ABRASIVE PARTICLES HAVING PARTICULAR SHAPES AND METHODS FOR FORMING SUCH PARTICLES

专利摘要:
abrasive particles having particular shapes and methods for forming such particles. a coated abrasive article comprising a backing, an adhesive layer disposed in a discontinuous distribution on at least a portion of the backing, wherein the discontinuous distribution comprises a plurality of adhesive contact regions having at least one of a lateral spacing or a longitudinal spacing between each of the adhesive contact regions; and at least one abrasive particle disposed in each adhesive contact region, the abrasive particles having a tip, and having at least one of a lateral spacing or a longitudinal spacing between each of the abrasive particles, and wherein at least 65% of the at least minus one of a lateral spacing and a longitudinal spacing between the tips of the abrasive particles is within 2.5 standard deviations of the mean.
公开号:BR112015024901B1
申请号:R112015024901-9
申请日:2014-03-31
公开日:2022-01-18
发明作者:Darrell K. Everts；Anuj Seth；Vivek CHERUVARI KOTTIETH RAMAN
申请人:Saint-Gobain Abrasifs；Saint-Gobain Abrasives, Inc；
IPC主号:

专利说明:

TECHNICAL FIELD
[1] The following pertains to abrasive articles, and particularly to methods for forming abrasive articles. FUNDAMENTALS OF THE TECHNIQUE
[2] Abrasive particles and prepared abrasive articles incorporating abrasive particles are useful for various material removal operations, including grinding, finishing and polishing. Depending on the type of abrasive material, these abrasive particles can be useful in shaping or grinding a wide variety of materials and surfaces in product manufacturing. Certain types of abrasive particles have been formulated to date that have particular geometries, such as abrasive particles in triangular shapes and abrasive articles that embody these objects. See, for example, US Patents 5,201,916; US 5,366,523; and US 5,984,988.
[3] Some basic technologies that have been employed to produce the abrasive particles having a specified shape are (1) melting, (2) sintering, and (3) chemical ceramics. In the melting process, the abrasive particles can be molded by a cooling roller, the face of which may or may not be etched, a mold into which the molten material is poured, or a heat-dissipating material immersed in an oxide molten mass. aluminum. See, for example, US Patent 3,377,660, disclosing a process comprising the steps of flowing an abrasive material from an oven melt over a fresh rotating shaping cylinder, rapidly solidifying the material to form a semi-solid bent thin sheet, densifying the material semi-solid with a pressure roller, and then partially fracture the strip of semi-solid material, reversing its curvature, moving it away from the cylinder with a rapidly driven cooled carrier.
[4] In the sintering process, abrasive particles can be formed from refractory powders having a particle size of 45 microns or less in diameter. Binders can be added to the powders together with a lubricant and a suitable solvent, for example water. The resulting mixtures or pastes can be molded into slabs or rods of different lengths and diameters. See, for example, US Patent 3,079,242, which discloses a method for preparing abrasive particles from calcined bauxite material comprising the steps of (1) reducing the material to a fine powder, (2) compacting under positive pressure, and forming the particles. fines of said powder into grain-sized agglomerates, and (3) sintering the particle agglomerates at a temperature below the melting temperature of bauxite to induce limited recrystallization of the particles, whereby abrasive grains are produced directly to size.
[5] Chemical ceramics technology involves: converting a colloidal dispersion or hydrosol (sometimes called a sol), optionally in a mixture, with solutions of other metal oxide precursors, to a gel; dry; and heating to obtain a ceramic material. See, for example, US Patents 4,744,802 and US 4,848,041.
[6] Yet there remains a need in the industry to improve the performance, life and effectiveness of abrasive particles, and abrasive articles that employ abrasive particles. BRIEF DESCRIPTION OF THE DRAWINGS
[7] The present disclosure may be better understood, and its numerous features and advantages made evident to those skilled in the art, by referring to the accompanying drawings.
[8] FIG. 1A includes a top view illustration of a portion of an abrasive article according to one embodiment.
[9] FIG. 1B includes a cross-sectional illustration of a portion of an abrasive article according to one embodiment.
[10] FIG. 1C includes a cross-sectional illustration of a portion of an abrasive article according to one embodiment.
[11] FIG. 1D includes a cross-sectional illustration of a portion of an abrasive article according to one embodiment.
[12] FIG. 2A includes a top view illustration of a portion of an abrasive article including abrasive particles molded in accordance with one embodiment.
[13] FIG. 2B includes a perspective view of an abrasive particle molded onto an abrasive article in accordance with one embodiment.
[14] FIG. 3A includes a top view illustration of a portion of an abrasive article in accordance with one embodiment.
[15] FIG. 3B includes a perspective view illustration of a portion of an abrasive article including molded abrasive particles having predetermined orientation characteristics relative to a grinding direction in accordance with one embodiment.
[16] FIG. 4 includes a top view illustration of a portion of an abrasive article according to one embodiment.
[17] FIG. 5 includes a top view of a portion of an abrasive article according to one embodiment.
[18] FIG. 6 includes a top view illustration of a portion of an abrasive article in accordance with one embodiment.
[19] FIG. 7A includes a top view illustration of a portion of an abrasive article according to one embodiment.
[20] FIG. 7B includes an illustration of a perspective view of a portion of an abrasive article in accordance with one embodiment.
[21] FIG. 8A includes an illustration of the perspective view of an abrasive particle molded in accordance with one embodiment.
[22] FIG. 8B includes a cross-sectional illustration of the shaped abrasive particle of FIG. 8A.
[23] FIG. 8C includes a side view illustration of an abrasive particle shaped in accordance with one embodiment.
[24] FIG. 9 includes an illustration of a portion of an alignment structure according to one embodiment.
[25] FIG. 10 includes an illustration of a portion of an alignment structure according to one embodiment.
[26] FIG. 11 includes an illustration of a portion of an alignment structure according to one embodiment.
[27] FIG. 12 includes an illustration of a portion of an alignment structure according to one embodiment.
[28] FIG. 13 includes an illustration of a portion of an alignment structure, including discrete contact regions comprising an adhesive according to an embodiment.
[29] FIGS. 14A-14H include top-down views of portions of tools for forming abrasive articles that have various patterned alignment structures including discrete contact regions of an adhesive material in accordance with the embodiments herein.
[30] FIG. 15 includes an illustration of a system for forming an article
[31] abrasive from FIG. 16 agreement includes a modality of illustration of a system to form an article
[32] abrasive according to one embodiment FIGS. 17A-17C include illustrations of systems to form an article.
[33] abrasive from FIG. 18 agreement includes a modality of illustration of a system to form an article
[34] abrasive from FIG. 19, in one embodiment, includes an illustration of a system for forming an abrasive article in accordance with one embodiment.
[35] FIG. 20A includes an image of a tool used to form an abrasive article in accordance with one embodiment.
[36] FIG. 20B includes an image of a tool used to form an abrasive article in accordance with one embodiment.
[37] FIG. 20C includes an image of a portion of an abrasive article in accordance with one embodiment.
[38] 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.
[39] FIG. 22 includes an image of a portion of an exemplary sample
[40] of the agreementFIG. 23 with an embodiment includes an image of a portion of a conventional sample.
[41] FIG. 24 includes a maximum lot of grains/cm2 and total number of grains/cm2 for two conventional samples and three representative samples of the modalities.
[42] FIGS. 25-27 include illustrations of locating lots of abrasive particles molded to form unshaded arrangements in accordance with embodiments.
[43] FIG. 28 is an illustration of an embodiment of rotary screen printing.
[44] FIG. 29 is a top-down illustration of a plurality of molded abrasive particles located in a plurality of discrete adhesive regions in accordance with one embodiment.
[45] FIG. 30 is an illustration of a plurality of discrete patch target locations and a plurality of discrete patch strike locations according to one embodiment.
[46] FIG. 31 is a flow diagram of a process for preparing a coated abrasive in accordance with one embodiment.
[47] FIG. 32 is an illustration of an unshaded phyllotactic distribution embodiment.
[48] FIG. 33 is an illustration of a rotogravure printing type embodiment.
[49] FIG. 34A is a photograph of a discontinuous distribution of adhesive contact regions where the coating does not contain any abrasive particles.
[50] FIG. 34B is a photograph of the same discontinuous distribution of adhesive contact regions as shown in FIG. 34A after abrasive particles are arranged in the discontinuous distribution of adhesive contact regions.
[51] FIG. 34C is a photograph of the discontinuous distribution of abrasive particles covered in the adhesive contact regions shown in FIG. 34B after a continuous size coating is applied.
[52] FIG. 35A is a conventional image of a coated abrasive which shows a mixture of vertical molded abrasive particles and spikes on the molded abrasive particles.
[53] FIG. 35B is an image of an abrasive coating embodiment, showing a majority of vertical molded abrasive particles and few spikes on the molded abrasive particles.
[54] FIG. 36 is a graph comparing the abrasive particle concentration and orientation (i.e., the abrasive grains in an upright position) of a conventional abrasive coating embodiment of the invention.
[55] FIG. 37 is a photograph of an inventive coated abrasive embodiment. DESCRIPTION OF MODALITIES
[56] The following is directed at: methods for forming and using molded abrasive particles, characteristics of molded abrasive particles; methods for forming and using abrasive articles that include molded abrasive particles; and characteristics of abrasive articles. Molded abrasive particles can be used in various abrasive articles, including, for example, bonded abrasive articles, coated abrasive articles, and the like. In particular cases, the abrasive articles of the embodiments herein may be coated with abrasive articles defined by a single layer of abrasive grains and, more particularly, a single discontinuous layer of molded abrasive particles that can be attached or coupled to a support and used to remove workpiece materials. Notably, the molded abrasive particles can be positioned in a controlled manner so that the molded abrasive particles define a predetermined distribution relative to each other. METHODS TO FORM 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, shaping, screen printing, rolling, casting, pressing, shaping, segmenting, sectioning and a combination thereof. In certain cases, the molded abrasive particles may be formed from a mixture, which may include a ceramic material and a liquid. In particular cases, the mixture can be a gel formed of a ceramic powder material and a liquid, wherein the gel can be characterized as a shape-stable material that has the ability to substantially retain a certain shape, even in the green state. (ie not heated). In one embodiment, the gel may be formed from 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, so that it has adequate rheological characteristics to form the molded abrasive particles. That is, in certain cases, the mixture may have a certain viscosity and, more particularly, suitable rheological characteristics that facilitate the formation of a dimensionally stable phase of material. A dimensionally stable phase of material is a material that can be formed to have a certain shape and substantially retain the shape so that the shape is present in the object finally formed.
[59] According to a particular embodiment, the mixture may be formed to have a certain solid material content, such as ceramic powder material. For example, in one embodiment, the blend may have a content of at least about 25% by weight, such as at least about 35% by weight, or even at least about 38% by weight for the total weight of the blend. . Still, in at least one non-limiting embodiment, the solid content of the mixture cannot be more than about 75% by weight, such as not more than 70% by weight, not more than 65% by weight, not more than 55% by weight. weight %, not more than 45% by weight, or not more than about 42% by weight. It will be appreciated that the content of solid materials in the mixture may be within a range between any of the minimum and maximum percentages noted above.
[60] In one embodiment, the ceramic powder material may include an oxide, a nitride, a carbide, a boride, an oxycarbon, an oxynitride, and a combination thereof. In particular cases, the ceramic material may include alumina. More specifically, the ceramic material may include a boehmite material, which may be an alpha alumina precursor. The term "boehmite" is generally used herein to denote alumina hydrates including mineral boehmite, typically being Al2O3^H2O and having a water content of the order of 15%, as well as pseudoboehmite, having a water content of greater than 15%, as 20-38% by weight. It is noted that boehmite (including pseudoboehmite) has a particular and identifiable crystal structure and therefore unique X-ray diffraction pattern, and as such is distinct from other aluminous materials, including other hydrated aluminas such as ATH ( aluminum trihydroxide) a common precursor of materials used herein for the manufacture of boehmite particulate materials.
[61] In addition, the mixture can be formed to have a certain 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 solids content of the mixture. In more particular cases, the mixture may have a liquid content of at least about 25% by weight, such as at least about 35% by weight, at least about 45% by weight, at least about 50% by weight , or even at least about 58% by weight to the total weight of the mixture. Still, in at least one non-limiting embodiment, the liquid content of the mixture cannot be greater than about 75% by weight, such as not greater than about 70% by weight, not greater than about 65% by weight. , not more than about 62% by weight, or even not more than about 60% by weight. It will be appreciated that the liquid content in the mixture can be within a range between any of the minimum and maximum percentages noted above.
[62] Also, for certain processes, the mixture may have a particular 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 even at least about 5x104 Pa. However, in at least one non-limiting embodiment, the blend cannot have a storage module equal to or greater than about 1x107 Pa, such as not greater than about 2x106 Pa. It will be appreciated that the blend storage module 101 can be within a range between any of the observed minimum and maximum values above.
[63] The storage module can be measured through a parallel plate system using ARES or AR-G2 rotational rheometers, with Peltier plate temperature control systems. For testing, the mixture can be drawn from within a gap between two plates that are defined to be approximately 8 mm apart. After removing the gel from the gap, the distance between the two plates defining 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 voltage sweep test conducted with instrument settings for a range of forces between 01% to 100%, at 6.28 rad/s (1 Hz), using 25 mm parallel plates and recording 10 points per decade. Within 1 hour of completion of the test, reduce the gap again by 0.1 mm and repeat the test. The test can be repeated at least 6 times. The first test may be different from the second and third tests. results from the second and third tests for each sample must be reported.
[64] In addition, to facilitate processing and formation of molded abrasive particles in accordance with 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 8x103 Pa s, at least about 10x103 Pa s, at least about 20x103 Pa s, at least about 30x103 Pa s, at least about 40x103 Pa s, at least about 50x103 Pa s, at least about 60x103 Pa s, at least about 65x103 Pa s. In at least one non-limiting embodiment, the mixture may have a viscosity of not more than about 100x103 Pa.s, not more than about 95x103 Pa.s, not more than about 90x103 Pa.s, or even not more than about 90x103 Pa.s. 85x103 Pa s. It will be appreciated that the viscosity of the mixture can be in the range between any of the minimum and maximum values noted above. Viscosity can be measured in the same way as the storage modulus as described above.
[65] In addition, the mixture can be formed to have a certain content of organic materials, including, for example, organic additives that can be distinguished from the liquid, to facilitate processing and the formation of molded abrasive particles in accordance with the specifications. modalities here. Some suitable organic additives may include stabilizers, binders such as fructose, sucrose, lactose, glucose, UV curable resins and the like.
[66] Notably, the embodiments described herein may utilize a blend that may be different from the pastes used in conventional forming operations. For example, the content of organic material within the mixture, in particular any of the organic additives noted above, may be a minor amount compared to other components within the mixture. 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 cases, 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. Still, in at least one non-limiting embodiment, the amount of organic materials in the mixture may be at least about 0.01% by weight, such as at least about 0.5% by weight, for the total weight of the mixture. It will be appreciated that the amount of organic materials in the mixture can be within a range between any of the minimum and maximum values noted above.
[67] In addition, the mixture may be formed to have a particular acid or base content distinct from the liquid to facilitate processing and formation of molded abrasive particles in accordance with the embodiments herein. Some suitable acids or bases may include nitric acid, sulfuric acid, citric acid, hydrochloric 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 particular forming method, the mixture can be used to form molded abrasive particles through a screen printing process. Generally, a screen printing process may include extrusion of the mixture in a die into the openings of a screen of an application zone. A substrate combination including a web having openings and a belt underlying the web can be translated under the die and the mixture can be released into the openings of the web. The mixture contained in the openings can then be extracted from the screen openings and contained in the belt. The molded portions resulting from the mixture may be precursors of molded abrasive particles.
[69] According to one embodiment, the screen may have one or more apertures having a predetermined two-dimensional shape, which can facilitate the formation of molded abrasive particles having substantially the same two-dimensional shape. It will be appreciated that there may be characteristics of the molded abrasive particles that cannot be replicated from the shape of the opening. According to one embodiment, the opening can have various shapes, for example, a polygon, an ellipsoid, a number, a letter of the Greek alphabet, a letter of the Latin alphabet, a character of the Russian alphabet, a Kanji character, a complex shape , including a combination of polygonal shapes, and a combination thereof. In particular cases, openings may have a two-dimensional polygonal shape, 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 quickly, so that the average residence time of the mixture inside 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 travels through the apertures in the screen, thus experiencing no change in the amount of components of the original blend, and may experience no appreciable drying at the apertures. of the screen.
[71] Belt and/or fabric can be translated at a particular rate to facilitate processing. For example, the belt and/or fabric can be translated at a rate of at least about 3 cm/sec. In other embodiments, the rate of translation of the belt and/or the web may be greater, such as at least about 4 cm/sec, at least about 6 cm/sec, at least about 8 cm/sec, or even at least about 8 cm/sec. minus about 10 cm/s. For certain processes in accordance with embodiments herein, the translation speed of the belt 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 molded abrasive particle precursor (ie, 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 that defines a point of separation between the screen and belt with respect to a point within the application zone, a viscosity of the mixture, a storage modulus of the mixture, the mechanical properties of the components within the application zone, thickness of the belt, the stiffness of the belt, a solids content of the mixture, a carrier content of the mixture, a release angle between the belt and the belt, a translation speed, a temperature, a release agent content on the belt or on the screen opening surfaces, a pressure exerted on the mixture to facilitate extrusion, a belt speed, and a combination thereof.
[73] After completing the shaping process, the resulting precursor of molded abrasive particles can be translated through a series of zones, where additional treatments can take place. Some examples of suitable additional treatments may include drying, heating, curing, reacting, radiation, mixing, stirring, flattening, calcining, sintering, milling, sieving, varnishing, and a combination thereof. In one embodiment, the molded abrasive particle precursors may be translated through an optional forming zone, wherein at least an outer surface of the particles may be further molded. Additionally or alternatively, the molded abrasive particle precursors may be translated through an application zone, wherein a dopant material can be applied to at least one external surface of the molded abrasive particle precursor. A dopant material can be applied using various methods including, for example, spraying, dipping, depositing, impregnating, transferring, piercing, cutting, pressing, crushing, and any combination thereof. In particular cases, the application zone may utilize a spray nozzle, or a combination of spray nozzles, to spray dopant material onto the precursor of molded abrasive particles.
[74] In one embodiment, the application of a 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 the 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 metal element). It will be appreciated that the salt may be in liquid form, as a mixture or in solution, comprising the salt and a liquid carrier. The salt may include nitrogen, and more particularly, 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 alkaline 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, cesium, praseodymium, niobium, hafnium, zirconium, tantalum , molybdenum, vanadium, chromium, cobalt, iron, germanium, manganese, nickel, titanium, zinc, and a combination thereof.
[76] In particular cases, the process of applying a dopant material may include selecting to place the dopant material on an external surface of a precursor of molded abrasive particles. For example, the process of applying a dopant material may include applying a dopant material to an upper surface or a lower surface of the molded abrasive particle precursor. In yet another embodiment, one or more side surfaces of the molded abrasive particle precursor may be treated so that a dopant material is applied thereto. It will be appreciated that various methods can be used to apply the dopant material to various external surfaces of the molded abrasive particle precursor. For example, a spraying process can be used to apply a dopant material to one side of the surface or top surface of the molded abrasive particle precursor. In yet an alternative embodiment, a dopant material can be applied to the undersurface of the molded abrasive particle precursor by a process such as dipping, depositing, impregnating, or a combination thereof. It will be appreciated that a surface of the belt may be treated with a dopant material to facilitate transfer of the dopant material to a lower surface of molded abrasive particle precursors.
[77] And additionally, the molded abrasive particle precursor can be translated on the belt through a post-forming zone, where a variety of processes, including, for example, drying, can be conducted on the molded abrasive particle precursor, as described here. Various processes can be conducted in the post-forming zone, including the treatment of the molded abrasive particle precursor. In one embodiment, the post-forming zone may include a heating process, wherein the molded abrasive particle precursor may be dried. Drying can include the removal of certain material content, including volatile materials such as water. In one embodiment, the drying process may be conducted at a drying temperature not higher than about 300°C, not higher than about 280°C, or even not higher than about 250°C. Further, in a non-limiting embodiment, the drying process may be conducted at a drying temperature of at least about 50°C. It will be appreciated that the drying temperature can be within a range between any of the minimum and maximum temperatures noted above. In addition, the molded abrasive particle precursor can be translated through the postform zone at a particular rate, such as at least about 0.2 ft/min. (0.06 m/min.) and not more than about 8 ft/min (2.4 m/min.).
[78] According to one embodiment, the process for forming molded abrasive particles may further comprise a sintering process. For certain processes of embodiments here, sintering can be performed after collecting the molded abrasive particle precursor from the belt. Alternatively, sintering may be a process that is carried out while the molded abrasive particle precursor is on the belt. Precursor sintering of molded abrasive particles can be used to densify the particles, which are generally in a green state. In a particular case, the sintering process can facilitate the formation of a high temperature phase of the ceramic material. For example, in one embodiment, the molded abrasive particle precursor can be sintered so that a high temperature phase of 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 the total weight of the particle. In other cases, the alpha alumina content may be higher, so that the shaped abrasive particle may consist essentially of alpha-alumina. MOLDED ABRASIVE PARTICLES
[79] Molded abrasive particles can be formed to have various shapes. In general, molded abrasive particles can be formed to have a modeling to approximate modeling components used in the forming process. For example, a molded abrasive particle may have a predetermined two-dimensional shape, as seen in any two-dimensional three-dimensional modeling models, and in particular in a dimension defined by the length and width of the particle. Some exemplary two-dimensional models may include a polygon, an ellipsoid, a numeral, a letter from the Greek alphabet, a letter from the Latin alphabet, a character from the Russian alphabet, a Kanji character, a complex shape, including a combination of polygonal models, and a combination of them. In particular cases, the shaped abrasive particle may have a two-dimensional polygonal pattern 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 pattern as illustrated in FIG. 8A. FIG. 8A includes a perspective view illustration of a molded abrasive particle in accordance with one embodiment. Furthermore, FIG. 8B includes a cross-sectional illustration of the shaped abrasive particle of FIG. 8A. The body 801 includes an upper surface 803 and a lower main surface 804 opposite the upper surface 803. The upper surface 803 and the lower surface 804 may be separated from each other by side surfaces 805, 806, and 807. As illustrated, the body 801 of the molded abrasive particle 800 may have a generally triangular pattern as seen in a plane of the upper surface 803. In particular, the body 801 may have a length (L-middle) as shown in FIG. 8B, which is measurable at the lower surface 804 of the body 801 and which extends from a corner on the lower surface corresponding to the corner 813 on the upper surface through a midpoint 881 of the body 801 to a midpoint at the opposite end of the body corresponding to the edge 814 on the upper surface of the body. Alternatively, the body may be defined by a length or second profile of length (Lp), which is the measurement of the dimension of the body from a side view on the top surface 803 from a first corner 813 to an adjacent corner 812. Namely , the length dimension (Lmiddle) can have a length defining a distance between a height of each corner (hc) and a height at the midpoint of an end (hm) opposite the corner. The dimension Lp can be a length along the side profile of the particle defining the distance between h1 and h2 (as explained here). The reference here to length may refer to Lmedium or Lp.
[81] The body 801 may further include a width (w) which is the longest dimension of the body and extending 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 a lateral surface of the body 801. Namely, as will be described in more detail here, the body 801 can be set to various heights depending on the location on the body. In specific cases, the width 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 here to any dimensional feature (eg, h1, h2, hi, w, Lmiddle, Lp, and the like) may refer to a single-particle dimension of a batch. Alternatively, any reference to any of the dimensional characteristics may refer to a median value or an average value derived from the analysis of an appropriate sample of particles from a batch. Unless explicitly stated, reference herein to a dimensional characteristic may be regarded as 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. Notably, for certain embodiments here, 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 run, and more particularly, can include an amount of molded abrasive particles suitable to form a commercial grade abrasive product, such as at least about 20 lbs. . of particles.
[83] According to one embodiment, the molded abrasive particle body 801 may have a first corner height (hc) at a first region of the body defined by a corner 813. Notably, the corner 813 may represent the point of greatest height. over body 801; however, the height at corner 813 does not necessarily represent the point of greatest height over body 801. Corner 813 can be defined as a point or region on body 301 defined by the junction of top surface 803 and two side surfaces 805 and 807. Body 801 may also include other spaced apart corners, including, for example, corner 811 and corner 812. As further illustrated, body 801 may include edges 814, 815, and 816 that may be separated from each other by corners 811 , 812, and 813. Edge 814 may be defined by an intersection of top surface 803 and side surface 806. Edge 815 may be defined by an intersection of top surface 803 and side surface 805 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 by a region at the midpoint of edge 814, which may be opposite the first end defined by corner 813. Shaft 850 may extend between the two ends of 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 (Lmid) between corner 813 and midpoint of edge 814 .
[85] According to one embodiment, the molded abrasive particles of the embodiments herein, including, for example, the particle of FIGs. 8A and 8B may have an average height difference, which is a measure of the difference between the hc and hm. By convention here, average difference in height will generally be identified as hc-hm, however, an absolute value of the difference is defined and it will be appreciated that the average difference in height can be calculated as the hm-hc when body height 801 , at the midpoint of the edge 814 is greater than the height of the corner 813. More particularly, the difference in average height can be calculated based on a plurality of molded abrasive particles of a suitable sample size, such as at least 40 particles of a batch as defined herein. The hc and hm heights of the particles can be measured using a STIL Profilemeter (Sciences et Techniques Industrielles de la Lumiere - France) of 3D surface micromeasurements (white light (LED), chromatic aberration technique) and the average difference in height 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 difference in height at different locations on the body. The body may have an average height difference, which may be the absolute value of [hc-hm] between the first corner height (hc) and the second midpoint height (hm) is 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 an edge midpoint is greater than the height of an opposite corner. In other cases, the average difference in height [hc-hm] may 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 even at least about 100 microns. In a non-limiting embodiment, the average difference in height may not be greater than or equal to about 300 microns, not greater than about 250 microns, not greater than about 220 microns, or even not greater than about 180 microns. It will be appreciated that the average height difference can be within a range between any of the minimum and maximum values noted above.
[87] In addition, it will be appreciated that the average height difference may be based on an average value of hc. For example, the average height of the body 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). Therefore, the average difference in height can be determined by the absolute value of the equation [Ahc-hi], where hi is the internal height, which can be the smallest dimension of the height of the body, measured along a dimension between any corner and midpoint of the edge of the opposite body. Furthermore, it will be appreciated that the average difference in height can be calculated using an internal median height (Mhi) calculated from a suitable sample of a batch of molded abrasive particles and an average height at the corners of all particles in the sample size. Therefore, the average difference in height can be given by the absolute value of the equation [Ahc-Mhi].
[88] In particular cases, the body 801 may be formed to have a primary aspect ratio, which is expressed as a width:length ratio, where the length may be L-half, having a value of at least 1:1. In other cases, the body may be formed so that the primary aspect ratio (w:1) is at least about 1.5:1, such as at least about 2:1, at least about 4:1, or even at least about 5:1. Still, in other cases, the abrasive particle may be formed so that the body has a primary aspect ratio, which is not greater than about 10:1, such as not greater than about 9:1, not greater than about 8: 1, or even greater than about 5:1. It will be appreciated that the body 801 may have a primary aspect ratio within a range between any of the ratios noted above. Furthermore, it will be appreciated that reference herein to a height is the maximum measurable height of the abrasive particle. It will be described later that the abrasive particle can have different heights, at different positions within the body 801.
[89] In addition to the primary aspect ratio, the abrasive particle can be formed so that the body 801 comprises a secondary aspect ratio, which can be defined as a length:height ratio, where the length can be L-half and the height is an internal height (hi). In certain cases, the secondary aspect ratio may be within a range of between about 5:1 and about 1:3, such as between about 4:1 and about 1:2, or between about 3:1 and about 1:2. It will be appreciated that the same ratio can be measured using the median values (e.g., median length and median internal height) for a batch of particles.
[90] According to another embodiment, the abrasive particle can be formed so that the body 801 comprises a tertiary aspect ratio, defined by the width:height ratio, where the height is an internal 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, such as between about 6:1 and about 1.5:1, or between about 4:1 and about 1.5:1. It will be appreciated that the same ratio can be measured using the median values (e.g., median length, median median length, and/or the median internal height) for a batch of particles.
[91] According to one embodiment, the molded abrasive particle body 801 can have particular dimensions, which can facilitate better performance. For example, in one case, the body may have an internal height (hi), which may be the smallest dimension of the body's height, measured along a dimension between a corner and the midpoint of the opposite edge on the body. In particular cases, where the body is a two-dimensional, generally triangular shape, the inner height (hi) may be the smallest height dimension (i.e., measured between the lower surface 804 and the upper surface 805) of the body for three measurements taken between each of the three corners and the midpoints of the opposite edges. The internal height (hi) of the body of a molded abrasive particle is illustrated in FIG. 8B. In one embodiment, the internal height (hi) can be at least about 28% of the width (w). The height (hi) of any particle can be measured by cutting or assembling and grinding the shaped abrasive particle and viewing it sufficiently (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 even at least about 33% of the body width. For a non-limiting modality, the height (hi) of the body may be not more than about 80% of the width, such as not more than 76%, not more than 73%, not more than 70%, not more than 68% of the width, not more than 56% of the width, not more than 48% of the width, or even not more than 40% of the width. It will be appreciated that the height (hi) of the body can be within a range between any of the minimum and maximum percentages noted above.
[92] A batch of molded abrasive particles can be manufactured, where the median internal height (Mhi) value can be controlled, which can facilitate better performance. In particular, the median internal height (hi) of a batch can be related to an average width of the shaped abrasive particles of the batch in the same manner as described above. Namely, the median internal height (Mhi) can be at least about 28%, such as at least about 29%, at least about 30%, or even at least about 33% of the average width of the molded abrasive particles in the batch. . For a non-limiting modality, the median internal height (Mhi) of the body can be no more than about 80%, no more than about 76%, no more than about 73%, no more than about 70%, not more than about 68% of the width, not more than about 56% of the width, not more than about 48% of the width, or even not more than about 40% of the median width. It will be appreciated that the median internal height (Mhi) of the body can be within a range between any of the minimum and maximum percentages noted above.
[93] In addition, the batch of molded abrasive particles may exhibit better 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 internal height variation (Vhi), which can be calculated as the standard deviation of the internal height (hi) for a suitable sample size of particles from a batch. In one embodiment, the internal 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 even no greater than about 54 microns. In a non-limiting embodiment, the internal height variation (Vhi) can be at least about 2 microns. It will be appreciated that the internal body height variation can 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 internal height (hi) of at least about 400 microns. More particularly, the height may be at least about 450 microns, such as at least about 475 microns, or even at least about 500 microns. In a still further non-limiting embodiment, the height of the body may be no more than about 3mm, such as no more than about 2mm, no more than about 1.5mm, no more than about 1mm, no greater than about 800 microns. It will be appreciated that the height of the body can be within a range between any of the minimum and maximum values noted above. Furthermore, it will be appreciated that the above range of values may be representative of a median internal height (Mhi) value for a batch of molded abrasive particles.
[95] For certain embodiments herein, the shaped abrasive particle body may have particular dimensions, including, for example, a width>length, a length>height, a width>height. More particularly, the molded abrasive particle body 801 may have a width (w) of at least about 600 microns, such as at least about 700 microns, at least about 800 microns, or even at least about 900 microns. In a non-limiting example, the body may have a width of not more than about 4mm, such as not more than about 3mm, not more than about 2.5mm, or even not more than about 2mm. It will be appreciated that the width of the body can be within a range between any of the minimum and maximum values noted above. Furthermore, it will be appreciated that the above range of values may be representative of a median width (Mw) for a batch of molded abrasive particles.
[96] The molded abrasive particle body 801 can have particular dimensions, including, for example, a length (Lmedium or Lp) of at least about 0.4mm, such as at least about 0.6mm, at least about of 0.8 mm, or even at least about 0.9 mm. Still, in at least one non-limiting embodiment, the body 801 may have a length of not more than about 4 mm, such as not more than about 3 mm, not more than about 2.5 mm, or even not more than about 2.5 mm. of 2 mm. It will be appreciated that the length of the body 801 can be within a range between any of the minimum and maximum values noted above. Furthermore, it will be appreciated that the above range of values may be representative of an average length (MI), which may more particularly be an average median length (MLmean) or median profile length (MLp) for a batch of molded abrasive particles. .
[97] The molded abrasive particle may have a body 801 having a particular amount of concavity, where the concavity value (d) can be defined as a ratio of the average height of the body 801 at the corners (Ahc) compared to the smallest dimension of the height of the body inside (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 the average of the values, and can be distinguished from a single height value at a corner (hc). The average height of the 801 body at the corners or inside can be measured using a STIL Profilemeter (Sciences et Techniques Industrielles de la Lumiere - France) of 3D surface micromeasurements (white light (LED), chromatic aberration technique). Alternatively, concaves can be based on an average corner particle height (Mhc) calculated from an appropriate sample of particles from a batch. Likewise, the internal height (hi) can be a median internal height (Mhi) derived from a suitable sample of molded abrasive particles from a batch. According to one embodiment, the concave value (d) may be no greater than about 2, such as no greater than about 1.9, and no greater than about 1.8, and no greater than about 1, 7, and not more than about 1.6, or even not more than about 1.5. Still, in at least one non-limiting embodiment, the concave value (d) can be at least about 0.9, as well as at least about 1.0. It will be appreciated that the concave ratio can be within a range between any of the minimum and maximum values noted above. Furthermore, it will be appreciated that the above concave values may be representative of a median concave value (Md) for a batch of molded abrasive particles.
[98] The molded abrasive particles of the embodiments herein, including, for example, the body 801 of the particle of FIG. 8A may have a lower surface 804 that defines a lower area (Ab). In particular cases, the lower surface 304 may be the largest surface of the body 801. The lower surface may have a surface area defined as the lower area (Ab) that is greater than the surface area of the upper surface 803. In addition , body 801 may have a midpoint cross-sectional area (Am) defining an area of a plane perpendicular to the lower area and extending through a midpoint 881 (one between the upper and lower surfaces) of the particle. In certain cases, the body 801 may have an area ratio less than the midpoint area (Ab/Am) of no more than about 6. In more particular cases, the area ratio can be no more than about 5 .5, such as not greater than about 5, not greater than about 4.5, and not greater than about 4, not greater than about 3.5, or even not greater than about 3. Yet, in in a non-limiting embodiment, the area ratio can be at least about 1.1, such as at least about 1.3, or even at least about 1.8. It will be appreciated that the area ratio can be within a range between any of the minimum and maximum values noted above. Furthermore, it will be appreciated that the above area ratios may be representative of a median area ratio for 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 may be no greater than about 0.26, no greater than about 0.22, or even no greater than or equal to about 0.19. Further, in a particular embodiment, the normalized height difference may be at least about 0.04, such as at least about 0.05, at least about 0.06. It will be appreciated that the normalized height difference can be within a range between any of the minimum and maximum values noted above. Furthermore, it will be appreciated that the above normalized height values may be representative of an average normalized height value for a batch of molded abrasive particles.
[100] In another case, the body 801 may have a ratio profile of at least about 0.04, where the ratio profile is defined as the ratio of the average height difference [hc-hm] to the length (Lmedium) of the molded abrasive particle, defined as the absolute value of [(hc-hm)/(Lmedium)]. It will be appreciated that the length (Lmid) of the body may be the distance between the body 801, as illustrated in FIG. 8B. In addition, the length may be an average or median length calculated from a suitable sample of particles from a batch of molded abrasive particles as defined herein. According to a particular embodiment, the ratio profile 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 0.08 about 0.09. Further, in a non-limiting embodiment, the ratio profile may be no greater than about 0.3, such as no greater than about 0.2, and no greater than about 0.18, no greater than about 0. 16, or even no greater than about 0.14. It will be appreciated that the ratio profile may fall within a range between any of the minimum and maximum values noted above. Furthermore, it will be appreciated that the above ratio profile may be representative of a median ratio profile for 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 a side surface 805, 806 or 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 may be within a range 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 such an angle of inclination can improve the abrasion capabilities of abrasive particles. Notably, the pitch angle can be within a range between any two pitch angles indicated 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 a trench region 818 may extend around the upper surface 803 and defines the ellipsoidal region 817. The ellipsoidal region 817 may encompass the midpoint 881. Furthermore, it is thought that the ellipsoidal region 817 defined on the top surface may be an artifact of the modeling process, and may be formed as a result of stresses imposed on the mixture during the formation of the abrasive particles molded according to the methods described herein.
[103] The molded abrasive particle can be formed so 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 may consist essentially of a polycrystalline material.
[104] In one aspect, the body of the abrasive particle may be in the form of an agglomerate that includes a plurality of abrasive particles, grain, and/or grains bonded together to form the body 801 of the abrasive particle 800. Suitable abrasive grains may include nitrides, oxides, carbides, borides, oxynitrides, oxyborides, diamond, superabrasives (eg cBN) and a combination thereof. In particular cases, 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 case, the abrasive particle 800 is formed so that the abrasive grains constituting 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, compact powders, of polycrystalline abrasive materials or superabrasives including a binder phase, which may include a metal, metal alloy, superalloy, cermet, and a combination thereof. Some exemplary binder materials may include cobalt, tungsten, and a combination thereof.
[105] The abrasive grains (ie, crystallites) contained within the body may have an average grain size that is generally not larger than about 100 microns. In other embodiments, the average grain size may be smaller, such as not exceeding 80 microns, not exceeding 50 microns, not exceeding 30 microns, not exceeding 20 microns, and not exceeding about 10 microns, or not greater than about 1 micron. Still, the average grain size of the abrasive grains contained within the body may be at least about 0.01 micron, such as at least about 0.05 micron, such as at least about 0.08 micron, at least about 0.08 micron. of 0.1 micron, or even at least about 1 micron. It will be appreciated that the abrasive grains may have an average grain size in the range between any of the minimum and maximum values noted 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 the different types of abrasive grains are abrasive grains having different compositions relative to each other. For example, the body may be formed to include 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 thereof.
[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. In fact, 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. 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 1.5 mm. 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 percentage flash which can facilitate better performance. Notably, the flasher defines an area of the particle, as seen along one side, as illustrated in FIG. 8C, where the flashing extends from a side surface of the body within housings 888 and 889. The flashing may represent tapered regions near the top surface and the bottom surface of the body. Intermittent 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 (e.g. 891) and an outermost point (e.g. 892). ) on the lateral surface of the body. In a particular case, the body may have a certain flash content, which may be the percentage of body area contained within boxes 888 and 889 in relation to the total body area contained within boxes 888, 889, and 890. according to one embodiment, the intermittent (f) percentage of the body may be at least about 10%. In another embodiment, the percentage of intermittents may be higher, such as at least about 12%, at least about 14%, at least about 16%, at least about 18%, or even at least about 20% . Still, in a non-limiting modality, the percentage of body intermittents can be controlled and can be no more than about 45%, no more than about 40%, or even no more than about 36%. It will be appreciated that the body intermittent percentage may be within a range between any of the above minimum and maximum percentages. In addition, it should be noted that the above intermittent percentages may be representative of an average intermittent percentage or a median intermittent percentage for a batch of molded abrasive particles.
[109] The percentage of flashes can be measured by mounting the molded abrasive particle on its side and viewing the body on the side to generate a black and white image, as illustrated in FIG. 8C. A suitable program for creating and analyzing images, including the calculation of burst can be ImageJ software. The percentage of flashers 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 on the side (total area shaded), including the area of the center 890 and within the boxes 888 and 889. This procedure can be completed for proper sampling of particles to generate mean, median and/or standard deviation values.
[110] A batch of abrasive particles molded according to here may exhibit better dimensional uniformity as measured by the standard deviation of a three-dimensional feature from an appropriate sample size. According to one embodiment, the molded abrasive particles may have an intermittent variation (Vf), which can be calculated as the standard deviation of the percentage of intermittents (f) for a suitable sample size of particles from a batch. In one embodiment, the intermittent variation may be no more than about 5.5%, no more than about 5.3%, no more than about 5%, or no more than about 4.8% , not more than about 4.6%, or even not more than about 4.4%. In a non-limiting embodiment, the intermittent variation (Vf) can be at least about 0.1%. It will be appreciated that the intermittent variation can be within a range between any of the maximum and minimum percentages noted above.
[111] Molded abrasive particles of embodiments of this invention may have a height (hi) and intermittent multiplier value (hiF) of at least 4000, where hiF = (hi)(f), a "hi" represents a minimum height internal body as described above and “f” represents the percentage of intermittents. In a particular case, the value of the height and intermittent multiplier (hiF) of the body may be greater, such as at least about 4500% in microns, at least about 5000% in microns, at least about 6000% in microns, at least minus about 7000% in microns, or even at least about 8000% in microns. Still, in a non-limiting modality, the height and modality value of the multiplier can be no more than about 45000% in microns, such as no more than about 30000% in microns, not more than about 25000% in microns, not more than about 20,000% in microns, or even not more than about 18000% in microns. It will be appreciated that the body height and flash multiplier value can be within a range between any of the maximum and minimum values and above. In addition, it will be appreciated that the above multiplier value may be representative of a median value multiplier (MhiF) for a batch of molded abrasive particles.
[112] Molded abrasive particles of the embodiments herein may have a concave (d) and intermittent (F) multiplier (dF) value as calculated by the equation dF = (d)(F), where dF is no greater than about 90%, “d” represents the concave value, and “f” represents the body intermittent percentage. In a particular case, the multiplier (dF) value of concave (d) and flashing (F) of the body can be no more than about 70%, such as no more than about 60%, no more than about 55% , not more than about 48%, not more than about 46%. Still, in a non-limiting embodiment, the multiplier (dF) value of concave (d) and intermittent (F) can be at least about 10%, such as at least about 15%, at least about 20%, at least about 22%, at least about 24%, or even at least about 26%. It will be appreciated that the concave (d) and flashing (F) multiplier (dF) value of the body can be within a range between any of the maximum and minimum values and above. Furthermore, it will be appreciated that the above multiplier value may be representative of a median multiplier value (MdF) for a batch of molded abrasive particles.
[113] The molded abrasive particles of the embodiments herein may have a ratio of height and concave (hi/d), as calculated by the equation hi/d = (hi)/(d), where hi/d is no greater than approx. of 1000, “hi” represents a minimum internal height, as described above, and “d” represents the concaves of the body. In a particular case, the body ratio (hi/d) may be no greater than about 900 microns, not greater than about 800 microns, not greater than about 700 microns, or even not greater than about 650 microns. Still, 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, of at least about 200 microns, at least about 250 microns, or even at least about 275 microns. It will be appreciated that the (hi/d) ratio of the body can be within a range between any of the above maximum and minimum values. In addition, it will be appreciated that the height to concave ratio above may be representative of the median height to concave 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 according to one embodiment. As illustrated, the abrasive article 100 can include a support 101. The support 101 can comprise an organic material, an inorganic material, and a combination thereof. In certain cases, the support 101 may comprise a woven material. However, the support 101 may be made of a non-woven material. Particularly suitable support materials may include organic materials, including polymers and, in particular, 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 appreciated that the abrasive article 100 may include other components, including, for example, adhesive layers (e.g., branding coating, size coating, front padding, etc.), which will be discussed in more detail herein.
[115] As further illustrated, the abrasive article 100 can include a molded abrasive particle 102 superimposed on the support 101, and, more particularly, attached to the support 101. Notably, the molded abrasive particle 102 can be positioned in a first predetermined position 112 on the holder 101. As further illustrated, the abrasive article 100 may further include a molded abrasive particle 103, which may overlap the holder 101, and more particularly, position coupled to the holder 101 in a second predetermined position 113. The abrasive article 100 may further including a molded abrasive particle 104 which overlies the support 101, and more particularly, coupled to the support 101 in a third predetermined position 114. As further illustrated in FIG. 1A, the abrasive article 100 may further include a molded abrasive particle 105 which overlays the support 101, and more particularly coupled to the support 101 in a fourth predetermined position 115. As further illustrated, the abrasive article 100 can include a molded abrasive particle which overlies the support 101 and more particularly coupled to the support 101 at a fifth, predetermined position 116. It will be appreciated that any of the molded abrasive particles described herein may be coupled to the support 101 through one or more adhesive layers as described herein.
[116] In one embodiment, the molded abrasive particle 102 may have a first composition. For example, the first composition may comprise a crystalline material. In a particular embodiment, the first composition may comprise a ceramic material, such as an oxide, carbide, nitride, boride, oxynitride, oxycarbide, and a combination thereof. More particularly, the first composition may consist essentially of a ceramic, so that it may consist essentially of an oxide, carbide, nitride, boride, oxynitride, oxycarbon, and a combination thereof. Further, in an alternative embodiment, the first composition may comprise a superabrasive material. In still other embodiments, the first composition may comprise a single-phase material, and more particularly may consist essentially of a single-phase material. Notably, the first composition may be a single-phase polycrystalline material. In specific cases, the first composition may have limited binder content, such that the first composition may have no more than about 1% binder material. Some examples of suitable binding materials may include organic materials, and more particularly polymers 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 comprise alumina, and more particularly, may consist essentially of alumina, such as alpha alumina.
[117] Yet, in yet another aspect, the molded abrasive particle 102 may have a first composition which may be a composite including at least two different types of abrasive grains within the body. It will be appreciated that the different types of abrasive grains are abrasive grains having different compositions relative to each other. For example, the body may be formed so that it is composed of 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 thereof.
[118] In one embodiment, the first composition may include a dopant material, wherein the dopant material is present in a minor amount. Some examples of suitable varnishing materials may comprise an element or compound, such as an alkaline element, alkaline earth element, rare earth element, hafnium, zirconium, niobium, tantalum, molybdenum, vanadium, or a combination thereof. In a particular embodiment, the dopant material comprises an element or compound including an element such as lithium, sodium, potassium, magnesium, calcium, strontium, barium, scandium, yttrium, lanthanum, cesium, 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 cases, the second composition of the second molded abrasive particle 103 can be substantially the same as the first composition of the first molded abrasive particle 102. More particularly, the second composition can be essentially 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 appreciated that the second composition can comprise any of the materials, elements and compounds described in accordance with the first composition.
[120] According to one embodiment, and as further illustrated 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 purposefully selected. A predetermined distribution may comprise a pattern, design, sequence, matrix or array. In a particular embodiment predetermined positions may define an array, such as a two-dimensional array, or a multidimensional array. A matrix may have short-range order defined by a unit, or group, of molded abrasive particles. A matrix can also be a pattern, having long-range order, including regular and repeating units linked together, so that the arrangement can be symmetrical and/or predictable; however, it should be noted that a predictable array is not necessarily a repeating array (ie, an array or pattern or array can be predictable and non-repeating). An array can have an order that can be predicted by a mathematical formula. It will be appreciated that the two-dimensional arrays may be formed in the form of polygons, ellipses, ornamental indicia, product indicia, or other designs. The predetermined distribution may also include an unshaded array. An unshaded array may comprise a controlled non-uniform distribution; a controlled uniform distribution; or a combination thereof. In particular cases, an unshaded array may comprise a radial pattern, a spiral pattern, a phyllotactic pattern, an asymmetric pattern, a self-avoiding random distribution, or a combination thereof. Unshaded arrangements may include a particular arrangement of abrasive particles (i.e., a particular arrangement of molded abrasive particles, conventional abrasive particles, or a combination thereof) and/or diluent particles, relative to one another, wherein the abrasive particles, thinner particles, or both may have a degree of overlap. The degree of overlap of the abrasive particles during an initial phase of a material removal operation not more than about 25%, not more than about 20%, not more than about 15%, not more than about 10% , or even not more than about 5%. In particular cases, an unshaded arrangement may comprise a distribution of abrasive particles where upon coupling with a workpiece, during an initial phase of a material removal operation, essentially none of the abrasive particles involve the surface region of the workpiece. of work.
[122] The predetermined distribution can be partially, substantially, or totally skewed. The predetermined distribution may overlap the entire abrasive article, may cover substantially the entire abrasive article (i.e., more than 50% but less than 100%), overlap several portions of the abrasive article, or overlap. if at a fraction of the abrasive article (ie less than 50% of the article's surface area).
[123] As used herein, "a phyllotactic pattern" means a pattern related to phyllotaxis. Phylotaxy is the arrangement of lateral organs such as leaves, flowers, scales, florets, seeds in many types of plants. Many phyllotactic patterns are marked by the naturally occurring phenomenon of conspicuous patterns with arcs, and spirals. The pattern of seeds on a sunflower's head is an example of this phenomenon. A further example of a phyllotactic pattern is the arrangement of scales on the axis of a pinecone or pineapple. In a specific embodiment, the predetermined distribution conforms to a phyllotactic pattern that describes the arrangement of the scales of a pineapple and that conforms to the mathematical model for describing the packing of circles on the surface of a cylinder. According to the following model, all components are found in a single generative helix generally characterized by the formula (1.1)Φ = n * a, r = const, H = h * N, (1,1) where:n is the order number of a scale, counting from the base of the cylinder; Φ, R, and H the cylindrical coordinates of the nth scale; α is the angle of divergence between two consecutive scales (assumed to be constant, for example, 137.5281 degrees); eh is the vertical distance between two consecutive scales (measured along the main axis of the cylinder).
[124] The pattern described by formula (1.1) is shown in FIG. 32, and is sometimes referred to here as a “pineapple pattern”. In a specific embodiment, the divergence angle (α) can be in a range of 135.918365° to 138.139542°.
[125] Further, according to one embodiment, an unshaded array may include a microunit, which may be defined as a smaller array of abrasive particles molded 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 particular cases, the macrounit may have a plurality of microunits arranged in a predetermined distribution relative to each other and repeated a plurality of times with the unshaded arrangement. Abrasive articles of embodiments of this invention may include one or more microunits. In addition, it will be appreciated that abrasive articles of embodiments of this invention may include one or more macrounits. In certain embodiments, the macrounits can be arranged in a uniform distribution having a predictable order. Still, in other cases, the macrounits may be arranged in a non-uniform distribution, which may include a random distribution, having no predictable long-range range or short-range order.
[126] Referring briefly to FIG. 25-27, different unshaded arrangements are illustrated. In particular, FIG. 25 includes an illustration of an unshaded arrangement, where the locations of 2501 represent the predetermined positions to be occupied by one or more molded abrasive particles, thinner particles, and a combination thereof. The 2501 locations can be defined as the 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 further illustrated, the microunits may be repeated across the surface of at least a portion of the article and define a macrounit 2530.
[127] FIG. 26 includes an illustration of an unshaded 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 further illustrated, the microunits may be repeated across the surface of at least a portion of the article and define at least one macrounit 2630. It will be appreciated, as illustrated, that other macrounits may exist.
[128] FIG. 27 includes an illustration of an unshaded 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, locations 2701 and 2702 may define a microunit 2720. Additionally, positions 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 macrounit 2730.
[129] A predetermined distribution among the molded abrasive particles can also be defined by at least one characteristic of a predetermined orientation of each of the molded abrasive particles. Exemplary predetermined orientation features may include a predetermined rotation 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 longitudinally and defines a width of support 101.
[130] According to one embodiment, the molded abrasive particle 102 may be located in a first predetermined position 112 defined by a particular first lateral position relative to the lateral axis of 181 of the support 101. In addition, the molded abrasive particle 103 may 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 apart from each other by a lateral space 121, defined as a shortest distance between the two particles adjacent molded abrasives 102 and 103, as measured along a lateral plane 184 parallel to the lateral axis 181 of the holder 101. In one embodiment, the lateral space 121 may be greater than 0, so that there is a certain distance between the molded abrasive particles of 102 and 103. However, although not illustrated, it will be appreciated that the side space 121 may be 0, which allows for contact and even the overlap between adjacent molded abrasive particle portions.
[131] 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. Still, 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 appreciated that side space 121 can be within a range between any of the minimum and maximum values noted above. Controlling the lateral space between adjacent molded abrasive particles can facilitate better abrasion performance of the abrasive article.
[132] According to one embodiment, the molded abrasive particle 102 may be in a first predetermined position 112 defined by a first longitudinal position with respect to a longitudinal axis 180 of the support 101. In addition, the molded abrasive particle 104 may be located in a third position 114 defined by a second longitudinal position with respect to the longitudinal axis 180 of the support 101. Also, as illustrated, a longitudinal space 123 may exist between the molded abrasive particles of 102 and 104, which may be defined as a smaller distance between the two 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, while not illustrated, it will be appreciated that the space longitudinal 123 may be 0, so that adjacent molded abrasive particles are touching or even overlapping each other.
[133] In other cases, the longitudinal gap 123 may be at least about 0.1 (w), where w is the width of the abrasive particle shaped as described herein. In other more particular examples, the longitudinal space may be at least about 0.2(w), at least about 0.5(w), at least about 1(w), or even at least about 2 (w). Still, the longitudinal space 123 can be no greater than about 100 (w), no greater than about 50 (w), or even no greater than about 20 (w). It will be appreciated that longitudinal space 123 can be within a range between any of the maximum and minimum values and above. Controlling the longitudinal space between adjacent molded abrasive particles can facilitate better abrasion performance of the abrasive article.
[134] According to one embodiment, the molded abrasive particles may be positioned in a predetermined distribution, wherein a particular relationship exists between the lateral space 121 and the 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 can be larger than the lateral space 121. In yet another embodiment, the molded abrasive particles can be positioned on the support 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 better abrasion performance.
[135] As further illustrated, a longitudinal space 124 can exist between the molded abrasive particles 104 and 105. Furthermore, the predetermined distribution can be formed such that a particular relationship can exist between the longitudinal space 123 and longitudinal space 124. For example, the longitudinal space 123 may be different than 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 better performance. abrasion of the abrasive article.
[136] In addition, the predetermined distribution of abrasive particles molded into the abrasive article 100 may be such that the side space 121 may have a particular relationship relative to the side space 122. For example, in one embodiment the side space 121 may be essentially the same. same as the side space 122. Alternatively, the predetermined distribution of abrasive particles molded into the abrasive article 100 can be controlled so that the side space 121 is different from the side space 122. Controlling the relative difference between the side spaces of different abrasive particles can facilitate better abrasion performance of the abrasive article.
[137] FIG. 1B includes a side view illustration of a portion of an abrasive article according to one embodiment. As illustrated, the abrasive article 100 can include a molded abrasive particle 102 overlying the support 101 and a molded abrasive particle 104 spaced from the molded abrasive particle 102 that overlaps the support 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 appreciated that any of the molded abrasive particles described herein may be coupled to the support 101 through one or more adhesive layers, as described herein.
[138] In one embodiment, the abrasive article 100 may include an adhesive layer 151 which overlays the backing. In one embodiment, the adhesive layer 151 may include a branded coating. The brand coating may overlap the surface of the backing 101 and surround at least a portion of the molded abrasive particles of 102 and 104. Abrasive articles of embodiments of this invention may further include an adhesive layer 152 that overlays the adhesive layer 151 and the backing. 101 and which surrounds at least a portion of the molded abrasive particles 102 and 104. Adhesive layer 152 may be a size coating in particular cases.
[139] A polymer formulation may be used to form any of a variety of adhesive layers 151 or 152 of the abrasive article, which may include, but are not limited to, a front fill, a pre-size coating, a branded coating, and /or an oversized coating. When used to form the front fill, the polymer formulation generally includes a polymer resin, fibrillated fibers (preferably in the form of cellulose), filler, and other optional additives. Formulations suitable for some forefill embodiments may include material 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 these 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 monoacrylated and multiacrylated 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 block copolymer of polyoxypropylene, polyoxytene, etc. The use of a front fill over the backing can improve surface uniformity, suitable for brand coating application and better application and guidance of molded abrasive particles in a predetermined orientation.
[140] 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 to the surface of the backing 101. Suitable materials of adhesive layer 151 for use as a brand coating may include organic materials, in particular 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 abrasive particulate material or to 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 this curing process.
[141] Adhesive layer 152 may be formed over the abrasive article, which may be in the form of a size coating. In a particular embodiment, the adhesive layer 152 may be a size coating formed to overlay and hold the molded abrasive particle 102 and 104 in place relative to the backing 101. The adhesive layer 152 may include an organic material, may be prepared essentially of a polymeric material, and in particular it can use polyesters, epoxy resins, polyurethanes, polyamides, polyacrylates, polymethacrylates, polyvinyl chlorides, polyethylene, polysiloxane, silicones, cellulose acetates, nitrocellulose, natural rubber, starch, shellac , and mixtures thereof.
[142] It will be appreciated that, although not illustrated, the abrasive article may include thinner abrasive particles other than the molded abrasive particles 104 and 105. For example, the thinner particles may differ from the molded abrasive particle 102 and 104 in composition, two-dimensional shape , three-dimensional shape, size, and a combination thereof. For example, abrasive particles 507 may represent conventional, crushed abrasive grains having random patterns. The abrasive particles 507 may have an average particle size smaller than the average particle size of the molded abrasive particles 505.
[143] As further illustrated, the molded abrasive particle 102 may be oriented in a lateral orientation relative to the support 101, wherein a lateral 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 closest to the upper surface of the holder 101. In one embodiment, the molded abrasive particle 102 may have a vertical orientation defined by an angle of inclination (AT1) 136 between the main surface 172 of the molded abrasive particle 102 and a major surface 161 of holder 101. Angle of inclination 136 may be defined as the smallest angle or acute angle between surface 172 of molded abrasive particle 102 and upper surface 161 of holder 101. In one embodiment, the molded abrasive particle 102 may be positioned in a position having a predetermined vertical orientation. In one embodiment, the angle of inclination 136 may be at least about 2°, such as 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°. Still, the angle of inclination 136 can be no more than about 90°, such as no more than about 85°, no more than about 80°, no more than about 75°, no more than about 70° , not more than about 65°, not more than about 60°, not more than about 55°, not more than about 50°, not more than about 45°, not more than about 40°, not more than about 35°, not more than about 30°, not more than about 25°, not more than about 20°, not more than about 15°, not more than about 10°, or even not more than about 5°. It will be appreciated that the angle of inclination 136 may be within a range between any of the above minimum and maximum degrees.
[144] As further illustrated, the abrasive article 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 closer to, an upper surface 161 of the holder. 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 the surface 161 of holder 101. Angle of inclination 137 may be defined as the smallest angle between a major surface 172 of molded abrasive particle 104 and an upper surface 161 of holder 101. Furthermore, angle of inclination 137 may have a value of at least about 2°, such as 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 55° 60°, at least about 70°, at least about 80°, or even at least about 85°. Still, the angle of inclination 136 can be no more than about 90°, such as no more than about 85°, no more than about 80°, no more than about 75°, no more than about 70° , not more than about 65°, not more than about 60°, not more than about 55°, not more than about 50°, not more than about 45°, not more than about 40°, not more than about 35°, not more than about 30°, not more than about 25°, not more than about 20°, not more than about 15°, not more than about 10°, or even not more than about 5°. It will be appreciated that the angle of inclination 136 may be within a range between any of the above minimum and maximum degrees.
[145] In one embodiment, the molded abrasive particle 102 may have a predetermined vertical orientation which is the same as the predetermined vertical orientation of the molded abrasive particle 104. Alternatively, the abrasive article 100 may be formed such that the predetermined vertical orientation of molded abrasive particle 102 may be different than the predetermined vertical orientation of molded abrasive particle 104.
[146] According to one embodiment, the molded abrasive particles 102 and 104 may be positioned on the support so that they have different predetermined vertical orientations defined by a vertical orientation difference. The vertical orientation difference may be the absolute value of the difference between the tilt angle 136 and the tilt angle 137. According to one embodiment, the vertical orientation difference may be at least about 2°, such as at least about 2°. from 5°, at least about 10°, at least about 15°, at least about 20°, at least about 25°, at least about 30°, to at least about 35°, at least about 35° 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 of 85°. Still, the vertical orientation difference may be no more than about 90°, such as not more than about 85°, not more than about 80°, not more than about 75°, not more than about 70° , not more than about 65°, not more than about 60°, not more than about 55°, not more than about 50°, not more than about 45°, not more than about 40°, not more than about 35°, not more than about 30°, not more than about 25°, not more than about 20°, not more than about 15°, not more than about 10°, or even not more than about 5°. It will be appreciated that the difference in vertical orientation may be in the range between any of the above minimum and maximum degrees. Controlling the difference in vertical orientation between molded abrasive particles of the abrasive article 100 can facilitate better grinding performance.
[147] As further illustrated, the molded abrasive particles can be positioned on the holder to have a predetermined point height. For example, the predetermined tip height (hT1) 138 of the molded abrasive particle 102 may be the greatest distance between the upper surface of the holder 161 and an uppermost surface 143 of the molded abrasive particle 102. In particular, the predetermined tip height 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 further illustrated, the molded abrasive particle 104 may have a predetermined tip height (hT2) 139 defined as the distance between the top surface 161 of the holder 101 and a top surface 144 of the molded abrasive particle 104. Measurements can be evaluated by means of X-ray, CT confocal microscopy, Micro measurement, white light interferometry, and a combination thereof.
[148] According to one embodiment, the molded abrasive particle 102 may be positioned on the holder 101 to have a predetermined tip height 138, which may be different from the predetermined tip height 139 of the molded abrasive particle 104. Notably, the difference in predetermined tip height (AhT) can be defined as the difference between the average tip height 138 and the average tip height 139. According to one embodiment, the difference in the predetermined tip height can be at least about 0.01 (w), where (w) is the width of the abrasive particle shaped as described herein. In other cases, the tip height difference 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 0.8 ( w). Also, in a non-limiting embodiment, the tip height difference may not be greater than about 2(w). It will be appreciated that the tip height difference can be in the range between any of the minimum and maximum values noted above. Control of the average tip height and more particularly the average tip height difference between the molded abrasive particles of the abrasive article 100 can facilitate better grinding performance.
[149] While references herein are made to molded abrasive particles having an average tip height difference, it will be appreciated that the molded abrasive particles of abrasive articles may have the same average tip height such that there is essentially no difference between the height point average between molded abrasive particles. For example, as described herein, molded abrasive particles from a group can be positioned on the abrasive article so that the vertical tip height of each of the molded abrasive particles from the group is substantially the same.
[150] FIG. 1C includes a cross-sectional illustration of a portion of an abrasive article according to one embodiment. As illustrated, the molded abrasive particles 102 and 104 may be oriented in a planar orientation relative to the support 101, wherein at least a portion of a major surface 174, and in particular the largest surface with the greatest surface area (i.e., the lower surface 174 opposite the upper main surface 172), of the molded abrasive particles 102 and 104 may be in direct contact with the support 101. Alternatively, in a flat orientation, a portion of the main surface 174 may not be in direct contact with the support 101, but may be the surface of the molded abrasive particle closest to the top surface 161 of support 101.
[151] FIG. 1D includes a cross-sectional illustration of a portion of an abrasive article according to one embodiment. As illustrated, the molded abrasive particles 102 and 104 may be oriented in an inverted orientation relative to the support 101, wherein at least a portion of a major surface 172 (i.e., the largest upper surface 172) of the molded abrasive particles 102 and 104 may be in direct contact with the support 101. Alternatively, in an inverted orientation, a portion of the main surface 172 may not be in direct contact with the support 101, but may be the surface of the molded abrasive particle closest to the top surface 161 of the support 101.
[152] FIG. 2A includes a top view illustration of a portion of an abrasive article including molded abrasive particles in accordance with one embodiment. As illustrated, the abrasive article may include a molded abrasive particle 102 overlying the support 101 in a first rotational position having a first orientation with respect to a lateral axis 181 that defines the width of the support 101 and is perpendicular to a longitudinal axis. 181. In particular, the molded abrasive particle 102 may have a predetermined rotational orientation defined by a first rotation angle between a lateral plane 184 parallel to the lateral axis 181 and a dimension of the molded abrasive particle 102. Notably, reference herein to a dimension may refer to a bisector 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 (directly or indirectly) to the support 101. Therefore, in the context of a molded abrasive particle positioned in a lateral orientation, (see, FIG. 1B), the bisector axis 231 is tends through a center point 221 and in the width direction (w) of a side 171 closest to the surface 181 of the support 101. Furthermore, the predetermined rotational orientation can be defined as the smallest angle 201 with the lateral plane 184 extending through midpoint 221. As illustrated in FIG. 2A, the molded abrasive particle 102 may have a predetermined angle of rotation, defined as the minor angle between a bisector axis 231 and the lateral plane 184. In one embodiment, the angle of rotation 201 may be 0°. In other embodiments, the angle of rotation may be greater, 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°. Still, the predetermined rotation orientation as defined by the rotation angle 201 may be no greater than about 90°, such as no greater than about 85°, no greater than about 80°, no greater than about 75° , not more than about 70°, not more than about 65°, not more than about 60°, not more than about 55°, not more than about 50°, not more than about 45°, not more than about 40°, not more than about 35°, not more than about 30°, not more than about 25°, not more than about 20°, not more than about 15°, not greater than about 10°, or even not greater than about 5°. It will be appreciated that the predetermined rotation orientation may be within a range between any of the above minimum and maximum degrees.
[153] As further illustrated in FIG. 2A, the molded abrasive particle 103 may be in a position 113 that overlaps the support 101 and has a predetermined rotational orientation. Notably, the predetermined rotational orientation of the molded abrasive particle 103 can be characterized as the smallest angle between the side of the plane 184 parallel to the lateral axis 181 and a dimension defined by a bisector 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 support 101. According to one embodiment, the angle of rotation 208 may be 0°. In other embodiments, the angle of rotation 208 can be greater, such as at least about 2°, at least about 5 degrees, 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°. Still, the predetermined rotation orientation, as defined by rotation angle 208, may be no greater than about 90°, no greater than about 85°, no greater than about 80°, no greater than about 75° , not more than about 70°, not more than about 65°, not more than about 60°, not more than about 55°, not more than about 50°, not more than about 45°, not more than about 40°, not more than about 35°, not more than about 30°, not more than about 25°, not more than about 20°, not more than about 15°, not greater than about 10°, or even not greater than about 5°. It will be appreciated that the predetermined rotation orientation may be within a range between any of the above minimum and maximum degrees.
[154] According to one embodiment, the molded abrasive particle 102 may have a predetermined rotational orientation, as defined by the rotation angle 201, which is different from the predetermined rotational orientation of the molded abrasive particle 103, as defined by the rotational angle 208 In particular, the difference between the angle of rotation 201 and the angle of rotation 208 between the molded abrasive particle 102 and 103 can define a difference from the predetermined orientation of rotation. In particular cases, the predetermined rotation orientation difference may be 0°. In other cases, the predetermined rotational orientation difference between any two molded abrasive particles may be greater, 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 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°. Still, the predetermined rotational orientation difference between any two molded abrasive particles can be no more than about 90°, no more than about 85°, no more than about 80°, no more than about 75° , not more than about 70°, not more than about 65°, not more than about 60°, not more than about 55°, not more than about 50°, not more than about 45°, not more than about 40°, not more than about 35°, not more than about 30°, not more than about 25°, not more than about 20°, not more than about 15°, not greater than about 10°, or even not greater than about 5°. It will be appreciated that the predetermined rotation orientation difference may be within a range between any of the above maximum and minimum values.
[155] FIG. 2B includes a perspective view illustration of a portion of an abrasive article that includes a molded abrasive particle, in accordance with one embodiment. As illustrated, the abrasive article may include a molded abrasive particle 102 overlying the support 101 at a first position 112 having a first rotational orientation relative to a lateral axis 181 that defines the width of the support 101. Certain aspects of a characteristic of Predetermined orientation of molded abrasive particles can be described with respect to the three-dimensional a, x, y, z axis as illustrated. For example, the predetermined longitudinal orientation of the 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 180 of the support 101. In addition, the predetermined lateral orientation of the molded abrasive particle 102 may be defined by the position of the molded abrasive particle on the x-axis, which extends parallel to the lateral axis 181 of the support 101. Furthermore, the predetermined rotational orientation of the molded abrasive particle 102 can be defined as the angle of rotation 102 between the x-axis , which corresponds to an axis or plane parallel to the lateral axis 181 and the bisector axis 231 of the molded abrasive particle 102 that extends through the midpoint 221 of the side 171 of the molded abrasive particle 102 attached (directly or indirectly) to the support 101. As illustrated in general, the molded abrasive particle 102 may still have a predetermined vertical orientation and predetermined tip height. nothing, as described here. 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, which has not previously been contemplated or implemented in the industry.
[156] For simplicity of explanation, the embodiments here refer to certain characteristics with respect to a plane defined by X, Y, and Z directions. However, it is appreciated and contemplated that abrasive articles may have other shapes (e.g., belts coated abrasives defining a curled or ellipsoidal geometry or abrasive sanding discs, whether or not coated with an annular shaped backing). The description of features herein is not limited to planar configurations of abrasive articles and the features described herein are applicable to abrasive articles of any geometry. In those cases where the support has a circular geometry, the longitudinal and lateral axis of the axis may be of two diameters extending through the center point of the support and having an orthogonal relationship to each other.
[157] 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 can 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 characteristic that is the same for each of the molded abrasive particles. Exemplary predetermined orientation features may include a predetermined rotation 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 relative to one another. As further illustrated, abrasive article 300 may include another group 303 including a plurality of molded abrasive particles, including, for example, molded abrasive particles, 321, 323, 322 and 324 (321324). 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 the same predetermined lateral orientation relative to each other (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 the same predetermined longitudinal orientation relative to each other (e.g. molded abrasive particles 321 and 324 and molded abrasive particles 322 and 323).
[158] As further illustrated, 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 predetermined orientation characteristic. ordinary. As illustrated in the embodiment of FIG. 3A, the plurality of abrasive particles molded within the group 305 may have the same predetermined rotational orientation relative to one another. In addition, at least a portion of the plurality of molded abrasive particles of group 305 may have the same predetermined lateral orientation with respect to each other (e.g. molded abrasive particles 332 and 333). In addition, 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 in particular a combination of groups of molded abrasive particles having the characteristics described herein can facilitate improved performance of the abrasive article.
[159] As further illustrated, the abrasive article 300 may include groups 301, 303, and 305, which may be separated by channel regions 307 and 308 extending between groups 301, 303, 305. In particular cases, the regions channel may be regions on the abrasive article which may be substantially free of molded abrasive particles. In addition, channel regions 307 and 308 can be configured to move liquid between groups 301, 303, and 305, which can improve iron filings 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 particularly, greater in width and/or length, than the longitudinal space or lateral space between adjacent molded abrasive particles in the groups. 301, 303, and 305.
[160] The channel regions 307 and 308 may extend along a direction either parallel or perpendicular to the longitudinal axis 180 or parallel or perpendicular to the lateral axis 181 of the support 101. In particular cases, the channel regions 307 and 308 may have axes, 351 and 352, respectively, that extend along a center of channel regions 307 and 308 and along a longitudinal dimension of channel regions 307 and 308 may have a predetermined angle with respect to 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 with respect to the lateral axis 181 of the support 101. Controlled orientation of the channel regions can facilitate better performance of the abrasive article.
[161] 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 direction that is parallel or perpendicular to the grinding direction 350. In particular cases, 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 better performance of the abrasive article.
[162] For 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 A plurality of molded abrasive particles 311-314 may be arranged relative to one another in a predetermined distribution that further defines a two-dimensional matrix, such as in the shape of a quadrilateral, as viewed from above. A matrix is a pattern having short-range order defined by an array unit of molded abrasive particles and additionally having more long-range order, including regular and repeating units linked together. It will be appreciated that other two-dimensional arrangements may be formed, including other polygonal shapes, ellipses, ornamental indicia, product indicia, or other designs. As further illustrated, the group 303 may include a plurality of molded abrasive particles 321-324, which may also be arranged in a pattern 325 defining a quadrilateral two-dimensional array. In addition, the group 305 can include a plurality of molded abrasive particles 331-334 that can be arranged relative to one another to define a predetermined distribution in the form of a triangular pattern 335.
[163] In one embodiment, the plurality of molded abrasive particles of one group 301 may define a pattern that is different from the 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, compared to the pattern orientation of a second group (e.g. 303 or 305) relative to the grinding direction 350.
[164] Notably, any of the groups (301, 303, or 305) of the molded abrasive particles may have a pattern that defines one or more vectors (e.g., 361 or 362 of group 305) that may have a particular orientation with respect to to the grinding direction. In particular, the molded abrasive particles of a group may 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 with respect to milling direction 350. Vectors 361 and 362 may have various orientations including, for example, a parallel orientation, orientation perpendicular, or even a non-orthogonal or non-parallel orientation (i.e. angled to define an acute angle or an obtuse angle) relative to the grinding direction 350.
[165] According to 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 molded abrasive particles of 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. Still, in one particular aspect, all 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.
[166] According to another embodiment, at least a portion of the molded abrasive particles of 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 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.
[167] Furthermore, 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. In one 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.
[168] In addition, at least a portion of the molded abrasive particles of group 301 may have a predetermined vertical orientation which is different from the predetermined vertical orientation of at least a portion of the molded abrasive particles of group 303. , all molded abrasive particles of group 301 may have a predetermined vertical orientation which is different from the predetermined vertical orientation of all molded abrasive particles of group 303
[169] Further, in one embodiment, at least a portion of the molded abrasive particles of group 301 may have a predetermined tip height that is different from the predetermined tip height of at least a portion of the molded abrasive particles of group 303. In In yet another particular embodiment, all molded abrasive particles of group 301 may have a predetermined tip height that is different from the predetermined tip height of all molded abrasive particles of group 303.
[170] It will be appreciated that any number of groups may be included in the abrasive article by creating multiple regions on the abrasive article having predetermined orientation characteristics. Also, each of the groups may be different from each other, as described above for groups 301 and 303.
[171] As described in one or more embodiments herein, the abrasive particles may be arranged in a predetermined distribution defined by predetermined positions on the support. Most notably, the predetermined distribution may define an unshaded arrangement between two or more molded abrasive particles. For example, in a particular embodiment, the abrasive article may include a first abrasive particle molded in a first predetermined position, and a second abrasive particle molded in a second predetermined position, such that the first and second abrasive particles molded define an arrangement not shaded relative to each other. An unshaded arrangement can be defined by an arrangement of the abrasive particles molded in such a way that they are configured to make initial contact with the workpiece at separate locations on the workpiece and to limit or avoid initial overlap at the location of removal of the workpiece. starting material on the workpiece. An unshaded arrangement can facilitate better grinding performance. In a particular embodiment, the molded first abrasive particle can be part of a group defined by a plurality of molded abrasive particles, and the second molded abrasive particle can be part of a second group defined by a plurality of molded abrasive particles. The first group can define a first line on the support and the second group can define a second line on the support, and each of the molded abrasive particles of the second group can be staggered one with respect to each of the molded abrasive particles of the first group , thus defining a particular unshaded array.
[172] FIG. 3B includes a perspective view illustration of a portion of an abrasive article including molded abrasive particles having predetermined orientation characteristics relative 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 orientation characteristics predetermined with respect to the grinding direction 385 may facilitate better abrasion performance of the abrasive article. Grinding direction 385 may be an intended direction of movement of the abrasive article relative to a workpiece in a material removal operation. In particular cases, the grinding direction 385 can be related to the dimensions of the support 101. For example, in one embodiment, the grinding direction 385 can be substantially perpendicular to the lateral axis 181 of the support and substantially parallel to the longitudinal axis 180 of the support. 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 workpiece. For example, molded abrasive particle 102 may 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 may position the particle so that the main surface 363 is configured to make initial contact with a workpiece before the other surfaces of the molded abrasive particle 102. This orientation can be considered a forward orientation with respect to the grinding direction 385. More particularly, the molded abrasive particle 102 may have a bisector axis 231 having a particular orientation with respect to the milling direction. For example, as illustrated, the grinding direction vector 385 and the bisector axis 231 are substantially perpendicular to each other. It will be appreciated that, just as any range of predetermined rotational orientations is contemplated for a molded abrasive particle, any range of orientations of the molded abrasive particles with respect to grinding direction 385 is contemplated and may be used.
[173] The molded abrasive particle 103 can have different predetermined orientation characteristics with respect to the molded abrasive particles 102 and the grinding direction 385. As illustrated, the molded abrasive particle 103 can include major surfaces 391 and 392, which can be joined by side surfaces 371 and 372. Also, as illustrated, the molded abrasive particle 103 may have a bisector axis 373 forming 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 milling direction 385 such that the angle between the bisector axis 373 and the milling direction 385 is essentially 0 degrees. Accordingly, the predetermined orientation characteristics of the molded abrasive particle facilitate initial contact of the side surface 372 with a workpiece before any of the other surfaces of the molded abrasive particle. This orientation of the molded abrasive particle 103 can be considered a lateral orientation with respect to the grinding direction 385.
[174] It will be appreciated that the abrasive article may include one or more groups of molded abrasive particles that may be arranged in a predetermined distribution relative to each other, and, more particularly, may have distinct predetermined orientation characteristics, which define groups of particles. molded abrasives. The groups of molded abrasive particles, as described herein, may have a predetermined orientation with respect to a grinding direction. Furthermore, the abrasive articles herein may have one or more groups of molded abrasive particles, each of the groups having a different predetermined orientation with respect to a grinding direction. The use of groups of molded abrasive particles having different predetermined orientations with respect to a grinding direction can facilitate better performance of the abrasive article.
[175] FIG. 4 includes a top view illustration of a portion of an abrasive article according to 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 particularly, the predetermined distribution may be in the form of a pattern 423 as viewed from above, and more particularly the definition of a two-dimensional triangular mold matrix. As illustrated further below, the group 401 may be disposed on the abrasive article 400 defining a predetermined macroshape 431 which overlaps the support 101. According to one embodiment, the macroshape 431 may have a two-dimensional mold as viewed in particular from top to bottom. . Some exemplary two-dimensional patterns may include polygons, ellipsoids, numbers, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, Arabic alphabet characters, kanji characters, complex patterns, designs, any combination thereof. In particular cases, the formation of a group having a particular macroform can facilitate better performance of the abrasive article.
[176] As further illustrated, the abrasive article 400 may include a group 404 including a plurality of molded abrasive particles that may be disposed on the surface of the support 101 to define a predetermined distribution. Notably, the predetermined distribution may include an array of a plurality of molded abrasive particles that define a pattern, and more particularly, a general quadrilateral pattern 424. As illustrated, the group 404 may define a macroshape 434 on the surface of the abrasive article 400. In In one embodiment, a macroshape 434 of group 404 may have a two-dimensional shape, as viewed from above, including, for example, a polygonal shape, and more particularly, a generally quadrangular (diamond) shape, as viewed from above on the surface of the abrasive article 400. In the illustrated embodiment of FIG. 4, group 401 may have a macroform 431 that is substantially the same as macroform 434 of group 404. However, it will be appreciated that in other embodiments, several different groups may be used on the surface of the abrasive article, and more particularly where each of the different groups has a different macroform.
[177] As further illustrated, the abrasive article may include groups 401, 402, 403, and 404 which may be separated by channel regions 422 and 421 extending between groups 401-404. In particular cases, the channel region may be substantially free of molded abrasive particles. In addition, channel regions 421 and 422 can be configured to move liquid between groups 401-404 and further improve iron swarf removal and grinding performance of the abrasive article. Furthermore, in one embodiment, 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 In particular cases, channel regions 421 and 422 may represent a regular, repeating array of features that extend across a surface of the abrasive article.
[178] FIG. 5 includes a top view of a portion of an abrasive article according to one embodiment. Notably, the abrasive article 500 may include molded abrasive particles 501 overlying and, more particularly, coupled to the support 101. In at least one embodiment, the abrasive articles of embodiments herein may include a row 511 of molded abrasive particles. Line 511 may include a group of molded abrasive particles 501, wherein each of the molded abrasive particles 501 within line 511 may have the same predetermined lateral orientation with respect to each other. In particular, as illustrated, each of the molded abrasive particles 501 of the line 511 can have the same predetermined lateral orientation with respect to the lateral axis 551. In addition, each of the molded abrasive particles 501 of the first line 511 can be part of a group and thus having at least one other predetermined orientation feature that is the same with respect to each other. For example, each of the molded abrasive particles 501 of line 511 may be part of a group having the same predetermined vertical orientation, and may define a vertical group. In at least one other embodiment, each of the molded abrasive particles 501 of the line 511 may be part of a group having the same predetermined rotation orientation, and may define a rotation group. Furthermore, each of the molded abrasive particles 501 of the line 511 can be part of a group having the same predetermined point height with respect to each other, and can define a point height group. Furthermore, as illustrated, the abrasive article 500 may include a plurality of groups in the orientation of the line 511, which may be spaced from one another along the longitudinal axis 180, and more particularly, separated from each other by other intervening lines, including, for example, lines 521, 531, and 541.
[179] As further illustrated in FIG. 5 , abrasive article 500 may include molded abrasive particles 502 that can be arranged relative to one another to define a line 521. Line 521 of molded abrasive particles 502 may include any of the features described in accordance with line 511. Notably , the molded abrasive particles 502 of the line 521 may have the same predetermined lateral orientation with respect to each other. In addition, the molded abrasive particles 502 of line 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 line 511. For example, as illustrated, each one of the molded abrasive particles 502 of line 521 may have the same predetermined rotational orientation that is different from the predetermined rotational orientation of each of the molded abrasive particles 501 of line 511.
[180] In another embodiment, the abrasive article 500 may include molded abrasive particles 503 disposed relative to one another and defining a line 531. Line 531 may have any of the characteristics described, in accordance with other embodiments, particularly with respect to to line 511 or line 521. In addition, each of the molded abrasive particles 503 within line 531 may have at least one predetermined orientation characteristic that are the same with respect to each other. In addition, each of the molded abrasive particles 503 within line 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 line 511 or the molded abrasive particles 502 of line 521. Notably, as illustrated, each of the molded abrasive particles 503 of line 531 can have the same predetermined rotational orientation that is different with respect to the predetermined rotational orientation of the molded abrasive particles 501 and line 511 and the predetermined rotational orientation of molded abrasive particles 502 and line 521.
[181] As further illustrated, the abrasive article 500 may include molded abrasive particles 504 disposed relative to each other and defining a line 541 on the surface of the abrasive article 500. As illustrated, each of the molded abrasive particles 504 and the line 541 may have at least least one of the same predetermined orientation characteristics. Further, according to one embodiment, each of the molded abrasive particles 504 may have at least one of the same predetermined orientation characteristics, such as a predetermined rotational orientation that is different from the predetermined rotational orientation of any of the molded abrasive particles 501 of the line 511, molded abrasive particles 502 of line 521, and molded abrasive particles 503 of line 531.
[182] As further illustrated, the abrasive article 500 may include a column 561 of molded abrasive particles, including at least one molded abrasive particle from each of lines 511, 521, 531, and 541. Notably, each of the molded abrasive particles within column 561 may share at least one predetermined orientation feature, and more particularly 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 cases, the array of molded abrasive particles in groups, which may include the array of particles Molded abrasives in rows, columns, vertical groups, rotation groups and nose height groups can facilitate better performance of the abrasive article.
[183] FIG. 6 includes a top view illustration of a portion of an abrasive article according to one embodiment. Notably, the abrasive article 600 can include molded abrasive particles 601 that can be arranged relative to one another to define a column 621 extending along a longitudinal plane 651 and having at least one of the same predetermined orientation characteristics with respect to a the other. For example, each of the molded abrasive particles 601 of the group 621 may have the same predetermined longitudinal orientation with respect to each other and to the longitudinal axis 651. It will be appreciated that the molded abrasive particles 601 of the column 621 may share at least one other orientation characteristic. predetermined, including, for example, the same predetermined rotation orientation with respect to each other.
[184] As further illustrated, the abrasive article 600 may include molded abrasive particles 602 disposed relative to one another on the support 101 and defining a column 622 relative to one another along a longitudinal plane 652. It will be appreciated that the molded abrasive particles 602 of column 622 may share at least one other predetermined orientation characteristic, including, for example, the same predetermined rotation orientation with respect to each other. Further, each of the molded abrasive particles 602 of the column 622 may define a group that has 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. More particularly , each of the molded abrasive particles 602 of the column 622 can define a group that has a combination of predetermined orientation characteristics different from a combination of predetermined orientation characteristics of the molded abrasive particles 601 of the column 621.
[185] In addition, as illustrated, the abrasive article 600 may include molded abrasive particles 603 having the same predetermined longitudinal orientation relative to each other along the longitudinal plane 653 on the support 101 and defining a column 623. Further, each one of the molded abrasive particles 603 of the column 623 may define a group that has 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 particulate abrasive 602 of column 622. More particularly, each of the molded abrasive particles 603 of the 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 of column 621 and the abrasive particles molded 602 of column 622.
[186] FIG. 7A includes a top-down view of a portion of an abrasive article according to one embodiment. In particular cases, the abrasive articles herein may further include orientation regions that facilitate positioning of the molded abrasive particles in the 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 branded coating or a size coating. In yet another embodiment, the guidance regions may be superimposed on the support 101, or even, more particularly, integrated with the support 101.
[187] As illustrated in FIG. 7A, the abrasive article 700 can include molded abrasive particles 701, 702, 703, (701-703), and each of the molded abrasive particles 701-703 can be coupled with a respective orientation region 721, 722, and 723 (721-703). 723). In one embodiment, orientation region 721 can be configured to define at least one (or a combination of) predetermined orientation characteristic of molded abrasive particle 701. For example, orientation region 721 can be configured to define an orientation of rotation, a predetermined lateral orientation, a predetermined longitudinal orientation, a predetermined vertical orientation, a predetermined nose height, and a combination thereof with respect to the molded abrasive particle 701. Further, in a particular embodiment, the orientation regions 721, 722 and 723 may be associated with a plurality of molded abrasive particles 701703 and may define a group 791.
[188] According to one embodiment, the orientation regions 721-723 may be associated with an alignment structure, and more particularly, part of an alignment structure (e.g., discrete contact regions), as described in more detail. on here. Guidance regions 721-723 can be integrated within any of the components of the abrasive article, including, for example, the backing 101 or adhesive layers, and thus can be considered contact regions as described in more detail here. Alternatively, guide regions 721-723 may be associated with an alignment structure used in forming the abrasive article, which may be a separate component of the support and integrated within the abrasive article, and which may not necessarily form a region of contact associated with the abrasive article.
[189] As further illustrated, abrasive article 700 may further include molded abrasive particles 704, 705, 706 (704706), wherein each of molded abrasive particles 704-706 may be associated with an orientation region 724, 725, 726 , respectively. Orientation regions 724-726 can be configured to control at least one predetermined orientation characteristic of molded abrasive particles 704-706. In addition, orientation regions 724-726 can be configured to define a group 792 of molded abrasive particles 704-706 . According to one embodiment, orientation regions 724-726 may be spaced between orientation regions 721-723. More particularly, 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.
[190] FIG. 7B includes an illustration of a portion of an abrasive article according to one embodiment. In particular, FIG. 7B includes an illustration of particular embodiments of alignment structures and the contact regions that may be used and configured to facilitate at least one predetermined orientation characteristic of one or more molded abrasive particles associated with the alignment structure and contact regions.
[191] FIG. 7B includes a portion of an abrasive article that includes a backing 101, a first group 791 of molded abrasive particles 701 and 702 overlying the backing 101, a second group 792 of molded abrasive particles 704 and 705 overlying the backing 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 appreciated that while several and multiple different groups 791, 792, 793, and 794 are illustrated, the illustration is in no way limiting, and the abrasive articles of the embodiments herein may include any number and arrangement of groups.
[192] 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 can be used to facilitate placement of molded abrasive particles 701 and 702 in desired orientations on the support and in relation to the other. The alignment structure 761 of the embodiments herein may be a permanent part of the abrasive article. For example, alignment structure 761 may include contact regions 721 and 722, which overlap support 101, and in some cases directly contact support 101. In particular cases, alignment structure 761 may be integral with the support structure 761. abrasive article, and may overlap the support, underlying an adhesive layer that overlaps the support, or even be an integral part of one or more adhesive layers overlapping the support.
[193] According to one embodiment, the alignment structure 761 may be configured to release and, in particular cases, temporarily or permanently hold the molded abrasive particle 701 in a first position 771. In particular cases, as illustrated in FIG. 7B, alignment structure 761 may include a contact zone 721, which may have a two-dimensional mold as viewed in particular from top to bottom and defined by the contact zone width (wcr) and the contact zone length (lcr) , wherein the length is the longest dimension of the contact region 721. According to at least one embodiment, the contact region may be formed to have a mold (e.g., a two-dimensional mold), which can facilitate orientation molded abrasive particle 701. More particularly, the contact region 721 may have a two-dimensional mold configured to control one or more (e.g., at least two of) a particular predetermined orientation feature, including, for example, an orientation of predetermined rotation, a predetermined lateral orientation, and a predetermined longitudinal orientation.
[194] In particular cases, the contact regions 721 and 722 can be formed to have controlled two-dimensional molds that can facilitate a predetermined rotational orientation of the corresponding molded abrasive particles 701 and 702. For example, the contact region 721 can have a Predetermined, controlled two-dimensional mold configured to determine a predetermined rotational orientation of the molded abrasive particle 701. In addition, the contact region 722 may have a predetermined, controlled two-dimensional mold configured to determine a predetermined rotational orientation of the molded abrasive particle 702.
[195] 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 permanently or temporarily supply and retain one or more abrasive particles. molded. In some cases, the alignment structure may include a net, a fibrous material, a mesh, a solid structure that has openings, a belt, a roller, a patterned material, a discontinuous layer of material, a patterned adhesive material, and a combination thereof.
[196] The plurality of contact regions 721 and 722 can 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 particle molded abrasive, 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 molded abrasive particles, the predetermined tip height, a predetermined tip height difference between two molded abrasive particles. In particular cases, as illustrated in FIG. 7B , a 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 pattern with respect to to the other, as will become apparent from other embodiments described herein, the first contact region 721 and the second contact region 722 may be formed to have two different two-dimensional molds. Furthermore, although not illustrated, it will be appreciated that the alignment structures of the embodiments herein may include first and second contact regions configured to release and contain molded abrasive particles in different predetermined rotational orientations relative to each other.
[197] In a particular embodiment, contact regions 721 and 722 may have a two-dimensional shape selected from the group consisting of polygons, ellipsoids, numerals, crosses, multi-armed polygons, Greek alphabet characters, Latin alphabet characters, alphabet characters Russian, 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 substantially the same two-dimensional shape, it will be appreciated that, in alternative embodiments, the contact regions 721 and 722 may have different two-dimensional shapes. Two-dimensional shapes are the shapes of the contact regions 721 and 722 as seen in the plane of the length and width of the contact regions, which may be the same plane defined by the upper surface of the support.
[198] Furthermore, it will be appreciated that the alignment structure 761 may be a temporary part of the abrasive article. For example, alignment structure 761 can represent a model or any other object that temporarily fixes molded abrasive particles at the contact regions, which facilitates positioning the molded abrasive particles in a desired position having one or more predetermined orientation characteristics. After positioning the molded abrasive particles, the alignment structure can be removed, leaving the molded abrasive particle on the support in predetermined positions.
[199] According to a particular embodiment, the alignment structure 761 may be a discontinuous layer of material, including a plurality of contact regions 721 and 722 which may be made of an adhesive material. In more particular examples, 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 shaped abrasive particle. It will be appreciated that, in accordance with at least one embodiment, the adhesive material may include an organic material, and more particularly, at least one resin material.
[200] Furthermore, the plurality of contact zones 721 and 722 may be disposed on the surface of the support 101 to define a predetermined distribution of contact regions. The predetermined distribution of contact regions may have any characteristic of predetermined distributions described herein. In particular, the predetermined distribution of contact regions may define a controlled unshaded array. The predetermined distribution of contact regions may define and correspond substantially to the same predetermined distribution of abrasive particles molded onto the support, wherein each contact region may define a position of a molded abrasive particle.
[201] As illustrated, in certain cases the contact regions 721 and 722 may be moved away 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 731 between the contact regions 721 and 722 is generally the smallest distance between the adjacent contact regions 721 and 722 in a direction parallel to the lateral axis 181 or longitudinal axis 180.
[202] 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 can be a pattern of apertures which is used to temporarily place the molded abrasive particles in particular positions on the support 101. The plurality of apertures may extend partially or entirely through the thickness of the blade. alignment structure. Alternatively, 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 particular cross-sectional shapes that can be complementary to a cross-sectional shape of the molded abrasive particles to facilitate placement of the molded abrasive particles in predetermined positions and with one or more predetermined orientation characteristics.
[203] 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 distinct regions from the discrete contact regions. and may be substantially 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 particular embodiment, the non-contact region may define regions configured to be essentially free of molded abrasive particles.
[204] Various methods can be used to form an alignment structure and discrete contact regions, including but not limited to coating, spraying, depositing, printing, etching, masking, stripping, shaping, casting, stamping, heating, curing, adhesion. , fixing, pressing, rolling, sewing, adhesion, irradiation, and a combination thereof. In particular cases, 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 areas of non-contact, the process of formation may include a selective deposition of the adhesive material. *
[205] As illustrated and indicated 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 region of contact. contact 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 herein, alignment structure 762 can have any of the characteristics of alignment structures described herein. It will be appreciated that alignment structure 762 may be a permanent or temporary part of the final abrasive article. Alignment structure 762 may be an integral part of the abrasive article, and may overlap with backing 101, underlying an adhesive layer overlaying backing 101, or even be an integral part of one or more adhesive layers overlaying backing 101. support 101.
[206] According to one embodiment, the alignment structure 762 may be configured to release and, in particular cases, temporarily or permanently hold the molded abrasive particle 704 in a first position 773. In particular cases, as illustrated in FIG. 7B, alignment structure 762 may include a contact region 724, which may have a particular two-dimensional shape as viewed from top to bottom and defined by the contact zone width (wcr) and contact region length (lcr), where length is the longest dimension of the contact region 724.
[207] 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 may facilitate orientation of the molded abrasive particle 704. More particularly, the region of Contact 724 may have a two-dimensional shape configured to control one or more (e.g., at least two) particular predetermined orientation features, including, for example, a predetermined rotational orientation, a predetermined lateral orientation, and a 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 area 724 (e.g., length and/or width) substantially correspond to and are substantially the same as the dimensions of the contact area 724. molded abrasive particle 704, thereby facilitating positioning of molded abrasive particle at position 772 and facilitating one or a combination of predetermined orientation characteristics of molded abrasive particle 704. In addition, 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.
[208] As further illustrated, and in accordance with one embodiment, the alignment structure 762 may be configured to release and, in particular cases, temporarily or permanently retain the molded abrasive particles 705 at a second position 774. In particular cases, such as illustrated in FIG. 7B, alignment structure 762 may include a contact region 725, which may have a two-dimensional shape as viewed in particular from top to bottom and defined by the contact region width (wcr) and the 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.
[209] As illustrated and indicated 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 positioning of molded abrasive particles 744 and 745 in desired orientations on support 101 and with respect to each other. As noted herein, alignment structure 763 can have any of the characteristics of alignment structures described herein. It will be appreciated that alignment structure 763 may be a permanent or temporary part of the final abrasive article. Alignment structure 763 may be an integral part of the abrasive article, and may overlay backing 101, underlying an adhesive layer overlaying backing 101, or even be an integral part of one or more adhesive layers overlying backing 101.
[210] According to one embodiment, the alignment structure 763 may be configured to release and in particular cases, temporarily or permanently retain the molded abrasive particles 744 in a first position 775. Likewise, as illustrated, the alignment structure 763 may be configured to release and in particular cases, temporarily or permanently retain the molded abrasive particles 745 in a second position 776.
[211] In particular cases, as illustrated in FIG. 7B, alignment structure 763 may include a contact region 754, which may have a particular two-dimensional shape viewed from above. As illustrated, the contact region 754 may have a two-dimensional circular shape, which may be defined in part by a diameter (dcr).
[212] In accordance with at least one embodiment, the contact region 754 may be formed to have a shape (e.g., a two-dimensional shape) that can facilitate controlled orientation of the molded abrasive particle 744. More particularly, the contact region Contact 754 may have a two-dimensional shape configured to control one or more (e.g., at least two of) particular predetermined orientation features, including, for example, a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation. In at least one alternative embodiment as illustrated, the contact region 754 may have a circular shape that may facilitate freedom from a predetermined rotational orientation. For example, in comparing molded abrasive particles 744 and 745, each of which are associated with contact regions 754 and 755, respectively, and yet each of contact regions 754 and 755 have two-dimensional circular shapes, the particles molded abrasives 744 and 745 have different predetermined rotational orientations relative to each other. The two-dimensional circular shape of the contact regions 754 and 755 can facilitate preferential lateral orientation of the molded abrasive particles 744 and 745, while also allowing a degree of freedom in at least one predetermined orientation characteristic (i.e., a predetermined rotation orientation) in relationship to each other.
[213] It will be appreciated, that in at least one embodiment, dimensions of the contact region 754 (e.g., diameter) may substantially correspond to and may substantially equal a dimension of the molded abrasive particle 744 (e.g., a length of a surface side), which can facilitate positioning of the molded abrasive particle 744 at position 775 and facilitate one or a combination of predetermined orientation features of the molded abrasive particle 744. In addition, according to one embodiment, the alignment structure 763 can 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 appreciated that while the alignment structure 763 above includes contact regions 754 and 755 having substantially similar shapes, the alignment structure 763 may include a plurality of contact regions having a plurality of different two-dimensional shapes.
[214] As illustrated and noted above, FIG. 7B further includes a fourth group 794 of molded abrasive particles 746 and 747 superimposed on 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 herein, alignment structure 764 can have any of the characteristics of alignment structures described herein. It will be appreciated 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 overlap backing 101, underlying an adhesive layer overlying backing 101, or even being an integral part of one or more adhesive layers overlying backing 101.
[215] According to one embodiment, the alignment structure 764 may be configured to release and, in particular cases, temporarily or permanently retain the molded abrasive particle 746 in a first position 777. Likewise, as illustrated, the alignment structure Alignment 764 may be configured to release and in particular cases, temporarily or permanently retain the molded abrasive particle 747 in a second position 778.
[216] In particular cases, as illustrated in FIG. 7B, alignment structure 763 may include a contact region 756, which may have a particular two-dimensional shape viewed from above. As illustrated, the contact region 756 may have a two-dimensional cross-shaped shape, which may be defined in part by a length (lcr).
[217] In accordance with at least one embodiment, the contact region 756 may be formed to have a shape (e.g., a two-dimensional shape) that can facilitate controlled orientation of the molded abrasive particle 746. More particularly, the region of contact 756 may have a two-dimensional shape configured to control one or more (e.g., at least two of) particular predetermined orientation features, including, for example, a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation. In at least one alternative embodiment as illustrated, the contact region 756 can have a two-dimensional cross-shaped shape that can facilitate some freedom from a predetermined rotational orientation of the molded abrasive particle 746.
[218] For example, in comparison of molded abrasive particles 746 and 747, each of which is associated with contact regions 756 and 757, respectively, and yet each of contact regions 756 and 757 have two-dimensional shapes in cross-shaped, molded abrasive particles 746 and 747 may have different predetermined rotational orientations relative to each other. The two-dimensional cross-shaped shapes of the contact regions 756 and 757 can facilitate a preferred lateral orientation of the molded abrasive particles 746 and 747, while also allowing a degree of freedom in at least one predetermined orientation characteristic (i.e., a rotation orientation). predetermined) in relation to each other. As illustrated, the molded abrasive particles 746 and 747 are oriented substantially perpendicular to each other. The two-dimensional cross-shaped shape of the contact regions 756 and 757 generally facilitates two preferred predetermined rotational orientations of the molded abrasive particles, each of which is associated with the direction of the arms of the cross-shaped contact regions 756 and 757, and each of the two orientations is illustrated by molded abrasive particles 746 and 747.
[219] It will be appreciated, that in at least one embodiment, dimensions of the contact region 756 (e.g., length) may substantially correspond to, and may be substantially equal to, a dimension of the molded abrasive particle 746 (e.g., a length of a surface side), which can facilitate positioning of the molded abrasive particle 746 at position 777 and facilitate one or a combination of predetermined orientation features of the molded abrasive particle 746. In addition, according to one embodiment, the alignment structure 764 can 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 appreciated that while the alignment structure 764 above includes contact regions 756 and 757 having substantially similar shapes, the alignment structure 764 may include a plurality of contact regions having a plurality of different two-dimensional shapes.
[220] An abrasive article may have several discrete contact regions. The number of contact regions can influence the amount of abrasive particles adhered to the abrasive article, which in turn can influence the abrasive performance of the abrasive article. In one embodiment, the number of contact regions can be specific or variable. In one embodiment, the number of contact regions can be at least 1, such as at least 5, at least 10, at least 100, at least 500, at least 1000, at least 2000, at least 5000, at least 7500, at least minus 10,000; at least 15,000; at least 17,000; at least 20,000; at least 30,000; at least 40,000; or at least 50,000. In one embodiment, the number of contact regions may not exceed 100,000; as not exceeding 90,000; not more than 80,000, not more than 70,000; not more than 60,000; not more than 50,000; not more than 40,000; not exceeding 30,000 or not exceeding 20,000. It will be appreciated that the number of contact regions can be in a range of any maximum or minimum value indicated above. In a specific embodiment, the number of contact regions is in a range of 1000 to 50,000; like 5,000 to 40,000, like 10,000 to 17,000. In a specific modality, the number of contact regions is 10,000. In another specific modality, the number of contact regions is 17,000.
[221] As stated elsewhere here, the size of an individual contact region, and likewise an adhesive region size, can be specific or variable. In one embodiment, the size of a contact region can be defined by its average area or average diameter (polygon or circular).
[222] In one embodiment, a contact region may have a mean area of at least 0.01 mm2, such as at least 0.02 mm2, at least 0.05 mm2, at least 0.1 mm2, at least 0, 2 mm2, at least 0.3 mm2, at least 0.4 mm2, at least 0.5 mm2, at least 0.60 mm2, at least 0.70 mm2, at least 0.80 mm2, at least 0.90 mm2 , or at least 1 mm2. In one embodiment, a contact region may have an average area not exceeding 800 cm2, such as not exceeding 500 cm2, not exceeding 200 cm2, not exceeding 100 cm2, not exceeding 10 cm2, not exceeding 5 cm2, or not exceeding 3.5 cm2. It will be appreciated that the number of adhesive regions can be in the range of any maximum or minimum value indicated above. On average, the area of the contact region is in a range of 0.1 mm2 to 100 cm2; such as 0.1 mm2 to 10 cm2. In a specific embodiment, the average area of a contact region is in a range of 0.1 mm2 to 20 mm2.
[223] In one embodiment, a contact region may have an average diameter of at least 0.3 mm, such as at least 0.05 mm, at least 0.06 mm, at least 0.7 mm, at least 0, 8 mm, at least 0.9 mm, or at least 1 mm. In one embodiment, a contact region may have an average diameter not exceeding 40 cm, such as not exceeding 30 cm, not exceeding 20 cm, not exceeding 15 cm, not exceeding 10 cm, not exceeding 5 cm, or not exceeding 3.5 cm. It will be appreciated that the number of adhesive regions can be in the range of any maximum or minimum value indicated above. On average, the diameter of a contact region is in a range of 0.1 mm to 40 cm; as 0.1 mm to 10 cm. In a specific embodiment, the average diameter of a contact region is in a range of 0.1 mm to 20 mm. METHODS AND SYSTEMS TO FORM ABRASIVE ARTICLES
[224] The foregoing has described abrasive articles of embodiments having predetermined distributions of molded abrasive particles. The following describes different methods used to form these abrasive articles of the embodiments herein. It will be appreciated that any of the methods and systems described herein can be used in combination to facilitate the formation of an abrasive article in accordance with one embodiment.
[225] According to one embodiment, a method of forming an abrasive article includes positioning a molded abrasive particle on the support in a first position defined by one or more predetermined orientation features. In particular, the method of positioning the molded abrasive particle may include a shaping process. A shaping process may make use of an alignment structure, which can be configured to retain (temporarily or permanently) one or more molded abrasive particles in a predetermined orientation and release one or more molded abrasive particles to the abrasive article at a position defined predetermined orientation having one or more predetermined orientation characteristics.
[226] According to one embodiment, the alignment structure may be a number of 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 stamped adhesive material, and a combination thereof. In a particular embodiment, the alignment structure may include a discrete contact region configured to retain a molded abrasive particle. In other cases, the alignment structure may include a plurality of spaced discrete contact regions spaced apart 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 position the 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 the molded first abrasive particle and position the molded first abrasive particle in the first position. Notably, for embodiments utilizing a permanent retention between the discrete contact region and the molded abrasive particle, the alignment structure can be integrated within the finished abrasive article.
[227] Some exemplary alignment structures according to embodiments herein are illustrated in FIGs. 9-11. FIG. 9 includes an illustration of a portion 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 superimposed on one another. 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 particular illustrated embodiment, discrete contact regions 904-906 may be defined by an intersection of fibers 901 and 902, and more particularly, a hinge 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 positioning and retention of the molded abrasive particles 911-913.
[228] As will be appreciated, the construction and arrangement of fibers 901 and 902 can facilitate control of discrete contact regions 904-906 and may further facilitate control of one or more predetermined orientation characteristics of the abrasive particles molded into the abrasive article. For example, discrete contact regions 904-906 may be configured to define at least one of a predetermined rotational orientation of a molded abrasive particle, a predetermined rotational orientation difference 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 between two molded abrasive particles , a predetermined tip height orientation of a molded abrasive particle, a predetermined tip height difference between two molded abrasive particles, and a combination thereof.
[229] 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 having discrete contact regions 1002 and 1003 configured to engage and retain molded abrasive particles 1011 and 1012. In one embodiment, alignment structure 1000 may include discrete contact regions 1002 and 1003 as apertures in the alignment structure. Each of the openings may be shaped to retain one or more molded abrasive particles. Notably, each of the apertures may be shaped to hold one or more molded abrasive particles in a predetermined position to facilitate positioning of the one or more molded abrasive particles on the support in a predetermined position with one or more predetermined orientation characteristics. In at least one embodiment, the apertures defining the discrete contact regions 1002 and 1003 may have a cross-sectional shape complementary to a cross-sectional shape of the molded abrasive particles. Also, in certain cases, apertures defining discrete contact regions may extend through the entire thickness of the alignment structure (ie, belt 1001). In yet another embodiment, the alignment structure may include discrete contact regions defined by apertures, wherein the apertures partially extend through the entire thickness of the alignment structure. For example, FIG. 11 includes an illustration of a portion of an alignment structure according to one embodiment. Notably, alignment structure 1100 may be in the form of a thicker structure in which apertures defining discrete contact regions 1102 and 1103 configured to retain molded abrasive particles 1111 and 1112 do not extend through the entire thickness of the substrate. 1101.
[230] 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 roller 1201 having apertures 1203 in the outer surface and defining discrete contact regions. Discrete contact regions 1203 may have particular dimensions configured to facilitate retention of molded abrasive particles 1204 on roll 1201 until a portion of molded abrasive particles is contacted with abrasive article 1201. Upon contact with abrasive article 1201, molded abrasive particles 1204 can be released from roller 1201 and released to abrasive article 1201 at a particular position defined by one or more predetermined orientation features. In this regard, the shape and orientation of the openings 1203 in the roller 1201, the position of the roller 1201 in relation to the abrasive article 1201, the rate of translation of the roller 1201 in relation to the abrasive article 1201 can be controlled to facilitate the positioning of the abrasive particles. molded 1204 in a predetermined distribution.
[231] Various processing steps can be used to facilitate positioning of the molded abrasive particles in 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, particular devices may be used to facilitate the orientation of the abrasive particles molded into the alignment structure, including, for example, chambers, acoustics, and a combination thereof.
[232] In yet 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 portions, wherein the adhesive portions define discrete contact regions configured to retain (temporarily or permanently) one or more molded abrasive particles. According to one embodiment, the discrete contact regions may include an adhesive, and more particularly, the discrete contact regions are defined by an adhesive layer, and even more particularly, each of the discrete contact regions is defined by an adhesive region. discreet. In certain cases, the adhesive may include a resin, and more particularly, may include a material to be used as a branded coating as described in embodiments herein. Furthermore, the discrete contact regions may define a predetermined distribution relative to each other, and may further define 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 equal to a predetermined distribution of molded abrasive particles superimposed on the backing. In a particular case, the discrete contact regions comprising the adhesive may be arranged in a predetermined distribution, may be configured to retain a molded abrasive particle, and further may define at least one of a predetermined orientation characteristic for each molded abrasive particle.
[233] In one embodiment, the number of adhesive regions can be specific or variable. In one embodiment, the number of adhesive regions can be at least 1, such as at least 5, at least 10, at least 100, at least 500, at least 1000, at least 2000, at least 5000, at least 7500, at least 10,000; at least 15,000; at least 17,000; at least 20,000; at least 30,000; at least 40,000; or at least 50,000. In one embodiment, the number of adhesive regions may not exceed 100,000; as not exceeding 90,000; not more than 80,000, not more than 70,000; not more than 60,000; not more than 50,000; not more than 40,000; not exceeding 30,000 or not exceeding 20,000. It will be appreciated that the number of adhesive regions can be in the range of any maximum or minimum value indicated above. In a specific embodiment, the number of adhesive regions is in a range of 1000 to 50,000; like 5,000 to 40,000, like 10,000 to 17,000. In a specific embodiment, the number of adhesive regions is 10,000. In another specific embodiment, the number of adhesive regions is 17,000.
[234] FIG. 13 includes an illustration of a portion of an alignment structure including discrete contact regions comprising an adhesive according to an embodiment. As illustrated, alignment structure 1300 may include a first discrete contact region 1301 comprising a discrete adhesive region and configured to engage a molded abrasive 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 a first discrete contact region 1301 may have a width (w) 1304 related to at least least one dimension of the molded abrasive particle, which can facilitate positioning of the molded abrasive particle in a particular orientation relative to the support. For example, certain suitable orientations with respect to the support may include a side orientation, a planar orientation, and an inverted orientation. According to a particular embodiment, the first discrete contact region 1301 may have a width (w) 1304 related to a height (h) of the molded abrasive particle to facilitate lateral orientation of the molded abrasive particle. It will be appreciated that reference herein to a height may refer to an average height or 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 particle. 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). 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). Still 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 be within a range between any of the minimum and maximum values noted above.
[235] In accordance with a particular embodiment, the first discrete contact region 1301 may be spaced apart from the second discrete contact region 1302 through a longitudinal gap 1305, which is a measure of the shortest distance between discrete contact regions 1301 and 1302 immediately adjacent in a direction parallel to the longitudinal axis 180 of the holder 101. In particular, controlling the longitudinal gap 1305 can facilitate control of the predetermined distribution of the abrasive particles molded onto the surface of the abrasive article, which can facilitate performance improvement. In one embodiment, the longitudinal gap 1305 may relate to a dimension of one or a sample of the molded abrasive particle. For example, the longitudinal gap 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 herein to the width (w) of the molded abrasive particle may refer to an average width or median width of a suitable sample size of a batch of molded abrasive particles. In a particular case, the longitudinal gap 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 2(w), at least about 2.5(w), at least about 3(w) or even at least about 4(w). Still in a non-limiting embodiment, the longitudinal gap 1305 may be no greater than about 10(w), no greater than about 9(w), no greater than about 8(w), or even no greater than about 8(w). of 5(w). It will be appreciated that the longitudinal gap 1305 can be within a range between any of the minimum and maximum values noted above.
[236] According to a particular embodiment, the second discrete contact region 1302 may be spaced apart from the third discrete contact region 1303 through a lateral gap 1306, which is a measure of the shortest distance between discrete contact regions 1302 and 1303 immediately adjacent in a direction parallel to the lateral axis 181 of the holder 101. In particular, controlling the side gap 1306 can facilitate control of the predetermined distribution of the abrasive particles molded onto the surface of the abrasive article, which can facilitate performance improvement. In one embodiment, the lateral gap 1306 may be related to a size of one or a sample of the molded abrasive particle. For example, the side gap 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 herein to the width (w) of the molded abrasive particle may refer to an average width or median width of a suitable sample size of a batch of molded abrasive particles. In particular cases, the lateral gap 1306 may be smaller than the width of the molded abrasive particle. In still other cases, the lateral gap 1306 may be greater than the width of the molded abrasive particle. According to one aspect, the side gap 1306 may be zero. In yet another aspect, the side gap 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). In yet a non-limiting embodiment, the side opening 1306 may be no greater than about 100(w), no greater than about 50(w), no greater than about 20(w), or even no greater than about 20(w). of 10(w). It will be appreciated that the side gap 1306 may be within a range between any of the minimum and maximum values noted above.
[237] The first discrete contact region 1301 can be formed on an upper main surface of a support using various methods, including, for example, printing, patterning, gravure, engraving, stripping, coating, deposition, and a combination thereof. FIGs. 14A-14H include top-down views of tooling portions for forming abrasive articles having various structures of patterned alignment including discrete contact regions of an adhesive material, in accordance with embodiments herein. In particular cases, the tools may include a modeling structure that can be contacted with the support and transfer the standardized alignment structure to the support. In a particular embodiment, the tool may be a gravure roller having a patterned alignment structure comprising discrete contact regions of adhesive material which can be rolled over a support to transfer the patterned alignment structure to the support. After which, molded abrasive particles can be positioned on the support in the regions corresponding to the discrete contact regions. FIG. 33 illustrates an embodiment of a gravure roller having a patterned alignment structure comprising an open cell pattern on the surface of the roller capable of capturing and transferring adhesive material to form discrete contact regions of adhesive material on a backing. FIG. 32 is an illustration of an unshaded phyllotactic pattern "(pineapple pattern") suitable for use in a gravure roller or other rotary printing embodiment. FIG. 34A is a photograph of a discontinuous distribution of adhesive contact regions composed of a brand coating that does not contain any abrasive particles. FIG. 34B is a photograph of the same discontinuous distribution of adhesive contact regions as shown in FIG. 34A after abrasive particles were arranged in the discontinuous distribution of adhesive contact regions. FIG. 34 is a photograph of the abrasive particle covered discontinuous distribution of adhesive contact regions indicated in FIG. 34B after a continuous size coating is applied.
[238] In at least one particular aspect, an abrasive article of one embodiment may include forming a patterned structure comprising an adhesive on at least a portion of the backing. Notably, in one case, the patterned structure may be in the form of a patterned branded coating. The patterned brand coating may be a discontinuous layer including at least one adhesive region overlying the backing, a second adhesive region overlying the backing separate from the first adhesive region, and at least one exposed region between the first and second adhesive regions. The at least one exposed region may be essentially free of adhesive material and represents a gap in the mark coating. In one embodiment, the patterned mark coating 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 brand coating with a predetermined distribution of the adhesive regions on the backing can facilitate the positioning of the molded abrasive grains in a predetermined distribution, and particularly, the predetermined distribution of the adhesive regions of the patterned brand coating may correspond to the positions of the particles. molded abrasives, wherein each of the molded abrasive particles can be adhered to the support in the adhesive regions and therefore correspond to the predetermined distribution of molded abrasive particles on the support. Furthermore, in at least one embodiment, essentially no molded abrasive particles of the plurality of molded abrasive particles are superimposed on the exposed regions. Furthermore, it will be appreciated that a single adhesive region can be molded and sized to accommodate a single molded abrasive particle. However, in an alternative embodiment, an adhesive region may be molded and sized to accommodate a plurality of molded abrasive particles.
[239] As already stated, a branded coating can be selectively applied to a support so that a portion of the surface of the support is not covered with any branded coating material. Any portion not covered by a branded coating, however, may be partially to fully covered by another coating layer, such as an oversized coating or an oversized coating. Alternatively, portions of the support surface may be free of any overlays (i.e., “uncovered” portions). A portion of the surface of the support not covered with branded coating material may be defined as a fraction of the total surface of the support. Likewise, a portion of the surface of the support not covered with overlay coating can be defined as a fraction of the total surface of the support. It will be appreciated that the total contact area for the abrasive article is based on the sum of the discrete contact areas (i.e., the sum of all discrete contact areas) and may equal the fraction of the total surface area of the support that is covered with branded coating. In one embodiment, the portion of the support covered by branded coating material can range from 0.01 to 1.0 of the total support surface. In a specific embodiment, the portion of the total support surface area covered by branded coating material can range from 0.05 to 0.9 of the total support surface, such as 0.1 to 0.8 of the total support surface. . In a specific embodiment, the portion of the total support surface covered by branded coating material is in the range of 0.1 to 0.6 of the total support surface, such as 0.15 to 0.55, such as 0.16 to 0.16 to 0.5 of the total support surface. In one embodiment, the portion of the surface of the support not covered by any superimposed coating material (i.e., "uncovered" surface) can range from 0.0 to 0.99 of the total support surface. In a specific embodiment, the portion of the support surface that is uncovered can range from 0.1 to 0.95 of the total support surface, such as 0.2 to 0.9 of the total support surface. In a specific embodiment, the uncovered part of the surface of the support is in a range of 0.4 to 0.85 of the surface of the total support.
[240] Various processes can be used to form a patterned structure, including, for example, a patterned branded coating. In one embodiment, the process may include selectively depositing the mark coating. In another embodiment, the process may include selectively removing at least a portion of the mark coating. Some exemplary processes may include coating, spraying, rolling, printing, masking, irradiating, etching, and a combination thereof. According to a particular embodiment, forming the patterned overlay may include providing a patterned overlay on a first structure and transferring the patterned overlay to at least a portion of the backing. For example, a gravure roll may be provided with a layer of patterned brand coating, and the roll can be translated over at least a portion of the backing and transferring the patterned branded coating from the surface of the roll to the surface of the backing. METHODS TO APPLY ADHESIVE COATING
[241] In one embodiment, an adhesive layer may be applied by a screen printing process. The screen printing process may be a discrete adhesive layering process, a semi-continuous adhesive layering process, a continuous adhesive layering process, or combinations thereof. In one embodiment, the application process includes the use of a rotating screen. In a particular embodiment, a rotating screen may be in the form of a hollow cylinder, or drum, having a plurality of openings located in the wall of the cylinder or drum. An aperture, or combination of apertures, may correspond to the desired position of a discrete contact region, or a combination of discrete contact regions. A discrete contact region may include one or more discrete adhesive regions. In a particular embodiment, a contact region includes a plurality of discrete adhesive regions. Adhesive regions can be arranged as an unshaded pattern. Methods to Prepare
[242] FIG. 31 illustrates a flow diagram for a method 3100 for preparing an abrasive article, as shown in FIG. 32. In step 3101, application of an adhesive layer to the backing takes place. The adhesive layer may be a polymeric binder composition (i.e., polymeric resin) corresponding to a branding layer 3202 (i.e., branding resin) disposed over a major surface 3204 of a backing 3206 in a plurality of discrete areas, such as discrete contact areas or discrete adhesive regions 3208. The discrete adhesive regions can be arranged to provide random, semi-random, or ordered distribution. An exemplary distribution is an unshaded distribution as shown in FIGs. 25, 26, 27 and 32. The arrangement (application) of the abrasive particles 3210 over the discrete adhesive regions of the proximate brand resin occurs in step 3103. In step 3105, curing of the brand resin occurs at least partially to fully to provide the abrasive article. Optionally, a functional powder, such as a mineral powder, can be applied over the entire coated support and then removed from those areas that do not contain the branded resin. Optionally, size A 3212 coating (i.e. size resin) can then be preferably applied over the abrasive particles and the brand resin. The size coating can be in contact with open areas 3214 of the backing (ie areas where branded resin has not been applied), in contact with areas where branded resin has been applied, or combinations thereof. In a specific embodiment, the size resin is applied over the prepared mark in a way that does not completely cover the mark resin and does not extend beyond the mark resin. Optionally, curing of the size resin then takes place to provide the abrasive article. In one embodiment, when applying an adhesive layer to the backing, particularly as a branding layer, the branding resin may contain suitable additives and fillers, but not contain any abrasive particles (i.e., the branding resin is not an abrasive paste). ). In a specific embodiment, the adhesive resin is a branded resin and does not contain any abrasive particles. Furthermore, it will be appreciated that although the discrete adhesive regions may be arranged as a discontinuous unshaded distribution, such as a branded coating having a discontinuous unshaded distribution, that any size of coating which is optionally applied over the branded coating may be continuous. or discontinuous, as any oversize coating that is optionally applied over the size coating may be continuous or discontinuous. In a specific embodiment, a size coating and an increased size coating are discontinuous and are applied so that the size coating and the increased size coating correspond with the brand coating distribution. In another specific embodiment, a size coating and an increased size coating are discontinuous and are applied so that the size coating and the increased size coating partially match the brand coating distribution. In another specific embodiment, a continuous size coating is applied over the discontinuous brand coating and an increased size coating is applied over the size coating. In another specific embodiment, a discontinuous size coating is applied over the discontinuous branded coating (corresponding or partially matching the branded coating) and a continuous increased size coating is applied over the size coating.
[243] Selective application of a branded resin and a size resin can be accomplished using contact and print coating methods, non-contact and print coating methods, transfer and print contact coating methods, or a combination of them. Suitable methods include mounting a template, such as a stencil or canvas, against the article support to mask areas of the support that are not to be coated. A screen printing process can be a discrete adhesive application process, a semi-continuous adhesive application process, a continuous adhesive application process, or combinations thereof. In one embodiment, the application process may include the use of a rotating screen. In a particular embodiment, a rotating screen 2801 may be in the form of a hollow cylinder, or drum, having a plurality of openings 2803 located in the wall of the cylinder or drum. In one embodiment, an opening or combination of openings may be located in the wall of the rotating screen. The apertures may correspond to one or more discrete contact regions, including one or more discrete adhesive regions 2805.
[244] In one embodiment, the number of openings can be specific or variable. In one embodiment, the number of apertures can be at least 1, such as at least 5, at least 10, at least 100, at least 500, at least 1000, at least 2000, at least 5000, at least 7500, at least 10,000 ; at least 15,000; at least 17,000; at least 20,000; at least 30,000; at least 40,000; or at least 50,000. In one embodiment, the number of openings may not exceed 100,000; as not exceeding 90,000; not more than 80,000, not more than 70,000; not more than 60,000; not more than 50,000; not more than 40,000; not exceeding 30,000 or not exceeding 20,000. It will be appreciated that the number of openings can be in the range of any maximum or minimum value indicated above. In a specific embodiment, the number of openings is in a range of 1000 to 50,000; like 5,000 to 40,000, like 10,000 to 17,000. In a specific modality, the number of openings is 10,000. In another specific modality, the number of openings is 17,000.
[245] A rotating screen process may include an open squeegee system or a closed squeegee system. In a specific embodiment, the rotating screen process includes a 2809 closed squeegee system. The rotating screen may be filled with 2811 adhesive resin (i.e., polymeric resin for use in one or more specific coating layers, such as resin, brand resin, size resin) and the squeegee, or the like, can be used to guide the resin through the openings. Enclosed rotary squeegee systems can have several advantages over other coating and printing systems. For example, rotary screen printing systems allow the screen and support material to run at the same speed, reducing friction, sometimes marked by no friction between the screen and the support material. In addition, the strain on the support material is reduced, allowing for more delicate or sensitive support materials such as much thinner support materials or open support materials to be coated effectively. In addition, rotary screen printing systems can reduce or eliminate the pressure required to push an adhesive material through the openings of the rotating screen, which allows for enhanced control of the thickness of the adhesive material applied to the backing. In one embodiment, the thickness of the adhesive material is precisely controlled and applied at a thickness that promotes at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about of 75%, at least about 80%, at least about 85%, at least about 90%, or at least about 95% of the abrasive particles having spikes that are upright. The thickness of the adhesive material may be the mark layer thickness alone, or it may be the thickness in combination with the size layer. The thickness of the adhesive layer can be adversely affected by penetration into the support material. Penetration of the adhesive material into the backing material can be reduced, if desired, in order to control the strikethrough of the adhesive material and selectively control the flexibility of the backing material, also known as the “hand” of the backing material, when dealing with a fabric support. Another benefit of a rotary screen printing system is that the form of adhesive material deposited on the backing will be less disturbed, so discontinuous distributions of the branded coating resin, such as a discontinuous distribution of dots, stripes, or the like, as described here will have in a more controlled manner, thus providing sharply defined coating areas, or images, on the substrate. Suitable rotary screen process modes that include a closed squeegee system may include makes and models of Specific STORK printing machines. An illustration of a rotating screen process system is shown in FIG. 28. FIG. 32 is an illustration of an unshaded phyllotactic pattern suitable for use in a rotary screen printing modality. PHYLOTATIC
[246] In one embodiment, the adhesive layer may have a substantially uniform thickness. The thickness can be less than the d50 height of the abrasive particle. The thickness can be less than 50% of the abrasive particle height, as less than 45%, as less than 40%, as less than 35%, as less than 30%, as less than 25%, as less than 20%, less than 15%, less than 10%, less than 5%, less than 4%, less than 3%, less than 2%, less than 1%, less than 0.5%.
[247] In one embodiment, the width of the discrete adhesive contact regions may be the same or different. In one embodiment, the width of the discrete adhesive contact region is substantially equal to the d50 width of the at least one abrasive particle.
[248] In an alternative embodiment, stencil printing may be used, such as by using a frame to support a resin blocking stencil. The stencil can be a woven or non-woven material. The stencil can form open areas allowing resin transfer to produce a sharply defined image on a substrate. A roller or squeegee can be moved across the screen stencil, forcing or pumping resin or paste through open areas in the stencil, such as open areas in the mesh of a woven stencil.
[249] Screen printing can also include a method of printing mark stencil in which a design is imposed on a silk screen or other fine mesh, in which portions of the support that are desired to be blank areas, or open areas, are coated with an impermeable substance, and the resin or paste is forced through the mesh onto the print surface (i.e., the desired support or substrate). The printing of low-profile, high-fidelity features can be screen-enabled.
[250] An alternative embodiment includes a method for contacting that includes a combination of screen printing and stencil printing, where a fabric mesh is used to support a stencil. The stencil includes open mesh areas through which resin (adhesive) can be deposited in a desired distribution, such as a pattern of discrete areas for the support material. The resin can be applied as a branded coating, a size coating, an increased size coating, or other coating layer known in the art, or combinations thereof.
[251] In an alternative embodiment, a method may include inkjet printing and other technologies capable of selectively coating patterns onto the support without the need for a template.
[252] Another suitable method is a continuous light touch coating operation where the adhesive material (brand coating or size coating) is coated onto the backing material by passing the backing material between a release roller and a pinch roller. . This method may be suitable for coating a size coating over abrasive particles by passing the backing sheet between a release roller and a pinch roller. Optionally, the adhesive resin can be measured directly onto the release roller. The final coated material can then be cured to provide the finished article. FIG. 33 illustrates an embodiment of a gravure roller having a patterned alignment structure comprising an open cell pattern on the surface of the roller capable of capturing and transferring adhesive material to form discrete contact regions of adhesive material on a backing during a coating operation. light touch. FIG. 32 is an illustration of an unshaded phyllotactic pattern suitable for use in a gravure roller or other rotary printing embodiment. FIG. 34A is a photograph of a discontinuous distribution of adhesive contact regions composed of a brand coating that does not contain any abrasive particles. FIG. 34B is a photograph of the same discontinuous distribution of adhesive contact regions as shown in FIG. 34A after abrasive particles were arranged in the discontinuous distribution of adhesive contact regions. FIG. 34 is a photograph of the abrasive particle covered discontinuous distribution of adhesive contact regions indicated in FIG. 34B after a continuous size coating is applied.
[253] A rotating screen for preparing a patterned coated abrasive article may include a generally cylindrical body and a plurality of perforations extending through the body. Alternatively, a stencil for preparing a patterned coated abrasive article may include a generally planar body and a plurality of perforations extending through the body. Optionally, a frame can partially or completely surround the stencil.
[254] A screen or stencil can be made of any material generally known in the art, such as a natural fiber, polymer, metal, ceramic, composite, or combinations thereof. The material can be of any desired dimension. In one embodiment, the fabric is preferably thin. In one embodiment, combinations of metal and plastic fabrics are used. Metal stencils can be engraved in one or more patterns, or a combination of patterns. Other suitable screen and stencil materials include polyester films, such as those having a thickness ranging from 1 to 20 mils (0.076 to 0.51 millimeters), more preferably ranging from 3 to 7 mils (0.13 to 0.25 millimeters). .
[255] As mentioned above, a rotating screen can be advantageously used to provide precisely defined coating patterns. In one embodiment, a layer of branded resin is selectively applied to the support by rotating the rotating fabric over the support by a desired distance (to determine coating thickness) and applying the branded resin across the rotating fabric. The brand resin can be applied in a single pass or multiple passes using a squeegee, scraper blade, or other blade-like device.
[256] The viscosity of the brand resin can be manipulated to be in a range that is high enough that the distortion of the overall distribution pattern as well as the individual adhesive contact regions (e.g. dots, stripes, etc.) minimized, and, in some embodiments, eliminated (ie, undetectable). sticker spacing
[257] The adhesive application methods described above can be used to impart one or more desirable orientation characteristics to the discrete adhesive regions or to establish one or more desirable predetermined distributions of the discrete adhesive regions. A predetermined distribution between discrete adhesive regions may also be defined by at least one of a predetermined orientation characteristic of each of the discrete adhesive regions. Exemplary predetermined orientation features may include a predetermined rotation orientation, a predetermined lateral orientation, a predetermined longitudinal orientation, a predetermined vertical orientation, and combinations thereof.
[258] As shown in FIG. 29, in one embodiment, support 2901 may be defined by a longitudinal axis 2980 that extends along and defines a length of support 2901 and a lateral axis 2981 that extends along and defines a width of support 2901. discrete adhesive 2902 may be located at a first predetermined position 2912 defined by a particular first lateral position with respect to the lateral axis of 2981 of the support 2901. In addition, the discrete adhesive region 2903 may have a second predetermined position defined by a second lateral position relative to the lateral axis 2981 of the support 2901. Notably, the discrete adhesive regions 2902 and 2903 may be spaced apart from each other by a lateral space 2921, defined as a shortest distance between the two adjacent discrete adhesive regions 2902 and 2903 as measured by along a lateral plane 2984 parallel to the lateral axis 2981 of the support 2901. In accordance with one embodiment, the lateral space 2921 may be greater than zero (0), so that some distance exists between discrete adhesive regions 2902 and 2903. However, while not illustrated, it will be appreciated that lateral space 2921 can be zero (0), allowing contact and even overlap between portions of adjacent discrete adhesive regions.
[259] In other embodiments, the lateral space 2921 may be at least about 0.1 (w), where w represents the width of the discrete adhesive region 2902. In one embodiment, the width of the discrete adhesive region is the longest dimension of the body extending along one side. In another embodiment, the side space 2921 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. In still at least one non-limiting embodiment, side space 2921 can be no greater than about 100(w), no greater than about 50(w), no greater than about 20(w). It will be appreciated that side space 2921 can be within a range between any of the minimum and maximum values noted above. Controlling the lateral space between adjacent discrete adhesive regions can facilitate improved grinding performance of the abrasive article.
[260] In accordance with one embodiment, the discrete adhesive region 2902 may be in a first predetermined position 2912 defined by the first longitudinal position with respect to a longitudinal axis 2980 of the support 2901. In addition, the discrete adhesive region 2904 may be located at a third predetermined position 2914 defined by a second longitudinal position with respect to the longitudinal axis 2980 of the support 2901. Also, as illustrated, a longitudinal space 2923 may exist between discrete adhesive regions 2902 and 2904, which may be defined as a smaller distance between the two adjacent discrete adhesive regions 2902 and 2904, as measured in a direction parallel to the longitudinal axis 2980. In accordance with one embodiment, the longitudinal space 2923 may be greater than zero (0). Still, while not illustrated, it will be appreciated that the longitudinal space 2923 may be zero (0), such that adjacent discrete adhesive regions are touching, or even overlapping, one another.
[261] In other cases, the longitudinal space 2923 may be at least about 0.1(w), where w is the width of the discrete adhesive region as described here. In other more particular cases, the longitudinal space may be at least about 0.2(w), at least about 0.5(w), at least about 1(w), or even at least about 2 (w). Further, longitudinal space 2923 may be no greater than about 100(w), no greater than about 50(w), no greater than about 20(w). It will be appreciated that longitudinal space 2923 can be within a range between any of the above minimum and maximum values. Controlling the longitudinal space between adjacent discrete adhesive regions can facilitate improved grinding performance of the abrasive article.
[262] According to one embodiment, the discrete adhesive regions may be positioned in a predetermined distribution, wherein a particular relationship exists between lateral space 2921 and longitudinal space 2923. For example, in one embodiment, lateral space 2921 may be greater than the longitudinal space 2923. In yet another non-limiting embodiment, the longitudinal space 2923 can be larger than the side space 2921. In yet another embodiment, discrete adhesive regions may be positioned on the backing so that the side space 2921 and longitudinal space 2923 are essentially equal with respect to each other. Controlling the relative relationship between longitudinal space and side space can facilitate improved grinding performance.
[263] According to one embodiment, the discrete adhesive region 2905 may be located at a fourth predetermined position 2915 defined by a third longitudinal position with respect to the longitudinal axis 2980 of the support 2901. Further, as illustrated, a longitudinal space 2925 may exists between discrete adhesive regions 2902 and 2905, which may be defined as a shortest distance between two adjacent discrete adhesive regions 2902 and 2905, as measured in a direction parallel to longitudinal axis 2980. In accordance with one embodiment, longitudinal space 2925 can be greater than zero (0). Still, while not illustrated, it will be appreciated that the longitudinal space 2925 may be zero (0), such that adjacent discrete adhesive regions are touching, or even overlapping, one another.
[264] In other cases, the longitudinal space 2925 may be at least about 0.1(w), where w is the width of the discrete adhesive region as described here. In other more particular cases, the longitudinal space may be at least about 0.2(w), at least about 0.5(w), at least about 1(w), or even at least about 2 (w). Further, longitudinal space 2925 may be no greater than about 100(w), no greater than about 50(w), no greater than about 20(w). It will be appreciated that longitudinal space 2925 can be within a range between any of the above minimum and maximum values. Controlling the longitudinal space between adjacent discrete adhesive regions can facilitate improved grinding performance of the abrasive article.
[265] As further illustrated, a longitudinal space 2924 may exist between the discrete adhesive regions 2904 and 2905. Furthermore, the predetermined distribution may be formed such that a particular relationship may exist between the longitudinal space 2923 and longitudinal space 2924. For example, longitudinal space 2923 may be different from longitudinal space 2924. Alternatively, longitudinal space 2923 may be essentially the same as longitudinal space 2924. Controlling the relative difference between longitudinal spaces of different abrasive particles can facilitate improved grinding performance of the abrasive article. As further illustrated, a longitudinal space 2927 may exist between discrete adhesive regions 2903 and 2906. Furthermore, predetermined distribution may be formed such that a particular relationship may exist between longitudinal space 2927 and longitudinal space 2926. For example, longitudinal space 2927 may be different from longitudinal space 2926. Alternatively, longitudinal space 2927 may be substantially the same as longitudinal space 2926. Further, longitudinal space 2927 may be different from, or essentially the same as, longitudinal space 2923. Likewise , longitudinal space 2928 may be different from, or essentially the same as, longitudinal space 2924. Controlling the relative difference between longitudinal spaces of different abrasive particles can facilitate improved grinding performance of the abrasive article.
[266] In addition, the predetermined distribution of abrasive particles molded into the abrasive article 2900 may be such that the side space 2921 may have a particular relationship to the side space 2922. For example, in one embodiment, the side space 2921 may be essentially equal to the side space 2922. Alternatively, the predetermined distribution of abrasive particles molded into the abrasive article 2900 can be controlled so that the side space 2921 is different from the side space 2922. Controlling the relative difference between side spaces of different abrasive particles can facilitate the improved grinding performance of the abrasive article.
[267] As further illustrated, a longitudinal space 2926 may exist between the discrete adhesive regions 2903 and 2906. Furthermore, the predetermined distribution may be formed such that a particular relationship may exist between the longitudinal space 2925 and longitudinal space 2926. For example, longitudinal space 2925 may be different from longitudinal space 2926. Alternatively, longitudinal space 2925 may be essentially the same as longitudinal space 2926. Controlling the relative difference between longitudinal spaces of different abrasive particles can facilitate improved grinding performance of the abrasive article. In addition to the latitudinal spacing and longitudinal spacing already described here, the spacing between discrete contact regions, discrete adhesive regions, or abrasive particles can also be described as having a variable or particular "adjacent spacing" where said adjacent spacing need not be strictly latitudinal or longitudinal (but may be the shortest distance that extends between adjacent discrete contact regions, discrete adhesive regions, or abrasive particles even if at an oblique angle. Adjacent spacing may be constant or variable.
[268] In one embodiment, adjacent spacing can be defined as a fraction of the abrasive particle length, abrasive particle width, discrete contact area length, discrete contact area width, discrete adhesive region length, region width adhesive, or combinations thereof. In one embodiment, adjacent spacing is defined as a fraction of the length of the abrasive particle (l). In one embodiment, adjacent spacing is at least 0.5(l), such as at least 0.5(l), at least 0.6(l), at least 0.7(l), at least 1.0 (l), or at least 1.1(l). In one embodiment, adjacent spacing is not greater than 10(l), such as not greater than 9(l), not greater than 8(l), not greater than 7(l), not greater than 6(l), not greater than 5(l), not greater than 4(l), or not greater than 3(l). It will be appreciated that adjacent spacing may be in a range of any maximum or minimum value indicated above. In one embodiment, adjacent spacing is in a range of 0.5(l) to 3(l), such as 1(l) to 2.5(l), such as 1.25(l) to 2.25(l). ), such as 1.25(l) to 1.75(l), such as 1.5(l) to 1.6(l).
[269] In one embodiment, adjacent spacing is at least 0.2 mm, such as at least 0.3 mm, such as at least 0.4 mm, such as at least 0.5 mm, such as at least 0.6 mm, as at least 0.7 mm, as at least 1.0 mm. In one embodiment, the adjacent spacing may be no more than 4.0mm, no more than 3.5mm, no more than 2.8mm, or no more than 2.5mm. It will be appreciated that the adjacent spacing may be in an array of any maximum or minimum value indicated above. In a particular embodiment, adjacent spacing is in a range of 1.4 mm to 2.8 mm.
[270] In one embodiment, the adjacent spacing between discrete contact areas may be at least about .0.1 (W), where in W is the dexterity of the discrete adhesive region as described here.
[271] It will be appreciated that abrasive particles, such as molded abrasive particle embodiments described herein, may be arranged in the discrete adhesive regions described above. The number of abrasive particles arranged in a discrete abrasive region can be 1 to n, where n= 1 to 3. The number of abrasive particles arranged per discrete abrasive region can be the same or different. Furthermore, a predetermined distribution of molded abrasive particles can be defined through the predetermined distribution of distinct adhesive regions to which they are relatively adhered. A predetermined distribution of discrete adhesive regions can also be defined by the precision and accuracy of the actual positioning of a discrete adhesive region (i.e., an adhesive strike site) with respect to its target location (i.e., adhesive target site), and more precisely defined by the precision and accuracy of positioning the center (or centroid) of an adhesive strike area compared to the center (or centroid) of the intended adhesive target area. The difference in distance between the adhesive target site and the adhesive target site is the differential distance. Differential distance control can facilitate improved grinding performance of the abrasive article. As explained in more detail below, differential distance control can be defined by one or more of several known measures of variability, such as Range, Interquartile Range, Variance, and Standard Deviation, among others.
[272] In accordance with one embodiment, FIG. 30 illustrates a predetermined or controlled distribution 3000 of discrete adhesive regions with respect to their intended target locations. As shown, the predetermined distribution of discrete adhesive regions 3000 may include a first adhesive target area 3002 and a first adhesive tap area 3004. The relationship between the first adhesive target area 3002 and the first adhesive tap area 3004 may be defined by a first differential distance 3001 between the adhesive target location 3003 (i.e., the center or centroid of the first adhesive target area) and the adhesive tap location 3005 (i.e., the center or centroid of the first adhesive tap area). Preferably, the differential distance will be zero, but in reality, it will probably be an acceptably small value. In one embodiment, the first differential distance 3001 may be zero (0), or an acceptable distance greater than zero, such that the distance may exist between locations 3003 and 3005. Furthermore, as illustrated, the first differential distance 3001 may be less than the length or width or diameter of the first adhesive tap area 3004 or the first adhesive target area 3002, allowing contact and even overlap between portions of the first adhesive tap area 3004 and the first adhesive tap area 3002. Furthermore, while not illustrated, it will be appreciated that the first differential distance 3001 may be zero (0), indicating the completely accurate positioning of the first adhesive strike area 3004 in the first adhesive target area 3002.
[273] In one embodiment, the first differential distance 3001 may be less than about 0.1(d), where (d) represents the diameter of the first adhesive tapping area 3004. The diameter of the adhesive tapping area is the greatest dimension of the strike area, including for non-circular shapes, extending through its center. In one embodiment, the differential distance 3001 can be less than about 5(d), less than about 2(d), less than about 1(d), less than about 0.5(d), less than about 0.2(d) or even less than about 0.1(d). It will be appreciated that the first differential distance 3001 may be within a range between any of the minimum and maximum values noted above. Controlling the differential distance between the adhesive strike area and the adhesive target area can facilitate improved grinding performance of the abrasive article.
[274] In one embodiment, a predetermined or controlled distribution 3000 may also include a second adhesive target area 3006 and a second adhesive tap area 3008. Similar to the first adhesive target and first adhesive tap area, the relationship between the second adhesive target area 3006 and second adhesive tap area 3008 may be defined by a second differential distance 3010 between the second adhesive target location 3007 and adhesive tap location 3009. Preferably, the second differential distance will be zero, but in reality , will likely be an acceptably small value. In one embodiment, the second differential distance 3010 may be zero (0), or an acceptable distance greater than zero, so that some distance may exist between locations 3007 and 3009. As illustrated, the second differential distance 3010 may be less than the length or width, or diameter of the second adhesive tapping area 3008 or the second adhesive targeting area 3006, allowing contact and even overlapping between portions of the second adhesive tapping area 3006 and the second adhesive tapping area 3006. Further, while not illustrated, it will be appreciated that the second differential distance 3010 may be zero (0), indicating the completely accurate positioning of the second adhesive strike area 3008 in the second adhesive target area 3006.
[275] Likewise, the predetermined distribution 3000 of adhesive areas can also include three or more adhesive target areas and three or more adhesive target areas, such as a third adhesive target area 3011 and a third adhesive strike area 3013, or a plurality from other target areas and strike areas as illustrated in FIG. 30.
[276] Still in relation to differential distance, like the first differential distance 3001, second differential distance 3010 or any other of the plurality of differential distances can be defined as a vector, having a magnitude (i.e. distance or length) and a direction (or degree of rotation). As illustrated in FIG. 30 , first differential distance 3001 and second differential distance 3010 have substantially similar or identical vectors. However, it is considered within the scope of the invention that the magnitude of the differential distances may be the same or different, including the direction or degree of rotation. For example, a first differential distance 3001 and a second differential distance 3010 can have the same magnitude (length), but they can have different meanings. Likewise, a first differential distance 3001 and a second differential distance 3010 may have the same direction or degree of rotation, but may have different magnitudes. In either case, as described in more detail below, vector measurement is just one of several methods available for determining the accuracy, precision, and variability of positioning an adhesive strike area relative to an adhesive target area.
[277] As mentioned earlier, regions of adhesive contact that are applied with a high level of control (ie, high accuracy, high precision, low variability) can facilitate improved grinding performance of the abrasive article. In one embodiment, a considerable number (greater than 50%) of the adhesive contact regions are applied “on target”, i.e., so that the magnitude and direction (or degree of rotation) of the differential distance between an adhesive strike area and an adhesive target area is zero or an acceptably small value. In one embodiment, the number of adhesive contact regions that are “on target” in a given sample area (such as 1 square meter) is at least about 55%, such as at least about 60%, at least about 65 %, at least about 68%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95% , at least about %, at least about 98%, at least about 99%, at least about 99.5%, or even about 100% (all measured values are within an acceptable range). In another embodiment, the accuracy and precision of application and positioning of adhesive contact areas (as defined by the differential distance between the adhesive target site and adhesive tapping site) can be measured as a percentage of adhesive contact regions that are “ on target” within one standard deviation. In one embodiment, the number of adhesive contact regions that are "on target" within one standard deviation is at least about 65%, at least about 68%, at least about 70%, at least about 75% , at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about 97%, at least about 98%, at least about 99%, at least about 99.5%, or even about 100% (all measured values are within an acceptable range). In another embodiment, at least a specific number or percentage of adhesive contact regions have a differential distance that is within one standard deviation of the mean differential distance of the sample population. In a specific embodiment, at least about 68% of the population (or alternatively a sample of the population) of adhesive contact regions are within one (1) standard deviation of the mean differential distance of the population or sample population. In another embodiment, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about %, at least about 95%, at least about 97 %, at least about 98%, at least about 99%, at least about 99.5%, or up to about 100% (all measured values are within an acceptable range) of adhesive contact regions if they are within one (1) standard deviation of the population mean differential distance or sample population. side spacing
[278] As mentioned earlier, adhesive contact regions can be spaced apart from each other by a lateral spacing, defined as the shortest distance between two adjacent adhesive contact regions, as measured along a lateral plane parallel to the lateral axis of the surface. support on which the adhesive contact regions are arranged. In one embodiment, *the lateral spacing between regions of adhesive contact may have a high level of control (ie, high accuracy, high precision, low variability). In one embodiment, a considerable number (greater than 50%) of the adhesive contact regions are applied “on the target”, so that the difference between the lateral spacing of adjacent adhesive contact areas is zero or an acceptably small value. In one embodiment, at least about 55%, such as at least about 60%, at least about 65%, at least about 68%, at least about 70%, at least about 75%, at least about at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about %, at least about 98%, at least about 99%, at least about 99 .5%, or even about 100% (all measured values are within an acceptable range) of the lateral spacing between adjacent adhesive contact regions is within 2.5 standard deviations of the mean. In another embodiment, at least about 65% of a sample population of the lateral clearance between adjacent adhesive contact areas is within 2.5 standard deviations of the mean, such as within 2.25 standard deviations, within 2.0 deviations standard, within 1.75 standard deviations, within 1.5 standard deviations, within 1.25 standard deviations, or within 1.0 standard deviations of the mean. It will be appreciated that alternative ranges can be constructed using the above combinations of percentages and deviations from the mean. Longitudinal Spacing
[279] As mentioned earlier, adhesive contact regions can be spaced apart from each other by a longitudinal spacing, defined as the shortest distance between two adjacent adhesive contact regions, as measured along a longitudinal plane parallel to the longitudinal axis of the surface. support on which the adhesive contact regions are arranged. In one embodiment, *the longitudinal spacing between regions of adhesive contact may have a high level of control (ie, high accuracy, high precision, low variability). In one embodiment, a considerable number (greater than 50%) of the adhesive contact regions are applied "on the target", so that the difference between the longitudinal spacing of adjacent adhesive contact areas is zero or an acceptably small value. In one embodiment, at least about 55%, such as at least about 60%, at least about 65%, at least about 68%, at least about 70%, at least about 75%, at least about at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about %, at least about 98%, at least about 99%, at least about 99 .5%, or even about 100% (all measured values are within an acceptable limit) of the longitudinal spacing between adjacent adhesive contact regions is within 2.5 standard deviations of the mean. In another embodiment, at least about 65% of a sample population of the longitudinal spacing between adjacent adhesive contact areas is within 2.5 standard deviations of the mean, such as within 2.25 standard deviations, within 2.0 deviations standard, within 1.75 standard deviations, within 1.5 standard deviations, within 1.25 standard deviations, or within 1.0 standard deviations of the mean. It will be appreciated that alternative ranges can be constructed using the above combinations of percentages and deviations from the mean.
[280] As mentioned above, at least one abrasive particle can be disposed in a region of adhesive contact. Similar to lateral spacing and longitudinal spacing between adjacent adhesive contact areas, a lateral spacing and longitudinal spacing may exist between at least one abrasive particle disposed in adjacent contact regions.
[281] In one embodiment, the lateral spacing between at least one abrasive particle may have a high level of control (ie, high accuracy, high precision, low variability). In one embodiment, a considerable number (greater than 50%) of the at least one abrasive particle is applied "on target" such that the difference between the lateral spacing of the at least one abrasive particle is zero or an acceptably small value. In one embodiment, at least about 55%, such as at least about 60%, at least about 65%, at least about 68%, at least about 70%, at least about 75%, at least about at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about %, at least about 98%, at least about 99%, at least about 99 .5%, or even about 100% (all measured values are within an acceptable limit) of the lateral spacing between regions of at least one adjacent abrasive particle is within 2.5 standard deviations of the mean. In another embodiment, at least about 65% of a sample population of the lateral clearance between at least one abrasive particle is within 2.5 standard deviations of the mean, such as within 2.25 standard deviations, within 2.0 deviations standard, within 1.75 standard deviations, within 1.5 standard deviations, within 1.25 standard deviations, or within 1.0 standard deviations of the mean. It will be appreciated that alternative ranges can be constructed using the above combinations of percentages and deviations from the mean.
[282] As mentioned earlier, at least one abrasive particle may be spaced apart from each other by a longitudinal space, defined as the shortest distance between at least one abrasive particle as measured along a longitudinal plane parallel to the longitudinal axis of the support. on which at least one abrasive particle is disposed. In one embodiment, the longitudinal spacing between at least one abrasive particle may have a high level of control (ie, high accuracy, high precision, low variability). In one embodiment, a considerable number or percentage (greater than 50%) of the at least one abrasive particle is applied "on target" such that the difference between the longitudinal spacing of the at least one abrasive particle is zero or an acceptably small value. In one embodiment, at least about 55%, such as at least about 60%, at least about 65%, at least about 68%, at least about 70%, at least about 75%, at least about at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about %, at least about 98%, at least about 99%, at least about 99 .5%, or even about 100% (all measured values are within an acceptable limit) of the longitudinal spacing between at least one abrasive particle is within 2.5 standard deviations of the mean. In another embodiment, at least about 65% of a sample population of the longitudinal spacing between adjacent adhesive contact areas is within 2.5 standard deviations of the mean, such as within 2.25 standard deviations, within 2.0 deviations standard, within 1.75 standard deviations, within 1.5 standard deviations, within 1.25 standard deviations, or within 1.0 standard deviations of the mean. It will be appreciated that alternative ranges can be constructed using the above combinations of percentages and deviations from the mean.
[283] High accuracy, high accuracy, low variability positioning of adhesive contact regions can directly contribute to improved abrasive performance of the abrasive article by directly improving accuracy, precision, less variability in the positioning of abrasive particles, as well as promoting removal of abrasive particles. efficient filings. It will be appreciated that several different measures of variability related to the location of the predetermined distribution of adhesive contact regions can be evaluated. These measures may include known analytical statistical measures including variability, standard deviation, interquartile range, range, mean difference, median absolute deviation, mean absolute deviation, distance standard deviation, coefficient of variation, quartile coefficient of dispersion, mean relative difference, variance , variance to mean ratio, or combinations thereof. For example, the variance to mean ratio may not be greater than 35%, as well as not greater than 30%, as well as not greater than 20%. Whichever tool is used, the objective for analysis is to measure the accuracy and precision of modalities that can be defined by locating a predetermined distribution of sticky hit areas relative to sticky target areas. As used herein, "accuracy" and "accuracy" are terms meaning the degree to which repeated measurements under unchanged conditions give the same results. As used here, “accuracy” and “exact” are terms meaning how close a measure is to its actual value, or target value.
[284] Abrasive particles can be arranged on an adhesive layer (e.g. brand layer, size layer, or other layer of the abrasive article) using a suitable deposition method such as electrostatic coating process, gravity drop coating, and all other abrasive particle deposition processes described herein. During electrostatic coating, the abrasive particles are applied in an electric field, allowing the particles to be advantageously aligned with their long axes normal to the main surface. In another embodiment, the abrasive particles are coated over the entire surface of the brand coating that has been applied to the backing. In another embodiment, the abrasive particles are applied to only a portion of the brand coating that has been applied to the backing. Abrasive particles will preferentially bind to areas coated with the branded resin.
[285] As mentioned earlier, the molded abrasive particles can be arranged in the region of adhesive contact, so that the footprint of the abrasive particle can be substantially equal to the region of discrete adhesive contact. Thus, the lateral and longitudinal spacing between adjacent adhesive contact regions and associated abrasive particles can be controlled.
[286] In one embodiment, the process of releasing molded abrasive particles to the abrasive article may include expelling the first molded abrasive particle from an opening within the alignment structure. Some exemplary methods suitable for expelling may include applying a force to the molded abrasive particle and removing it from the alignment structure. For example, in certain cases, the molded abrasive particle can be contained within the alignment structure and expelled from the alignment structure using gravity, electrostatic attraction, surface tension, differential pressure, mechanical force, magnetic force, agitation, vibration, and a combination of the following. same. In at least one embodiment, the molded abrasive particles may be contained in the alignment structure until a surface of the molded abrasive particles is contacted to a surface of the backing, which may include an adhesive material, and the molded abrasive particles are removed from the alignment structure. and released to a predetermined position on the support.
[287] In another aspect, the molded abrasive particles can be released to the surface of the abrasive article in a controlled manner by sliding the molded abrasive particles along a path. For example, in one embodiment, the molded abrasive particles can be released to a predetermined position on the support by sliding the abrasive particles down a path 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 support 1501 that can be translated under the funnel 1502. As illustrated, the molded abrasive particles 1503 may be released by a path 1504 connected to the funnel 1502 and released to a surface of the support 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 particular cases, path 1504 may be sized and molded to deliver a particular number of molded abrasive particles at a particular rate to facilitate formation of the predetermined distribution of molded abrasive particles. In addition, funnel 1502 and path 1504 are movable relative to support 1501 to facilitate formation of selected predetermined distributions of molded abrasive particles.
[288] 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 in the support 1501 to facilitate improved orientation of the molded abrasive particles.
[289] In yet another embodiment, the molded abrasive particles can be released to a predetermined position by expelling individual molded abrasive particles onto the support through a release process. In the release process, the molded abrasive particles can be accelerated and expelled from a container at a rate sufficient to retain the abrasive particles in a predetermined position on the support. For example, FIG. 16 includes an illustration of a system using a release process in which molded abrasive particles 1602 are expelled from a release unit 1603 which can accelerate the molded abrasive particles through a force (e.g. differential pressure) and release the particles molded abrasives 1602 of the release unit 1603 by a path 1605, which may be associated with the release unit 1603 and on a holder 1601 in a predetermined position. The support 1601 can be translated under the release 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 support 1601 and retain the abrasive particles. molded 1602 in their predetermined positions.
[290] FIG. 17A includes an illustration of an alternative release process according to one embodiment. Notably, the release process may include expelling a molded abrasive particle 1702 from a release unit 1703 over a gap 1708 to facilitate positioning of the molded abrasive particle 1702 on the support in a predetermined position. It will be appreciated that the force to expel, the orientation of the molded abrasive particle 1702 after being expelled, the orientation of the release 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 molded abrasive particles 1702 on the support 1701 relative to each other. 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.
[291] In particular cases, the molded abrasive particles 1702 can be formed to have a coating. The coating may be superimposed on at least part of the outer surface of the molded abrasive particles 1702. In a particular embodiment, the coating may include an organic material, and more particularly, a polymer, and even more particularly an adhesive material. The coating comprising an adhesive material can facilitate bonding of the molded abrasive particles 1702 to the support 1701.
[292] FIG. 17B includes an illustration of an alternative release process according to one embodiment. In particular, the embodiment of FIG. 17B details a particular release unit 1721 configured to direct molded abrasive particles 1702 into abrasive article 1701. In one embodiment, release unit 1721 may include a funnel 1723 configured to contain a plurality of molded abrasive particles 1702. In addition , the hopper 1723 may be configured to release one or more molded abrasive particles 1702 in a controlled manner to an acceleration zone 1725, wherein the molded abrasive particles 1702 are accelerated and directed towards the abrasive article 1701. In a particular embodiment, the unit release unit 1721 may include a system 1722 utilizing a pressurized fluid, such as a controlled gas flow or an air knife unit, to facilitate acceleration of molded abrasive particles 1702 in the acceleration zone 1725. As further illustrated, the release unit 1721 may utilize a 1726 blade configured to generally direct molded abrasive particles. 1702 toward abrasive article 1701. In one embodiment, the release unit and/or blade 1726 may be movable between a plurality of positions and configured to facilitate the release of individual molded abrasive particles to particular positions on the abrasive article. , thus facilitating the formation of the predetermined distribution of molded abrasive particles.
[293] FIG. 17A includes an illustration of an alternative release process according to one embodiment. The illustrated embodiment of FIG. 17C details an alternative release unit 1731 configured to direct molded abrasive particles 1702 into abrasive article 1701. In one embodiment, the release unit may include a hopper 1734 configured to contain a plurality of molded abrasive particles 1702 and release one or more plus molded abrasive particles 1702 in a controlled manner to an acceleration zone 1725, wherein the molded abrasive particles 1702 are accelerated and directed towards the abrasive article 1701. In a particular embodiment, the release unit 1731 may include a rod 1732 that can be rotated around an axis and configured to rotate a pallet 1733 at a particular rate of revolutions. The molded abrasive particles 1702 may be released from the hopper 1734 to the pallet 1733 and accelerated in a particular from the pallet 1733 towards the abrasive article 1701. As will be appreciated, the rate of rotation of the rod 1732 may be controlled to control the predetermined distribution of the molded abrasive particles 1702 in the abrasive article 1701. In addition, the release unit 1731 may be movable between a plurality of positions and configured to facilitate the release of individual molded abrasive particles to particular positions on the abrasive article, thus facilitating the formation of the distribution. predetermined amount of molded abrasive particles.
[294] According to another embodiment, the process for releasing the molded abrasive particles in a predetermined position in the abrasive article and forming an abrasive article having a plurality of molded abrasive particles in a predetermined distribution with respect to each other may include the application 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 molded abrasive particles 1802 to a first conveying belt 1803.
[295] As illustrated, the molded abrasive particles 1802 can be translated along the belt 1803 to an alignment structure 1805 configured to contain each of the molded abrasive particles in a region of discrete contact. In one embodiment, molded abrasive particles 1802 may be transferred from belt 1803 to alignment frame 1805 via transfer roller 1804. In particular cases, transfer roller 1804 may utilize a magnet to facilitate controlled removal of the molded abrasive particles 1802 from belt 1803 to alignment frame 1805. Providing a coating comprising a magnetic material can facilitate the use of transfer roller 1804 with magnetic capabilities.
[296] The molded abrasive particles 1802 can be released from the alignment frame 1805 to a predetermined position on the support 1807. As illustrated, the support 1807 can be translated on a separate belt and from the alignment structure 1805 and contact the structure aligner to facilitate transfer of molded abrasive particles 1802 from alignment frame 1805 to support 1807.
[297] In yet another embodiment, the process for releasing the molded abrasive particles in a predetermined position in the abrasive article and forming an abrasive article having a plurality of molded abrasive particles in a predetermined distribution relative to each other may include the use of a magnet array. 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 may include an array of magnets 1905, which includes a plurality of magnets arranged in a predetermined distribution relative to the support. 1906. In one embodiment, the array of magnets 1905 can be arranged in a predetermined distribution that can be substantially equal to the predetermined distribution of abrasive particles molded onto the support.
[298] In addition, each of the magnets of the array of magnets 1905 can be movable between a first position and a second position, which can facilitate control of the shape of the array of magnets 1905 and further facilitate control of the predetermined distribution of the magnets and of the predetermined distribution of the molded abrasive particles 1902 on the support. In one embodiment, the matrix of magnets 1905 may be altered to facilitate control of one or more predetermined orientation characteristics of the molded abrasive particles 1902 on the abrasive article.
[299] In addition, each of the magnets in the magnet array 1905 may be operable between a first state and a second state, wherein a first state may be associated with a first magnetic force (e.g., an on state) and the second state can be associated with a second magnetic force (for example, an off state). Controlling the state of each of the magnets can facilitate the selective release of molded abrasive particles to particular 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 onto the abrasive article.
[300] FIG. 20A includes an image of a tool used to form an abrasive article in accordance with an embodiment. Notably, tool 2051 may include a substrate, which may be an alignment structure having apertures 2052 defining discrete contact regions configured to contain the molded abrasive particles and aid in the transfer and positioning of 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 in the alignment structure. In particular, the apertures 2052 may be arranged in one or more groups 2053 having a predetermined distribution relative to one another, which may facilitate positioning of the abrasive particles molded into the abrasive article in a predetermined distribution defined by one or more predetermined orientation features. . In particular, tool 2051 may include a group 2053 defined by a line of apertures 2052. Alternatively, tool 2051 may have a group 2055 defined by all apertures 2052 illustrated, since each of the apertures has substantially the same orientation of predetermined rotation relative to the substrate.
[301] FIG. 20B includes an image of a tool used to form an abrasive article in accordance with an embodiment. Notably, as illustrated in FIG. 20B, molded abrasive particles 2001 are contained in tool 2051 of FIG. 20A, and more particularly, the tool 2051 may be an alignment structure, wherein each of the openings 2052 contains a single molded abrasive particle 2001. In particular, the molded abrasive particles 2001 may have a two-dimensional triangular shape, as seen from above. down. In addition, molded abrasive particles 2001 can be positioned in openings 2052 such that a tip of the molded abrasive particle extends through openings 2052 to the opposite side of tool 2051. Apertures 2052 can be sized and shaped so that substantially complement at least a portion (if not all) of the contour of the molded abrasive particles 2001 and retain them in a position defined by one or more predetermined orientation features in the tool 2051, which will facilitate the transfer of the molded abrasive particles 2001 from the tool 2051 to a support while maintaining the predetermined orientation characteristics. As illustrated, molded abrasive particles 2001 may be contained within openings 2052 such that at least a portion of the surfaces of molded abrasive particles 2001 extend above the surface of the tool, 2051, which can facilitate transfer of molded abrasive particles 2001 from 2052 openings for a support.
[302] As illustrated, the molded abrasive particles 2001 may define a group 2002. The group 2002 may have a predetermined distribution of molded abrasive particles 2001, wherein each of the molded abrasive particles has substantially the same predetermined rotation orientation. In addition, each of the molded abrasive particles 2001 has substantially the same predetermined vertical orientation and predetermined tip height orientation. In addition, group 2002 includes several lines (e.g. 2005, 2006, and 2007) oriented in a plane parallel to a lateral axis 2081 of tool 2051. Also, within group 2002, smaller groups (e.g. 2012, 2013 and 2014) of the molded abrasive particles 2001 may exist, 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 inclined 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 a 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, which can be considered a triangular pattern 2011. In addition, the group 2002 can be arranged so that the boundary of the group defines a two-dimensional macro shape of a quadrilateral. (see dotted line).
[303] FIG. 20C includes an image of a portion of an abrasive article in accordance with an embodiment. In particular, the abrasive article 2060 includes a holder 2061 and a plurality of molded abrasive particles 2001, which have been transferred to the openings 2052 of the tool 2051 of the holder 2061. As illustrated, the predetermined distribution of the openings 2052 of the tool may correspond to the predetermined distribution. of the molded abrasive particles 2001 of the group 2062 contained in the support 2061. The predetermined distribution of molded abrasive particles 2001 can be defined by one or more predetermined orientation characteristics. Furthermore, as evidence from FIG. 20C, the molded abrasive particles 2001 can be arranged into groups that substantially correspond to the molded abrasive particle groups of FIG. 20B, when molded abrasive particles 2001 were contained in tool 2051.FIGs.
[304] For certain abrasive articles herein, at least about 75% of the plurality of abrasive particles molded into the abrasive article may have a predetermined orientation relative to the support, including, for example, a lateral orientation, as described in the embodiments herein. Further, the percentage can be higher, 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 abrasive particles molded herein, wherein no more than about 99% of the total content of the abrasive particles molded have a predetermined lateral orientation. It will be appreciated that reference herein to percentages of abrasive particles molded in a predetermined orientation are based on a statistically relevant number of abrasive particles molded and a random sampling of the total content of abrasive particles molded.
[305] To determine the percentage of particles in a predetermined orientation, a 2D microfocus X-ray image of the abrasive article is obtained using a CT scanning machine performed under the conditions in Table 1 below. The 2D X-ray image was performed using Quality Assurance software. The specimen mounting fixture uses a plastic frame with a 4” x 4” window and a 00.5” solid metal rod, the top half of which is flattened with two screws to secure the frame. Prior to imaging, a sample was cut along one side of the frame where the screw heads faced the direction of incidence of the x-rays (FIG. 1(b)). Then five regions within the 4”x4” window area are selected for imaging at 120kV/80μA. Each 2D projection was recorded with the X-ray compensation/gain corrections and a magnification.

[306] The image is then imported and analyzed using the ImageJ program, where different orientations are assigned values according to Table 2 below.

[307] Three calculations are then performed as given below in Table 3. After performing the calculations, the percentage of abrasive particles molded in a lateral orientation per square centimeter can be derived. Notably, a particle having a lateral orientation is a particle having a vertical orientation, as defined by the angle between a major surface of the molded abrasive particle and the surface of the support, where the angle is 45 degrees or greater. In this sense, a molded abrasive particle having an angle of 45 degrees or greater is considered to remain in one or having a lateral orientation, a molded abrasive particle having an angle of 45 degrees is considered to remain inclined, and a molded abrasive particle having a smaller angle. that 45 degrees is considered to have a downward orientation.
- These are all normalized 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.
[308] 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 the molded abrasive particles in 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 having a coating density of molded abrasive particles of no greater than about 70 particles/cm 2 . In other cases, the density of the molded abrasive particle per square centimeter of the abrasive article may not be more than 65 particles/cm2, such as not more than about 60 particles/cm2, 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-coated coated abrasive using the abrasive particle molded herein can be at least about 5 particles/cm 2 , or even at least about 10 particles/cm 2 . It will be appreciated that the density of the molded abrasive particles per square centimeter of the abrasive article can be within a range between any of the above minimum and maximum values.
[309] In certain cases, the abrasive article may have an open coating density of no more than about 50% of abrasive particles covering the outer abrasive surface of the article. In other embodiments, the coating percentage of the abrasive particles in relation to the total area of the abrasive surface may be not more than about 40%, not more than about 30%, not more than about 25%, or even not more. to 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 15%. of 20%, at least about 25%, at least about 30%, at least about 35%, or even at least about 40%. It will be appreciated that the percentage coverage of the molded abrasive particles to the total area of the abrasive surface may be within a range between any of the above minimum and maximum values.
[310] Some abrasive articles may have a particular 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 kg/ream (148 grams/m 2 ), at least about 15 kg/ream, at least about 20 lbs/ream. ream, such as 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 of not more than about 60 lbs/ream (890 grams/m 2 ), such as not more than about 50 lbs/ream, or even no more than about 45 lbs/ream. It will be appreciated that the abrasive articles of the embodiments herein may utilize a standard weight of molded abrasive particle within a range between any of the above minimum and maximum values.
[311] Applicants have noted that certain abrasive article embodiments in accordance with the teachings herein exhibit a beneficial amount of mark coating material (also known as the "mark weight") compared to the amount of abrasive particles (also known as as “grain weight”) arranged on the support. In one embodiment, the ratio of brand weight to grain weight may be constant or variable. In one embodiment, the ratio of brand weight to grain weight may be in a range of 1:40 to 1:1, such as 1:40 to 1:1.3, such as 1:25 to 1:2, such as 1:20 to 1:5. In a particular embodiment, the ratio of brand weight to grain weight is in a range of 1:20 to 1:9.
[312] In one embodiment, the mark weight may be at least 0.1 pound per ream, such as at least 0.2 pound per ream, at least 0.3 pound per ream, at least 0.4 pound per ream , at least 0.5 pound per ream, at least 0.6 pound per ream, at least 0.7 pound per ream, at least 0.8 pound per ream, at least 0.9 pound per ream, or at least 1 .0 pounds per ream. In one embodiment, the mark weight may be not more than 40 pounds per ream, such as not more than 35 pounds per ream, not more than 30 pounds per ream, not more than 28 pounds per ream, not more than 25 pounds per ream , not more than 20 pounds per ream, or not more than 15 pounds per ream. It will be appreciated that the tag weight can be in a range of any of the aforementioned maximum and minimum values. In a specific embodiment, the brand weight can be in a range from 0.5 lbs per ream to 20 lbs per ream, such as 0.6 lbs per ream to 15 lbs per ream, such as 0.7 lbs per ream to 10 lbs. per ream. In one particular embodiment, the mark weight is in a range of 0.5 lbs per ream to 5 lbs per ream.
[313] In certain cases, abrasive articles may be used on particular 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
[314] A 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. Returning briefly to FIG. 3B, the molded abrasive particle 102 has a forward oriented grinding direction 385 such that the main 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 the 385 grinding direction. 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 workpiece. For each test, 10 repeat samples were run and the results analyzed and averaged. The change in furrow cross-sectional area from beginning to end of zero length was measured to determine grain wear.
[315] A second set of samples (Sample B) is 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 backing with respect to the grinding direction. Returning 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 major 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 forming a particular 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 grinding direction. 385, so that the angle between bisector axis 373 and grinding direction 385 is essentially 0 degrees. In this regard, the lateral orientation of the molded abrasive particle 103 can facilitate initial contact of the lateral surface 372 with a workpiece before any of the other surfaces of the molded abrasive particle 103.
[316] 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. FIG. 21 illustrates the normal force required to grind the workpiece 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 (e.g., front orientation and side orientation) of the molded abrasive particles relative to a desired grinding direction to facilitate improved grinding performance. In particular, as illustrated in FIG. 21, a combination of orientations of the molded abrasive particles relative to a grinding direction can facilitate lower normal forces over the life of the abrasive article, improved grinding efficiency, and longer life of the abrasive article. Example 2
[317] Five samples are analyzed to compare the orientation of the molded abrasive particles. Three samples (Samples S1, S2 and S3) are prepared according to one embodiment. Sample S1 was prepared using the contact model and process. The abrasive particles were arranged in and held in place by a template having a desired predetermined abrasive particle distribution. A backing substrate having a continuous mark coating was contacted with the abrasive particles so that the abrasive particles are adhered to the mark coating of the desired predetermined abrasive particle distribution. Samples S2 and S3 were prepared using a continuous electrostatic projection process. The molded abrasive particles were projected onto a supporting substrate having a discontinuous brand coating. Brand coating was previously applied as a predetermined distribution of an unshaded pattern of discrete circular adhesive contact areas (also called here as brand coating “dots”). The pattern was a phyllotactic pattern in accordance with formula 1.1, described here, (also called a pineapple pattern). The brand coating for S2 and S3 comprised 17,000 circular adhesive contact regions distributed along the surface of the backing material. The mark weight for the S2 and S3 abrasive sample was approximately 0.84 pounds per ream. The grain weight for samples S2 and S3 was approximately 17.7 pounds per ream. An image of sample S2 and S3 is shown in FIG. 37. Image analysis was performed to determine various spatial properties about the pattern. The average size of the adhesive contact areas (ie the brand coating spots) was approximately 1,097 mm2. The adjacent spacing between the brand coating points was approximately 2.238 mm. The ratio of area covered with brand coating to area not covered with brand coating was 0.1763 (i.e. approximately 17.6% of the surface of the support was covered with brand coating).
[318] FIG. 22 includes an image of a portion of Sample S1 using a 2D microfocus X-ray through a CT scanner under the conditions described herein. 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 S1 included commercially available molded grains from 3M as Cubitron II. Inventive samples S2 and S3 included next generation molded abrasive particles available from Saint-Gobain Abrasives. FIG. 23 includes an image of a portion of Sample CS2 using a 2D microfocus X-ray through a CT scanner under the conditions described herein. Each of the samples is evaluated according to the conditions described herein to evaluate the orientation of the molded abrasive particles through x-ray analysis.
[319] FIG. 24 includes a graph of grains/cm2 and total number of grains/cm2 for each of the comparative samples (Sample CS1 and Sample CS2) and the inventive samples (Samples S1, S2 and S3). It should be noted that sample CS1 and CS2 are different tests of the same belt. The grinding machine broke after CS1 was tested and had to be repaired and recalibrated. The comparative sample was rerun and reported as CS2. Values for CS1 are included because they still appear to be instructive; however, the most appropriate comparison is between the values for CS2 and S1, S2, and S3, which were all tested under the same grinding conditions. 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 (i.e. 100% of molded abrasive particles were vertical with “up” grinding tips), while only 72 percent of the total number of molded abrasive particles of CS2 had a lateral orientation (i.e., only 72% of molded abrasive particles were in a vertical position with the grinding tips facing up). In addition, 100% of the molded abrasive particles from sample S1 were in a controlled rotation alignment. Inventive samples S2 and S3 also show a higher number of abrasive particles molded in a vertical position with grinding tips upwards compared to C2. As evidenced, conventional state of the art (C2) abrasive articles using molded abrasive particles have not achieved the orientation accuracy of the abrasive articles described herein. Example 3
[320] Another inventive coated abrasive embodiment was prepared in a similar manner to S2 and S3. The brand coating was applied according to a discontinuous distribution, not shaded following the pineapple pattern; however, the total number of discrete adhesive contact regions was 10,000. The brand weight was approximately 1.6 lb/rm and the grain weight was approximately 19.2 lb/rm. Molded abrasive particles (Cubitron II), as described above in Example 2, were then applied to the mark coating contact regions. The inventive coated abrasive had an abrasive particle density (abrasive grain density) of 19 grains/cm 2 . X-ray analysis was conducted, similarly to Example 2 above, to evaluate the orientation of molded abrasive particles of the inventive embodiment and a conventional comparative coated abrasive product. FIG. 35A is exemplary of the comparative product. FIG. 35. B is an example of the inventive method. A graphical representation of the orientation analysis results is shown by FIG. 36. The inventive embodiment had a surprisingly improved amount of abrasive grains, 89%, in an upright position, whereas the comparative example only had 72% of the abrasive grains in an upright position.
[321] The present application represents a starting point of the state of the art. While the industry has recognized that molded abrasive particles can be formed through processes such as molding and screen printing, the processes and modalities here are distinct from these processes. Notably, the embodiments herein include a combination of process characteristics, facilitating the formation of molded abrasive particle batches having particular characteristics. In addition, the abrasive articles of the embodiments herein may have a particular combination of characteristics distinct from other abrasive articles, including, but not limited to, a predetermined distribution of molded abrasive particles, use of a combination of characteristics of predetermined orientation, groups, rows, columns , companies, macro shapes, channel regions, aspects of molded abrasive particles, including but not limited to proportion, composition, additives, two-dimensional shape, three-dimensional shape, height difference, height profile difference, flash percentage, height, concavity , specific milling energy half-life change, and a combination thereof. And indeed, the abrasive articles of the embodiments here can facilitate improved grinding performance. While the industry has generally recognized that certain abrasive articles can be formed by having an order for certain abrasive units, these abrasive units are traditionally limited to abrasive composites that can be easily molded through a binder system, or using traditional abrasive grains or superabrasives. The industry has not contemplated or developed systems for forming abrasive articles from molded abrasive particles having predetermined orientation characteristics as described herein. Manipulating shaped abrasive particles in order to effectively control predetermined orientation characteristics is a non-trivial issue, exponentially improving particle control in three-dimensional space, which is not disclosed or suggested in the art. Reference herein to the term "the same" will be understood to mean substantially the same.
[322] Item 1. A coated abrasive article, comprising: a backing; an adhesive layer disposed in a discontinuous distribution on at least a portion of the backing, wherein the discontinuous distribution comprises a plurality of adhesive contact regions having at least one of a lateral spacing or a longitudinal spacing between each of the adhesive contact regions; and at least one abrasive particle disposed in most regions of adhesive contact, the abrasive particles having a tip, and having at least one of a lateral spacing or a longitudinal spacing between each of the abrasive particles, and wherein at least 65% of the at least one of a lateral spacing and a longitudinal spacing between the tips of the abrasive particles is within 2.5 standard deviations of the mean.
[323] Item 2. The coated abrasive of item 1, where at least 55% of the abrasive particle tips are vertical.
[324] Item 3. The coated abrasive article of item 1, where the variance to mean ratio is not more than 35%.
[325] Item 4. The coated abrasive of item 1, wherein the discontinuous distribution is an unshaded pattern, a controlled non-uniform pattern, a semi-random pattern, a random pattern, a regular pattern, an alternating pattern, or combinations thereof .
[326] Item 5. The coated abrasive particle of item 2, wherein the at least one abrasive particle disposed in most adhesive contact regions comprises a molded first abrasive particle coupled to a first adhesive contact region in a first position; and a second molded abrasive particle coupled to a second adhesive contact region; wherein the first molded abrasive particle and the second molded abrasive particle are arranged in an unshaded controlled arrangement with respect to each other, the unshaded controlled arrangement comprising at least two of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation.
[327] Item 6. The coated abrasive of item 1, wherein at least 65% of at least one of the lateral spacing and longitudinal spacing between adhesive contact regions is within 2.5 standard deviations of the mean.
[328] Item 7. The coated abrasive of item 1, wherein the adhesive layer has a substantially uniform thickness less than the height d50 of at least one abrasive particle.
[329] Item 8. The coated abrasive of item 8, wherein the width of each of the discrete adhesive contact regions is substantially equal to the d50 width of at least one abrasive particle.
[330] Item 9. The coated abrasive article of item 1, further comprising: a second adhesive layer disposed in a discontinuous distribution over the first adhesive layer, wherein the second adhesive layer covers a smaller surface area than the first adhesive layer and does not extend beyond the first adhesive layer.
[331] Item 10. The coated abrasive article of item 1, 5 or 9, wherein at least one abrasive particle is disposed in each region of adhesive contact.
[332] Item 11. A method for preparing a coated abrasive article comprising: applying an adhesive composition to a backing using a continuous screen printing process, wherein the adhesive composition is applied as a discontinuous distribution comprising a plurality of adhesive contact regions having at least one of a lateral spacing and a longitudinal spacing between each of the adhesive contact regions, disposing at least one abrasive particle in each of the discrete adhesive contact regions, the abrasive particles having a tip, and having at least one a lateral spacing or a longitudinal spacing between each of the abrasive particles and curing the binder composition.
[333] Item 12. The method of item 11, wherein at least 65% of at least one of a lateral spacing and a longitudinal spacing between the tips of the adhesive particle is within 2.5 standard deviations of the mean.
[334] Item 13. A coated abrasive article comprising: a backing; a branded coating disposed on the backing in a predetermined distribution; and a plurality of molded abrasive particles, wherein the predetermined distribution comprises a discontinuous pattern of a plurality of discrete contact regions, wherein at least one molded abrasive particle of the plurality of molded abrasive particles is disposed in each of the discrete contact regions, and wherein the ratio of brand weight to grain weight is in a range of 1:40 to 1:1.
[335] Item 14. A coated abrasive article comprising: a backing; a branded coating disposed on the backing in a predetermined distribution; and a plurality of molded abrasive particles, wherein the predetermined distribution comprises a discontinuous pattern of a plurality of discrete contact regions, wherein at least one molded abrasive particle of the plurality of molded abrasive particles is disposed in each of the discrete contact regions, and wherein the number of discrete contact regions is in a range from 1000 to 40,000, and wherein more than 50% of the molded abrasive particles are in a vertical position.
[336] Item 15. The coated abrasive article of item 14, wherein the discrete contact regions have adjacent spacing in a range of 0.5 to 3 times the average length of the molded abrasive particle.
[337] Item 16. The coated abrasive article of item 14, wherein the discrete contact regions are adjacently spaced in a range of 0.2 mm to 2.2 mm.
[338] Item 17. The coated abrasive article of item 14, wherein the discontinuous brand coating covers at least 1% to 95% of the backing.
[339] Item 18. The coated abrasive article of item 14, wherein the discrete contact regions have a mean diameter in a range of 0.3 mm to 20 mm.
[340] Item 19. The coated abrasive article of item 14, in which 4% to 85% of the backing is uncovered.
[341] Item 20. The abrasive article of item 14, wherein more than 75% of the molded abrasive particles are in a vertical position.
[342] The above disclosed matter is considered illustrative, not restrictive, and the appended items are intended to cover all such modifications, improvements, and other embodiments, which are within the true scope of the present invention. Thus, to the fullest extent permitted by law, the scope of the present invention shall be determined by the broadest permissible interpretation of the following items and their equivalents, and shall not be restricted or limited by the description detailed above.
[343] 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 items. Furthermore, in the foregoing Detailed Description of the Drawings, various features may be grouped or described in a single embodiment, for the purpose of simplifying disclosure. This disclosure is not to be interpreted as reflecting an intention that the modalities in the items require more features than are expressly recited in each item. Rather, as the following items reflect, inventive matter may be directed to less of all the features of any of the disclosed embodiments. Thus, the following items are incorporated into the Detailed Description of the Drawings, with each independent item defining materials in the items separately.

权利要求:
Claims (14)
[0001]
1. Coated abrasive article (100), characterized in that it comprises: a support (101); an adhesive layer (151) arranged in a discontinuous distribution on at least a portion of the support (101), wherein the discontinuous distribution comprises a plurality of adhesive contact region (721) having at least one of a lateral spacing or a longitudinal spacing between each of the adhesive contact region (721); and at least one abrasive particle disposed in most of the adhesive contact region (721), the abrasive particles having a tip, and having at least one of a lateral spacing or a longitudinal spacing between each of the abrasive particles (102, 103, 104, 105, 106), and wherein at least 65% of at least one of a lateral spacing and a longitudinal spacing between the tips of the abrasive particles (102, 103, 104, 105, 106), is within 2.5 standard deviations of the medium, wherein at least one abrasive particle disposed in the majority of the adhesive contact region (721) comprises a molded first abrasive particle coupled to a first adhesive contact region (721) in a first position; and a second molded abrasive particle coupled to a second adhesive contact region (721); wherein the first molded abrasive particle and the second molded abrasive particle are arranged in an unshaded controlled arrangement with respect to each other, the unshaded controlled arrangement comprising at least two of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation.
[0002]
2. Coated abrasive, according to claim 1, characterized in that at least 55% of the abrasive particle tips are vertical.
[0003]
3. Coated abrasive article (100), according to claim 1, characterized in that the variance to average ratio is not more than 35%.
[0004]
4. Coated abrasive according to claim 1, characterized in that the discontinuous distribution is an unshaded pattern, a controlled non-uniform pattern, a semi-random pattern, a random pattern, a regular pattern, an alternating pattern, or combinations of the same.
[0005]
5. Coated abrasive according to claim 1, characterized in that at least 65% of at least one of the lateral spacing and the longitudinal spacing between the adhesive contact region (721) is within 2.5 standard deviations of the average.
[0006]
6. Coated abrasive according to claim 1, characterized in that the adhesive layer (151) has a substantially uniform thickness that is less than the height d50 of at least one abrasive particle.
[0007]
7. Coated abrasive according to claim 6, characterized in that the width of each of the discrete adhesive contact region (721) is substantially equal to the d50 width of at least one abrasive particle.
[0008]
8. Coated abrasive article (100) according to claim 1, characterized in that it further comprises: a second adhesive layer (151) arranged in a discontinuous distribution over the first adhesive layer (151), wherein the second layer adhesive (151) covers a smaller surface area than the first adhesive layer (151) and does not extend beyond the first adhesive layer (151).
[0009]
9. Coated abrasive article (100), according to claim 1, characterized in that at least one abrasive particle is arranged in each region of adhesive contact (721).
[0010]
10. A method for preparing a coated abrasive article (100), characterized in that it comprises: applying an adhesive composition to a support (101) using a continuous screen printing process, wherein the adhesive composition is applied as a discontinuous distribution comprising a plurality of discrete adhesive contact region (721) having at least one of a lateral spacing and a longitudinal spacing between each of the adhesive contact region (721), disposing at least one abrasive particle in each of the discrete adhesive contact region (721), the abrasive particles having a tip, and having at least one of a lateral spacing or a longitudinal spacing between each of the abrasive particles (102, 103, 104, 105, 106) and curing the binder composition.
[0011]
11. Method according to claim 10, characterized in that at least 65% of at least one of a lateral spacing and a longitudinal spacing between the tips of the adhesive particle is within 2.5 standard deviations of the mean.
[0012]
12. Coated abrasive article (100), characterized in that it comprises: a support (101); a branded coating disposed on the support (101) in a predetermined distribution; and a plurality of molded abrasive particles (102, 103, 104, 105, 106), wherein the predetermined distribution comprises a discontinuous pattern of a plurality of discrete contact region (721), wherein at least one molded abrasive particle of the plurality of molded abrasive particles (102, 103, 104, 105, 106) are disposed in each of the discrete contact region (721), and wherein the ratio of brand weight to grain weight is in a range of 1:40 at 1:1.
[0013]
13. Coated abrasive article (100), characterized in that it comprises: a support (101); a branded coating disposed on the support (101) in a predetermined distribution; and a plurality of molded abrasive particles (102, 103, 104, 105, 106), wherein the predetermined distribution comprises a discontinuous pattern of a plurality of discrete contact regions (721), wherein at least one molded abrasive particle of the plurality of molded abrasive particles (102, 103, 104, 105, 106) is arranged in each of the discrete contact region (721), and wherein the number of discrete contact region (721) is in a range of 1000 to 40,000, and in that more than 50% of the molded abrasive particles (102, 103, 104, 105, 106) are in a vertical position.
[0014]
14. Coated abrasive article (100) according to claim 13, characterized in that the discrete contact region (721) has adjacent spacing in a range of 0.5 to 3 times the average length of the molded abrasive particle .

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法律状态:
2018-02-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-11-05| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-08-03| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2021-11-30| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2022-01-18| 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 31/03/2014, 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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US201361806741P| true| 2013-03-29|2013-03-29|

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US61/806,741|2013-03-29|

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PCT/US2014/032397|WO2014161001A1|2013-03-29|2014-03-31|Abrasive particles having particular shapes and methods of forming such particles|

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