ABRASIVE PARTICLES HAVING PARTICULAR FORMATS AND METHODS FOR FORMING SUCH PARTICLES

专利摘要:
abrasive particles having particular shapes and methods for forming such particles. an abrasive article comprising a first group that includes a plurality of molded abrasive particles coating a backing, wherein the plurality of molded abrasive particles of the first group define a first distribution without shadowing one another.
公开号:BR112015008144B1
申请号:R112015008144-4
申请日:2013-10-15
公开日:2022-01-04
发明作者:Anuj Seth；Doruk O. Yener；Jennifer H. Czerepinski；Sujatha Iyengar；Anthony C. Gaeta；Christopher Arcona；Frank J. Csillag；William C. Rice；Satyalakshmi K. Ramesh；Gregory G. Lafond；Sidath S. Wijesooriya；Adam D. Lior；Alan J. Brandes；Anil Parmar；Paul Braun；Darrell K. Everts
申请人:Saint-Gobain Abrasives, Inc.；Saint-Gobain Abrasifs；
IPC主号:

专利说明:

Disclosure Field
[1] The following disclosure concerns abrasive articles and, particularly, methods for forming abrasive articles. Description of Related Technique
[2] Abrasive particles and abrasive articles made from abrasive particles are useful for various material removal operations, including grinding, finishing and polishing. Depending on the type of abrasive material, such abrasive particles can be useful in molding or grinding a wide variety of materials and surfaces in the manufacture of goods. Certain types of abrasive particles have been formulated to date that have particular geometries, such as triangle-shaped abrasive particles or articles incorporating such objects. See, for example, Pat. US No. 5,201,916; 5,366,523; and 5,984,988.
[3] Some basic technologies that have been employed to produce abrasive particles with a specific shape are (1) melting, (2) sintering, and (3) chemical ceramics. In the melting process, the abrasive particle may be molded by a cooling cylinder, the face of which may or may not be etched, a mold into which the molten material is poured, or a heat sink material immersed in a molten mass of aluminum oxide. See, for example, Pat. US No. 3,377,660, which discloses a process comprising the steps of flowing a molten abrasive material from a furnace to a cooled rotating molding cylinder, rapidly solidifying the material to form a thin, semi-solid curved sheet, densifying the semi-solid material with a pressure roller, and then partially fracturing the strip of semi-solid material by reversing its curvature by pulling it away from the cylinder rapidly propelling a cooled transmitter.
[4] In the sintering process, abrasive particles can be formed from refractory powder having a particle size of 45 micrometers or less in diameter. Binders can be added to the powder together with a lubricant and a suitable solvent, eg water. The resulting mixtures or slurries can be molded into slabs or rods of various sizes and diameters. See, for example, Pat. US No. 3,079,242, which discloses a method of producing abrasive particles from calcined brauxite material, comprising the steps of (1) reducing the material to a fine powder, (2) compacting under affirmative pressure and forming fine particles of the said powder into grain-sized agglomerates, and (3) synthesizing the particle agglomerates at a temperature below the melting temperature of the brauxite to induce limited recrystallization of the particles, whereby abrasive grains are produced directly to size.
[5] Chemical ceramic technology involves converting a colloidal disperser or hydrosol (sometimes called a sol), optionally in a mixture, with solutions of other metal oxide precursors, to a gel, drying, and firing to obtain a ceramic material. See, for example, Pat. US Nos. 4,744,802 and 4,848,041.
[6] There still remains a need in the industry to improve the performance, life and effectiveness of abrasive particles, and abrasive articles that use abrasive particles. ABSTRACT
[7] According to a first aspect, an abrasive article includes a backing, an adhesive layer covering the backing, a first molded abrasive particle coupled to the backing in a first position, a second molded abrasive particle coupled to the backing in a second position , and wherein the first molded abrasive particle and the second molded abrasive particle are arranged in a controlled, non-shading arrangement with respect to each other, the controlled, non-shading arrangement comprising at least two of a predetermined rotating orientation, a predetermined lateral orientation and a predetermined longitudinal orientation.
[8] According to a first aspect, an abrasive article includes a backing, an adhesive layer overlying the backing, a first group comprising a plurality of molded abrasive particles coupled to the backing, wherein each of the plurality of molded abrasive particles of the backing the first group shares at least one of a predetermined rotational orientation, a predetermined lateral orientation and a predetermined longitudinal orientation, and a second group comprising a plurality of molded abrasive particles distinct from the first group and coupled to the support, wherein each of the plurality of molded abrasive particles of the second group shares at least one of a predetermined rotational orientation, a predetermined lateral orientation and a predetermined longitudinal orientation.
[9] For another aspect, an abrasive article includes a backing, and a first group comprising a plurality of molded abrasive particles coupled to the backing in a discontinuous layer, the plurality of molded abrasive particles arranged in a shadowless arrangement with respect to each other. , and defining the same rotational orientation, the same lateral orientation, the same lateral orientation space, the same longitudinal orientation and the same longitudinal orientation space.
[10] In one aspect, an abrasive article includes a first group that includes a plurality of molded abrasive particles coating a backing, wherein the plurality of molded abrasive particles of the first group define a first pattern relative to one another.
[11] For yet another aspect, an abrasive article includes a backing and a first group having a plurality of molded abrasive particles coupled to the backing in a discontinuous layer, the plurality of molded abrasive particles of the first group defined by a combination of at least two of the same predetermined swivel orientation, the same predetermined lateral orientation, the same predetermined longitudinal orientation, the same predetermined vertical height and the same predetermined tip height.
[12] In one aspect, an abrasive article includes a plurality of molded abrasive particles of a first group overlying a backing, wherein the plurality of molded abrasive particles of the first group define a shadowless arrangement relative to each other, and in that at least about 80% of a total content of the molded abrasive particles are arranged in a lateral orientation relative to the support.
[13] In one aspect, a method of forming an abrasive article includes providing a support, placing a first molded abrasive particle on the support in a first position defined by at least two of a predetermined rotating orientation, a lateral orientation, predetermined and a predetermined longitudinal orientation, and placing a second molded abrasive particle on the support in a second position defined by at least two of the predetermined swivel orientations, a predetermined lateral orientation, a predetermined longitudinal orientation . BRIEF DESCRIPTION OF THE FIGURES
[14] The present disclosure may be better understood, and its numerous features and advantages will become apparent to those skilled in the art by referring to the accompanying figures.
[15] FIG. 1A includes a top view illustration of a portion of an abrasive article in accordance with one embodiment.
[16] FIG. 1B includes a cross-sectional illustration of a portion of an abrasive article in accordance with one embodiment.
[17] FIG. 1C includes a cross-sectional illustration of a portion of an abrasive article in accordance with one embodiment.
[18] FIG. 1D includes a cross-sectional illustration of a portion of an abrasive article in accordance with one embodiment.
[19] FIG. 2A includes a top view illustration of a portion of an abrasive article including abrasive particles molded in accordance with one embodiment.
[20] FIG. 2B includes a perspective view of an abrasive particle molded into an abrasive article in accordance with one embodiment.
[21] FIG. 3A includes a top view illustration of a portion of an abrasive article in accordance with one embodiment.
[22] FIG. 3B includes a perspective view illustration of a portion of an abrasive article including molded abrasive particles having predetermined orientation characteristics with respect to a grinding direction in accordance with one embodiment.
[23] FIG. 4 includes a top view illustration of a portion of an abrasive article in accordance with one embodiment.
[24] FIG. 5 includes a top view illustration of a portion of an abrasive article in accordance with one embodiment.
[25] FIG. 6 includes a top view illustration of a portion of an abrasive article in accordance with one embodiment.
[26] FIG. 7A includes a top view illustration of a portion of an abrasive article in accordance with one embodiment.
[27] FIG. 7B includes a perspective view illustration of a portion of an abrasive article in accordance with one embodiment.
[28] FIG. 7C includes a top view illustration of an unshaded array being formed over a portion of an abrasive article which is provided in accordance with one embodiment.
[29] FIG. 7D includes an image of a portion of an abrasive article having a shadowless array of molded abrasive particles in accordance with one embodiment.
[30] FIG. 8A includes a perspective view illustration of a molded abrasive particle in accordance with one embodiment.
[31] FIG. 8B includes a cross-sectional illustration of the molded abrasive particle of FIG. 8A.
[32] FIG. 8C includes an illustration of a perspective view of a molded abrasive particle in accordance with one embodiment.
[33] FIG. 9 includes an illustration of a part of an alignment structure according to one embodiment.
[34] FIG. 10 includes an illustration of a portion of an alignment structure according to one embodiment.
[35] FIG. 11 includes an illustration of a part of an alignment structure according to one embodiment.
[36] FIG. 12 includes an illustration of a portion of an alignment structure according to one embodiment.
[37] FIG. 13 includes an illustration of a portion of an alignment structure including discrete contact regions comprising an adhesive in accordance with an embodiment.
[38] FIGs. 14A-14H include complete views of parts of tools for forming abrasive articles having various patterned alignment structures including discrete contact regions of an adhesive material in accordance with embodiments herein.
[39] FIG. 15 includes an illustration of a system for forming an abrasive article according to one embodiment.
[40] FIG. 16 includes an illustration of a system for forming an abrasive article according to one embodiment.
[41] FIGs. 17A-17C include illustrations of systems for forming an abrasive article according to one embodiment.
[42] FIG. 18 includes an illustration of a system for forming an abrasive article according to one embodiment.
[43] FIG. 19 includes an illustration of a system for forming an abrasive article according to one embodiment.
[44] FIG. 20A includes an image of a tool used to form an abrasive article in accordance with one embodiment.
[45] FIG. 20B includes an image of a tool used to form an abrasive article in accordance with one embodiment.
[46] FIG. 20C includes an image of a part of an abrasive article in accordance with one embodiment.
[47] FIG. 21 includes a plot of normal force (N) versus cut number for Sample A and Sample B according to the grinding test of Example 1.
[48] FIG. 22 includes an image of a portion of an exemplary sample in accordance with an embodiment.
[49] FIG. 23 includes an image of a portion of a conventional sample.
[50] FIG. 24 includes a graphical representation of top grains/cm2 and total number of grains/cm2 for two conventional samples and three representative samples of embodiments.
[51] FIGs. 25-27 include illustrations of graphical representations of the locations of abrasive particles molded into a backing to form shadowless arrangements in accordance with embodiments.
[52] FIG. 28 includes an illustration of a graphical representation of the locations of abrasive particles molded into a backing to form shadowless arrangements in accordance with one embodiment.
[53] FIG. 29 includes an image of a conventional sample having a shaded array of abrasive particles molded onto the support.
[54] FIG. 30 includes an image of a portion of a floor surface using a sample representing an embodiment.
[55] FIG. 31 includes an image of a portion of a floor surface using a sample representing a conventional embodiment. DETAILED DESCRIPTION
[56] The following description is directed to methods for forming molded abrasive particles, characteristics of molded abrasive particles, methods of forming abrasive articles using molded abrasive article, and characteristics of abrasive articles. The molded abrasive particles can be used in various abrasive articles, including, for example, bonded abrasive articles, coated abrasive articles, and the like. In some examples, the abrasive articles of the embodiments herein may be coated abrasive articles defined by a single layer of abrasive grains, and more especially a single discontinuous layer of molded abrasive particles, which may be bonded or coupled to a support and used to remove parts material. Notably, the molded abrasive particles can be placed in a controlled manner so that the molded abrasive particles define a predetermined distribution relative to each other. METHODS FOR FORMATION OF MOLDED ABRASIVE PARTICLES
[57] Various methods can be employed to form shaped abrasive particles. For example, molded abrasive particles can be formed using techniques such as extrusion, molding, screen printing, laminating, melting, pressing, casting, segmenting, partitioning, and a combination of these techniques. In certain examples, the molded abrasive particles may be formed from a mixture which may include a ceramic material and a liquid. In specific examples, the mixture may be a gel formed of a powdered ceramic material and a liquid, wherein the gel may be characterized as a shape-stable material having the ability to substantially hold a given shape even in its state. (ie not fired) green. In one embodiment, the gel can be formed of a ceramic powder material as an integrated network of discrete particles.
[58] The mixture may contain a certain content of solid material, liquid material, and additives, such that it is suitable to have rheological characteristics for the formation of molded abrasive particles. That is, in certain instances, the mixture may have a certain viscosity, and more particularly, suitable rheological characteristics that facilitate the formation of a dimensionally stable stage of the material. A dimensionally stable material phase is a material that can be formed to have a particular shape and substantially maintain the shape such that the shape is present in the final formed object.
[59] According to a specific embodiment, the mixture may be formed to have a specific content of solid materials, such as ceramic powder material. For example, in one embodiment, the blend may have a solids content of at least 25% by weight, such as 35% by weight, or even at least 38% by weight, for the total weight of the blend. Further, in at least one non-limiting embodiment, the solids content of the mixture can be no greater than about 75% by weight, such as no greater than about 70%, no greater than about 65% by weight, no greater than about 55% by weight, not more than about 45% by weight, and not more than about 42% by weight. It will be contemplated that the content of the solids materials in the mixture may be within a range between any of the minimum and maximum percentages mentioned above.
[60] In one embodiment, the ceramic powder material can be an oxide, a nitrile, a carbide, a boride, an oxycarbon, an oxynitride, and a combination thereof. In particular cases, the ceramic material may include alumina. But specifically, the ceramic material may include boehmite material, which may be an alpha alumina precursor. The term "boehmite" is generally used in this document to denote alumina hydrates, including boehmite mineral, typically being Al2O3*H2O and having a water content of the order of 15%, as well as pseudoboehmite, having a water content of greater than 15% , such as 20-38% by weight. Note that boehmite (including pseudoboehmite) has a specific and identifiable crystal structure and unique X-ray diffraction pattern and as such is distinct from other aluminous materials including other hydrated aluminas such as ATH (aluminum trihydroxide) from a common precursor material used in this document for the manufacture of boehmite particulate materials.
[61] In addition, the mixture can be formed to have a particular content of liquid material. Some suitable liquids may include water. In one embodiment, the mixture may be formed to have a liquid content less than the solid content of the mixture. In more specific instances, the mixture may have a liquid content of at least 25% by weight, for example, at least about 35% by weight, at least about 45% by weight, at least about 50% by weight , or even at least about 58% by weight of the total weight of the mixture. Further, in at least one non-limiting embodiment, the net content of the mixture may be no greater than about 75% by weight, no greater than about 70%, no greater than about 65% by weight, no greater than about of 62% by weight, and even not greater than about 60% by weight. It will be contemplated that the content of liquid in the mixture may be within a range between any of the minimum and maximum percentages noted above.
[62] Also, for certain processes, the mixture may have a specific storage module. For example, the blend may have a storage modulus of at least about 1x104 Pa, such as at least about 4x104 Pa, or at least about 5x104 Pa. However, in at least one non-limiting embodiment, the blend may have a storage module of not greater than about 1x107 Pa, such as not greater than about 2x106 Pa. It will be contemplated that the storage module of the mixture 101 may be within a range between any of the minimum and maximum values mentioned above.
[63] The storage module can be measured via a parallel plate system using ARES or ARG2 rotational rheometers, with a Peltier plate temperature control system. For testing, the mixture can be extruded into a gap between the two plates that are approximately 8 mm apart. After extruding the gel into the gap, the distance between the two plates, which defines the gap, is reduced to 2 mm, until the mixture completely fills the gap between the plates. After cleaning the excess mixture, the gap is reduced by 0.1 mm and the test is started. The test is an oscillation strain scan test conducted with instrument settings a strain range between 01% to 100% at 6.28 rad/s (1 Hz) using a 25-mm parallel plate and recording 10 points per decade. Within 1 hour after completing the inside, lower the gap again by 0.1 mm and repeat the test. The test can be repeated up to 6 times. The first test may differ from the second and third test. Only the results of the second and third tests for each specimen should be reported.
[64] In addition, to facilitate processing and formation of the molded abrasive particles in accordance with the embodiments herein, the mixture may have a particular viscosity. For example, the mixture may have a viscosity of at least about 4x103 Pa s, at least about 5x103 Pa s, at least about 6x103 Pa s, at least about 8x 103 Pa s, at least about 10x103 Pa s , at least about 20x103 Pa s, at least about 30x103 Pa s, at least about 40x103 Pa s, at least about 50x103 Pa s, at least about 60x103 Pa s, at least about 65x103 Pa s. In at least one non-limiting embodiment, the mixture may have a viscosity of not greater than about 100x103 Pa s, not greater than about 95x103 Pas, not greater than about 90x103 Pa s, or even not greater than about 85x103 Pa s . It will be contemplated that the viscosity of the mixture may be within a range between any of the minimum and maximum values mentioned above. Viscosity can be measured in the same way as the storage module as described above.
[65] In addition, the mixture may be formed to have a particular content of organic materials, including, for example, organic additives which may be distinct from the liquid, to facilitate the formation and processing of the molded abrasive particles in accordance with the embodiments herein. document. Some suitable organic additives may include stabilizers, binders, such as fructose, sucrose, lactose, glucose, UV curable resins, and the like.
[66] Notably, the embodiments in this document may utilize a mixture that may be distinct from the slurries used in conventional forming operations. For example, the content of organic materials within the blend, particularly any of the organic additives noted above, may be a minor amount compared to other components within the blend. In at least one embodiment, the blend can be formed to have no more than about 30% by weight of organic material for the total weight of the blend. In other instances, the amount of organic materials may be less, such as not more than about 15% by weight, not more than about 10% by weight, or even not more than about 5% by weight. In a non-limiting embodiment, the amount of organic material within the mixture can be at least about 0.01% by weight, such as at least about 0.5% by weight for a total weight of the mixture. It will be contemplated that the amount of organic materials in the mixture may be within a range between any of the minimum or maximum values noted above.
[67] In addition, the mixture can be formed to have a particular content of acids or bases other than the liquid, to facilitate the formation and processing of the molded abrasive particles in accordance with the embodiments herein. Some suitable acids or bases may include nitric acid, sulfuric acid, citric acid, chloric acid, tartaric acid, phosphoric acid, ammonium nitrate, ammonium citrate. In a particular embodiment, the mixture may have a pH of less than about 5, and more particularly, within a range of between about 2 and about 4, using a nitric acid additive.
[68] According to a specific forming method, the mixture can be used to form molded abrasive particles through a screen printing process. Generally, a set printing process may include extrusion of the mixture from a die into openings of a screen in an application zone. A combination of substrates including a web having openings and a belt underlying the web can be translated under the die and the mixture can be delivered into openings in the web. The mixture contained in the openings can later be extracted from the screen openings and contained in the belt. The molded parts resulting from the mixing may be precursor molded abrasive particles.
[69] According to one embodiment, the screen may have one or more apertures having a predetermined two-dimensional shape that can facilitate the formation of molded abrasive particles having substantially the same two-dimensional shape. It will be contemplated that there may be characteristics of the molded abrasive particles that cannot be replicated by the shape of the aperture. According to one embodiment, the opening can have various shapes, for example, a polygon, an ellipsoid, a numeral, a letter of the Greek alphabet, a letter of the Latin alphabet, a character of the Russian alphabet, a kanji character, a shape complex including a combination of polygonal shapes and a combination thereof. In particular cases, openings may have two-dimensional polygonal shapes, such as a triangle, a rectangle, a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, a nonagon, a decagon, and a combination thereof.
[70] Notably, the mixture can be forced through the screen in a rapid manner, such that the average residence time of the mixture with the openings can be less than about 2 minutes, less than about 1 minute, less than about 40 seconds, or even less than about 20 seconds. In particular non-limiting embodiments, the blend may be substantially unchanged during printing as it passes through the screen openings, thus undergoing no change in the amount of components of the original blend, and may undergo no appreciable drying at the screen openings.
[71] Belt and/or fabric can be translated at a particular rate to facilitate processing. For example, the belt and/or screen can be translated at a rate of at least 3 cm/sec. In other embodiments, the belt and/or web translation rate may be greater, such as at least about 4 cm/sec, at least about 6 cm/sec, at least about 8 cm/sec, or up to at least about 6 cm/sec. minus about 10 cm/sec For certain processes in accordance with embodiments herein, the rate of translation of the belt, as compared to the rate of extrusion of the mixture, can be controlled to facilitate proper processing.
[72] Certain processing parameters can be controlled to facilitate characteristics of the precursor molded abrasive particles (eg, the particles resulting from the molding process) and the finally formed molded abrasive particles described herein. Some exemplary process parameters may include a release distance defining a separation point between the fabric and the belt relative to the point within the application zone, a viscosity of the mixture, a storage modulus of the mixture, mechanical properties of the components within the zone. of application, web thickness, web stiffness, a solid content of the mixture, a conveyor content of the mixture, a release angle between the belt and the web, a translation speed, a temperature, a content of the release agent on the belt or on the screen openings surfaces, a pressure exerted on the mixture to facilitate extrusion, a belt speed and a combination of these.
[73] Upon completion of the molding process, the resulting precursor molded abrasive particles can be translated through a series of zones, where further treatments can take place. Some suitable exemplary additional treatments may include drying, heating, curing, reacting, radiating, stirring, agitating, planing, calcining, sintering, grinding, sieving, doping, and a combination thereof. In one embodiment, the precursor molded abrasive particles can be translated through an optional molding zone, wherein at least an outer surface of the particles can be further molded. In addition, or alternatively, the precursor molded abrasive particles may be translated through an application zone where the dopant material can be applied to at least one exterior surface of the precursor molded abrasive particles. A dopant material can be applied using various methods, including, for example, spraying, dipping, impregnating, transferring, drilling, cutting, pressing, crushing, or any combination thereof. In particular instances, the application zone may utilize a spray nozzle, or a combination of spray nozzles, to spray the dopant material onto the precursor molded abrasive particles.
[74] In accordance with one embodiment, the application of the dopant material may include the application of a particular material, such as a precursor. Some exemplary precursor materials may include a dopant material to be incorporated into finally formed molded abrasive particles. For example, the metal salt may include an element or compound that is the precursor to the dopant material (e.g., a metallic element). It will be contemplated that a saline material may be in liquid form, such as a mixture or solution comprising a salt and a liquid carrier. The salt may include nitrogen, and more particularly, it may include a nitrate. In other embodiments, the salt can be a chloride, sulfate, phosphate, and a combination thereof. In one embodiment, the salt may include a metal nitrate, and more particularly, consist essentially of a metal nitrate.
[75] In one embodiment, the dopant material may include an element or compound such as an alkyl element, alkaline earth element, rare earth, hafnium, zirconium, niobium, tantalum, molybdenum, vanadium, or a combination thereof. In a particular embodiment, the dopant material includes an element or compound, including an element such as lithium, sodium, potassium, magnesium, calcium, strontium, barium, scandium, yttrium, lanthanum, cerium, praseodymium, niobium, hafnium, zirconium, tantalum, molybdenum, vanadium, chromium, cobalt, iron, germanium, manganese, nickel, titanium, zinc, and a combination thereof.
[76] In particular instances, the process of applying a dopant material may include selecting to place the dopant material on an exterior surface of a precursor molded abrasive particle. For example, the process of applying the dopant material may include applying the dopant material to a top surface or bottom surface of precursor molded abrasive particles. In yet another embodiment, one or more side surfaces of the precursor molded abrasive particles may be treated such that dopant material is applied thereto. It will be appreciated that various methods may be used to apply the dopant material to various exterior surfaces of the precursor molded abrasive particles. For example, the spraying process can be used to apply the dopant material to a top surface or side surface of a precursor molded abrasive particle. Still, in an alternative embodiment, a dopant material can be applied to the bottom surface of the precursor molded abrasive particles through a process such as dipping, depositing, impregnating, or a combination thereof. It will be contemplated that the surface of the belt may be treated with the dopant material to facilitate transfer of the dopant material with the bottom surface of the precursor molded abrasive particles.
[77] Furthermore, the abrasive precursor particles can be translated into a chorea via a post-forming zone, in which a variety of processes, including, for example, drying, can be conducted on the precursor shaped abrasive particle, as described in modalities in this document. Various processes can be conducted in the postforming zone, including treating the precursor shaped abrasive particles. In one embodiment, the post-forming zone can include a heating process in which the precursor molded abrasive particles can be dried. Drying may include removing a particular content from the material, including volatiles such as water. According to one embodiment, the drying process may be conducted at a drying temperature of not greater than about 300°C, such as not greater than about 280°C, or even not greater than about 250°C. Further, in a non-limiting embodiment, the drying process may be conducted at a drying temperature of at least 50°C. It will be contemplated that the drying temperature may be within a range between any of the minimum or maximum temperatures mentioned above. In addition, precursor molded abrasive particles can be translated through a postform zone at a particular rate, such as at least about 0.2 ft/min (0.06 m/min) and no greater than about 8 ft. /min (2.4 m/min).
[78] In accordance with one embodiment, the process for forming the molded abrasive particles may further comprise a sintering process. For certain processes of embodiments herein, sintering may be conducted after collecting the shaped abrasive particles precursors from the belt. Alternatively, sintering may be a process that is conducted while the precursor molded abrasive particles are on the belt. Sintering the precursor molded abrasive particles can be used to densify the particles, which are generally in a green state. In a specific instance, the sintering process can facilitate the formation of a high temperature phase of a ceramic material. For example, in one embodiment, the precursor molded abrasive particles can be sintered such that the high temperature phase of the alumina, such as alpha alumina, is formed. In one instance, a molded abrasive particle may comprise at least about 90% by weight alpha alumina for a total weight of the particle. In other instances, the alpha alumina content may be higher, such that the shaped abrasive particle may consist essentially of alpha alumina. MOLDED ABRASIVE PARTICLES
[79] Molded abrasive particles can be molded into a variety of shapes. In general, molded abrasive particles can be formed to have a shape close to the shape of the components used in the forming process. For example, a molded abrasive particle may have a predetermined two-dimensional shape as seen in either two-dimensional or three-dimensional shapes, and especially in a dimension defined by the length and width of the particle. Some exemplary two-dimensional shapes might include a polygon, an ellipsoid, a numeral, a Greek alphabet letter, a Latin alphabet letter, a Russian alphabet character, a kanji character, a complex shape including a combination of polygonal shapes, and a combination of these. In particular cases, the molded abrasive particle may have a two-dimensional polygonal shape, such as a triangle, a rectangle, a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, a nonagon, a decagon, and a combination thereof. .
[80] In a particular aspect, the molded abrasive particles can be formed to have a shape as illustrated in FIG. 8A. FIG. 8A includes a perspective view illustration of a molded abrasive particle in accordance with one embodiment. Additionally, FIG. 8B includes a cross-sectional illustration of the molded abrasive particle of FIG. 8A. The body 801 includes a top surface 803, a bottom surface 804 opposite the top surface 803. The top surface 803 and the bottom surface 804 may be separated from each other by side surfaces 805, 806, and 807. As illustrated, the body 801 of molded abrasive particle 800 may have a generally triangular shape as seen in a plane of top surface 803. In particular, body 801 may have a length (Lmiddle) as shown in FIG. 8B which is measurable at the bottom surface 804 of the body 801 and extends from a corner on the bottom surface corresponding to the corner 813 on the top surface through a center 881 of the body 801 to a center on the opposite edge of the body corresponding to the edge 814 on the upper surface of the body. Alternatively, the body may be defined by a second length or profile length (Lp), which is the measurement of the dimension of the body from a side view of the top surface 803 from a first corner 813 to an adjacent corner 812. Notably, the dimension of Lmiddle can be a length that defines the distance between a height at a corner (hc) and a height at a midpoint (hm) opposite the corner. The dimension Lp can be a profile length along one side of the particle defining the distance between h1 and h2 (as explained in this document). The reference in this document for the length may be reference to Lmiddle or Lp.
[81] The body 801 may further include a width (w) which is the longest dimension of the body and extends along one side. The molded abrasive particle may further include a height (h), which may be a dimension of the molded abrasive particle extending in a direction perpendicular to the length and width in a direction defined by the lateral surface of the body 801. Namely, as will be described in more detail in this document, the body 801 can be set to various heights depending on the location of the body. In specific cases, the side can be greater than or equal to the length, the length can be greater than or equal to the height, and the width can be greater than or equal to the height.
[82] Furthermore, reference in this document to any dimensional characteristic (e.g., h1, h2, hi, w, Lmiddle, Lp, and the like) may refer to a single particle dimension of a batch. Alternatively, any reference to dimensional characteristics may refer to an average value or an average value derived from the analysis of a suitable sample of particles from a batch. Unless explicitly stated, reference in this document to a dimensional characteristic may be considered a reference to a median value that is based on a statistically significant value derived from a sample size of an adequate number of particles in a batch. Namely, for certain embodiments herein, the sample size may include at least 40 particles randomly selected from a batch of particles. A batch of particles can be a group of particles that are collected from a single process performed and, more particularly, can include an amount of molded abrasive particles suitable to form a commercial grade abrasive product, such as at least 20 lbs. of particles.
[83] According to one embodiment, the body 801 of a molded abrasive particle may have a height of the first corner (hc) in a first region of a body defined by a corner 813. Notably, the corner 813 may represent the furthest point. high on body 801, however, the height at a corner 813 does not necessarily represent the highest point on body 801. Corner 813 can be defined as a point or region on a body 301, defined by the junction of top surface 803, and two side surfaces 805 and 807. Body 801 may further include other spaced apart corners including, for example, corner 811 and corner 812. As further illustrated, body 801 may include edges 814, 815, 816 which may be separated from each other by corners 811, 812, and 813. Edge 814 may be defined by an intersection of a top surface 803 and a side surface 806. Edge 815 may be defined by an intersection of top surface 803 and side surface 805 in between corners 811 and 813. Edge 816 may be defined by an intersection of top surface 803 and side surface 807 between corners 812 and 813.
[84] As further illustrated, body 801 may include a second midpoint height (hm) at a second end of body 801 which may be defined as the region at the midpoint of edge 814 which may be opposite the first end defined by a corner 813. The shaft 850 may extend between the two ends of the body 801. FIG. 8B is a cross-sectional illustration of body 801 along axis 850, which may extend through a midpoint 881 of body 801 along the length dimension (Lmiddle) between corner 813 and edge midpoint 814.
[85] In one embodiment, the molded abrasive particles of the embodiments herein, including, for example, the particle of FIGs. 8A and 85B, may have an average height difference, which is a measure of the difference between the hc and hm. By convention in this document, the average height difference will generally be identified as hc-hm, however, an absolute value of the difference is defined and it will be contemplated that the average height difference can be calculated as hm-hc when the height of the body 801 at the midpoint of the edge 814 is greater than the height at the corner 813. More particularly, the average difference in height can be calculated based on the plurality of molded abrasive particles of a suitable sample size, such as at least 40 particles from a batch as defined in this document. The hc and hm heights of the particles can be measured using a Micro Measure 3D Surface Profilometer from STIL (Sciences et Techniques Industrielles dela Lumiere - France) (white light chromatic aberration technique (LED)) , and the average height difference can be calculated based on the average values of hc and hm of the sample.
[86] As illustrated in FIG. 8B, in a particular embodiment, the molded abrasive particle body 801 may have an average height difference at different locations on the body. The body may have an average height difference, which may be the absolute value [hc-hm] between a height of the first corner (hc) and the height of the second midpoint (hm) being at least about 20 microns. It will be appreciated that the average height difference can be calculated as hm-hc when the height of the body 801 at a midpoint of the edge is greater than the height at the opposite corner. In other instances, the average height difference [hc-hm] can be at least about 25 microns, at least about 30 microns, at least about 36 microns, at least about 40 microns, at least about 60 microns such as at least about 65 microns, at least about 70 microns, at least about 75 microns, at least about 80 microns, at least about 90 microns, or up to at least about 100 microns. In a non-limiting embodiment, the average height difference may be no greater than about 300 microns, such as no greater than about 250 microns, no greater than about 220 microns, or no greater than about 180 microns. It will be contemplated that the average height difference may be within the range between any of the minimum or maximum values noted above.
[87] In addition, it will be contemplated that the mean height difference can be based on the mean value of hc. For example, the average body height at corners (Ahc) can be calculated by measuring the body height at all corners and averaging the values, and can be distinguished from a single height value at a corner (hc). Consequently, the average difference in height can be given by the absolute value of the equation [Ahc-hi], where hi is the interior height which can be the smallest dimension of the height of the body as measured along the dimension between any corner and the edge opposite center in the body. Furthermore, it will be contemplated that the average height difference can be calculated using a median interior height (Mhi), calculated from a suitable sample size of a batch of molded abrasive particles, and an average height at the corners for all particles. in the sample size. Accordingly, the average height difference can be given by an absolute value of the equation [Ahc-Mhi].
[88] In particular instances, the body 801 may be formed to have a primary aspect ratio, which is a ratio expressed as width:length, where the length may be Lmiddle, having a value of at least 1:1. In other instances, the body may be formed such that the primary aspect ratio (w:l) is at least about [1]:1, such as at least 2:1, at least 4:1, or even at least minus 5:1. Yet, in other instances, the abrasive particle may be shaped such that the body has a primary aspect ratio that is not greater than about 10:1, such as not greater than 9:1, not greater than 8:1, or even not greater than 5:1. It will be contemplated that the body 801 may have a primary aspect ratio within a range between any of the aforementioned ratios. Furthermore, it will be contemplated that the reference in this document to a height is the maximum measurable height of an abrasive particle. It will be described later that an abrasive particle can have different heights at different positions within a body 801.
[89] In addition to the primary aspect ratio, the abrasive particle can be formed such that the body 801 comprises a secondary aspect ratio, which can be defined as the length:height ratio, where the height can be Lmiddle and the height is an interior height (hi). In certain cases, the secondary aspect ratio can be within a range of between about 5:1 and about 1:3, such as between about 4:1 and about 1:2, or even between about 3:1. and about 1:2. It will be appreciated that the same ratio can be measured using average values (eg average length and average interior height) for a batch of particles.
[90] According to another embodiment, the abrasive particle can be formed such that the body 801 comprises a tertiary aspect ratio, defined by the width:height ratio, where the height is an interior height (hi). The tertiary aspect ratio of the body 801 can be within a range of between about 10:1 and about 1.5:1, such as between about 8:1 and about 1.5:1, between about 6:1 and about 1.5:1. about 1.5:1, or even between about 4:1 and about 1.5:1. It will be appreciated that the same ratio can be measured using average values (e.g. average length, average middle length and/or average interior height) for a batch of particles.
[91] According to one embodiment, the body 801 of a molded abrasive particle can have particular dimensions that can facilitate improved performance. For example, in one instance, the body can have an interior height (hi), which is the smallest dimension of the body's height, as measured along the dimension between any corner or opposite midpoint edge on a body. In particular instances, where the body is generally of a two-dimensional triangular shape, the interior height (hi) may be the smallest dimension of the height (i.e., the measurement between the bottom surface 804 and the top surface 805) of the body for three measurements taken between each of the three corners and the opposite midpoint edges. The interior height (hi) of the body of a molded abrasive particle is illustrated in FIG. 8B. In one embodiment, the inner height (hi) can be at least about 28% of the width (w). The height (hi) of any particle can be measured by sectioning or assembling and grinding the molded abrasive particle and viewed in a sufficient manner (e.g. light microscope or SEM) to determine the smallest height (hi) within the interior of the body. 801. In a particular embodiment, the height (hi) can be at least about 29% of the width, such as at least about 30%, or up to at least about 33% of the body width. In a non-limiting embodiment, the height (hi) of the body may be no greater than about 80% of the width, with no greater than about 76%, no greater than about 73%, no greater than about 70%, no greater than about 68%, no greater than about 56%. not greater than about 48%, or even not greater than about 40% of the width. It will be contemplated that the height (hi) of the body may be within a range between any of the minimum and maximum percentages mentioned above.
[92] A batch of abrasive particles can be manufactured, where the median interior height (Mhi) value can be controlled, which can facilitate improved performance. In particular, the median interior height (hi) of a batch can be related to the median width of a molded abrasive particle of a batch in the same manner as described above. Notably, the median interior height (Mhi) can be at least about 28%, such as at least about 29%, at least about 30%, or up to at least about 33% of the median width of the molded abrasive particles of a batch. In a non-limiting embodiment, the median interior height (Mhi) of the body may be no greater than about 80% of the width, with no greater than about 76%, no greater than about 73%, no greater than about 70 %, not greater than about 68%, not greater than about 56%. not greater than about 48%, or even not greater than about 40% of the median width. It will be contemplated that the median interior height (Mhi) of the body may be within a range between any of the aforementioned minimum and maximum percentages.
[93] In addition, the batch of molded abrasive particles can exhibit improved dimensional uniformity as measured by the standard deviation of a dimensional characteristic of a suitable sample size. In one embodiment, the molded abrasive particles may have an interior height variation (Vhi), which can be calculated as the standard deviation of an interior height (hi) for a suitable sample size of particles in a batch. According to one embodiment, the interior height variation may be no greater than about 60 microns, such as no greater than about 58 microns, no greater than about 56 microns, or no greater than about 54 microns. In a non-limiting embodiment, the interior height variation (Vhi) can be at least about 2 microns. It will be contemplated that the variation of the interior height of the body may be within a range between any of the minimum and maximum values noted above.
[94] For another embodiment, the molded abrasive particle body may have an interior height (hi) of at least 400 microns. More particularly, the height can be at least about 450 microns, such as at least about 475 microns, or up to at least about 500 microns. In still a non-limiting embodiment the height of the body may be no greater than about 3 mm, such as no greater than about 2 mm, no greater than about 1.5 mm, no greater than about 1 mm, no greater than about 1 mm. about 800 microns. It will be contemplated that the height (hi) of the body may be within a range between any of the minimum and maximum percentages mentioned above. Furthermore, it will be contemplated that the above range of values may be representative of a median interior height (Mhi) value for a batch of molded abrasive particles.
[95] For certain embodiments herein, the body of a molded abrasive particle may have particular dimensions, including, for example, a width >length, a length >height, and a width >height. More particularly, the body 801 of a molded abrasive particle may have a width (w) of at least about 600 microns, such as at least about 700 microns, at least about 800 microns, or up to at least about 900 microns. In a non-limiting instance, the body may have a width of no greater than about 4 mm, such as not greater than about 3 mm, such as not greater than about 2.5 mm, such as not greater than about 2 mm. It will be contemplated that the width of the body may be within a range between any of the minimum and maximum percentages mentioned above. Furthermore, it will be contemplated that the above range of values may be representative of a median width (Mhi) for a batch of molded abrasive particles.
[96] The body 801 of the molded abrasive particles can have particular dimensions, including, for example, a length (L middle or Lp) or at least about 0.4 mm, such as at least about 0.6 mm, at least about 0.8 mm, or even at least about 0.9 mm. Further, in at least one non-limiting embodiment, the body 801 may have a length of no greater than about 4 mm, no greater than about 3 mm, no greater than about 2.5 mm, or even no greater than about 2 mm. mm It will be contemplated that the length of the body 801 may be within a range between any of the minimum and maximum values mentioned above. Furthermore, it will be contemplated that the above ranges of values may be representative of a median length (MI), which may more particularly be an average median length (MLmiddle) or median length profile (MLp) for a batch of abrasive particles. molded.
[97] The molded abrasive particle may have a body 801 having a particular amount of bulge, where the bulge value (d) can be defined as the ratio of an average height of a body 801 at its corners (Ahc), as compared to the smallest dimension of the height of the body inside it (hi). The average height of the body 801 at corners (Ahc) can be calculated by measuring the height of the body at all corners and averaging the values, and can be distinguished from a single height value at a corner (hc). The average height of the body 801 in the corners or inside can be measured using a Micro Measure 3D Surface Profilometer from STIL (Sciences et Techniques Industrielles dela Lumiere - France) (chromatic aberration technique of light white (LED)). Alternatively, dishing can be done based on the median height of particles in a corner (Mhc) calculated from an adequate sampling of particles from a batch. Likewise, the interior height (hi) can be a median interior height (Mhi) derived from a proper sampling of molded abrasive particles from a batch. According to one embodiment, the dishing value (d) may be no greater than about 2, such as no greater than about 1.9, no greater than about 1.8, no greater than about 1.7, not greater than about 1.6, or even not greater than about 1.5. Still, in at least one non-limiting embodiment, the dishing value (d) can be at least about 0.9, such as at least about 1.0. It will be contemplated that the dishing ratio can be within a range between any of the minimum and maximum values mentioned above. Furthermore, it will be contemplated that the above dishing values may be representative of a median dishing value (Md) for a batch of molded abrasive particles.
[98] Abrasive particles of the embodiments herein, including, for example, the particle body 801 of FIG. 8A may have a bottom surface 804 defining a bottom area (Ab). In particular instances, the bottom surface 304 may be the largest surface of a body 801. The bottom surface may have a surface area, defined as the bottom area (Ab), that is greater than the top surface area 803. Additionally , the body 801 may have a transverse midpoint area (Am) defining an area from a plane perpendicular to the lower area and extending through the midpoint 881 (one between the top and bottom surfaces) of the particle. In certain instances, the body 801 may have a bottom area to midpoint area (Ab/Am) ratio of no more than about 6. in more particular instances, the area ratio can be no greater than about of 5.5, not greater than about 5, not greater than about 4.5, not greater than about 4, not greater than about 3.5, or not greater than about 3. Yet, in a non-limiting embodiment, the area ratio can be at least about 1.1, such as at least about 1.3, or up to at least about 1.8. It will be contemplated that the area ratio can be within a range between any of the minimum and maximum values mentioned above. Furthermore, it will be appreciated that the above area ratio may be representative of an area ratio of a batch of molded abrasive particles.
[99] In addition, the molded abrasive particles of the embodiments herein, including, for example, the particle of FIG. 8B may have a normalized height difference of at least about 0.3. The normalized height difference can be defined by the absolute value of the equation [(hc-hm)/(hi)]. In other embodiments, the normalized height difference cannot be greater than about 0.26, such as not greater than about 0.22, or even not greater than about 0.19. Further, in a specific embodiment, the normalized height difference may be at least 0.04 such as at least about 0.05, at least about 0.06. It will be contemplated that the normalized height difference may be within a range between any of the minimum and maximum values mentioned above. Furthermore, it will be contemplated that the above normalized height values may be representative of a median normalized height value for a batch of abrasive particles.
[100] In another instance, the body 801 may have a profile ratio of at least about 0.04, where the profile ratio is defined as a ratio of an average difference in height [hc-hm] to length (Lmiddle) of a molded abrasive particle, defined as the absolute value of [(hc-hm)/(Lmiddle)]. It will be contemplated that the length (Lmiddle) of the body may be the distance along the body 801, as illustrated in FIG. 8B. In addition, the length may be a median or average length calculated from a suitable sample of particles from a batch of molded abrasive particles, as defined herein. According to a specific embodiment, the profile ratio can be at least about 0.05, at least about 0.06, at least about 0.07, at least about 0.08, or even at least about of 0.09. Further, in a non-limiting embodiment, the profile ratio may be no greater than about 0.3, such as not greater than about 0.2, not greater than about 0.18, not greater than about 0. 16, or even no greater than about 0.14. It will be contemplated that the profile ratio may be within a range between the minimum and maximum values mentioned above. Furthermore, it will be appreciated that the profile ratio above may be representative of a profile ratio of a batch of molded abrasive particles.
[101] According to another embodiment, the body 801 may have a particular angle of inclination, which may be defined as an angle between the bottom surface 804 and the side surface 805, 806 and 807 of the body. For example, the angle of inclination may be within a range of between about 1° and about 80°. For other particles herein, the angle of inclination can be within a range of between about 5° and 55°, such as between about 10° and about 50°, between about 15° and 50°, or even between about 10° and about 50°. 20° and 50°. The formation of an abrasive particle having an angle of inclination can improve the abrasive capabilities of the abrasive particle. Notably, the angle of inclination can be within a range between any of the two angles of inclination mentioned above.
[102] In another embodiment, the abrasive particles molded herein, including, for example, the particles of FIGs. 8A and 8B may have an ellipsoidal region 817 on the upper surface 803 of the body 801. The ellipsoidal region 817 may be defined by the trench region 818 which may extend around the upper surface 803 and define the ellipsoidal region 817. The ellipsoidal region 817 may span the midpoint 881. Furthermore, it is envisioned that the ellipsoidal region 817 defined on the top surface may be an artifact of the forming process, and may be formed as a result of stress imposed on the mixture during formation of the molded abrasive particles according to the methods described in this document.
[103] The molded abrasive particles can be formed such that the body includes a crystalline material, and more particularly, a polycrystalline material. Notably, the polycrystalline material may include abrasive grains. In one embodiment, the body may be essentially free of an organic material, including, for example, a binder. More particularly, the body consists essentially of a polycrystalline material.
[104] In one aspect, the molded abrasive particle body may have an agglomerate, including a plurality of abrasive particles, gravel and/or grains bonded together to form a body 801 of an abrasive particle 800. Suitable abrasive grains may include nitrides, oxides, carbides, borides, oxynitrides, oxyborides, diamond, superabrasives (eg cBN), and a combination thereof. In particular instances, the abrasive grains may include an oxide compound or complex, such as aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, and a combination thereof. In a particular instance, the abrasive particle 800 is formed such that the abrasive grains forming the body 800 include alumina, and, more particularly, may consist essentially of alumina. In an alternative embodiment, the molded abrasive particles may include geosets, including, for example, polycrystalline compacts of abrasive or superabrasive materials including a binder phase, which may include a metal, a metal alloy, superalloy, cermet, and a combination thereof. Some exemplary binder materials may include cobalt, tungsten and a combination thereof.
[105] Abrasive grains (ie, crystallites) contained within the body can have an average grain size that is generally no larger than about 100 microns. In other embodiments, the average grain size may be smaller, such as not larger than about 80 microns, not larger than about 50 microns, not larger than about 30 microns, not larger than about 20 microns, not larger than about 20 microns. 10 microns or even no larger than about 1 micron. Further, the average grain size of the abrasive grains contained within the body may be at least about 0.01 microns, such as at least about 0.05 microns, such as at least about 0.08 microns, at least about 0.08 microns, 0.1 micron, or up to at least about 1 micron. It will be contemplated that the abrasive particle may have an average grain size within a range between any minimum and maximum value mentioned above.
[106] In accordance with certain embodiments, the abrasive particle may be a composite article, including at least two different types of abrasive grains within the body. It will be appreciated that different types of abrasive grains are abrasive grains having different compositions relative to each other. For example, the body may be formed in such a way that it includes at least two different types of abrasive grains, where the two different types of abrasive grains may be nitrides, oxides, carbides, borides, oxynitrides, oxyborides, diamonds, and a combination of the same.
[107] In one embodiment, the abrasive particle 800 may have an average particle size, as measured by the largest measurable dimension on the body 801, of at least about 100 microns. Indeed, the abrasive particle 800 may have an average particle size of at least about 150 microns, such as at least about 200 microns, at least about 300 microns, at least about 400 microns, at least about 400 microns. at least about 500 microns, at least about 600 microns, at least about 700 microns, at least about 800 microns, or even at least about 900 microns. In addition, the abrasive particle 800 may have an average particle size that is not greater than about 5 mm, such as not greater than about 3 mm, not greater than about 2 mm, or even not greater than about 2 mm. than about 1.5 mm. It will be appreciated that the abrasive particle 100 may have an average particle size in the range between any of the minimum and maximum values noted above.
[108] The molded abrasive particles of embodiments of this invention may have a percent flash that can facilitate better performance. Notably, the blink defines an area of the particle as seen along one side, as illustrated in FIG. 8C, in which the flash extends from a side surface of the body within boxes 888 and 889. The flash may represent tapered regions near the top surface and the bottom surface of the body. Flashing can be measured as the percentage of body area along the side surface contained within a box that extends between an innermost point on the side surface (eg 891) and an outermost point (eg 892) on the lateral surface of the body. In a particular case, the body may have a certain blink content, which may be the percentage of body area contained within boxes 888 and 889 relative to the total body area contained within boxes 888, 889, and 890. according to one embodiment, the flashing percentage (f) of the body may be at least about 10%. In another embodiment, the intermittent percentage may be greater, such as at least about 12%, such as at least about 14%, at least about 16%, at least about 18%, or even at least about 20 %. Further, in a non-limiting embodiment, the body flashing percentage can be controlled and can be no greater than about 45%, such as no greater than about 40%, or even no greater than about 36%. It will be contemplated that the body flashing percentage may be within a range between any of the minimum and maximum percentages mentioned above. In addition, it should be noted that the above flashing percentages may be representative of an average flashing percentage or a median flashing percentage for a batch of molded abrasive particles.
[109] Percent flash can be measured by mounting the molded abrasive particle on the side and viewing the body on the side to generate a black and white image, as illustrated in FIG. 8C. A suitable program for image creation and analysis including flashing calculation can be done by ImageJ software. The percentage of flashing can be calculated by determining the area of the body 801 in boxes 888 and 889 in relation to the total area of the body as seen from the side (total shaded area), including the zone in the center 890 and within the boxes 888 and 889 Such a procedure can be completed for a suitable sampling of particles to generate mean, median and/or standard deviation values.
[110] A batch of abrasive particles molded in accordance with embodiments herein may exhibit improved dimensional uniformity as measured by the standard deviation of a three-dimensional feature from a suitable sample size. According to one embodiment, the abrasive particles in shape may have an intermittent variation (Vf), which can be calculated as the standard deviation of the percentage intermittent (f) for a suitable sample size of particles from a batch. According to one embodiment, the flashing variation may be no greater than about 5%, such as no greater than about 5.3%, no greater than about 5%, no greater than about 4.8%, no greater than about 4.6%, or even no greater than about 4.4%. In a non-limiting embodiment, the flashing variation (Vf) can be at least about 0.1%. It will be contemplated that the flashing variation may be within a range between any of the minimum and maximum percentages mentioned above.
[111] Molded abrasive particles of embodiments of this invention may have a height (hi) and intermittent multiplier (hiF) value of at least 4000, where hiF = (hi)(f), a "hi" represents a minimum height inside the body as described above and "f" represents the flashing percentage. In a particular case, the body height and intermittent multiplier (hiF) value may be greater, such as at least about 4500 microns%, at least about 5000 microns%, at least about 6000 microns%, at least about of 7000 microns%, or even at least about 8000 microns%. Further, in a non-limiting embodiment, the height and flash multiplier value may be no greater than about 45000 micron%, such as no greater than about 30000% micron, no greater than about 25000% micron, no greater than about 20000% micron, or even not greater than about 18000% micron. It should be noted that the body height and flashing multiplier value can be within a range between any of the above maximum and minimum values. In addition, it is noted that the above multiplier value may be representative of a median value multiplier (MhiF) for a batch of shaped abrasive particles.
[112] Abrasive particles in the form of embodiments of this invention may have bulging (d) and flashing (F) multiplier (dF) value, as calculated by the equation dF = (d), (F), where dF is no greater than about 90%, "d" represents the bulge value, and "f" represents the flashing percentage of the body. In a specific instance, the bulging (d) and flashing (F) multiplier value of the body may not be greater than about 70%, such as not greater than about 60%, not greater than about 55%, no greater than about 48%, not greater than about 46%. Further, in a non-limiting embodiment, the multiplier value (dF) of bulging (d) and flashing (F) can be at least about 10%, such as at least about 15%, at least about 20%, at least about 20%, least about 22%, at least about 24%, or even at least about 26%. Note that the dishing (d) and flashing (F) multiplier value of the body can be within a range between any of the above maximum and minimum values. In addition, it is noted that the above multiplier value may be representative of a median value multiplier (MdF) for a batch of molded abrasive particles.
[113] The molded abrasive particles of embodiments here can have a ratio between height and dishing (hi/d), as calculated by the equation hi/d = (hi)/(d), where hi/d is no greater than around 1000, "hi" represents a minimum interior height as described above, and "d" represents body dishing. In a particular case, the body ratio (hi/d) may be no greater than about 900 microns, no more than about 800 microns, and no greater than about 700 microns, or even no greater than about 700 microns. of 650 microns. Further, in a non-limiting embodiment, the ratio (hi/d) can be at least about 10 microns, such as at least about 50 microns, at least about 100 microns, at least about 150 microns, at least about 200 microns, at least about 250 microns, or even at least about 275 microns. It will be contemplated that the ratio (hi/d) of the body may be within a range between any of the minimum and maximum values mentioned above. Furthermore, it will be appreciated that the above height and bulge ratio may be representative of a median height and bulge ratio (Mhi/d) for a batch of molded abrasive particles. ABRASIVE ARTICLES
[114] FIG. 1A includes a top view illustration of a portion of an abrasive article in accordance with one embodiment. As illustrated, the abrasive article 100 can include a support 101. The support 101 can include an organic material, an inorganic material, and a combination thereof. In certain cases, the support 101 may include a fabric material. However, the support 101 may be made of a non-woven material. Particularly suitable support materials may include organic materials, including polymers, and particularly polyester, polyurethane, polypropylene, polyimides such as DuPont's KAPTON and paper. Some suitable inorganic materials may include metals, metal alloys and, in particular, sheets of copper, aluminum, steel, and a combination thereof. It will be contemplated that the abrasive article 100 may include other components, including for example adhesive layers (e.g., make coat, size coat, front fill, etc.) which will be discussed in more detail in this document.
[115] As further illustrated, the abrasive article 100 can include a molded abrasive particle 102 which overlays the support 101, and more specifically, coupled to the support 101. Notably, the molded abrasive particle 102 can be placed in a first position 112 on the support 101. As further illustrated, the abrasive article 100 may include a molded abrasive particle 103 which overlays the support 101, and more specifically, coupled to the support 101 in a second predetermined position 113. abrasive 100 may additionally include an abrasive particle 104 which overlies the support 101, and more specifically, coupled to the support 101 in a third predetermined position 114. As further illustrated in FIG. 1A, the abrasive particle 100 may additionally include an abrasive particle 105 which overlays the support 101, and more specifically, coupled to the support 101 at a fourth predetermined position 115. As further illustrated, the abrasive article 100 may include an abrasive particle. overlying support 101, and more specifically, coupled to support 101 in a predetermined fifth position 116. It will be contemplated that any of the molded abrasive particles described herein may be coupled to support 101 through one or more adhesive layers as described in this document.
[116] In one embodiment, the molded abrasive particle 102 may have a first composition. For example, the first composition may include a crystalline material. In a particular embodiment, the first composition may include a ceramic material, such as an oxide, carbide, nitride, boride, oxynitride, oxycarbide, and a combination thereof. More especially, the first composition may consist essentially of a ceramic, such that it may consist essentially of an oxide, carbide, nitride, boride, oxynitride, oxycarbide and a combination thereof. Further, in an alternative embodiment, the first composition may include a superabrasive material. In still other embodiments, the first composition may include a single-phase material, and more especially, may consist essentially of a single-phase material. Notably, the first composition can be a single-phase polycrystalline material. In specific instances, the first composition may have a limited binder content, such that the first composition may have no more than about 1% binder material. Some exemplary suitable binding materials may include organic materials, and more especially, polymer-containing compounds. Most notably, the first composition can be essentially free of binder material and can be essentially free of an organic material. In one embodiment, the first composition may include amine, and more especially, may consist essentially of alumina, such as alpha alumina.
[117] In yet another aspect, the molded abrasive particle 102 may have a first composition which may be a compound including at least two different types of abrasive grains within the body. It will be appreciated that different types of abrasive grains are abrasive grains having different compositions relative to each other. For example, the body may be formed in such a way that it includes at least two different types of abrasive grains, where the two different types of abrasive grains may be nitrides, oxides, carbides, borides, oxynitrides, oxyborides, diamonds, and a combination of the same.
[118] In one embodiment, the first composition may include a dopant material, wherein the dopant material is present in a minor amount. Some suitable exemplary dopant materials may include an element or compound such as an alkyl element, alkaline earth element, rare earth element, hafnium, zirconium, niobium, tantalum, molybdenum, vanadium, or a combination thereof. In a particular embodiment, the dopant material includes an element or compound, including an element such as lithium, sodium, potassium, magnesium, calcium, strontium, barium, scandium, yttrium, lanthanum, cerium, praseodymium, niobium, hafnium, zirconium, tantalum, molybdenum, vanadium, chromium, cobalt, iron, germanium, manganese, nickel, titanium, zinc, and a combination thereof.
[119] The molded second abrasive particle 103 may have a second composition. In certain instances, the second composition of the second molded abrasive particle 103 can be significantly the same as the first composition of the first molded abrasive particle 102. More especially, the second composition can be substantially the same as the first composition. Still, in an alternative embodiment, the second composition of the second molded abrasive particle 103 can be significantly different from the first composition of the first molded abrasive particle 102. It will be contemplated that the second composition can include any of the materials, elements and compounds described in accordance with first composition.
[120] According to one embodiment, and as illustrated further in FIG. 1A, the first molded abrasive particle 102 and the second molded abrasive particle 103 can be arranged in a predetermined distribution relative to each other.
[121] A predetermined distribution can be defined by a combination of predetermined positions on a support that is selected intentionally. The predetermined distribution may include a pattern, so that the predetermined positions may define a two-dimensional array. An arrangement may include/have a short order of variation defined by a unit of molded abrasive particles. An array may also be a pattern having a long range order including regular and repeating units linked together, so that the array may be symmetrical and/or predictable. An array can have an order that can be predicted by a mathematical formula. It will be contemplated that two-dimensional arrangements can be formed in the form of polygons, ellipses, ornamental signs, product signs or other designs.
[122] A predetermined distribution may also include an unshaded array. An unshaded array can include a controlled, non-uniform distribution, a controlled uniform distribution, and a combination of these. In particular instances, a shadowless array may include a radial pattern, a spiral pattern, a phyllotactic pattern, an asymmetric pattern, a self-avoiding random distribution, a self-avoiding random distribution, and a combination of these. Shadeless arrangements include a specific arrangement of abrasive particles (e.g. molded abrasive particles and/or thinner particles) in relation to one another, where the degree of overlap of the abrasive particles during an initial phase of a material removal operation not greater than about 25%, such as not greater than about 20%, not greater than about 15%, not greater than about 10%, or even not greater than about 5%. In specific instances, a shadowless arrangement may include an abrasive particle distribution, where upon coupling with a part during an early stage of a material removal operation, a part (e.g. a minority of all molded abrasive particles) on the backing, a majority of all abrasive particles molded onto the backing, or even essentially all) of the abrasive particles fit into different regions of the surface of the part. A shadowless arrangement may utilize a specific distribution of molded abrasive particles with respect to each other and with respect to the grinding direction as described in the embodiments herein. The use of an abrasive particle that employs a shadowless arrangement of abrasive particles can facilitate improvement in grinding performance over other abrasive articles using standard conventional arrangements (e.g. shade arrangement) and may limit unwanted effects such as abrasive article steering. during operation.
[123] The predetermined distribution can be partially, significantly or completely skewed. The predetermined distribution may overlap the entire abrasive article, may significantly cover the abrasive article (e.g. greater than 50% but less than 100%), overlap multiple parts of the abrasive article, or overlap a fraction of the abrasive article (e.g. (eg, less than 50% of the article's surface area.) As used in this document, "a phyllotactic pattern" means a pattern relating to phyllotaxis. Phyllotaxis is an arrangement of lateral organs such as leaves, flowers, scales, small flowers and seeds in many types of plants. Many phyllotactic patterns are marked by the naturally occurring phenomenon of conspicuous patterns having arcs, whorls and whorls. The seed patterns on a daisy's head is an example of this phenomenon.
[124] Further, according to one embodiment, a shadowless array may include a microunit which may be defined as the smallest of arrays of molded abrasive particles relative to one another. The microunit may repeat a plurality of times across at least a portion of the surface of the abrasive article. An unshaded array may further include a macrounit which may include a plurality of microunits. In specific examples, the macrounit may have a plurality of microunits arranged in a predetermined distribution relative to each other and repeated times with the unshaded arrangement. Abrasive articles of the embodiments herein may include one or more microunits. In addition, it will be contemplated that abrasive articles of the modalities in this document may include one or more macrounits. In certain embodiments, the macrounits can be arranged in a uniform distribution having a predictable order. In yet other examples, the macrounits may be arranged in a non-uniform distribution, which may include a random distribution, having no predictable long variation or short variation order.
[125] Referring briefly to FIGs. 25-27, different unshaded arrangements are illustrated. In particular, FIG. 25 includes an illustration of a shadowless arrangement, where locations 2501 represent predetermined positions to be occupied by one or more molded abrasive particles, diluent particles, and a combination thereof. The 2501 locations can be defined as positions on the X and Y axes as illustrated. Additionally, locations 2506 and 2507 may define a microunit 2520. Additionally, 2506 and 2509 may define a microunit 2521. As illustrated further, the microunits may be repeated across the surface of at least a portion of the article and define a macrounit 2530. In a specific instance, the locations 2501 representing the positions of the molded abrasive particles are arranged in a shadowless arrangement with respect to the grinding direction that is parallel to the Y axis.
[126] FIG. 26 includes an illustration of a shadowless arrangement, where the locations (shown as dots on the X and Y axes) represent predetermined positions to be occupied by one or more molded abrasive particles, thinner particles, and a combination thereof. In one embodiment, sites 2601 and 2602 may define a microunit 2620. Additionally, sites 2603, 2604, and 2605 may define a microunit 2621. As illustrated further, the microunits may be repeated across the surface of at least a portion of the surface. article and define at least one macrounit 2630. The existence of other macrounits will be contemplated, as illustrated. In a specific instance, the 2601 locations representing the positions of the molded abrasive particles are arranged in a shadowless arrangement with respect to the grinding direction that is parallel to the Y axis or X axis.
[127] FIG. 27 includes an illustration of a shadowless arrangement, where the locations (shown as dots on the X and Y axes) represent predetermined positions to be occupied by one or more molded abrasive particles, diluent particles, and a combination thereof. In one embodiment, sites 2701 and 2702 may define a microunit 2720. Additionally, sites 2701 and 2703 may define a microunit 2721. As further illustrated, the microunits may be repeated across the surface of at least a portion of the article and define at least one 2730 macrounit. In a specific instance, all locations representing positions of the molded abrasive particles are arranged in a shadowless arrangement with respect to the grinding direction that is parallel to the Y axis or X axis.
[128] A predetermined distribution among the molded abrasive particles can also be defined by at least one predetermined orientation characteristic of each of the molded abrasive particles. Exemplary predetermined orientation features may include a predetermined swivel orientation, a predetermined lateral orientation, a predetermined longitudinal orientation, a predetermined vertical orientation, a predetermined tip height, and a combination thereof. Support 101 may be defined by a longitudinal axis 180 that extends along and defines a length of support 101 and a lateral axis 181 that extends along and defines a width of support 101.
[129] According to one embodiment, the molded abrasive particle 102 may be located in a first predetermined position 112 defined by a specific first lateral position with respect to the lateral axis of 181 of the support 101. In addition, the molded abrasive particle 103 can have a second predetermined position defined by a second lateral position with respect to the lateral axis 181 of the support 101. Notably, the molded abrasive particles 102 and 103 can be spaced from one another by a lateral space 121, defined as the smaller of the distances between two adjacent molded abrasive particles 102 and 103, as measured along a lateral plane 184 parallel to the lateral axis 181 of the support 101. In one embodiment, the lateral space 121 may be greater than 0, so that there is some distance between the molded abrasive particles 102 and 103. However, since it has not been illustrated, it will be contemplated that the lateral space 121 could be 0, eg allowing contact and even overlap between adjacent abrasive particle parts.
[130] In other embodiments, the side space 121 may be at least about 0.1 (w), where w represents the width of the molded abrasive particle 102. In one embodiment, the width of the molded abrasive particle is the longest dimension of the body that extends along one side. In another embodiment, the side space 121 can be at least about 0.2 (w), such as at least about 0.5 (w), at least about 1 (w), at least about 2 ( w), or even greater. Further, in at least one non-limiting embodiment, the side space 121 may be no greater than about 100(w), no greater than about 50(w), or even no greater than about 20(w). It will be contemplated that the side space 121 may be within a range between any of the above mentioned minimum and maximum values. Controlling the lateral space between adjacent molded abrasive particles can facilitate improved grinding performance of the abrasive article.
[131] According to one embodiment, the molded abrasive particle 102 may be located in a first predetermined position 112 defined by a first longitudinal position with respect to the longitudinal axis 181 of the support 101. In addition, the molded abrasive particle 104 by be located at a third predetermined position 114 defined by a second longitudinal position to the longitudinal axis 180 of the support 101. Furthermore, as illustrated, there may be a longitudinal space 123 between the molded abrasive particles 102 and 104, which may be defined as the smallest of the distances between the two adjacent molded abrasive particles 102 and 104 as measured in a direction parallel to the longitudinal axis 180. According to one embodiment, the longitudinal space 123 may be greater than 0, further, as not illustrated , it will be contemplated that the longitudinal space 123 could be 0, so that the molded abrasive particles are touching or even overlapping u but the others.
[132] In other instances, the longitudinal gap 123 may be at least 0.1(w), where w is the width of the shaped abrasive particle as described herein. In other specific instances, the longitudinal space may be at least about 0.2(w), at least 0.5(w), at least 1(w), or even at least about 2(w). Further, the longitudinal space 123 may be no greater than about 100(w), such as no greater than about 50(w), or even no greater than about 20(w). It will be contemplated that the longitudinal space 123 may be within a range between any of the minimum and maximum values mentioned above. Controlling the longitudinal space between adjacent molded abrasive particles can facilitate improving the grinding performance of the abrasive article.
[133] According to one embodiment, the molded abrasive particles may be placed in a predetermined distribution, wherein there is a specific relationship between the lateral space 121 and longitudinal space 123. For example, in one embodiment the lateral space 121 may be greater than the longitudinal space 123. In yet another non-limiting embodiment, the longitudinal space 123 may be larger than the lateral space 121. In yet another embodiment, the molded abrasive particles may be placed on the backing so that the space lateral 121 and longitudinal space 123 are essentially the same with respect to each other. Controlling the relative relationship between longitudinal space and lateral space can facilitate the improvement of grinding performance.
[134] As further illustrated, the longitudinal space 124 can exist between the molded abrasive particles 104 and 105. Furthermore, the predetermined distribution can be formed so that the specific relationship can exist between the longitudinal space 123 and longitudinal space. 124. For example, the longitudinal space 123 may be different from the longitudinal space 124. Alternatively, the longitudinal space 123 may be essentially the same as the longitudinal space 124. Controlling the relative difference between the longitudinal spaces of different abrasive particles can facilitate improvement the grinding performance of the abrasive article.
[135] In addition, the predetermined distribution of the abrasive particles molded onto the abrasive article 100 may be such that the side space 121 can have a specific relationship to the side space 122. For example, in one embodiment the side space 121 can be essentially the same as the side space 122. Alternatively, the predetermined distribution of the abrasive particles molded onto the abrasive article 100 can be controlled so that the side space 121 is different from the side space 122. Control of the relative difference between the side spaces of different abrasive particles can facilitate the improvement of the grinding performance of the abrasive article.
[136] FIG. 1B includes a side view illustration of a portion of an abrasive article in accordance with one embodiment. As illustrated, the abrasive article 100 may include a molded abrasive particle 102 that overlays the backing 101 and a molded abrasive particle 104 spaced between the molded abrasive particle 102 that overlies the backing 101. In one embodiment, the molded abrasive particle 102 may be coupled to the backing 101 via the adhesive layer 151. In addition or alternatively, the molded abrasive particle 102 may be coupled to the backing 101 via the adhesive layer 152. It will be contemplated that any of the molded abrasive particles described herein may be coupled to the backing 101 through one or more adhesive layers as described in this document.
[137] In one embodiment, the abrasive article 100 may include an adhesive layer 151 that overlays the backing. In one embodiment, the adhesive layer 151 may include a make coat. The make coat coating may overlap the surface of the backing 101 and surround at least a portion of the molded abrasive particles 102 and 104. The abrasive articles of embodiments herein may further include an adhesive layer 152 that overlays the adhesive layer 151 and backing 101. and surrounding at least a portion of the molded abrasive particles 102 and 104. Adhesive layer 152 may be a size coat in specific instances.
[138] A polymer formulation may be used to form a variety of adhesive layers 151 and 152 of the abrasive article which may include, but are not limited to, a frontfill coating, a pre-size coat, a make coat, a size coat and/or a supersize coat. When used to form the frontfill, the polymer formulation generally includes a polymer resin, fibrillated fibers (preferably in pulp form), filler, and other optional additives. Formulations suitable for some frontfill embodiments may include materials such as a phenolic resin, wollastonite filler, defoamer, surfactant, a fibrillated fiber, and a water balance. Suitable polymeric resin materials include curable resins selected from thermally curable resins, including phenolic resins, urea/formaldehyde resins, phenolic/latex resins, as well as combinations of such resins. Other suitable polymeric resin materials may also include radiation curable resins, such as resins curable using electron beams, UV radiation, or visible light, such as epoxy resins, acrylated oligomers of acrylated epoxy resins, polyester resins, acrylated urethanes and polyester acrylates and acrylated monomers, including multi-acrylated monomers. The formulation may also comprise a non-reactive thermoplastic resin binder which can enhance the self-sharpening characteristics of the deposited abrasive composites by increasing erodibility. Examples of such thermoplastic resins include polypropylene glycol, polyethylene glycol, and polyoxypropylene-polyoxyethylene block copolymer, etc. Use of a frontfill over the backing can improve surface uniformity, for proper application of the size and improved application and orientation of molded abrasive particles from a predetermined orientation.
[139] Either of the adhesive layers 151 and 152 can be applied to the surface of the backing 101 in a single process, or alternatively, the molded abrasive particles 102 and 104 can be combined with a material from one of the adhesive layers 151 or 152 and applied as a mixture for the surface of support 101. Suitable materials of adhesive layer 151 for use as a make coat may include organic materials, especially polymeric materials, including, for example, polyesters, epoxy resins, polyurethanes, polyamides, polyacrylates , polymethacrylates, polyvinyl chlorides, polyethylene, polysiloxane, silicones, cellulose acetates, nitrocellulose, natural rubber, starch, shellac, and mixtures thereof. In one embodiment, the adhesive layer 151 may include a polyester resin. The coated support 101 can then be heated to cure the resin and particulate abrasive material onto the substrate. In general, the coated support 101 can be heated to a temperature of between about 100°C to less than about 250°C during such a curing process.
[140] Adhesive layer 152 may be formed over the abrasive article which may be in the form of a size coat. In a specific embodiment, the adhesive layer 152 may be a size coat formed to overlay and bond the molded abrasive particles 102 and 104 in place relative to the backing 101. The adhesive layer 152 may include an organic material and may be substantially of a polymeric material, and notably, it can use polyesters, epoxy resins, polyurethanes, polyamides, polyacrylates, polymethacrylates, polyvinyl chlorides, polyethylene, polysiloxane, silicones, cellulose acetates, nitrocellulose, natural rubber, starch, shellac, and their mixtures.
[141] It will be appreciated that, although not illustrated, the abrasive article may include abrasive particles from diluents other than molded abrasive particles 104 and 105. For example, the diluent particles may differ from molded abrasive particles 102 and 104 in composition, two-dimensional shape , three-dimensional shape, size, and a combination thereof. For example, abrasive particles may represent conventional abrasive, crushed in random shapes. Abrasive particles 507 may have an average particle size smaller than the average particle size of molded abrasive particles 505.
[142] As illustrated, the molded abrasive particle 102 may be oriented in a lateral orientation with respect to the support 101, wherein a side surface 171 of the molded abrasive particle 102 may be in direct contact with the support 101 or at least one surface of the molded abrasive particle 102 to the upper surface of support 101. In one embodiment, molded abrasive particle 102 may have a vertical orientation defined by an angle of inclination (AT1) 136 between a major surface 172 of molded abrasive particle 102 and a major surface 161 of holder 101. Angle of inclination 136 may be defined as the smallest of the angles or acute angle between surface 172 of molded abrasive particle 102 and upper surface 162 of holder 101. In one embodiment, the abrasive particle mold 102 can be placed in a position having a predetermined vertical orientation. In one embodiment, the angle of inclination 136 may be at least about 2°, at least about 5°, at least about 10°, at least about 15°, at least about 20°, at least about 20°, at least about 25°, at least about 30°, at least about 35°, at least about 40°, at least about 45°, at least about 50°, at least about 55°, at least about 60°, at least about 70°, at least about 80°, or even at least about 85°. Further, the angle of inclination 136 may not be greater than about 90°, such as not greater than about 85°, not greater than about 80°, not greater than about 75°, not greater than about 70° , not greater than about 65°, not greater than about 60°, not greater than about 55°, not greater than about 50°, not greater than about 45°, not greater than about 40°, no greater than about 35°, not greater than about 30°, not greater than about 25°, not greater than about 20°, not greater than about 15°, not greater than about 10°, or not yet greater than about 5°. It will be contemplated that the angle of inclination 136 may be within a range between any of the minimum or maximum degrees described above.
[143] As illustrated, the abrasive particle 100 may include a molded abrasive particle 104 in a lateral orientation, wherein a side surface 171 of the molded abrasive particle 104 is in direct contact with or closest to the top surface 161 of the support 101. In one embodiment, the molded abrasive particle 104 may be in a position having a predetermined vertical orientation defined by a second angle of inclination (AT2) 137 defining an angle between a major surface 172 of the molded abrasive particle 104 and a surface 161 of the holder 101. The angle of inclination 137 can be defined as the smallest of the angles between a major surface 172 of the molded abrasive particle 104 and the upper surface 161 of the holder 101. In addition, the angle of inclination 137 can have a value at least about 2°, at least about 5°, at least about 10°, at least about 15°, at least about 20°, at least about 25°, at least about 30°, at least about 35°, at least about 40°, at least about 45°, at least about 50°, at least about 55°, at least about 60°, at least about 60° of 70°, at least about 80°, or even at least about 85°. Further, the angle of inclination 136 may not be greater than about 90°, such as not greater than about 85°, not greater than about 80°, not greater than about 75°, not greater than about 70° , not greater than about 65°, not greater than about 60°, not greater than about 55°, not greater than about 50°, not greater than about 45°, not greater than about 40°, no greater than about 35°, not greater than about 30°, not greater than about 25°, not greater than about 20°, not greater than about 15°, not greater than about 10°, or not yet greater than about 5°. It will be contemplated that the angle of inclination 136 may be within a range between any of the minimum or maximum degrees described above.
[144] In one embodiment, the molded abrasive particle 102 may have a predetermined vertical orientation that is the same as the predetermined vertical orientation of the molded abrasive particle 104. Alternatively, the abrasive particle 100 may be formed that the predetermined vertical orientation of the molded abrasive particle 102 may be different from the predetermined vertical orientation of the molded abrasive particle 104.
[145] According to one embodiment, the molded abrasive particles 102 and 104 can be placed on the support so that they have different predetermined vertical orientations defined by a difference in vertical orientation. The difference in vertical orientation can be an absolute value of the difference between the angle of inclination 136 and the angle of inclination 137. According to one embodiment, the difference in vertical orientation can be at least about 2°, at least about 2°. 5°, at least about 10°, at least about 15°, at least about 20°, at least about 25°, at least about 30°, at least about 35°, at least about 40° °, at least about 45°, at least about 50°, at least about 55°, at least about 60°, at least about 70°, at least about 80°, or even at least about 85°. Also, the difference in vertical orientation may not be greater than about 90°, such as not greater than about 85°, not greater than about 80°, not greater than about 75°, not greater than about 70° , not greater than about 65°, not greater than about 60°, not greater than about 55°, not greater than about 50°, not greater than about 45°, not greater than about 40°, no greater than about 35°, not greater than about 30°, not greater than about 25°, not greater than about 20°, not greater than about 15°, not greater than about 10°, or not yet greater than about 5°. It will be contemplated that the difference in vertical orientation may be within a range between any of the minimum or maximum degrees described above. Controlling the vertical orientation difference between the abrasive particles molded from the abrasive particle 100 can facilitate improved grinding performance.
[146] As illustrated later, the molded abrasive particles can be placed on the support to have a predetermined slope height. For example, the predetermined pitch height (hT1) 138 of the molded abrasive particle 102 may be a greater distance between an upper surface of the support 161 and a higher surface 143 of the molded abrasive particle 102. Specifically, the predetermined pitch height -a determined 138 of the molded abrasive particle 102 can define the greatest distance above the upper surface of the support 161 that the molded abrasive particle 102 extends. As illustrated later, the molded abrasive particle 104 can have a predetermined pitch height (hT2) 139 defined as the distance between the upper surface 161 of the holder 101 and a higher surface 144 of the molded abrasive particle 104. Measurements can be taken. evaluated using X-ray, CT confocal microscopy, micromeasurement, white light interferometry and a combination of these.
[147] According to one embodiment, the molded abrasive particle 102 may be placed on the support 101 to have a predetermined pitch height 138 which may be different from the predetermined pitch height 139 of the molded abrasive particle 104. Notably , the difference in the predetermined tilt height (hT) can be defined as the difference between the average tilt height 138 and the average tilt height 139. According to one embodiment, the difference in the predetermined tilt height may be at least about 0.01(w), where (w) is the width of the shaped abrasive particle as described herein. In other instances, the difference in slope height may be at least about 0.05(w), at least about 0.1(w), at least about 0.2(w), at least about 0.4(w), at least about 0.5(w), at least about 0.6(w), at least about 0.7(w), or even at least about 0.08( w). Also, in a non-limiting mode, the slope height difference may not be greater than about 2(w). It will be contemplated that the difference in pitch height may be within the range between any of the minimum or maximum values noted above. Controlling the average slant height, and more specifically the difference in average slant height, between the molded abrasive particles of the abrasive article 100 can facilitate improvement in grinding performance.
[148] While reference is made to molded abrasive particles having a difference in average rake height, it will be appreciated that molded abrasive particles of abrasive articles may have the same average rake height so that there is essentially no difference between the rake height average between the molded abrasive particles. For example, as described herein, the molded abrasive particles of a group can be positioned on the abrasive article so that the vertical slope height of each of the molded abrasive particles of the group is essentially the same.
[149] FIG. 1C includes a cross-sectional illustration of a portion of an abrasive article in accordance with one embodiment. As illustrated, the molded abrasive particles 102 and 104 may be oriented in a plane orientation relative to the support 101, wherein at least a portion of a larger surface 174, and specifically the larger surface having the largest surface area (e.g., bottom surface 174 opposite the major top surface 172), of the molded abrasive particles 102 and 104 may be in direct contact with the backing 101. Alternatively, in a flat orientation, the major surface portion 174 may not be in direct contact with the backing 101. support 101, however, may be the surface of the molded abrasive particle closest to the top surface 161 of support 101.
[150] FIG. 1D includes a cross-sectional illustration of a portion of an abrasive article in accordance with one embodiment. As illustrated, molded abrasive particles 102 and 104 may be oriented in an inverted orientation relative to support 101, wherein at least a portion of a major surface 172 (e.g., upper major surface 172), molded abrasive particles 102 and 104 may be in direct contact with support 101. Alternatively, in an inverted orientation, the larger surface portion 172 may not be in direct contact with support 101, but may be the surface of the molded abrasive particle closest to the upper surface. 161 from support 101.
[151] FIG. 2A includes a top view illustration of a portion of an abrasive article including abrasive particles molded in accordance with one embodiment. As illustrated, the abrasive article may include a molded abrasive particle 102 which overlays the support 101 in a first position having a first rotational orientation with respect to a lateral axis 181 defining the width of the support 101 and perpendicular to the longitudinal axis 181. In particular, molded abrasive particle 102 may have a predetermined rotational orientation defined by a first rotational angle between lateral plane 184 parallel to lateral axis 181 and a dimension of molded abrasive particle 102. Notably, reference to a dimension in this document may be referenced to a split axis 231 of the molded abrasive particle that extends through a center point 221 of the molded abrasive particle 102 along a surface (e.g., a side or an edge) connected to (directly or indirectly) the support 101. Consequently, in the context of a molded abrasive particle positioned in a lateral orientation (see FIG. 1B), the diameter axis view 231 extends through a center point 221 and in the width direction (w) of a width 171 closest to the surface 181 of the support 101. Furthermore, the predetermined swivel orientation can be defined as the smallest of the angles 201 with lateral plane 184 extending through a midpoint 221. As illustrated in FIG. 2A, the molded abrasive particle 102 may have a predetermined swivel angle defined as the smallest angle between a split axis 231 and the lateral plane 184. In one embodiment, the swivel angle 201 may be 0°. In other embodiments, the angle of rotation can be at least about 2°, at least about 5°, at least about 10°, at least about 15°, at least about 20°, at least about 25°. °, at least about 30°, at least about 35°, at least about 40°, at least about 45°, at least about 50°, at least about 55°, at least about 60° , at least about 70°, at least about 80°, or even at least about 85°. Further, the predetermined swivel orientation as defined by swivel angle 201 may not be greater than about 90°, such as not greater than about 85°, not greater than about 80°, not greater than about 80°, 75°, not greater than about 70°, not greater than about 65°, not greater than about 60°, not greater than about 55°, not greater than about 50°, not being greater than about 45°, not greater than about 40°, not greater than about 35°, not greater than about 30°, not greater than about 25°, not greater than about 20° °, such as not greater than about 15°, not greater than about 10°, or even not greater than about 5°. It will be contemplated that the predetermined swivel orientation may be within a range between any of the minimum or maximum degrees described above.
[152] As further illustrated in FIG. 2A, the molded abrasive particle 103 may be in a position 113 overlapping the support 101 and having a predetermined rotational orientation. Notably, the predetermined rotational orientation of the molded abrasive particle 103 can be characterized as the smallest of the angles between the lateral plane 184 parallel to the lateral axis 181 and a dimension defined by a division axis 232 of the molded abrasive particle 103 extending through a center point 222 of the molded abrasive particle 102 in the width direction (w) of a side closest to the surface 181 of the holder 101. In one embodiment, the rotational angle 208 may be 0°. In other embodiments, the pivot angle 208 may be, such as at least about 2°, at least about 5°, at least about 10°, at least about 15°, at least about 20°, at least about 25°, at least about 30°, at least about 35°, at least about 40°, at least about 45°, at least about 50°, at least about 55°, at least about of 60°, at least about 70°, at least about 80°, or even at least about 85°. Further, the predetermined swivel orientation as defined by swivel angle 208 may not be greater than about 90°, such as not greater than about 85°, not greater than about 80°, not greater than about 80°, 75°, not greater than about 70°, not greater than about 65°, not greater than about 60°, not greater than about 55°, not greater than about 50°, not being greater than about 45°, not greater than about 40°, not greater than about 35°, not greater than about 30°, not greater than about 25°, not greater than about 20° °, such as not greater than about 15°, not greater than about 10°, or even not greater than about 5°. It will be contemplated that the predetermined swivel orientation may be within a range between any of the minimum or maximum degrees described above.
[153] According to one embodiment, the molded abrasive particle 102 may have a predetermined rotational orientation as defined by the rotational angle 201 that is different from the predetermined rotational orientation of the molded abrasive particle 103 as defined by the rotational angle 208. In In particular, the difference between the rotating angle 201 and the rotating angle 208 between the molded abrasive particles 102 and 103 can define a predetermined rotational orientation difference. In specific instances, the difference in predetermined swivel orientation may be 0°. In other instances, the difference in predetermined rotation orientation between either of the two shaped abrasive particles, such as at least about 1°, at least about 3°, at least about 5°, at least about 10° , at least about 15°, at least about 20°, at least about 25°, at least about 30°, at least about 35°, at least about 40°, at least about 45°, at least about 50°, at least about 55°, at least about 60°, at least about 70°, at least about 80°, or even at least about 85°. Further, the difference in predetermined rotational orientation between either of the two molded abrasive particles may be no greater than 90°, such as no greater than about 85°, no greater than about 80°, no greater than about 75°. °, not greater than about 70°, not greater than about 65°, not greater than about 60°, not greater than about 55°, not greater than about 50°, not greater than about 45°, not greater than about 40°, not greater than about 35°, not greater than about 30°, not greater than about 25°, not greater than about 20°, such as not greater than about 15°, not greater than about 10°, or even not greater than about 5°. It will be contemplated that the difference in predetermined swivel orientation may be within a range between any of the minimum or maximum values described above.
[154] FIG. 2B includes a perspective view illustration of a portion of an abrasive article including a molded abrasive particle in accordance with an embodiment. As illustrated, the abrasive article may include a molded abrasive particle 102 which overlays the support 101 at a first position 112 having a first rotational orientation with respect to a lateral axis 181 defining the width of the support 101. Certain aspects of the pre-orientation characteristics A determined number of molded abrasive particles can be described in relation to a three-dimensional x, y, z axis, as illustrated. For example, the predetermined longitudinal orientation of the molded abrasive particle 102 can be defined by the position of the molded abrasive particle on the y-axis, which extends parallel to the longitudinal axis 180 of the support 101. Furthermore, the predetermined lateral orientation of the molded abrasive particle molded abrasive particle 102 may be defined by the position of the molded abrasive particle on the y-axis, which extends parallel to the longitudinal axis 181 of support 101. Furthermore, the predetermined rotational orientation of molded abrasive particle 102 may be defined as the angle pivot 102 between the x axis, which corresponds to an axis or plane parallel to the lateral axis 181 to the division axis 231 of the molded abrasive particle 102 which extends through the center point 221 of the side 171 of the molded abrasive particle 102 connected to (directly or indirectly) support 101. As illustrated in general, the molded abrasive particle 102 can still have a predetermined vertical orientation and infill height. predetermined slope as described in this document. Notably, the controlled placement of a plurality of molded abrasive particles that facilitates control of the predetermined orientation characteristics described herein is a highly involved process that has not been previously contemplated or employed in the industry.
[155] For simplicity of explanation, the embodiments in this document mention certain characteristics relating to a plane defined by the X, Y, Z directions. However, it will be contemplated and appreciated that abrasive articles may have other shapes (e.g. coated abrasive belts defining an ellipsoidal or circular geometry or coated abrasive discs having a support molded into rings). The description of features in this document are not limited to flat configurations of abrasive articles and the features described in this document are applicable to abrasive articles of any geometry. In such instances, where the support has a circular geometry, the longitudinal axis and lateral axis may have two diameters extending through the center point of the support and having an orthogonal relationship to each other.
[156] FIG. 3A includes a top view illustration of a portion of an abrasive article 300 in accordance with one embodiment. As illustrated, the abrasive article 300 may include a first group 301 of molded abrasive particles, including molded abrasive particles 311, 312, 313, and 314 (311-314). As used herein, a group can refer to a plurality of molded abrasive particles that have at least one (or a combination of) predetermined orientation characteristics that are the same for each of the molded abrasive particles. Exemplary predetermined orientation features may include a predetermined swivel orientation, a predetermined lateral orientation, a predetermined longitudinal orientation, a predetermined vertical orientation, and a predetermined tip height. For example, the first group 301 of molded abrasive particles includes a plurality of molded abrasive particles having substantially the same predetermined rotational orientation with respect to one another. As illustrated later, abrasive particle 300 may include another group 303 including a plurality of molded abrasive particles, including for example molded abrasive particles 321, 322, 323, and 324 (321-324). As illustrated, group 303 may include a plurality of molded abrasive particles having the same predetermined rotational orientation. In addition, at least a portion of the molded abrasive particles of group 303 may have a predetermined lateral orientation with respect to one another (e.g. molded abrasive particles 321 and 322 and molded abrasive particles 323 and 324). In addition, at least a portion of the molded abrasive particles of group 303 may have a predetermined lateral orientation with respect to one another (e.g. molded abrasive particles 321 and 322 and molded abrasive particles 323 and 324).
[157] As illustrated later, the abrasive article may include a group 305. The group 305 may include a plurality of molded abrasive particles, including molded abrasive particles 331, 332 and 333 (331-333) having at least one pre-orientation characteristic. - determined in common. As illustrated in the embodiment of FIG. 3A, a plurality of abrasive particles molded within the group 305 may have the same predetermined rotational orientation with respect to one another. Furthermore, at least a portion of the molded abrasive particles of group 305 may have a predetermined lateral orientation with respect to one another (e.g. molded abrasive particles 322 and 333). Furthermore, at least a portion of the plurality of molded abrasive particles of group 305 may have the same predetermined longitudinal orientation with respect to one another. The use of groups of molded abrasive particles and specifically a combination of groups of molded abrasive particles having characteristics described herein can facilitate improved performance of the abrasive article.
[158] As illustrated later, the abrasive article 300 may include groups 301, 303, and 305, which may be separated by channel regions 307 and 308 that extend between groups 301, 303, 305. In specific instances, the regions of the channel may be regions on the abrasive article that may be significantly free of abrasive particles. Furthermore, the channel regions 307 and 308 can be configured to move liquids between groups 301, 303 and 305, which can improve metal particulate removal and grinding performance of the abrasive article. Channel regions 307 and 308 may be predetermined regions on the surface of the molded abrasive article. Channel regions 307 and 308 may define dedicated regions between groups 301, 303, and 305 that are different, and more especially, greater in width and/or length, than the longitudinal space or lateral space between adjacent molded abrasive particles. in groups 301, 303 and 305.
[159] Channel regions 307 and 308 may extend along a direction that is parallel or perpendicular to longitudinal axis 180 or parallel or perpendicular to lateral axis 181 of support 101. In specific instances, channel regions 307 and 308 may have axes, 351 and 352 respectively, that extend along a center of the channel regions 307 and 308 and along a longitudinal dimension of the channel regions 307 and 308 may have a predetermined angle with respect to the axis longitudinal axis 380 of the support 101. In addition, the axes 351 and 352 of the channel regions 307 and 308 can form a predetermined angle relative to the lateral axis 181 of the support 101. Controlled orientation of the channel regions can facilitate improved performance of the support. abrasive article.
[160] In addition, the channel regions 307 and 308 can be formed so that they have a predetermined orientation with respect to the grinding direction 350. For example, the channel regions 307 and 308 can extend along a a direction that is parallel or perpendicular to the grinding direction 350. In specific instances, the channel regions 307 and 308 may have axes, 351 and 352, respectively, that extend along a center of the channel regions 307 and 308 and along a longitudinal dimension of the channel regions 307 and 308 can be at a predetermined angle to the grinding direction 350. Controlled orientation of the channel regions can facilitate improved performance of the abrasive article.
[161] In at least one embodiment, as illustrated, the group 301 may include a plurality of molded abrasive particles, wherein at least a portion of the plurality of molded abrasive particles in the group 301 may define a pattern 315. As illustrated, the plurality of abrasive particles 311-314 can be arranged with respect to each other in a predetermined distribution which further defines a two-dimensional arrangement, such as in the shape of a quadrilateral, as viewed from top to bottom. An array is a pattern having short range order defined by a particle unit array of molded abrasive particles and others having long range order including regular and repeating units linked together. It will be contemplated that two-dimensional arrangements may be formed, including other shapes of polygons, ellipses, ornamental signs, product signs or other designs. As illustrated later, the group 303 may include a plurality of abrasive particles 321-324 which may also be arranged in a pattern 325 defining a two-dimensional quadrilateral arrangement. In addition, the group 305 may include a plurality of molded abrasive particles 331-334 which may be arranged with respect to each other to define a predetermined distribution in the form of a triangular pattern 335.
[162] In one embodiment, the plurality of molded abrasive particles of one group 301 may define a pattern that is different from molded abrasive particles of another group (e.g., group 303 or 305). For example, molded abrasive particles of group 301 may define a pattern 315 that is different from pattern 335 of group 305 with respect to orientation on the support 101. In addition, molded abrasive particles of group 301 may define a pattern 315 that has a first orientation relative to the grinding direction 350 as compared to the orientation of the pattern of a second group (e.g. 303 or 305) relative to the grinding direction 350.
[163] Notably, one of the groups (301, 303 or 305) of molded abrasive particles may have a pattern defining one or more vectors (e.g. 361 or 362 of group 305) that have a specific orientation with respect to the of grinding. In particular, the molded abrasive particles of a group have a predetermined orientation characteristic that defines a pattern of the group, which may further define one or more vectors of the pattern. In an exemplary embodiment, vectors 361 and 362 of pattern 335 may be controlled to form a predetermined angle to the milling direction 350. Vectors 361 and 362 have various orientations including, for example, a parallel orientation, perpendicular orientation, or still a non-orthogonal or non-parallel orientation (e.g. angled to define an acute angle or obtuse angle) with respect to the grinding direction 350.
[164] In one embodiment, the plurality of molded abrasive particles of the first group 301 may have at least one predetermined orientation characteristic that is different from the plurality of abrasive particles in another group (e.g., 303 or 305). For example, at least a portion of the molded abrasive particles of group 301 may have a predetermined rotational orientation that is different from the predetermined rotational orientation of at least a portion of the molded abrasive particles of group 303. Further, in a specific aspect , the molded abrasive particles of group 301 may have a predetermined rotational orientation that is different from the predetermined rotational orientation of all molded abrasive particles of group 303.
[165] In another embodiment, at least a portion of the molded abrasive particles of the group 301 may have a predetermined lateral orientation that is different from the predetermined lateral orientation of at least a portion of the molded abrasive particles of the group 303. For yet another embodiment, all molded abrasive particles of group 301 may have a predetermined lateral orientation that is different from the predetermined lateral orientation of all molded abrasive particles of group 303.
[166] Further, in another embodiment, at least a portion of the molded abrasive particles of the group 301 may have a predetermined longitudinal orientation which may be different from the predetermined longitudinal orientation of at least a portion of the molded abrasive particles of the group 303. For another embodiment, all molded abrasive particles of group 301 may have a predetermined longitudinal orientation which may be different from the predetermined longitudinal orientation of all molded abrasive particles of group 303.
[167] In addition, at least a portion of the molded abrasive particles of group 301 may have a predetermined vertical orientation that is different from the predetermined vertical orientation of at least a portion of the molded abrasive particles of group 303. Further, for In one aspect, all molded abrasive particles of group 301 may have a predetermined vertical orientation that is different from the predetermined vertical orientation of all molded abrasive particles of group 303.
[168] Further, in one embodiment, at least a portion of the molded abrasive particles of the group 301 may have a predetermined rake height that is different from the predetermined rake height of at least a portion of the molded abrasive particles of the group 301. 303. In yet another specific embodiment, all molded abrasive particles of group 301 may have a predetermined rake height that is different from the predetermined rake height of all molded abrasive particles of group 303.
[169] It will be contemplated that any number of groups may be included in the abrasive article by creating multiple regions on the abrasive article having predetermined orientation characteristics. Furthermore, each of the groups may be different from each other as described in the preceding item for groups 301 and 303.
[170] As described in one or more embodiments herein, the molded abrasive particles may be arranged in a predetermined distribution defined by predetermined positions on the support. Most notably, the predetermined distribution can define a shadowless arrangement between one or more molded abrasive particles. For example, in a specific embodiment, the abrasive article may include a first abrasive particle at a first predetermined position and a second abrasive particle molded at a second predetermined position, such that the first and second abrasive particles molded define a arrangement without shadow in relation to each other. A shadowless arrangement can be defined by an arrangement of abrasive particles molded in such a way that they are configured to make initial contact with the part at separate locations on the part and limiting or preventing an initial overlap at the site of initial material removal on the part. . A shadeless arrangement can facilitate improvement in grinding performance. In a specific embodiment, the molded first abrasive particle can be part of a group defined by a plurality of molded abrasive particles, and a second molded abrasive particle can be part of a second group defined by a plurality of molded abrasive particles. The first group may define a first arrow on the support and a second group may define a second arrow on the support, and each of the molded abrasive particles of the second group may be staggered with respect to each of the molded abrasive particles of the first group, therefore, defined a specific unshaded arrangement.
[171] FIG. 3B includes a perspective view illustration of a portion of an abrasive article including molded abrasive particles having predetermined orientation characteristics with respect to a grinding direction in accordance with one embodiment. In one embodiment, the abrasive article may include a molded abrasive particle 102 having a predetermined orientation with respect to another molded abrasive particle 103 and/or with respect to a grinding direction 385. Control of one or a combination of characteristics of predetermined orientation with respect to grinding direction 385 can facilitate improved grinding performance of the abrasive particle. Grinding direction 385 may be an intended direction of movement of the abrasive article relative to a part in a material removal operation. In specific instances, the grinding direction 385 may be relative to dimensions of the holder 101. For example, in one embodiment, the grinding direction 385 may be significantly perpendicular to the lateral axis 181 of the holder and substantially parallel to the longitudinal axis 180 of the holder 101. The predetermined orientation characteristics of the molded abrasive particle 102 can define an initial contact surface of the molded abrasive particle 102 with a part. For example, molded abrasive particle 102 can have major surfaces 363 and 364, and side surfaces 365 and 366 that extend between major surfaces 363 and 364. Predetermined orientation characteristics of molded abrasive particle 102 can position the molded abrasive particle 102 such that the major surface 363 is configured to make initial contact with a part before other surfaces of the molded abrasive particle 102. This orientation can be considered a forward orientation with respect to the grinding direction 385. More specifically, the molded abrasive particle 102 can having a split axis 231 having a specific orientation with respect to the milling direction. For example, as illustrated, the grinding direction vector 385 and the splitting axis 231 are significantly perpendicular to each other. It will be appreciated that just as any variety of predetermined rotational orientations are contemplated for a molded abrasive particle, any variety of orientations of the molded abrasive particles with respect to the grinding direction 385 is contemplated and can be used.
[172] The molded abrasive particle 103 can have predetermined orientation characteristics with respect to the molded abrasive particle 102 and the grinding direction 385. As illustrated, the molded abrasive particle 103 can include larger surfaces 391 and 392 that can be joined by side surfaces 371 and 372. Also, as illustrated, the molded abrasive particle 103 may have a split axis 372 forming a specific angle with respect to the grinding direction vector 385. As illustrated, the split axis 373 of the molded abrasive particle 103 may have a significant parallel orientation with milling direction 385 such that the angle between split axis 373 and milling direction 385 is essentially 0 degrees. Accordingly, the predetermined orientation characteristics of the molded abrasive particle facilitate initial contact of surface 372 with a skin before other surfaces of the molded abrasive particle. Such an orientation of the molded abrasive particle 103 can be considered a lateral orientation with respect to the grinding direction 385.
[173] It will be appreciated that the molded abrasive article may include one or more groups of molded abrasive particles which may be arranged in a predetermined distribution relative to one another, and more specifically may have distinct predetermined orientation characteristics that define groups of molded abrasive particles. The groups of molded abrasive particles as described herein may have a predetermined orientation with respect to a grinding direction. The groups of molded abrasive particles as described herein may have a predetermined orientation with respect to a grinding direction. The use of groups of molded abrasive particles having different predetermined orientations with respect to the grinding direction can facilitate improved performance of the abrasive article.
[174] FIG. 4 includes a top view illustration of a portion of an abrasive article in accordance with one embodiment. In particular, the abrasive article 400 may include a first group 401, including a plurality of molded abrasive particles. As illustrated, the molded abrasive particles can be arranged relative to each other to define a predetermined distribution. More specifically, the predetermined distribution may be in the form of a pattern 423 as viewed from above, and more specifically defining a molded triangular two-dimensional array. As illustrated later, the group 401 may be arranged on the abrasive article 400 defining a predetermined micro-unit 431 that overlaps the support 101. In one embodiment, the micro-unit 431 may have a specific two-dimensional shape as seen from above. down. Some exemplary two-dimensional shapes may include polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, Arabic alphabet characters, kanji characters, complex shapes, designs, and any combination thereof. In specific examples, forming a group having a specific microunit can facilitate improvement in the performance of the abrasive article.
[175] As illustrated later, the abrasive article 400 can include a group 404 that encompasses a plurality of abrasive particles that can be arranged on the surface of the support 101 to define a predetermined distribution. Notably, the predetermined distribution can include an array of a plurality of molded abrasive particles that define a pattern, and more specifically, a general quadrilateral pattern 424. As illustrated, the group 404 can define a micro-unit 434 on the surface of the abrasive article. 400. In one embodiment, the microunit 434 of group 404 may have a two-dimensional shape as viewed from top to bottom, including, for example, a polygon shape, and more specifically, a general quadrilateral (diamond) shape, as viewed downwards over the surface of the abrasive article 400. In the illustrated embodiment of FIG. 4, the group 401 may have a microunit 431 that is significantly the same as the microunit 434 of the group 404. However, it will be contemplated that in other embodiments, several different groups may be used on the surface of the abrasive article, and more specifically where each one of the different groups has a different microunit.
[176] As illustrated later, the abrasive article may include groups 401, 402, 403, and 404 that may be separated by channel regions 422 and 421 that span between groups 401 to 404. In specific instances, the channel regions may be significantly free of abrasive particles. Furthermore, channel regions 421 and 422 can be configured to move liquids between groups 401-404, which can improve metal particulate removal and grinding performance of the abrasive article. Additionally, in certain embodiments, the abrasive article 400 may include channel regions 421 and 422 that extend between groups 401-404, wherein the channel regions 421 and 422 may be patterned on the surface of the abrasive article 400. In instances For specific purposes, channel regions 421 and 422 may represent a regular, repeating array of features that extend across a surface of the abrasive article.
[177] FIG. 5 includes a top view illustration of a portion of an abrasive article in accordance with one embodiment. Notably, the abrasive article 500 may include a molded abrasive particle 501 that overlies, and more specifically, coupled to the support 101. In at least one embodiment, the abrasive articles of the embodiments herein may include an arrow 511 of the molded abrasive particles. . Arrow 511 may include a group of molded abrasive particles 501, wherein each of the molded abrasive particles 501 within arrow 511 may have the same predetermined lateral orientation with respect to one another. In particular, as illustrated, each of the molded abrasive particles 501 of the arrow 511 may have a predetermined lateral orientation with respect to the lateral axis 551. In addition, each of the molded abrasive particles 501 of the first arrow 511 may be part of a group and, therefore, having at least one predetermined orientation characteristic that is the same with respect to each other. For example, each of the molded abrasive particles 501 of arrow 511 may be separate from a group having the same predetermined vertical orientation, and may define a vertical association. In yet another embodiment, each of the molded abrasive particles 501 of the arrow 511 can be part of a group having the same predetermined spin orientation and can define a spin association. Furthermore, each of the molded abrasive particles 501 of the arrow 511 may be part of a group having the same predetermined pitch height with respect to each other and may define a pitch height association. Additionally, as illustrated, the abrasive article 500 may include a plurality of groups in the direction of arrow 511 that may be spaced from one another along longitudinal axis 180, and more specifically, separated from one another by other intervening arrows, including, for example arrow 521, 531 and 541.
[178] As further illustrated in FIG. 5, the abrasive article 500 can include molded abrasive particles 502 that can be arranged relative to one another to define an arrow 521. The arrow 521 of the molded abrasive particles 502 can include any of the features described in accordance with arrow 511. Notably, the molded abrasive particles 502 of the arrow 521 may have the same predetermined lateral orientation with respect to each other. Furthermore, the molded abrasive particles 502 of arrow 521 may have at least one predetermined orientation characteristic that is different from a predetermined orientation characteristic of any of the molded abrasive particles 501 of arrow 511. molded abrasive particles 502 of arrow 521 may have at least one predetermined orientation characteristic that is different from a predetermined orientation characteristic of any of the molded abrasive particles 501 of arrow 511.
[179] In accordance with another embodiment, the abrasive article 500 may include molded abrasive particles 503 arranged relative to one another and defining an arrow 531. Arrow 531 may have any of the characteristics as described in accordance with other embodiments, specifically, with with respect to arrow 511 and arrow 521. Furthermore, as illustrated, each of the molded abrasive particles 503 within arrow 531 can have at least one predetermined orientation characteristic that is the same with respect to one another. Furthermore, each of the molded abrasive particles 503 within the arrow 531 may have at least one predetermined orientation characteristic that is different from a predetermined orientation characteristic with respect to any of the molded abrasive particles 501 of the arrow 511 of the molded abrasive particles 502 of the arrow 521. Notably, as illustrated, each of the molded abrasive particles 503 of the arrow 531 can have the same predetermined rotational orientation that is different with respect to a predetermined rotational orientation of the molded abrasive particles 501 and arrow 511 and predetermined rotational orientation of the molded abrasive particles 502 of arrow 521.
[180] As illustrated later, the abrasive article 500 may include molded abrasive particles 504 arranged relative to one another and defining an arrow 541 on the surface of the abrasive article. 500. As illustrated, each of the molded abrasive particles 504 and arrow 541 can have at least the same predetermined orientation characteristic. Additionally, according to one embodiment, each of the molded abrasive particles 504 may have at least the same predetermined orientation characteristic, such as a predetermined rotational orientation that is different from the predetermined rotational orientation of any of the particles. 501 molded abrasives from arrow 511, and molded abrasive particles from arrow 531.
[181] As illustrated later, the abrasive article 500 may include a column 561 of molded abrasive particles, including at least one molded abrasive particle from each of arrows 511, 521, 531, and 541. Notably, each of the molded abrasive particles within of column 561 may share at least one predetermined orientation feature and, more specifically, at least one predetermined longitudinal orientation with respect to each other. As such, each of the molded abrasive particles within the column 561 may have a predetermined longitudinal orientation with respect to each other and a longitudinal plane 562. In certain instances, the arrangement of molded abrasive particles in groups, which may include the arrangement of abrasive particles molded into arrows, columns, vertical associations, swivel associations, and slope height associations can facilitate improvement in abrasive article performance.
[182] FIG. 6 includes a top view illustration of a portion of an abrasive article in accordance with one embodiment. Notably, the abrasive article 600 can include molded abrasive particles that can be arranged relative to one another to define a column 621 that extends along the longitudinal plane 651 and having at least the same predetermined orientation characteristics relative to each other. others. For example, each of the molded abrasive particles 601 of the association 621 may have the same predetermined longitudinal orientation with respect to each other and the longitudinal axis 651. It will be contemplated that the abrasive particles 601 of the column 621 may share at least one other characteristic of predetermined orientation, including, for example, the same predetermined swivel orientation with respect to each other.
[183] As illustrated later, the abrasive article 600 may include molded abrasive particles 602 arranged relative to one another on the support 101, and defining a column 622 with respect to one another along a longitudinal plane 652. It will be contemplated that the abrasive particles 602 of column 622 may share at least one other predetermined orientation characteristic, including, for example, the same predetermined rotational orientation with respect to each other. Further, each of the molded abrasive particles 602 of column 622 may define a group having at least one predetermined orientation characteristic different from at least one predetermined orientation characteristic of at least one of the molded abrasive particles 621 of column 621. More specifically, each of the molded abrasive particles 602 of the column 622 may define a group having a combination of predetermined orientation characteristics different from a combination of predetermined orientation characteristics of the molded abrasive particles 601 of the column 621.
[184] In addition, as illustrated, the abrasive article 600 may include molded abrasive particles 603 having the same predetermined longitudinal orientation with respect to each other along the longitudinal plane 653 on the support 101 and defining a column 623. Further, each of the molded abrasive particles 603 of the column 623 may define a group having at least one predetermined orientation characteristic different from at least one predetermined orientation characteristic of at least one of the molded abrasive particles 621 of the column 621 and the particles molded abrasive particles 602 of column 622. More specifically, each of the molded abrasive particles 603 of column 623 may define a group having a combination of predetermined orientation characteristics different from a combination of predetermined orientation characteristics of the molded abrasive particles 601 column 621 and molded abrasive particles 602 from column 622.
[185] FIG. 7A includes a top view of a portion of an abrasive article in accordance with one embodiment. In specific instances, the abrasive articles herein may further include orientation regions that facilitate placement of molded abrasive particles in predetermined orientations. The guide regions can be coupled to the support 101 of the abrasive article. Alternatively, the guide regions may be part of an adhesive layer, including, for example, a make coat or a size coat. In yet another embodiment, the guidance regions may be overlapping the support 101 or even more specifically integrated with the support 101.
[186] As illustrated in FIG. 7A, the abrasive article 700 may include molded abrasive particles 701, 702, 703, (701-703), and each of the abrasive particles 701-703 may be coupled with a respective orientation region 721, 722, and 723 (732-723). ). In one embodiment, orientation region 721 can be configured to define at least one (or a combination of) predetermined orientation characteristics of a molded abrasive particle 701. For example, orientation region 721 can be configured to defining a predetermined swivel orientation, a predetermined lateral orientation, a predetermined longitudinal orientation, a predetermined vertical orientation, a predetermined pitch height, and a combination thereof with respect to the molded abrasive particle 701. In addition Furthermore, in a specific embodiment, orientation regions 721, 722 and 723 may be associated with a plurality of molded abrasive particles 701-703 and may define a group 791.
[187] According to one embodiment, orientation regions 721723 may be associated with an alignment structure, and more specifically, to an alignment structure (eg, discrete contact regions) as described in more detail in this document. Orientation regions 721-723 may be integrated with any of the components of the abrasive article, including for example the backing 101 or adhesive layers, and thus may be considered contact regions as described in more detail herein. Alternatively, guidance regions 721-723 may be associated with the use of alignment structures in forming the abrasive article, which may be an individual component of the support and integrated with the abrasive article, and which may not necessarily form a contact region. associated with the abrasive article.
[188] As illustrated later, the abrasive article 700 may further include molded abrasive particles 704, 705, 706, (705-706), wherein each of the molded abrasive particles 704-706 may be associated with an orientation region 724, 725, 726, respectively. Orientation regions 724-726 may be configured to control at least one predetermined orientation characteristic of molded abrasive particles 704-706. Furthermore, orientation regions 724-726 can be configured to define a group 792 of the molded abrasive particle 704-706. According to one embodiment, the orientation regions 724-726 may be spaced apart from each other from the orientation regions 721-723. More specifically, orientation regions 724-726 may be configured to define a group 792 having at least one predetermined orientation characteristic that is different from a predetermined orientation characteristic of the molded abrasive particles 701-703 of group 791.
[189] FIG. 7B includes an illustration of a view of a portion of an abrasive article in accordance with one embodiment. In particular, FIG. 7B includes an illustration of specific embodiments of alignment structures and contact regions that can be used and configured to facilitate at least one predetermined orientation characteristic of one or more abrasive particles associated with an alignment structure and contact regions.
[190] FIG. 7B includes a portion of an abrasive article including a support 101 of a first group 791 of molded abrasive particles 701 and 702 which overlay the support 101, a second group 792 of molded abrasive particles 704 and 705 which overlay the support 101, a third group 793 of molded abrasive particles 744 and 745 which overlay support 101, and a fourth group 794 of molded abrasive particles 746 and 747 which overlay support 101. It will be contemplated that although several different multiple groups 791, 792, 793 and 794 are illustrated, the illustration is not limiting in any way, and the abrasive articles of the embodiments herein may include any number of group arrangements.
[191] The abrasive article of FIG. 7B further includes an alignment structure 761 having a first contact region 721 and a second contact region 722. Alignment structure 761 may be used to facilitate placement of molded abrasive particles 701 and 702 in desired orientations on the support and in relationship to each other. The alignment structure 761 of the embodiments of this document may be a permanent part of the abrasive article. For example, alignment structure 761 may include contact regions 721 and 722, which may overlap support 101, and in some instances, directly contact support 101. In specific instances, alignment structure 761 may be integral with the abrasive article and may overlay the backing, support the adhesive layer overlaying the backing, or be an integral part of one or more adhesive layers overlaying the backing.
[192] According to one embodiment, alignment structure 761 may be configured to deliver and in specific instances, temporarily or permanently retain abrasive particle 701 in a first position 771. In specific instances, as illustrated in FIG. 7B, alignment structure 761 may include a contact region 721, which may have a specific two-dimensional shape as viewed from above and defined by the contact region width (wcr) and contact region length (lcr), wherein the length is the longest dimension of the contact region 721. In accordance with at least one embodiment, the contact region can be formed to have a shape (e.g., the two-dimensional shape) that can facilitate controlled orientation of the contact region. molded abrasive particle 701. More specifically, the contact region 721 may have a two-dimensional shape configured to control one or more (e.g., at least two of) specific predetermined orientation characteristics, including, for example, a predetermined rotational orientation. determined, a predetermined lateral orientation, and a predetermined longitudinal orientation.
[193] In specific instances, the contact regions 721 and 722 may be formed to have controlled two-dimensional shapes that can facilitate a predetermined rotational orientation of the corresponding molded abrasive particles 701 and 702. For example, the contact region 721 may have a controlled or predetermined two-dimensional shape configured to determine a predetermined rotational orientation of the molded abrasive particle 701. In addition, the contact region 722 may have a controlled or predetermined two-dimensional shape configured to determine a predetermined rotational orientation of the molded abrasive particle 702.
[194] As illustrated, the alignment structure may include a plurality of discrete contact regions 721 and 722, wherein each of the contact regions 721 and 722 may be configured to temporarily or permanently deliver and retain one or more abrasive particles. molded. In some instances, the alignment structure may include a net, a fibrous material, a mesh, a solid structure having openings, a belt, a roller, a patterned material, a discontinuous layer of material, a patterned adhesive material, and a combination thereof. .
[195] The plurality of contact regions 721 and 722 may define at least one of the predetermined rotational orientations of a molded abrasive particle, a predetermined rotational orientation difference between at least two molded abrasive particles, the predetermined longitudinal orientation of a molded abrasive particle, a longitudinal space between two molded abrasive particles, the predetermined lateral orientation, a lateral space between two molded abrasive particles, a predetermined vertical orientation, a predetermined vertical orientation difference between two particles molded abrasives, a predetermined slope height between two abrasive particles. In specific instances, as illustrated in FIG. 7B, the plurality of discrete contact regions may include a first contact region 721 and a second contact region 722 distinct from the first contact region 721. While the contact regions 721 and 722 are illustrated as having the same general shape one in with respect to each other, as will be apparent based on further embodiments described herein, the first contact region 721 and second contact region 722 may be formed to have two different two-dimensional shapes. Furthermore, although not illustrated, it will be contemplated that the alignment structures of the embodiments herein may include first and second contact regions configured to deliver and count molded abrasive particles in different predetermined rotational orientations with respect to each other.
[196] In a specific embodiment, contact regions 721 and 722 may have a two-dimensional group format consisting of polygons, ellipsoids, numerals, crosses, multi-branched polygons, Greek alphabet characters, Latin alphabet characters, Russian alphabet, Arabic alphabet characters, rectangle, quadrilateral, pentagon, hexagon, heptagon, octagon, nonagon, decagon and a combination thereof. Furthermore, while the contact regions 721 and 722 are illustrated as having significantly the same two-dimensional shape, it will be contemplated that, in alternative embodiments, the contact regions 721 and 722 may have different two-dimensional shapes. Two-dimensional shapes are shapes of contact regions 721 and 722 as viewed in the plane of the length and width of the contact regions, which can be the same plane defined by the top surface of the bracket.
[197] In addition, it will be contemplated that the alignment structure 761 may be a temporary part of the abrasive article. For example, alignment structure 761 may represent a model of another object that temporarily fixes molded abrasive particles at the contact regions, facilitating placement of molded abrasive particles in a desired position having one or more predetermined orientation characteristics. After placement of the molded abrasive particles, the alignment structure can be removed leaving the molded abrasive particle on the support in predetermined positions.
[198] According to a specific embodiment, the alignment structure 761 may be a discontinuous layer of material, including the plurality of contact regions 721 and 722 which may be made of an adhesive material. In more specific instances, the contact region 721 may be configured to adhere to at least one molded abrasive particle. In other embodiments, the contact region 721 may be formed to adhere to more than one molded abrasive particle. It will be contemplated that according to at least one specific embodiment, the adhesive material may include an organic material, and more specifically, at least one resin material.
[199] In addition, the plurality of contact regions 721 and 722 may be arranged on the surface of support 101 to define a predetermined distribution of contact regions. The predetermined distribution of contact regions can have any characteristic of the predetermined distributions described in this document. In particular, the pre-determined distribution of the contact regions can define a controlled overhang arrangement. The predetermined distribution of contact regions may define and significantly correspond to the same predetermined distribution of abrasive particles molded onto the support, wherein each of the contact regions may define a position of a molded abrasive particle.
[200] As illustrated, in certain instances, contact regions 721 and 722 may be spaced apart from each other. In at least one embodiment, the contact regions 721 and 722 may be spaced apart from each other by a distance 731. The distance 721 between the contact regions 721 and 722 is generally the shortest distance between the adjacent contact regions 721 and 722 in a direction parallel to the lateral axis 181 or longitudinal axis 180.
[201] According to one embodiment, the discrete contact regions of the plurality of discrete contact regions may be spaced from one another by a spacing distance that extends in either direction between adjacent discrete contact regions and over a region without contact, wherein essentially no adhesive material is provided on the backing 101. For example, the spacing distance may be the distance 731 between the discrete contact regions 721 and 722 from a direction parallel to the lateral axis 181. Alternatively, in another embodiment, the spacing distance can be a distance 723 that extends in a direction parallel to the longitudinal axis 180. The preceding examples are non-limiting and the spacing distance can extend in any variety of directions depending on the shortest distance between a first region discrete contact region and a second contact region, while extending over a non-contact region. In one embodiment, the spacing distance may be at least about 0.5(w), where (w) corresponds to a width of a body of a molded abrasive particle. In other instances, the spacing distances can be at least about 0.7(w), at least about 0.9(w), at least about 1(w), at least about 1.1(w), at least about 1.3(w). Also, in a non-limiting embodiment, the spacing distance may be no greater than about 100(w), no greater than about 50(w). The formation of discrete contact regions of certain dimensions can improve processing over other methods using a continuous material coating. For example, in certain instances, the use of a continuous coating comprising discrete contact regions can reduce processing time and reduce blistering associated with abrasive articles using a continuous material coating. Furthermore, and unexpectedly, the molded abrasive can undergo anchoring improvements using a discontinuous coating as opposed to a continuous coating.
[202] For another embodiment, the spacing distance may be at least about 0.1 mm, such as at least about 0.5 mm, at least about 1 mm, at least about 2 mm, or even at least about 2.5 mm. In yet another non-limiting embodiment, the spacing distance may be no greater than about 50 mm, such as no greater than about 40 mm, or no greater than about 20 mm.
[203] In certain embodiments, discrete contact regions 721 and 722 may have a specific width (wcr) relative to a dimension of a molded abrasive particle body, which may facilitate the features of the embodiments herein. For example, the discrete containment region 721 can have a width (wcr) defining a minimum dimension of the discrete containment region which can be at least about 0.5(h), where (h) is a height of one body of an abrasive particle shaped as described in embodiments herein. In another instance, the width of discrete contact region 721 may be at least about 0.7(h), such as at least about 0.9(h), at least about 1(h), at least about 1.1(h), at least about 1.3(h). Further, in a non-limiting embodiment, the width of discrete contact region 721 may be no greater than about 100(h), such as no greater than about 50(h). It will be appreciated that the width of the discrete contact region 721 may vary between any of the aforementioned minimum and maximum values. Furthermore, it will be contemplated that the width of discrete contact region 721 may be assigned to any discrete contact regions of the embodiments herein, and it is further understood that a width may correlate to a diameter in the context of a discrete contact region having a circular shape (eg, discrete contact region 763).
[204] For another embodiment, the width of the discrete contact region 721 may be no greater than about 5 mm, such as no greater than about 4 mm, no greater than about 3 mm, no greater than about 2 mm, not greater than about 1 mm, or even not greater than about 0.8 mm. In yet another non-limiting embodiment, the width of discrete contact region 721 may be at least about 0.01 mm, such as at least about 0.05 mm, or even at least about 0.1 mm. It will be appreciated that the width of the discrete contact region 721 may vary between any of the aforementioned minimum and maximum values. Furthermore, it will be contemplated that the width of discrete contact region 721 may be assigned to any discrete contact regions of the embodiments herein, and it is further understood that a width may correlate to a diameter in the context of a discrete contact region having a circular shape (eg, discrete contact region 763).
[205] Control of the size and shape of discrete contact regions can be achieved by controlling a rheology of an adhesive material used to form each of the discrete contact regions of the plurality of discrete contact regions. However, it will be appreciated that other process controls may be used.
[206] In an alternative embodiment, the plurality of discrete contact regions 721 and 722 may be openings in a structure, such as a substrate. For example, each of the contact regions 721 and 722 may be apertures in a template that are used to temporarily allocate the molded abrasive particles to specific positions on the support 101. The plurality of apertures may extend partially or entirely through the thickness of the blade. alignment structure. Alternatively, the contact regions 7821 and 722 may be openings in a structure, such as a substrate or layer that is permanently part of the support and final abrasive article. The apertures may have specific cross-sectional shapes which may be complementary to a cross-sectional shape of molded abrasive particles to facilitate placement of molded abrasive particles in predetermined positions and with one or more predetermined orientation characteristics.
[207] Furthermore, according to one embodiment, the alignment structure may include a plurality of discrete contact regions separated by non-contact regions, where the non-contact regions are regions distinct from the discrete contact regions and may be significantly free. of molded abrasive particles. In one embodiment, the non-contact regions may define regions configured to be essentially free of adhesive material and separating contact regions 721 and 722. In a specific embodiment, the non-contact region may define regions configured to be essentially free of molded abrasive particles.
[208] Various methods can be used to form an alignment structure and discrete contact regions, including, but not limited to, processes such as coating, spraying, depositing, printing, etching, masking, stripping, molding, casting, stamping, heating, curing, clamping, pinning, fixing, pressing, laminating, sewing, sticking, irradiating, and a combination thereof. In specific instances, where the alignment structure is in the form of a discontinuous layer of adhesive material, which may include a plurality of discrete contact regions, including an adhesive material spaced from one another by non-contact regions, the forming process may include a selective deposition of adhesive material.
[209] As illustrated and noted above, FIG. 7B further includes a second group 792 of molded abrasive particles 704 and 705 which overlay the support 101. The second group 792 may be associated with an alignment structure 762, which may include a first contact region 724 and a second contact region 725. Alignment structure 762 may be used to facilitate placement of molded abrasive particles 704 and 705 in desired orientations on support 101 and relative to each other. As noted in this document, alignment structure 762 can have any of the characteristics of alignment structures described in this document. It will be contemplated that alignment structure 762 may be a permanent or temporary part of the final abrasive article. Alignment structure 762 may be integral with the abrasive article, and may overlay backing 101, supporting an adhesive layer overlaying backing 101, or be an integral part of one or more adhesive layers overlying backing 101.
[210] According to one embodiment, alignment structure 762 may be configured to deliver and in specific instances, temporarily or permanently retain abrasive particle 704 in a first position 773. In specific instances, as illustrated in FIG. 7B, alignment structure 762 may include a contact region 724, which may have a specific two-dimensional shape as viewed from above and defined by the contact region width (wcr) and contact region length (lcr), where length is the longest dimension of the contact region 724.
[211] In accordance with at least one embodiment, the contact region 724 may be formed to have a shape (e.g., a two-dimensional shape) which can facilitate controlled orientation of the molded abrasive particle 704. More specifically, the region of Contact 724 may have a two-dimensional shape configured to control one or more (e.g., at least two of) specific predetermined orientation features, including, for example, a predetermined swivel orientation, a predetermined lateral orientation, and a predetermined orientation. predetermined longitudinal orientation. In at least one embodiment, the contact region 724 may be formed to have a two-dimensional shape, wherein the dimensions of the contact region 724 (e.g., length and/or width) significantly correspond to and are significantly the same dimensions as the abrasive particle. mold 704, thereby facilitating positioning of the molded abrasive particle at position 772 and facilitating one or a combination of predetermined orientation characteristics of molded abrasive particle 704. Further, according to one embodiment, alignment structure 762 may include a plurality of contact regions having controlled two-dimensional shapes configured to facilitate and control one or more predetermined orientation characteristics of associated molded abrasive particles.
[212] As illustrated later, and in accordance with one embodiment, the alignment structure 762 may be configured to deliver and, in specific instances, temporarily or permanently retain the molded abrasive particle 705 in a second position 774. In specific instances, such as illustrated in FIG. 7B, alignment structure 762 may include a contact region 725, which may have a specific two-dimensional shape as viewed from above and defined by the contact region width (wcr) and contact region length (lcr), where the length is the longest dimension of the contact region 725. Notably, the contact regions 724 and 725 of the alignment structure may have a different orientation relative to the contact regions 721 and 722 of the alignment structure 761 to facilitate different predetermined orientation characteristics between molded abrasive particles 701 and 702 of group 791 and molded abrasive particles 704 and 705 of group 792.
[213] As illustrated and noted above, FIG. 7B further includes a third group 793 of molded abrasive particles 744 and 745 which overlay the support 101. The third group 793 may be associated with an alignment structure 763, which may include a first contact region 754 and a second contact region 755. Alignment structure 763 can be used to facilitate placement of molded abrasive particles 744 and 745 in desired orientations on support 101 and relative to each other. As noted in this document, alignment structure 763 can have any of the characteristics of alignment structures described in this document. It will be contemplated that alignment structure 763 may be a permanent or temporary part of the final abrasive article. Alignment structure 763 may be integral with the abrasive article, and may overlay backing 101, supporting an adhesive layer overlaying backing 101, or be an integral part of one or more adhesive layers overlying backing 101.
[214] In one embodiment, alignment structure 763 may be configured to deliver and in specific instances temporarily or permanently retain abrasive particle 744 in a first position 775. Likewise, as illustrated, alignment structure 763 can be configured to deliver and, in specific instances, temporarily or permanently retain the molded abrasive particle 745 in a second position 776.
[215] In specific instances, as illustrated in FIG. 7B, alignment structure 763 may include a contact region 754, which may have a specific two-dimensional shape as viewed from above. As illustrated, the contact region 754 can have a two-dimensional circular shape that can be defined in part by a diameter (dcr).
[216] In accordance with at least one embodiment, the contact region 754 may be formed to have a shape (e.g., a two-dimensional shape) which can facilitate controlled orientation of the molded abrasive particle 744. More specifically, the region of Contact 724 may have a two-dimensional shape configured to control one or more (e.g., at least two of) specific predetermined orientation features, including, for example, a predetermined swivel orientation, a predetermined lateral orientation, and a predetermined orientation. predetermined longitudinal orientation. In at least one alternative embodiment as illustrated, the contact region 754 may be circular in shape, which may facilitate some freedom from the predetermined pivotal orientation. For example, in comparison to molded abrasive particles 744 and 745, each lime associated with contact regions 754 and 755, respectively, and even more where each of contact regions 754 and 755 have two-dimensional circular shapes, molded abrasive particles 744 and 745 have different predetermined swivel orientations with respect to each other. The two-dimensional circular shape of the contact regions 754 and 755 can facilitate preferential lateral orientation of molded abrasive particles 744 and 745, while allowing a degree of freedom in at least one predetermined orientation characteristic (e.g., a predetermined swivel orientation) with respect to each other.
[217] It will be contemplated that in at least one embodiment, the dimensions of the contact region 754 (e.g., diameter) may significantly correspond to and may be significantly the same dimensions as the molded abrasive particle 744 (e.g., a width of a side surface ), which can facilitate positioning of the molded abrasive particle 744 at position 775 and facilitate one or a combination of predetermined orientation characteristics of the molded abrasive particle 744. In addition, according to one embodiment, the alignment structure 762 may include a plurality of contact regions having controlled two-dimensional shapes configured to facilitate and control one or more predetermined orientation characteristics of associated molded abrasive particles. It will be contemplated that while the preceding alignment structure 763 includes contact regions 754 and 755 having significantly similar shapes, alignment structure 763 may include a plurality of contact regions having a plurality of different two-dimensional shapes.
[218] As illustrated and noted above, FIG. 7B further includes a third group 794 of molded abrasive particles 746 and 747 which overlay the support 101. The fourth group 794 may be associated with an alignment structure 764 which may include a first contact region 756 and a second contact region 757. Alignment structure 764 can be used to facilitate placement of molded abrasive particles 746 and 747 in desired orientations on support 101 and relative to each other. As noted in this document, alignment structure 764 can have any of the characteristics of alignment structures described in this document. It will be contemplated that alignment structure 764 may be a permanent or temporary part of the final abrasive article. Alignment structure 764 may be integral with the abrasive article, and may overlay backing 101, supporting an adhesive layer overlaying backing 101, or be an integral part of one or more adhesive layers overlying backing 101.
[219] In one embodiment, alignment structure 764 may be configured to deliver and in specific instances, temporarily or permanently retain abrasive particle 746 in a first position 777. Likewise, as illustrated, alignment structure 764 can be configured to deliver and, in specific instances, temporarily or permanently retain the molded abrasive particle 747 in a second position 778.
[220] In specific instances, as illustrated in FIG. 7B, alignment structure 763 may include a contact region 756, which may have a specific two-dimensional shape as viewed from above. As illustrated, the contact region 756 can have a two-dimensional transverse shape that can be defined in part by a length (Icr).
[221] In at least one embodiment, the contact region 756 can be formed to have a shape (e.g., a two-dimensional shape) that can facilitate controlled orientation of the molded abrasive particle 746. More specifically, the contact region Contact 756 may have a two-dimensional shape configured to control one or more (e.g., at least two of) specific predetermined orientation features, including, for example, a predetermined swivel orientation, a predetermined lateral orientation, and a predetermined orientation. predetermined longitudinal orientation. In at least one alternative embodiment as illustrated, the contact region 756 may have a two-dimensional transverse shape, which may facilitate some freedom from the predetermined rotational orientation of the molded abrasive particle 746.
[222] For example, in comparison to molded abrasive particles 746 and 747, each associated with contact regions 756 and 757, respectively, and yet where each of contact regions 756 and 757 have two-dimensional transverse shapes, the particles molded abrasives 746 and 747 may have different predetermined rotational orientations with respect to each other. The two-dimensional transverse shapes of the contact regions 756 and 757 can facilitate preferential lateral orientation of molded abrasive particles 746 and 747, while allowing a degree of freedom in at least one predetermined orientation characteristic (e.g., a predetermined swivel orientation) with respect to each other. As illustrated, the molded abrasive particles 746 and 747 are significantly oriented perpendicular to each other. The two-dimensional transverse shape of the contact regions 756 and 757 generally facilitates two preferred predetermined rotational orientations of the molded abrasive particles, each associated with the direction of the ramifications of the transverse contact regions 756 and 757, and each of the two orientations being illustrated by molded abrasive particles 746 and 747.
[223] It will be contemplated that in at least one embodiment, the dimensions of the contact region 756 (e.g., length) may significantly correspond to and may be significantly the same dimensions as the molded abrasive particle 746 (e.g., a length of a side surface ), which can facilitate positioning of the molded abrasive particle 746 at position 777 and facilitate one or a combination of predetermined orientation characteristics of the molded abrasive particle 746. In addition, according to one embodiment, the alignment structure 764 may include a plurality of contact regions having controlled two-dimensional shapes configured to facilitate and control one or more predetermined orientation characteristics of associated molded abrasive particles. It will be contemplated that while the preceding alignment structure 764 includes contact regions 756 and 757 having significantly similar shapes, the alignment structure 764 may include a plurality of contact regions having a plurality of different two-dimensional shapes.
[224] Turning briefly to FIG. 7C includes a top view illustration of an unshaded array being formed over a portion of an abrasive article which is provided in accordance with one embodiment. As illustrated, the abrasive article portion may include a support 101, a first group of discrete contact regions 781 extending over support 101, a second group of discrete contact regions 782 extending over support 101, and a third group of discrete contact regions 783 that extend over the support 101. Each of the groups of discrete contact regions 781, 782 and 783 may have a plurality of discrete contact regions that extend linearly over a surface of the support. Furthermore, each of the discrete contact regions within a group can extend significantly in the same direction, so that each of the discrete contact regions within a group can be significantly parallel to each other. Furthermore, discrete contact regions of different groups can intersect with each other. For example, each of the discrete contact regions of the first group of discrete contact regions 781 may intersect in at least one discrete contact region of at least one second group of discrete contact region 782 and the third group of discrete contact region discreet 783.
[225] According to one embodiment, each of the discrete contact regions, in particular, each of the discrete contact regions within groups of discrete contact regions 781, 782, and 783 may span at least a portion of the width. of the support 101. In certain instances, each of the groups of discrete contact regions 781, 782, and 783 may span at least a majority of the width of the support 101, which can be defined as distances along the support 101 in the direction of the lateral axis 181.
[226] In another embodiment, each of the discrete contact regions, and in particular, each of the groups of discrete contact regions 781, 782, and 783 may span at least a portion of the length of support 101. In certain instances , each of the groups of discrete contact regions 781, 782 and 783 can extend at least a majority of the length of the support 101, which can be defined as distances along the support 101 in the direction of the longitudinal axis 180. Further, in another non-limiting embodiment, only one of the groups of discrete contact regions, such as the group of discrete contact regions 783, can span a majority of the length of the support 101, while each of the discrete contact regions of the discrete contact region groups 781 and 782 extends a distance less than the full length of the support 101.
[227] FIG. 7C further includes an illustration of molded abrasive particles placed in each of groups of discrete contact regions 781, 782, and 783. That is, the abrasive article may have a first group of molded abrasive particles 784 associated with the first group of molded abrasive regions 784. discrete contact 781, and a second group of molded abrasive particles 785 can be associated with the second group of discrete containment regions 782, and a third group of molded abrasive particles 792 can be associated with the third group of discrete containment regions 789.
[228] FIG. 7D includes an image of a part of a group of molded abrasive particles associated with a discrete contact region. Notably, the first group of molded abrasive particles 787 may include a first molded abrasive particle 788 coupled to the support 101 at a first position 795 and a second molded abrasive particle 789 coupled to the support 101 at a second position 796. the molded abrasive particle 788 and a second molded abrasive particle 789 may be arranged in a shadowless controlled arrangement. In a shadowless controlled arrangement, the first molded abrasive particle 788 and a second molded abrasive particle 789 can have at least two of predetermined rotational orientations, a predetermined lateral orientation, and a predetermined longitudinal orientation, and a combination of these. More specifically, at least a portion of the molded first abrasive particle 788 may be touching a portion of the molded abrasive second particle 789. Unlike some other embodiments of this document, in certain instances, molded abrasive particles within a group may be adjacent to each other. others. For example, in at least one embodiment, a corner of the first molded abrasive particle 788 may be adjacent to a corner of the second molded abrasive particle 789. Notably, the degree of overlap between adjacent particles may be less than the width of the particles, and more specifically, less than half the width of the particles.
[229] In the illustrated embodiment of FIG. 7D, at least a portion, e.g. a minority or majority, of each of the molded abrasive particles of the first group of molded abrasive particles 787 including the first molded abrasive particle 788 and the second molded abrasive particle 789 may be arranged in line with respect each other. Furthermore, at least a portion of the molded abrasive particles in the molded abrasive particle group 787 may be touching at least one another immediately adjacent to the molded abrasive particles. Without wishing to be bound by a particular theory, it appears that some contact between the abrasive particles may be adequate to support the group of molded abrasive particles and improve grain retention and grinding performance. In addition, one or more molded abrasive particles in a group of molded abrasive particles may be in direct contact with immediately adjacent grains to facilitate larger grain weights and improved grinding performance in certain applications. METHODS AND SYSTEMS FOR FORMING ABRASIVE ARTICLES
[230] The preceding items described abrasive articles of the embodiments having predetermined distributions of molded abrasive particles. The following describes various methods used to form such abrasive articles from the embodiments of this document. It will be contemplated that any of the methods and systems described herein may be used in combination to facilitate the formation of an abrasive article in accordance with one embodiment.
[231] According to one embodiment, a method of forming an abrasive article includes placing a molded abrasive particle onto the support in a first position defined by one or more predetermined orientation characteristics. In particular, the molded abrasive particle placement method may include a template process. A model process may make use of an alignment structure, which may be configured to retain (temporarily or permanently) one or more molded abrasive particles in a predetermined orientation and deliver one or more molded abrasive particles onto the abrasive article in a position defined predetermined has one or more predetermined orientation characteristics.
[232] According to one embodiment, the alignment structure may have various structures, including, but not limited to, a net, a fibrous material, a mesh, a solid structure having openings, a belt, a roller, a patterned material. , a discontinuous layer of material, a patterned adhesive material, and a combination thereof. In a specific embodiment, the alignment structure may include a discrete contact region configured to retain a molded abrasive particle. In certain instances, the alignment structure may include a plurality of discrete contact regions spaced from one another and configured to retain a plurality of molded abrasive particles. For certain embodiments herein, a discrete contact region may be configured to temporarily retain a molded abrasive particle and place a first molded abrasive particle in a predetermined position on the abrasive article. Alternatively, in another embodiment, the discrete contact region may be configured to permanently retain a first molded abrasive particle and place the molded abrasive particle in a first position. Notably, for embodiments using a permanent retention between the discrete contact region and the molded abrasive particle, the alignment structure can be integrated within the finished abrasive article.
[233] Some exemplary alignment structures in accordance with the embodiments of this document are illustrated in FIGs. 9-11. FIG. 9 includes an illustration of a part of an alignment structure according to one embodiment. In particular, alignment structure 900 may be in the form of a net or mesh including fibers 901 and 902 that overlap each other. In particular, alignment frame 900 may include discrete contact regions 904, 905, and 906, which may be defined by a plurality of intersections of alignment frame objects. In the specific illustrated embodiment, the discrete contact regions 904-906 may be defined by an intersection of fibers 901 and 902, and more specifically, a junction between the two fibers 901 and 902, configured to retain the molded abrasive particles 911, 912 and 913. In accordance with certain embodiments, the alignment structure may further include discrete contact regions 904-906 which may include an adhesive material to facilitate retention placement of molded abrasive particles 911-913.
[234] As will be contemplated, the construction and arrangement of fibers 901 and 902 may facilitate control of discrete contact regions 904906 and may further facilitate control of one or more predetermined orientation characteristics of the abrasive particles molded onto the abrasive article. . For example, discrete contact regions 904-906 may be configured to define at least one of the predetermined rotational orientations of a molded abrasive particle, a predetermined rotational orientation between at least two molded abrasive particles, a predetermined longitudinal orientation of a molded abrasive particle, a longitudinal space between two molded abrasive particles, a predetermined lateral orientation, a lateral space between two molded abrasive particles, a predetermined vertical orientation of a molded abrasive particle, a predetermined vertical orientation difference -determined between two molded abrasive particles, a predetermined slope height orientation of a molded abrasive particle, a predetermined slope height difference between two molded abrasive particles, and a combination thereof.
[235] FIG. 10 includes an illustration of a portion of an alignment structure according to one embodiment. In particular, alignment structure 1000 may be in the form of a belt 1001 with discrete contact regions 1002 and 1003 configured to engage and secure molded abrasive particles 1011 and 1012. In one embodiment, alignment structure 1000 may include discrete contact regions 1002 and 1003 in the form of openings in the alignment structure. Each opening can be configured with a shape that holds one or more molded abrasive particles. Notably, each aperture may be shaped to hold one or more molded abrasive particles in a predetermined position to facilitate placement of one or more molded abrasive particles on the bearing in a predetermined position with one or more predetermined orientation characteristics. In at least one embodiment, the apertures for defining the discrete contact regions 1002 and 1003 may have a cross-sectional shape complementary to the cross-sectional shape of the molded abrasive particles. Also, in certain cases, openings defining discrete contact regions may extend through the entire thickness of the alignment structure (ie, belt 1001).
[236] In yet another embodiment, the alignment structure may include discrete contact regions defined by the apertures, wherein the apertures extend partially through the entire thickness of the alignment structure. For example, FIG. 11 includes an illustration of a part of an alignment structure according to one embodiment. Notably, the alignment structure 1100 may be in the form of a thicker structure, wherein the apertures defining discrete contact regions 1102 and 1103 configured to hold the molded abrasive particles 1111 and 1112 do not extend through the entire thickness of the substrate. 1101.
[237] FIG. 12 includes an illustration of a portion of an alignment structure according to one embodiment. Notably, alignment structure 1200 may be in the form of a roll 1201 with apertures 1203 in the outer surface and which define discrete contact regions. Discrete contact regions 1203 may have particular dimensions configured to facilitate attachment of molded abrasive particles 1204 to roll 1201 until a portion of molded abrasive particles is in contact with abrasive article 1201. After contacting abrasive article 1201, the molded abrasive particles 1204 may be released from a roller 1201 and delivered to the abrasive article 1201 at a specific position defined by one or more predetermined orientation characteristics. Therefore, the shape and orientation of the openings 1203 in the roller 1201, the position of the roller 1201 relative to the abrasive article 1201, the rate of translation of the roller 1201 relative to the abrasive article 1201 can be controlled to facilitate the positioning of the molded abrasive particles 1204 in a predetermined distribution.
[238] Various processing steps can be used to facilitate placement of the molded abrasive particles into the alignment structure. Suitable processes may include, but are not limited to, vibration, adhesion, electromagnetic attraction, patterning, printing, pressure differential, coating roll, gravity drop, and a combination thereof. In addition, specific devices can be used to facilitate the orientation of the abrasive particles molded into the alignment structure including, for example, cams, acoustics and combinations thereof.
[239] In another embodiment, the alignment structure may be in the form of a layer of adhesive material. Notably, the alignment structure may be in the form of a discontinuous layer of adhesive parts, these adhesive parts defining discrete contact regions configured to attach (temporarily or permanently) one or more molded abrasive particles. In one embodiment, the discrete contact regions may include an adhesive, and more specifically, the discrete contact regions are defined by an adhesive layer, and even more specifically, each discrete contact region is defined by a discrete adhesive region. In certain cases, the adhesive may include a resin and, more specifically, may include a material to be used as a sizing as described in embodiments herein. Furthermore, the discrete contact regions may define a predetermined distribution with respect to each other and, furthermore, may define the positions of the abrasive particles molded into the abrasive article. Furthermore, the discrete contact regions comprising the adhesive may be arranged in a predetermined distribution, which is substantially equivalent to the predetermined distribution of molded abrasive particles that overlay the backing. In a specific case, the discrete contact regions comprising the adhesive may be arranged in a predetermined distribution, may be configured to hold a molded abrasive particle, and may define at least one predetermined orientation characteristic for each molded abrasive particle.
[240] FIG. 13 includes an illustration of a portion of an alignment structure including discrete contact regions comprising an adhesive in accordance with an embodiment. As illustrated, alignment structure 1300 may include a first discrete contact region 1301 that comprises a discrete region of adhesive and configured to abrasively couple a particle. Alignment structure 1300 may also include a second discrete contact region 1302 and a third discrete contact region 1303. According to one embodiment, at least the first discrete contact region 1301 may have a width (w) 1304 related to at least least one dimension of the molded abrasive particle that can facilitate positioning of the molded abrasive particle in a specific orientation with respect to the backing. For example, certain orientations suitable for the support may include a side orientation, a planar orientation, and an inverted orientation. According to a specific embodiment, the first discrete contact region 1301 may have a width (w) 1304 related to at least a height (h) of the molded abrasive particle to facilitate lateral orientation of the molded abrasive particle. It will be appreciated that reference in this document to a height may be a reference to an average height or a median height of a suitable sample size of a batch of molded abrasive particles. For example, the width 1304 of the first discrete contact region 1301 may not be greater than the height of the molded abrasive particles. In other cases, the width 1304 of the first discrete contact region 1301 may not be greater than about 0.99(h), such as not greater than about 0.95(h), not greater than about 0.9 (h), not more than about 0.85(h), not more than about 0.8(h), not more than about 0.75(h), or even not more than about 0, 5(h). Further, in a non-limiting embodiment, the width 1304 of the first discrete contact region 1301 can be at least about 0.1(h), at least about 0.3(h), or even at least about 0 .5(h). It will be appreciated that the width 1304 of the first discrete contact region 1301 can vary between any of the aforementioned minimum and maximum values.
[241] According to a specific embodiment, the first discrete contact region 1301 may be spaced from the second discrete contact region 1302 by a longitudinal span 1305, which is a measure of the shortest distance between the immediately adjacent discrete contact regions 1301 and 1302 in a direction parallel to the longitudinal axis 180 of the support 101. In particular, control of the longitudinal span 1305 may facilitate control of the predetermined distribution of molded abrasive particles on the surface of the abrasive article which may facilitate improved performance. In one embodiment, the longitudinal span 1305 may be related to a dimension or a sampling of the molded abrasive particles. For example, the longitudinal span 1305 can be at least equal to the width (w) of a molded abrasive particle, where the width is a measurement of the longest side of the particle, as described herein. It will be appreciated that reference in this document to a width (w) of the molded abrasive particle may be a reference to an average width or a median width of a suitable sample size of a batch of molded abrasive particles. In a specific case, the longitudinal span 1305 may be greater than the width, such as at least about 1.1(w), at least about 1.2(w), at least about 1.5(w), at least about 1.5(w). at least about 2(w), at least about 2.5(w), at least about 3(w) or even at least about 4(w). Further, in a non-limiting embodiment, the longitudinal span 1305 may not be greater than about 10(w), not greater than about 9(w), not greater than about 8(w), or even not greater than about 8(w). of 5(w). It will be appreciated that the longitudinal span 1305 can vary between any minimum and maximum value mentioned above.
[242] According to a specific embodiment, the second discrete contact region 1302 may be spaced from the third discrete contact region 1303 by a side span 1306, which is a measure of the shortest distance between the immediately adjacent discrete contact regions 1302 and 1303 in a direction parallel to the lateral axis 181 of the support 101. In particular, controlling the side gap 1306 can facilitate control of the predetermined distribution of the molded abrasive particles on the surface of the abrasive article which can facilitate improved performance. In one embodiment, the side span 1306 may be related to a dimension or a sampling of the molded abrasive particles. For example, the side span 1306 can be at least equal to the width (w) of a molded abrasive particle, where the width is a measurement of the longest side of the particle, as described herein. It will be appreciated that reference in this document to a width (w) of the molded abrasive particle may be a reference to an average width or a median width of a suitable sample size of a batch of molded abrasive particles. In a given case, the side gap 1306 may be smaller than the width of the molded abrasive particle. In still other cases, the side span 1306 may be greater than the width of the molded abrasive particle. In one aspect, the side span 1306 may be zero. In yet another aspect, the side span 1306 can be at least about 0.1(w), at least about 0.5(w), at least about 0.8(w), at least about 1(w). w), at least about 2(w), at least about 3(w), or even at least about 4(w). Further, in a non-limiting embodiment, the side span 1306 may not be greater than about 100(w), not greater than about 50(w), not greater than about 20(w), or even not greater than about 50(w). of 10(w). It will be appreciated that side span 1306 can vary between any minimum and maximum value mentioned above.
[243] The first discrete contact region 1301 can be formed on a main top surface of an abutment using various methods including, for example, printing, patterning, gravure rolling, etching, stripping, coating, depositing and their combinations. FIGs. 14A-14H include complete views of parts of tools for forming abrasive articles having various patterned alignment structures including discrete contact regions of an adhesive material in accordance with embodiments herein. In specific cases, the tools may include a modeling structure that can contact the support and transfer the standardized alignment structure to the support. In one embodiment, the tool may be an gravure roller with a patterned alignment structure comprising discrete contact regions of adhesive material that can be rolled over a backing to transfer the patterned alignment structure to the backing. After that, molded abrasive particles can be placed on the support in the regions corresponding to the discrete contact regions.
[244] In at least one specific aspect, an abrasive article of one embodiment may even form a patterned structure comprising an adhesive on at least a portion of the backing. Notably, in one example, the patterned structure may be in the form of a patterned coat. The patterned size can be a discontinuous layer including at least one adhesive region that overlaps the backing, a second adhesive region that overlaps the backing separate from the first adhesive region, and at least one exposed region between the first and second adhesive regions. . At least one exposed region may be essentially free of adhesive material and represent a gap in the sizing. In one embodiment, the patterned size may be in the form of an array of adhesive regions coordinated with respect to one another in a predetermined distribution. The formation of the patterned size with a predetermined distribution of adhesive regions on the backing can facilitate the placement of abrasive shaped grains in a predetermined distribution and, particularly, the predetermined distribution of the adhesive regions of the patterned size can correspond to the positions of the molded abrasive particles, in that each molded abrasive particle can be adhered to the backing in the adhesive regions and thus correspond to the predetermined distribution of molded abrasive particles on the backing. Furthermore, in at least one embodiment, essentially no molded abrasive particles of the various molded abrasive particles overlap the exposed regions. Furthermore, it will be appreciated that a single adhesive region can be shaped and sized to accommodate a single molded abrasive particle. However, in an alternative embodiment, an adhesive region may be shaped and sized to accommodate various molded abrasive particles.
[245] Various processes can be used to form a patterned structure including, for example, patterned sizing. In one embodiment, the process may include selective depositing of the glue. In yet another embodiment, the process may include selectively removing at least a portion of the size. Some exemplary processes include coating, spraying, rolling, printing, masking, irradiating, etching, and combinations thereof. According to a specific embodiment, forming the patterned size may include providing a patterned size to a first structure and transferring the patterned size to at least a portion of the backing. For example, an gravure roller can be provided with a patterned size coat and the roller can be translated over at least a portion of the backing and transfer the patterned size from the surface of the roller to the backing surface.
[246] The foregoing described specific abrasive articles and structures (eg alignment structures) suitable for use in forming the abrasive articles. The following embodiments describe specific methods that can be used in conjunction with the embodiments mentioned herein or separately, which facilitate the formation of abrasive articles in accordance with the embodiments.
[247] In accordance with one embodiment, the method of delivering molded abrasive particles into the abrasive article may include expelling the first molded abrasive particle from an opening within the alignment structure. Some exemplary methods suitable for expulsion may include applying a force to the molded abrasive particles and removing them from the alignment structure. For example, in certain cases, the molded abrasive particle may be contained within the alignment structure and can be expelled from the alignment structure using gravity, electrostatic attraction, surface tension, pressure differential, mechanical force, magnetic force, agitation, vibration and their combinations. In at least one embodiment, the molded abrasive particles may be contained in the alignment structure until the surface of the molded abrasive particles contacts a surface of the backing, which may include an adhesive material, and the molded abrasive particles are removed from the molded abrasive structure. alignment and delivered to a predetermined position on the support.
[248] In another aspect, the molded abrasive particles can be delivered to the surface of the abrasive article in a controlled manner by sliding them along a path. For example, in one embodiment, the molded abrasive particles can be delivered to a predetermined position on the support by sliding them into a pathway and through an opening through gravity. FIG. 15 includes an illustration of a system according to one embodiment. Notably, the system 1500 may include a funnel 1502 configured to contain a content of molded abrasive particles 1503 and deliver the molded abrasive particles 1503 to a surface of a bearing 1501 which is translatable under the funnel 1502. As illustrated, the molded abrasive particles 1503 may be delivered via a lane 1504 attached to hopper 1502 and delivered to a bearing surface 1501 in a controlled manner to form a coated abrasive article including molded abrasive particles arranged in a predetermined distribution relative to each other. In specific cases, the lane 1504 may be sized and shaped to deliver a specified number of molded abrasive particles at a specific rate to facilitate formation of the predetermined distribution of molded abrasive particles. In addition, funnel 1502 and track 1504 may be movable with respect to support 1501 to facilitate formation of predetermined and selected distributions of molded abrasive particles.
[249] In addition, the support 1501 can be further translated on a vibrating table 1506 which can agitate or vibrate the support 1501 and the molded abrasive particles contained on the support 1501 to facilitate improved orientation of the molded abrasive particles.
[250] In yet another embodiment, the molded abrasive particles can be delivered to a predetermined position by expelling individual molded abrasive particles onto the backing through a flinging process. In the pitching process, the molded abrasive particles can accelerate and be expelled from a container at a rate sufficient to maintain the molded abrasive particles in a predetermined position on the support. For example, FIG. 16 includes an illustration of a system using a blasting process in which molded abrasive particles 1602 are expelled from a blasting unit 1603 that can accelerate the molded abrasive particles through a force (e.g., pressure differential) and deliver the molded abrasive particles 1602 of the blasting unit 1603 via a path 1605, which may be attached to the blasting unit 1603 and the support 1601 in a predetermined position. The backing 1601 is translatable under the pitching unit 1603 so that, after initial placement, the molded abrasive particles 1602 can undergo a curing process that can cure an adhesive material on the surface of the backing 1601 and retain the molded abrasive particles. 1602 in their predetermined positions.
[251] FIG. 17A includes an illustration of an alternative throwing method according to one embodiment. Notably, the blasting process may include expelling a molded abrasive particle 1702 from a blasting unit 1703 over a gap 1708 to facilitate placement of the molded abrasive particle 1702 onto the pad in a predetermined position. It will be appreciated that the expulsion force, the orientation of the molded abrasive particle 1702 after expulsion, the orientation of the pitch unit 1703 with respect to the support 1701 and the gap 1708 can be controlled and adjusted to adjust the predetermined position of the molded abrasive particle 1702 and the predetermined distribution of the molded abrasive particles 1702 on the bearing 1701 relative to one another. It will be appreciated that the abrasive article 1701 may include an adhesive material 1712 on a portion of the surface to facilitate adhesion between the molded abrasive particles 1702 and the abrasive article 1701.
[252] In specific cases, molded abrasive particles 1702 can be formed to have a coating. The coating may overlay at least a portion of the outer surface of the molded abrasive particles 1702. In one embodiment, the coating may include an organic material and, more specifically, a polymer, and even more specifically, an adhesive material. The coating comprising an adhesive material can facilitate attachment of the molded abrasive particles 1702 to the backing 1701.
[253] FIG. 17B includes an illustration of an alternative throwing method according to one embodiment. In the specific embodiment of FIG. 17B details a specific throwing unit 1721 configured to direct the molded abrasive particles 1702 into the abrasive article 1701. In one embodiment, the throwing unit 1721 may include a hopper 1723 configured to contain a plurality of molded abrasive particles 1702. hopper 1723 may be configured to deliver one or more molded abrasive particles 1702 in a controlled manner to an acceleration zone 1725, where molded abrasive particles 1702 are accelerated and directed to abrasive article 1701. In a specific embodiment, the pitch unit 1721 may include a system 1722 that utilizes a pressurized fluid such as a controlled gas flow or a pneumatic cutting unit to facilitate acceleration of the molded abrasive particles 1702 in the acceleration zone 1725. As further illustrated, the throwing unit 1721 may utilize a 1726 slider configured to generally direct abrasive particles molds 1702 toward the abrasive article 1701. In one embodiment, the pitch unit 1731 and/or the slider 1726 may move between various positions and may be configured to facilitate delivery of individual molded abrasive particles to specific positions on the abrasive article. thus facilitating the formation of the predetermined distribution of molded abrasive particles.
[254] FIG. 17A includes an illustration of an alternative throwing method according to one embodiment. In the illustrated embodiment of FIG. 17C details an alternate throwing unit 1731 configured to direct molded abrasive particles 1702 into abrasive article 1701. In one embodiment, the throwing unit 1731 may include a hopper 1734 configured to contain a plurality of molded abrasive particles 1702 and deliver one or more particles molded abrasive particles 1702 in a controlled manner to an acceleration zone 1735, where the molded abrasive particles 1702 are accelerated and directed to the abrasive article 1701. In one embodiment, the pitching unit 1731 may include a spindle 1732 which can rotate about an axis and be configured to rotate on a 1733 stage at a specific rate of revolutions. Molded abrasive particles 1702 may be delivered from hopper 1734 to stage 1733 and accelerated from stage 1733 towards abrasive article 1701. As will be appreciated, the rotation rate of spindle 1732 may be controlled to control the predetermined distribution. of molded abrasive particles 1702 onto the abrasive article 1701. In addition, the pitch unit 1731 can move between various positions and can be configured to facilitate delivery of individual molded abrasive particles to specific positions on the abrasive article, thus facilitating formation predetermined distribution of molded abrasive particles.
[255] In another embodiment, the process of delivering the molded abrasive particles in a predetermined position on the abrasive article and forming an abrasive article with a number of molded abrasive particles in a predetermined distribution relative to each other may include applying of magnetic force. FIG. 18 includes an illustration of a system according to one embodiment. System 1800 may include a hopper 1801 configured to contain a plurality of molded abrasive particles 1802 and deliver the molded abrasive particles 1802 to a first translation belt 1803.
[256] As illustrated, molded abrasive particles 1802 can translate along belt 1803 to an alignment structure 1805 configured to contain molded abrasive particles in a discrete contact region. In one embodiment, molded abrasive particles 1802 may be transferred from belt 1803 to alignment frame 1805 via transfer roller 1804. In specific cases, transfer roller 1804 may utilize a magnet to facilitate controlled removal. of molded abrasive particles 1802 from belt 1803 to alignment frame 1805. Providing a coating comprising a magnetic material can facilitate use of transfer roller 1804 with magnetic capabilities.
[257] Molded abrasive particles 1802 can be delivered from alignment frame 1805 to a predetermined position on bearing 1807. As illustrated, bearing 1807 can be translated on a separate belt and alignment frame 1805 and contact the bearing 1807. alignment frame to facilitate transfer of molded abrasive particles 1802 from alignment frame 1805 to support 1807.
[258] In yet another embodiment, the process of delivering the molded abrasive particles in a predetermined position on the abrasive article and forming an abrasive article with a number of molded abrasive particles in a predetermined distribution relative to each other may include the use of an array of magnets. FIG. 19 includes an illustration of a system for forming an abrasive article according to one embodiment. In particular, system 1900 may include molded abrasive particles 1902 contained within an alignment structure 1901. As illustrated, system 1900 includes an array of magnets 1905 that includes a number of magnets arranged in a predetermined distribution relative to support 1906. In one embodiment, the array of magnets 1905 may be arranged in a predetermined distribution which may be substantially the same as the predetermined distribution of abrasive particles molded onto the bearing.
[259] In addition, each magnet of the magnet array 1905 can move between a first position and a second position, which can facilitate control of the shape of the magnet array 1905 and further facilitate control of the predetermined distribution of magnets and the predetermined distribution of 1902 molded abrasive particles on the backing. In one embodiment, the magnet array 1905 may be altered to facilitate control of one or more predetermined orientation features of the molded abrasive particles 1902 onto the abrasive article.
[260] In addition, each magnet in the array of magnets 1905 may be operable between a first state and a second state, where a first state may be associated with a first magnetic force (e.g., an on state) and the second state may be associated with a second magnetic force (eg, an off state). Controlling the state of each magnet can facilitate selective delivery of the molded abrasive particles to certain regions of the 1906 support and further facilitate control of the predetermined distribution. In one embodiment, the state of the magnets in the magnet array 1905 may be altered to facilitate control of one or more predetermined orientation characteristics of the molded abrasive particles 1902 on the abrasive article.
[261] FIG. 20A includes an image of a tool used to form an abrasive article in accordance with one embodiment. Notably, the tool 2051 may include a substrate, which may be an alignment structure with apertures 2052 that define discrete contact regions configured to contain molded abrasive particles and aid in the transfer and placement of the molded abrasive particles into a finally formed abrasive article. As illustrated, the apertures 2052 may be arranged in a predetermined distribution relative to each other on the alignment structure. In particular, the openings 2052 may be arranged in one or more groups 2053 with a predetermined distribution relative to each other, which may facilitate placement of the molded abrasive particles on the abrasive article in a predetermined distribution defined by one or more characteristics of predetermined orientation. In particular, tool 2051 may include a group 2053 defined by a row of apertures 2052. Alternatively, tool 2051 may have a group 2055 defined by all apertures 2052 illustrated, provided that each aperture has substantially the same predetermined rotational orientation with respect to to the substrate.
[262] FIG. 20B includes an image of a tool used to form an abrasive article in accordance with one embodiment. Notably, as illustrated in FIG. 20B , molded abrasive particles 2001 are contained in tool 2051 of FIG. 20A, and more particularly, tool 2051 may be an alignment structure, wherein each opening 2052 contains a single molded abrasive particle 2001. In particular, molded abrasive particles 2001 may have a two-dimensional triangular shape, as viewed from top to bottom. . In addition, molded abrasive particles 2001 may be placed in openings 2052 so that a tip of the molded abrasive particle extends into and through openings 2052 to the opposite side of tool 2051. Apertures 2052 may be of the size and shape of such that they substantially complement at least a portion (if not all) of the contour of the molded abrasive particles 2001 and maintain them in a position defined by one or more predetermined orientation features in the tool 2051, which will facilitate transfer of the molded abrasive particles 2001 from the tool 2051 for a support, maintaining the predetermined orientation characteristics. As illustrated, the molded abrasive particles 2001 can be contained within the openings 2052 so that at least a portion of the surfaces of the molded abrasive particles 2001 extend above the surface of the tool, 2051, which can facilitate transfer of the molded abrasive particles 2001 of 2052 openings for a backup.
[263] As illustrated, molded abrasive particles 2001 may define a group 2002. Group 2002 may have a predetermined distribution of molded abrasive particles 2001, wherein each molded abrasive particle has substantially the same predetermined rotational orientation. In addition, each molded abrasive particle 2001 has substantially the same predetermined vertical orientation and predetermined tip height orientation. In addition, group 2002 includes several rows (e.g. 2005, 2006, and 2007) oriented in a plane parallel to a lateral axis 2081 of tool 2051. Additionally, within the group, 2002, there may be smaller groups (e.g., 2012, 2013 and 2014) of the molded abrasive particles 2001, wherein the molded abrasive particles 2001 share the same difference in a combination of a predetermined lateral orientation and predetermined longitudinal orientation with respect to each other. Notably, the molded abrasive particle 2001 of the 2012, 2013 and 2014 groups may be oriented in sorted columns, wherein the group extends at an angle to the longitudinal axis 2080 of the tool 2051, however, the molded abrasive particles 2001 may have substantially the same same difference in predetermined longitudinal orientation and predetermined lateral orientation with respect to each other. As also illustrated, the predetermined distribution of molded abrasive particles 2001 can define a pattern that can be considered a triangular pattern 2011. Additionally, the group 2002 can be arranged so that the group boundary defines a two-dimensional micro unit of a quadrilateral ( see dotted line).
[264] FIG. 20C includes an image of a part of an abrasive article in accordance with one embodiment. In particular, the abrasive article 2060 includes an abutment 2061 and various molded abrasive particles 2001 that have been transferred from the openings 2052 of the tool 2051 to the abutment 2061. As illustrated, the predetermined distribution of the openings 2052 of the tool may correspond to the predetermined distribution of abrasive particles. molds 2001 of group 2062 contained in support 2061. The predetermined distribution of molded abrasive particles 2001 may be defined by one or more predetermined orientation characteristics. Furthermore, as evidence from FIG. 20C, molded abrasive particles 2001 may be arranged in groups that substantially correspond to groups of molded abrasive particles of FIG. 20B, when molded abrasive particles 2001 were contained in tool 2051.
[265] For certain abrasive articles mentioned herein, at least about 75% of the various abrasive particles molded onto the abrasive article may have a predetermined orientation with respect to the bearing including, for example, a lateral orientation described in the embodiments cited herein. However, the percentage can be greater, such as at least about 77%, at least about 80%, at least about 81%, or even at least about 82%. And for a non-limiting embodiment, an abrasive article can be formed using the molded abrasive particles mentioned herein, wherein no more than about 99% of the total content of molded abrasive particles has a predetermined lateral orientation. It will be appreciated that the reference in this document to percentages of abrasive particles molded in a predetermined orientation is based on a statistically relevant number of abrasive particles molded and a random sampling of the total content of abrasive particles molded.
[266] To determine the percentage of particles with a predetermined orientation, a 2D microfocus x-ray image of the abrasive article is obtained using a CT scanner under the conditions in Table 1 below. 2D X-ray imaging was performed using Quality Assurance software. An exemplary fixture uses a plastic frame with a 4" x 4" window and a 00.5" solid metal rod, the top of which is flattened half with two screws to secure the frame. the model was cut along one side of the frame where the screw heads were facing the direction of incidence of the X-rays. Next, five regions within the 4" x 4" window area are selected for imaging in 120kV / 80A. Each 2D projection was recorded with X-ray compensation/gain corrections and at a magnification

[267] The image is then imported and analyzed using the ImageJ program, where the different orientations are assigned the values according to Table 2 below. FIG. 32 includes representative images of parts of an abrasive material coated in accordance with one embodiment and are used to analyze the orientation of abrasive particles molded into the backing.

[268] Three calculations are then performed as provided below in Table 3. After the calculations have been performed, the percentage of abrasive particles molded in a lateral orientation per square centimeter can be derived. Notably, a particle with a lateral orientation is a particle with a vertical orientation, as defined by the angle between a large surface of the molded abrasive particle and a surface of the bearing, at which the angle is 45 degrees or greater. Therefore, an abrasive particle molded with an angle of 45 degrees or greater is considered permanent or with a lateral orientation, an abrasive particle molded with an angle of 45 degrees is considered inclined, and an abrasive particle molded with an angle of less than 45 degrees is considered to have a downward orientation.
* - All of these are normalized with respect to the representative area of the image.+ - A scale factor of 0.5 has been applied to account for the fact that they are not fully present in the image.
[269] In addition, abrasive articles made with the molded abrasive particles can utilize various contents of the molded abrasive particles. For example, the abrasive articles can be coated abrasive articles, including a single layer of molded abrasive particles of an open coat configuration or a closed coat configuration. However, it was unexpectedly found that molded abrasive particles demonstrate superior results in an open coating configuration. For example, the plurality of molded abrasive particles can define an open coating abrasive product with a coating density of molded abrasive particles of no greater than about 70 particles/cm 2 . In other cases, the density of molded abrasive particles per square centimeter of the abrasive article may not be greater than about 65 particles/cm 2 , such as not more than about 60 particles/cm 2 , not more than about 55 particles / cm2, or even not more than about 50 particles / cm2. Further, in a non-limiting embodiment, the density of the open coating abrasive using the particulate abrasive of this invention can be at least about 5 particles/cm 2 , or even at least about 10 particles/cm2. cm2. It should be noted that the density of molded abrasive particles per square centimeter of abrasive article can be within a range between any of the above maximum and minimum values.
[270] In certain cases, the abrasive article may have an open coating density of a coating not greater than about 50% of abrasive particles covering the outer abrasive surface of the article. In other embodiments, the coating percentage of the abrasive particles relative to the total area of the abrasive surface may be no greater than about 40%, no greater than about 30%, no greater than about 25%, or even not greater than about 20%. Further, in a non-limiting embodiment, the coating percentage of the abrasive particles relative to the total area of the abrasive surface may be at least about 5%, such as at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, or even at least about 40%. It should be noted that the percentage coverage of molded abrasive particles to the total abrasive surface area can be within a range between any of the above maximum and minimum values.
[271] Some abrasive articles may have a certain content of abrasive particles for a length (eg ream) of the backing. For example, in one embodiment, the abrasive article may utilize a standard weight of molded abrasive particles of at least about 10 lbs/ream (148 grams/m 2 ), such as at least about 15 lbs/ream, at least at least about 20 lbs/ream, at least about 25 lbs/ream, or even at least about 30 lbs/ream. Further, in a non-limiting embodiment, the abrasive articles may include a standard weight of molded abrasive particles not greater than about 60 lbs/ream (890 grams/m 2 ), such as not greater than about 50 lbs/ream, or even no greater than about 45 lbs/ream. It will be appreciated that the abrasive articles of embodiments herein may utilize a standard weight of molded abrasive particles within a range between any of the above maximum and minimum values.
[272] In certain cases, abrasive articles may be used on certain workpieces. A suitable exemplary workpiece may include an inorganic material, an organic material, a natural material, and a combination thereof. In a particular embodiment, the workpiece may include a metal or metal alloy, such as an iron-based material, a nickel-based material, and the like. In one embodiment, the workpiece may be of steel, and more particularly, may consist essentially of stainless steel (e.g. 304 stainless steel). Example 1
[273] The grinding test is performed to evaluate the effect of orientation of a molded abrasive grain with respect to a grinding direction. In the test, a first set of molded abrasive particles (Sample A) is oriented in forward orientation with respect to the grinding direction. Turning briefly to FIG. 3B, the molded abrasive particle 102 has a forward oriented grinding direction, so that the major surface 363 defines a plane substantially perpendicular to the grinding direction, and more particularly, the bisector axis 231 of the molded abrasive particle 102 is substantially perpendicular. to grinding direction 385. Sample A was mounted on a stand in a front orientation to an austenitic stainless steel part. Wheel speed and working speed were maintained at 22 m/s and 16 mm/s, respectively. The depth of cut can be selected between 0 and 30 microns. Each test consisted of 15 passes along the 8-inch length of the part. For each test, 10 repeat samples were run and the results analyzed and weighted. The change in furrow cross-sectional area from start to finish of scratch length was measured to determine gravel wear.
[274] A second set of samples (Sample B) was also tested according to the grinding test described above for Sample "A". Notably, however, the molded abrasive particles of Sample B have a lateral orientation on the bearing with respect to the grinding direction. Turning briefly to FIG. 3B, molded abrasive particle 103 is illustrated as having a lateral orientation with respect to grinding direction 385. As illustrated, molded abrasive particle 103 may include larger surfaces 391 and 392, which may be joined by lateral surfaces 371 and 372, and the molded abrasive particle 103 may have a bisector axis 373 that forms a specific angle with respect to the grinding direction vector 385. As illustrated, the bisector axis 373 of the molded abrasive particle 103 may have an orientation substantially parallel to the direction of grinding. grinding 385 such that the angle between bisector axis 373 and grinding direction 385 is essentially 0 degrees. Consequently, the lateral orientation of the molded abrasive particle 103 can facilitate initial contact of the lateral surface 372 with a part before any other surfaces of the molded abrasive particle 103.
[275] FIG. 21 includes a plot of normal force (N) versus shear number for Sample A and Sample B according to the grinding test of Example 1. FIG. 21 illustrates the normal force required to grind the part with the molded abrasive particles from representative samples A and B for multiple passes or cuts. As illustrated, the normal force of Sample A is initially less than the normal force of Sample B. However, as the test continues, the normal force of Sample A exceeds the normal force of Sample B. Therefore, in some cases an abrasive article may utilize a combination of different orientations (eg, front orientation and side orientation) of the molded abrasive particles relative to an intended grinding direction to facilitate improved grinding performance. In particular, as illustrated in FIG. 21, a combination of molded abrasive particle orientations relative to a grinding direction can facilitate lower normal forces over the life of the abrasive article, better grinding efficiency, and longer life of the abrasive article. Thus, Example 1 demonstrates, among others, that the use of different groups of molded abrasive particles with different predetermined orientation characteristics relative to each other and the grinding direction can facilitate improved performance over standards with conventional standardized grains. Example 2
[276] Five samples are analyzed to compare the orientation of the molded abrasive particles. Three samples (Samples S1, S2 and S3) are made according to one embodiment. FIG. 22 includes an image of a part of the sample S1 using a 2D microfocus x-ray through a computed tomography machine according to the conditions described in this document. Two other samples (Samples CS1 and CS2) are representative of conventional abrasive products, including molded abrasive particles. Samples CS1 and CS2 are commercially available from 3M as Cubitron II. Sample CS2 is commercially available from 3M as Cubitron II. FIG. 23 includes an image of a part of the CS2 sample using a 2D microfocus x-ray through a computed tomography machine according to the conditions described in this document. Each sample is evaluated according to the conditions described in this document to evaluate the orientation of the molded abrasive particles, through x-ray analysis.
[277] FIG. 24 includes a graphical representation of maximum grains/cm2 and total number of grains/cm2 for each sample (Sample 1 and Sample C1). As illustrated, Samples CS1 and CS2 demonstrate significantly fewer molded abrasive particles oriented in a lateral orientation (ie vertical orientation) compared to Samples S1, S2 and S3. In particular, Sample S1 demonstrated that all molded abrasive particles (i.e. 100%) measured were oriented in a lateral orientation, whereas only 72% of the total number of molded abrasive particles of CS2 had a lateral orientation. As evidenced, conventional prior art abrasive articles (C1) using molded abrasive particles did not achieve the orientation accuracy of the currently described abrasive articles. Example 3
[278] Two samples were taken and tested to analyze the effect of various distributions on milling efficiency. A first sample (Sample S4) was made according to an embodiment with an unshaded distribution as demonstrated by the pattern illustrated in FIG. 28. The arrangement of the molded abrasive particles did not have a non-shading arrangement with respect to a grinding direction extending substantially parallel to the Y axis of the graphical representation and substantially parallel to a supporting longitudinal axis. Sample S4 used molded abrasive particles with a two-dimensional triangular shape with approximately 20 lbs/ream of molded abrasive particles and at least 70% of the molded abrasive particles were oriented in a lateral orientation.
[279] A second sample (Sample CS3) was made with a conventional pattern of molded abrasive particles, which was an example of a type of shading distribution demonstrated in FIG. 29, which is an image of a portion of Sample CS3 demonstrating a square pattern where the sides of the square repeat unit are aligned with the longitudinal axis and lateral axis of the support. The same size, shape and amount of molded abrasive particles used in Sample S4 were used in Sample CS3, with the only substantial difference being the arrangement of molded abrasive particles in the backing. As illustrated, the arrangement of molded abrasive particles is a shading arrangement with respect to the lateral axis and longitudinal axis of the bearing. The grinding direction was substantially parallel to the longitudinal axis of the support.
[280] The samples were tested under the conditions outlined in Table 4 below.

[281] Parts used for testing were analyzed using Nanovea 3D Optical Profiling (white light chromatic aberration technique) to determine the surface characteristics of the part after the milling operation. For each part tested, an area was profiled on each sample using a 5.0 mm x 5.0 mm area scan. A step size of 10 μm was used for the X and Y axes for all samples. The unfiltered area parameters (Sx) were calculated for the full scan. Twenty line profiles were extracted from the area scan and average parameters were calculated (Px). All profile parameters reported in the sample data are explained in specific detail in an additional slider for reference. The analysis allowed the calculation of 6 surface characterizations as provided in Table 4 below. Note that Sa is the deviation from the arithmetic mean of the surface according to the EUR 15178 EN Report (i.e. “The Development of Methods for the Characterization of Roughness in Three Dimensions,” Stout, KJ, et al. Published on behalf of the Commission of the European Communities). Sq is the mean square deviation of the surface according to the EUR 15178 Report EN. St is the total height of the surface and is a measure of the difference in height between the highest peak and the deepest valley. Sp is the maximum height of the summits and is a measure of the difference in height between the highest peak and the midplane. Sv is the maximum depth of the valleys and is a measure of the distance between the midplane and the deepest valley. Sz is the point average ten of the surface and is the average of the distance between the five highest peaks and the five deepest valleys according to Report EUR 15178 EN.Table 5

[282] FIG. 29 includes an image of a portion of the surface of the part after performing the grinding operation with the S4 Sample abrasive. FIG. 90 includes an image of a portion of the surface of the part after performing the grinding operation with the CS3 Sample abrasive. As clearly demonstrated in a comparison between the images and the data in Table 5, the unshaded arrangement of the molded abrasive particles associated with Sample S4 resulted in better grinding performance and overall workpiece surface finish compared to the results obtained. in the grinding operation using Sample CS3, which used a shaded pattern of molded abrasive particles.
[283] For each sample (ie S4 and CS3), three test runs were completed and the amount of material removed for the test run was calculated and weighted. The average material removed for Sample S4 was 16% higher compared to Sample CS3, thus demonstrating improved material removal capabilities compared to Sample CS3.
[284] The present application represents a departure from the prior art. While the industry has recognized that molded abrasive particles can be formed through processes such as molding and screen printing, the processes of the embodiments herein are distinct from those processes. Notably, embodiments herein include a combination of process features facilitating the formation of molded abrasive particle batches having particular characteristics. In addition, abrasive articles of embodiments herein may have a specific combination of features distinct from other abrasive articles including, but not limited to, a predetermined distribution of molded abrasive particles, use of a combination of predetermined orientation features, groups, rows, columns, associations, microunits, channel regions, aspects of the molded abrasive particles including but not limited to image aspect ratio, composition, additives, two-dimensional shape, three-dimensional shape, height difference, height profile difference, flashing percentage, height , dishing and their combinations. And indeed, abrasive articles of the modalities of this document can facilitate the improvement of grinding performance. While the industry has generally recognized that certain abrasive articles can be formed in an order with respect to certain abrasive units, these abrasive units have traditionally been limited to abrasive composites that can be easily molded through a binder system or using traditional abrasive or superabrasive gravels. The industry has not contemplated or developed systems for forming abrasive articles from molded abrasive particles with predetermined orientation characteristics as described herein. The manipulation of molded abrasive particles in order to effectively control predetermined orientation characteristics is a non-trivial matter, having exponentially improved the control of particles in three-dimensional space, which is neither disclosed nor suggested in the art. Reference in this document to the term "the same" will be understood to be substantially the same. In addition, it will be appreciated that while the embodiments in this document have referred to generally rectangular shaped bearings, the arrangement of the molded abrasive particles in an unshaded arrangement may be equally applicable to other bearing shapes (e.g. round or ellipsoidal bearings).
[285] The subject matter disclosed above is considered illustrative and not restrictive, and the appended claims are intended to cover all such modifications, improvements, and other embodiments, which encompass the true scope of the present invention. Accordingly, to the fullest extent permitted by law, the scope of the present invention is determined by the broadest permissible interpretation of the following claims and their equivalents and will not be restricted or limited by the detailed description cited above. The description of the modalities combined with the figures is presented to aid in understanding the teachings disclosed herein and should not be interpreted as limiting the scope or applicability of the teachings. Other modalities may be used based on the teachings disclosed in this application.
[286] The terms "comprises," "comprising," "includes," "including," "has," "having" or any other variation thereof, are intended to encompass a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited to just those features, but may include other features not expressly listed or inherent in such method, article, or apparatus. Also, unless expressly stated otherwise, "or" refers to an inclusive-or and not an exclusive-or. For example, a condition A or B is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present), and B is true (or present) and both A and B are true (or present).
[287] Also, the use of "a" or "an" is employed to describe the elements and components described herein. This is done purely for convenience and to give a general idea of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it means otherwise. For example, when a single item is described here, more than one item may be used in place of a single item. Likewise, where more than one item is described in this document, a single item may be substituted for more than one item.
[288] Benefits, other advantages, and solutions to problems have been described above with respect to specific modalities. However, benefits, advantages, solutions to problems, and none of the features that could cause any benefit, advantage, or solution to occur or become more pronounced should not be interpreted as a critical, required, or essential feature. of some or all of the claims.
[289] After reading the specification, persons skilled in the art will appreciate that certain features are, for clarity, described in the context of different modalities, may also be anticipated in combination in a single modality. Conversely, the various features which, for brevity, are described in the context of a single embodiment, may also be provided separately or in any subcombination. Still further, references to values indicated on the scales include each value within that scale.
[290] The Disclosure Summary is provided in accordance with the Patent Act and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Furthermore, in the Detailed Description of the Figures cited above, various features may be grouped or described in a single embodiment for the purpose of simplifying disclosure. This disclosure is not to be construed as reflecting an intention that the claimed modalities require more features than are expressly recited in each claim. On the contrary, as the following claims reflect, inventive subject matter may be directed to less than all of the features of any of the disclosed claims. Accordingly, the following claims are incorporated into the Detailed Description of the Figures, with each claim building upon itself as it defines the separately claimed subject matter.

权利要求:
Claims (12)
[0001]
1. Abrasive article, characterized in that it comprises a first group (301) that includes a plurality of molded abrasive particles (311) coating a support, wherein the plurality of molded abrasive particles (311) of the first group (301) define a first arrangement without shading one another, wherein the degree of overlap of the molded abrasive particles during an initial phase of a material removal operation is not more than 25%, wherein each of several molded abrasive particles of the first group shares at least one of a predetermined rotational orientation, a predetermined lateral orientation and a predetermined longitudinal orientation; a second group (303) comprising a plurality of shaped abrasive particles (321) distinct from the first group (301) and coupled to the support, in that each of the various molded abrasive particles of the second group shares at least one predetermined rotational orientation, a the predetermined lateral orientation and a predetermined longitudinal orientation; and a channel region (307) extending between the first group and the second group, wherein the channel region is free of molded abrasive particles.
[0002]
2. Abrasive article according to claim 1, characterized in that at least approximately 80% of the total content of molded abrasive particles is arranged in a lateral orientation.
[0003]
3. Abrasive article according to claim 1, characterized in that the first group comprises at least one characteristic different from the characteristics of the second group, wherein the characteristic is selected from the characteristic group consisting of average sizes of particle, two-dimensional particle shape, orientation with respect to milling direction, mean lateral space, mean longitudinal space, lateral orientation, inverted orientation, planar orientation, composition, and predetermined distribution.
[0004]
4. Abrasive article according to claim 1, characterized in that the second group is different from the first group in at least one of the predetermined swivel orientation, the predetermined lateral orientation, the predetermined longitudinal orientation, a predetermined vertical orientation, a predetermined end height and a combination thereof.
[0005]
5. Abrasive article, according to claim 1, characterized in that the first group is defined by a first, non-uniform, controlled distribution, and the second group is defined by a second, non-uniform, controlled distribution, in which the first controlled and non-uniform distribution is different from the second controlled and non-uniform distribution.
[0006]
6. Abrasive article according to claim 1, characterized in that the first group defines a first unshaded arrangement and the second group defines a second unshaded arrangement different from the first unshaded arrangement.
[0007]
7. Abrasive article according to claim 1, characterized in that the first group comprises a first molded abrasive particle coupled to the support in a first position, wherein the second group comprises a second molded abrasive particle coupled to the support in a second position and wherein the first molded abrasive particle and the second molded abrasive particle are arranged in a controlled, non-shading arrangement relative to each other, the controlled, non-shading arrangement comprising at least two of a predetermined rotating orientation, a predetermined lateral orientation and a predetermined longitudinal orientation.
[0008]
8. Abrasive article according to claim 7, characterized in that the first position has a first rotating orientation defining a first rotating angle between a plane parallel to a dimension of the first molded abrasive particle and the lateral axis of the support and the The second position has a second pivotal orientation defining a second pivotal angle between a plane parallel to a dimension of the second molded abrasive particle and the lateral axis of the holder.
[0009]
9. Abrasive article according to claim 7, characterized in that the second molded abrasive particle comprises a two-dimensional shape equal to the two-dimensional shape of the first molded abrasive particle.
[0010]
10. Abrasive article according to claim 7, characterized in that at least a portion of the first molded abrasive particle is abutting a portion of the second molded abrasive particle.
[0011]
11. Abrasive article according to claim 1, characterized in that the abrasive article is part of a fixed abrasive article selected from the group consisting of a coated abrasive article and a bonded abrasive article.
[0012]
12. Method of forming an abrasive article, as defined in claim 1, characterized in that it comprises: positioning a plurality of molded abrasive particles on a support in a non-shading arrangement, wherein the degree of overlap of the molded abrasive particles during an initial phase of a material removal operation is not more than 25%, and wherein at least 80% of the total content of the molded abrasive particles is disposed in a lateral orientation with respect to the support, in which a region of the channel ( 307) extends between a first group (301) and a second group (303) different from the first group, wherein the channel region is free of molded abrasive particles; wherein each of a plurality of molded abrasive particles (311) of the first group shares at least one of a predetermined rotational orientation, a predetermined lateral orientation and a predetermined longitudinal orientation, and wherein each of a plurality of molded abrasive particles (311) 321) of the second group shares at least one of a predetermined swivel orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation.

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同族专利:

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公开号 | 公开日

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US20140106126A1|2014-04-17|

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US11154964B2|2021-10-26|

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EP2906392A4|2016-07-13|

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KR20150067357A|2015-06-17|

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WO2014062701A1|2014-04-24|

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CA2887561C|2019-01-15|

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KR101736085B1|2017-05-16|

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RU2015117928A|2016-12-10|

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RU2614488C2|2017-03-28|

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JP6427147B2|2018-11-21|

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US20190217442A1|2019-07-18|

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BR112015008144A2|2017-07-04|

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JP2017007088A|2017-01-12|

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CN104822494B|2017-11-28|

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CA2887561A1|2014-04-24|

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CN108015685A|2018-05-11|

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JP5982580B2|2016-08-31|

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IL238225A|2017-11-30|

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IL238225D0|2015-06-30|

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CN104822494A|2015-08-05|

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EP2906392A1|2015-08-19|

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JP2015532218A|2015-11-09|

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US20170050293A1|2017-02-23|

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法律状态:
2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2018-03-20| B06I| Publication of requirement cancelled [chapter 6.9 patent gazette]|Free format text: ANULADA A PUBLICACAO CODIGO 6.6.1 NA RPI NO 2462 DE 13/03/2018 POR TER SIDO INDEVIDA. |

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2019-10-15| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-06-15| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2021-10-26| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2022-01-04| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 15/10/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201261714028P| true| 2012-10-15|2012-10-15|

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US61/714,028|2012-10-15|

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US201261747535P| true| 2012-12-31|2012-12-31|

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US61/747,535|2012-12-31|

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PCT/US2013/065085|WO2014062701A1|2012-10-15|2013-10-15|Abrasive particles having particular shapes and methods of forming such particles|

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