, not greater than about 6% by weight, or even not greater than about 5% by weight. Still, the amount of additive in at least one non-limiting modality can be at least about 0.5% by weight, such as at least about 1% by weight of at least about 1.3% by weight of at least about 1.8% by weight of at least about 2 by weight, at least about 2.3% by weight of at least about 2.8 by weight, or even at least about 3% by weight. It will be appreciated that the amount of additive within a body of an abrasive particle form can be within a range between each of the maximum and minimum percentages noted above.
[0251] FIG. 65A includes a top-down image of an abrasive particle shape formed in accordance with a particular embodiment. As illustrated, the abrasive particle shaped 6500 can define a star-shaped body, as seen in two dimensions. In particular, abrasive particles shaped like 6500 may include a body 6501 having a central portion 6502 and a first arm 6503, a second arm 6504 and a third arm 6505 extending from the central portion 6502. The body 6501 may have a length (l) measured as the longest dimension along one side of the particle and a width (w) measured as the longest dimension of the particle between a midpoint 6553 of a side by midpoint 6590 of the body 6501 to a first tip 6506 of the first arm 6503. The width may extend in a direction perpendicular to the length dimension. The body 6501 may have a height (h) that extends in a direction perpendicular to the upper surface 6510 of the body 6501 which defines the third side surface 6556 between the upper surface and the base surface of 6511 as illustrated in FIG. 65B, which is an image side view illustration of the particle of FIG. 65A.
[0252] The shape of the 6500 abrasive particles may have a body of 6501 in the form of a three-pointed star defined by the first arm 6503, second arm 6504, and the third arm of 6505 extending from the central portion 6502 According to a certain embodiment, at least one of the arms, including, for example, the first arm 6503, may have a midpoint width 6513 which is less than the width of the central portion 6512. The central portion 6502 can be defined as a region between the midpoints 6551, 6552 and 6553 of the first side surface 6554, second side surface 6555 and third side surface 6556, respectively. The width of the center portion 6512 of the first arm 6503 may be the width of the dimension between midpoints 6551 and 6552. The width of the midpoint 6513 may be the width of the line at a midpoint between the line of the width of the center portion 6510 and the tip 6506 of the first arm 6503 along a first axis 6560. In certain cases, the width of the midpoint 6513 may not be greater than about 90% of the width of the central portion 6512, such as no greater than about 80%, not more than about 70%, not more than about 65%, or even not more than about 60%. Still, the width of midpoint 6513 can be at least about 10%, such as at least about 20%, at least about 30%, or even at least about 40% of the width of center portion 6510. It is appreciated that the width of the center point 6513 may have a width relative to the width of the center portion of 6512 in the range between any of the above minimum and maximum percentages.
[0253] On the other hand, the 6501 body may have at least one arm, such as the first arm of 6503, having a tip width 6514 at the tip 6506 of the first arm of 6503, which is less than a width of the midpoint 6513. In such cases where tip 6506 is sharply formed, the width of tip 6514 can be considered 0. In cases where tip 6506 has a radius of curvature, the width of tip 6514 can be considered the diameter of the circle defined by radius of curvature. According to a modality, tip width 6514 may not be greater than about 90% of midpoint width 6513, such as no greater than about 80%, no greater than about 70%, no greater than that about 60%, not more than about 50%, not more than about 40%, not more than about 30%, not more than 20%, or even not more than about 10%. Further, in certain non-limiting embodiments, the width of tip 6514 can be at least about 1%, such as at least about 2%, at least about 3%, at least about 5%, or even at least about 2%. minus about 10% width of midpoint 6513. It will be appreciated that width of point 6514 may have a width relative to width of centerpoint 6513 in the range between any of the above minimum and maximum percentages.
[0254] As further illustrated, the body 6501 may have a first arm of 6503 that includes a first point 6506 that defines a first point angle 6521 between the first side surface 6554 and the second side surface 6555. According to an embodiment, the first tip angle can be less than about 60 degrees, such as not more than about 55 degrees, no more than about 50 degrees, no more than about 45 degrees, or even no more than about 40 degrees. Still, the first tip angle can be at least about 5 degrees, such as at least about 8 degrees, at least about 10 degrees, at least about 15 degrees, at least about 20 degrees, at least about 25 degrees or even at least about 30 degrees. The first tip angle can be within a range between any of the minimum and maximum values noted above.
[0255] The body 6501 may include a second arm 6504 having a second point 6507 defining a second point angle 6522 between the second side surface 6555 and third side surface 6556. The second point angle may be substantially the same as the first angle edge, such as within 5% of the angle numerical value. Alternatively, the second nose angle may be substantially different from the first nose angle.
[0256] The body 6501 may include a third arm 6505 having a third prong 6508 that defines a third prong angle 6523 between the first lateral surface 6554 and the third lateral surface 6556. The third prong angle may be substantially the same as the first tip angle or second tip angle, such as within 5% of the angle numerical value. Alternatively, the third nose angle may be substantially different from the nose angle of the first or second nose angle.
[0257] The 6501 body can have a total angle, which is the sum of the value of the first nose angle, second nose angle, and third nose angle which can be less than about 180 degrees. In other embodiments, the total angle may be no more than about 175 degrees, such as no more than about 170 degrees, no more than about 165 degrees, no more than about 150 degrees, such as no more than about 140 degrees, not more than about 130 degrees, not more than about 125 degrees, or even not more than about 120 degrees. Further, in a non-limiting embodiment, body 6501 may have a total angle of at least about 60 degrees, such as at least about 70 degrees, at least about 80 degrees, at least about 90 degrees, such as , at least about 95 degrees, at least about 100 degrees, or even at least about 105 degrees. It will be appreciated that the total sum angle may fall within a range between any of the maximum values noted above and the minimum.
[0258] As indicated herein, the body 6501 may have a first side surface 6554 that extends between the first arm 6506 and the third arm 6508. In certain cases, the first side surface 6554 may have an arcuate contour. For example, by quickly transforming FIG. 65C, a top view image of an abrasive particulate in accordance with an embodiment is provided. Notably, abrasive particles shaped like Figure 65C may include a three-pointed star with a body 6581 and an arcuate side surface 6582 that extends between two points. In particular instances, side surface 6582 may have a concave contour, defining a curved portion, extending inwardly toward central portion 6583 of body 6581.
[0259] Referring again to FIG. 65A, body 6501 may have a first side surface 6554 has a first side section 6558 and a second side section 6559. The first side section 6558 may extend between the first prong 6506 and the center point 6551 and the second side section 6559 may extend between third point 6508 and center point 6551. First side section 6558 and second side section 6559 may define an interior angle 6562 which may be obtuse. For example, the interior angle 6562 can be greater than about 90 degrees, such as greater than about 95 degrees, greater than about 100 degrees, greater than about 110 degrees, or even greater than about 120 degrees . Further, in an unlimited embodiment, the interior angle 6562 may be no more than about 320 degrees, such as no more than about 300 degrees, or even no more than about 270 degrees. It will be appreciated that the interior angle can be within a range between any of the maximum and minimum values noted above.
[0260] The first side of section 6558 may extend for a significant portion of the length of the first side surface 6554. For example, the first side section 6558 may extend for at least about 20%, such as at least about 25%, at least about 30%, at least about 35%, or even at least about 40% of the total length of the first side surface 6554. Still, in an unlimited modality, the first side of the section 6558 may have a length (lsl) between the midpoint 6551 and the first point 6506 not more than about 80%, such as no more than about 75%, no more than about 70%, or even no more than about 65% of the total length of the side surface 6554. It will be appreciated that the length of the first side section 6558 may fall within a range between each of the maximum and minimum percentages noted above.
[0261] The second side section 6559 can span a significant portion of the length of the first side surface 6554. For example, the first side section 6558 can span at least about 20%, such as at least about 25%, at least about 30%, at least about 35%, or even at least about 40% of the total length of the first side surface 6554. Still, in a non-limiting embodiment, the second side section 6559 may have a length (ls2) between the point 6551 and the third point of 6508 is not more than about 80%, such as not more than about 75%, not more than about 70%, or even is not greater than about 65% of the total length of the side surface 6554, as a straight line between the first prong 6506 and the third prong 6508. It will be appreciated that the length of the first side section 6559 may be within a range between each of the maximum and minimum percentages noted above.
[0262] The 6501 body may further include a 6570 fractured region of at least a portion of the surface on one side. For example, the body 6501 may have a 6570 fractured region over a portion of the 6554 side surface between the midpoint 6551 and the third tip 6508. The 6570 fracture region may be intersecting at least a portion of an edge defining the base surface 6511. Alternatively, or in addition, fracture region 6570 may intersect at least a portion of an edge, defining upper surface 6510. The fracture region may be characterized by having a surface roughness greater than a roughness of surface of at least upper surface 6510 or base surface 6511 of body 6501. Fractured region 6570 may define a portion of the body extending from base surface 6511. In certain cases, fractured region 6570 may be characterized by irregularly shaped protrusions and grooves extending from base surface 6511 along first side surface 6554. In certain cases, fractured region 6570 may appear as and define a serrated edge. A fracture region 6583 is also illustrated on the side surface 6582 of the abrasive particle in the form of FIG. 65C.
[0263] In certain cases, the 6570 fracture region may preferentially be located at or near the tips of the arms of the body. Fractured region 6570 may extend from bottom surface 1703 and extend vertically for a fraction of the entire height of the side surface or even the entire height of the side surface.
[0264] While the precedent of the 6501 body of the three-pointed star has been shown to have an upper surface 6510 having a two-dimensional shape, as shown in the plane of the length and width of the body, which is substantially the same as the two-dimensional surface of base 6511 of the body 6501, other shapes are contemplated. For example, in one modality, the cross-shape of the body on the base surface can define a base surface shape of the group consisting of a three-pointed star, one four-pointed star, one cross-shaped, a polygon, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, having a combination of polygonal shapes and a combination of complex shapes. In addition, the shape of the cross-section of the body on the upper surface can define a shape of the upper surface, which may be different than the shape of the base surface and selected from the group of a three-pointed star, a four-pointed star. , a cross shape, a polygon, ellipsoids, numbers, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes with a combination of polygonal shapes, and a combination thereof.
[0265] In particular cases, the top surface shape may have an arcuate shape of the base surface shape. For example, the top surface shape can define a three-pointed two-dimensional arcuate shape, where the three-pointed two-dimensional arcuate shape defines arms having rounded ends. In particular, the arms as defined on the base surface may have a smaller radius of curvature at the tip compared to the corresponding radius of curvature at the tip at the upper surface.
[0266] As described in other embodiments herein, it will be appreciated that at least one of the arms of the 6501 body may be formed to have a twist such that the arm turns around a central axis. For example, first arm 6503 may rotate about axis 6560. In addition, body 6501 may be formed such that at least one arm extends in an arcuate path from the central region.
[0267] FIG. 66A includes a top-down image of an abrasive particle shape formed in accordance with a particular embodiment. As illustrated, the shape of the 6600 abrasive particles can define a star-shaped body, as seen in a plane defined by the two dimensions of length and width. In particular, the shape of the abrasive particles 6600 may include a body 6601 having a central portion of 6602 and a first arm of 6603, a second arm of 6604, a third arm of 6605, and a fourth arm of 6606 extending therefrom. of central portion 6602. Body 6601 may have a length (l), measured as the longest dimension along one side of the particle and a width (w), and measured as the longest dimension of the particle between two opposing arm points and through the midpoint of 6609 the body 6601. The width may extend in a direction perpendicular to the length dimension. The body 6601 may have a height (h) that extends in a direction perpendicular to the upper surface 6610 of the body 6601, which defines the third side surface 6656 between the upper surface and the base surface of 6611, as illustrated in FIG. 66B. Notably, body 6601 can have more than one height as will be described in more detail here.
[0268] The shape of the abrasive particles 6600 can have a body of 6601 in the form of a four-pointed star defined by the first arm 6603, a second arm of 6604, a third arm of 6605, and the fourth arm 6606 extending from the center portion of 6602. The body 6601 can have any of the functions described in the embodiments herein. For example, in accordance with a particular embodiment, at least one of the arms, including, for example, the first arm of 6603, may have a midpoint width that is less than a center portion width, as described in accordance with with the embodiment of FIG. 65A. In addition, body 6601 may have at least one arm, such as the first arm of 6603, having an end-to-end width of the first arm that is less than a midpoint width, as described, according to the embodiment of FIG. 65A.
[0269] In one aspect, the body 6601 may have a first arm of 6603 that includes a first point 6607 that defines a first point angle 6621 between the first side surface 6654 and the second side surface 6655. According to an embodiment, the first tip angle can be less than about 60 degrees, such as not more than about 55 degrees, no more than about 50 degrees, no more than about 45 degrees, or even no more than about 40 degrees. Still, first tip angle 6621 can be at least about 5 degrees, such as at least about 8 degrees, at least about 10 degrees, at least about 15 degrees, or even at least about 20 degrees. The first tip angle 6621 can be within a range between any of the maximum values noted above and the minimum. Likewise, any of the other prongs, including second prong 6608 of second arm 6604, third prong 6609 of third arm 6605, or fourth prong 6610 of fourth arm 6606 may have a point angle having the same characteristics as described in terms with the first point angle 6621 above.
[0270] According to an embodiment the second tip 6608 can define a second tip angle that is substantially the same as the first tip angle 6621, such as within 5% of the angle numerical value. Alternatively, the second nose angle may be substantially different from the first nose angle 6621. The third nose angle 6609 may define a nose angle that the third is substantially the same as the first nose angle 6621, such as within 5 % of numerical value angle. Alternatively, the third point angle may be substantially different from the first point angle 6621. The fourth point angle 6610 may define a fourth point angle that is substantially the same as the first point angle 6621, such as within 5% of the numerical value angle. Alternatively, the fourth nose angle may be substantially different from the first nose angle 6621.
[0271] According to an embodiment, body 6601 may include a first arm 6603, second arm 6604, third arm 6605, and fourth arm 6606 that are substantially uniformly spaced apart from each other. As illustrated, arms 6603-6606 may be spaced substantially uniformly around central portion 6602. In a particular embodiment, arms 6603-6606 may be spaced apart from one another at substantially orthogonal angles to one another. In other embodiments, the first arm of 6603 and second arm 6604 can be spaced apart based on the spacing angle 6631 defined by the angle between the axis of 6690 extending between opposite ends 6609 and 6607 and 6609, through the point. median with respect to axis 6691 extending between 6608 and 6610 tips and by midpoint 6609. First arm and second arm 6603 6604 can be offset from each other as defined by spacing angle 6631 by at least about about 45 degrees, such as at least about 60 degrees, or even at least about 70 degrees. In still other embodiments, the offset angle 6631 can be less than or equal to about 120 degrees, such as not more than about 110 degrees, or up to about 90 degrees. Spacing angle 6631 can be within a range between any of the minimum and maximum observed values.
[0272] In certain cases, body 6601 may be formed such that at least one side surface such as first side surface 6654 may have an arcuate contour. In more particular embodiments, the surface of at least one side may have a concave curvature for at least a part of the length of the entire side surface.
[0273] In yet another embodiment, at least one side surface of the body 6601, such as the first side surface 6654, may have a first portion 6625 and a second section 6626 that can be joined to a midpoint of the surface of the first side. 6627 and the definition of a first interior angle 6628. According to one embodiment, the first interior angle may be greater than about 90 degrees, such as greater than about 95 degrees, more than about 100 degrees, more than about 130 degrees, more than about 160 degrees, more than about 180 degrees, or even greater than about 210 degrees. Also, in a non-limiting embodiment, the first interior angle may not be greater than about 320 degrees, not greater than about 300 degrees, or even not greater than about 270 degrees. The first interior angle may be within a range between each of the aforementioned minimum and maximum values. In addition, the body may include a second interior angle 6629 of the second side surface 6655, a third interior angle 6632 of the third side surface 6656, and a fourth interior angle 6633 on fourth side surface 6657. Each of the interior angles may have the characteristics described with respect to first interior angle 6628. In addition, each and every second side surface 6655, third side surface 6656, and fourth side surface 6657 can have any of the features of the first side surface 6654.
[0274] The body 6601 may have a first arm of 6603 and a third arm of 6605 extending in opposite directions from the center portion 6602 of the body 6601 relative to each other. In addition, second arm 6604 and fourth arm 6606 may extend in opposite directions relative to each other. According to one embodiment, second arm 6604 may have a length, measured from the boundary between central portion 6602 to tip 6608 along axis 6691, which may be substantially the same as a length of fourth arm 6606. in another example, second arm 6604 may have a length that is substantially different than (e.g., shorter or longer than) a length of first arm 6603 or third arm 6605.
[0275] Although the anterior body 6601 of the four-pointed star has been shown to have an upper surface 6640, having a two-dimensional shape, as seen in the plane of the length and width of the body, which is substantially the same as the two-dimensional shape of the base surface 6641 of body 6501, other shapes are contemplated. For example, in one modality, the cross-shape of the body on the base surface can define a base surface shape of the group consisting of a three-pointed star, one four-pointed star, one cross-shaped, a polygon, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, having a combination of polygonal shapes and a combination of complex shapes. In addition, the shape of the cross-section of the body on the upper surface can define a shape of the upper surface, which may be different than the shape of the base surface and selected from the group of a three-pointed star, a four-pointed star. , a cross shape, a polygon, ellipsoids, numbers, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes with a combination of polygonal shapes, and a combination thereof.
[0276] In particular cases, the shape of the top surface may have an arcuate shape in the shape of the base surface. For example, the shape of the top surface can define a four-pointed two-dimensional arcuate shape, where the four-pointed two-dimensional arcuate shape defines arms having rounded ends. In particular, the arms as defined on the base surface may have a smaller radius of curvature at the tip compared to the corresponding radius of curvature at the tip at the upper surface.
[0277] According to a particular aspect, the body can be formed to have limited deformation or warping of the body. For example, the body may have a curl factor (ht/hi) of no more than about 10, where the curl factor is defined as a ratio of the greatest height of the body to the tip of an arm (ht ), compared to a smaller height dimension of the body, inside (hi) (eg inside central part 6602). For example, turning to a side view illustration of a shaped abrasive particle of Fig. 66B, the body 6601 may have an interior height, which represents the smallest height of the particle, as seen from the side. The greatest height (ht) of the body is represented by the distance between the bottom surface (or the bottom surface plane) and the highest point of the 6601 body, as seen from the side, which may be the tip of a curled arm. The shaped abrasive particles of the embodiments herein demonstrate limited deformation, having a winding factor that is no more than about 5, no more than about 3, no more than about 2, and no more than about 1 .8, and not more than about 1.7, and not more than about 1.6, and not more than about 1.5, and not more than about 1.3, and not more than about 1 .2, and not greater than about 1.14, or even less than or equal to about 1.10. Appropriate computer programs, such as ImageJ software, can be used to perform an accurate analysis of the abrasive particle images in order to measure the ripple factor.
[0278] FIG. 67 includes a top-down image of an abrasive particle shape formed in accordance with a particular embodiment. As illustrated, the shape of the 6700 abrasive particles can define a cross-shaped body, as seen in a plane defined by the two dimensions of length and width. In particular, the shape of the abrasive particles 6700 may include a body 6701 having a central portion of 6702 and a first arm of 6703, a second arm of 6704, a third arm of 6705, and a fourth arm 6706 extending therefrom. of central portion 6702. Body 6701 may have a length (l), measured as the longest dimension along one side of the particle and a width (w), and measured as the longest dimension of the particle between two points of opposite arms. and through the midpoint of 6709 the body 6701. The width may extend in a direction perpendicular to the length dimension. The body 6701 may have a height (h) that extends in a direction perpendicular to the upper surface 6710 of the body 6701 that defines a side surface between the upper surface 6710 and the base surface 6711. The body 6701 may have either , or a combination of features described in any of the embodiments of the present invention.
[0279] The body 6701 may have at least one arm, such as the first arm of 6703 which has a center point width 6714, which is substantially the same as a width of the center portion 6712 of the first arm 6703. the length of the arm between points 6715 and 6716, on the axis 6790 define the width of the body 6701 may be less than the width of the first arm 6703. In particular cases, the length may be greater than about 90% of the width, such as not greater than about 80%, not greater than about 70%, not greater than about 60%. Further, in a non-limiting embodiment, the length of the first arm of 6703 may be at least about 10%, such as at least about 20% of the width of the first arm of 6703. The length may have a dimension relative to the width. in the range between any of the maximum and minimum percentages indicated above. Reference to first arm width 6703 may be reference to center portion width 6712 or midpoint width 6714. Either arm of body 6701 may have the same characteristics as first arm 6703.
[0280] FIG. 68 includes a top view image of an abrasive particle shaped in accordance with an embodiment. As shown, the 6800 abrasive particle shape can define a cross-shaped body in general, as seen in a plane defined by both the length and width dimensions. In particular, the shape of abrasive particles 6800 may include a body 6801 having a central portion of 6802 and a first arm of 6803, a second arm of 6804, a third arm of 6805, and a fourth arm of 6806 extending therefrom. of central portion 6802. Body 6801 may have a length (l), measured as the longest dimension along one side of the particle and a width (w), and measured as the longest dimension of the particle between two opposing arm points. and through the midpoint of 6809 the body 6801. The width may extend in a direction perpendicular to the length dimension. Body 6701 may have a height (h) that extends in a direction perpendicular to upper surface 6810 of body 6801 that defines a side surface between upper surface 68 and base surface 6811. Body 6801 may have either , or a combination of the features described in any of the embodiments in this document.
[0281] In the specific embodiment of FIG. 68, the body may have a particular combination of two-dimensional shapes of base surface 6811 and top surface 6810. For example, the body may have a two-dimensional (i.e., cross-sectional) shape of the body on the base surface which defines a shape of the base surface, and a two-dimensional shape of the body for the upper surface which defines a molded upper surface, and in particular, the shape of the base surface may be cross-shaped generally the shape of the top surface may be a rounded quadrilateral shape. The quadrilateral rounded shape can be defined by a top surface 6810 (edges shown by dotted line) which has four sides joined rounded corners, wherein the corners generally correspond to the cross-shaped arms defined by the base surface. Notably, the upper surface cannot define arm parts, separated by a side surface, having at least two surface side sections angled with respect to each other, which are shown by the outline of the cross-shaped base surface shape.
[0282] FIG. 69A includes an illustration of a side view of an abrasive particle shaped in accordance with an embodiment. As illustrated, the shape of the abrasive particles 6900 may include a body 6901 which includes a first layer of 6902 and a second layer 6903 overlies the first layer 6902. In one embodiment, the body 6901 may have layers 6902 and 6903 arranged in a configuration scaled in relation to each other. A level configuration can be characterized by the region of at least one plateau 6920 on an upper surface 6910 of the first layer 6902 between a side surface 6904 of the first layer 6902 and a side surface 6905 of the second layer 6903. The size and shape of the region Plateaus 6920 can be controlled or predetermined by one or more processing parameters and can facilitate better implantation of abrasive particles into an abrasive article and abrasive article performance.
[0283] In one embodiment, the plateau region 6902 may have a lateral distance 6921, which can be defined as the greatest distance between the edge 6907 between the top surface 6910 of the first layer 6902 and a lateral surface 6904 of the first layer to surface side 6905 of the second layer. Lateral distance analysis 6921 can be facilitated by a top view image of the body 6901 as shown in FIG. 69B. As illustrated, lateral distance 6921 may be the greatest distance from plateau region 6902. In one embodiment, lateral distance 6921 may have a length less than the length 6910 of first layer 6902 (i.e., largest layer). In particular, the lateral distance 6921 may not be greater than about 90%, such as no greater than about 80%, no greater than about 70%, no greater than about 60%, no greater than about 50%, not more than about 40%, not more than about 30%, or even not more than about 20% of the length of the first layer 6902 of the body 6901 6910. lateral distance 6921 can have a length that is at least 2%, at least about 5%, at least about 8%, at least about 10%, at least about 20%, at least about 25%, at least about 30%, or even at least about 50% of the length of the first layer 6902 of the body 6901. It will be appreciated that the lateral distance 6921 can have a length in the range between any of the maximum and minimum percentages noted above.
[0284] The second layer 6903 may have a particular length 6909, which is the longest dimension of one side, as shown in FIG. 69B, with respect to a length 6910 of first layer 6902 that can facilitate improved implantation of abrasive particles into an abrasive article and/or abrasive article performance. For example, the length 6909 of second layer 6903 may be less than or equal to about 90%, such as not more than about 80%, not more than about 70%, not more than about 60% , not greater than about 50%, not greater than about 40%, not greater than about 30%, or even not greater than about 20% of the length of 6910 the first layer 6902 of the body 6901. Further, in a non-limiting embodiment, second layer 6903 may have a length of 69,909 which may be at least about 2%, at least about 10%, at least about 20%, at least about 30%, at least about 40%, at least about 50%, at least about 60%, or even at least about 70% of the length of 6910 first layer 6902 of body 6901. It will be appreciated that the length 6909 the second layer 6903 relative to the length 6910 of the first layer 6902 may be within a range between each of the maximum and minimum percentages observed.
[0285] The above in the form of abrasive particles of FIGs. 69A and 69B can be formed using multiple sheets of material, multiple screens, and/or multiple mold blanks. For example, a process might include the use of a first screen, which is completely or partially filled with a mixture of the first screen, and the provision of a second screen, which may be different in size, shape, or orientation from the first screen and the provision of a second mixture within the openings of the second screen. The second screen can be placed over the first screen or over a precursor in the form of abrasive particles formed from the first screen. The second mixture may be provided on top of the abrasive particulate form precursor of the first abrasive particulate form precursor mixture having the stepped and layered configuration. Notably, the openings of the second screen can be smaller than the openings of the first screen. It will be appreciated that the first and second screen may have, but need not necessarily use, different sized apertures, different two-dimensional shapes of apertures and a combination thereof.
[0286] Also, in certain cases, the first ply and second ply can be used at the same time as a composite ply to shape the mixture. In such cases, the screen of the first and second screen may be affixed to each other to facilitate proper and continuous alignment between the openings of the screen of the first and second screen. The second ply may be oriented in the first ply to facilitate alignment between openings in the first ply and openings in the second plies to facilitate proper delivery of the mixture into openings in the first and second ply ply.
[0287] Also, the first and second screen can be used in separate processes. For example, where the first mix is delivered to the first screen a first time, and the second mix is delivered to the second screen a second time. More particularly, the first mixture can be supplied in the openings of the first fabric, and after the first mixture has been formed in the openings of the first fabric, the second mixture can be supplied in the first mixture. Such a process can be conducted while the first mixture is contained in the first openings of the first screen. In another example, the first mixture can be removed from the openings of the first web to create the abrasive particulate precursor of the first mixture. Thereafter, the abrasive particulate precursor of the first mixture can be oriented relative to the openings of the second screen, and the second mixture can be placed in the openings of the second screen and to the abrasive particulate precursor of the first mixture to facilitate the formation of precursor compound in the form of abrasive particles, including mixing the first and second mixtures. The same process can be used with a mold and a screen. Furthermore, the same process can be carried out using first and second molds to form the first and second layers, respectively.
[0288] It will be appreciated that none of the features of the modalities at this point can be attributed to a lot of abrasive particulate form. A batch of shaped abrasive particles can include, but does not necessarily include, a group of shaped abrasive particles made by the same forming process. In another instance, a batch of shaped abrasive particles can be a group of shaped abrasive particles, an abrasive article, such as a fixed abrasive article, and more particularly, a coated abrasive article, which can be independent of a particular formation method, but having one or more defining characteristics present in a particular population of particles. For example, a batch of particles can include an amount of abrasive particles shaped appropriately to form a commercial grade abrasive product, such as at least about 20 lbs of particles.
[0289] In addition, any of the features of the modalities at this point (eg, aspect ratio, multiple parts, number of arms, midpoint width, center part width, two-dimensional shape, wavy factor, etc.) can be a single particle characteristic, a median value of a sample of particles from a batch, or an average value derived from the analysis of a sample of particles from a batch. Unless explicitly stated, the reference at this point to the characteristics may be considered a reference to an average value that is one based on a statistically significant value derived from a random sampling of an adequate number of particles from a batch. Namely, for certain embodiments at this point, the sample size can include at least 10, and more generally, at least 40 randomly selected particles from a batch of particles.
[0290] Any of the features described in the embodiments in this point can represent features that are present at least a part of a batch of abrasive particles. The part can be a minority part (eg less than 50% and any whole number between 1% and 49%) of the total number of particles in a batch, a part of the majority (eg 50% or greater and any integer between 50% and 99%) of the total number of particles in the batch, or even essentially all particles in a batch (eg between 99% and 100%). Providing one or more characteristics of any abrasive particles in the form of a batch can facilitate alternative or improved implantation of the particles in an abrasive article and can further facilitate improving the performance or usability of the abrasive article.
[0291] A batch of particulate material may include a first part including a first type of shaped abrasive particles and a second part including a second type of shaped abrasive particles. The contents of the first part and second part within the batch can be controlled at least in part based on certain processing parameters. Providing a batch that has a first part and a second part can facilitate alternative implementation or improvement of particles in an abrasive article and can further facilitate improving the performance or usability of the abrasive article.
[0292] The first part may include a plurality of shaped abrasive particles, in which each of the particles of the first part may have substantially the same characteristics, including, for example, but not limited to, the same two-dimensional shape of a larger surface. . The batch can include various contents of the first part. For example, the first part may be present in a minority or majority amount. In particular instances, the first part may be present in an amount of at least about 1%, such as at least about 5%, at least about 10%, at least about 20%, at least about 30% , at least about 40%, at least about 50%, at least about 60%, or even at least about 70% of the total content of parts within the batch. In yet another modality, the batch may include no greater than about 99%, such as no greater than about 90%, no greater than about 80%, no greater than about 70%, no greater than that about 60%, not more than about 50%, not more than about 40%, not more than about 30%, not more than 20%, not more than about 10%, not more than about 8%, not more than about 6%, or even not more than about 4% of the total parts within the batch. The batch may include a content of the first part within a range between each of the minimum and maximum percentages noted above.
[0293] The second part of the batch may include a plurality of shaped abrasive particles, in which each of the second part's shaped abrasive particles may have substantially the same function, for example, including, but not limited to, the same two-dimensional shape of a main surface. The second part may have one or more features of the embodiments at this point, which may be distinct compared to the plurality of abrasive particles shaped by the first part. In certain cases, the batch may include a smaller content of the second part relative to the first part, and more particularly, it may include a minority content of the second portion relative to the total content of particles in the batch. For example, the batch may contain a certain content of the second part, including, for example, not more than about 40%, such as not more than about 30%, not more than 20%, not more than about 10%, not more than about 8%, not more than about 6%, or even not more than about 4%. Still, in at least the non-limiting modality, the batch may contain at least about 0.5%, such as at least about 1%, at least about 2%, at least about 3% at least about 4%, at least about 10%, at least about 15%, or even at least about 20% of the second part of the total parts content within the batch. It will be appreciated that the batch may contain a content of the second part within a range between each of the minimum and maximum percentages noted above.
[0294] Still, in an alternative embodiment, the batch may include a higher content of the second part in relation to the first part, and more particularly, may include a content of the majority of the second part of the total content of particles in the batch. For example, in at least one embodiment, the batch may contain at least about 55%, such as at least about 60% of the second part to the total parts of the batch.
[0295] It will be appreciated that the batch may include other parts, including, for example, a third portion comprising a plurality of abrasive particles shaped to have a third characteristic which may be distinct from the particle characteristics of the first and second parts. The batch may include various contents of the third part in relation to the second part and the first part. The third part can be present in a smaller amount or a larger amount. In particular instances, the third part may be present in an amount of not more than about 40%, such as not more than about 30%, not more than 20%, not more than about 10%, not more than about 8 %, not more than about 6%, or even not more than about 4% of the total parcels within the lot. Still, in other embodiments the batch may include a minimum third-part content, such as at least about 1%, such as at least about 5%, at least about 10%, at least about 20%, at least about 30%, at least about 40%, or even at least about 50%. The batch may include a third-party content in the range between any of the above-stated maximum and minimum percentages. In addition, the batch may include a diluent content, randomly, in the form of abrasive particles, which may be present in amounts equal to either part of the embodiments herein. EXAMPLES Example 1
[0296] The mixture in gel form is obtained having about 42% solids loading of boehmite commercially available as Catapal B from Sasol Corp. combined with 58% by weight of water containing a minority content of nitric acid and organic additives. The gel has a viscosity of approximately 3X103 to 4X104 Pa.s and a storage modulus of 3X104 to 2X105 Pa.
[0297] The gel is expelled from a die using a pressure of up to 80 psi (552 kPa) into a blank polycarbonate mold and into a plurality of openings, each opening being shaped like a three-pointed star. . The surfaces of the openings within the blank mold have been coated with canola oil. The openings define three pointed two-dimensional star shapes with a length of approximately 5-7 mm, a width of 3 to 5 mm and a depth of approximately 0.8 mm. The openings have tip angles of approximately 35 degrees and an interior angle between the three arms of approximately 225 degrees.
[0298] The gel is expelled at the openings and the gel is then dried for approximately 24-48 hours in air, under atmospheric conditions and inside the mold in a precursor form in the form of abrasive particles. The abrasive particulate precursors were calcined in a box furnace at around 600 °C for 1 hour and then the abrasive particulate precursors were sintered in a furnace tube above 1320 °C for 3 rd 20 minutes. FIG. 65 A is a representative image of a particle formed in example 1. The body has a ripple factor of minus 5. Example 2
[0299] The process of Example 1 was used with the exception that the blank of the mold used openings defining a four-point star shaped two-dimensionally, with a length of approximately 7-9 mm, a width of 7- 9 mm and a depth of about 0.8 mm. The openings have tip angles of approximately 35 degrees and an interior angle between the three arms of approximately 250 degrees. FIG. 66A is a representative image of a particle formed from example 2. The body has a ripple factor of less than 5. Example 3
[0300] The process of Example 1 was used with the exception that the blank used mold openings define a two-dimensional cross-shaped shape having a length of about 5-6 mm, a width of 5-6 mm, and a depth of about 0.8 mm. The arms are approximately 2 mm wide and approximately 1 mm long. FIG. 67 is a representative image of a particle formed from example 3. The body has a ripple factor of less than 5.
[0301] The present application represents a starting point of the prior art. While the industry has recognized that molded abrasive particles can be formed through processes such as molding and screen printing, the processes of the modalities here are distinct from such processes. Furthermore, the resulting abrasive particles have one or a combination of characteristics distinct from particles formed according to conventional approaches. The shaped abrasive particles of the embodiments at this point may have a particular combination of characteristics distinct from other conventional particles including, but not limited to, part composition, additives, two-dimensional shape, three-dimensional shape, tread configuration, ripple factor, angles of tip, interior angles and the like. Notably, the modalities at this point include a combination of features that facilitate the formation of batches in the form of abrasive particles having specific characteristics. And in fact, one or more features facilitate alternative implantation of the particles in abrasive articles and can further facilitate better performance in the context of fixed abrasives, such as bonded abrasives or coated abrasives.
[0302] The subject matter disclosed above is considered indicative and not restrictive, and the appended claims are intended to cover all such modifications, improvements and other arrangements within the true scope of the present invention. Thus, to the fullest extent permitted by law, the scope of the present invention is determined by the broadest permissible interpretation of the following claims and their equivalents and is not restricted or limited by the description detailed above.
[0303] The summary of disclosure is provided in accordance with patent law and is sent with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Furthermore, in the above detailed description, several features can be grouped or described in a single embodiment for the purpose of simplifying the description. This disclosure is not to be interpreted as reflecting an intention that the modalities require more resources than expressly recited in each claim. Rather, as the following claims reflect, the subject of the invention may be directed to less than all features of any of the disclosed embodiments. Thus, the following claims are incorporated into the detailed description, with each standing claim in its own right separately defining the claimed subject matter.

权利要求:
Claims (10)
[0001]
1. Molded abrasive particle (6500), comprising: a body, having a length (l), a width (w) and a height (h), characterized in that the body comprises a three-pointed star (6501), with a first arm (6503), a second arm (6504), and a third arm (6505) extending from a central portion (6502), and wherein the first arm (6503), second arm (6504) and third arm (6505) define a total angle of less than 180 degrees and where the body comprises a swell factor of not more than 10, where the swell factor is defined as a ratio of the greatest height of the body to a tip of an arm (ht) (6506, 6507, 6508), compared to the smallest dimension of the body height inside (hi)
[0002]
2. Molded abrasive particle according to claim 1, characterized in that at least one of the arms (6503, 6504, 6505) comprises a midpoint width (6513) which is less than the width of the central part (6512).
[0003]
3. Molded abrasive particle according to claim 2, characterized in that the midpoint width (6513) is not greater than 90% of the central width (6512).
[0004]
4. Molded abrasive particle according to claim 2, characterized in that the body comprises a tip width (6514) and wherein the tip width is not greater than 90% of the midpoint width.
[0005]
5. Molded abrasive particle according to claim 1, characterized in that the body further comprises a first side surface (6554) extending between the first arm (6503) and the second arm (6504) and between a base surface ( 6511) and an upper surface (6510) and wherein the first side surface (6554) comprises an arcuate contour.
[0006]
6. Molded abrasive particle according to claim 5, characterized in that the first side surface (6554) comprises a first section (6625) and a second section (6626) joined to an interior angle (6628), wherein the angle interior sets an angle greater than 90 degrees
[0007]
7. Molded abrasive particle according to claim 1, characterized in that the arms (6503, 6504, 6505) extending from the central part (6502) have a smaller radius of curvature on a base surface (6511) compared to with a radius of curvature on an upper surface (6510).
[0008]
8. Molded abrasive particle according to claim 1, characterized in that the first arm (6503) defines an angle of the first arm less than 60 degrees.
[0009]
9. Molded abrasive particle according to claim 1, characterized in that the arms (6503, 6504, 6505) define a total angle of less than 175 degrees.
[0010]
10. Molded abrasive particle according to claim 1, characterized in that the body comprises a lateral surface having a fractured region (6570) crossing at least a portion of an edge defining the base surface (6511).

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同族专利:

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公开号 | 公开日

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EP3705177A1|2020-09-09|

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EP2802436A1|2014-11-19|

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CA2987793A1|2013-07-18|

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CA2860755A1|2013-07-18|

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US10106715B2|2018-10-23|

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US20210395587A1|2021-12-23|

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KR101667943B1|2016-10-20|

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US9771506B2|2017-09-26|

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RU2014131771A|2016-02-27|

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US8753742B2|2014-06-17|

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CA3056658A1|2013-07-18|

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CN104136172B|2017-06-09|

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BR112014017050A2|2017-06-13|

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US20180002584A1|2018-01-04|

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CN104136172A|2014-11-05|

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US20190338173A1|2019-11-07|

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CA2860755C|2018-01-30|

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JP2017031392A|2017-02-09|

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AU2013207946A1|2014-08-07|

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AU2013207946B2|2016-07-07|

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EP2802436A4|2016-04-27|

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BR112014017050A8|2017-07-04|

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US9567505B2|2017-02-14|

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JP2015508444A|2015-03-19|

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EP2802436B1|2019-09-25|

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US20140182217A1|2014-07-03|

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US11142673B2|2021-10-12|

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US10364383B2|2019-07-30|

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US20130236725A1|2013-09-12|

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JP5966019B2|2016-08-10|

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WO2013106597A1|2013-07-18|

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US20170145274A1|2017-05-25|

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US9238768B2|2016-01-19|

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US20210108118A1|2021-04-15|

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US20160090516A1|2016-03-31|

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CA2987793C|2019-11-05|

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JP6235655B2|2017-11-22|

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RU2602581C2|2016-11-20|

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KR20140123058A|2014-10-21|

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US20180237675A1|2018-08-23|

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法律状态:
2018-03-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-09-03| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-08-11| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

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2021-02-23| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-05-11| 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 10/01/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201261584998P| true| 2012-01-10|2012-01-10|

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US61/584,998|2012-01-10|

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PCT/US2013/021065|WO2013106597A1|2012-01-10|2013-01-10|Abrasive particles having complex shapes and methods of forming same|

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