ceramic shaped abrasive particle, plurality of abrasive particles, abrasive article and method for p

专利摘要:
ABRASIVE PARTICLES, METHOD TO PRODUCE ABRASIVE PARTICLES AND ABRASIVE ARTICLES. The present invention deals with shaped abrasive particles of ceramic which include a first surface having a perimeter comprising at least a first and a second edge. A first region of the perimeter includes the second edge and extends inwards and ends at two corners that define a first and a second acute internal angle. The perimeter has a maximum of four corners that define acute internal angles. A second surface is disposed opposite, and is not in contact with, the first surface. A peripheral surface is arranged between the first and second surfaces and connects them. The peripheral surface has a first predetermined shape. Methods for producing the shaped ceramic abrasive particles and abrasive articles including them are also disclosed.
公开号:BR112014024937B1
申请号:R112014024937-7
申请日:2013-03-15
公开日:2021-01-12
发明作者:Negus B. Adefris
申请人:3M Innovative Properties Company；
IPC主号:

专利说明:

Field of invention
[001] The present disclosure relates, in general, to abrasive particles, abrasive articles and methods for producing and using them. Background
[002] In recent years, shaped abrasive particles produced by molding a sol-gel, drying and sintering the dry sun-gel to obtain a ceramic shaped abrasive particle have gained popularity in the abrasive industry. Diamond turning techniques are commonly used to produce suitable molds, specifically those for the production of fine grades of abrasive particles, but have been limited in terms of the mold cavity shapes that can be produced. summary
[003] The present inventor has found that by reducing the angle formed by the peripheral corners of shaped ceramic abrasive particles, improved abrasive properties can be achieved.
[004] Shaped abrasive particles can, in general, outperform randomly crushed abrasive particles. By controlling the abrasive particle shape, it is possible to control the performance resulting from the abrasive article. The inventor found that by producing at least one edge in the form of abrasive particles that extend inward, the adjacent corners are typically sharp, leading to unexpected improvement in abrasion performance.
[005] In one aspect, the present description features a ceramic shaped abrasive particle comprising: a first surface having a perimeter comprising at least first and second edges, wherein a first region of the perimeter comprises the second edge and extends inwards and ends at two corners that define the first and second acute internal angles, and in which the perimeter has, at most, four corners that define the acute internal angles; a second surface opposite the first surface and not in contact with it; and a peripheral surface disposed between the first and the second surfaces and which connects them, in which the peripheral surface comprises a first wall which comes into contact with the perimeter of the first edge, where the peripheral surface comprises a second wall which comes into contact with contact with the perimeter of the second edge and where the peripheral surface has a first predetermined shape.
[006] In another aspect, the present description features a plurality of abrasive particles, wherein the plurality of abrasive particles comprises, on a numerical basis, at least 10, 20, 30, 40, 50, 60, 70, 80, 90 , 95 or even at least 99 percent of the abrasive particles shaped from ceramic in accordance with the present disclosure.
[007] The abrasive particles according to the present disclosure are useful, for example, in the manufacture and use of abrasive articles.
[008] In yet another aspect, the present description features abrasive articles that comprise abrasive particles shaped from ceramic, in accordance with the present description, retained in a binder.
[009] The present inventors have also developed methods that allow the manufacture of shaped abrasive particles of ceramic (including fine grades) according to the present disclosure.
[010] Consequently, in yet another aspect, the present description presents a method for producing shaped abrasive ceramic particles, the method comprising the steps: a) providing a mold that defines a mold cavity, in which the cavity mold has an external opening defined by a perimeter, where the perimeter comprises at least the first and second edges, where a first region of the perimeter comprises the second edge and extends inwards and ends at two corners that define a first and a second internal acute angles, and where the perimeter has a maximum of four corners that define the internal acute angles and where the mold cavity is delimited laterally by a peripheral surface of the mold comprising a first mold wall, which it crosses the perimeter on the first edge and a second mold wall that crosses the perimeter on the second edge; b) positioning a ceramic precursor material within the mold cavity; c) converting the ceramic precursor material positioned within the mold cavity to obtain a shaped precursor particle of ceramic; and d) converting the ceramic shaped precursor particle to the ceramic shaped abrasive particle.
[011] In some embodiments, the method further comprises separating the shaped precursor particles from the mold before step d). In some embodiments, step d) comprises sintering the precursor particle made of ceramic. In some embodiments, step d) comprises the calcination of the shaped precursor particle in ceramic in order to provide a shaped precursor particle in calcined ceramic and the sintering of the shaped precursor particle in calcined ceramic.
[012] The following definitions are applied throughout the specification and the claims.
[013] The term “angle” is defined below, for example, with reference to Figures 6A to 6D.
[014] The term "calcination" refers to the removal of volatile matter (eg, free water) from a ceramic precursor by heating under lower temperature conditions than typically used for sintering.
[015] The term "ceramic abrasive particle" refers to an abrasive particle that comprises ceramic material.
[016] The term “corner” refers to the place, position or angle formed by the meeting of two converging lines or edges. A corner can be sharp, such as a point or an edge. A corner can also be a generally rounded region that connects adjacent lines or faces.
[017] The term "exit angle" refers to a tapering angle, embedded in a wall of a mold cavity so that the opening of the mold cavity is wider than its base. Now referring to Figure 1, which shows a cross section of the mold 100 and mold cavity 105, an outlet angle μ is the angle between the mold base 150 and the mold wall 130. The outlet angle can be varied to change the relative dimensions of the first and second surfaces and the sides of the peripheral surface. In various embodiments of the present description, the exit angle μ can be 90 degrees or in a range of about 95 degrees and about 130 degrees, from about 95 degrees and about 125 degrees, from about 95 degrees and about 120 degrees, from about 95 degrees to about 115 degrees, from about 95 degrees to about 110 degrees, about 95 degrees to about 105 degrees, or about 95 degrees and about 100 degrees. For use in the present invention, the term exit angle also refers to the tapering angle of the walls of a molded body that corresponds to the exit angle of the mold used in its production. For example, an exit angle of the exemplary ceramic shaped abrasive particle 300 in Figure 3 would be the angle between the second surface 370 and the wall 384.
[018] The term "face" refers to a substantially flat surface that can comprise minor imperfections, for example, such as those that arise during manufacture.
[019] The term “internal angle” refers to an angle, within the perimeter, defined by two adjacent edges of the perimeter.
[020] The term "length" refers to the maximum extent of an object over its largest dimension.
[021] The term "main surface" refers to a surface that is larger than at least half of the surfaces of the object to be referenced.
[022] The term “perimeter” refers to a closed contour of a surface, which can be a flat surface or a non-flat surface.
[023] The term "predetermined shape" means that the shape is replicated from a mold cavity used during the production of the ceramic abrasive particle. The term "predetermined shape" excludes random shapes obtained by a mechanical crushing operation.
[024] The term "sintering" refers to a process in which the heating of a ceramic precursor material causes it to undergo a substantial transformation to a corresponding ceramic material.
[025] The term "thickness" refers to the maximum extent of something along an orthogonal dimension in both length and width.
[026] The term "width" refers to the maximum extent of something along a dimension orthogonal to the length.
[027] The characteristics and advantages of the present description will be better understood taking into account the detailed description, as well as the attached claims. Brief description of the drawings
[028] Figure 1 is a schematic cross-sectional edge view of an example mold that shows how to determine an exit angle.
[029] Figure 2 is a schematic perspective view of an abrasive particle shaped from exemplary ceramic according to the present disclosure.
[030] Figure 3 is a schematic perspective view of an abrasive particle shaped from exemplary ceramic according to the present disclosure.
[031] Figure 4 is a schematic perspective view of another abrasive particle shaped from exemplary ceramic according to the present disclosure.
[032] Figures 5A to 5C are schematic top views of other exemplary ceramic shaped abrasive particles in accordance with the present disclosure.
[033] Figures 6A to 6D are schematic top views of various corners showing how to calculate their angle.
[034] Figure 7 is a schematic perspective view in cutout of an exemplary mold useful in the production of abrasive particles shaped from ceramic according to the present disclosure.
[035] Figure 8 is a cross-sectional edge view of an exemplary coated abrasive article in accordance with the present disclosure.
[036] Figure 9 is a perspective view of an abrasive article bonded in accordance with the present disclosure.
[037] Figure 10 is an enlarged side view of a nonwoven abrasive article in accordance with the present disclosure.
[038] Figure 11 is a photomicrograph of SAP1 ceramic shaped abrasive particles.
[039] Figure 12 is a photomicrograph of shaped alumina abrasive particles, prepared according to the disclosure of paragraph [0128] of Publ. Pat. US No. 2010/0146867 (Boden et al.) Using a 98 degree exit angle.
[040] Figures 13 and 14 are plots that compare the cut rate and the cumulative cut of abrasive discs in Example 1 and Comparative Examples A and B.
[041] Figure 15 is a photomicrograph of SAP2 ceramic shaped abrasive particles.
[042] Figure 16 is a photomicrograph of SAP3 ceramic shaped abrasive particles.
[043] Figure 17 is a plot that compares the performance of discs made from particles of Example 1, Example 2, Example 3 and Comparative Example C in 1045 Carbon Steel.
[044] Figure 18 is a plot that compares the performance of the disks of Example 4, Example 5, Example 6 and Comparative Example D when used to abrasion 304 Stainless Steel.
[045] Figure 19 is a plot that compares the performance of the disks of Example 4, Example 5, Example 6 and Comparative Example D.
[046] Figure 20A is a photomicrograph of shaped abrasive particles of SAPB alumina, prepared according to the disclosure of US patent No. 8,142,531 (Adefris et al.).
[047] Figure 20B is a photomicrograph of SAP4 ceramic shaped abrasive particles.
[048] Figure 21 is a graph comparing the performance of the disks in Example 7, Comparative Example E and Comparative Example F.
[049] Figures 22 and 23 are plots that compare the performance of the disks of Example 8 and Comparative Example G when used to abrasion 1045 Carbon Steel and 304 Stainless Steel, respectively.
[050] Although the figures identified above demonstrate various modalities of this disclosure, other modalities are also contemplated; for example, as noted in the discussion. In all cases, the description is presented through representation and not limitation. It should be understood that those skilled in the art may contemplate several other modifications and modalities that are included in the character and scope of the principles of this description. Figures may not be drawn to scale. Similar reference numbers can be used in all figures to denote similar parts. Detailed Description
[051] Now referring to Figure 2, the example shaped ceramic abrasive particle 200 comprises a first surface 210 having perimeter 220. The second surface 270 is opposite, and does not come in contact with the first surface 210. The peripheral surface 280 has a predetermined shape, and is arranged between and connects the first and second main surfaces 210, 270. The perimeter 220 comprises a first and a second edge 230, 232. The peripheral surface 280 comprises a first and a second wall 282, 284 The first and second edges 230, 232 represent, respectively, the intersection of the first and second walls 282, 284 with perimeter 220. The first region 290 of perimeter 220 comprises the first edge 230 and extends inward and ends at first and second corners 250, 252 which define the respective internal acute angles 260, 262.
[052] In some embodiments, a region that extends into a ceramic-shaped abrasive particle according to the present description may have a maximum depth that is at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55 or even 60 percent of the maximum dimension of the shaped ceramic abrasive particle parallel to the maximum depth. For example, a reference is made to Figure 2, which shows a maximum dimension 218 parallel to a maximum depth 215. Similarly, in Figure 3, a maximum dimension 318 is parallel to a maximum depth 315.
[053] In the embodiment shown in Figure 2, the first surface 210 has a first predetermined shape that corresponds to the base of a mold cavity used to form it. However, if the mold with two opposite openings is used (for example, as in the case of a perforated plate), none of the first or second main surfaces can have a predetermined shape, whereas the peripheral surface will have.
[054] In some embodiments, the ceramic shaped abrasive particles according to the present disclosure have a peripheral surface that includes at least three walls. Referring now to Figure 3, the exemplary ceramic shaped abrasive particle 300 comprises the first surface 310 which has the perimeter 320 The perimeter 320 comprises the first, second and third edges 330, 332, 334. The first edge 330 is a monotonic concave curve, while the second and third edges 332, 334 are substantially straight edges. The second surface 370 is opposite the first main surface 310 and does not come into contact with it. The peripheral surface 380 has a predetermined shape and is arranged between the first and second surfaces 310, 370 and connects them. The peripheral surface 380 comprises the first, second and third walls 382, 384, 386. The first, second and third edges 330, 332, 334 represent, respectively, the intersection of the first, second and third walls 382 , 384, 386 with the perimeter The first region 390 of the perimeter 320 comprises the first edge extending inwards 330 and ending at the first and second corners 350, 352 which define the respective first and second acute internal angles 360, 362.
[055] As shown in Figures 2 and 3, the first region of the perimeter may comprise a single curved edge extending inward, however, it is also contemplated that the first region of the perimeter may comprise multiple edges (for example, 2, 3 , 4, 5, 6, 7, 8, 9, 10 edges or more).
[056] Now referring to Figure 4, the exemplary ceramic shaped abrasive particle 400 comprises a first surface 410 which has a perimeter 420. The perimeter 420 comprises the first, second, third and fourth substantially straight edges 430, 432 , 434, 436. The second surface 470 is opposite the first surface 410 and does not come into contact with it. The peripheral surface 480 comprises the first, second, third and fourth walls 482, 484, 486, 488. The peripheral surface 480 has a predetermined shape and is arranged between the first and second main surfaces 410, 470 and connects the same. The first, second, third and fourth edges 430, 432, 434, 436 represent, respectively, the intersection of the first, second, third and fourth walls 482, 484, 486, and 488 with the perimeter 420. The first region 490 of the perimeter 420 comprises the first edge 430 and the fourth edge 436, and extends inward. The first region 490 ends at the first and second corners 450, 452 which define the respective first and second acute internal angles 460, 462.
[057] Figures 3 and 4 represent ceramic shaped abrasive particles that have perimeters that are shaped like an arrowhead. Similarly, in some embodiments, the ceramic-shaped abrasive particles themselves may themselves be arrowhead-shaped.
[058] In some modalities, more than one region and / or perimeter edge may extend inward. For example, now referring to Figure 5A, the exemplary ceramic shaped abrasive particle 500a has a perimeter 520a of a first surface 510a with two inwardly extending regions 590a, 592a formed by edges 530a, 532a where each ends in two among the sharp corners 550a, 552a, 554a. Referring now to Figure 5B, the example ceramic shaped abrasive particle 500 has the perimeter 520b of the first surface 510b with three regions extending inwardly 590b, 592b, 594b formed by the edges 530b, 532b, 534b where each ends in two of the sharp corners 550b, 552b, 554b. Similarly, now referring to Figure 5C, the exemplary ceramic shaped abrasive particle 500c of the first surface 510c has the perimeter 520c with four regions extending inwardly 590c, 592c, 594c, 596c formed by the edges 530c, 532c, 534c , 536c where each ends at two corners 550c, 552c, 554c, 556c that define the internal acute angles (not shown).
[059] By definition, the perimeter of the first main surface, except for any of the regions that extend inward, extends outward. For example, the perimeter may extend outward, except for one, two, three, or four regions that extend inward. The region (s) extending into the perimeter may comprise, for example, simple curved edge (s) (e.g., monotonic curved edge (s) ( s)), or multiple curved or substantially straight edges (for example, linear), or a combination of curved and substantially straight edges.
[060] Typically, the ceramic shaped abrasive particles according to the present disclosure have thicknesses that are substantially less than their length and / or width, although this is not a requirement. For example, the thickness of the shaped ceramic abrasive particle can be less than or equal to one third, one fifth or one tenth of its length and / or width.
[061] Generally, the first and second surfaces are substantially parallel or even parallel; however, this is not a requirement. For example, random deviations due to drying can cause one or both of the first and second main surfaces to not be flat. Similarly, the first and / or second main surface may have parallel grooves formed therein, for example, as described in Publ. Pat. No. 2010/0146867 A1 (Boden et al.).
[062] The abrasive particles formed from ceramic according to the present disclosure comprise ceramic material. In some embodiments, they may consist essentially of ceramic material or even consist of ceramic material, although they may contain non-ceramic phases (for example, as in a glass-ceramic). Examples of suitable ceramic materials include alpha alumina, fused alumina-fused zirconia and fused oxy-nitrides. Additional details regarding sol-gel-derived ceramic materials suitable for use in the shaped ceramic abrasive particles according to the present disclosure can be found in, for example, US Patent No. 4,314,827 (Leitheiser et al.); US patent No. 4,518,397 (Leitheiser et al.); US patent No. 4,623,364 (Cottringer et al.); US patent No. 4,744,802 (Schwabel); US patent No. 4,770,671 (Monroe et al.); US patent No. 4,881,951 (Wood et al.); US patent No. 4,960,441 (Pellow et al.); US patent No. 5,139,978 (Wood); US patent No. 5,201,916 (Berg et al.); US patent No. 5,366,523 (Rowenhorst et al.); US patent No. 5,429,647 (Larmie); US patent No. 5,547,479 (Conwell et al.); US patent No. 5,498,269 (Larmie); US patent No. 5,551,963 (Larmie); US patent No. 5,725,162 (Garg et al.), and US patent No. 6,054,093 (Torre et al.).
[063] In order to facilitate the removal of a mold used to produce them and, typically, to increase performance in abrasion applications, the shaped abrasive particles of ceramic according to the present disclosure can be tapered corresponding to an angle of mold exit, for example, as described in Publ. Pat. US No. 2010/0151196 A1 (Adefris et al.). In other embodiments, the peripheral surface may not taper (that is, it may be vertical) and / or the first and second surfaces may be the same size and shape.
[064] In some embodiments, the internal angles formed between the region extending inward and one or both adjacent ends of the perimeter are smaller than would be the case if the region extending inward were replaced, for example, by a single straight line segment or a convex edge. For example, in the case of an equilateral triangle, all corners have an internal angle of 60 degrees, while for the corresponding shapes that have a concave edge replacing one of the edges of the triangle according to a modality of the present description, the internal angles the two corners adjacent to the region extending inward can be substantially reduced. For example, in the case of generally shaped triangular abrasive ceramic particles, the internal angles can be in a range from 5, 10, 15, 20, 25 or 30 degrees to 35, 40, 45, 50 or 55 degrees or 40 at 55 degrees. In some modalities, the internal angles can be in a range of 35 to 55 degrees, from 40 to 55 degrees, or even from 45 to 55 degrees, although other values are also possible. Similarly, if two (or three) of the triangle's edges are replaced with inner curves that extend inward, the internal angles of their adjacent corners may be in the same range or even smaller. The same trend occurs in the case of perimeters that have four or more edges, although the values of the internal angles may tend to be higher.
[065] In order to measure the internal angle (θ) of a corner of the perimeter, take the angle formed between the tangents (T1, T2) of the respective edges forming the corner at its closest point to the corner, which has not an inflection point has passed after the region that extends inward. In the case of crossing straight edges (for example, as shown in Figure 6A), tangents T1a and T2a have the same slope as the edges themselves and the internal angle can be easily determined. In the case where one or both, or the edges are monotonic curves that extend inward (for example, as shown in Figures 6B and 6C), the tangents (T1b and T2b or T1c and T2c), respectively) can be , similarly, readily determined when approaching the corner along the curved edge (s). However, if the corner is round or otherwise deformed (for example, as shown in Figure 6D), measuring the corner's internal angle can become more problematic. Consequently, in such cases, the tangents T1d and T2d) must be determined by measuring the tangent of each adjacent edge as they approach the inflection points (if present) near the corner, shown as P1 and P2 in Figure 6D .
[066] The ceramic shaped abrasive particles according to the present disclosure are typically used as a plurality of particles which may include the ceramic shaped abrasive particles of the present description, other shaped abrasive particles, and / or crushed abrasive particles. For example, a plurality of abrasive particles according to the present description can comprise, on a numerical basis, at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 95 or even 99 percent, or plus percent of ceramic shaped abrasive particles described herein. Shaped ceramic abrasive particles can have the same nominal size and shape, although in some embodiments, it may be useful to use a combination of sizes and / or shapes.
[067] Typically, the ceramic shaped abrasive particles according to the present disclosure have a relatively small maximum particle size; for example, less than about 1 centimeter (cm), 5 mm (mm), 2 mm, 1 mm to 200 micrometers, 100 micrometers, 50 micrometers, 20 micrometers, 10 micrometers, or even less than 5 micrometers, although they can be other sizes are used.
[068] Any of the abrasive particles referred to in the present disclosure can be sized according to abrasives of specified nominal grade recognized in the industry. Exemplary classification standards recognized by the abrasives industry include those promulgated by ANSI (American National Standards Institute), FEPA (Federation of European Producers of Abrasives), and JIS (Japanese Industrial Standard). Such industrially accepted classification standards include, for example: ANSI 4, ANSI 6, ANSI 8, ANSI 16, ANSI 24, ANSI 30, ANSI 36, ANSI 40, ANSI 50, ANSI 60, ANSI 80, ANSI 100, ANSI 120, ANSI 150, ANSI 180, ANSI 220, ANSI 240, ANSI 280, ANSI 320, ANSI 360, ANSI 400 and ANSI 600; FEPA P8, FEPA P12, FEPA P16, FEPA P24, FEPA P30, FEPA P36, FEPA P40, FEPA P50, FEPA P60, FEPA P80, FEPA P100, FEPA P120, FEPA P150, FEPA P180, FEPA P220, FEPA P320, FEPA P400 , FEPA P500, FEPA P600, FEPA P800, FEPA P1000, and FEPA P1200; and JIS 8, JIS 12, JIS 16, JIS 24, JIS 36, JIS 46, JIS 54, JIS 60, JIS 80, JIS 100, JIS 150, JIS 180, JIS 220, JIS 240, JIS 280, JIS 320, JIS 360, JIS 400, JIS 400, JIS 600, JIS 800, JIS 1000, JIS 1500, JIS 2500, JIS 4000, JIS 6000, JIS 8000, and JIS 10,000. More typically, shaped ceramic abrasive particles are independently sized according to the classification standards for ANSI 60 and 80 or FEPA P60 and P80.
[069] The term “rated, specified, industry-recognized abrasives” also includes selected, specified, industry-recognized grade abrasives. For example, the selected, specified, nominal grade may use US standard test sieves, according to ASTM E-11-09 “Standard Specification for Wire Cloth and Sieves for Testing Purposes”. The ASTM E-11-09 standard prescribes the requirements for the design and construction of test sieves using a woven wire cloth medium mounted on a structure for the classification of materials, according to a designated particle size. A typical designation can be represented as -18 + 20, which means that the shaped ceramic abrasive particles pass through a test sieve that complies with ASTM E11-09 specifications “Standard Specification for Woven Wire Test Sieve Cloth and Test Sieves ”for sieve number 18 and are retained in a test sieve that complies with ASTM E11-09 specifications for sieve number 20. In one embodiment, the shaped ceramic abrasive particles have a particle size of at least 90 percent so that most particles pass through a screen test screen 18 and can be retained in a screen test screen 20, 25, 30, 35, 40, 45 or 50. In various embodiments, the particles Shaped ceramic abrasives can have a rating subjected to nominal screening which comprises: -18 + 20, -20 / + 25, -25 + 30, -30 + 35, -35 + 40, 5 -40 + 45, -45+ 50, -50 + 60, -60 + 70, -70 / + 80, -80 + 100, -100 + 120, -120 + 140, -140 + 170, - 170 + 200, -200 + 230, -230 +270 , -270 + 325, -325 + 400, -400 + 450, -450 + 500, or - 500 + 635.
[070] In some embodiments, shaped ceramic abrasive particles can be produced according to a multi-step process. The process can be carried out using a ceramic precursor dispersion (for example, a dispersion (for example, a sol-gel), which comprises a ceramic precursor material).
[071] Briefly, the method comprises the steps of producing a dispersion of ceramic precursor or seeded or not seeded, which can be converted into a corresponding ceramic (for example, a bohemian sol-gel that can be converted to alpha alumina) ; filling one or more mold cavities with the desired external shape of the shaped abrasive particle with a ceramic precursor dispersion, drying the ceramic precursor dispersion to form precursor shaped ceramic particles; removing the shaped abrasive particles of precursor ceramics from the mold cavities; calcining the precursor ceramic shaped abrasive particles to form calcined precursor ceramic shaped abrasive particles and then sintering the calcined precursor ceramic shaped abrasive particles to form conformed ceramic abrasive particles.
[072] In some embodiments, the calcination step is omitted and the shaped ceramic precursor particles are sintered directly after removal of the mold. In some embodiments, the mold can be made of a sacrificial material (for example, a polyolefin material), which is burned during calcination or sintering, thereby eliminating to separate the precursor ceramic particles during processing.
[073] The process will now be described in more detail in the context of shaped ceramic abrasive particles containing alpha alumina.
[074] The first process step involves providing a seeded or non-seeded dispersion of a ceramic precursor material (ie, a ceramic precursor dispersion), which can be converted into a ceramic material. The ceramic precursor dispersion often comprises a liquid volatile component. In one embodiment, the volatile liquid component is water. The ceramic precursor dispersion must comprise a sufficient amount of liquid so that the viscosity of the abrasive dispersion is low enough to allow the filling of the mold cavities and the replication of the mold surfaces, but not so much liquid as to cause the subsequent removal of the liquid from the mold. mold cavity, making it prohibitively expensive. In one embodiment, the ceramic precursor dispersion comprises 2 to 90 percent by weight of particles that can be converted to ceramic, such as particles of aluminum oxide monohydrate (bohemite) or other precursor to alumina, and at least 10 to 98 percent. percent by weight or 50 to 70 percent by weight or 50 to 60 percent by weight of the volatile component such as water. On the other hand, the dispersion of ceramic precursor in some embodiments, contains 30 to 50 percent, or 40 to 50 percent by weight of solids.
[075] Useful examples for dispersion of ceramic precursor include zirconium oxide sol, vanadium oxide sol, cerium oxide sol, aluminum oxide sol and combinations thereof. Useful aluminum oxide dispersions include, for example, bohemian dispersions and other aluminum oxide hydrate dispersions. Boeite can be prepared by known techniques or can be obtained commercially. Examples of bohemian available for sale include products bearing the trade names "DISPERAL", and "DISPAL", both available from Sasol North America, Inc. or "HIQ-40" available from BASF Corporation. These aluminum oxide monohydrates are relatively pure; that is, they include relatively little or no hydrate phase other than monohydrates, and have a high surface area.
[076] The physical properties of the resulting ceramic shaped abrasive particles will, in general, depend on the type of material used in the dispersion of ceramic precursor. For use in the present invention, a "gel" is a three-dimensional network of solids dispersed in a liquid.
[077] The ceramic precursor dispersion may contain a modifying additive or a modifying additive precursor. The modifying additive can work to improve some desirable properties of the abrasive particles or to increase the effectiveness of the subsequent sintering step. Modification additives or modification additive precursors can be in the form of soluble salts, typically water-soluble salts. They typically consist of a metal-containing compound and can be a precursor to magnesium oxide, zinc, iron, silicon, cobalt, nickel, zirconium, hafnium, chromium, yttrium, praseodymium, samarium, ytterbium, neodymium, lanolin, gadolinium, cerium, dysprosium, erbium, titanium and mixtures thereof. The particular concentrations of these additives that may be present in the dispersion of ceramic precursor can be varied based on skill in the art.
[078] Typically, the introduction of a modifying additive or precursor to a modifying additive will induce the dispersion of ceramic precursor to gel. The dispersion of ceramic precursor can also be induced to gel by applying heat over a period of time to reduce the liquid content in the dispersion through evaporation. The ceramic precursor dispersion may also contain a nucleating agent. Nucleating agents suitable for this description include fine particles of alpha alumina, ferric oxide alpha or its precursor, titanium oxides and titanates, chromium oxides or any other material that will nuclear the transformation. The amount of nucleating agent, if used, must be sufficient to effect the transformation of alpha alumina. The nucleation of such alpha alumina precursor dispersions is disclosed in U.S. Patent No. 4,744,802 (Schwabel).
[079] The peptizing agent can be added to the ceramic precursor dispersion to produce a more stable hydrosol or colloidal ceramic precursor dispersion. Suitable peptizing agents are monoprotic acids or acid compounds such as acetic acid, hydrochloric acid, formic acid and nitric acid. Multiprotic acids can also be used, but they can quickly gel the dispersion of ceramic precursor, making it difficult to handle or introduce additional components to it. Some commercial bohemian sources contain an acidic titration (such as absorbed formic acid or nitric acid) that will assist in the formation of a stable ceramic precursor dispersion.
[080] The dispersion of ceramic precursor can be formed by any suitable means; for example, in the case of a sol-gel alumina, by simply mixing aluminum oxide monohydrate with water containing a peptizing agent or forming an aluminum oxide monohydrate slurry to which the peptizing agent is added.
[081] Foam eliminators or other suitable chemicals can be added to reduce the tendency to bubble or enter air under mixing. Additional chemicals such as wetting agents, alcohols or binding agents can be added if desired.
[082] The second step of the process involves providing a mold that has at least one mold cavity and preferably a plurality of cavities formed on at least one main mold surface.
[083] Now referring to Figure 7, the example mold 700 defines the mold cavity 795. The mold cavity 795 is laterally bounded by the surface of the peripheral mold 780 which comprises a first, second and third mold walls 782, 784, 786. The mold cavity 795 has an outer opening 797 defined by a perimeter 720. The first mold wall 782 crosses the perimeter 720 at the first edge 730 The second mold wall 784 crosses the perimeter 720 at the second edge 732. A the first region 790 of the perimeter 720 extends inward and comprises the first edge 730, which ends at the first and second corners 750, 752, which define the respective first and second acute internal angles 760, 762.
[084] In some embodiments, the mold is formed as a production tool, which can be, for example, a mat, a blade, a continuous mat, a coating cylinder such as a gravure cylinder, a sleeve mounted on a cylinder coating or a dye. In one embodiment, the production tool comprises polymeric material. Examples of suitable polymeric materials include thermoplastics such as polyesters, polycarbonates, polyl (sulfone ether), poly (methyl methacrylate), polyurethanes, polyvinyl chloride, polyolefin, polystyrene, polypropylene, polyethylene or combinations thereof, or heat-hardened materials. In one embodiment, all tools are made of polymeric or thermoplastic material. In another embodiment, the surfaces of the tool in contact with the dispersion of ceramic precursor during washing, such as the surfaces of the plurality of cavities, comprise polymeric or thermoplastic materials and other portions of the tooling can be produced from other materials. A suitable polymeric coating can be applied to a metallic tool to change its surface tension properties as an example.
[085] A polymeric or thermoplastic production tool can be replicated from a metal master tool. The master tool will have a pattern opposite to that desired for the production tool. The master tool can be produced in the same way as the production tool. In one embodiment, the master tool is made of metal, for example, nickel and is turned by diamond. In one embodiment, the master tool is at least partially formed using stereolithography. The polymeric blade material can be heated together with the master tool such that the polymeric material is embossed with the standard master tool by pressing both. A polymeric or thermoplastic material can also be extruded or molded on the master tool and then pressed. The thermoplastic material is cooled to solidify and produce the production tool. If a thermoplastic production tool is used, care must be taken not to generate excessive heat that could distort the thermoplastic production tool, limiting its life. Further information on the design and manufacture of production tools or master tools can be found in US Patent Nos. 5,152,917 (Pieper et al.); 5,435,816 (Spurgeon et al.); 5,672,097 (Hoopman et al.); 5,946,991 (Hoopman et al.); 5,975,987 (Hoopman et al.); and 6,129,540 (Hoopman et al.).
[086] Access to the cavities can take the form of an opening in the top surface or in the bottom surface of the mold. In some cases, the cavities may extend across a thickness of the mold. Alternatively, the cavities can extend only a portion of the thickness of the mold. In one embodiment, the top surface is substantially parallel to the bottom surface of the mold, with the cavities having a substantially uniform depth. At least one edge of the mold, that is, the edge on which the cavities are formed, can remain exposed to the surrounding atmosphere during the stage when the volatile component is removed.
[087] The cavities have a specified three-dimensional shape to produce the shaped abrasive ceramic particles. The depth dimension is equal to the perpendicular distance from the top surface to the lowest point on the bottom surface. The depth of a given cavity can be uniform or can vary over its length and / or width. The cavities of a given mold can be of the same or different shapes.
[088] The third stage of the process involves filling the cavities in the mold with the dispersion of ceramic precursor (for example, by a conventional technique). In some embodiments, a knife cylinder coating application device or vacuum slit die coating application device may be used. A mold release can be used as an aid to remove particles from the mold, if desired. Typical mold release agents include oils such as peanut oil or mineral oil, fish oil, silicones, polytetrafluoroethylene, zinc stearate and graphite. In general, the mold release agent such as peanut oil, in a liquid, such as water or alcohol, is applied to the surfaces of the production tooling in contact with the ceramic precursor dispersion in such a way that between about 0.02 mg / cm2 (0.1 mg / in2) to about 0.5 mg / cm2 (3.0 mg / in2), or between about 0.02 mg / cm2 (0.1 mg / in2) to about 0 , 8 mg / cm2 (5.0 mg / in2) of the mold release agent is present per unit area of the mold when a mold release is desired. In some embodiments, the top surface of the mold is coated with the dispersion of ceramic precursor. The ceramic precursor dispersion can be pumped over the top surface.
[089] Subsequently, a scraper or leveling bar (ie a screed) can be used to force the dispersion of the ceramic precursor completely into the mold cavity. The remaining portion of the ceramic precursor dispersion that does not enter the cavity can be removed from the top surface of the mold and recycled. In some embodiments, a small portion of the ceramic precursor dispersion may remain on the top surface, and in other embodiments, the top surface is substantially free of dispersion. The pressure applied by the scraper or leveling bar is typically less than 0.7 MPa (100 psi), less than 0.3 MPa (50 psi), or even less than 69 kPa (10 psi). In some embodiments, no exposed surface of the ceramic precursor dispersion extends substantially beyond the top surface.
[090] In these modalities, where it is desired to have the exposed surfaces of the cavities, result in substantially flat faces of the shaped ceramic abrasive particles, it may be desirable to fill the cavities (for example, with the use of a set of micro-nozzles) and slowly dry the ceramic precursor dispersion.
[091] The fourth step of the process involves removing the volatile component to dry the dispersion. Desirably, the volatile component is removed by rapid evaporation rates. In some embodiments, the removal of the volatile component through evaporation occurs at temperatures above the boiling point of the volatile component. An upper limit for the drying temperature often depends on the material from which the mold is made. For polypropylene tooling, the temperature must be lower than the melting point of the plastic. In one embodiment, for a water dispersion of between about 40 to 50 percent solids and a polypropylene mold, drying temperatures can be between about 90 ° C to about 165 ° C, or between about 105 ° C to about 150 ° C, or between about 105 ° C to about 120 ° C. Higher temperatures can lead to improved production speeds, but it can also lead to the degradation of the polypropylene matrix tool, limiting its service life as a mold.
[092] The fifth stage of the process involves removing abrasive particles formed from ceramic precursor resulting from the mold cavities. The formatted precursor ceramic particles can be removed from the cavities using the following processes, alone or in combination in the mold: gravity, vibration, ultrasonic vibration, vacuum or pressurized air to remove particles from the mold cavities.
[093] The shaped ceramic precursor particles can additionally be dried out of the mold. If the dispersion of the ceramic precursor is dried to the desired level in the mold, this additional drying step will not be necessary. However, in some cases, it may be more economical to employ this additional drying step in order to minimize the time that the ceramic precursor dispersion remains in the mold. Typically, the shaped ceramic precursor particles will be dried for 10 to 480 minutes, or 120 to 400 minutes, at a temperature of 50 ° C to 160 ° C, or 120 ° C to 150 ° C.
[094] The sixth stage of the process involves the calcination of shaped particles of precursor ceramics. During calcination, essentially all the volatile material is removed and the various components that are present in the dispersion of the ceramic precursor are transformed into metal oxides. Shaped precursor ceramic particles are, in general, heated to a temperature of 400 ° C to 800 ° C, and kept within this temperature range until free water and more than 90 percent by weight of any bound volatile material are removed. In an additional step, it may be desirable to introduce the modifying additive through an impregnation process. A water soluble salt can be introduced by impregnating the pores of the calcined precursor-formatted ceramic particles. Then, the shaped ceramic precursor particles are preheated again. This option is further described in US Patent No. 5,164,348 (Wood).
[095] The seventh stage of the process involves sintering the shaped particles of calcined ceramic precursor to form ceramic particles. Prior to sintering, the shaped calcined precursor ceramic particles are not completely densified and therefore do not contain the desired hardness content to be used as shaped abrasive ceramic particles. Sintering takes place by heating the shaped particles of calcined precursor ceramics to a temperature of 1,000 ° C to 1,650 ° C. The amount of time that the calcined precursor-formatted ceramic particles must be exposed to the sintering temperature to achieve this level of conversion depends on several factors, but is typically from five seconds to 48 hours, typically.
[096] In another mode, the duration for the sintering step is in the range of one minute to 90 minutes. After sintering, the shaped abrasive ceramic particles can have a Vickers hardness of 10 GPa (gigapascals), 16 GPa, 18 GPa, 20 GPa or greater.
[097] Other steps can be used to modify the described process such as, for example, quickly heating the material from the calcination temperature to the sintering temperature, centrifuging the ceramic precursor dispersion to remove sediment and / or residues. In addition, the process can be modified by combining two or more process steps, if desired. The steps of the conventional process that can be used to modify the process of that description are more fully described in patent No. U.S.4.314.827 (Leitheiser).
[098] Shaped ceramic abrasive particles composed of alpha alumina crystallites, magnesium spinel alumina and a rare earth hexagonal aluminate can be prepared using the sol-gel precursor alpha alumina particles according to the methods described, for example, in US patent No. 5,213,591 (Celikkaya et al.) and US patent applications of patent application numbers 2009/0165394 A1 (Culler et al.) and 2009/0169816 A1 (Erickson et al.) . Abrasive alpha alumina particles may contain zirconia as disclosed in US Patent No. 5,551,963 (Larmie). Alternatively, the alpha alumina abrasive particles may have a microstructure or additives, for example, as described in US patent No. 6,277,161 (Castro). More information related to methods for producing shaped abrasive ceramic particles is presented in U.S. Patent Application Patent Application No. 2009/0165394 Al (Culler et al.).
[099] Surface coatings on ceramic shaped abrasive particles can be used to improve adhesion between ceramic shaped abrasive particles and a binder material in abrasive articles, or can be used to assist in electrostatic deposition of ceramic shaped abrasive particles . In one embodiment, surface coatings, as described in US Patent No. 5,352,254 (Celikkaya), can be used in an amount of 0.1 to 2 percent coating surface for the weight of shaped abrasive particle. Such surface coatings are described in US Patent Nos. 5,213,591 (Celikkaya et al.); 5,011,508 (Wald et al.); 1,910,444 (Nicholson); 3,041,156 (Rowse et al.); 5,009,675 (Kunz et al.); 5,085,671 (Martin et al.); 4,997,461 (Markhoff-Matheny et al.); and 5,042,991 (Kunz et al.). Additionally, the surface coating can prevent welding or adhesion of the abrasive particle formed on the top of the abrasive grain (capping). Welding or Adhesion is the term to describe the phenomenon in which metal particles in the workpiece that undergo abrasion become welded to the tops of the shaped abrasive ceramic particles. Surface coatings for performing the above functions are known to those skilled in the art.
[0100] The ceramic shaped abrasive particles of the present description can typically be made using tools (or molds that are replicas of them) cut with the use of diamond tooling that provides a higher characteristic definition than others manufacturing alternatives such as stamping or punching. Typically, cavities on the tool surface have smooth faces that meet along sharp edges, although this is not a requirement. The resulting shaped ceramic abrasive particles have a respective nominal average shape that corresponds to the shape of the cavities on the tool surface; however, variations (for example, random variations) of the nominal average shape may occur during manufacture, and the shaped ceramic abrasive particles that exhibit these variations are included within the definition of shaped ceramic abrasive particles as used here.
[0101] Shaped ceramic abrasive particles are useful, for example, in the construction of abrasive articles, including, for example, agglomerate of abrasive grains, coated abrasive articles (e.g., coated abrasive articles of conventional manufacture and size, coated abrasive articles of slurries and structured abrasive articles), abrasive brushes, non-woven abrasive articles and bonded abrasive articles such as emery, sharpening and grinding stones. In general, abrasive articles comprise a plurality of abrasive particles trapped in a binder.
[0102] Coated abrasive articles generally include a support, abrasive particles, and at least one binder for attaching abrasive particles to the support. The support can be any suitable material, including fabric, polymeric film, fiber, non-woven blanket, paper, combinations thereof, and treated versions of them. Suitable binders include inorganic or organic binders (including thermally curable resins and radiation curable resins). The abrasive particles can be present in one layer, or in two layers of the coated abrasive article.
[0103] An example of a coated abrasive article is shown in Figure 8. Referring to Figure 8, an exemplary coated abrasive article 800 has a support (substrate) 802 and abrasive layer 803. Abrasive layer 803 includes abrasive particles shaped from ceramic 804 attached to a main support surface 802 by the base layer 805 and dimension layer 806. In some cases, an oversizing coating (not shown) is used.
[0104] Bonded abrasive articles typically include a shaped mass of abrasive particles held together by an organic, metallic or vitrified binder. This shaped mass can be, for example, in the form of a wheel, such as an emery wheel or wheel. The diameter of the grinders is typically about 1 cm to more than 1 meter; the diameter of the wheels is about 1 cm to more than 80 cm (more typically 3 cm to about 50 cm). The thickness of the wheel is typically about 0.5 mm to about 5 cm, more typically about 0.5 mm to about 2 cm. The shaped mass can also be in the form, for example, of a hone, a segment, an assembled point, a disc (for example, double disc crusher) or other conventional abrasive shape. Bonded abrasive articles typically comprise from about 3 to 50% by volume of bonding material, about 30 to 90% by volume of abrasive particles (or mixtures of abrasive particles), up to 50% by volume of additives (including grinding aids) ) and up to 70% by volume of pores, based on the total volume of the bonded abrasive article.
[0105] An exemplary emery is shown in Figure 9. With reference to Figure 9, the exemplary emery 900 is shown, which includes the 911 shaped ceramic abrasive particles according to the present disclosure, molded on a wheel and mounted on the part central 912.
[0106] Non-woven abrasive articles typically include a structure of high open porous polymer filaments that have ceramic shaped abrasive particles produced in accordance with the present disclosure distributed throughout the structure and bonded adherent thereto through a organic binder. Examples of filaments include polyester fibers, polyamide fibers and polyamide fibers. An exemplary non-woven abrasive article is shown in Figure 10. Referring to Figure 10, a very enlarged schematic representation of a typical 1000 non-woven abrasive article is shown, comprising an elevated open fibrous mat 1050 as a substrate, on which particles ceramic shaped abrasives produced in accordance with the present disclosure 1052 are adhered by a binder 1054.
[0107] Useful abrasive brushes include those that have a plurality of unitary bristles with a support (see, for example, US patent No. 5,427,595 (Pihl et al.), US patent No. 5,443,906 (Pihl et al. .), US patent No. 5,679,067 (Johnson et al.), and US patent No. 5,903,951 (Ionta et al.)). Desirably, these brushes are produced by injection molding a mixture of polymer and abrasive particles.
[0108] Organic binders suitable for the manufacture of abrasive articles include heat-hardened organic polymers. Examples of suitable heat-cured organic polymers include phenolic resins, urea-formaldehyde resins, melamine-formaldehyde resins, urethane resins, acrylate resins, polyester resins, aminoplastic resins having pendant α, β-unsaturated groups, epoxy resins, acrylated urethane, acrylated epoxies and combinations thereof. The binder and / or abrasive article may also include additives, such as fibers, lubricants, wetting agents, thixotropic materials, surfactants, pigments, dyes, antistatic agents (for example, carbon black, vanadium oxide, or graphite), coupling agents (for example, silanes, titanates or zir-coaluminates), plasticizers, suspending agents. The quantities of these optional additives are selected to provide the desired properties. Coupling agents can optimize adhesion to abrasive particles and / or fillers. The binder chemistry can be thermally cured, cured by radiation or combinations thereof. Additional details on binder chemistry can be found in US Patent No. 4,588,419 (Caul et al.), US Patent No. 4,751,138 (Tumey et al.), And US Patent No. 5,436,063 ( Follett et al.).
[0109] More specifically with regard to vitrified bonded abrasives, glassy bonding materials, which exhibit an amorphous structure and are typically hard, are well known in the art. In some cases, the vitreous bonding material includes crystalline phases. Vitrified, bonded abrasive articles produced in accordance with the present disclosure may be in the form of a wheel (including cutting wheels), hone, mounted points or other conventional abrasive shape. In some embodiments, a vitrified abrasive article produced in accordance with the present disclosure is in the form of an emery.
[0110] Examples of metal oxides that are used to form the glass bonding materials include: silica, silicates, alumina, soda, calcium, potash, titania, iron oxide, zinc oxide, lithium oxide, magnesium oxide, barium , aluminum silicate, borosilicate glass, aluminum and lithium silicate, combinations thereof. Typically, glass bonding materials can be formed from a composition comprising 10 to 100 percent glass frit, although more typically the composition comprises 20 to 80 percent glass frit, or 30 to 70 percent glass fries. The remaining portion of the glass bonding materials can be a non-frying material. Alternatively, the glass bond can be derived from a composition that does not contain fries. Glassy bonding materials are typically matured at temperature (s) in the range of about 700 ° C to about 1,500 ° C, generally in the range of about 800 ° C to about 1,300 ° C, sometimes in the range of about 900 ° C to about 1,200 ° C, or even in a range of about 950 ° C to about 1,100 ° C. The actual temperature at which the bond is matured depends, for example, on the chemistry of the specific bond.
[0111] In some embodiments, vitrified bonding materials include those comprising silica, alumina (desirably at least 10 percent by weight of alumina) and boron (desirably at least 10 percent by weight of boron) . In most cases, the glazed bonding material further comprises alkali metal oxide (s) (eg Na2O and K2O) (in some cases at least 10 percent by weight of metal oxide (s) alkali).
[0112] Binder materials can also contain filler materials or crushing aids, typically in the form of a particulate material. Typically, particulate materials are inorganic materials. Examples of payloads for this disclosure include: metal carbonates (eg, calcium carbonate (eg, chalk, calcite, marl, travertine, marble and limestone), calcium magnesium carbonate, sodium carbonate, magnesium carbonate ), silica (for example, quartz, glass beads, glass bubbles and glass fibers) silicates (for example, talc, clays, (montmorillonite) feldspar, mica, calcium silicate, calcium metasilicate, sodium aluminosilicate, sodium silicate), metal sulphates (eg calcium sulphate, barium sulphate, sodium sulphate, aluminum sodium sulphate, aluminum sulphate), natural plaster, vermiculite, wood flour, aluminum trihydrate, black smoke, metal oxides (eg calcium oxide (lime), aluminum oxide, titanium dioxide) and metal sulfites (eg calcium sulfite).
[0113] In general, the addition of a crushing aid increases the life of the abrasive article. A crushing aid is a material that has a significant effect on the physical and chemical processes of abrasion, which results in improved performance. While not wishing to be limited in theory, it is believed that a crushing aid (s) will (a) decrease the friction between abrasive particles and the abrasive workpiece, (b) prevent the abrasive particles from being capped (that is, preventing the metal particles from being welded to the upper parts of the abrasive particles) or, at least, reducing the tendency of the abrasive particles to be capped, (c) lowering the interface temperature between the abrasive particles and the workpiece, or (d) decrease the crushing forces.
[0114] Crushing aids cover a wide variety of different materials and can be inorganic or organic. Examples of chemical groups of grinding aids include waxes, organic halide compounds, halide salts and metals and their alloys. Organic halide compounds will typically decompose during abrasion and release a halogen acid or a gaseous halide compound. Examples of such materials include chlorinated waxes such as tetrachloronaphthalene, pentachloronaphthalene and polyvinyl chloride. Examples of halide salts include sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluorides, potassium chloride, and magnesium chloride. Examples of metals include tin, lead, bismuth, cobalt, antimony, cadmium, iron and titanium. Other varied crushing aids include sulfur, organic sulfur compounds, graphite and metal sulfides. It is also within the scope of the present disclosure to use a combination of different crushing aids and, in some cases, this can produce a synergistic effect.
[0115] Crushing aids can be particularly useful in coated and bonded abrasive articles. In coated abrasive articles, the crushing aid is typically used in the oversizing coating, which is applied to the surface of the abrasive particles. Sometimes, however, the crushing aid is added to the sizing coating. Typically, the amount of crushing aid incorporated in coated abrasive articles is about 50 to 300 g / m2 (desirably about 80 to 160 g / m2). In vitrified bonded abrasive articles, the crushing aid is typically impregnated in the pores of the article.
[0116] Abrasive articles may contain 100 percent ceramic-shaped abrasive particles produced in accordance with the present disclosure, or mixtures of such abrasive particles with other abrasive particles and / or diluent particles. However, at least about 2 weight percent desirably at least about 5 weight percent and most desirably about 30-100 weight percent of the abrasive particles in the abrasive articles must be ceramic shaped abrasive particles produced accordingly. with the present revelation. In some cases, the abrasive particles produced in accordance with the present disclosure can be mixed with other abrasive particles and / or diluent particles in a ratio between 5 to 75 weight percent about 25 to 75 weight percent about 40 to 60 percent by weight or about 50 to 55 percent by weight (i.e., in equal amounts by weight). Examples of suitable conventional abrasive particles include molten aluminum oxide (including molten white alumina, heat-treated aluminum oxide and brown aluminum oxide), silicon carbide, boron carbide, titanium carbide, diamond, cubic boron nitride, garnet, fused alumina-zirconia, and abrasive particles derived from solgel. In some cases, blends of abrasive particles can result in an abrasive article that exhibits improved grinding performance compared to abrasive articles that comprise 100 percent of either type of abrasive particles.
[0117] Examples of suitable diluent particles include marble, natural plaster, stone, silica, iron oxide, aluminum silicates, glass (including glass bubbles and glass microspheres), alumina bubbles, alumina microspheres and diluent agglomerates.
[0118] Abrasive particles can be uniformly distributed in the abrasive article or concentrated in selected areas or portions of the abrasive article. For example, in a coated abrasive, there may be two layers of abrasive particles. The first layer comprises abrasive particles in addition to the shaped ceramic abrasive particles produced in accordance with the present disclosure, and the second (outermost) layer comprises shaped ceramic abrasive particles produced in accordance with the present disclosure. Similarly in an abrasive, there can be two distinct sections of the grinder. The outermost section may comprise abrasive particles produced in accordance with the present description, while the innermost section does not comprise them. Alternatively, the shaped ceramic abrasive particles produced in accordance with the present disclosure can be evenly distributed throughout the abrasive article.
[0119] More details on coated abrasive articles can be found, for example, in US Patent No. 4,734,104 (Broberg), US Patent No. 4,737,163 (Larkey), US Pat. No. 5,203,884 (Buchanan et al.), US patent No. 5,152,917 (Pieper et al.), US patent No. 5,378,251 (Culler et al.), US patent No. 5,417,726 (Stout et al.), US patent No. 5,436,063 (Follett et al.), US patent No. 5,496,386 (Broberg et al.), US patent No. 5,609,706 (Bento et al.), US patent No. 5,520,711 (Helmin), US Patent No. 5,954,844 (Law et al.), US Patent No. 5,961,674 (Gagliardi et al.), And US Patent No. 5,975,988 (Christianson). More details on bonded abrasive articles can be found, for example, in US Patent No. 4,543,107 (Rue), US Patent No. 4,741,743 (Narayanan et al.), US Patent No. 4,800,685 (Haynes et al. .), US Patent No. 4,898,597 (Hay et al.), US Patent No. 4,997,461 (Markhoff-Matheny et al.), US Patent No. 5,037,453 (Narayanan et al.), US Patent No. 5,110,332 (Narayanan et al.), And US patent no. 5,863,308 (Qi et al.). Further details regarding vitreous bonded abrasives can be found, for example, in US Patent No. 4,543,107 (Rue), US Patent No. 4,898,597 (Hay et al.), US Patent No. 4,997,461 (Markhoff - Matheny et al.), US patent No. 5,094,672 (Giles Jr. et al.), US patent No. 5,118,326 (Sheldon et al.), US patent No. 5,131,926 (Sheldon et al.) , US patent No. 5,203,886 (Sheldon et al.), US patent No. 5,282,875 (Wood et al.), US patent No. 5,738,696 (Wu et al.), and US patent No. 5,863. 308 (Qi). More details on non-woven abrasive articles can be found, for example, in US Patent No. 2,958,593 (Hoover et al.).
[0120] The present disclosure presents a method for abrasion of a surface, the method comprising bringing into contact at least one abrasive particle shaped from ceramic produced in accordance with the present disclosure with a surface of a workpiece; and moving at least one of the ceramic shaped abrasive particles or the surface in contact to abrasion at least a portion of said surface with the abrasive particle. Methods for making abrasion with ceramic shaped abrasive particles produced in accordance with the present disclosure ranging from dredging (i.e., removing high-pressure stock solution) to polishing (for example, polishing medical implants with coated abrasive mats), in that the latter is typically made with finer grades (eg, ANSI 220 and finer) of abrasive particles. Shaped ceramic abrasive particles can also be used in precision abrasion applications, such as grinding cam shafts with vitrified bonded wheels. The size of the abrasive particles used to abrasion a specific application will be evident to those skilled in the art.
[0121] Abrasion with ceramic shaped abrasive particles produced in accordance with the present disclosure can be carried out dry or wet. For wet abrasion, the liquid supplied can be introduced in the form of a light mist to complete the soaking. Examples of commonly used liquids include: water, water-soluble oil, organic lubricant, and emulsions. The liquid can serve to reduce the heat associated with abrasion and / or act as a lubricant. The liquid may contain smaller amounts of additives, such as bactericides, defoamers.
[0122] Shaped ceramic abrasive particles produced in accordance with the present disclosure can be useful, for example, for abrasion of workpieces, such as aluminum metal, carbon steel, mild steel, tool steel, stainless steel, steel hardened, titanium, glass, ceramic, wood, wood-like materials (eg plywood and particleboard), paint, painted surfaces, organic coated surfaces and the like. The force applied during abrasion is typically in the range of about 1 to about 100 kilograms. Selected modalities of the present description
[0123] In embodiment 1, the present description features a ceramic shaped abrasive particle comprising: a first surface having a perimeter comprising at least a first and a second edge, where a first region of the perimeter comprises the second edge and extends inward and ends at two corners that define the first and second acute internal angles, and in which the perimeter has, at most, four corners that define the acute internal angles; a second surface opposite the first surface and not in contact with it; and a peripheral surface disposed between the first and the second surfaces and which connects them, in which the peripheral surface comprises a first wall which comes into contact with the perimeter of the first edge, where the peripheral surface comprises a second wall which comes into contact with contact with the perimeter of the second edge, and in which the peripheral surface has a first predetermined shape.
[0124] In mode 2, the present description presents an abrasive particle shaped from ceramic according to mode 1, in which the second surface has a second predetermined shape.
[0125] In modality 3, the present description presents an abrasive particle shaped from ceramic according to modality 1 or 2, in which the second surface has the same shape as the first surface.
[0126] In modality 4, the present description presents an abrasive particle shaped from ceramic according to any of the modalities 1 to 3, in which the first acute internal angle is in the range of 5 to 55 degrees, inclusive.
[0127] In embodiment 5, the present description presents an abrasive particle shaped from ceramic according to any of embodiments 1 to 4, in which the peripheral surface comprises a third wall which is in contact with the first surface on a third edge, wherein the first region of the perimeter further comprises the third edge and at least one of the second edge or the third edge is substantially straight.
[0128] In embodiment 6, the present description presents an abrasive particle shaped from ceramic according to embodiment 5, in which the first and third edges are substantially straight.
[0129] In embodiment 7, the present description presents an abrasive particle shaped from ceramic according to any of embodiments 4 to 6, in which the peripheral surface consists of the first, second and third walls.
[0130] In embodiment 8, the present description presents an abrasive particle shaped from ceramic according to any of embodiments 4 to 7, in which the peripheral surface additionally comprises a fourth wall that crosses the perimeter on a fourth edge.
[0131] In mode 9, the present description presents an abrasive particle shaped from ceramic according to mode 8, in which the first, second, third and fourth edges extend inwards.
[0132] In modality 10, the present description presents an abrasive particle shaped from ceramic according to any one of modalities 1 to 9, in which the second edge is a monotonic concave curve.
[0133] In embodiment 11, the present description presents a ceramic shaped abrasive particle according to any of the modalities 1 to 10, wherein the ceramic shaped abrasive particle has a thickness that is less than or equal to one third of its width .
[0134] In modality 12, the present description presents an abrasive particle shaped of ceramic according to modality 11, and in which the second acute internal angle is in the range of 5 to 55 degrees, inclusive.
[0135] In embodiment 13, the present description presents a ceramic shaped abrasive particle according to any of the modalities 1 to 12, wherein the ceramic shaped abrasive particle has a length less than or equal to one centimeter.
[0136] In embodiment 14, the present description features a ceramic shaped abrasive particle according to any of embodiments 1 to 13, wherein the ceramic shaped abrasive particles consist essentially of ceramic material.
[0137] In modality 15, the present description presents an abrasive particle shaped of ceramic according to modality 14, in which the ceramic material comprises alpha alumina.
[0138] In embodiment 16, the present description features an abrasive particle shaped from ceramic according to any of embodiments 1 to 15, wherein the first and second surfaces are substantially parallel.
[0139] In embodiment 17, the present description presents a ceramic shaped abrasive particle according to any of embodiments 1 to 16, in which the angular coefficients of the peripheral surface extend inwardly from the first surface towards the second surface .
[0140] In modality 18, the present description presents an abrasive particle shaped from ceramic according to any one of modalities 1 to 17, in which the angular coefficients of the peripheral surface have an exit angle in the range of 92 to 105 degrees, inclusive .
[0141] In embodiment 19, the present description features an abrasive particle shaped from ceramic according to any of embodiments 1 to 18, wherein the first surface is larger than the second surface.
[0142] In modality 20, the present description presents an abrasive particle shaped from ceramic according to any of modalities 1 to 19, in which the first region of the perimeter is a monotonic curve.
[0143] In embodiment 21, the present description features an abrasive particle shaped from ceramic according to any of embodiments 1 to 20, in which the perimeter of the first edge is substantially straight and that of the second edge is curved.
[0144] In embodiment 22, the present description presents an abrasive particle shaped from ceramic according to any of embodiments 1 to 21, in which the perimeter of the first edge is substantially straight and that of the second edge is curved.
[0145] In modality 23, the present description presents an abrasive particle shaped of ceramic according to any one of modalities 1 to 22, in which the perimeter is shaped like an arrowhead.
[0146] In embodiment 24, the present description features a plurality of abrasive particles, wherein the plurality of abrasive particles comprises, on a numerical basis, at least 10 percent of the shaped abrasive particles of ceramic according to any one of the modalities 1 to 23.
[0147] In embodiment 25, the present description features a plurality of abrasive particles, wherein the plurality of abrasive particles comprises, on a numerical basis, at least 30 percent of the abrasive particles shaped from ceramic according to any of the modalities 1 to 23.
[0148] In embodiment 26, the present description features a plurality of abrasive particles, wherein the plurality of abrasive particles comprises, on a numerical basis, at least 50 percent of the abrasive particles shaped from ceramic according to any of the modalities 1 to 23.
[0149] In embodiment 27, the present description features a plurality of abrasive particles, wherein the plurality of abrasive particles comprises, on a numerical basis, at least 70 percent of the abrasive particles shaped from ceramic according to any of the modalities 1 to 23.
[0150] In embodiment 28, the present description presents a plurality of abrasive particles according to any one of embodiments 24 to 27, additionally comprising crushed abrasive particles.
[0151] In embodiment 29, the present description features an abrasive article comprising a plurality of abrasive particles according to any of embodiments 24 to 28 retained in a binder.
[0152] In embodiment 30, the present description presents an abrasive article according to embodiment 29, wherein the abrasive article comprises a bonded abrasive article.
[0153] In embodiment 31, the present description presents an abrasive article according to embodiment 30, wherein the bonded abrasive article comprises a bonded abrasive wheel.
[0154] In embodiment 32, the present description presents an abrasive article according to embodiment 29, wherein the abrasive article comprises a coated abrasive article, the coated abrasive article comprises the plurality of abrasive particles attached to a support that has third and fourth opposite main surfaces.
[0155] In embodiment 33, the present description presents an abrasive article according to embodiment 29, wherein the abrasive article comprises a nonwoven abrasive article, wherein the nonwoven abrasive article comprises the plurality of abrasive particles attached to a mat high open non-woven fiber.
[0156] In modality 34, the present description presents a method for producing shaped abrasive particles of ceramic, the method comprises the steps of: a) providing a mold that defines a mold cavity, in which the mold cavity has an external opening defined by a perimeter, where the perimeter comprises at least the first and second edges, where a first region of the perimeter comprises the second edge and extends inwards and ends at two corners that define first and second acute internal angles , and where the perimeter has a maximum of four corners that define the acute internal angles, and where the mold cavity is delimited laterally by a peripheral surface of the mold comprising a first mold wall, which crosses the perimeter on the first edge and a second mold wall that crosses the perimeter on the second edge; b) positioning a ceramic precursor material within the mold cavity; c) converting the ceramic precursor material positioned within the mold cavity to obtain a shaped precursor particle of ceramic; and d) converting the ceramic shaped precursor particle to the ceramic shaped abrasive particle.
[0157] In modality 35, the present description presents a method according to modality 34, in which the first corner has a first acute internal angle with a value in the range of 5 to 55 degrees, inclusive
[0158] In mode 36, the present description presents a method according to mode 34 or 35, in which the mold comprises an open mold.
[0159] In mode 37, the present description presents a method according to mode 34 or 35, in which the mold additionally comprises a surface of the bottom of the mold in contact with the first and second walls of the mold.
[0160] In embodiment 38, the present description presents a method according to any of embodiments 34 to 37, in which the mold cavity has a depth, and in which the first and second walls tilt inward with depth growing.
[0161] In mode 39, the present description presents a method according to any of modes 34 to 38, wherein the second edge comprises a curved edge.
[0162] In mode 40, the present description presents a method according to any one of modes 34 to 39, in which the first region of the perimeter is a monotonic curve.
[0163] In embodiment 41, the present description presents a method according to any of embodiments 34 to 40, wherein the perimeter comprises at least one substantially straight edge and at least one curved edge.
[0164] In embodiment 42, the present description presents a method according to any of embodiments 34 to 41, wherein the perimeter comprises at least two substantially straight edges and a curved edge.
[0165] In embodiment 43, the present description presents a method according to any of embodiments 34 to 42, in which the perimeter consists of two substantially straight edges and a curved edge.
[0166] In embodiment 44, the present description presents a method according to any of embodiments 34 to 42, in which the peripheral surface of the mold additionally comprises a third wall of the mold, and in which the third wall of the mold crosses the perimeter on a third edge.
[0167] In mode 45, the present description presents a method according to mode 44, in which the third edge extends inwards with respect to the perimeter.
[0168] In modality 46, the present description presents a method according to any of the modalities 34 to 45, in which the perimeter is shaped like an arrowhead.
[0169] In embodiment 47, the present description presents a method according to any of embodiments 34 to 46, wherein the perimeter comprises at least two substantially straight edges.
[0170] In mode 48, the present description presents a method according to mode 47, in which the peripheral surface additionally comprises a fourth mold wall, and in which the fourth mold wall crosses the perimeter on a fourth edge.
[0171] In embodiment 49, the present description presents a method according to any of embodiments 34 to 48, wherein the method further comprises separating the shaped particle of precursor ceramic from the mold before step d).
[0172] In modality 50, the present description presents a method according to modality 49, in which step d) comprises sintering the shaped particle of precursor ceramics.
[0173] In mode 51, the present description presents a method according to mode 49, wherein step d) comprises calcining the precursor ceramic shaped particle to provide a precursor ceramic shaped particle and sintering the precursor ceramic shaped particle calcined.
[0174] In embodiment 52, the present description presents a method according to any of embodiments 34 to 51, wherein the ceramic shaped abrasive particle comprises alpha alumina.
[0175] In embodiment 53, the present description presents a method according to any of embodiments 34 to 52, in which the ceramic precursor material comprises a sol-gel.
[0176] In embodiment 54, the present description presents a method according to any of embodiments 34 to 53, in which the ceramic precursor material comprises an alpha alumina precursor.
[0177] In mode 55, the present description presents a method according to any of modes 34 to 54, in which each mold cavity has a maximum lateral dimension less than or equal to one centimeter.
[0178] In embodiment 56, the present description presents a method according to any of embodiments 34 to 55, wherein each of the shaped ceramic abrasive particles has a thickness that is less than or equal to one third of its width.
[0179] The objectives and advantages of this description are further illustrated by the following non-limiting examples, but the specific materials and proportions of them mentioned in these examples, as well as the other conditions and details, should not be understood as unduly limiting this description. Examples
[0180] Except where otherwise specified, all parts, percentages, ratios, etc., in the examples and the rest of the specification are expressed in weight. Preparation of shaped ceramic abrasive particles
[0181] A sample of bohemian sol-gel was made using the following recipe: aluminum oxide monohydrate powder (1,600 parts) available as DISPERAL from Sasol North America, Inc., was dispersed by mixing high shearing in a solution containing water (2,400 parts) and 70 of aqueous nitric acid (72 parts) for 11 minutes. The resulting sol-gel was aged for at least 1 hour before coating. The sol-gel was forced into production tooling that has shaped mold cavities of dimensions reported in Table 1 (below), where “NA” means not applicable. The SAPA shaped alumina particles were prepared according to the disclosure of paragraph [0128] of Publ. Pat. US No. 2010/0146867 (Boden et al.) Using an exit angle of 98 degrees. The Shaped Ceramic Abrasive Particles of the same general shape and composition as SAPB were prepared according to the disclosure of US patent No. 8,142,531 (Adefris et al.) TABLE 1

[0182] A mold release agent, 1 percent peanut oil in methanol was used with about 0.08 mg / cm2 (0.5 mg / in2) of peanut oil applied to the production tooling that has a mold cavity matrix. The excess methanol was removed by placing the production tooling blades in an air convection oven for 5 minutes at 45 ° C. The sol-gel was introduced into the cavities with the help of a spatula, so that all openings in the production tooling were completely filled. The production tooling coated with sol-gel was placed in an air convection oven at 45 ° C for at least 45 minutes for drying. The abrasive particles formed from precursor ceramics were removed from the production tool by passing it over an ultrasonic horn. The shaped precursor ceramic particles were calcined at approximately 650 ° C and then saturated with a mixed nitrate solution of MgO, Y2O3, CoO, and La2O3.
[0183] All ceramic shaped abrasive particles described in the Examples have been treated to enhance the electrostatic application of ceramic shaped abrasive particles in a similar way to the method used to produce crushed abrasive particles as described in US Patent No. 5,352,254 (Celikkaya ). The shaped abrasive particles of calcined precursor ceramics were impregnated with a rare earth oxide (REO) solution comprising 1.4 percent MgO, 1.7 percent Y2O3, 5.7 percent La2O3 and 0.07 percent CoO. In 70 grams of the REO solution, 1.4 grams of 0.5 micron HYDRAL COAT 5 particle size aluminum trihydroxide powder available from Almatis of Leetsdale, Pennsylvania, USA were dispersed by stirring in an open beaker . About 100 grams of abrasive particles formed from calcined precursor ceramics were then impregnated with the 71.4 grams of HYDRAL COAT 5 powder dispersion in the REO solution. The impregnated, calcined, precursor shaped ceramic abrasive particles were left to dry, after which the particles were again calcined at 650 ° C and sintered at approximately 1,400 ° C until final hardness. Both calcination and sintering were performed using rotary tube furnaces under ambient atmosphere. The resulting composition was an alumina composition containing 1 weight percent MgO, 1.2 weight percent Y2O3, 4 weight percent La2O3 and 0.05 weight percent CoO, with traces of TiO2, SiO2, and CaO. General procedure for the preparation of abrasive discs
[0184] The abrasive articles were prepared from the abrasive particles prepared as described above and the coating compositions shown in Table 2. 17.8 cm (7 inches) in diameter, with fiber discs of 2 mm diameter mandrel holes. , 2 cm (7/8 inches) of a vulcanized fiber support having a thickness of 0.83 mm (33 mils) (obtained as DYNOS VULCANIZED FIBER from DYNOS Gmbh, Troisdorf, Germany) were coated with 3.5 grams / disk of the basic coating composition, electrostatically coated with 15.0 grams / disk of abrasive particles, and then 13.0 grams / disk of the sizing coating composition were applied. All discs that were used to grind stainless steel samples were additionally coated with 10 grams of oversizing coating after partially curing the discs at 90 ° C for 90 minutes. After curing at 102 ° C for 10 hours, the discs were flexed. TABLE 2a

Abrasion test
[0185] The abrasive discs were tested using the following procedure. For evaluation, abrasive discs of 17.8 cm (7 inches) in diameter were attached to a rotary crusher fitted with a face plate of disc block provided with ribs of 17.8 cm (7 inches) 80514 EXTRA HARD RED, obtained with 3M Company, St. Paul, Minnesota, USA. The grinder was then activated and propelled against an end face of a 1.9 x 1.9 cm (0.75 x 0.75 inch) pre-weighed 1045 carbon steel bar (or, alternatively, steel 304) under a load of 53.4 N (12 pounds (4.5 kg)). The rotational speed of the disk block face plate under the condition of loading up against the workpiece was maintained at 5,000 rpm. The workpiece was abraded under these conditions for a total of fifty (50) grinding intervals (cycles) of 10 seconds. After each 10-second cycle, the workpiece was allowed to cool to room temperature and weighed to determine the cut of the abrasive operation. The test results were reported as cut rate, incremental cut and / or accumulated cut as a function of the number of cycles. Example 1 and comparative examples A - B
[0186] Example 1 and Comparative Examples A and B show the effect of abrasive articles comprising the particles of the present disclosure when compared to abrasive articles comprising previously known abrasive particles.
[0187] Example 1 was prepared according to the general procedure for preparing abrasive discs using SAP1 abrasive particles.
[0188] Comparative Example A was a 17.8 cm (7 inch) diameter fiber disk with a 2.2 cm (7/8 inch) hole made with SAPA and is available for sale as “CUBITRON II FIBER DISC 982C, 36+ ”with 3M, Saint Paul, Minnesota, USA.
[0189] Comparative Example B was a 17.8 cm (7 inch) diameter fiber disc with a 2.2 cm (7/8 inch) hole made with 3M Ceramic Abrasive Grain conventionally ground and is available for commercial use like “988C” with 3M, Saint Paul, Minnesota, USA.
[0190] Abrasive discs according to Example 1 and Comparative Examples A and B were tested according to the Abrasion Test. The comparative cut rate and cumulative cut data are shown in Figures 13 and 14, where the coated abrasive from Example 1 exhibited a cut that was at least 60 percent better than Comparative Example A (an abrasive particle made of comparable ceramic with straight edges), and more than twice as good as the comparable crushed ceramic grain of Comparative Example B. Examples 2 to 6 and comparative example C
[0191] Examples 2 to 6 were prepared to compare with Example 1 to demonstrate the effects of changing the angle of intersection created by an edge extending inwardly with another edge.
[0192] Example 2 was prepared in the same way as Example 1 with the exception that the abrasive particles were SAP2 instead of SAP1.
[0193] Example 3 was prepared in the same way as Example 1 with the exception that the abrasive particles were SAP3 instead of SAP1.
[0194] Example 4 was prepared in the same way as Example 1 with the exception that an oversizing coating was applied.
[0195] Example 5 was prepared in the same way as Example 2 with the exception that an oversizing coating was applied.
[0196] Example 6 was prepared in the same way as Example 3 with the exception that an oversizing coating was applied.
[0197] Comparative Example C was prepared in the same way as Example 1, with the exception that the abrasive particles were SAPA instead of SAP1.
[0198] Comparative Example D was prepared in the same way as Comparative Example C, with the exception that an oversizing coating was applied.
[0199] Examples 1, 2 and 3 were tested according to the Abrasion Test. Figure 17 shows the comparison of the performance of discs produced with particles of Example 1, Example 2, Example 3 and Comparative Example C in Carbon Steel 1045. The initial cut rates of all discs produced with particles that have a wall that extends to inside (concave) were larger than discs produced with particles with straight edges. The Example 2 disc performed best. It maintained a higher cut rate throughout the test.
[0200] Figure 18 shows the performance comparison of the blades of Example 4, Example 5, Example 6 and Comparative Example D when used to abrasion 304 Stainless Steel. The initial cut rates of all blades produced with particles that were provided with concavities were superior to those of discs produced with conventional particles. In particular, the disk of Example 6 produced with SAP3 particles had the best performance. It kept the cut rate higher than Comparative Example D, as well as the other Example disks throughout the test. This superior performance can best be demonstrated as a cumulative cut as a function of the number of cycles as shown in Figure 19. Example 7 and comparative example E
[0201] Example 7 and Comparative Example E are abrasive articles that demonstrate the effects of an alternative particle modality of the invention, when compared with similar particles with straight edges, and also with the conventional ground ceramic abrasive grain and is available for commercialization as 321 3M Ceramic Abrasive Grain 321 with 3M, Saint Paul, Minnesota, USA.
[0202] Example 7 was produced in the same way as Example 1 with the exception that SAP4 was replaced by SAP1.
[0203] Comparative Example E was produced in the same way as Example 1 with the exception that SAPB was replaced by SAP1.
[0204] Comparative Example F was produced in the same way as Example 1 with the exception that “3M Ceramic Abrasive Grain 321” (3M, Saint Paul, Minnesota, USA) has been replaced by SAP1.
[0205] Example 7 and Comparative Examples E and F were tested according to the Abrasion Test on 1045 carbon steel. The test results are shown in Figure 21, again showing that including a region that extends inwards ( for example, concave) in the shaped ceramic abrasive particles turns shaped particles of less satisfactory performance into particles with better performance when compared to particles conventionally ground in abrasive disc articles. Example 8 and comparative example G
[0206] Example 8 and Comparative Example G show the effect of abrasive articles comprising yet another embodiment of the particles of the present disclosure when compared to abrasive articles comprising previously known abrasive particles. Example 8 was prepared according to the general procedure for preparing abrasive discs using SAP5 abrasive particles. Comparative Example G was prepared in the same way as Example 1 with the exception that the abrasive particles were SAPC instead of SAP1 and the discs were coated with 2.5 grams / disc of the basic coating composition, electrostatically coated with 5 , 5 grams / disc of abrasive particles, and then 6.0 grams / disc of the sizing coating and 6.0 grams of the oversizing coating composition were applied.
[0207] Example 8 and Comparative Example G were tested according to the Abrasion Test on 1045 carbon steel and 304 stainless steel. Comparative cut rate data are shown in Figure 22 for carbon steel and Figure 23 for stainless steel.
[0208] All patents and publications presented here are incorporated by reference in their entirety. All examples given in this document are to be considered as non-limiting, except where indicated otherwise. Various modifications and alterations to this disclosure can be made by those skilled in the art without departing from the scope and spirit of this disclosure, and it should be understood that this disclosure should not be unduly limited to the illustrative modalities presented here.

权利要求:
Claims (15)
[0001]
1. Shaped abrasive ceramic particle CHARACTERIZED by the fact that it comprises: a first surface having a perimeter comprising at least a first and a second edge, where a first region of the perimeter comprises the second edge and extends inward as a curve monotonic concave and ends at two corners that define the first and the second internal acute angle, where the first internal acute angle is in a range of 35 to 55 degrees, where the second internal acute angle is in the range of 35 to 55 degrees, where the first region of the perimeter has a maximum depth that is at least 5% of the maximum dimension of the ceramic shaped abrasive particle parallel to the maximum depth, and where the perimeter has a maximum of four corners that define the acute internal angles ; a second surface opposite to, which is not in contact with, the first surface; and a peripheral surface disposed between the first and the second surface and which connects them, wherein the peripheral surface comprises a first wall that comes into contact with the perimeter on the first edge, where the peripheral surface comprises a second wall that comes into contact contact with the perimeter on the second edge, and where the peripheral surface has a first predetermined shape.
[0002]
2. Shaped ceramic abrasive particle according to claim 1, CHARACTERIZED by the fact that the shaped ceramic abrasive particle has a thickness that is less than or equal to one third of its width.
[0003]
3. Shaped ceramic abrasive particle according to claim 1 or 2, CHARACTERIZED by the fact that shaped ceramic abrasive particles essentially consist of ceramic material.
[0004]
4. Plurality of abrasive particles CHARACTERIZED by the fact that the plurality of abrasive particles comprises, on a numerical basis, at least 10 percent of the shaped ceramic abrasive particles as defined in any of claims 1 to 3.
[0005]
5. Abrasive article CHARACTERIZED by the fact that it comprises the plurality of abrasive particles, as defined in claim 4, retained in a binder.
[0006]
6. Abrasive article according to claim 5, CHARACTERIZED by the fact that the abrasive article comprises a bonded abrasive article.
[0007]
7. Abrasive article according to claim 6, CHARACTERIZED by the fact that the bonded abrasive article comprises a bonded abrasive wheel.
[0008]
8. Abrasive article according to claim 5, CHARACTERIZED by the fact that the abrasive article comprises a coated abrasive article, the coated abrasive article comprises the plurality of abrasive particles attached to a support that has a third and fourth opposite larger surfaces .
[0009]
9. Abrasive article according to claim 5, CHARACTERIZED by the fact that the abrasive article comprises a non-woven abrasive article, wherein the non-woven abrasive article comprises the plurality of abrasive particles attached to a high open non-woven fiber mat .
[0010]
10. Method for producing shaped abrasive ceramic particles, as defined in claim 1, CHARACTERIZED by the fact that it comprises the steps of: a) providing a mold that defines a mold cavity, in which the mold cavity has a defined external opening perimeter, where the perimeter comprises at least the first and second edges, where a first region of the perimeter comprises the second edge and extends inwards and ends at two corners that define a first and a second acute internal angle, and where the perimeter has a maximum of four corners that define the acute internal angles, and where the mold cavity is laterally connected by a peripheral surface of the mold comprising a first mold wall that crosses the perimeter on the first edge and a second mold wall that crosses the perimeter on the second edge; b) positioning a ceramic precursor material within the mold cavity; c) converting the ceramic precursor material positioned inside the mold cavity into a shaped precursor particle of ceramic; and d) converting the ceramic shaped precursor particle into the ceramic shaped abrasive particle.
[0011]
11. Method, according to claim 10, CHARACTERIZED by the fact that the first corner has a first acute internal angle with a value in the range of 5 to 55 degrees, inclusive.
[0012]
12. Method according to claim 11, CHARACTERIZED by the fact that the method further comprises separating the shaped ceramic precursor particle from the mold before step d).
[0013]
13. Method, according to claim 12, CHARACTERIZED by the fact that step d) comprises sintering the shaped precursor particle of ceramic.
[0014]
14. Method, according to claim 12, CHARACTERIZED by the fact that step d) comprises calcining the shaped precursor particle of ceramics to provide a shaped precursor particle of calcined ceramic, and sintering the shaped precursor particle of calcined ceramic.
[0015]
15. Method according to any one of claims 11 to 14, CHARACTERIZED by the fact that the ceramic shaped abrasive particle comprises alpha alumina.

类似技术:

---

公开号 | 公开日 | 专利标题

---

BR112014024937B1|2021-01-12|ceramic shaped abrasive particle, plurality of abrasive particles, abrasive article and method for producing ceramic shaped abrasive particles

---

JP6640110B2|2020-02-05|Abrasive particles and abrasive articles containing the same

---

JP5774105B2|2015-09-02|Crossed plate molding abrasive particles

---

KR102002194B1|2019-07-19|Bonded abrasive article

---

CA2797096C|2018-07-10|Ceramic shaped abrasive particles, methods of making the same, and abrasive articles containing the same

---

JP5651190B2|2015-01-07|Dual taper shaped abrasive particles

---

BR112015009886B1|2021-06-08|shaped abrasive particles, methods of preparing said particles, abrasive articles including the same and workpiece abrasion method

---

CA2791475C|2018-05-15|Bonded abrasive wheel

---

BRPI0918330A2|2020-08-04|abrasive particles

---

KR20110099736A|2011-09-08|Shaped abrasive particles with a sloping sidewall

---

CN108883520B|2020-11-03|Elongated shaped abrasive particles, methods of making the same, and abrasive articles comprising the same

同族专利:

---

公开号 | 公开日

---

US20150052825A1|2015-02-26|

---

CA2869434C|2021-01-12|

---

EP2834040A4|2016-04-13|

---

KR20150005941A|2015-01-15|

---

WO2013151745A1|2013-10-10|

---

EP2834040A1|2015-02-11|

---

US10301518B2|2019-05-28|

---

EP2834040B1|2021-04-21|

---

JP2015518505A|2015-07-02|

---

MX350057B|2017-08-25|

---

US20170335158A1|2017-11-23|

---

KR102075072B1|2020-02-10|

---

CN104254429A|2014-12-31|

---

MX2014011917A|2014-11-10|

---

RU2621085C2|2017-05-31|

---

RU2014139785A|2016-05-27|

---

US20190233694A1|2019-08-01|

---

US9771504B2|2017-09-26|

---

CN104254429B|2019-06-14|

---

JP6072223B2|2017-02-01|

---

CA2869434A1|2013-10-10|

引用文献:

---

公开号 | 申请日 | 公开日 | 申请人 | 专利标题

---

---

CA743715A|1966-10-04|The Carborundum Company|Manufacture of sintered abrasive grain of geometrical shape and controlled grit size|

---

US1910444A|1931-02-13|1933-05-23|Carborundum Co|Process of making abrasive materials|

---

US3041156A|1959-07-22|1962-06-26|Norton Co|Phenolic resin bonded grinding wheels|

---

US3079243A|1959-10-19|1963-02-26|Norton Co|Abrasive grain|

---

DE1694594C3|1960-01-11|1975-05-28|Minnesota Mining And Manufacturing Co., Saint Paul, Minn. |Cleaning and polishing media|

---

GB986847A|1962-02-07|1965-03-24|Charles Beck Rosenberg Brunswi|Improvements in or relating to abrasives|

---

US3481723A|1965-03-02|1969-12-02|Itt|Abrasive grinding wheel|

---

US3387957A|1966-04-04|1968-06-11|Carborundum Co|Microcrystalline sintered bauxite abrasive grain|

---

US3608050A|1969-09-12|1971-09-21|Union Carbide Corp|Production of single crystal sapphire by carefully controlled cooling from a melt of alumina|

---

US3874856A|1970-02-09|1975-04-01|Ducommun Inc|Porous composite of abrasive particles in a pyrolytic carbon matrix and the method of making it|

---

US3909991A|1970-09-22|1975-10-07|Norton Co|Process for making sintered abrasive grains|

---

US4028453A|1975-10-20|1977-06-07|Lava Crucible Refractories Company|Process for making refractory shapes|

---

US4518397A|1979-06-29|1985-05-21|Minnesota Mining And Manufacturing Company|Articles containing non-fused aluminum oxide-based abrasive mineral|

---

US4314827A|1979-06-29|1982-02-09|Minnesota Mining And Manufacturing Company|Non-fused aluminum oxide-based abrasive mineral|

---

US4588419A|1980-10-08|1986-05-13|Carborundum Abrasives Company|Resin systems for high energy electron curable resin coated webs|

---

JPS6339381B2|1983-06-20|1988-08-04|Shingijutsu Kaihatsu Jigyodan|

---

US4623364A|1984-03-23|1986-11-18|Norton Company|Abrasive material and method for preparing the same|

---

CA1266569A|1984-05-09|1990-03-13|Minnesota Mining And Manufacturing Company|Coated abrasive product incorporating selectivemineral substitution|

---

CA1266568A|1984-05-09|1990-03-13|Minnesota Mining And Manufacturing Company|Coated abrasive product incorporating selectivemineral substitution|

---

US4800685A|1984-05-31|1989-01-31|Minnesota Mining And Manufacturing Company|Alumina bonded abrasive for cast iron|

---

US4543107A|1984-08-08|1985-09-24|Norton Company|Vitrified bonded grinding wheels containing sintered gel aluminous abrasive grits|

---

CA1254238A|1985-04-30|1989-05-16|Alvin P. Gerk|Process for durable sol-gel produced alumina-basedceramics, abrasive grain and abrasive products|

---

US4741743B1|1985-08-19|1992-12-22|Norton Co|

---

US4770671A|1985-12-30|1988-09-13|Minnesota Mining And Manufacturing Company|Abrasive grits formed of ceramic containing oxides of aluminum and yttrium, method of making and using the same and products made therewith|

---

US4751138A|1986-08-11|1988-06-14|Minnesota Mining And Manufacturing Company|Coated abrasive having radiation curable binder|

---

US5431967A|1989-09-05|1995-07-11|Board Of Regents, The University Of Texas System|Selective laser sintering using nanocomposite materials|

---

US4960441A|1987-05-11|1990-10-02|Norton Company|Sintered alumina-zirconia ceramic bodies|

---

AU604899B2|1987-05-27|1991-01-03|Minnesota Mining And Manufacturing Company|Abrasive grits formed of ceramic, impregnation method of making the same and products made therewith|

---

US4881951A|1987-05-27|1989-11-21|Minnesota Mining And Manufacturing Co.|Abrasive grits formed of ceramic containing oxides of aluminum and rare earth metal, method of making and products made therewith|

---

US4954462A|1987-06-05|1990-09-04|Minnesota Mining And Manufacturing Company|Microcrystalline alumina-based ceramic articles|

---

US4848041A|1987-11-23|1989-07-18|Minnesota Mining And Manufacturing Company|Abrasive grains in the shape of platelets|

---

CH675250A5|1988-06-17|1990-09-14|Lonza Ag|

---

US4898597A|1988-08-25|1990-02-06|Norton Company|Frit bonded abrasive wheel|

---

US5011508A|1988-10-14|1991-04-30|Minnesota Mining And Manufacturing Company|Shelling-resistant abrasive grain, a method of making the same, and abrasive products|

---

YU32490A|1989-03-13|1991-10-31|Lonza Ag|Hydrophobic layered grinding particles|

---

US5035723A|1989-04-28|1991-07-30|Norton Company|Bonded abrasive products containing sintered sol gel alumina abrasive filaments|

---

US5009676A|1989-04-28|1991-04-23|Norton Company|Sintered sol gel alumina abrasive filaments|

---

US4997461A|1989-09-11|1991-03-05|Norton Company|Nitrified bonded sol gel sintered aluminous abrasive bodies|

---

US5037453A|1989-09-13|1991-08-06|Norton Company|Abrasive article|

---

US5007943A|1989-11-03|1991-04-16|Norton Company|Sol-gel process alumina abrasive grain blends in coated abrasive material|

---

US5094672A|1990-01-16|1992-03-10|Cincinnati Milacron Inc.|Vitreous bonded sol-gel abrasive grit article|

---

US5049166A|1990-02-27|1991-09-17|Washington Mills Ceramics Corporation|Light weight abrasive tumbling media and method of making same|

---

FI84979C|1990-04-06|1992-02-25|Ahlstroem Oy|FILTER FOR SEPARATION WITH PARTICULAR FREON AND HET GASSTROEM.|

---

US5085671A|1990-05-02|1992-02-04|Minnesota Mining And Manufacturing Company|Method of coating alumina particles with refractory material, abrasive particles made by the method and abrasive products containing the same|

---

US5118326A|1990-05-04|1992-06-02|Norton Company|Vitrified bonded grinding wheel with mixtures of sol gel aluminous abrasives and silicon carbide|

---

US5139978A|1990-07-16|1992-08-18|Minnesota Mining And Manufacturing Company|Impregnation method for transformation of transition alumina to a alpha alumina|

---

US5090968A|1991-01-08|1992-02-25|Norton Company|Process for the manufacture of filamentary abrasive particles|

---

US5378251A|1991-02-06|1995-01-03|Minnesota Mining And Manufacturing Company|Abrasive articles and methods of making and using same|

---

US5152917B1|1991-02-06|1998-01-13|Minnesota Mining & Mfg|Structured abrasive article|

---

US5131926A|1991-03-15|1992-07-21|Norton Company|Vitrified bonded finely milled sol gel aluminous bodies|

---

US5203886A|1991-08-12|1993-04-20|Norton Company|High porosity vitrified bonded grinding wheels|

---

US5316812A|1991-12-20|1994-05-31|Minnesota Mining And Manufacturing Company|Coated abrasive backing|

---

AT176883T|1991-12-20|1999-03-15|Minnesota Mining & Mfg|COVERED SANDING BELT WITH ENDLESS, NON-BANDLESS CARRIER AND MANUFACTURING METHOD|

---

US5282875A|1992-03-18|1994-02-01|Cincinnati Milacron Inc.|High density sol-gel alumina-based abrasive vitreous bonded grinding wheel|

---

TW307801B|1992-03-19|1997-06-11|Minnesota Mining & Mfg|

---

US5203884A|1992-06-04|1993-04-20|Minnesota Mining And Manufacturing Company|Abrasive article having vanadium oxide incorporated therein|

---

RU95105160A|1992-07-23|1997-01-10|Миннесота Майнинг энд Мануфакчуринг Компани |Method of preparing abrasive particles, abrasive articles and articles with abrasive coating|

---

US5201916A|1992-07-23|1993-04-13|Minnesota Mining And Manufacturing Company|Shaped abrasive particles and method of making same|

---

AU672992B2|1992-07-23|1996-10-24|Minnesota Mining And Manufacturing Company|Shaped abrasive particles and method of making same|

---

US5366523A|1992-07-23|1994-11-22|Minnesota Mining And Manufacturing Company|Abrasive article containing shaped abrasive particles|

---

US5304331A|1992-07-23|1994-04-19|Minnesota Mining And Manufacturing Company|Method and apparatus for extruding bingham plastic-type materials|

---

US5213591A|1992-07-28|1993-05-25|Ahmet Celikkaya|Abrasive grain, method of making same and abrasive products|

---

US5312791A|1992-08-21|1994-05-17|Saint Gobain/Norton Industrial Ceramics Corp.|Process for the preparation of ceramic flakes, fibers, and grains from ceramic sols|

---

CA2142466A1|1992-09-25|1994-04-14|Henry A. Larmie|Abrasive grain including rare earth oxide therin|

---

DE69309478T2|1992-09-25|1997-07-10|Minnesota Mining & Mfg|ALUMINUM OXIDE AND ZIRCONIUM OXIDE CONTAINING ABRASIVE GRAIN|

---

WO1994007970A1|1992-09-25|1994-04-14|Minnesota Mining And Manufacturing Company|Method of making abrasive grain containing alumina and ceria|

---

US5435816A|1993-01-14|1995-07-25|Minnesota Mining And Manufacturing Company|Method of making an abrasive article|

---

CA2115889A1|1993-03-18|1994-09-19|David E. Broberg|Coated abrasive article having diluent particles and shaped abrasive particles|

---

US5436063A|1993-04-15|1995-07-25|Minnesota Mining And Manufacturing Company|Coated abrasive article incorporating an energy cured hot melt make coat|

---

US5441549A|1993-04-19|1995-08-15|Minnesota Mining And Manufacturing Company|Abrasive articles comprising a grinding aid dispersed in a polymeric blend binder|

---

EP0720520B1|1993-09-13|1999-07-28|Minnesota Mining And Manufacturing Company|Abrasive article, method of manufacture of same, method of using same for finishing, and a production tool|

---

US5409645A|1993-12-20|1995-04-25|Saint Gobain/Norton Industrial Ceramics Corp.|Molding shaped articles|

---

CA2177702A1|1993-12-28|1995-07-06|Stanley L. Conwell|Alpha alumina-based abrasive grain having an as sintered outer surface|

---

US5443603A|1994-01-11|1995-08-22|Washington Mills Ceramics Corporation|Light weight ceramic abrasive media|

---

EP0739263B1|1994-01-13|1999-04-21|Minnesota Mining And Manufacturing Company|Abrasive article, method of making same, and abrading apparatus|

---

AT240188T|1994-09-30|2003-05-15|Minnesota Mining & Mfg|COATED ABRASIVE OBJECT AND METHOD FOR THE PRODUCTION THEREOF|

---

US6054093A|1994-10-19|2000-04-25|Saint Gobain-Norton Industrial Ceramics Corporation|Screen printing shaped articles|

---

US5725162A|1995-04-05|1998-03-10|Saint Gobain/Norton Industrial Ceramics Corporation|Firing sol-gel alumina particles|

---

US5679067A|1995-04-28|1997-10-21|Minnesota Mining And Manufacturing Company|Molded abrasive brush|

---

US6080215A|1996-08-12|2000-06-27|3M Innovative Properties Company|Abrasive article and method of making such article|

---

US5975987A|1995-10-05|1999-11-02|3M Innovative Properties Company|Method and apparatus for knurling a workpiece, method of molding an article with such workpiece, and such molded article|

---

DE69622734T2|1995-10-20|2003-04-24|Minnesota Mining & Mfg|ABRASIVE WITH INORGANIC METALLIC ORTHOPHOSPHATE|

---

US5903951A|1995-11-16|1999-05-18|Minnesota Mining And Manufacturing Company|Molded brush segment|

---

BR9708934A|1996-05-08|1999-08-03|Minnesota Mining & Mfg|Abrasive abrasive article and process for producing an abrasive article|

---

US5738696A|1996-07-26|1998-04-14|Norton Company|Method for making high permeability grinding wheels|

---

US5776214A|1996-09-18|1998-07-07|Minnesota Mining And Manufacturing Company|Method for making abrasive grain and abrasive articles|

---

US5779743A|1996-09-18|1998-07-14|Minnesota Mining And Manufacturing Company|Method for making abrasive grain and abrasive articles|

---

US6206942B1|1997-01-09|2001-03-27|Minnesota Mining & Manufacturing Company|Method for making abrasive grain using impregnation, and abrasive articles|

---

US5893935A|1997-01-09|1999-04-13|Minnesota Mining And Manufacturing Company|Method for making abrasive grain using impregnation, and abrasive articles|

---

US8062098B2|2000-11-17|2011-11-22|Duescher Wayne O|High speed flat lapping platen|

---

US8256091B2|2000-11-17|2012-09-04|Duescher Wayne O|Equal sized spherical beads|

---

US5946991A|1997-09-03|1999-09-07|3M Innovative Properties Company|Method for knurling a workpiece|

---

US5863308A|1997-10-31|1999-01-26|Norton Company|Low temperature bond for abrasive tools|

---

AU7701498A|1998-01-28|1999-08-16|Minnesota Mining And Manufacturing Company|Method for making abrasive grain using impregnation and abrasive articles|

---

CN1139462C|1998-02-19|2004-02-25|美国3M公司|Adrasive article and method for grinding glass|

---

US6080216A|1998-04-22|2000-06-27|3M Innovative Properties Company|Layered alumina-based abrasive grit, abrasive products, and methods|

---

US6228134B1|1998-04-22|2001-05-08|3M Innovative Properties Company|Extruded alumina-based abrasive grit, abrasive products, and methods|

---

US6019805A|1998-05-01|2000-02-01|Norton Company|Abrasive filaments in coated abrasives|

---

US6053956A|1998-05-19|2000-04-25|3M Innovative Properties Company|Method for making abrasive grain using impregnation and abrasive articles|

---

FR2797638B1|1999-08-20|2001-09-21|Pem Abrasifs Refractaires|ABRASIVE GRAINS FOR GRINDING WHEELS WITH IMPROVED ANCHORING CAPACITY|

---

US6277161B1|1999-09-28|2001-08-21|3M Innovative Properties Company|Abrasive grain, abrasive articles, and methods of making and using the same|

---

US6596041B2|2000-02-02|2003-07-22|3M Innovative Properties Company|Fused AL2O3-MgO-rare earth oxide eutectic abrasive particles, abrasive articles, and methods of making and using the same|

---

AT302094T|2000-05-09|2005-09-15|3M Innovative Properties Co|POROUS GRINDING WITH CERAMIC GRINDING COMPOSITES, METHOD OF PREPARATION AND METHOD OF USE|

---

JP3563017B2|2000-07-19|2004-09-08|ロデール・ニッタ株式会社|Polishing composition, method for producing polishing composition and polishing method|

---

US6776699B2|2000-08-14|2004-08-17|3M Innovative Properties Company|Abrasive pad for CMP|

---

EP1770144A3|2000-10-06|2008-05-07|3M Innovative Properties Company|Agglomerate abrasive grain and a method of making the same|

---

RU2297397C2|2001-08-02|2007-04-20|3М Инновейтив Пропертиз Компани|Glass ceramics|

---

WO2003014251A1|2001-08-09|2003-02-20|Hitachi Maxell, Ltd.|Non-magnetic particles having a plate shape and method for production thereof, abrasive material, polishing article and abrasive fluid comprising such particles|

---

US6833014B2|2002-07-26|2004-12-21|3M Innovative Properties Company|Abrasive product, method of making and using the same, and apparatus for making the same|

---

US7811496B2|2003-02-05|2010-10-12|3M Innovative Properties Company|Methods of making ceramic particles|

---

US7300479B2|2003-09-23|2007-11-27|3M Innovative Properties Company|Compositions for abrasive articles|

---

US20050132655A1|2003-12-18|2005-06-23|3M Innovative Properties Company|Method of making abrasive particles|

---

TW200538237A|2004-04-06|2005-12-01|Kure Norton Co Ltd|Porous vitrified grinding wheel and method for production thereof|

---

US7297402B2|2004-04-15|2007-11-20|Shell Oil Company|Shaped particle having an asymmetrical cross sectional geometry|

---

US7867302B2|2005-02-22|2011-01-11|Saint-Gobain Abrasives, Inc.|Rapid tooling system and methods for manufacturing abrasive articles|

---

US7524345B2|2005-02-22|2009-04-28|Saint-Gobain Abrasives, Inc.|Rapid tooling system and methods for manufacturing abrasive articles|

---

US7875091B2|2005-02-22|2011-01-25|Saint-Gobain Abrasives, Inc.|Rapid tooling system and methods for manufacturing abrasive articles|

---

US20070020457A1|2005-07-21|2007-01-25|3M Innovative Properties Company|Composite particle comprising an abrasive grit|

---

US7556558B2|2005-09-27|2009-07-07|3M Innovative Properties Company|Shape controlled abrasive article and method|

---

DK2125984T3|2007-01-23|2012-04-02|Saint Gobain Abrasives Inc|Coated abrasive products containing aggregates|

---

US20090120009A1|2007-11-08|2009-05-14|Chien-Min Sung|Polycrystalline Grits and Associated Methods|

---

US8123828B2|2007-12-27|2012-02-28|3M Innovative Properties Company|Method of making abrasive shards, shaped abrasive particles with an opening, or dish-shaped abrasive particles|

---

US8034137B2|2007-12-27|2011-10-11|3M Innovative Properties Company|Shaped, fractured abrasive particle, abrasive article using same and method of making|

---

US8142891B2|2008-12-17|2012-03-27|3M Innovative Properties Company|Dish-shaped abrasive particles with a recessed surface|

---

US8142532B2|2008-12-17|2012-03-27|3M Innovative Properties Company|Shaped abrasive particles with an opening|

---

US8142531B2|2008-12-17|2012-03-27|3M Innovative Properties Company|Shaped abrasive particles with a sloping sidewall|

---

BRPI0922318B1|2008-12-17|2020-09-15|3M Innovative Properties Company|ABRASIVE PARTICLES MOLDED WITH GROOVES|

---

US10137556B2|2009-06-22|2018-11-27|3M Innovative Properties Company|Shaped abrasive particles with low roundness factor|

---

WO2011068724A2|2009-12-02|2011-06-09|3M Innovative Properties Company|Method of making a coated abrasive article having shaped abrasive particles and resulting product|

---

KR101863969B1|2009-12-02|2018-06-01|쓰리엠 이노베이티브 프로퍼티즈 컴파니|Dual tapered shaped abrasive particles|

---

JP5559893B2|2009-12-22|2014-07-23|ザプロクターアンドギャンブルカンパニー|Liquid cleaning and / or cleansing composition|

---

US8480772B2|2009-12-22|2013-07-09|3M Innovative Properties Company|Transfer assisted screen printing method of making shaped abrasive particles and the resulting shaped abrasive particles|

---

US9180573B2|2010-03-03|2015-11-10|3M Innovative Properties Company|Bonded abrasive wheel|

---

WO2011139562A2|2010-04-27|2011-11-10|3M Innovative Properties Company|Ceramic shaped abrasive particles, methods of making the same, and abrasive articles containing the same|

---

US8551577B2|2010-05-25|2013-10-08|3M Innovative Properties Company|Layered particle electrostatic deposition process for making a coated abrasive article|

---

US8765327B2|2010-07-12|2014-07-01|3M Innovative Properties Company|Fuel cell electrodes with conduction networks|

---

JP5774105B2|2010-08-04|2015-09-02|スリーエム イノベイティブ プロパティズ カンパニー|Crossed plate molding abrasive particles|

---

CN104726063B|2010-11-01|2018-01-12|3M创新有限公司|Shaped ceramic abrasive particle and forming ceramic precursors particle|

---

BR112013009469B1|2010-11-01|2020-08-25|3M Innovative Properties Company|abrasive particles with shape and production method|

---

PL2658680T3|2010-12-31|2021-05-31|Saint-Gobain Ceramics & Plastics, Inc.|Abrasive articles comprising abrasive particles having particular shapes and methods of forming such articles|

---

US8771801B2|2011-02-16|2014-07-08|3M Innovative Properties Company|Electrostatic abrasive particle coating apparatus and method|

---

WO2012112305A2|2011-02-16|2012-08-23|3M Innovative Properties Company|Coated abrasive article having rotationally aligned formed ceramic abrasive particles and method of making|

---

EP2697416B1|2011-04-14|2017-05-10|3M Innovative Properties Company|Nonwoven abrasive article containing elastomer bound agglomerates of shaped abrasive grain|

---

CN103619308A|2011-06-20|2014-03-05|宝洁公司|Personal care compositions comprising shaped abrasive particles|

---

EP2731922A2|2011-07-12|2014-05-21|3M Innovative Properties Company|Method of making ceramic shaped abrasive particles, sol-gel composition, and ceramic shaped abrasive particles|

---

EP2753457B1|2011-09-07|2016-09-21|3M Innovative Properties Company|Method of abrading a workpiece|

---

EP3590657A1|2011-09-07|2020-01-08|3M Innovative Properties Company|Bonded abrasive article|

---

JP6099660B2|2011-11-09|2017-03-22|スリーエム イノベイティブ プロパティズ カンパニー|Compound polishing wheel|

---

US8753742B2|2012-01-10|2014-06-17|Saint-Gobain Ceramics & Plastics, Inc.|Abrasive particles having complex shapes and methods of forming same|

---

JP6550335B2|2012-10-31|2019-07-24|スリーエム イノベイティブ プロパティズ カンパニー|Shaped abrasive particles, method of making the same, and abrasive articles comprising the same|PL2658680T3|2010-12-31|2021-05-31|Saint-Gobain Ceramics & Plastics, Inc.|Abrasive articles comprising abrasive particles having particular shapes and methods of forming such articles|

---

US8840694B2|2011-06-30|2014-09-23|Saint-Gobain Ceramics & Plastics, Inc.|Liquid phase sintered silicon carbide abrasive particles|

---

CN108262695A|2011-06-30|2018-07-10|圣戈本陶瓷及塑料股份有限公司|Include the abrasive product of silicon nitride abrasive grain|

---

EP2760639B1|2011-09-26|2021-01-13|Saint-Gobain Ceramics & Plastics, Inc.|Abrasive articles including abrasive particulate materials, coated abrasives using the abrasive particulate materials and methods of forming|

---

JP5903502B2|2011-12-30|2016-04-13|サン−ゴバン セラミックス アンド プラスティクス，インコーポレイティド|Particle material with shaped abrasive particles|

---

KR20170018102A|2011-12-30|2017-02-15|생-고뱅 세라믹스 앤드 플라스틱스, 인코포레이티드|Shaped abrasive particle and method of forming same|

---

CN104114664B|2011-12-30|2016-06-15|圣戈本陶瓷及塑料股份有限公司|Form molding abrasive grains|

---

US8840696B2|2012-01-10|2014-09-23|Saint-Gobain Ceramics & Plastics, Inc.|Abrasive particles having particular shapes and methods of forming such particles|

---

US8753742B2|2012-01-10|2014-06-17|Saint-Gobain Ceramics & Plastics, Inc.|Abrasive particles having complex shapes and methods of forming same|

---

US9242346B2|2012-03-30|2016-01-26|Saint-Gobain Abrasives, Inc.|Abrasive products having fibrillated fibers|

---

JP6219557B2|2012-05-16|2017-10-25|スリーエム イノベイティブ プロパティズ カンパニー|Decorative sheet and structure|

---

KR101888347B1|2012-05-23|2018-08-16|생-고뱅 세라믹스 앤드 플라스틱스, 인코포레이티드|Shaped abrasive particles and methods of forming same|

---

US10106714B2|2012-06-29|2018-10-23|Saint-Gobain Ceramics & Plastics, Inc.|Abrasive particles having particular shapes and methods of forming such particles|

---

US9440332B2|2012-10-15|2016-09-13|Saint-Gobain Abrasives, Inc.|Abrasive particles having particular shapes and methods of forming such particles|

---

EP2938459B1|2012-12-31|2021-06-16|Saint-Gobain Ceramics & Plastics, Inc.|Particulate materials and methods of forming same|

---

US9457453B2|2013-03-29|2016-10-04|Saint-Gobain Abrasives, Inc./Saint-Gobain Abrasifs|Abrasive particles having particular shapes and methods of forming such particles|

---

TW201502263A|2013-06-28|2015-01-16|Saint Gobain Ceramics|Abrasive article including shaped abrasive particles|

---

JP2016538149A|2013-09-30|2016-12-08|サン−ゴバン セラミックス アンド プラスティクス，インコーポレイティド|Shaped abrasive particles and method for forming shaped abrasive particles|

---

EP3089851B1|2013-12-31|2019-02-06|Saint-Gobain Abrasives, Inc.|Abrasive article including shaped abrasive particles|

---

US9771507B2|2014-01-31|2017-09-26|Saint-Gobain Ceramics & Plastics, Inc.|Shaped abrasive particle including dopant material and method of forming same|

---

CA2945493C|2014-04-14|2020-08-04|Saint-Gobain Ceramics & Plastics, Inc.|Abrasive article including shaped abrasive particles|

---

EP3131706A4|2014-04-14|2017-12-06|Saint-Gobain Ceramics and Plastics, Inc.|Abrasive article including shaped abrasive particles|

---

EP3134227B1|2014-04-21|2019-09-11|3M Innovative Properties Company|Abrasive particles and abrasive articles including the same|

---

US9902045B2|2014-05-30|2018-02-27|Saint-Gobain Abrasives, Inc.|Method of using an abrasive article including shaped abrasive particles|

---

ES2798323T3|2014-06-18|2020-12-10|Klingspor Ag|Multilayer abrasive particle|

---

US9707529B2|2014-12-23|2017-07-18|Saint-Gobain Ceramics & Plastics, Inc.|Composite shaped abrasive particles and method of forming same|

---

US9914864B2|2014-12-23|2018-03-13|Saint-Gobain Ceramics & Plastics, Inc.|Shaped abrasive particles and method of forming same|

---

US9676981B2|2014-12-24|2017-06-13|Saint-Gobain Ceramics & Plastics, Inc.|Shaped abrasive particle fractions and method of forming same|

---

EP3277459A4|2015-03-31|2018-11-14|Saint-Gobain Abrasives, Inc.|Fixed abrasive articles and methods of forming same|

---

TWI634200B|2015-03-31|2018-09-01|聖高拜磨料有限公司|Fixed abrasive articles and methods of forming same|

---

BR112017022200A2|2015-04-14|2018-07-03|3M Innovative Properties Co|non-woven abrasive article and method of manufacture|

---

CA3118239A1|2015-06-11|2016-12-15|Saint-Gobain Ceramics & Plastics, Inc.|Abrasive article including shaped abrasive particles|

---

KR20180069079A|2015-11-13|2018-06-22|쓰리엠 이노베이티브 프로퍼티즈 컴파니|Bonded abrasive article and method of making same|

---

EP3374098A4|2015-11-13|2019-07-17|3M Innovative Properties Company|Method of shape sorting crushed abrasive particles|

---

CN105837184B|2016-03-24|2018-10-26|湖州华通研磨制造有限公司|Extra heavy magnalium pottery grinding stone|

---

CN105837179B|2016-03-24|2018-05-25|湖州华通研磨制造有限公司|A kind of silica-alumina ceramic matter grinding stone and preparation method thereof|

---

EP3436217B1|2016-04-01|2022-02-23|3M Innovative Properties Company|Elongate shaped abrasive particles, and methods of making the same|

---

US10988648B2|2016-09-21|2021-04-27|3M Innovative Properties Company|Elongated abrasive particle with enhanced retention features|

---

EP3519134A4|2016-09-29|2020-05-27|Saint-Gobain Abrasives, Inc.|Fixed abrasive articles and methods of forming same|

---

CN109890931B|2016-10-25|2021-03-16|3M创新有限公司|Magnetizable abrasive particles and abrasive articles comprising magnetizable abrasive particles|

---

EP3532246A1|2016-10-25|2019-09-04|3M Innovative Properties Company|Shaped vitrified abrasive agglomerate with shaped abrasive particles, abrasive articles, and related methods|

---

US10563105B2|2017-01-31|2020-02-18|Saint-Gobain Ceramics & Plastics, Inc.|Abrasive article including shaped abrasive particles|

---

US10759024B2|2017-01-31|2020-09-01|Saint-Gobain Ceramics & Plastics, Inc.|Abrasive article including shaped abrasive particles|

---

US20200140733A1|2017-06-13|2020-05-07|3M Innovative Properties Company|Abrasive particles|

---

CN110719946A|2017-06-21|2020-01-21|圣戈本陶瓷及塑料股份有限公司|Particulate material and method of forming the same|

---

WO2019069157A1|2017-10-02|2019-04-11|3M Innovative Properties Company|Elongated abrasive particles, method of making the same, and abrasive articles containing the same|

---

US20190284460A1|2018-03-13|2019-09-19|Saint-Gobain Ceramics & Plastics, Inc.|Particulate material and method for forming same|

---

CN109127009B|2018-08-31|2021-02-02|贺州市骏鑫矿产品有限责任公司|Ball mill for grinding potash-sodalite|

---

CN109290893A|2018-12-05|2019-02-01|马鞍山迪斯福工业设计有限公司|A kind of timber deburring device|

---

CN109760473B|2019-01-25|2021-11-05|泰州神舟传动科技有限公司|Waterproof hub|

---

WO2021152444A1|2020-01-31|2021-08-05|3M Innovative Properties Company|Coated abrasive articles|

---

WO2021161129A1|2020-02-10|2021-08-19|3M Innovative Properties Company|Coated abrasive article and method of making the same|

---

WO2021245494A1|2020-06-04|2021-12-09|3M Innovative Properties Company|Shaped abrasive particles and methods of manufacture the same|

---

WO2022003498A1|2020-06-30|2022-01-06|3M Innovative Properties Company|Coated abrasive articles and methods of making and using the same|

---

WO2022023879A1|2020-07-28|2022-02-03|3M Innovative Properties Company|Coated abrasive article and method of making the same|

---

WO2022023845A1|2020-07-30|2022-02-03|3M Innovative Properties Company|Abrasive article and method of making the same|

---

WO2022034397A1|2020-08-10|2022-02-17|3M Innovative Properties Company|Abrasive system and method of using the same|

---

WO2022034443A1|2020-08-10|2022-02-17|3M Innovative Properties Company|Abrasive articles and method of making the same|

法律状态:
2018-03-27| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|

---

2019-09-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|

---

2020-07-07| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application according art. 36 industrial patent law|

---

2020-11-10| B09A| Decision: intention to grant|

---

2021-01-12| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 15/03/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

---

申请号 | 申请日 | 专利标题

---

US201261620224P| true| 2012-04-04|2012-04-04|

---

US61/620.224|2012-04-04|

---

PCT/US2013/031972|WO2013151745A1|2012-04-04|2013-03-15|Abrasive particles, method of making abrasive particles, and abrasive articles|

---