Abrasive article and method of forming same

Abstract

The invention relates to an abrasive article and a method of forming the same. The present disclosure provides a coated abrasive article that includes a substrate and a plurality of abrasive particles overlying the substrate, and the plurality of abrasive particles includes tapered abrasive particles having a standard deviation of taper fraction of at least 0.025 and not greater than 0.090.

Description

[0001] This application is a divisional application of the invention patent application with application date of December 23, 2020, application number 202080090657.5, and invention name “Abrasive products and methods for forming the same”. Technical Field

[0002] The following relates to coated abrasive articles, and in particular to coated abrasive articles including conical abrasive particles. Background Art

[0003] Abrasive articles containing abrasive particles can be used for various material removal operations, including grinding, finishing, polishing, etc. Depending on the type of abrasive, such abrasive particles can be used to shape or grind various materials in the manufacture of goods. To date, certain types of abrasive particles have been formulated that have specific geometric shapes, such as triangular abrasive particles and abrasive articles containing such objects. See, for example, U.S. Patents Nos. 5,201,916, 5,366,523, and 5,984,988.

[0004] Previously, the three basic technologies that have been used to produce abrasive particles with specific shapes are fusion, sintering and chemical ceramics. In the fusion process, the abrasive particles can be formed by cooling rollers with or without engravings on the surface, molds for pouring molten materials, or heat dissipation materials immersed in alumina melts. See, for example, U.S. Patent No. 3,377,660. In the sintering process, the abrasive particles can be formed by refractory powders with a particle size of up to 10 microns in diameter. A binder can be added to the powder together with a lubricant and a suitable solvent to form a mixture that can be formed into sheets or rods with various lengths and diameters. See, for example, U.S. Patent No. 3,079,243. Chemical ceramic technology involves converting a colloidal dispersion or hydrosol (sometimes called a sol) into a gel or any other physical state that limits the mobility of the components, drying and firing to obtain a ceramic material. See, for example, U.S. Patents No. 4,744,802 and No. 4,848,041. Additional relevant disclosures regarding abrasive particles and related methods of formation, as well as abrasive articles incorporating such particles, are available at http: / / www.abel-ip.com / publications / .

[0005] The industry continues to demand improved abrasives and abrasive articles. Summary of the invention

[0006] According to one aspect, a coated abrasive article includes a substrate and a plurality of abrasive particles overlying the substrate, wherein the plurality of abrasive particles include tapered abrasive particles having a taper fraction standard deviation of at least 0.025 and no greater than 0.090.

[0007] According to another aspect, a coated abrasive article includes a substrate and a plurality of abrasive particles, each particle of the abrasive particles of the plurality of abrasive particles having a body including a length, a width, and a thickness, wherein the plurality of abrasive particles have an average first-stage batch aspect ratio [B(length / width)] in a range of at least 2.1 to no more than 4.7, and a first-stage batch aspect ratio standard deviation [STDEV-B(length / width)] of at least 0.05 and no more than 0.55. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

[0009] Figure 1 Included is an illustration of a system for forming tapered abrasive particles according to one embodiment.

[0010] Figure 2A Includes an image of multiple conical abrasive particles.

[0011] Figure 2B An image of a conical abrasive particle in a plane defined by the length and width of the body is included as viewed from a first perspective.

[0012] Figure 2C An image of the conical abrasive particles in a plane defined by the length and width of the body is included as viewed from a second viewing angle opposite the first viewing angle.

[0013] Figure 2D An image of a conical abrasive particle in a plane defined by the length and thickness of the body is included as viewed from a first perspective.

[0014] Figure 2E An image of the tapered abrasive particles in a plane defined by the length and thickness of the body is included as viewed from a second viewing angle opposite the first viewing angle.

[0015] Figure 2F An illustration of a portion of a base region of a conical abrasive particle according to one embodiment is included.

[0016] Figure 2G A perspective view of a portion of a base region including conical abrasive particles according to one embodiment.

[0017] Figure 3 Included is a cross-sectional illustration of a portion of a coated abrasive article according to one embodiment.

[0018] Figure 4 Included are images of various hook-shaped abrasive particles.

[0019] Figure 5 Included is a top view illustration of a portion of a coated abrasive article according to one embodiment.

[0020] Figure 6 Included is a top view illustration of a portion of a coated abrasive article according to one embodiment.

[0021] Figure 7 Included is a top view illustration of a portion of a coated abrasive article according to one embodiment.

[0022] Figure 8 Included is a side view illustration of abrasive particles on a backing according to one embodiment.

[0023] Fig. 9 Included are graphs of the median force per total area removed from a workpiece for the abrasive particles of Example 1 and conventional extruded particles.

[0024] Fig.10 Included is a graphic representation of a best fit ellipse on a conical abrasive particle according to one embodiment.

[0025] Fig.11 Included is an illustration of an outline of a conical abrasive particle including a skeleton formed by image processing software according to one embodiment.

[0026] Fig.12 Included are graphs of distance to the skeleton versus distance along the skeleton for calculating the taper fraction and elongation fraction of the abrasive particles.

[0027] Fig.13 Included is a black and white image of the outline of a conical abrasive particle according to an embodiment used to calculate solidity.

[0028] Fig.14A Included are images of shaped abrasive particles according to one embodiment.

[0029] Fig. 14B Includes images of shaped abrasive particles.

[0030] Fig.15 Included is a graphical representation of a graph of grinding energy versus cumulative material removed.

[0031] Fig.16 Included is a graph of specific grinding energy versus cumulative material removed for a coated abrasive article according to one embodiment and a conventional coated abrasive article. DETAILED DESCRIPTION

[0032] The following description in conjunction with the accompanying drawings is provided to help understand the teachings disclosed herein. The following discussion will focus on the specific implementation and embodiments of the teachings. This emphasis is provided to help describe the teachings and should not be interpreted as limiting the scope or applicability of the teachings. However, other teachings may certainly be used in this application.

[0033] As used herein, the terms "comprises / comprising / includes / including", "has / having" or any other variations thereof are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited to only those features but may include other features not expressly listed or inherent to such method, article, or apparatus. In addition, unless expressly stated to the contrary, "or" refers to an inclusive "or" and not an exclusive "or". For example, any of the following may satisfy condition A or B: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

[0034] Moreover, "a" or "an" is used to describe the elements and components described herein. This is done only for convenience and to give a general sense of the scope of the invention. Unless it is obvious that it is otherwise intended, this description should be understood to include one or at least one, and the singular also includes the plural, or vice versa. For example, when a single embodiment is described herein, more than one embodiment can be used to replace the single embodiment. Similarly, where more than one embodiment is described herein, a single embodiment can replace more than one embodiment.

[0035] Unless otherwise defined, all technical terms and scientific terms used herein have the same meaning as those generally understood by those of ordinary skill in the art to which the present invention belongs. Materials, methods and examples are illustrative only and not restrictive. With respect to aspects where certain details about specific materials and processing methods are not described, such details may include conventional methods, which may be found in reference books and other sources in the field of manufacturing. In addition, unless otherwise stated, references to any quantitative values ​​will be understood to be average values ​​based on statistically relevant sample sizes.

[0036] The following is directed to coated abrasive articles including tapered abrasive particles, methods of forming tapered abrasive particles, and methods of forming coated abrasive articles including tapered abrasive particles.Abrasive articles can be used in a variety of material removal operations on a variety of workpieces.

[0037] Figure 1 Included is an illustration of a system for forming conical abrasive particles according to one embodiment. It should be understood that although Figure 1 The schematic system of provides an explanation for the process of forming conical abrasive particles, which embodiment should not be construed as limiting. Other processes can be used to form conical abrasive particles. Some suitable processes may include, but are not limited to, alternative extrusion techniques, printing, molding, casting, stamping, embossing, fracturing, or any combination thereof.

[0038] Refer again Figure 1 , system 100 may include a production tool 101 that is arranged and configured to move around rollers 105, 106, 107, and 108 (105-108). The production tool may include a cavity that may extend through the entire thickness of the production tool 101 and facilitate movement of the mixture 113 through the cavity. The mixture 113 may be extruded by an extruder 103 through the cavity in the production tool to facilitate shaping of the mixture 113 to form precursor conical abrasive particles.

[0039] In one non-limiting embodiment, the mixture 113 may include at least a ceramic material and a liquid. In particular, the mixture 113 may be a gel formed from a ceramic powder material and a liquid, wherein the gel may be characterized as a shape-stable material having the ability to maintain a given shape even in a green state (i.e., an unfired or undried gel). According to one embodiment, the gel may be formed from a ceramic powder material as an integrated network of discrete particles.

[0040] In some aspects, the control of certain processing conditions may be suitable for forming conical abrasive particles. For example, the mixture 113 may be formed by a specific content of solid material to facilitate the proper formation of conical abrasive particles. In one embodiment, the mixture 113 may have a high solid content, including, for example, a solid content of at least about 25wt% of the total weight of the mixture 113, such as at least about 35wt%, at least about 42wt%, at least about 44wt%, at least about 46wt%, at least about 48wt%, at least about 50wt% or even at least about 51wt%. In addition, in at least one non-limiting embodiment, the solid content of the mixture 113 may be no more than about 80wt%, no more than about 75wt%, such as no more than about 70wt%, no more than about 65wt%, no more than about 60wt%, no more than about 58wt% or no more than about 56wt%. It should be understood that the content of the solid material in the mixture 113 may be within the range between any minimum percentage to the maximum percentage mentioned above.

[0041] According to one embodiment, the ceramic powder material may include oxides, nitrides, carbides, borides, carbon oxides, nitrogen oxides, superabrasive materials, or any combination thereof. It should be understood that in certain alternative embodiments, instead of ceramic powder materials, a precursor of ceramic powder materials may be selected. The precursor may be a material, which may or may not be in powder form, which is configured to change at least a portion of its composition or physical properties during processing to form a ceramic material. In certain cases, the ceramic material may include aluminum oxide. More specifically, the ceramic material may include a boehmite material, which may be a precursor of alpha alumina. The term "boehmite" is generally used to refer to hydrated aluminum oxide, including the mineral boehmite (typically Al2O3·H2O and having a water content of about 15%) and pseudo-boehmite having a water content greater than 15% (such as 20-38% by weight). It should be noted that boehmite (including pseudo-boehmite) has a specific and identifiable crystal structure and therefore has a unique X-ray diffraction pattern, which distinguishes it from other aluminum materials, including other hydrated aluminum oxides, such as ATH (aluminum trihydroxide), a common precursor material used in this article to make boehmite particulate materials.

[0042] In addition, the mixture 113 can be formed into a liquid material with a specific content. Some suitable liquids may include inorganic materials, such as water; or various organic materials, such as alcohol, etc. According to one embodiment, the mixture 113 can be formed into a liquid content with less than the solid content of the mixture 113. In a more specific case, the mixture 113 may have a liquid content of at least about 20wt%, such as at least about 25wt% of the total weight of the mixture 113. In other cases, the liquid content in the mixture 113 may be greater, such as at least 35wt%, at least 40wt%, at least 42wt%, or at least 44wt%, or at least 46wt%, or at least 48wt% or at least 50wt%. In addition, in at least one non-limiting embodiment, the liquid content of the mixture may be no more than about 80wt%, such as no more than about 65wt%, no more than about 60wt% or no more than about 55wt%. It should be understood that the liquid content in the mixture 113 may be within the range between any minimum percentage and maximum percentage mentioned above.

[0043] In some cases, mixture 113 can have specific rheological properties to promote the formation of conical abrasive particles. For example, mixture 113 can have specific storage modulus. In a non-limiting embodiment, mixture 113 can have at least about 1x 104Pa storage modulus, such as at least about 4x 104Pa, such as at least about 8x 104Pa, at least about 1x 105Pa, at least about 5x 106Pa, at least about 1x 106Pa, at least about 5x 106Pa or at least about 1x 107Pa. In at least one non-limiting embodiment, mixture 113 can have not more than about 1x 1010Pa, not more than about 1x 109Pa, not more than about 1x108Pa or even not more than about 1x 107Pa storage modulus. It should be understood that the storage modulus of mixture 113 can be in the range between any minimum and maximum values ​​mentioned above.

[0044] The storage modulus can be measured using an ARES or AR-G2 rotational rheometer and a Peltier plate temperature control system using a parallel plate system. For testing, the mixture 113 can be extruded into the gap between two plates, which are set to be approximately 8 mm apart from each other. After the gel is extruded into the gap, the distance between the two plates defining the gap is reduced to 2 mm until the mixture 113 completely fills the gap between the plates. After wiping off the excess mixture, the gap is reduced by 0.1 mm and the test is started. The test is an oscillating strain sweep test performed under the following conditions: an instrument setting with a strain range between 0.01% and 100% and an angular velocity of 6.28 rad / s (1 Hz); using 25-mm parallel plates; and recording 10 points per decade. Within 1 hour after the test is completed, the gap is reduced again by 0.1 mm and the test is repeated. The test can be repeated at least 6 times. The first test can be different from the second and third tests. Only the results of the second and third tests of each sample should be reported.

[0045] In another non-limiting embodiment, the mixture 113 may have a specific viscosity that promotes the formation of conical abrasive particles. For example, the mixture 113 may have a viscosity of at least about 1x 105Pa s, at least about 5x 105Pa s, at least about 1x 106Pa s, at least about 5x 106Pa s, at least about 1x 107Pa s, at least about 5x 107Pa s, at least about 1x 108Pa s, at least about 5x108Pa s, at least about 1x 109Pa s, at least about 5x 109Pa s, at least about 1x 1010Pa s. In at least one non-limiting embodiment, the mixture 113 may have a viscosity of not more than about 1x 1015Pa s, not more than about 1x 1013Pa s, not more than about 1x 1012Pa s, or even not more than about 1x 1010Pa s. It will be appreciated that the viscosity of the mixture 113 can be within a range between any of the minimum and maximum values ​​noted above. The viscosity can be measured in the same manner as the storage modulus noted above.

[0046] In another non-limiting embodiment, the mixture 113 may have a specific yield stress. For example, the mixture 113 may have at least about 1x 102Pa, at least about 5x 102Pa, at least about 1x 104Pa, at least about 5x 104Pa, at least about 1x105Pa, at least about 5x 105Pa, at least about 1x 106Pa s, at least about 5x 106Pa s, at least about 1x 107Pa, at least about 5x 107Pa or even at least about 1x 108Pa yield stress. In at least one non-limiting embodiment, the mixture 113 may have not more than about 1x 1010Pa, not more than about 1x 109Pa, not more than about 1x 108Pa or even not more than about 1x 107Pa yield stress. It should be understood that the yield stress of the mixture 113 can be in the range between any minimum and maximum values ​​mentioned above. The yield stress can be measured in the same manner as the above-mentioned storage modulus.

[0047] The rheological properties of the mixture 113 may differ from conventional mixtures and gels, such as those described in certain references. In addition, the mixture 113 may be formed to have a specific relationship between one or more rheological properties (e.g., viscosity, yield stress, storage modulus, etc.) to facilitate formation. Notably, the gel may be significantly more "hard" and have shear thinning properties that may be completely different from mixtures used in other formation methods.

[0048] In some optional embodiments, the mixture 113 can be formed to have a specific content of organic materials, including, for example, organic additives that may be different from liquids, to facilitate the processing and formation of shaped abrasive particles according to embodiments of the present invention. Some suitable organic additives may include stabilizers, binders, such as fructose, sucrose, lactose, glucose, UV curable resins, etc. It should be understood that the total content of all materials in the mixture (e.g., ceramic powder material, water, additives, etc.) does not add up to more than 100%.

[0049] Embodiments herein may use a mixture 113 that may be different from certain types of slurries. For example, the content of organic material in the mixture 113, particularly the content of any organic additives described above, may be small compared to other components in the mixture 113. In at least one embodiment, the mixture 113 may be formed to have an organic material of no more than about 30wt% of the total weight of the mixture 113. In other cases, the content of organic material may be less, such as no more than about 15wt%, no more than about 10wt%, or even no more than about 5wt%. In addition, in at least one non-limiting embodiment, the content of organic material in the mixture 113 may be at least about 0.5wt% of the total weight of the mixture 113. It should be understood that the content of organic material in the mixture 113 may be within a range between any minimum and maximum values ​​described above. In at least one alternative aspect, the mixture 113 may be substantially free of organic material.

[0050] In some embodiments, the mixture 113 can be formed to have a specific content of acid or base, which can facilitate processing. Some suitable acids or bases can include nitric acid, sulfuric acid, citric acid, hydrochloric acid, tartaric acid, phosphoric acid, ammonium nitrate and / or ammonium citrate. According to a specific embodiment, using a nitric acid additive, the mixture 113 can have a pH of less than about 5, more specifically, in a range of at least about 2 and not more than about 4. Alternatively, the rheology of the acidic gel can be further changed by converting the acidic gel into an alkaline gel using alkalis (such as ammonium hydroxide, sodium hydroxide), organic amines (such as hexamethylenetetramine, etc.).

[0051] In one embodiment, the extrusion of the mixture 113 from the extruder 103 and through the cavity in the production tool 101 may include applying force on the mixture 113 to promote extrusion. According to one embodiment, a specific pressure may be used during extrusion. For example, the pressure may be at least about 10kPa, such as at least about 50kPa, at least about 100kPa, at least about 200kPa, or at least about 300kPa, or at least about 400kPa, or at least about 500kPa. In addition, in at least one non-limiting embodiment, the pressure used during extrusion may be no more than 10000kPa, such as no more than about 8000kPa, or no more than 6000kPa, or no more than 3000kPa, or no more than about 1000kPa, or no more than 800kPa. It should be understood that the pressure used to extrude the mixture 113 may be within the range between any minimum and maximum values ​​mentioned above.

[0052] According to one embodiment, the mixture 113 may have a coiling value of at least about 1800N. The coiling value can be measured on an instrument called the Shimpo Compression Tester manufactured by Shimpo Instruments of Itasca, Illinois, using a mixture sample with a mass range of 30-60 grams, which is manually pressed into a plastic / stainless steel cylinder with a diameter of 2 inches. At the extrusion end of the cylinder, a plastic insert with a cylindrical hole establishes a compressed extrudate size of approximately 0.25 inches in diameter. The plunger slides into the cylinder, and when the test begins, once the threshold coiling force is reached, the plunger will extrude the gel. When the cylinder assembly is in place, the Shimpo Compression Tester moves the force probe downward toward the plunger at a constant rate of 95-97mm / min. When the threshold coiling force is reached, the gel is squeezed out of the insert hole, and the output meter produces a peak force, i.e., the coiling value. In another embodiment, the coiling value of the mixture 113 may be at least about 200 N, such as at least about 300 N, at least about 400 N, at least about 500 N, at least about 600 N, at least about 700 N, at least about 800 N, at least about 900 N, at least about 1000 N. In a non-limiting embodiment, the coiling value of the mixture 113 may be not greater than about 3000 N, such as not greater than about 2500 N or even not greater than about 2000 N. Thus, certain mixtures according to embodiments herein may be significantly more flow resistant than conventional mixtures.

[0053] According to one embodiment, the production tool 101 may include a cavity in the form of a hole that extends through the thickness of the production tool 101. The production tool 101 may be in the form of an endless belt for continuous operation. In addition, the production tool may include multiple cavities for increasing the throughput of the process. Depending on the expected cross-sectional shape of the conical abrasive particles, the cavity may have any two-dimensional shape and size. In a specific embodiment, the cavity may have a quadrilateral two-dimensional shape when viewed in a plane of the length and width of the production tool 101.

[0054] like Figure 1 As shown, mixture 113 can be extruded through the cavities of production tool 101. More specifically, in one embodiment, mixture 113 can be extruded from extruder 103 and through the cavities in production tool 101 as the cavities translate past the die openings of extruder 103. As production tool 101 continues to translate, the cavities move past the die openings, preventing further extrusion of mixture 113 into the filled cavities. Extrusion can continue into the next set of cavities exposed to the die openings. The mixture 113 forced through the cavities can extend through the cavities on a side of production tool 101 that is opposite to the side of production tool 101 that is adjacent to the die openings of extruder 103.

[0055] In one embodiment, the translation rate of production tool 101 can be controlled to promote the formation of precursor pyramidal abrasive particles and pyramidal abrasive particles having one or more features of the embodiments herein. In one particular embodiment, the translation rate of production tool 101 can be controlled relative to the extrusion rate.

[0056] In one non-limiting embodiment, the mixture 113 can be extruded at an extrusion rate of at least 0.0015 cm / s, such as at least 0.005 cm / s, at least 0.008 cm / s, at least 0.01 cm / s, at least 0.015 cm / s, at least 0.02 cm / s, at least 0.05 cm / s, at least 0.08 cm / s, at least 0.10 cm / s, at least 0.20 cm / s, at least 0.30 cm / s, at least 0.40 cm / s, at least 0.50 cm / s. In addition, in one non-limiting embodiment, the mixture 113 can be extruded at an extrusion rate of no more than 5 m / s, such as no more than 1 m / s, no more than 0.5 m / s, no more than 100 cm / s, no more than 50 cm / s, no more than 10 cm / s, no more than 1 cm / s. It should be understood that the mixture 113 can be extruded at an extrusion rate within a range between any minimum and maximum values ​​described above.

[0057] In one non-limiting embodiment, the production tool can translate at a translation rate of at least 0.10 cm / s, such as at least 0.50 cm / s, at least 0.80 cm / s, at least 1.0 cm / s, at least 1.5 cm / s, at least 2 cm / s, at least 3 cm / s, at least 4 cm / s, at least 5 cm / s, at least 6 cm / s, at least 7 cm / s, at least 8 cm / s, at least 9 cm / s. In addition, in one non-limiting embodiment, the production tool 101 can translate at a rate of no greater than 5 m / s, such as no greater than 1 m / s, no greater than 0.5 m / s, no greater than 100 cm / s, no greater than 50 cm / s, no greater than 25 cm / s, no greater than 15 cm / s. It should be understood that the production tool can translate at a rate within a range between any of the minimum and maximum values ​​noted above.

[0058] The formation of the conical abrasive particles with the features of the embodiments herein is based on empirical knowledge of the interrelationships between a plurality of processing variables, including, for example, but not limited to, mixture rheology, extrusion rate, translation rate, abrasive particle size or die opening size, and environmental conditions (e.g., temperature, humidity, etc.). In addition, the uncontrolled variation of one process variable may require controlled variations of two or more other process variable parameters to accommodate the uncontrolled variation. In addition, due to the relative size of the formed shape, the process requires precision, which may be affected by the uncontrolled variation of one or more process variables, thereby causing the abrasive particles to be not conical abrasive particles.

[0059] Production tool 101 may include inorganic materials including, for example, but not limited to, ceramics, metals, metal alloys, or any combination thereof. In alternative embodiments, production tool 101 may include organic materials such as polymers including, for example, fluoropolymers such as polytetrafluoroethylene (PTFE).

[0060] In alternative embodiments, production tool 101 may include specific ingredients that may impart to mixture 113 contained on the surface of the cavity. For example, the surface of the cavity may be coated with an additive. The additive may be an inorganic material, an organic material, or any combination thereof. In some cases, the additive may be a dopant. In such embodiments, mixture 113 may be doped while being extruded through the cavity of production tool 101.

[0061] After extruding the mixture 113, the extruded mixture can be translated on production tool 101 to receive further optional post-forming processing at step 109. Some non-limiting examples of post-forming processing at step 109 can include drying, cooling, spraying, doping, coating, or any combination thereof.

[0062] After any optional post-forming processing at step 109, the extruded mixture can be translated to a release zone 110 where the extruded mixture portion is released from the cavity of the production tool 101 to form a precursor conical abrasive particle. The extruded mixture portion can be released from the production tool 101 using a variety of techniques, including but not limited to mechanical manipulation, vibration, impact of gas or liquid phase materials, temperature changes (i.e., heating, cooling, freezing, etc.), etc. In a preferred embodiment, the extruded mixture portion is engaged with a blade that facilitates separation from the production tool 101.

[0063] According to one embodiment, the mixture 113 may experience a weight change of less than about 5% of the total weight of the mixture 113 over the duration that the mixture 113 is connected to the production tool 101. In other embodiments, the weight loss of the mixture 113 may be less, such as less than about 4%, less than about 3%, less than about 2%, less than about 1%, or even less than about 0.5%. Moreover, in a particular embodiment, the mixture 113 may experience substantially no weight change over the duration that the mixture 113 is in the production tool 101.

[0064] Furthermore, during processing, mixture 113 may experience limited volume changes (e.g., shrinkage) for the duration that mixture 113 is connected to production tool 101. For example, the volume change of mixture 113 may be less than about 5% of the total volume of mixture 113, such as less than about 4%, less than about 3%, less than about 2%, less than about 1%, or even less than about 0.5%. In a particular embodiment, mixture 113 undergoes substantially no volume change for the entire duration that mixture 113 is connected to production tool 101.

[0065] In one non-limiting embodiment, when the mixture 113 is connected to the production tool 101, the mixture 113 may be subjected to a controlled heating process. For example, the heating process may include heating the mixture at a temperature above room temperature for a limited time. The temperature may be at least about 30°C, such as at least about 35°C, at least about 40°C, such as at least about 50°C, at least about 60°C, or even at least about 100°C. In addition, the temperature may be no more than about 300°C, such as no more than about 200°C, or even no more than at least about 150°C, or even no more than about 100°C. The duration of heating may be particularly short, such as no more than about 10 minutes, no more than about 5 minutes, no more than about 3 minutes, no more than about 2 minutes, or even no more than about 1 minute.

[0066] The heating process can utilize a radiant heat source, such as an infrared lamp, to facilitate controlled heating of the mixture 113. Additionally, the heating process can be adapted to control properties of the mixture and facilitate particular aspects of shaped abrasive particles according to embodiments herein.

[0067] In some cases, the precursor conical abrasive particles may be aggregated and further processed. For example, further processing may include doping, calcining, impregnation, drying, sintering, etc. In one embodiment, the precursor conical abrasive particles may have a dopant material applied to one or more outer surfaces. According to one embodiment, applying the dopant material may include applying a specific material, such as a salt, which may be a precursor salt material including a dopant material to be incorporated into the final formed shaped abrasive particles. For example, a metal salt may include an element or compound as a dopant material. It should be understood that the salt material may be in liquid form, such as in a dispersion comprising a salt and a liquid carrier. The salt may include nitrogen, and more specifically, may include a nitrate. In one embodiment, the salt may include a metal nitrate, and more specifically, may be substantially composed of a metal nitrate.

[0068] In one embodiment, the dopant material may include an element or compound such as an alkali metal element, an alkaline earth element, a rare earth element, hafnium, zirconium, niobium, tantalum, molybdenum, vanadium, or any combination thereof. In a specific embodiment, the dopant material includes an element or compound including elements 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, silicon, boron, carbon, and combinations thereof.

[0069] In one embodiment, the precursor conical abrasive particles can be dried. Drying can include removing a specific amount of material, including volatiles, such as water. According to one embodiment, the drying process can be carried out at a drying temperature of not more than about 300°C, such as not more than about 280°C, or even not more than about 250°C. In addition, in a non-limiting embodiment, the drying process can be carried out at a drying temperature of at least about 10°C, such as at least 20°C, or at least 30°C, or at least 40°C. It should be understood that the drying temperature can be within the range between any of the minimum and maximum temperatures mentioned above.

[0070] According to one embodiment, the process of forming the conical abrasive grains may include calcining, which includes removing volatiles and phase changes in the material, including, for example, high temperature phase materials (e.g., alpha alumina). In yet another embodiment, the method for forming the conical abrasive grains may include impregnating the calcined precursor conical abrasive grains with a dopant. In another embodiment, the formation of the conical abrasive grains from the precursor conical abrasive grains may include sintering. Sintering may be performed to densify the grains. In certain cases, the sintering process may promote the formation of high temperature phase ceramic materials. For example, in one embodiment, the shaped abrasive grain precursor may be sintered so as to form a high temperature phase of aluminum oxide, such as alpha alumina. It should be understood that certain additional processes, such as cleaning, may be completed on the production tool 101 to facilitate regular and repeated processing.

[0071] After forming the pyramidal abrasive particles, such particles can be disposed on a substrate to form a fixed abrasive article, such as a coated abrasive article. Further details regarding coated abrasive articles and methods of forming such articles are described herein.

[0072] Reference now Figure 2A-2G , describing the characteristics of conical abrasive particles. Figure 2A An image including a plurality of conical abrasive particles. According to one embodiment, a plurality of abrasive particles included in a coated abrasive article may include at least a portion of conical abrasive particles. For example, in one embodiment, at least 5% of the abrasive particles in the plurality of abrasive particles on the coated abrasive article may include conical abrasive particles calculated based on the number of particles. In other embodiments, the content of conical abrasive particles may be greater, such as at least 10%, or at least 20%, or at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 90%, or at least 95% or at least 99%. In one embodiment, a plurality of abrasive particles on a coated abrasive may be completely composed of conical abrasive particles. In addition, in a non-limiting embodiment, a plurality of abrasive particles may include no more than 99% of the conical abrasive particles calculated from the number of particles in a plurality of abrasive articles, such as no more than 95%, or no more than 90%, or no more than 80%, or no more than 70%, or no more than 60% or no more than 50%. It should be understood that the percentage of tapered abrasive particles in the plurality of abrasive particles can be within a range including any minimum and maximum percentages described above. The above percentages can represent a weight percentage based on the total weight of the plurality of abrasive particles based on the total count percentage of the abrasive particles.

[0073] According to a non-limiting embodiment, a plurality of abrasive particles may include a blend of different types of abrasive particles. The blend may include a first portion of abrasive particles and a second portion of abrasive particles. In one embodiment, conical abrasive particles may be present in the first portion, the second portion, or both the first portion and the second portion. In one case, the first portion or the second portion may only include conical abrasive particles. According to one embodiment, the blend may include a first portion of a first type of abrasive particles and a second portion of a second type of abrasive particles, wherein the first type and the second type are different from each other based on at least one abrasive feature, and the abrasive feature is selected from the following group: average grain size, average grain size, brittleness, toughness, hardness, two-dimensional shape, three-dimensional shape, any feature described in the embodiments herein, or any combination thereof.

[0074] In one non-limiting aspect, the plurality of abrasive grains can include at least 10 grams of abrasive grains, such as at least 100 grams of abrasive grains, at least 500 grams of abrasive grains, at least 1 kg of abrasive grains, or at least 10 kg of abrasive grains.

[0075] In another aspect, a plurality of abrasive grains may include at least 10 abrasive grains, such as at least 20 abrasive grains, or at least 30 abrasive grains, or at least 50 abrasive grains, or at least 100 abrasive grains, or at least 500 abrasive grains. It should be understood that the number of abrasive grains in a plurality of abrasive grains may be in the range of at least 10 abrasive grains to no more than 100,000 abrasive grains, such as in the range of at least 10 abrasive grains to no more than 1000 abrasive grains or in the range of at least 20 abrasive grains to no more than 100 abrasive grains.

[0076] In yet another aspect, the plurality of abrasive particles may include at least a portion of the abrasive particles contained in a fixed abrasive article (such as a coated abrasive article), and in some cases include all of the abrasive particles. In another embodiment, the plurality of abrasive particles may include all of the abrasive particles in a plurality of fixed abrasive articles.

[0077] Figure 2B An image of a conical abrasive particle in a plane defined by the length and width of the body is included as viewed from a first perspective. Figure 2C An image of the conical abrasive particles in a plane defined by the length and width of the body is included as viewed from a second viewing angle opposite the first viewing angle. Figure 2D An image of a conical abrasive particle in a plane defined by the length and thickness of the body is included as viewed from a first perspective. Figure 2E An image of the tapered abrasive particles in a plane defined by the length and thickness of the body is included as viewed from a second viewing angle opposite the first viewing angle. Figure 2F include Figure 2B A perspective view of the base of a conical abrasive particle. Figure 2G include Figure 2B A perspective view of the base of a conical abrasive particle.

[0078] like Figure 2B-2GAs shown in the non-limiting embodiment of , the conical abrasive particle 200 may include a body 201 having a length (L), a width (W), and a thickness (t). In one embodiment, the length may be greater than the width. In another embodiment, the length may be greater than the thickness. In yet another embodiment, the width may be greater than, equal to, or less than the thickness. Unless otherwise stated, reference to any dimension described herein should be understood as a reference to an average value from a suitable sample size of the measurement and / or particle. For example, the length mentioned includes an average length measured as close to the midpoint of the body 201 as possible along the longitudinal axis 280. It should be noted that the length or average length may be different from the skeleton length, which is calculated using imaging processing and is described in more detail herein. The width can be measured in a direction perpendicular to the longitudinal axis 280 in the plane of the length and width. The width can be measured as close to the midpoint of the body 201 as possible, which midpoint can be assumed to be the midpoint between the points where the longitudinal axis 280 intersects the edge of the body 201. The thickness, as Figure 2D and Figure 2E As shown, the measurement may be taken as close as possible to the midpoint of the body 201 , which may be assumed to be the midpoint between the endpoints on the longitudinal axis 280 , which are defined by the intersection of the longitudinal axis 280 with the edges of the body 201 .

[0079] In one non-limiting embodiment, the conical abrasive particle can include a body 201 having a tip region 210 including a tip 211 and a base region 212 including a base 214. The base region 212 can be at an opposite end of the body relative to the tip region 210 along the length of the body 201. In another aspect, the body 201 can be substantially linear for a majority of the total length of the body 201. As used herein, the term substantially linear means that the body deviates from a linear axis by no more than 20%, such as no more than 10% or no more than 5%.

[0080] In one non-limiting aspect, the tip 211 may be defined by the intersection of at least two surfaces of the body 201. For example, the body 201 may include surfaces 221, 222, 223, and 224 (221-224) extending between the tip region 210 and the base region 212. In one embodiment, at least two surfaces (221-224) may intersect to form at least a portion of the tip 211. In some non-limiting examples, the tip 211 may be defined by the intersection of surface 223 and surface 224, which generally define the thickness of the body 201. In another embodiment, the surfaces 221 and 222 may intersect and be separated from each other at the tip 211 by a tip edge 213. In such an embodiment, the tip 211 may be in the form of a wedge, wherein the body 201 intersects to the tip edge 213 in the thickness dimension, and the surfaces 221 and 222 defining the width of the body 201 may be kept separated at the tip 211 by the tip edge 213. As Figure 2Dand Figure 2E As best shown, tip 211 includes a tip edge 213 that is primarily defined by the intersection of surfaces 223 and 224 and extends between terminal corners of surfaces 221 and 222 .

[0081] In other aspects, the tip 211 can be defined by the intersection of more than two surfaces, such as at least three surfaces or at least four surfaces of the body 201. In such embodiments, the tip 211 can have a tip edge defined by the intersection of at least three or more surfaces of the body.

[0082] According to one non-limiting embodiment, the tip edge 213 may have a tip edge length 233 defined by the shortest distance between the outer corners 231 to 232, which is less than the average thickness (t) of the body 201, such as no more than 95%, or no more than 90%, or no more than 85%, or no more than 80%, or no more than 75%, or no more than 70%, or no more than 60%, or no more than 50%, or no more than 40%, or no more than 30% of the average thickness of the body 201. In addition, in another non-limiting embodiment, the tip edge length 233 may be at least 20% of the average thickness of the body 201, such as at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 90%, or at least 95% of the average thickness of the body 201. It should be understood that the tip edge length 233 may be within a range including any of the minimum and maximum percentages described above, including, for example, within a range of at least 20% and not more than 95% of the average thickness of the body 201 or within a range of at least 50% and not more than 95%.

[0083] In yet another non-limiting embodiment, the tip edge length 233 may have a specific relationship to the width of the body 201. In one case, the tip edge length 233 may be less than the average width of the body 201. According to a non-limiting embodiment, the tip edge length 233 may be no greater than 99% of the average width of the body 201, such as no greater than 95%, or no greater than 90%, or no greater than 85%, or no greater than 80%, or no greater than 75%, or no greater than 70%, or no greater than 60%, or no greater than 50%, or no greater than 40%, or no greater than 30%. In addition, in another non-limiting embodiment, the tip edge length 233 may be at least 0.1% of the average width of the body 201, such as at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 90%, or at least 95% of the average width of the body 201. It should be understood that the tip edge length 233 can be within a range including any of the minimum and maximum percentages described above, including, for example, within a range of at least 20% and not more than 95% of the average width of the body 201 or within a range including at least 50% and not more than 95%. In addition, in another non-limiting embodiment, the tip edge length 233 can be substantially similar to the average width of the width of the body 201.

[0084] According to one aspect, the tip region 210 may be defined by a taper that includes a reduction in the width and / or thickness of the body 201 in the tip region 210. According to one embodiment, the tip region 210 may include a reduction in the width of the body 201 in the tip region 210. In another non-limiting embodiment, the tip region 210 may include a reduction in the thickness of the body 201 in the tip region 210. In another alternative embodiment, the tip region 210 may be defined by a taper that includes a reduction in both the width and thickness of the body 201 in the tip region 210. Further, in another embodiment, the tip region 210 may be defined by a taper that includes a change in the width of the body 201 in the tip region 210 that is greater than the change in thickness. For another embodiment, the tip region 210 may be defined by a taper that includes a change in the thickness of the body 201 in the tip region 210 that is greater than the change in width. According to one non-limiting embodiment, the tip region 210 may be defined by a taper that includes a change in the thickness of the body 201 and an area of ​​substantially the same average width throughout the tip region 210. For at least one other non-limiting embodiment, the tip region 210 may be defined by a taper that includes a change in width of a region of body 201 and having a substantially constant average thickness throughout the tip region 210 .

[0085] In another non-limiting embodiment, the tip region 210 may have a tip region length of no more than 90% of the length of the body 201, such as no more than 80% of the total average length of the body, or no more than 70%, or no more than 60%, or no more than 50%, or no more than 40%, or no more than 30%, or no more than 20%, or no more than 10%, or no more than 5%. In yet another non-limiting embodiment, the tip region may have a tip region length of at least 5% of the length of the body 201, such as at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 40%. It should be understood that the tip region length may be within a range including any minimum and maximum percentages described above, including, for example, but not limited to, within a range of at least 5% and no more than 90% of the length of the body or within a range of at least 15% and no more than 50% of the length of the body.

[0086] According to another embodiment, the tip region 210 may include an asymmetric taper. An asymmetric taper is defined by one surface having a greater angle or curvature than another surface. In certain cases, the asymmetric taper may be characterized by a first surface of the body (e.g., surface 224) having a different profile than another surface of the body (e.g., surfaces 221, 222, and / or surface 223). For example, the first surface may have a greater curvature than the second surface. In certain non-limiting embodiments, the second surface may be substantially linear and the first surface may be in a non-parallel relationship that is angled or curved relative to the second surface. The first surface and the second surface may intersect at the tip 211. The first surface may be longer than the second surface in the tip region 210.

[0087] In another non-limiting embodiment, the conical abrasive particles may have a specific cone angle. For example, the surface (e.g., surface 224) with the maximum curvature in the tip region 210 may define the cone angle 252 as the angle between the tangent of point 255 on the surface 224 and the point 251 farthest from point 255 at the tip 211. Point 255 defines the starting point of the conical region 210 on the surface 224. According to one embodiment, the cone angle 252 may be at least 1 degree, such as at least 5 degrees, or at least 8 degrees, or at least 10 degrees, or at least 15 degrees, or at least 20 degrees, or at least 25 degrees, or at least 30 degrees, or at least 40 degrees or at least 45 degrees. In another non-limiting embodiment, the cone angle 252 may be not more than 90 degrees, such as not more than 85 degrees, or not more than 80 degrees, or not more than 70 degrees, or not more than 60 degrees, or not more than 50 degrees, or not more than 40 degrees or not more than 30 degrees. It should be understood that the taper angle 252 can be within a range including any of the minimum and maximum values ​​described above, including, for example, but not limited to, at least 5 degrees and no more than 90 degrees, or at least 5 degrees and no more than 70 degrees, or at least 10 degrees and no more than 50 degrees. In some cases, but not all cases, the taper angle may be apparent only in a plane defined by the length and width of the body 201.

[0088] As described herein, each of the conical abrasive particles may include a base region 212 at an opposite end of the body 201 relative to the tip region 210. The base region 212 may include a base 214. According to one embodiment, the base 214 may include a protrusion 215 extending from the body 201. More specifically, the protrusion 215 may extend from the body 201 in a direction away from the longitudinal axis 280. In certain cases, the protrusion 215 may extend away from the tip 211. In some embodiments, but not all embodiments, the protrusion 215 may be apparent only when the particle is viewed from a plane defined by the length and width of the body 201.

[0089] In one aspect, the body 201 of the conical abrasive particles may have a base angle 261, which may define the angle at which the protrusion extends from the body 201. The base angle 261 may be the angle between the surface 224 of the body 201 and the surface 262 extending from the outer angle 217 of the base surface 216. In a non-limiting embodiment, the base angle 261 may be an obtuse angle. For example, the base angle 261 may be at least 91 degrees, such as at least 92 degrees, or at least 93 degrees, or at least 94 degrees, or at least 95 degrees, or at least 97 degrees, or at least 99 degrees, or at least 105 degrees, or at least 110 degrees, or at least 120 degrees, or at least 130 degrees, or at least 140 degrees. In another non-limiting embodiment, the base angle 261 may be no greater than 180 degrees, such as no greater than 178 degrees, or no greater than 170 degrees, or no greater than 160 degrees, or no greater than 150 degrees. It should be understood that the base angle 261 may be within the range between any minimum and maximum values ​​included above.

[0090] In another non-limiting embodiment, the base 214 may include a protrusion 215 having a protrusion length (Lp). The protrusion length may be the length of the longest side of the protrusion 215 in the base region 212 excluding the base surface 216. For example, Figure 2B As shown in , the protrusion length can be measured as the length of the surface 264. In one non-limiting embodiment, the length of the surface 264 can be measured from the outer corner 218. In one non-limiting embodiment, the protrusion length (Lp) can be less than the average length (L) of the body 201. In certain embodiments, the protrusion length (Lp) can be no greater than 90% of the average length (L) of the body 201, such as no greater than 80%, or no greater than 70%, or no greater than 60%, or no greater than 50%, or no greater than 40%, or no greater than 30%, or no greater than 20%, or no greater than 10%, or no greater than 5%. In another non-limiting embodiment, the protrusion length (Lp) can be at least 1% of the average length (L) of the body 201, such as at least 3%, or at least 5%, or at least 8%, or at least 10%, or at least 15% of the total average length (L) of the body 201. It should be understood that the protrusion length (Lp) can be within a range including any minimum and maximum values ​​described above.

[0091] As another non-limiting example, the base 214 may include a base surface 216. The base surface 216 may extend between outer corners 217 and 218. The outer corner 217 may be the angle between the base surface 216 and the surface 224, wherein the surface 224 may be the most curved surface in the tip region 210 in some cases. The outer corner 217 may be an upper corner 217 and the outer corner 218 may be a lower corner 218 spaced apart from the upper corner over the length of the base surface 216. In one embodiment, the outer corner 218 may be the corner on the base 214 farthest from the tip 211. In another embodiment, the outer corner 218 may be the corner on the base 214 that is closer to the longitudinal axis 280 than the outer corner 217.

[0092] In one non-limiting embodiment, the outer corner 217 may have a fillet radius that is smaller than the fillet radius of the tip 211. Additionally, in another embodiment, the fillet radius of the outer corner 218 may have a fillet radius that is smaller than the fillet radius of the tip 211.

[0093] In yet another embodiment, the base 216 may extend at an angle relative to the longitudinal axis 280 of the body 201. For example, the base 216 may be angled relative to the longitudinal axis 280 to define a base angle 237. In one embodiment, the base angle 237 may be an acute angle. According to another non-limiting embodiment, the base angle 237 may be no greater than 90 degrees, such as no greater than 88 degrees, or no greater than 86 degrees, or no greater than 84 degrees, or no greater than 82 degrees, or no greater than 80 degrees, or no greater than 75 degrees, or no greater than 70 degrees, or no greater than 65 degrees, or no greater than 60 degrees, or no greater than 55 degrees, or no greater than 50 degrees, or no greater than 45 degrees, or no greater than 40 degrees. In another non-limiting embodiment, base angle 237 can be at least 5 degrees, such as at least 10 degrees, or at least 15 degrees, or at least 20 degrees, or at least 25 degrees, or at least 30 degrees, or at least 35 degrees, or at least 40 degrees, or at least 45 degrees, or at least 50 degrees, or at least 55 degrees. It should be understood that base angle 237 can be within a range including any minimum and maximum values ​​described above.

[0094] In another embodiment, the base region 212 may have a main peak angle 238 at the outer corner 218 between the base surface 216 and the surface 264. In one aspect, the main peak angle 238 may be at least 45 degrees and no greater than 150 degrees, as viewed in a plane defined by the length and width of the body 201. According to one embodiment, the main peak angle 238 may be at least 50 degrees, such as at least 55 degrees, or at least 60 degrees, or at least 65 degrees, or at least 70 degrees, or at least 75 degrees, or at least 80 degrees, or at least 85 degrees, or at least 90 degrees, or at least 95 degrees, or at least 100 degrees. In another non-limiting embodiment, the main peak angle 238 may be no greater than 145 degrees, or no greater than 140 degrees, or no greater than 135 degrees, or no greater than 130 degrees, or no greater than 125 degrees, or no greater than 120 degrees, or no greater than 115 degrees, or no greater than 110 degrees, or no greater than 100 degrees, or no greater than 95 degrees. It will be appreciated that the main peak angle 238 can be within a range including any of the minimum and maximum values ​​noted above.

[0095] According to another embodiment, the outer angle 218 can define a main peak as viewed in a plane defined by the length and width of the body 201. According to one embodiment, the main peak can have a tip sharpness, measurable by a main peak angle 238, that is less than the tip sharpness of the tip 211 of the body 201, which can also be measured at a point 251 on the tip 211 of the body 201 by a tip angle 277. According to one particular embodiment, the main peak angle 238 can be at least 5% less than the tip angle 277, such as at least 8% less, or at least 10% less, or at least 12% less, or at least 15% less, or at least 20% less, or at least 25% less, or at least 30% less, or at least 40% less, or at least 50% less, or at least 60% less, or at least 70% less, or at least 80% less, or at least 90% less. In one non-limiting embodiment, the main peak angle 238 can be no greater than 99% less than the tip angle 277, such as no greater than 95%, or no greater than 90%, or no greater than 80%, or no greater than 60%, or no greater than 40%. It should be understood that the main peak angle 238 can be less than the tip angle 277 within a range including any of the minimum and maximum values ​​described above.

[0096] In another aspect, it is unexpected that the base region 212 will have at least one or more sharper tips than the tip region 210. This is particularly noteworthy because the base region 212 may generally include a greater volume of material than the tip region 210 based on the cross-sectional area of ​​the base region 212.

[0097] In one non-limiting aspect, the base surface 218 may have a specific surface topography, which may promote unexpected and improved performance. According to one embodiment, the base surface 218 may include at least one peak 233, such as a plurality of peaks 233 extending from the base surface 218. In another embodiment, the base surface 218 may include at least one valley 234, such as a plurality of valleys 234 extending across at least a portion of the base surface 218 between the plurality of peaks 233. According to another non-limiting embodiment, the plurality of peaks 233 and valleys 234 may be randomly distributed on the base surface 218.

[0098] In some cases, but not all cases, the surface roughness of the base surface 218 may be different from the surface roughness of at least one of the surfaces (221-224) of the body 201. In one embodiment, the surface roughness of the base surface 218 may be greater than the surface roughness of the side surfaces of the body (221-224) in the tip region 210 or the elongated region 240 of the body 201.

[0099] According to another embodiment, the base surface 218 may include at least one peak of the plurality of peaks 233 having a tip radius that is smaller than the tip radius of the tip 211 of the body 201. Furthermore, in another non-limiting embodiment, the base surface 218 may include at least two peaks of the plurality of peaks 233 having a tip radius that is smaller than the tip radius of the tip 211 of the body 201.

[0100] In certain conical abrasive particles of the embodiments herein, the base region 212 may include a first peak 235 and a second peak 236 as viewed in two dimensions of a plane defined by the length and thickness of the body 201, such as Figure 2D and 2E In one non-limiting embodiment, the first peak 235 and the second peak 236 can be separated from each other by a first valley 239.

[0101] According to another non-limiting aspect, base surface 216 may include one or more facets 241. Facets 241 define substantially flat areas on the base surface. In certain cases, facets 241 may extend between a plurality of peaks 233 and valleys 234 of base surface 215. In some cases, base surface 218 may include at least two faces that abut each other and define a common edge extending between the two faces.

[0102] As described herein, the conical abrasive particles of certain embodiments may include a tip region 210, a base region 212, and an elongated region 240 distributed between the tip region 210 and the base region 212. More specifically, the elongated region 240 may extend between the tip region 210 and the base region 212. In one non-limiting embodiment, the elongated region 240 between the tip region 210 and the base region 212 has a substantially constant width. For example, in one embodiment, the elongated region 240 may have a width variation of no more than 10% of the length variation of the elongated region 240, such as no more than 8%, or no more than 5%, or no more than 3%. In at least one embodiment, the elongated region 240 may have a width variation of at least 0.5%, such as at least 1% or at least 2%, of the length variation of the elongated region 240. It should be understood that the width variation of the body 201 of the elongated region 240 may be within a range between any minimum percentage and maximum percentage included above.

[0103] In another embodiment, the elongated region 240 can have a thickness variation of no more than 10%, such as no more than 8%, or no more than 5%, or no more than 3%, of the length variation of the elongated region 240. In at least one embodiment, the elongated region 240 can have a thickness variation of at least 0.5%, such as at least 1%, or at least 2%, of the length variation of the elongated region 240. It should be appreciated that the thickness variation of the body 201 of the elongated region 240 can be within a range including any of the minimum and maximum percentages noted above.

[0104] In other cases, the conical abrasive particles may have other features. For example, in some cases, the body may include stripes 271. Such stripes may be present on at least one surface, such as surfaces 221-224. More specifically, stripes 271 may be present on at least a portion of all side surfaces 222-224. In another non-limiting embodiment, stripes 271 may extend in the length direction of the body 201. In yet another embodiment, stripes 271 may extend to a majority of the surface area of ​​at least one or more surfaces 221-224. According to a specific embodiment, stripes 271 extend to a majority of the surface area of ​​all surfaces 221-224.

[0105] According to one embodiment, the body 201 of the conical abrasive particles may have a specific first-order aspect ratio (length / width), which may be produced by the disclosed formation method and may also promote certain features and / or improved performance. According to one embodiment, the conical abrasive particles may have a first-order aspect ratio (length / width) of at least 1.1, or at least 1.2, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 3.5, or at least 4, or at least 4.5, or at least 5, or at least 5.5, or at least 6, or at least 8, or at least 10. In another non-limiting embodiment, the body 201 may have a first-order aspect ratio of not more than 1000, or not more than 100, or not more than 50, or not more than 20, or not more than 10, or not more than 5, or not more than 3, or not more than 2.8, and the first-order aspect ratio is expressed as length: width. It should be understood that the first-order aspect ratio of the body 201 may be within the range of any minimum ratio to maximum ratio mentioned above. Furthermore, it should be understood that the first order aspect ratio can represent the first order aspect ratio of a single pyramidal abrasive grain or an average of a plurality of pyramidal abrasive grains.

[0106] All aspect ratios of the embodiments herein are measured by image processing. A plurality of conical abrasive particles are mounted and arranged on a stage for imaging. Imaging can be accomplished by an optical microscope (such as a DSX 700 Olympus) at a suitable magnification (such as 2X-8X). After taking suitable images of particles of a suitable statistically relevant sample size (e.g., at least 200 particles), the images (RGB color or grayscale) are saved as representative images of the length and width dimensions of the particles. See, e.g. Fig.10 . The particles are then rotated 90 degrees around the longitudinal axis so that the thickness dimension of each particle is visible. Images of the particles are taken and saved as being related to the thickness of each particle. The length, width and thickness of each particle are measured, and the average length, width and thickness are calculated from the image by image processing software (e.g. ImageJ). For the first picture of the particle in the length and width plane, the image is converted to a black and white image by the Otsu method, wherein the white pixels represent the body of the particle. From the black and white image, the best fit ellipse is fitted around each image in the particle image. The best fit ellipse is generated so as to retain the secondary moment of the region. The vertical axis (i.e., major axis and minor axis) of the ellipse is used for length and width, wherein the longer axis represents the length, and the shorter axis represents the width or thickness depending on the plane of the image. The major axis defining the length is defined as the axis where the focus of the fitted ellipse is located. The minor axis defining the width of the body is perpendicular to the major axis of the fitted ellipse. The average length and average width are calculated from the image for multiple particles. Fig.10 Includes images of conical abrasive particles in the length and width planes with best fit ellipses fitted on the images. The average thickness of the particles is measured in the same manner using images of the particles in the length and thickness dimensions. The images are changed to black and white only, a best fit ellipse is created around each image of each particle, and the thickness is measured as the value of the shortest axis of the ellipse. The average thickness is calculated from all measured thickness values. Primary, secondary, and tertiary standard deviations are also calculated from the measured length, width, and thickness values.

[0107] In another aspect, the conical abrasive particles can have a specific first order aspect ratio standard deviation that is different from other abrasive particles, particularly elongated shaped abrasive particles, which can be formed by a specific process, including but not limited to extrusion. According to one embodiment, the body 201 can have a first order aspect ratio standard deviation [STDEV (length / width)] of not more than 0.55, or not more than 0.52, or not more than 0.50, or not more than 0.48, or not more than 0.45, or not more than 0.42, or not more than 0.40, or not more than 0.38, or not more than 0.35, or not more than 0.32, or not more than 0.30, or not more than 0.28, or not more than 0.25, or not more than 0.22, or not more than 0.20, or not more than 0.18, or not more than 0.15. In addition, in another non-limiting embodiment, the first-order aspect ratio standard deviation [STDEV (length / width)] can be at least 0.01, or at least 0.05, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35, or at least 0.4. It should be understood that the first-order aspect ratio of the body 201 can be within a range including any minimum ratio and maximum ratio described above. In addition, it should be understood that the first-order aspect ratio can represent the first-order aspect ratio of a single conical abrasive particle or an average of a plurality of conical abrasive particles.

[0108] According to one embodiment, the body 201 of the conical abrasive particles may have a specific second-order aspect ratio (length / thickness), which may be produced by the disclosed formation method and may also promote certain features and / or improved performance. In a non-limiting embodiment, the body 201 may have a second-order aspect ratio (length / thickness) of at least 1.1, or at least 1.2, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 3.5, or at least 4, or at least 4.5, or at least 5, or at least 5.5, or at least 6, or at least 8, or at least 10. In addition, in another non-limiting embodiment, the second-order aspect ratio (length / thickness) may be no greater than 1000, or no greater than 100, or no greater than 50, or no greater than 20, or no greater than 10, or no greater than 5, or no greater than 3, or no greater than 2.8. It should be understood that the second-order aspect ratio of length / thickness may be within a range between any minimum ratio and maximum ratio including the above. Furthermore, it should be understood that the second order aspect ratio can represent the second order aspect ratio of a single pyramidal abrasive grain or an average of a plurality of pyramidal abrasive grains.

[0109] In another aspect, the conical abrasive particles can have a specific second-order aspect ratio standard deviation that is different from other abrasive particles, particularly elongated shaped abrasive particles, which can be formed by a specific process (including but not limited to extrusion). According to one embodiment, the second-order aspect ratio standard deviation [STDEV (length / thickness)] of the body 201 can be no greater than 0.55, such as no greater than 0.52, or no greater than 0.50, or no greater than 0.48, or no greater than 0.45, or no greater than 0.42, or no greater than 0.40, or no greater than 0.38, or no greater than 0.35, or no greater than 0.32, or no greater than 0.30, or no greater than 0.28, or no greater than 0.25, or no greater than 0.22, or no greater than 0.20, or no greater than 0.18, or no greater than 0.15, or no greater than 0.12, or no greater than 0.10. In addition, in another non-limiting embodiment, the second-order aspect ratio standard deviation [STDEV (length / thickness)] can be at least 0.01, or at least 0.05, or at least 0.07, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35, or at least 0.4. It should be understood that the second-order aspect ratio standard deviation of the body 201 can be within a range including any minimum ratio and maximum ratio described above. In addition, it should be understood that the second-order aspect ratio can represent the second-order aspect ratio of a single conical abrasive particle or an average value of a plurality of conical abrasive particles.

[0110] According to one embodiment, the body 201 of the conical abrasive particles may have a specific tertiary aspect ratio (width / thickness), which may be produced by the disclosed formation method and may also promote certain features and / or improved performance. In another aspect, the body 201 may have a tertiary aspect ratio (width / thickness) of at least 0.5, such as at least 0.6, or at least 0.7, or at least 0.8, or at least 0.9, or at least 1.0, or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 4. In another non-limiting embodiment, the tertiary aspect ratio (width / thickness) may be no more than 10, such as no more than 8, or no more than 5, or no more than 3, or no more than 2, or no more than 1.5, or no more than 1.3, or no more than 1.1. It should be understood that the tertiary aspect ratio may be within the range between any minimum ratio and the maximum ratio included above. Furthermore, it should be understood that the tertiary aspect ratio can represent the tertiary aspect ratio of a single pyramidal abrasive grain or an average of a plurality of pyramidal abrasive grains.

[0111] In another aspect, the conical abrasive particles can have a specific tertiary aspect ratio standard deviation that is different from other abrasive particles, particularly elongated shaped abrasive particles, which can be formed by a specific process, including but not limited to extrusion. According to one embodiment, the body 201 can have a tertiary aspect ratio standard deviation [STDEV (width / thickness)] of not more than 0.55, or not more than 0.52, or not more than 0.50, or not more than 0.48, or not more than 0.45, or not more than 0.42, or not more than 0.40, or not more than 0.38, or not more than 0.35, or not more than 0.32, or not more than 0.30, or not more than 0.28, or not more than 0.25, or not more than 0.22, or not more than 0.20, or not more than 0.18, or not more than 0.15, or not more than 0.12, or not more than 0.10. In addition, in another non-limiting embodiment, the third order aspect ratio standard deviation [STDEV (width / thickness)] is at least 0.01, or at least 0.05, or at least 0.07, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35, or at least 0.4. It should be understood that the third order aspect ratio standard deviation of the body 201 can be within a range including any minimum ratio and maximum ratio described above. In addition, it should be understood that the third order aspect ratio can represent the third order aspect ratio of a single conical abrasive grain or an average value of a plurality of conical abrasive grains.

[0112] In some cases, a plurality of abrasive grains can only include the blend of conical abrasive grains or conical abrasive grains and particles of different shapes.A plurality of abrasive grains can have specific " batch " feature as described in the embodiments herein.According to one aspect, a plurality of abrasive grains can have specific batch aspect ratio and batch aspect ratio standard deviation, which can be produced by method disclosed herein and can further promote improved performance.In a non-limiting embodiment, a plurality of abrasive grains can have at least 1.1, or at least 1.2, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 3.5, or at least 4, or at least 4.5, or at least 5, or at least 5.5, or at least 6, or at least 8, or at least 10 first-stage batch aspect ratios [B (length / width)]. In another non-limiting embodiment, the first-stage batch aspect ratio [B (length / width)] may be no greater than 1000, or no greater than 100, or no greater than 50, or no greater than 20, or no greater than 10, or no greater than 5, or no greater than 3, or no greater than 2.8. It should be understood that the first-stage batch aspect ratio may be within a range including any minimum ratio and maximum ratio described above. The batch aspect ratio and batch aspect ratio standard deviation are measured in the same manner as the aspect ratio and aspect ratio standard deviation provided above for the conical abrasive particles.

[0113] In another aspect, the plurality of abrasive particles can have a specific first-stage batch aspect ratio standard deviation that is different from other abrasive particles, particularly elongated shaped abrasive particles, which are formed by a specific process (including but not limited to extrusion). According to one embodiment, the plurality of particles can have a first-stage batch aspect ratio standard deviation [STDEV-B (length / width)] of not greater than 0.55, such as not greater than 0.52, or not greater than 0.50, or not greater than 0.48, or not greater than 0.45, or not greater than 0.42, or not greater than 0.40, or not greater than 0.38, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28, or not greater than 0.25, or not greater than 0.22, or not greater than 0.20, or not greater than 0.18, or not greater than 0.15. Furthermore, in another non-limiting embodiment, the first level batch aspect ratio standard deviation [STDEV-B (length / width)] can be at least 0.01, or at least 0.05, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35, or at least 0.4. It should be appreciated that the first level batch aspect ratio standard deviation can be within a range including any of the minimum and maximum ratios described above.

[0114] In one non-limiting embodiment, a plurality of abrasive grains may have a secondary batch aspect ratio [B (length / thickness)] of at least 1.1, or at least 1.2, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 3.5, or at least 4, or at least 4.5, or at least 5, or at least 5.5, or at least 6, or at least 8, or at least 10. In another non-limiting embodiment, the secondary batch aspect ratio [B (length / thickness)] may be no greater than 1000, or no greater than 100, or no greater than 50, or no greater than 20, or no greater than 10, or no greater than 5, or no greater than 3, or no greater than 2.8. It should be understood that the secondary batch aspect ratio may be within a range including any minimum ratio and maximum ratio described above.

[0115] In another aspect, a plurality of abrasive grains may have a specific second batch aspect ratio standard deviation different from other abrasive grains. According to one embodiment, a plurality of grains may have a second batch aspect ratio standard deviation [STDEV-B (length / thickness)] of not more than 0.55, such as not more than 0.52, or not more than 0.50, or not more than 0.48, or not more than 0.45, or not more than 0.42, or not more than 0.40, or not more than 0.38, or not more than 0.35, or not more than 0.32, or not more than 0.30, or not more than 0.28, or not more than 0.25, or not more than 0.22, or not more than 0.20, or not more than 0.18, or not more than 0.15, or not more than 0.12, or not more than 0.10. Furthermore, in another non-limiting embodiment, the second batch aspect ratio standard deviation [STDEV-B (length / thickness)] can be at least 0.01, or at least 0.05, or at least 0.07, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35, or at least 0.4. It should be understood that the second batch aspect ratio standard deviation can be within a range including any minimum ratio and maximum ratio described above.

[0116] In one non-limiting embodiment, a plurality of abrasive grains may have a third batch aspect ratio [B (width / thickness)] of at least 0.5, or at least 0.6, or at least 0.7, or at least 0.8, or at least 0.9, or at least 1.0, or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 4. In another non-limiting embodiment, the third batch aspect ratio [B (width / thickness)] may be no greater than 10, or no greater than 8, or no greater than 5, or no greater than 3, or no greater than 2, or no greater than 1.5, or no greater than 1.3, or no greater than 1.1. It should be understood that the third batch aspect ratio may be within the range between any minimum ratio and the maximum ratio including those described above.

[0117] In another aspect, a plurality of abrasive grains may have a specific third batch aspect ratio standard deviation different from other abrasive grains. According to one embodiment, a plurality of grains may have a third batch aspect ratio standard deviation [STDEV-B (width / thickness)] of not more than 0.55, such as not more than 0.52, or not more than 0.50, or not more than 0.48, or not more than 0.45, or not more than 0.42, or not more than 0.40, or not more than 0.38, or not more than 0.35, or not more than 0.32, or not more than 0.30, or not more than 0.28, or not more than 0.25, or not more than 0.22, or not more than 0.20, or not more than 0.18, or not more than 0.15, or not more than 0.12, or not more than 0.10. Furthermore, in another non-limiting embodiment, the third batch aspect ratio standard deviation [STDEV-B (width / thickness)] can be at least 0.01, or at least 0.05, or at least 0.07, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35, or at least 0.4. It should be understood that the third batch aspect ratio standard deviation can be within a range including any minimum ratio and maximum ratio described above.

[0118] The conical abrasive grain of this paper embodiment can have and comprise crystalline material, and more specifically, comprise the main body of polycrystalline material.It should be noted that polycrystalline material can comprise abrasive grain (i.e. crystal).In one embodiment, the main body of conical abrasive grain can be substantially free of organic material, and this organic material comprises for example bonding agent.In at least one embodiment, conical abrasive grain can be substantially composed of polycrystalline material.

[0119] The abrasive particles (i.e., crystals) contained in the body 201 of the conical abrasive particles may have an average grain size of no more than 20 microns, such as no more than 18 microns, or no more than 16 microns, or no more than 14 microns, or no more than 12 microns, or no more than 10 microns, or no more than 8 microns, or no more than 5 microns, or no more than 2 microns, or no more than 1 micron, or no more than 0.9 microns, or no more than 0.8 microns, or no more than 0.7 microns, or no more than 0.6 microns or no more than 0.2 microns. In addition, the average grain size of the abrasive particles contained in the body of conical abrasive particles may be at least 0.01 microns, such as at least 0.05 microns, or at least 0.06 microns, or at least 0.07 microns, or at least 0.08 microns, or at least 0.09 microns, or at least 0.1 microns, or at least 0.12 microns, or at least 0.15 microns, or at least 0.17 microns, or at least 0.2 microns or even at least 0.5 microns. It will be appreciated that the abrasive particles can have an average grain size within a range between any of the minimum and maximum values ​​noted above. The average grain size can be calculated using an uncorrected intercept method known to those skilled in the art.

[0120] According to one embodiment, the main body 201 of conical abrasive grain can have the mean grain diameter of at least about 100 microns as measured with maximum dimension (that is, length). According to one embodiment, the main body 201 of conical abrasive grain can have the mean grain diameter of at least 150 microns, such as at least 200 microns or at least 300 microns or at least 400 microns or at least 500 microns or at least 500 microns or at least 600 microns or at least 800 microns or even at least 900 microns. In addition, the main body 201 of conical abrasive grain can have the mean grain diameter of not more than 5mm, such as not more than 3mm, not more than 2mm or even not more than 1.5mm. It should be appreciated that the main body of conical abrasive grain can have the mean grain diameter in the scope between any minimum and maximum values ​​mentioned above.

[0121] Particles used in the abrasives industry are typically graded to a given particle size distribution prior to use. Such distributions typically have a particle size range from coarse particles to fine particles. In the abrasives art, this range is sometimes referred to as "coarse," "control," and "fine" fractions. Abrasive particles graded according to a classification standard recognized by the abrasives industry specifies a particle size distribution for each nominal grade within a numerical range. Such industry-recognized classification standards (i.e., nominal grades specified by the abrasives industry) include: American National Standards Institute (ANSI) standards, European Abrasive Manufacturers Federation (FEPA) standards, and Japanese Industrial Standards (JIS) standards. ANSI grade numbers (i.e., specified nominal grades) include: ANSI 4, ANSI 6, ANSI 8, ANSI 16, ANSI 24, ANSI 36, ANSI 40, ANSI 50, ANSI 60, ANSI 80, ANSI 100, ANSI 120, ANSI 150, ANSI 180, ANSI 220, ANSI240, ANSI 280, ANSI 320, ANSI 360, ANSI 400 and ANSI 600. FEPA grade numbers include P8, P12, P16, P24, P36, P40, P50, P60, P80, P100, P120, P150, PI 80, P220, P320, P400, P500, P600, P800, P1000 and P1000. JIS grade designations include JIS8, JIS12, JIS16, JIS24, JIS36, JIS46, JIS54, JIS60, JIS80, JIS100, JIS150, JIS180, JIS220, JIS240, JIS280, JIS320, JIS360, JIS400, JIS600, JIS800, JIS1000, JIS1500, JIS2500, JIS4000, JIS6000, JIS8000, and JIS10,000. Alternatively, the abrasive particles can be classified to nominal sieving grades using American standards. American standard test sieves that meet the "Standard Specifications for Screen Cloths and Sieve for Test Purposes" of ASTM E-1 1 are classified as nominal sieving grades. ASTM E-1 1 specifies the design and construction requirements for test sieves that use a woven mesh cloth as the medium mounted in a frame to classify materials according to a specified particle size. A typical designation may be expressed as -18+20, which means that particles can pass through a test sieve that meets the ASTM E-1 1 specification of 18 mesh and are retained on a test sieve that meets the ASTM E-1 1 specification of 20 mesh.In various embodiments, the particulate material may have a nominal screen grade including: -18+20, -20 / +25, -25+30, -30+35, -35+40, -40+45, -45+50, 50+60, -60+70, -70 / +80, -80+100, -100+120, -120+140, -140+170, -170+200, -200+230, -230+270, -270+325, -325+400, -400+450, -450+500, or -500+635. Alternatively, a custom mesh size such as -90+100 may be used. The body of the particulate material may be in the form of shaped abrasive particles, as described in detail herein.

[0122] Some suitable materials for the body 201 of the conical abrasive particles may include ceramic materials, including but not limited to nitrides, oxides, carbides, borides, oxynitrides, oxyborides, oxycarbides, carbon-based materials, diamonds, naturally occurring minerals, rare earth-containing materials, natural minerals, synthetic materials, or any combination thereof. In certain cases, the conical abrasive particles may include oxide compounds such as aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, magnesium oxide, rare earth oxides, or any combination thereof.

[0123] In a particular embodiment, the body 201 may include at least 95 wt% of alumina accounting for the total weight of the body 201. In addition, in some cases, the body may include no more than 99.5 wt% of alumina accounting for the total weight of the body. In at least one embodiment, the body 201 may be substantially composed of alumina, more specifically, substantially composed of alpha alumina. In some cases, the body 201 may be formed so that it includes no more than about 1 wt% of any low-temperature alumina phase. As used herein, the low-temperature alumina phase may include transition phase alumina, bauxite or hydrated alumina, including, for example, gibbsite, boehmite, diaspore, and mixtures containing such compounds and minerals. Certain low-temperature alumina materials may also include a certain amount of iron oxide. In addition, the low-temperature alumina phase may include other minerals such as goethite, hematite, kaolinite and anatase.

[0124] In addition, in certain cases, the body 201 of the conical abrasive particles can be formed by a seeded sol-gel. In at least one embodiment, the body of any conical abrasive particles of the embodiments herein can be substantially free of iron, rare earth oxides, and combinations thereof. References herein to a body having certain characteristics (e.g., composition) will also be understood to refer to a batch of conical abrasive particles that can have the same characteristics (e.g., composition).

[0125] According to certain embodiments, certain conical abrasive particles may be a compositionally composite material such that at least two different types of grains are included in the body of the conical abrasive particles. It should be understood that different types of grains are grains having different compositions from each other. For example, the body of the conical abrasive particles may be formed such that it includes at least two different types of grains, wherein the grain types are selected from nitrides, oxides, carbides, borides, oxynitrides, oxyborides, oxycarbides, carbon-based materials, diamonds, naturally occurring minerals, rare earth-containing materials, natural minerals, synthetic materials, and combinations thereof.

[0126] The main body 201 of conical abrasive particles may include additives, such as dopants, which may be in the form of elements or compounds (e.g., oxides). Some suitable additives may include any of the materials described herein. The main body of conical abrasive particles may include one or more additives (e.g., dopants) of a specific content. For example, the main body may include an additive not greater than about 30wt% of the total weight of the main body. In some other embodiments, the amount of the additive may be less, such as not greater than about 25wt%, or not greater than about 20wt%, or not greater than about 18wt%, or not greater than about 15wt%, or not greater than about 12wt%, or not greater than about 10wt%, or not greater than about 8wt%, or not greater than about 5wt%, or not greater than about 2wt%. In addition, the amount of the additive may be at least about 0.5wt% of the total weight of the main body, such as at least about 1wt%, or at least about 2wt%, or at least about 3wt%, or at least about 4wt%, or at least about 5wt%, or at least about 8wt%, or even at least about 10wt%. It will be appreciated that the amount of additive within the body can be within a range including any of the minimum and maximum percentages noted above.

[0127] The body of the conical abrasive particles can be particularly dense. For example, the body can have a density of at least 95% of theoretical density, such as at least 96%, or at least 97%, or at least 98%, or at least 99% theoretical density.

[0128] The conical abrasive particles of the embodiments of this article are a specific type of shaped abrasive particles. The shaped abrasive particles can be formed by a specific process including molding, printing, casting, extrusion, etc. The shaped abrasive particles can be formed so that each particle has a substantially identical arrangement of surfaces and edges relative to each other. For example, the surfaces and edges of a group of shaped abrasive particles generally have the same arrangement and direction and / or two-dimensional shape as each other. Therefore, the shaped abrasive particles have a relatively high shape fidelity and consistency in the arrangement of surfaces and edges relative to each other. In addition, contour abrasive particles (CHAP) can also be formed by a specific process, which facilitates the formation of thin bodies, which can have irregular two-dimensional shapes when the main surfaces are viewed from top to bottom. CHAP can have a smaller shape fidelity than shaped abrasive particles, but can have a substantially flat and parallel main plane separated by a side surface.

[0129] In contrast, non-shaped particles can be formed by different processes and have different shape attributes than shaped abrasive particles and CHAPs. For example, non-shaped particles are typically formed by a comminution process, in which a large amount of material is formed and then crushed and sieved to obtain abrasive particles of a certain size. However, non-shaped particles will have a generally random arrangement of surfaces and edges, and generally lack any identifiable two-dimensional or three-dimensional shape in the surface and edge arrangement. In addition, non-shaped particles do not have to have shapes that are consistent with each other, so their shape fidelity is much lower than that of shaped abrasive particles or CHAPs. Non-shaped particles are generally defined by the random arrangement of each particle with respect to the surfaces and edges of other non-shaped particles.

[0130] Figure 3 A cross-sectional illustration of a coated abrasive article incorporating conical abrasive particles according to one embodiment is included. As shown, the coated abrasive 300 may include a substrate 301 and a primer layer 303 covering the surface of the substrate 301. In a particular embodiment, the coated abrasive 300 may further include a plurality of abrasive particles 305. The plurality of abrasive particles 305 may include but need not include different types of abrasive particles. For example, the plurality of abrasive particles 305 may include a first type of abrasive particles 406 (e.g., conical abrasive particles), a second type of abrasive particles 307 (e.g., unshaped or irregular abrasive particles), and optionally a third type of abrasive particles 308 (e.g., diluted abrasive particles), which may have a random shape. The coated abrasive 300 may further include a primer layer 304, which covers and bonds to the plurality of abrasive particles 305 and the primer layer 303.

[0131] According to one embodiment, substrate 301 may include organic materials, inorganic materials and combinations thereof. In some instances, substrate 301 may include woven materials. However, substrate 301 may be made of nonwoven materials. Particularly suitable substrate materials may include organic materials, including polymers, especially polyesters, polyurethanes, polypropylenes, polyimides such as KAPTON of DuPont and paper. Some suitable inorganic materials may include metals, metal alloys, especially foils of copper, aluminum, steel and combinations thereof.

[0132] The primer layer 303 can be applied to the surface of the substrate 301 in a single process, or alternatively, a plurality of abrasive particles 305 can be combined with the primer layer 303 material and applied to the surface of the substrate 301 as a mixture. Suitable primer layer 303 materials can include organic materials, particularly polymer materials, including, for example, polyesters, epoxy resins, polyurethanes, polyamides, polyacrylates, polymethacrylates, polyvinyl chlorides, polyethylenes, polysiloxanes, silicones, cellulose acetates, nitrocelluloses, natural rubbers, starches, shellacs, and mixtures thereof. In one embodiment, the primer layer 303 can include a polyester resin. The coated substrate can then be heated to cure the resin and abrasive particle material to the substrate. Typically, during this curing process, the coated substrate 301 can be heated to a temperature of about 100° C. to less than about 250° C.

[0133] In addition, it should be understood that the coated abrasive article 300 may include one or more types of abrasive particles in the plurality of abrasive particles 305. Different types of abrasive particles may differ from each other in composition, two-dimensional shape, three-dimensional shape, grain size, particle size, hardness, brittleness, agglomeration, or any combination thereof. In one embodiment, the coated abrasive article 300 may include different types of abrasive particles depending on the amount of application. It should be understood that in certain embodiments, the coated abrasive may not necessarily include different types of shaped abrasive particles, and may be substantially composed of a single type of shaped abrasive particles.

[0134] According to a particular embodiment, the plurality of abrasive grains 305 may include a limited content of agglomerated grains, more specifically, a limited content of agglomerated conical grains. Some agglomerates of conical abrasive grains may be joined or sinter-bonded to each other. In one aspect, the plurality of abrasive grains 305 may include no more than 50% agglomerated grains, such as no more than 48%, or no more than 46%, or no more than 44%, or no more than 42%, or no more than 40%, or no more than 38%, or no more than 36%, or no more than 34%, or no more than 32%, or no more than 30%, or no more than 28%, or no more than 26%, or no more than 24%, or no more than 22%, or no more than 20%, or no more than 18%, or no more than 16%, or no more than 14%, or no more than 12%, or no more than 10%, or no more than 8%, or no more than 6%, or no more than 4%, or no more than 2%, of the total number of grains in the plurality of abrasive grains 305. In a particular embodiment, the plurality of abrasive grains 305 may be free of agglomerated grains, and more specifically, may be free of conical abrasive grains that are bonded or sinter-bonded to one another. It is worth noting that in certain conventional fixed abrasive articles including shaped abrasive particles, the fixed abrasive particles can be agglomerated in the form of "twins" or "triplets," which are particles sintered to each other. The methods herein can facilitate the formation of batches of abrasive particles and fixed abrasive particles, including a plurality of abrasive particles having a limited content of agglomerated particles.

[0135] In addition, in one embodiment, the plurality of abrasive particles 305 may include a limited content of hook-shaped abrasive particles. The hook-shaped abrasive particles may include extruded hook-shaped abrasive particles. The hook-shaped abrasive particles are characterized in that at least one end of the body is significantly curled back toward the particle to be characterized as a hook shape. Figure 4 Included are images of various hook-shaped abrasive particles.

[0136] Abrasive particles may be placed on a backing (i.e., substrate) using a variety of methods, including, for example, but not limited to, projection (e.g., mechanical or electrostatic), gravity feed, production tooling with appropriately sized openings to temporarily hold the abrasive particles in a desired orientation until they are transferred to a backing or adhesive layer, vibration, pick-and-place systems, etc. Certain methods may be more suitable for controlling one or more aspects of the position and / or orientation of the abrasive particles relative to each other and the backing.

[0137] According to a particular embodiment, the conical abrasive particles can have a particular orientation, such as a perpendicular orientation relative to the substrate 301. As described in other embodiments herein, the conical abrasive particles 306 can have a tip region 210 and a base region 212 opposite the tip region 210 across the length of the body. In one aspect, a certain content of the conical abrasive particles 306 can be oriented with the tip region 210 closer to the substrate 301 than the base region 212. In at least one embodiment, a higher content of conical abrasive particles can have their tip region 210 closer to the substrate 301 than their base region 212, compared to a content of conical abrasive particles whose base region 212 is closer to the substrate 301 than their tip region 210. According to a particular embodiment, at least 60%, such as at least 70%, or at least 80%, or at least 90% of the conical abrasive particles have their tip region 210 closer to the substrate 301 than their base region 212.

[0138] After the base coat 303 having the plurality of abrasive grains 305 contained therein is fully formed, a size coat 304 may be formed to cover the plurality of abrasive grains 305 and bond them to the substrate 301. The size coat 304 may include an organic material, may be substantially made of a polymer material, and notably, polyester, epoxy resin, polyurethane, polyamide, polyacrylate, polymethacrylate, polyvinyl chloride, polyethylene, polysiloxane, silicone, cellulose acetate, nitrocellulose, natural rubber, starch, shellac, and mixtures thereof may be used.

[0139] Figure 5 A top view illustration of a portion of a coated abrasive article according to one embodiment is included. As shown, the coated abrasive article 500 may include a backing 501 and a plurality of abrasive particles 503, including conical abrasive particles 504, 505, 506, 507 and 508 (504-508) covered on the backing 501, more specifically, the coupling value backing 501. It should be understood that the conical abrasive particles are depicted as circles for ease of reference and not for accuracy of shape. In one embodiment, at least a portion of the plurality of abrasive particles 503, such as most or even all, may be placed at a predetermined position on the backing 501. According to one embodiment, the plurality of abrasive particles 503 may have a predetermined position relative to each other. In a particular embodiment, the plurality of abrasive particles 503 may have at least one of a predetermined lateral position, a predetermined longitudinal position, a predetermined radial position, a predetermined rotational direction and / or a predetermined tilt angle relative to the backing 501 and relative to each other. In a more particular embodiment, the plurality of abrasive particles 503 can have a combination of two or more of a predetermined lateral position, a predetermined longitudinal position, a predetermined radial position, a predetermined rotational orientation, or a predetermined tilt angle relative to the backing 501 and relative to each other.

[0140] According to a particular embodiment, each of the conical abrasive particles 504-508 can be disposed at a predetermined position on the backing 501. For example, each of the conical abrasive particles 504-508 can have at least one of a predetermined lateral position, a predetermined longitudinal position, a predetermined radial position, and / or a predetermined rotational orientation relative to the backing 501 and relative to each other. In a more particular embodiment, each of the conical abrasive particles 504-508 can have a combination of two or more of a predetermined lateral position, a predetermined longitudinal position, a predetermined radial position, and / or a predetermined rotational orientation relative to the backing 501 and relative to each other.

[0141] According to one aspect, the conical abrasive particles 504-508 are disposed at predetermined lateral and longitudinal locations on the backing 501. Figure 5 In the non-limiting embodiment shown in FIG. 5 , the conical abrasive particles 504 are disposed at predetermined positions 514, the conical abrasive particles 505 are disposed at predetermined positions 515, the conical abrasive particles 506 are disposed at predetermined positions 516, the conical abrasive particles 507 are disposed at predetermined positions 517, and the conical abrasive particles 508 are disposed at predetermined positions 518. Each of the predetermined positions 514, 515, 516, 517, and 518 (514-518) defines a position on the backing relative to the longitudinal axis 580 and the transverse axis 581, respectively. The longitudinal axis 580 may extend along the backing 501 and define its length, while the transverse axis 581 may extend along the backing 501 and define its width. The transverse axis 581 may be perpendicular to the longitudinal axis 580 in the plane of the backing 501. It should be understood that the spacing between adjacent abrasive particles (e.g., conical abrasive particles 504-508) may vary depending on the content and desired distribution of the abrasive particles. Furthermore, it should be understood that such predetermined positions are equally applicable to elliptical backings, which do not necessarily have longitudinal and transverse axes, but rather have radial axes extending 360 degrees and spaced a certain distance from the center.

[0142] According to another embodiment, when viewed from top to bottom, a plurality of abrasive grains 503 on the coated abrasive article may be arranged in a predetermined distribution relative to each other. The predetermined distribution may be defined by a combination of predetermined positions on a backing selected on purpose. In one embodiment, the predetermined distribution may include a pattern so that the predetermined position may define a two-dimensional array. In another embodiment, the array may include a short-range order defined by an abrasive grain unit. In yet another aspect, the array may also be a pattern with a long-range order including regular and repeating units connected together so that the arrangement may be symmetrical and / or predictable. In some cases, the array may have an order that can be predicted by a mathematical formula. It should be understood that the two-dimensional array may be formed into a polygon, an ellipsis, a decorative mark, a product mark, or other designed shapes.

[0143] In another aspect, the predetermined distribution may also include a non-shielded arrangement. For example, the non-shielded arrangement may include a controlled non-uniform distribution, a controlled uniform distribution, and a combination thereof. In some non-limiting cases, the non-shielded arrangement may include a radial pattern, a spiral pattern, a leaf pattern, an asymmetric pattern, a self-avoiding random distribution, a self-avoiding random distribution, and a combination thereof. In one embodiment, the non-shielded arrangement may include a specific arrangement of abrasive particles (i.e., shaped abrasive particles and / or dilution particles) relative to each other, wherein the degree of overlap of the abrasive particles during the initial stage of the material removal operation is not greater than about 25%, such as not greater than about 20%, not greater than about 15%, not greater than about 10%, or even not greater than about 5%. In certain cases, the non-shielded arrangement may include a distribution of abrasive particles, wherein when engaging with the workpiece during the initial stage of the material removal operation, a portion of the abrasive particles (e.g., a minority of all shaped abrasive particles on the backing, a majority of all shaped abrasive particles on the backing, or even substantially all) engage different regions of the workpiece surface. The non-masked arrangement can utilize a specific distribution of the shaped abrasive particles relative to each other and to one or more axes of the grinding direction and / or the backing.

[0144] In one embodiment, the predetermined distribution may be partially, substantially, or completely asymmetric. For example, according to one embodiment, the predetermined distribution may cover the entire abrasive article, may substantially cover the entire abrasive article (i.e., greater than 50% but less than 100%), cover multiple portions of the abrasive article, or cover a portion of the abrasive article (i.e., less than 50% of the surface area of ​​the article). As used herein, "phyllotaxis pattern" refers to a pattern associated with phyllotaxis. Phyllotaxis is the arrangement of lateral organs such as leaves, flowers, scales, florets, and seeds in various plants. Many phyllotaxis patterns are characterized by naturally occurring phenomena with significant patterns of arcs, spirals, and whorls. The seed pattern on a sunflower head is an example of this phenomenon.

[0145] Figure 6A top view illustration of a portion of a coated abrasive article according to one embodiment is included. The coated abrasive article 600 includes a backing 601 and a plurality of abrasive particles 602, which may include one or more conical abrasive particles. In one embodiment, at least a portion of the plurality of abrasive particles 602 may have a predetermined rotational orientation, which may be an orientation of the abrasive particles around a Z-axis extending perpendicular to a plane of the backing 601. In one embodiment, an abrasive particle 603 may cover the backing 601 in a first position 613, the first position having a first rotational orientation relative to a transverse axis 681, which defines the width of the backing 601. In a particular aspect, the abrasive particle 603 may have a predetermined rotational orientation defined by a rotation angle 620. The rotation angle 620 may be the minimum angle formed between a transverse plane 684 extending through a center point 621 and a bisector axis 631 parallel to a reference dimension (e.g., thickness or width) of the particle, which also extends through the center point 621 when viewed from top to bottom. According to one embodiment, the abrasive particles 602 can have a predetermined rotational orientation defined by a rotation angle 620 measured as the minimum angle between the bisector axis 631 and the transverse plane 184. According to one embodiment, the rotation angle 201 can be 0 degrees, such as at least about 2 degrees, at least about 5 degrees, at least about 10 degrees, at least about 15 degrees, at least about 20 degrees, at least about 25 degrees, at least about 30 degrees, at least about 35 degrees, at least about 40 degrees, at least about 45 degrees, at least about 50 degrees, at least about 55 degrees, at least about 60 degrees, at least about 70 degrees, at least about 80 degrees, or even at least about 85 degrees. In addition, the predetermined rotational orientation defined by the rotation angle 201 may be no greater than about 90 degrees, such as no greater than about 85 degrees, no greater than about 80 degrees, no greater than about 75 degrees, no greater than about 70 degrees, no greater than about 65 degrees, no greater than about 60 degrees, such as no greater than about 55 degrees, no greater than about 50 degrees, no greater than about 45 degrees, no greater than about 40 degrees, no greater than about 35 degrees, no greater than about 30 degrees, no greater than about 25 degrees, no greater than about 20 degrees, such as no greater than about 15 degrees, no greater than about 10 degrees, or even no greater than about 5 degrees. It should be understood that the predetermined rotational orientation may be within a range between any of the minimum and maximum values ​​above.

[0146] Figure 7A top view diagram of a portion of a coated abrasive article according to an embodiment is included. In one embodiment, a coated abrasive article 700 may include a substrate 701, which includes a longitudinal axis 780 and a transverse axis 781. The coated abrasive article 700 may further include a plurality of regions, such as a first region 710, a second region 720, a third region 730, and a fourth region 740. In one aspect, each region in regions 710, 720, 730, and 740 may be separated by a channel region 750, wherein the channel region 750 defines a particle-free region of a backing. The channel region 750 may have any size and shape, and may be particularly useful for removing chips and improving grinding operations. In a particular embodiment, the channel region 750 may have a length (i.e., the longest dimension) and a width (i.e., the shortest dimension perpendicular to the length) of the average spacing between the abrasive particles in any region of the immediate vicinity of regions 710, 720, 730, and 740. For any one of the embodiments herein, the channel region 750 is an optional feature.

[0147] According to one embodiment, the first region 710 may include a set of abrasive particles 711 having substantially random rotational orientations relative to each other. The set of abrasive particles 711 may be arranged in a random distribution relative to each other such that there is no discernible short-range or long-range order in the placement of the abrasive particles 711. In one embodiment, the set of abrasive particles 711 may be substantially uniformly distributed within the first region 710 such that the formation of agglomerates (two or more particles in contact with each other) is limited.

[0148] In another aspect, the second region 720 may include a group of abrasive particles 721 arranged in a controlled distribution relative to each other. For one embodiment, the group of abrasive particles 721 may have a regular and controlled rotational orientation relative to each other. In another embodiment, the group of shaped abrasive particles 721 may have a rotational orientation substantially the same as defined by the same rotation angle on the backing of the coated abrasive 701. In one aspect, the group of shaped abrasive particles 721 may be substantially uniformly distributed in the second region 720 so that the formation of agglomerates (two or more particles in contact with each other) is limited.

[0149] According to another aspect, the third region 730 may include a group of abrasive particles 731 and secondary particles 732. In one embodiment, the group of abrasive particles 731 and secondary particles 732 may be arranged in a controlled distribution relative to each other. For example, the group of shaped abrasive particles 731 may have a regular and controlled rotational orientation relative to each other. According to another non-limiting embodiment, the group of shaped abrasive particles 731 may generally have one of two types of rotational orientations on the backing of the coated abrasive 701. In one case, the group of shaped abrasive particles 731 and secondary particles 732 may be substantially uniformly distributed in the third region 730 so that the formation of agglomerates (two or more particles in contact with each other) is limited.

[0150] For another aspect, the fourth region 740 may include a group of abrasive particles 741 and secondary particles 742, which have a roughly random distribution relative to each other. For example, the group of abrasive particles 741 may have a random rotational orientation relative to each other. In one embodiment, the group of abrasive particles 741 and secondary particles 742 may be arranged with a random distribution relative to each other so that there is no discernible short-range or long-range order. In another embodiment, the group of shaped abrasive particles 741 and secondary particles 742 may be substantially uniformly distributed in the fourth region 740 so that the formation of agglomerates (two or more particles in contact with each other) is limited.

[0151] The coated abrasive article 700 may include different regions 710, 720, 730, and 740, each of which may include different groups of particles, such as shaped particles and secondary particles. The coated abrasive article 700 is intended to illustrate different types of groupings, arrangements, and distributions of particles that may be produced using the systems and processes of embodiments herein. The description is not intended to be limited to only those groups of particles, and it should be understood that various types of particles may be produced, such as shaped particles and secondary particles. Figure 7 The coated abrasive article shown in FIG. includes only one region. It should also be understood that Figure 7 Other coated abrasive articles including different combinations or arrangements of one or more regions are shown in FIG.

[0152] Figure 8 Includes a side view illustration of abrasive particles on a backing according to one embodiment. In one aspect, the coated abrasive articles of the embodiments herein can have a plurality of abrasive particles with controlled tilt angles, which can facilitate improved performance. To better understand these features, Figure 8A side view illustration of three abrasive particles in different orientations is provided. It should be understood that, as described in more detail herein, the coated abrasive articles of the embodiments herein may have particles in various contents in the depicted orientations. The first particle 802 may have a particle axis 803 extending at a specific tilt angle 804 relative to the surface of the backing 801. The particle axis 803 may be parallel to the longitudinal axis of the first particle 802 that defines the length of the first particle 802. The first particle 802 represents a particle with an upright orientation at a tilt angle 804 in the range of greater than 71 degrees to 90 degrees. The second particle 811 may have a particle axis 812 extending at a specific tilt angle 813 relative to the surface of the backing 801. The particle axis 812 may be parallel to the longitudinal axis of the second particle 811 that defines the length of the second particle 811. The second particle 811 represents a particle with an inclined orientation at a tilt angle 813 in the range of greater than 44 degrees to 71 degrees. The third particle 821 may have a particle axis 822 extending at a specific tilt angle 823 relative to the surface of the backing 801. The particle axis 822 can be parallel to the longitudinal axis of the third particle 821 defining the length of the third particle 821. The third particle 821 represents a flat oriented particle with an inclination angle 823 in the range of at least 0 degrees to no more than 44 degrees. It should be understood that the first particle 802, the second particle 811, and the third particle 821 can be any type of particle as described in the embodiments of this article, including but not limited to conical abrasive particles.

[0153] According to one aspect, a plurality of abrasive grains on the coated abrasive can have a specific tilt angle, such as at least 2 degrees, such as at least 5 degrees, at least 10 degrees, at least 15 degrees, at least 20 degrees, at least 25 degrees, at least 30 degrees, at least 35 degrees, at least 40 degrees, at least 45 degrees, at least 50 degrees, at least 55 degrees, at least 60 degrees, at least 70 degrees, at least 80 degrees or even at least 85 degrees. In addition, the tilt angle 136 can be no more than about 90 degrees, such as no more than about 85 degrees, no more than about 80 degrees, no more than about 75 degrees, no more than about 70 degrees, no more than about 65 degrees, no more than about 60 degrees, such as no more than about 55 degrees, no more than about 50 degrees, no more than about 45 degrees, no more than about 40 degrees, no more than about 35 degrees, no more than about 30 degrees, no more than about 25 degrees, no more than about 20 degrees, such as no more than about 15 degrees, no more than about 10 degrees or even no more than about 5 degrees. It should be understood that the tilt angle may be within the range between any minimum and maximum percentages above. The tilt angle may be measured using the techniques disclosed in US2019 / 0160630, which is incorporated herein by reference in its entirety.

[0154] According to a particular aspect, the content of the abrasive grains covering the backing can be controlled based on the intended application. For example, a plurality of abrasive grains can cover at least 5% of the total surface area of ​​the backing, such as at least 10%, or at least 20%, or at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 90%. In yet another embodiment, the coated abrasive article can be substantially free of silane.

[0155] In addition, the abrasive articles of the embodiments herein may have particles covering a specific content of the substrate. In one embodiment, these particles may define a sparse coating abrasive product, and the coating density of its particles (that is, abrasive particles, secondary particles, or both abrasive particles and secondary particles) is not more than about 70 particles / cm2. In other cases, the density of particles per square centimeter of abrasive article may be not more than about 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. In addition, in a non-limiting embodiment, the density of the sparse coating coated abrasive may be at least about 5 particles / cm2 or even at least about 10 particles / cm2. It should be understood that the density of particles per square centimeter of abrasive article may be in the range between any minimum and maximum values ​​above.

[0156] In some cases, the density of the sparse coating of the abrasive article may be no greater than about 50% of the particles (i.e., abrasive particles or secondary particles or all abrasive particles and secondary particles) covering the outer abrasive surface of the article. In other embodiments, the area of ​​the particles may be no greater than about 40%, such as no greater than about 30%, no greater than about 25%, or even no greater than about 20%, relative to the total area of ​​the surface on which the particles are placed. In addition, in a non-limiting embodiment, the coating percentage of the particles may be at least about 5%, such as at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, or even at least about 40%, relative to the total area of ​​the surface. It should be understood that the coverage percentage of the particles may be within the range between any minimum percentage and maximum percentage above.

[0157] For a given area (e.g., ream, where 1 ream = 30.66 m2) of backing, some abrasive articles may have a specific content of particles (i.e., abrasive particles or secondary particles or all abrasive particles and secondary particles). For example, in one embodiment, the abrasive article may utilize a normalized particle weight of at least about 1 lb / ream (14.8 g / m2), such as at least 5 lb / ream, or at least 10 lb / ream, or at least about 15 lb / ream, or at least about 20 lb / ream, or at least about 25 lb / ream, or even at least about 30 lb / ream. In addition, in a non-limiting embodiment, the abrasive article may contain a normalized particle weight of not more than about 90 lb / ream (1333.8 g / m2), such as not more than 80 lb / ream, or not more than 70 lb / ream, or not more than 60 lb / ream, or not more than about 50 lb / ream, or even not more than about 45 lb / ream. It will be appreciated that the abrasive articles of embodiments herein can utilize a normalized particle weight within a range between any of the minimum and maximum values ​​noted above.

[0158] In some cases, the abrasive article can be used on a specific workpiece. Suitable exemplary workpieces can include inorganic materials, organic materials, natural materials, and combinations thereof. According to specific embodiments, the workpiece can include a metal or metal alloy, such as an iron-based material, a nickel-based material, etc. In one embodiment, the workpiece can be steel, and more specifically, can be substantially composed of stainless steel (e.g., 304 stainless steel).

[0159] According to another aspect, the conical abrasive particles can have specific features that can be produced by the disclosed formation method and can promote improved performance. In one embodiment, the conical abrasive particles can have a specific taper fraction value that defines the taper of the main body portion to a specific degree. According to one embodiment, the conical abrasive particles can have an average taper fraction value of at least 0.05, or at least 0.08, or at least 0.1, or at least 0.12, or at least 0.14, or at least 0.16, or at least 0.18, or at least 0.20, or at least 0.22, or at least 0.24, or at least 0.26, or at least 0.28, or at least 0.30, or at least 0.32, or at least 0.34, or at least 0.35. In addition, in another non-limiting embodiment, the conical abrasive particles can have an average taper fraction value of not greater than 0.8, or not greater than 0.75, or not greater than 0.70, or not greater than 0.65, or not greater than 0.60, or not greater than 0.55, or not greater than 0.50, or not greater than 0.45, or not greater than 0.40, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28. It should be understood that the conical abrasive particles can have an average taper fraction value within a range including any minimum and maximum values ​​described above.

[0160] The average taper score value is measured by photographing a statistically relevant sample size of the conical abrasive particles of a batch or fixed abrasive article. The image can be taken by a suitable optical imaging device (e.g., Olympus DSX) at a suitable magnification (e.g., 10-20X). The image is then saved and analyzed using image processing software, such as the skimage library (version 0.13.1) for the python programming language (version 3.6.3). A separate image is created for each conical abrasive particle. Each of the images of the conical abrasive particles is converted to a black and white image only. The skeletonized image is then used by the skeletonization function of the image processing software. Fig.11 Included is an illustration of the profile of a conical abrasive particle according to one embodiment, the conical abrasive particle including a skeleton formed by image processing software. Using the software, a graph of the distance from the skeleton to the border (pixels) versus the distance along the skeleton (pixels) is used. Fig.12 A graph of the distance to the skeleton versus the distance along the skeleton is included for calculating the taper fraction and elongation fraction of the abrasive grain. The graph is then used to calculate the Dmax and D75 values ​​shown, where Dmax represents the point along the graph having the maximum distance between the boundary and the skeleton. D75 represents the value on the graph being 75% of Dmax, or D75 = (Dmax x 0.75). D75 further defines a point along the X-axis (i.e., the distance along the skeleton) as L75. Dmax also defines a point along the X-axis, which is defined as Lmax. Note also that, as Fig.12 As provided in , the tip defines the starting point, so Ltip=0 on the x-axis. The total length of the skeleton is defined as Ls. The taper score value for each image of each particle is calculated as L75 / Ls. The mean taper score value is the average of the taper score values ​​of all measured particles. The taper score standard deviation is also calculated from the entire taper score values ​​measured for the particles in the sample.

[0161] In another aspect, the conical abrasive grain can have a specific taper fraction standard deviation. For example, the conical abrasive grain can have at least 0.025, such as at least 0.028, or at least 0.030, or at least 0.032, or at least 0.035, or at least 0.038, or at least 0.040, or at least 0.042, or at least 0.045, or at least 0.048, or at least 0.050, or at least 0.052, or at least 0.055, or at least 0.058, or at least 0.060 taper fraction standard deviation. Furthermore, in another non-limiting embodiment, the taper score standard deviation may be no greater than 0.090, such as no greater than 0.088, or no greater than 0.085, or no greater than 0.082, or no greater than 0.080, or no greater than 0.078, or no greater than 0.075, or no greater than 0.072, or no greater than 0.070, or no greater than 0.068, or no greater than 0.065, or no greater than 0.062, or no greater than 0.060, or no greater than 0.058, or no greater than 0.055, or no greater than 0.052, or no greater than 0.050, or no greater than 0.048, or no greater than 0.045, or no greater than 0.042, or no greater than 0.040. It should be understood that the tapered abrasive particles can have a taper fraction standard deviation within a range including any of the minimum and maximum values ​​described above, including, for example but not limited to, within a range of at least 0.025 and not more than 0.085, or within a range of at least 0.028 and not more than 0.070, or within a range of at least 0.03 and not more than 0.06.

[0162] In another embodiment, a plurality of abrasive grains can have a specific average batch taper fraction value. The average batch taper fraction value can be calculated from a plurality of particles in the same manner as the average batch taper fraction value for the conical abrasive grains provided above. For example, a plurality of abrasive grains can have an average batch taper fraction value of at least 0.05, such as at least 0.08, or at least 0.1, or at least 0.12, or at least 0.14, or at least 0.16, or at least 0.18, or at least 0.20, or at least 0.22, or at least 0.24, or at least 0.26, or at least 0.28, or at least 0.30, or at least 0.32, or at least 0.34, or at least 0.35. In addition, in another non-limiting embodiment, a plurality of abrasive grains may have an average batch taper fraction value of not more than 0.8, or not more than 0.75, or not more than 0.70, or not more than 0.65, or not more than 0.60, or not more than 0.55, or not more than 0.50, or not more than 0.45, or not more than 0.40, or not more than 0.35, or not more than 0.32, or not more than 0.30, or not more than 0.28. It should be understood that the average batch taper fraction value may be within the range including any minimum and maximum values ​​mentioned above.

[0163] According to another aspect, the conical abrasive grains may have specific features that can be produced by the disclosed formation method and can promote improved performance. In one embodiment, the conical abrasive grains may have a specific average elongation fractional value that defines the taper in the elongation zone of each body of the conical abrasive grains. According to one embodiment, the conical abrasive grains may have an average elongation fractional value of at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6. In addition, in another non-limiting embodiment, the conical abrasive grains may have an average elongation fractional value of not more than 0.9, or not more than 0.8, or not more than 0.7, or not more than 0.6. It should be understood that the conical abrasive grains may have an average elongation fractional value in the range including any minimum and maximum values ​​mentioned above.

[0164] The mean elongation score value was calculated using the same imaging technique and information collected to calculate the mean taper score value and the taper score standard deviation. Fig.11 and Fig.12 , elongation fraction value = [(L75-Lmax) / Ls], where (L75-Lmax) is an absolute value. The average elongation fraction value can be calculated from the overall elongation fraction values ​​of all measured abrasive particles.

[0165] In yet another aspect, the conical abrasive grain can have a specific elongation fraction standard deviation. For example, the conical abrasive grain can have at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1, or at least 0.11, or at least 0.12, or at least 0.13, or at least 0.14 elongation fraction standard deviation. In addition, in another non-limiting embodiment, the elongation fraction standard deviation may be no more than 0.3, or no more than 0.25, or no more than 0.2, or no more than 0.19, or no more than 0.18, or no more than 0.17, or no more than 0.16, or no more than 0.15, or no more than 0.14, or no more than 0.13. It should be appreciated that the conical abrasive grain can have the elongation fraction standard deviation in the scope comprising any minimum and maximum values ​​mentioned above.

[0166] In yet another aspect, a plurality of abrasive grains can have specific elongation fractional value, and this elongation fractional value is defined as average batch elongation fractional value.In one embodiment, a plurality of abrasive grains comprise at least 0.2, such as at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 average batch elongation fractional value.In addition, in another embodiment, a plurality of abrasive grains can have not more than 0.9, such as not more than 0.8, not more than 0.7 or not more than 0.6 average batch elongation fractional value.It should be appreciated that a plurality of abrasive grains can have the average batch elongation fractional value in the scope comprising any minimum and maximum values ​​mentioned above.Average batch elongation fractional value can be calculated from a plurality of particles in the same manner as the average elongation fractional value for the conical abrasive grain provided above.

[0167] In yet another aspect, a plurality of abrasive grains can have a specific elongation fraction standard deviation, and this elongation fraction standard deviation is defined as a batch elongation fraction standard deviation. For example, a plurality of abrasive grains can have a batch elongation fraction standard deviation of at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1, or at least 0.11, or at least 0.12, or at least 0.13, or at least 0.14. In addition, in another non-limiting embodiment, the batch elongation fraction standard deviation may be not more than 0.3, or not more than 0.25, or not more than 0.2, or not more than 0.19, or not more than 0.18, or not more than 0.17, or not more than 0.16, or not more than 0.15, or not more than 0.14, or not more than 0.13. It will be appreciated that the plurality of abrasive grains can have a bulk elongation fraction standard deviation within a range including any of the minimum and maximum values ​​noted above.

[0168] In yet another aspect, it has been noted that the conical abrasive particles can be formed to have a specific relationship between the average taper fraction value and the average elongation fraction value. For example, in one non-limiting embodiment, the average elongation fraction value can be greater than the average taper fraction value, which is different from other two-dimensional shapes such as triangles, which have a consistent taper along the entire length of the body, so the average taper fraction value is likely to be significantly greater than the average elongation fraction value. According to one embodiment, the average elongation fraction value can be at least 10% greater than the average taper fraction value, wherein the average elongation fraction value>[average taper fraction value+(average taper fraction value×10%)]. In addition, in another non-limiting embodiment, the average elongation fraction value may be greater than the average taper fraction value, such as at least 20% greater, or at least 30% greater, or at least 40% greater, or at least 50% greater, or at least 60% greater, or at least 70% greater, or at least 80% greater, or at least 90% greater, or at least 100% greater, or at least 120% greater, or at least 140% greater, or at least 160% greater, or at least 180% greater, or at least 200% greater, or at least 250% greater, or at least 300% greater than the average taper fraction value. According to one non-limiting embodiment, the average elongation fraction value may be no more than 1000% greater than the average taper fraction value, such as no more than 900%, or no more than 800%, or no more than 700%, or no more than 600%, or no more than 500%, or no more than 400%, or no more than 300%, or no more than 200%, or no more than 150%. It will be appreciated that the average elongation fraction value can be greater than the average taper fraction value within a range including any of the minimum and maximum percentages noted above, including for example but not limited to at least 50% greater and no more than 500% greater than the average taper fraction.

[0169] In yet another aspect, the conical abrasive particles can have a special regular shape defined by compactness. The compactness of the particles is measured by dividing the actual area of ​​the body of the particles observed in two dimensions by the convex hull area of ​​the body of the particles observed in two dimensions. The measurement of the actual area of ​​the particles and the convex hull area can be carried out by photographing the statistically relevant sample size of the conical abrasive particles from batches or fixed abrasive products. The image can be taken by a suitable optical imaging device (e.g., OlympusDSX) with a suitable magnification (e.g., 10-20X). The image is then saved and analyzed using image processing software such as ImageJ. A separate image is created for each conical abrasive particle. Each image in the image of the conical abrasive particle has become an image of only black and white. Fig.13 A two-dimensional black and white image of a conical abrasive particle according to one embodiment is included. Fig.13The image processing software calculates the white area as the actual area of ​​the body of the particle observed in two dimensions of length and width or length and thickness. Using the image processing software, a convex hull is drawn around the perimeter of the particle using the shape filter plug-in in ImageJ. The imaging processing software then calculates the area within the convex hull. The compactness of each particle is calculated based on the actual area of ​​each particle divided by the convex hull area. The average compactness is the average of the compactness values ​​of all measured particles. The compactness standard deviation is also calculated from all compactness values ​​measured for particles in the sample.

[0170] According to one embodiment, the conical abrasive grain can have a specific compactness, which can be produced by a formation method and can also promote improved performance. For example, the conical abrasive grain can have an average compactness of at least 0.87, or at least 0.88, or at least 0.89, or at least 0.90, or at least 0.91, or at least 0.92, or at least 0.93, or at least 0.94, or at least 0.95, or at least 0.96, or at least 0.97. In another non-limiting embodiment, the conical abrasive grain can have an average compactness of not more than 0.99, or not more than 0.98, or not more than 0.97, or not more than 0.96, or not more than 0.95. It should be understood that the average compactness of the conical abrasive grain can be in the scope between any minimum and maximum values ​​mentioned above.

[0171] In yet another aspect, the conical abrasive grains can have a specific compactness standard deviation, which can be significantly different from other shaped abrasive grains and represent a high degree of shape fidelity. For example, the conical abrasive grains can have a compactness standard deviation of not more than 0.05, or not more than 0.045, or not more than 0.04, or not more than 0.035, or not more than 0.030, or not more than 0.025, or not more than 0.020. In a non-limiting embodiment, the conical abrasive grains can have a compactness standard deviation of at least 0.0001, or at least 0.001, or at least 0.01, or at least 0.015, or at least 0.020. It should be understood that the compactness standard deviation can be in the range including any minimum and maximum values ​​mentioned above.

[0172] According to one embodiment, a plurality of abrasive grains may have a specific compactness, which may be produced by a formation method and may also promote improved performance. For example, a plurality of abrasive grains may have an average batch compactness of at least 0.87, or at least 0.88, or at least 0.89, or at least 0.90, or at least 0.91, or at least 0.92, or at least 0.93, or at least 0.94, or at least 0.95, or at least 0.96, or at least 0.97. In another non-limiting embodiment, a plurality of abrasive grains may have an average batch compactness of not more than 0.99, or not more than 0.98, or not more than 0.97, or not more than 0.96, or not more than 0.95. It should be understood that the average batch compactness of a plurality of abrasive grains may be in the range between any minimum and maximum values ​​mentioned above. The average batch density of a plurality of abrasive grains may be measured in the same manner as for measuring the average compactness of a conical abrasive grain, but instead measured on a sample representing a batch or a fixed abrasive article.

[0173] In yet another aspect, a plurality of abrasive grains may have a specific batch density standard deviation, which may be significantly different from other shaped abrasive grains and represent a high degree of shape fidelity. For example, a plurality of abrasive grains may have a batch density standard deviation of not more than 0.05, or not more than 0.045, or not more than 0.04, or not more than 0.035, or not more than 0.030, or not more than 0.025, or not more than 0.020. In a non-limiting embodiment, a plurality of abrasive grains may have a batch density standard deviation of at least 0.0001, or at least 0.001, or at least 0.01, or at least 0.015, or at least 0.020. It should be understood that the batch density standard deviation may be within the range between any minimum and maximum values ​​included above.

[0174] Many different aspects and embodiments are possible. Some of these aspects and embodiments are described herein. After reading this specification, those skilled in the art will appreciate that those aspects and embodiments are merely illustrative and do not limit the scope of the invention. Embodiments may be according to any one or more embodiments listed below.

[0175] According to another non-limiting aspect, a coated abrasive article including extruded abrasive particles having one or more features of the tapered abrasive particles of the embodiments herein can have specific grinding properties. Fig.15 Includes a graphical representation of a graph of grinding energy versus cumulative material removed. Specifically, Fig.15The graph 1501 includes a curve 1501 defining an initial specific grinding energy (i.e., specific grinding energy) at the intersection of the curve 1502 and the Y-axis. The graph 1501 also has a second specific grinding energy value 1503, which is defined by a point on the Y-axis at a cumulative material removal of 1000 grams. In the illustrated embodiment, the curve 1501 also includes a third specific grinding energy value 1504 associated with the end of the curve 1501, which is associated with a cumulative material removal of 2000 grams.

[0176] Various properties of the coated abrasive article used to form the curve can be calculated from the curve 1501. For example, in one non-limiting embodiment, the coated abrasive article can have a total ΔSGE factor, which is calculated by dividing the total change in specific grinding energy by the total material removed from the curve 1501. That is, the total ΔSGE factor = [(1504-1502) / 2000 g]. In one non-limiting embodiment, for at least 1500 g of total material removed, the total ΔSGE factor can be no greater than 6 x 10-4 [(Hp / in3 / min) / g]. According to another non-limiting embodiment, the total ΔSGE factor may be no greater than 5.5 x 10-4 [(Hp / in3 / min) / g] for at least 1500 g of total removed material, such as no greater than 5 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.8 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.7 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.6 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.5 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.4 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.2 x 10-4 [(Hp / in3 / min) / g], or no greater than 4 x 10-4 [(Hp / in3 / min) / g] for at least 1500 g of total removed material. 10-4 [(Hp / in3 / min) / g]. Further, in another non-limiting embodiment, for at least 1500 g of total material removal, the total ΔSGE factor may be at least 0.1x10-6 [(Hp / in3 / min) / g], such as at least 0.1x 10-5 [(Hp / in3 / min) / g], or at least 0.1x 10-4 [(Hp / in3 / min) / g], or at least 1x 10-4 [(Hp / in3 / min) / g], or at least 3x 10-4 [(Hp / in3 / min) / g] for at least 1500 g of total material removal. It should be understood that the total ΔSGE factor can be within a range including any of the minimum and maximum values ​​noted above. Further, as noted above, the total ΔSGE factor is preferably calculated based on a minimum of 1500 grams of material removed by a given coated abrasive sample on a steel workpiece under the conditions described in Example 3 herein. However, in certain non-limiting cases, if at least 1500 g is not removed, an overall ΔSGE factor may still be calculated based on the total material removed.

[0177] In another aspect, the coated abrasive article can have a specific initial ΔSGE factor calculated by the change in specific grinding energy for the first 1000 grams of cumulative material removed. According to curve 1501, initial ΔSGE factor = [(1503-1502) / 1000 g]. In one non-limiting embodiment, the initial ΔSGE factor may be no greater than 5 x 10-4 [(Hp / in3 / min) / g] for the first 1000 g of removed material, such as no greater than 4.9 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.8 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.7 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.6 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.5 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.4 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.2 x 10-4 [(Hp / in3 / min) / g] for the first 1000 g of removed material. In another non-limiting embodiment, the initial ΔSGE factor may be at least 0.1 x 10-6 [(Hp / in3 / min) / g] for the first 1000 g of removed material, or at least 0.1 x 10-5 [(Hp / in3 / min) / g], or at least 0.1 x 10-4 [(Hp / in3 / min) / g], or at least 1 x 10-4 [(Hp / in3 / min) / g], or at least 2 x 10-4 [(Hp / in3 / min) / g], or at least 3 x 10-4 [(Hp / in3 / min) / g] for the first 1000 g of removed material. It should be understood that the initial ΔSGE factor can be within a range including any of the minimum and maximum values ​​described above. As described above, the initial ΔSGE factor is preferably calculated based on the first 1000 grams of removed material under the conditions described in Example 3 herein. However, in certain non-limiting cases, if 1000 g is not removed, the initial ΔSGE factor can still be calculated based on the SGE value of 50% of the total cumulative removed material (i.e., from the SGE value of 0% of the total cumulative removed material to the SGE value of 50% of the total cumulative removed material).

[0178] In yet another non-limiting aspect, the coated abrasive article can have a specific final ΔSGE factor calculated from the change in specific grinding energy of the greater of: 1) at least the last 800 grams of cumulative material removed or 2) the cumulative material removed after the first 1000 grams of material have been removed. According to curve 1501, the final ΔSGE factor = [(1504-1503) / (2000-1000) g]. In one embodiment, the final ΔSGE factor may be no greater than 6 x 10-4 [(Hp / in3 / min) / g] for at least the final 800 g of cumulative material removed, such as no greater than 5.5 x 10-4 [(Hp / in3 / min) / g], or no greater than 5.3 x 10-4 [(Hp / in3 / min) / g], or no greater than 5 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.8 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.5 x 10-4 [(Hp / in3 / min) / g], or no greater than 4.3 x 10-4 [(Hp / in3 / min) / g], or no greater than 4 x 10-4 [(Hp / in3 / min) / g], or no greater than 3.9 x 10-4 [(Hp / in3 / min) / g] for at least the final 800 g of cumulative material removed. [(Hp / in3 / min) / g] or not more than 3.7x 10-4[(Hp / in3 / min) / g]. Moreover, in another embodiment, for at least the final 800 g of material, the final ΔSGE factor may be at least 1x 10-6[(Hp / in3 / min) / g], such as at least 1x 10-5[(Hp / in3 / min) / g], or at least 1x 10-4[(Hp / in3 / min) / g], or at least 2x 10-4[(Hp / in3 / min) / g] for at least the final 800 g of material. It should be understood that the final ΔSGE factor can be within a range including any of the minimum and maximum values ​​noted above. As described above, the final ΔSGE factor is preferably calculated based on at least the last 800 grams of removed material under the conditions described in Example 3 herein. However, in certain non-limiting cases, if 800 g is not removed, the final ΔSGE factor may still be calculated based on the SGE value after 50% of the total cumulative material removed (i.e., from the SGE value at 51% of the total cumulative material removed to the SGE value at 100% of the total cumulative material removed).

[0179] Example

[0180] Embodiment 1. A coated abrasive product, comprising:

[0181] substrate; and

[0182] A plurality of abrasive grains overlies the substrate, wherein the plurality of abrasive grains includes tapered abrasive grains having a taper fraction standard deviation of at least 0.025 and no greater than 0.090.

[0183] Embodiment 2. The coated abrasive article of embodiment 1, wherein at least 5% of the abrasive particles are conical abrasive particles, or at least 8%, or at least 10%, or at least 12%, or at least 15%, or at least 18%, or at least 20%, or at least 22%, or at least 25%, or at least 28%, or at least 30%, or at least 32%, or at least 35%, or at least 38%, or at least 40%, or at least 42%, or at least 45%, or at least 46%, or at least 47%, or at least 48%, or at least 49%, or at least 50%, or at least 51%, or at least 52%, or at least 53%, or at least 54%, or at least 55%, or at least 56%, or at least 57%, or at least 58%, or at least 59%, or at least 60%, or at least 61%, or at least 62%, or at least 63%, or at least 64%, or at least 65%, or at least 66%, or at least 67%, or at least 68%, or at least 69%, or at least 70%, or at least 71%, or at least 72%, or at least 73%, or at least 74%, or at least 75%, or at least 76%, or at least 77%, or at least 78%, or at least 79%, or at least 80%, or at least 81%, or at least 82%, or at least 83%, or at least 84%, or at least 85%, or at least 86%, or at least 87%, or at least 88%, or at least or at least 82%, or at least 85%, or at least 88%, or at least 90%, or at least 92%, or at least 95%, or at least 98%, or at least 99%.

[0184] Embodiment 3. The coated abrasive article of Embodiment 1, wherein the plurality of abrasive particles comprises only pyramidal abrasive particles.

[0185] Embodiment 4. The coated abrasive article of embodiment 1, wherein the plurality of abrasive particles comprises a blend comprising a first portion of abrasive particles and a second portion of abrasive particles, and wherein the pyramidal abrasive particles are included in the first portion, the second portion, or both.

[0186] Embodiment 5. The coated abrasive article of embodiment 1, wherein the plurality of abrasive particles comprises at least 10 grams of abrasive particles, or at least 100 grams of abrasive particles, or at least 500 grams of abrasive particles, or at least 1 kg of abrasive particles, or at least 10 kg of abrasive particles.

[0187] Embodiment 6. The coated abrasive article of embodiment 1, wherein the plurality of abrasive particles comprises at least 10 abrasive particles, or at least 20 abrasive particles, or at least 30 abrasive particles, or at least 50 abrasive particles, or at least 100 abrasive particles, or at least 500 abrasive particles.

[0188] Embodiment 7. The coated abrasive article of embodiment 1, wherein each of the conical abrasive particles comprises a body having a length, a width, and a thickness, wherein length>width>thickness.

[0189] Embodiment 8. The coated abrasive article of embodiment 7, wherein the conical abrasive particles have a first order aspect ratio (length / width) of at least 1.1, or at least 1.2, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 3.5, or at least 4, or at least 4.5, or at least 5, or at least 5.5, or at least 6, or at least 8, or at least 10.

[0190] Embodiment 9. The coated abrasive article of embodiment 8, wherein the first stage aspect ratio (length / width) is no greater than 1000, or no greater than 100, or no greater than 50, or no greater than 20, or no greater than 10, or no greater than 5, or no greater than 3, or no greater than 2.8.

[0191] Example 10. The coated abrasive article of Example 7, wherein the conical abrasive particles comprise a first order aspect ratio standard deviation [STDEV(length / width)] of not more than 0.55, or not more than 0.52, or not more than 0.50, or not more than 0.48, or not more than 0.45, or not more than 0.42, or not more than 0.40, or not more than 0.38, or not more than 0.35, or not more than 0.32, or not more than 0.30, or not more than 0.28, or not more than 0.25, or not more than 0.22, or not more than 0.20, or not more than 0.18, or not more than 0.15.

[0192] Example 11. The coated abrasive article of Example 10, wherein the first-order aspect ratio standard deviation [STDEV(length / width)] is at least 0.01, or at least 0.05, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35, or at least 0.4.

[0193] Embodiment 12. The coated abrasive article of embodiment 7, wherein the conical abrasive particles have a secondary aspect ratio (length / thickness) of at least 1.1, or at least 1.2, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 3.5, or at least 4, or at least 4.5, or at least 5, or at least 5.5, or at least 6, or at least 8, or at least 10.

[0194] Embodiment 13. The coated abrasive article of embodiment 12, wherein the secondary aspect ratio (length / thickness) is no greater than 1000, or no greater than 100, or no greater than 50, or no greater than 20, or no greater than 10, or no greater than 5, or no greater than 3, or no greater than 2.8.

[0195] Example 14. The coated abrasive article of Example 7, wherein the conical abrasive particles comprise a second order aspect ratio standard deviation [STDEV(length / thickness)] of not more than 0.55, or not more than 0.52, or not more than 0.50, or not more than 0.48, or not more than 0.45, or not more than 0.42, or not more than 0.40, or not more than 0.38, or not more than 0.35, or not more than 0.32, or not more than 0.30, or not more than 0.28, or not more than 0.25, or not more than 0.22, or not more than 0.20, or not more than 0.18, or not more than 0.15, or not more than 0.12, or not more than 0.10.

[0196] Example 15. The coated abrasive article of Example 14, wherein the second order aspect ratio standard deviation [STDEV(length / thickness)] is at least 0.01, or at least 0.05, or at least 0.07, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35, or at least 0.4.

[0197] Example 16. The coated abrasive article of Example 7, wherein the conical abrasive particles have a tertiary aspect ratio (width / thickness) of at least 0.5, or at least 0.6, or at least 0.7, or at least 0.8, or at least 0.9, or at least 1.0, or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 4.

[0198] Example 17. The coated abrasive article of Example 16, wherein the tertiary aspect ratio (width / thickness) is no greater than 10, or no greater than 8, or no greater than 5, or no greater than 3, or no greater than 2, or no greater than 1.5, or no greater than 1.3, or no greater than 1.1.

[0199] Example 18. The coated abrasive article of Example 7, wherein the conical abrasive particles comprise a third order aspect ratio standard deviation [STDEV(width / thickness)] of not greater than 0.55, or not greater than 0.52, or not greater than 0.50, or not greater than 0.48, or not greater than 0.45, or not greater than 0.42, or not greater than 0.40, or not greater than 0.38, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28, or not greater than 0.25, or not greater than 0.22, or not greater than 0.20, or not greater than 0.18, or not greater than 0.15, or not greater than 0.12, or not greater than 0.10.

[0200] Example 19. The coated abrasive article of Example 18, wherein the third-order aspect ratio standard deviation [STDEV(width / thickness)] is at least 0.01, or at least 0.05, or at least 0.07, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35 or at least 0.4.

[0201] Embodiment 20. The plurality of abrasive particles of Embodiment 1, wherein each particle of the abrasive particles of the plurality of abrasive particles comprises a body having a length, a width, and a thickness, wherein length>width>thickness.

[0202] Example 21. The coated abrasive article of Example 20, wherein the plurality of abrasive particles have a first batch aspect ratio [B (length / width)] of at least 1.1, or at least 1.2, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 3.5, or at least 4, or at least 4.5, or at least 5, or at least 5.5, or at least 6, or at least 8, or at least 10.

[0203] Example 22. The coated abrasive article of Example 21, wherein the first-stage batch aspect ratio [B (length / width)] is not greater than 1000, or not greater than 100, or not greater than 50, or not greater than 20, or not greater than 10, or not greater than 5, or not greater than 3, or not greater than 2.8.

[0204] Embodiment 23. A coated abrasive article according to embodiment 20, wherein the plurality of abrasive particles comprises a first order batch aspect ratio standard deviation [STDEV(length / width)] of not greater than 0.55, not greater than 0.52, or not greater than 0.50, or not greater than 0.48, or not greater than 0.45, or not greater than 0.42, or not greater than 0.40, or not greater than 0.38, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28, or not greater than 0.25, or not greater than 0.22, or not greater than 0.20, or not greater than 0.18, or not greater than 0.15.

[0205] Embodiment 24. A coated abrasive article according to embodiment 23, wherein the first-stage batch aspect ratio standard deviation [STDEV(length / width)] is at least 0.01, or at least 0.05, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35, or at least 0.4.

[0206] Embodiment 25. A coated abrasive article according to embodiment 20, wherein the plurality of abrasive particles have a second batch aspect ratio [B(length / thickness)] of at least 1.1, or at least 1.2, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 3.5, or at least 4, or at least 4.5, or at least 5, or at least 5.5, or at least 6, or at least 8, or at least 10.

[0207] Embodiment 26. A coated abrasive article according to Embodiment 25, wherein the second batch aspect ratio [B (length / thickness)] is not greater than 1000, or not greater than 100, or not greater than 50, or not greater than 20, or not greater than 10, or not greater than 5, or not greater than 3, or not greater than 2.8.

[0208] Embodiment 27. A coated abrasive article according to embodiment 20, wherein the plurality of particles comprises a second level batch aspect ratio standard deviation [STDEV(length / thickness)] of not more than 0.55, or not more than 0.52, or not more than 0.50, or not more than 0.48, or not more than 0.45, or not more than 0.42, or not more than 0.40, or not more than 0.38, or not more than 0.35, or not more than 0.32, or not more than 0.30, or not more than 0.28, or not more than 0.25, or not more than 0.22, or not more than 0.20, or not more than 0.18, or not more than 0.15, or not more than 0.12, or not more than 0.10.

[0209] Example 28. A coated abrasive product according to Example 27, wherein the second batch aspect ratio standard deviation [STDEV(length / thickness)] is at least 0.01, or at least 0.05, or at least 0.07, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35 or at least 0.4.

[0210] Embodiment 29. A coated abrasive article according to embodiment 20, wherein the plurality of abrasive particles have a third batch aspect ratio [B(width / thickness)] of at least 0.5, or at least 0.6, or at least 0.7, or at least 0.8, or at least 0.9, or at least 1.0, or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 4.

[0211] Embodiment 30. A coated abrasive article according to Embodiment 29, wherein the third batch aspect ratio [B(width / width)] is not greater than 10, or not greater than 8, or not greater than 5, or not greater than 3, or not greater than 2, or not greater than 1.5, or not greater than 1.3 or not greater than 1.1.

[0212] Embodiment 31. A coated abrasive article according to embodiment 20, wherein the conical abrasive particles comprise a third-order batch aspect ratio standard deviation [STDEV(width / thickness)] of not greater than 0.55, or not greater than 0.52, or not greater than 0.50, or not greater than 0.48, or not greater than 0.45, or not greater than 0.42, or not greater than 0.40, or not greater than 0.38, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28, or not greater than 0.25, or not greater than 0.22, or not greater than 0.20, or not greater than 0.18, or not greater than 0.15, or not greater than 0.12, or not greater than 0.10.

[0213] Example 32. A coated abrasive product according to Example 31, wherein the third-level batch aspect ratio standard deviation [STDEV(width / thickness)] is at least 0.01, or at least 0.05, or at least 0.07, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35 or at least 0.4.

[0214] Embodiment 33. A coated abrasive article according to embodiment 1, wherein each of the conical abrasive particles comprises a body, the body includes a tip region, the tip region includes a tip of the body, and the base region includes a base of the body, wherein the base region is at an opposite end of the body relative to the tip region along the length of the body.

[0215] Embodiment 34. The coated abrasive article of embodiment 33, wherein the tip is defined by the convergence of at least 2 surfaces of the body, or the convergence of at least 3 surfaces of the body, or the convergence of at least 4 surfaces of the body.

[0216] Embodiment 35. The coated abrasive article of embodiment 33, wherein the tip comprises a tip edge having a length less than an average width or an average thickness of the body.

[0217] Embodiment 36. A coated abrasive article according to embodiment 33, wherein the tip comprises a tip edge having a wedge shape defined by the convergence of side surfaces across a width dimension of the particle, wherein the tip edge length is substantially similar to the thickness of the body.

[0218] Embodiment 37. A coated abrasive product according to Embodiment 33, wherein the tip includes a tip edge having a tip edge length of not more than 99%, or not more than 95%, or not more than 90%, or not more than 85%, or not more than 80%, or not more than 75%, or not more than 70%, or not more than 60%, or not more than 50%, or not more than 40% or not more than 30% of the average thickness of the body.

[0219] Embodiment 38. A coated abrasive article according to Embodiment 37, wherein the tip edge length is at least 20%, or at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 90% or at least 95% of the average thickness of the body.

[0220] Embodiment 39. The coated abrasive article of Embodiment 33, wherein the tip comprises a tip edge having a length less than an average width of the body.

[0221] Embodiment 40. A coated abrasive product according to Embodiment 39, wherein the tip edge length is no greater than 99% of the average width, or no greater than 95% of the average width, or no greater than 90%, or no greater than 85%, or no greater than 80%, or no greater than 75%, or no greater than 70%, or no greater than 60%, or no greater than 50%, or no greater than 40% or no greater than 30%.

[0222] Embodiment 41. A coated abrasive article according to Embodiment 40, wherein the tip edge length is at least 0.1%, or at least 1%, or at least 2%, or at least 3%, or at least 5%, or at least 8%, or at least 10%, or at least 12%, or at least 15%, or at least 20% of the average width.

[0223] Embodiment 42. The coated abrasive article of Embodiment 33, wherein the tip comprises a tip edge having a length substantially similar to the thickness of the body.

[0224] Embodiment 43. The coated abrasive article of Embodiment 33, wherein the tip region is defined by a taper comprising a decrease in the width or thickness of the body over the length of the tip region.

[0225] Embodiment 44. The coated abrasive article of Embodiment 33, wherein the tip region is defined by a taper comprising a decrease in the width of the body over the length of the tip region.

[0226] Embodiment 45. The coated abrasive article of Embodiment 44, wherein the tip region is defined by a taper comprising a decrease in the width and thickness of the body over the length of the tip region.

[0227] Embodiment 46. The coated abrasive article of Embodiment 44, wherein the tip region is defined by a taper including a body having a width variation greater than a thickness variation of the body in the tip region.

[0228] Embodiment 47. The coated abrasive article of Embodiment 44, wherein the tip region is defined by a taper including a change in body width, and wherein the thickness is substantially the same throughout the length of the tip region.

[0229] Embodiment 48. The coated abrasive article of Embodiment 33, wherein the tip region comprises an asymmetric taper comprising a first surface and a second surface, wherein the first surface has a different profile than the second surface.

[0230] Embodiment 49. A coated abrasive article according to Embodiment 33, wherein the base includes a protrusion extending from the body, wherein the protrusion extends at an angle relative to the longitudinal axis of the body, wherein the base region includes a base angle of at least 91 degrees and no greater than 180 degrees.

[0231] Embodiment 50. The coated abrasive article of Embodiment 33, wherein the base region comprises a base having a base surface, wherein the base surface is angled relative to the longitudinal axis of the body.

[0232] Embodiment 51. The coated abrasive article of Embodiment 33, wherein the base region comprises a base having a base surface, wherein the base surface is angled relative to the longitudinal axis of the body.

[0233] Embodiment 52. The coated abrasive article of Embodiment 51, wherein the base surface is at an acute angle relative to the longitudinal axis of the body.

[0234] Example 53. A coated abrasive product according to Example 52, wherein the angle of the base surface relative to the longitudinal axis of the body is no greater than 90 degrees, or no greater than 88 degrees, or no greater than 86 degrees, or no greater than 84 degrees, or no greater than 82 degrees, or no greater than 80 degrees, or no greater than 75 degrees, or no greater than 70 degrees, or no greater than 65 degrees, or no greater than 60 degrees, or no greater than 55 degrees, or no greater than 50 degrees, or no greater than 45 degrees, or no greater than 40 degrees.

[0235] Embodiment 54. A coated abrasive article according to Embodiment 53, wherein the angle of the base surface relative to the longitudinal axis of the body is at least 5 degrees, or at least 10 degrees, or at least 15 degrees, or at least 20 degrees, or at least 25 degrees, or at least 30 degrees, or at least 35 degrees, or at least 40 degrees, or at least 45 degrees, or at least 50 degrees or at least 55 degrees.

[0236] Embodiment 55. The coated abrasive article of embodiment 33, wherein the base encloses a base surface, the base surface comprising peaks and valleys.

[0237] Embodiment 56. The coated abrasive article of Embodiment 55, wherein the arrangement of peaks and valleys is a random arrangement of peaks and valleys.

[0238] Embodiment 57. The coated abrasive article of Embodiment 33, wherein the base comprises a base surface having a surface roughness greater than a surface roughness of a side surface of the body in the elongated region or the tip region.

[0239] Embodiment 58. The coated abrasive article of Embodiment 33, wherein the base comprises a base surface having a plurality of peaks, wherein at least one peak of the plurality of peaks has a tip radius that is less than a tip radius of the tip of the body.

[0240] Embodiment 59. The coated abrasive article of Embodiment 58, wherein at least 2 different peaks in the plurality of peaks each have a tip radius that is less than the tip radius of the tip of the body.

[0241] Embodiment 60. The coated abrasive article of Embodiment 33, wherein the base comprises a primary peak observed in two dimensions defined by length and width, wherein the primary peak comprises a primary peak angle of at least 45 degrees and no greater than 150 degrees.

[0242] Embodiment 61. A coated abrasive article according to embodiment 60, wherein the first order peak angle is at least 50 degrees, or at least 55 degrees, or at least 60 degrees, or at least 65 degrees, or at least 70 degrees, or at least 75 degrees, or at least 80 degrees, or at least 85 degrees, or at least 90 degrees, or at least 95 degrees, or at least 100 degrees.

[0243] Embodiment 62. A coated abrasive product according to Embodiment 60, wherein the first-order peak angle is not greater than 145 degrees, or not greater than 140 degrees, or not greater than 135 degrees, or not greater than 130 degrees, or not greater than 125 degrees, or not greater than 120 degrees, or not greater than 115 degrees, or not greater than 110 degrees, or not greater than 100 degrees or not greater than 95 degrees.

[0244] Embodiment 63. The coated abrasive article of Embodiment 33, wherein the base comprises a base surface defined by one or more faces having a substantially flat surface extending toward a first order peak of the base surface.

[0245] Embodiment 64. The coated abrasive article of Embodiment 63, wherein the base surface comprises at least two faces, the at least two faces being adjacent to each other and defining a common edge extending between the two faces.

[0246] Embodiment 65. A coated abrasive article according to Embodiment 33, wherein the base includes a first order peak and a second order peak separated from each other by a first order peak observed in a two-dimensional plane defined by the length and thickness of the body or a two-dimensional plane defined by the length and width of the body.

[0247] Embodiment 66. A coated abrasive article according to Embodiment 33, wherein the base includes a first order peak observed in two dimensions defined by length and width, wherein the first order peak includes a tip sharpness greater than the tip sharpness of the tip of the body.

[0248] Example 67. A coated abrasive article according to Example 66, wherein the first-order peak tip sharpness (as measured by the tip angle in two dimensions defined by a plane of the length and width of the body) is at least 5%, or at least 8%, or at least 10%, or at least 12%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 90% less than the tip sharpness of the body (where the tip sharpness is measured by the tip angle in two dimensions defined by a plane of the length and width of the body).

[0249] Embodiment 68 The coated abrasive article of Embodiment 33, further comprising an elongated region extending between the tip region and the base region.

[0250] Embodiment 69. The coated abrasive article of Embodiment 68, wherein the elongated region defines a region having a substantially constant width between the tip region and the base region.

[0251] Embodiment 70. The coated abrasive article of Embodiment 68, wherein the elongated region defines a region having a substantially constant thickness between the tip region and the base region.

[0252] Embodiment 71. A coated abrasive article according to Embodiment 68, wherein the elongated region is defined by an area whose width or thickness varies by no more than 10%, or no more than 8%, or no more than 5%, or no more than 3% over the length of the elongated region.

[0253] Embodiment 72. The coated abrasive article of Embodiment 33, wherein the body is linear over at least a majority of the overall length of the body.

[0254] Embodiment 73. The coated abrasive article of Embodiment 1, wherein each of the pyramidal abrasive particles comprises striations on at least one surface.

[0255] Embodiment 74. A coated abrasive article according to Embodiment 73, wherein the stripes extend in the length direction of the body.

[0256] Example 75. According to the coated abrasive product described in Example 1, the abrasive product further includes not more than 50% of the total number of multiple abrasives, or not more than 48%, or not more than 46%, or not more than 44%, or not more than 42%, or not more than 40%, or not more than 38%, or not more than 36%, or not more than 34%, or not more than 32%, or not more than 30%, or not more than 28%, or not more than 26%, or not more than 24%, or not more than 22%, or not more than 20%, or not more than 18%, or not more than 16%, or not more than 14%, or not more than 12%, or not more than 10%, or not more than 8%, or not more than 6%, or not more than 4%, or not more than 2% of agglomerated particles, wherein the multiple abrasive particles do not contain agglomerated particles.

[0257] Example 76. A coated abrasive article according to Example 1, wherein the taper fraction standard deviation is at least 0.028, or at least 0.030, or at least 0.032, or at least 0.035, or at least 0.038, or at least 0.040, or at least 0.042, or at least 0.045, or at least 0.048, or at least 0.050, or at least 0.052, or at least 0.055, or at least 0.058, or at least 0.060.

[0258] Example 77. A coated abrasive article according to Example 1, wherein the taper fraction standard deviation is not greater than 0.088, or not greater than 0.085, or not greater than 0.082, or not greater than 0.080, or not greater than 0.078, or not greater than 0.075, or not greater than 0.072, or not greater than 0.070, or not greater than 0.068, or not greater than 0.065, or not greater than 0.062, or not greater than 0.060, or not greater than 0.058, or not greater than 0.055, or not greater than 0.052, or not greater than 0.050, or not greater than 0.048, or not greater than 0.045, or not greater than 0.042, or not greater than 0.040.

[0259] Embodiment 78. A coated abrasive article according to any of Embodiments 76 or 77, wherein the taper fraction standard deviation is in the range of at least 0.025 and no more than 0.085, or in the range of at least 0.028 and no more than 0.070, or in the range of at least 0.03 and no more than 0.06.

[0260] Embodiment 79. A coated abrasive article according to embodiment 1, wherein the conical abrasive particles have an average taper fraction value of at least 0.05, or at least 0.08, or at least 0.1, or at least 0.12, or at least 0.14, or at least 0.16, or at least 0.18, or at least 0.20, or at least 0.22, or at least 0.24, or at least 0.26, or at least 0.28, or at least 0.30, or at least 0.32, or at least 0.34, or at least 0.35.

[0261] Embodiment 80. A coated abrasive article according to embodiment 1, wherein the conical abrasive particles have an average taper fraction value of not greater than 0.8, or not greater than 0.75, or not greater than 0.70, or not greater than 0.65, or not greater than 0.60, or not greater than 0.55, or not greater than 0.50, or not greater than 0.45, or not greater than 0.40, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28.

[0262] Embodiment 81. The coated abrasive article of Embodiment 1, wherein the plurality of abrasive particles has a batch taper fraction standard deviation of at least 0.025 and no greater than 0.090.

[0263] Embodiment 82. A coated abrasive article according to embodiment 81, wherein the batch taper fraction standard deviation is at least 0.028, or at least 0.030, or at least 0.032, or at least 0.035, or at least 0.038, or at least 0.040, or at least 0.042, or at least 0.045, or at least 0.048, or at least 0.050, or at least 0.052, or at least 0.055, or at least 0.058, or at least 0.060.

[0264] Embodiment 83. A coated abrasive article according to embodiment 82, wherein the batch taper score standard deviation is not greater than 0.088, or not greater than 0.085, or not greater than 0.082, or not greater than 0.080, or not greater than 0.078, or not greater than 0.075, or not greater than 0.072, or not greater than 0.070, or not greater than 0.068, or not greater than 0.065, or not greater than 0.062, or not greater than 0.060, or not greater than 0.058, or not greater than 0.055, or not greater than 0.052, or not greater than 0.050, or not greater than 0.048, or not greater than 0.045, or not greater than 0.042, or not greater than 0.040.

[0265] Embodiment 84. A coated abrasive article according to any of Embodiments 82 or 83, wherein the batch taper fraction standard deviation is in the range of at least 0.025 and no more than 0.085, or in the range of at least 0.028 and no more than 0.070, or in the range of at least 0.03 and no more than 0.060.

[0266] Embodiment 85. A coated abrasive article according to embodiment 81, wherein the plurality of abrasive particles comprise an average batch taper fraction value of at least 0.05, or at least 0.08, or at least 0.1, or at least 0.12, or at least 0.14, or at least 0.16, or at least 0.18, or at least 0.20, or at least 0.22, or at least 0.24, or at least 0.26, or at least 0.28, or at least 0.30, or at least 0.32, or at least 0.34, or at least 0.35.

[0267] Embodiment 86. A coated abrasive article according to embodiment 81, wherein the plurality of abrasive particles comprise an average batch taper fraction value of not greater than 0.8, or not greater than 0.75, or not greater than 0.70, or not greater than 0.65, or not greater than 0.60, or not greater than 0.55, or not greater than 0.50, or not greater than 0.45, or not greater than 0.40, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28.

[0268] Embodiment 87. The coated abrasive article of Embodiment 1, wherein the tapered abrasive particles comprise an average elongation fraction value of at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6.

[0269] Embodiment 88. A coated abrasive article according to Embodiment 87, wherein the tapered abrasive particles comprise an average elongation fraction value of not greater than 0.9, or not greater than 0.8, or not greater than 0.7, or not greater than 0.6.

[0270] Embodiment 89. A coated abrasive article according to embodiment 87, wherein the conical abrasive particles have a standard deviation of the elongation fraction of at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1, or at least 0.11, or at least 0.12, or at least 0.13, or at least 0.14.

[0271] Embodiment 90. A coated abrasive article according to embodiment 87, wherein the conical abrasive particles have a standard deviation of the elongation fraction of not greater than 0.3, or not greater than 0.25, or not greater than 0.2, or not greater than 0.19, or not greater than 0.18, or not greater than 0.17, or not greater than 0.16, or not greater than 0.15, or not greater than 0.14, or not greater than 0.13.

[0272] Embodiment 91. The coated abrasive article of Embodiment 1, wherein the plurality of abrasive particles comprises an average bulk elongation value of at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6.

[0273] Embodiment 92. A coated abrasive article according to Embodiment 91, wherein the average batch elongation fraction value is not greater than 0.9, or not greater than 0.8, or not greater than 0.7, or not greater than 0.6.

[0274] Embodiment 93. A coated abrasive article according to embodiment 1, wherein the plurality of abrasive particles comprises a batch elongation fractional standard deviation of at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1, or at least 0.11, or at least 0.12, or at least 0.13, or at least 0.14.

[0275] Embodiment 94. A coated abrasive article according to Embodiment 93, wherein the batch elongation fraction standard deviation is not greater than 0.3, or not greater than 0.25, or not greater than 0.2, or not greater than 0.19, or not greater than 0.18, or not greater than 0.17, or not greater than 0.16, or not greater than 0.15, or not greater than 0.14, or not greater than 0.13.

[0276] Embodiment 95. The coated abrasive article of Embodiment 1, wherein each of the tapered abrasive particles comprises a body having an average taper fraction value and an average elongation fraction value, and wherein the average elongation fraction value is greater than the average taper fraction value.

[0277] Example 96. A coated abrasive product according to Example 95, wherein the average elongation fraction value is at least 10% greater, or at least 20% greater, or at least 30% greater, or at least 40% greater, or at least 50% greater, or at least 60% greater, or at least 70% greater, or at least 80% greater, or at least 90% greater, or at least 100% greater, or at least 120% greater, or at least 140% greater, or at least 160% greater, or at least 180% greater, or at least 200% greater, or at least 250% greater, or at least 300% greater than the average taper fraction value.

[0278] Example 97. A coated abrasive product according to Example 95, wherein the average elongation fraction value is not greater than 1000%, or not greater than 900%, or not greater than 800%, or not greater than 700%, or not greater than 600%, or not greater than 500%, or not greater than 400%, or not greater than 300%, or not greater than 200% or not greater than 150% of the average taper fraction value.

[0279] Embodiment 98. A coated abrasive article according to Embodiment 97, wherein the average elongation fraction value is at least 50% and no more than 500% greater than the average taper fraction value.

[0280] Embodiment 99. A coated abrasive article according to embodiment 1, wherein the conical abrasive particles comprise an average solidity of at least 0.87, or at least 0.88, or at least 0.89, or at least 0.90, or at least 0.91, or at least 0.92, or at least 0.93, or at least 0.94, or at least 0.95, or at least 0.96, or at least 0.97.

[0281] Embodiment 100. A coated abrasive article according to embodiment 99, wherein the average solidity is not greater than 0.99, or not greater than 0.98, or not greater than 0.97, or not greater than 0.96, or not greater than 0.95.

[0282] Embodiment 101. A coated abrasive article according to Embodiment 1, wherein the plurality of abrasive particles comprises an average batch density of at least 0.87, or at least 0.88, or at least 0.89, or at least 0.90, or at least 0.91, or at least 0.92, or at least 0.93, or at least 0.94, or at least 0.95, or at least 0.96, or at least 0.97.

[0283] Embodiment 102. The coated abrasive article of embodiment 101, wherein the average batch solidity is no greater than 0.99, or no greater than 0.98, or no greater than 0.97, or no greater than 0.96, or no greater than 0.95.

[0284] Embodiment 103. A plurality of abrasive particles according to Embodiment 1, wherein the conical abrasive particles comprise a solidity standard deviation of not greater than 0.05, or not greater than 0.045, or not greater than 0.04, or not greater than 0.035, or not greater than 0.030, or not greater than 0.025, or not greater than 0.020.

[0285] Embodiment 104. A coated abrasive article according to embodiment 103, wherein the solidity standard deviation is at least 0.0001, or at least 0.001, or at least 0.01, or at least 0.015, or at least 0.020.

[0286] Embodiment 105. A coated abrasive article according to embodiment 1, wherein the plurality of abrasive particles comprises a batch solidity standard deviation of no greater than 0.05, or no greater than 0.045, or no greater than 0.04, or no greater than 0.035, or no greater than 0.030, or no greater than 0.025, or no greater than 0.020.

[0287] Embodiment 106. The coated abrasive article of embodiment 105, wherein the batch solidity standard deviation is at least 0.01, or at least 0.015, or at least 0.020.

[0288] Embodiment 107. The coated abrasive article of Embodiment 1, wherein the plurality of abrasive particles have a predetermined lateral position, a predetermined longitudinal position, a predetermined radial position, a predetermined rotational direction, a predetermined tilt angle, or any combination thereof.

[0289] Embodiment 108. The coated abrasive article of Embodiment 1, wherein the plurality of abrasive particles are distributed on the substrate in a predetermined distribution.

[0290] Embodiment 109. The coated abrasive article of Embodiment 1, wherein the plurality of abrasive particles have a random rotational orientation.

[0291] Embodiment 110. The coated abrasive article of embodiment 1, wherein the plurality of abrasive particles are distributed in a two-dimensional array.

[0292] Embodiment 111. A coated abrasive article comprising:

[0293] substrate; and

[0294] A plurality of abrasive particles, each of the plurality of abrasive particles having a body including a length, a width, and a thickness, wherein the plurality of abrasive particles have an average first-stage batch aspect ratio [B(length / width)] in the range of at least 2.1 and not more than 4.7 and a first-stage batch aspect ratio standard deviation of at least 0.05 and not more than 0.55

[0295] [STDEV-B (length / width)].

[0296] Embodiment 112. A coated abrasive article according to Embodiment 111, wherein the average first-stage batch aspect ratio [B (length / width)] is at least 2.2, or at least 2.3, or at least 2.4, or at least 2.5, or at least 2.6, or at least 2.7, or at least 2.8.

[0297] Embodiment 113. A coated abrasive article according to embodiment 112, wherein the average first stage batch aspect ratio [B (length / width)] is not greater than 4.6, or not greater than 4.5, or not greater than 4.4, or not greater than 4.3.

[0298] Embodiment 114. A coated abrasive article according to Embodiment 111, wherein the plurality of abrasive particles comprises a first order batch aspect ratio standard deviation [STDEV(length / width)] of not greater than 0.52, or not greater than 0.50, or not greater than 0.48, or not greater than 0.45, or not greater than 0.42, or not greater than 0.40, or not greater than 0.38, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28, or not greater than 0.25, or not greater than 0.22, or not greater than 0.20, or not greater than 0.18, or not greater than 0.15.

[0299] Embodiment 115. A coated abrasive product according to Embodiment 114, wherein the first-stage batch aspect ratio standard deviation [STDEV(length / width)] is at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.10, or at least 0.12, or at least 0.15, or at least 0.20, or at least 0.25, or at least 0.30, or at least 0.33, or at least 0.35, or at least 0.37.

[0300] Embodiment 116. A coated abrasive product according to Embodiment 111, wherein the first-stage batch aspect ratio standard deviation [STDEV(length / width)] is in the range of at least 0.10 and not more than 0.5, or in the range of at least 0.15 and not more than 0.5, or in the range of at least 0.2 and not more than 0.45.

[0301] Embodiment 117. A coated abrasive article according to Embodiment 111, wherein the plurality of abrasive particles have an average second batch aspect ratio [B(length / thickness)] of at least 2.2, or at least 2.3, or at least 2.4, or at least 2.5, or at least 2.6, or at least 2.7, or at least 2.8.

[0302] Embodiment 118. A coated abrasive article according to Embodiment 117, wherein the second stage batch aspect ratio [B(length / thickness)] is not greater than 4.6, or not greater than 4.5, or not greater than 4.4, or not greater than 4.3.

[0303] Embodiment 119. A coated abrasive article according to Embodiment 111, wherein the plurality of abrasive particles comprises a second batch aspect ratio standard deviation [STDEV(length / thickness)] of not greater than 0.55, or not greater than 0.52, or not greater than 0.50, or not greater than 0.48, or not greater than 0.45, or not greater than 0.42, or not greater than 0.40, or not greater than 0.38, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28, or not greater than 0.25, or not greater than 0.22, or not greater than 0.20, or not greater than 0.18, or not greater than 0.15.

[0304] Example 120. A coated abrasive product according to Example 119, wherein the second batch aspect ratio standard deviation [STDEV(length / thickness)] is at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.10, or at least 0.12, or at least 0.15, or at least 0.20, or at least 0.25, or at least 0.30, or at least 0.33, or at least 0.35, or at least 0.37.

[0305] Embodiment 121. A coated abrasive article according to Embodiment 111, wherein the plurality of abrasive particles have a third-level batch aspect ratio [B(width / thickness)] of at least 0.5, or at least 0.6, or at least 0.7, or at least 0.8, or at least 0.9, or at least 1.0, or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 4.

[0306] Embodiment 122. A coated abrasive article according to Embodiment 121, wherein the tertiary batch aspect ratio [B(width / width)] is not greater than 5, or not greater than 4, or not greater than 2, or not greater than 1.5, or not greater than 1.3, or not greater than 1.1.

[0307] Embodiment 123. A coated abrasive article according to Embodiment 111, wherein the plurality of abrasive particles comprises a third level batch aspect ratio standard deviation [STDEV(width / thickness)] of not greater than 0.55, or not greater than 0.52, or not greater than 0.50, or not greater than 0.48, or not greater than 0.45, or not greater than 0.42, or not greater than 0.40, or not greater than 0.38, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28, or not greater than 0.25, or not greater than 0.22, or not greater than 0.20, or not greater than 0.18, or not greater than 0.15.

[0308] Embodiment 124. A coated abrasive article according to Embodiment 123, wherein the third-level batch aspect ratio standard deviation [STDEV(width / thickness)] is at least 0.01, or at least 0.05, or at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.30, or at least 0.35, or at least 0.4.

[0309] Embodiment 125. A coated abrasive article according to Embodiment 111, wherein the plurality of abrasive particles include conical abrasive particles, each of the conical abrasive particles includes a body, the body includes a tip region, the tip region includes a tip of the body, and the base region includes a base of the body, wherein the base region is at an opposite end of the body relative to the tip region along the length of the body.

[0310] Embodiment 126. The coated abrasive article of Embodiment 125, wherein the tip is defined by the convergence of at least 2 surfaces of the body, or the convergence of at least 3 surfaces of the body, or the convergence of at least 4 surfaces of the body.

[0311] Embodiment 127. The coated abrasive article of Embodiment 125, wherein the tip comprises a tip edge having a length less than an average width or an average thickness of the body.

[0312] Embodiment 128. A coated abrasive article according to Embodiment 125, wherein the tip region is defined by a taper comprising a decrease in the width or thickness of the body over the length of the tip region.

[0313] Embodiment 129. The coated abrasive article of Embodiment 125, wherein the base region comprises a base having a base surface, wherein the base surface is angled relative to the longitudinal axis of the body.

[0314] Embodiment 130. The coated abrasive article of Embodiment 129, wherein the base surface is at an acute angle relative to the longitudinal axis of the body.

[0315] Embodiment 131. A coated abrasive product according to Embodiment 130, wherein the angle formed by the base surface relative to the longitudinal axis of the body is no greater than 90 degrees, or no greater than 88 degrees, or no greater than 86 degrees, or no greater than 84 degrees, or no greater than 82 degrees, or no greater than 80 degrees, or no greater than 75 degrees, or no greater than 70 degrees, or no greater than 65 degrees, or no greater than 60 degrees, or no greater than 55 degrees, or no greater than 50 degrees, or no greater than 45 degrees, or no greater than 40 degrees.

[0316] Embodiment 132. A coated abrasive article according to Embodiment 130, wherein the angle of the base surface relative to the longitudinal axis of the body is at least 5 degrees, or at least 10 degrees, or at least 15 degrees, or at least 20 degrees, or at least 25 degrees, or at least 30 degrees, or at least 35 degrees, or at least 40 degrees, or at least 45 degrees, or at least 50 degrees or at least 55 degrees.

[0317] Embodiment 133. The coated abrasive article of embodiment 125, wherein the base encloses a base surface, the base surface comprising peaks and valleys.

[0318] Embodiment 134. The coated abrasive article of Embodiment 133, wherein the arrangement of peaks and valleys is a random arrangement of peaks and valleys.

[0319] Embodiment 135. A coated abrasive article according to Embodiment 125, wherein the base comprises a base surface having a surface roughness greater than a surface roughness of a side surface of the body in the elongated region or the tip region.

[0320] Embodiment 136. A coated abrasive article according to Embodiment 125, wherein the base comprises a base surface having a plurality of peaks, wherein at least one peak of the plurality of peaks has a tip radius that is less than the tip radius of the tip of the body.

[0321] Embodiment 137. The coated abrasive article of Embodiment 136, wherein at least 2 different peaks in the plurality of peaks each have a tip radius that is less than the tip radius of the tip of the body.

[0322] Embodiment 138. A coated abrasive article according to Embodiment 125, wherein the base includes a primary peak observed in two dimensions defined by length and width, wherein the primary peak includes a primary peak angle of at least 45 degrees and no greater than 150 degrees.

[0323] Embodiment 139. A coated abrasive article according to Embodiment 138, wherein the first order peak angle is at least 50 degrees, or at least 55 degrees, or at least 60 degrees, or at least 65 degrees, or at least 70 degrees, or at least 75 degrees, or at least 80 degrees, or at least 85 degrees, or at least 90 degrees, or at least 95 degrees, or at least 100 degrees.

[0324] Embodiment 140. A coated abrasive article according to Embodiment 138, wherein the first-order peak angle is not greater than 145 degrees, or not greater than 140 degrees, or not greater than 135 degrees, or not greater than 130 degrees, or not greater than 125 degrees, or not greater than 120 degrees, or not greater than 115 degrees, or not greater than 110 degrees, or not greater than 100 degrees, or not greater than 95 degrees.

[0325] Embodiment 141. A coated abrasive article according to Embodiment 125, wherein the base includes a base surface defined by one or more faces, the base surface having a substantially flat surface extending toward a first order peak of the base surface.

[0326] Embodiment 142. The coated abrasive article of Embodiment 141, wherein the base surface comprises at least two faces, the at least two faces being adjacent to each other and defining a common edge extending between the two faces.

[0327] Embodiment 143. A coated abrasive article according to Embodiment 125, wherein the base includes a first order peak and a second order peak separated from each other by a first order peak observed on a two-dimensional plane defined by the length and thickness of the body or a two-dimensional plane defined by the length and width of the body.

[0328] Embodiment 144. A coated abrasive article according to Embodiment 125, wherein the base includes a first order peak observed in two dimensions defined by length and width, wherein the first order peak includes a tip sharpness greater than the tip sharpness of the tip of the body.

[0329] Embodiment 145. A coated abrasive article according to Embodiment 144, wherein the first-order peak tip sharpness (as measured by the tip angle in two dimensions defined by a plane of the length and width of the body) is at least 5%, or at least 8%, or at least 10%, or at least 12%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 90% less than the tip sharpness of the body (where the tip sharpness is measured by the tip angle in two dimensions defined by a plane of the length and width of the body).

[0330] Embodiment 146 The coated abrasive article of Embodiment 125, further comprising an elongated region extending between the tip region and the base region.

[0331] Embodiment 147. The coated abrasive article of Embodiment 146, wherein the elongated region defines a region having a substantially constant width between the tip region and the base region.

[0332] Embodiment 148. The coated abrasive article of Embodiment 146, wherein the elongated region defines a region having a substantially constant thickness between the tip region and the base region.

[0333] Embodiment 149. A coated abrasive article according to Embodiment 146, wherein the elongated region is defined by an area whose width or thickness varies by no more than 10%, or no more than 8%, or no more than 5%, or no more than 3% over the length of the elongated region.

[0334] Embodiment 150. The coated abrasive article of Embodiment 146, wherein the body is linear over at least a majority of the total length of the body.

[0335] Embodiment 151. The coated abrasive article of Embodiment 111, wherein each of the pyramidal abrasive particles comprises striations on at least one surface.

[0336] Embodiment 152. A coated abrasive article according to Embodiment 151, wherein the stripes extend in the length direction of the body.

[0337] Embodiment 153. According to the coated abrasive product described in Embodiment 111, the abrasive product further includes not more than 50% of the total number of particles in the batch, or not more than 48%, or not more than 46%, or not more than 44%, or not more than 42%, or not more than 40%, or not more than 38%, or not more than 36%, or not more than 34%, or not more than 32%, or not more than 30%, or not more than 28%, or not more than 26%, or not more than 24%, or not more than 22%, or not more than 20%, or not more than 18%, or not more than 16%, or not more than 14%, or not more than 12%, or not more than 10%, or not more than 8%, or not more than 6%, or not more than 4%, or not more than 2% of agglomerated particles, wherein multiple abrasive particles do not contain agglomerated particles.

[0338] Embodiment 154. A coated abrasive article according to Embodiment 125, wherein the tip region comprises an asymmetric taper, the asymmetric taper comprising a first surface and a second surface, wherein the first surface has a different profile than the second surface.

[0339] Embodiment 155. The coated abrasive article of Embodiment 125, wherein the base comprises a protrusion extending from the body, wherein the protrusion extends at an angle relative to a longitudinal axis of the body.

[0340] Embodiment 156. The coated abrasive article of Embodiment 125, wherein the base region comprises a base having a base surface, wherein the base surface is angled relative to the longitudinal axis of the body.

[0341] Embodiment 157. A coated abrasive article according to embodiment 125, wherein at least 5% of the abrasive particles in the plurality of abrasive particles comprise at least 8%, or at least 10%, or at least 12%, or at least 15%, or at least 18%, or at least 20%, or at least 22%, or at least 25%, or at least 28%, or at least 30%, or at least 32%, or at least 35%, or at least 38%, or at least 40%, or at least 42%, or at least 45%, or at least 46%. At least 48%, or at least 50%, or at least 52%, or at least 55%, or at least 58%, or at least 60%, or at least 62%, or at least 65%, or at least 68%, or at least 70%, or at least 72%, or at least 75%, or at least 78%, or at least 80%, or at least 82%, or at least 85%, or at least 88%, or at least 90%, or at least 92%, or at least 95%, or at least 98%, or at least 99% conical abrasive particles.

[0342] Embodiment 158. The coated abrasive article of Embodiment 125, wherein the plurality of abrasive particles comprises only conical abrasive particles.

[0343] Embodiment 159. A coated abrasive article according to Embodiment 125, wherein the plurality of abrasive particles comprises a blend, the blend comprising a first portion of abrasive particles and a second portion of abrasive particles, and further comprising conical abrasive particles, the conical abrasive particles being contained in the first portion, the second portion, or both the first portion and the second portion.

[0344] Embodiment 160 The coated abrasive article of Embodiment 125, wherein the tapered abrasive particles have a taper fraction standard deviation of at least 0.025 and no greater than 0.095.

[0345] Embodiment 161. A coated abrasive article according to Embodiment 160, wherein the taper fraction standard deviation is at least 0.028, or at least 0.030, or at least 0.032, or at least 0.035, or at least 0.038, or at least 0.040, or at least 0.042, or at least 0.045, or at least 0.048, or at least 0.050, or at least 0.052, or at least 0.055, or at least 0.058, or at least 0.060.

[0346] Embodiment 162. A coated abrasive article according to Embodiment 160, wherein the taper fraction standard deviation is not greater than 0.088, or not greater than 0.085, or not greater than 0.082, or not greater than 0.080, or not greater than 0.078, or not greater than 0.075, or not greater than 0.072, or not greater than 0.070, or not greater than 0.068, or not greater than 0.065, or not greater than 0.062, or not greater than 0.060, or not greater than 0.058, or not greater than 0.055, or not greater than 0.052, or not greater than 0.050, or not greater than 0.048, or not greater than 0.045, or not greater than 0.042, or not greater than 0.040.

[0347] Embodiment 163. A coated abrasive article according to Embodiment 160, wherein the taper fraction standard deviation is in the range of at least 0.025 and not more than 0.085, or in the range of at least 0.028 and not more than 0.070, or in the range of at least 0.03 and not more than 0.06.

[0348] Embodiment 164. A coated abrasive article according to embodiment 125, wherein the conical abrasive particles have an average taper fraction value of at least 0.05, or at least 0.08, or at least 0.1, or at least 0.12, or at least 0.14, or at least 0.16, or at least 0.18, or at least 0.20, or at least 0.22, or at least 0.24, or at least 0.26, or at least 0.28, or at least 0.30, or at least 0.32, or at least 0.34, or at least 0.35.

[0349] Embodiment 165. A coated abrasive article according to embodiment 164, wherein the conical abrasive particles have an average taper fraction value of not greater than 0.8, or not greater than 0.75, or not greater than 0.70, or not greater than 0.65, or not greater than 0.60, or not greater than 0.55, or not greater than 0.50, or not greater than 0.45, or not greater than 0.40, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28.

[0350] Embodiment 166 The coated abrasive article of Embodiment 125, wherein the plurality of abrasive particles have a batch taper fraction standard deviation of at least 0.025 and no greater than 0.090.

[0351] Embodiment 167. A coated abrasive article according to Embodiment 166, wherein the batch taper fraction standard deviation is at least 0.028, or at least 0.030, or at least 0.032, or at least 0.035, or at least 0.038, or at least 0.040, or at least 0.042, or at least 0.045, or at least 0.048, or at least 0.050, or at least 0.052, or at least 0.055, or at least 0.058, or at least 0.060.

[0352] Embodiment 168. A coated abrasive article according to Embodiment 167, wherein the batch taper score standard deviation is not greater than 0.088, or not greater than 0.085, or not greater than 0.082, or not greater than 0.080, or not greater than 0.078, or not greater than 0.075, or not greater than 0.072, or not greater than 0.070, or not greater than 0.068, or not greater than 0.065, or not greater than 0.062, or not greater than 0.060, or not greater than 0.058, or not greater than 0.055, or not greater than 0.052, or not greater than 0.050, or not greater than 0.048, or not greater than 0.045, or not greater than 0.042, or not greater than 0.040.

[0353] Embodiment 169. A coated abrasive article according to Embodiment 166, wherein the batch taper fraction standard deviation is in the range of at least 0.025 and not more than 0.085, or in the range of at least 0.028 and not more than 0.070, or in the range of at least 0.03 and not more than 0.060.

[0354] Embodiment 170. A coated abrasive article according to Embodiment 125, wherein the plurality of abrasive particles comprise an average batch taper fraction value of at least 0.05, or at least 0.08, or at least 0.1, or at least 0.12, or at least 0.14, or at least 0.16, or at least 0.18, or at least 0.20, or at least 0.22, or at least 0.24, or at least 0.26, or at least 0.28, or at least 0.30, or at least 0.32, or at least 0.34, or at least 0.35.

[0355] Embodiment 171. A coated abrasive article according to Embodiment 170, wherein the plurality of abrasive particles comprise an average batch taper fraction value of not greater than 0.80, or not greater than 0.75, or not greater than 0.70, or not greater than 0.65, or not greater than 0.60, or not greater than 0.55, or not greater than 0.50, or not greater than 0.45, or not greater than 0.40, or not greater than 0.35, or not greater than 0.32, or not greater than 0.30, or not greater than 0.28.

[0356] Embodiment 172. A coated abrasive article according to embodiment 125, wherein each of the conical abrasive particles comprises a body having an elongated region, and wherein the elongated region taper fraction value is at least 0.15, or at least 0.18, or at least 0.20, or at least 0.25, or at least 0.30, or at least 0.35, or at least 0.40, or at least 0.45, or at least 0.50.

[0357] Embodiment 173. A coated abrasive article according to Embodiment 172, wherein the extended region taper fraction value is no greater than 1, or no greater than 0.9, or no greater than 0.8, or no greater than 0.7, or no greater than 0.6.

[0358] Embodiment 174. A coated abrasive article according to embodiment 125, wherein the conical abrasive particles include a body having an elongated region, and wherein the standard deviation of the elongated region taper score is at least 0.03, or at least 0.05, or at least 0.08, or at least 0.10, or at least 0.12, or at least 0.16, or at least 0.18.

[0359] Embodiment 175. A coated abrasive article according to embodiment 174, wherein the standard deviation of the extended region taper fraction is no greater than 0.3, or no greater than 0.2, or no greater than 0.18, or no greater than 0.16, or no greater than 0.15, or no greater than 0.14.

[0360] Embodiment 176. A coated abrasive article according to embodiment 125, wherein the conical abrasive particles comprise an average solidity of at least 0.87, or at least 0.88, or at least 0.89, or at least 0.90, or at least 0.91, or at least 0.92, or at least 0.93, or at least 0.94, or at least 0.95, or at least 0.96, or at least 0.97.

[0361] Embodiment 177. A coated abrasive article according to Embodiment 176, wherein the average solidity is not greater than 0.99, or not greater than 0.98, or not greater than 0.97, or not greater than 0.96, or not greater than 0.95.

[0362] Embodiment 178. A coated abrasive article according to Embodiment 125, wherein the plurality of abrasive particles comprise an average batch density of at least 0.87, or at least 0.88, or at least 0.89, or at least 0.90, or at least 0.91, or at least 0.92, or at least 0.93, or at least 0.94, or at least 0.95, or at least 0.96, or at least 0.97.

[0363] Embodiment 179. A coated abrasive article according to Embodiment 178, wherein the average batch solidity is not greater than 0.99, or not greater than 0.98, or not greater than 0.97, or not greater than 0.96, or not greater than 0.95.

[0364] Embodiment 180. A coated abrasive article according to embodiment 125, wherein the conical abrasive particles comprise a solidity standard deviation of not greater than 0.05, or not greater than 0.045, or not greater than 0.04, or not greater than 0.035, or not greater than 0.030, or not greater than 0.025, or not greater than 0.020.

[0365] Embodiment 181. A coated abrasive article according to Embodiment 180, wherein the standard deviation of solidity is at least 0.0001, or at least 0.001, or at least 0.01, or at least 0.015, or at least 0.020.

[0366] Embodiment 182. A coated abrasive article according to Embodiment 125, wherein the plurality of abrasive particles comprises a batch solidity standard deviation of not greater than 0.05, or not greater than 0.045, or not greater than 0.04, or not greater than 0.035, or not greater than 0.030, or not greater than 0.025, or not greater than 0.020.

[0367] Embodiment 183. A coated abrasive article according to Embodiment 182, wherein the batch solidity standard deviation is at least 0.0001, or at least 0.001, or at least 0.01, or at least 0.015, or at least 0.020.

[0368] Embodiment 184. A coated abrasive article according to Embodiment 111, wherein the plurality of abrasive particles comprises tapered abrasive particles having an average elongation fraction value of at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6.

[0369] Embodiment 185. A coated abrasive article according to Embodiment 184, wherein the tapered abrasive particles comprise an average elongation fraction value of not greater than 0.9, or not greater than 0.8, or not greater than 0.7, or not greater than 0.6.

[0370] Embodiment 186. A coated abrasive article according to Embodiment 111, wherein the plurality of abrasive particles include conical abrasive particles having a standard deviation of the elongation fraction of at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1, or at least 0.11, or at least 0.12, or at least 0.13, or at least 0.14.

[0371] Embodiment 187. A coated abrasive article according to Embodiment 186, wherein the conical abrasive particles have a standard deviation of the elongation fraction of not more than 0.3, or not more than 0.25, or not more than 0.2, or not more than 0.19, or not more than 0.18, or not more than 0.17, or not more than 0.16, or not more than 0.15, or not more than 0.14, or not more than 0.13.

[0372] Embodiment 188. A coated abrasive article according to Embodiment 111, wherein the plurality of abrasive particles comprises an average bulk elongation value of at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6.

[0373] Embodiment 189. A coated abrasive article according to Embodiment 188, wherein the average batch elongation fraction value is not greater than 0.9, or not greater than 0.8, or not greater than 0.7, or not greater than 0.6.

[0374] Embodiment 190. A coated abrasive article according to Embodiment 111, wherein the plurality of abrasive particles comprises a batch elongation fractional standard deviation of at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1, or at least 0.11, or at least 0.12, or at least 0.13, or at least 0.14.

[0375] Embodiment 191. A coated abrasive article according to Embodiment 190, wherein the batch elongation fraction standard deviation is not greater than 0.3, or not greater than 0.25, or not greater than 0.2, or not greater than 0.19, or not greater than 0.18, or not greater than 0.17, or not greater than 0.16, or not greater than 0.15, or not greater than 0.14, or not greater than 0.13.

[0376] Embodiment 192 The coated abrasive article of Embodiment 111, wherein the plurality of abrasive particles have predetermined positions relative to each other.

[0377] Embodiment 193. A coated abrasive article according to Embodiment 192, wherein the plurality of abrasive particles have a predetermined lateral position, a predetermined longitudinal position, a predetermined radial position, a predetermined rotational direction, a predetermined tilt angle, or any combination thereof.

[0378] Embodiment 194. The coated abrasive article of Embodiment 192, wherein a plurality of abrasive particles are distributed on the substrate in a predetermined distribution.

[0379] Embodiment 195. The coated abrasive article of Embodiment 192, wherein the plurality of abrasive particles have a random rotational orientation.

[0380] Embodiment 196. The coated abrasive article of Embodiment 192, wherein the plurality of abrasive particles are distributed in a two-dimensional array.

[0381] Embodiment 197. A coated abrasive article according to any of the preceding embodiments, wherein each body of each shaped abrasive particle in the plurality of shaped abrasive particles comprises a cross-sectional shape selected from the group consisting of: regular polygons, irregular polygons, ellipses, circles, or any combination thereof.

[0382] Embodiment 198. A coated abrasive article comprising:

[0383] substrate;

[0384] a plurality of abrasive particles overlying a substrate, the abrasive layer comprising extruded grains; and

[0385] Wherein the coated abrasive article comprises at least one of the following:

[0386] Total ΔSGE factor no greater than 6x10-4 [(Hp / in3 / min) / g] for a minimum amount of 1500 g of total material removed;

[0387] An initial ΔSGE factor of no greater than 5x10-4 [(Hp / in3 / min) / g] for the first 1000 g of material removed;

[0388] A final ΔSGE factor of no greater than 6 x 10-4 [(Hp / in3 / min) / g] for at least the final 800 g of material removed; or

[0389] Any combination of i-iii.

[0390] Embodiment 199. The coated abrasive article of embodiment 198, further comprising any of the features of embodiments 1-197.

[0391] Embodiment 200. A coated abrasive article according to Embodiment 198, wherein the total ΔSGE factor is no greater than 5.5×10-4 [(Hp / in3 / min) / g] for a minimum amount of 1500 g of total material removed, or no greater than 5×10-4 [(Hp / in3 / min) / g] for a minimum amount of 1500 g of total material removed (, or no greater than 4.8×10-4 [(Hp / in3 / min) / g] for a minimum amount of 1500 g of total material removed, or no greater than 4.7×10-4 [(Hp / in3 / min) / g] for a minimum amount of 1500 g of total material removed, or no greater than 5×10-4 [(Hp / in3 / min) / g] for a minimum amount of 1500 g of total material removed The minimum amount of total material 1500g is not more than 4.6x10-4[(Hp / in3 / min) / g], or the minimum amount of total material removed 1500g is not more than 4.5x10-4[(Hp / in3 / min) / g], or the minimum amount of total material removed 1500g is not more than 4.4x10-4[(Hp / in3 / min) / g], or the minimum amount of total material removed 1500g is not more than 4.2x10-4[(Hp / in3 / min) / g] or the minimum amount of total material removed 1500g is not more than 4x10-4[(Hp / in3 / min) / g].

[0392] Embodiment 201. A coated abrasive article according to Embodiment 198, wherein the total ΔSGE factor is at least 0.1×10-6 [(Hp / in3 / min) / g] for a minimum of 1500 g of total material removed, or at least 0.1×10-5 [(Hp / in3 / min) / g] for a minimum of 1500 g of total material removed (, or at least 0.1×10-4 [(Hp / in3 / min) / g] for a minimum of 1500 g of total material removed, or at least 1×10-4 [(Hp / in3 / min) / g] for a minimum of 1500 g of total material removed, or at least 3×10-4 [(Hp / in3 / min) / g] for a minimum of 1500 g of total material removed.

[0393] Embodiment 202. The coated abrasive article of embodiment 198, wherein the initial ΔSGE factor is no greater than 5×10-4 [(Hp / in3 / min) / g] for the first 1000 g of material removed, or no greater than 4.9×10-4 [(Hp / in3 / min) / g] for the first 1000 g of material removed, or no greater than 4.8×10-4 [(Hp / in3 / min) / g] for the first 1000 g of material removed, or no greater than 4.7×10-4 [(Hp / in3 / min) / g] for the first 1000 g of material removed, or no greater than 4.6×10-4 [(Hp / in3 / min) / g] for the first 1000 g of material removed. 4[(Hp / in3 / min) / g], or no more than 4.5x10-4[(Hp / in3 / min) / g] for the first 1000g of material removed, or no more than 4.4x10-4[(Hp / in3 / min) / g] for the first 1000g of material removed, or no more than 4.2x10-4[(Hp / in3 / min) / g] for the first 1000g of material removed, or no more than 4.1x10-4[(Hp / in3 / min) / g] for the first 1000g of material removed, or no more than 4x10-4[(Hp / in3 / min) / g] for the first 1000g of material removed.

[0394] Embodiment 203. A coated abrasive article according to Embodiment 198, wherein the initial ΔSGE factor is at least 0.1×10-6 [(Hp / in3 / min) / g] for the first 1000 g of material removed, or at least 0.1×10-5 [(Hp / in3 / min) / g] for the first 1000 g of material removed, or at least 0.1×10-4 [(Hp / in3 / min) / g] for the first 1000 g of material removed, or at least 1×10-4 [(Hp / in3 / min) / g] for the first 1000 g of material removed, or at least 2×10-4 [(Hp / in3 / min) / g] for the first 1000 g of material removed, or at least 3×10-4 [(Hp / in3 / min) / g] for the first 1000 g of material removed.

[0395] Embodiment 204. A coated abrasive article according to Embodiment 198, wherein the final ΔSGE factor is no greater than 6×10-4 [(Hp / in3 / min) / g] for at least the final 800 g of material removed, or no greater than 5.5×10-4 [(Hp / in3 / min) / g] for at least the final 800 g of material removed, or no greater than 5.3×10-4 [(Hp / in3 / min) / g] for at least the final 800 g of material removed, or no greater than 5×10-4 [(Hp / in3 / min) / g] for at least the final 800 g of material removed, or no greater than 4.8×10-4 [(Hp / in3 / min) / g] for at least the final 800 g of material removed. [(Hp / in3 / min) / g], or no more than 4.5x10-4[(Hp / in3 / min) / g] for at least the final 800g of material removed, or no more than 4.3x10-4[(Hp / in3 / min) / g] for at least the final 800g of material removed, or no more than 4x10-4[(Hp / in3 / min) / g] for at least the final 800g of material removed, or no more than 3.9x10-4[(Hp / in3 / min) / g] for at least the final 800g of material removed, or no more than 3.7x10-4[(Hp / in3 / min) / g] for at least the final 800g of material removed.

[0396] Embodiment 205. A coated abrasive article according to claim 198, wherein the final ΔSGE factor is at least 1x10-6 [(Hp / in3 / min) / g] for at least the final 800g of material removed, or at least 1x10-5 [(Hp / in3 / min) / g] for at least the final 800g of material removed, or at least 1x10-4 [(Hp / in3 / min) / g] for at least the final 800g of material removed, or at least 2x10-4 [(Hp / in3 / min) / g] for at least the final 800g of material removed.

[0397] Embodiment 206. The coated abrasive article of embodiment 198, the abrasive article further comprising:

[0398] The minimum amount of total material removed is 1500 g and is at least 0.1 x 10-6 [(Hp / in3 / min) / g] and no greater than 6 x 10-4

[0399] Total ΔSGE factor [(Hp / in3 / min) / g];

[0400] At least 1x10-6 [(Hp / in3 / min) / g] and no more than 5x10-4 for the first 1000g of material removed

[0401] Initial ΔSGE factor of [(Hp / in3 / min) / g]; and

[0402] At least 1x10-6 [(Hp / in3 / min) / g] and no more than 6x10-4 for at least the final 800 g of material removed

[0403] Final ΔSGE factor of [(Hp / in3 / min) / g].

[0404] Embodiment 207. A coated abrasive article according to any of the foregoing embodiments herein, wherein the plurality of abrasive particles comprise a blend, the blend comprising a first portion of abrasive particles comprising a first type of abrasive particles, the blend further comprising a second portion of abrasive particles comprising a second type of abrasive particles, wherein the first type and the second type differ from each other based on at least one abrasive property selected from the group consisting of average abrasive particle size, average particle size, brittleness, toughness, hardness, two-dimensional shape, three-dimensional shape, any feature described in the embodiments herein, or any combination thereof.

[0405] Embodiment 208 The coated abrasive article of any preceding embodiment herein, wherein the plurality of abrasive particles comprises a blend including a first portion of abrasive particles comprising pyramidal abrasive particles and a second portion comprising randomly shaped abrasive particles.

[0406] Examples

[0407] Example 1

[0408] Conical abrasive particles are prepared according to the following conditions. A mixture containing about 48-55 wt% boehmite is produced, which is purchased from Sasol. One suitable type of commercially available boehmite is a dispersion. The boehmite is mixed and seeded with 1% alpha alumina seeds relative to the total alumina content in the mixture. Alpha alumina seeds are prepared by grinding corundum using conventional techniques such as those described in US 4,623,364. The mixture also contains 45-52 wt% water and 2.5–7 wt% additional nitric acid. These ingredients are mixed in a planetary mixer of conventional design and mixed under reduced pressure to remove gaseous elements (e.g., bubbles) from the mixture. The coiling value is about 1000 to 1500 N.

[0409] After gelation, the mixture is extruded into and through the cavity of the production tool. The extrusion rate and translation rate of the production tool are precisely controlled to promote the formation of a batch of abrasive particles with a high content of conical shaped abrasive particles (e.g., greater than 65% of all total particles). Screening and sorting techniques are further used to increase the percentage of conical shaped abrasive particles in the batch. The cavity of the production tool has a quadrilateral shape with a side length of 0.5 mm. Before being removed from the cavity by contact with a brush on the back of the production tool, the gel mixture is extruded through the cavity of the production tool and dried for about 8 to 30 minutes. The precursor shaped abrasive particles are sintered between 1300° C. and 1350° C. for about 10 minutes.

[0410] Exemplary conical abrasive particles formed according to Example 1 provide Figure 2A The conical abrasive grains have an average length of about 2 mm, an average width of about 0.5 mm micrometers, and an average thickness of about 0.5 mm, with a quadrilateral cross-sectional shape observed in the elongated region in the plane of the width and thickness. The body of the conical abrasive grains is substantially formed of a seeded sol-gel alumina material having an average abrasive grain size of less than 1 micrometer.

[0411] Example 2

[0412] The particles from Example 1 (Sample S1) were tested in two different directions according to the single abrasive grinding test (SGGT): 1) the tip region upward direction, where the tip starts the grinding of the workpiece; and 2) the base region upward direction, where the base starts the grinding of the workpiece. During the SGGT, the single abrasive particles were fixed in the abrasive holder by an epoxy resin bonding material. The abrasive particles were fixed in the desired direction (i.e., the tip region upward direction or the base region upward direction) and moved on the 304 stainless steel workpiece using a wheel speed of 22m / s, the scratch length was 8 inches, and the initial scratch depth was 30 microns. The abrasive particles produced grooves with a cross-sectional area on the workpiece. For each sample group, each shaped abrasive particle completed 15 passes on a length of 8 inches, tested 10 individual particles in each direction, and the results were analyzed. The test measures the force applied by the grit to the workpiece. The tangential force (Ft) is in the direction parallel to the workpiece surface and in the direction of the groove. The normal force (Fn) perpendicular to the workpiece surface is also measured. A manual trigger that slowly feeds the rotating abrasive grain at micron intervals combined with the net change in measured cross-sectional area of ​​the groove from the beginning to the end of the scratch length is used to determine shaped abrasive particle wear. The net change in groove cross-sectional area can be measured for each pass. For SGGT, the net cross-sectional area of ​​the groove (A) is defined as the difference between the cross-sectional area of ​​the groove below the surface and the cross-sectional area of ​​the material displaced above the surface. Performance (Ft / A or Fn / A) is defined as the ratio of the tangential force or normal force to the net cross-sectional area of ​​the groove.

[0413] SGGT is performed using two different orientations of the abrasive particles relative to the workpiece as described above. The SGGT is performed with a first set of abrasive particle samples in a first orientation (e.g., the tip region of the conical abrasive particles is directed upward). The SGGT is also performed with a second set of abrasive particle samples in a second orientation (e.g., the tip region of the conical abrasive particles is directed upward).

[0414] Fig. 9 Included are plots of the median force per unit total area removed from the workpiece in the tip region upward direction and the base region upward direction for sample S1. Fig. 9 Also included are SGGT results for a conventional extruded particle (Sample C1) commercially available as Targa from Saint-Gobain Corporation and generally formed in accordance with US 5,090,968A. Notably and unexpectedly, the conical abrasive particles of Sample S1 exhibit more effective grinding in the base region up direction compared to the tip region up direction. Furthermore, the particles of Sample S1 have significantly different properties compared to the particles of Sample C1.

[0415] Table 3 includes a comparison of certain characteristics between samples S1, C1, and C2. Sample C2 is a shaped abrasive particle commercially available from 3M as Cubitron II. The batch means and standard deviations for S1, C1, and C2 are substantially the same as those reported for the individual samples in Table 1.

[0416] Table 1

[0417] S1 C1 C2 Average first-level aspect ratio 2.7 2.9 1 First level aspect ratio St.Dev. 0.40 0.64 0.03 Average second level aspect ratio 2.4 3.4 Second level aspect ratio St.Dev. 0.12 0.20 Average tertiary aspect ratio 1.0 1.1 Third level aspect ratio St.Dev. 0.4 0.07 Average elongation fraction 0.48 0.46 0.13 Elongation Fraction St. Dev. 0.11 0.17 0.01 Average taper score 0.21 0.22 0.37 Taper value St.Dev. 0.05 0.11 0.02 Average density 0.92 0.86 0.97 DensitySt.Dev. 0.03 0.06 0.01

[0418] Fig.14A Included are images of pyramidal abrasive particles having different first order aspect ratios, which are representative of the pyramidal abrasive particles in Sample S1. Fig. 14B Included with Fig.14A The particles have a larger aspect ratio compared to the image of the extruded abrasive particles. Fig. 14B The particles in are similar to those in sample C1. Fig.14A and 14B A comparison of particles of 1000 and 1000 g shows the variation in particle shape as aspect ratio varies. Notably, shapes with greater aspect ratios have been noted to have greater curvature and form hook-shaped particles, which may present additional challenges when attempting to orient the particles in a predetermined position and orientation in a fixed abrasive article (and, in particular, a coated abrasive article). Fig.14A The particles have Fig. 14B The smaller curvature of the particles can make them more easily placed in the desired location and orientation in the fixed abrasive article.

[0419] Example 3

[0420] Four types of coated abrasive samples were made and tested according to the following details. It is noteworthy that coated sample 1 (CaS1) includes only the abrasive particles of sample S1, the conventional coated sample (CaC2) is formed by abrasive particles C2, the coated sample (CaS3) is formed by a particle blend of samples S1 and C2, and the coated sample (CaS4) is formed by a particle blend of samples S1 and C2. Except that CaS3 has a thicker coating than CaS4, all samples have the same structure, which is shown below. At least two of each of the above samples are used for testing. A finished cloth backing of 47 pounds per ream is obtained and coated with a primer formulation containing phenolic resin provided in Table 4. Using an electrostatic deposition process, approximately 40 to 47 pounds of abrasive particles per ream are applied to the backing with the primer. The structure is dried in an oven at approximately 80°C for two hours. It should be understood that a primer layer is formed so that the sum of the components provided in Table 2 is equal to 100%.

[0421] Table 2: Base coat formulations

[0422] Primer Preparation Components percentage Filler NYAD Wollastonite 400 45-50wt% Wet Witcona 1260 0.10-.2wt% Resin, SI 45-50wt% Solmod Silane A1100 0.1-3wt% water 0.1-1wt%

[0423] The sample was then coated with a size layer having the formulation shown in Table 3. The structure was heat treated in an oven set to a final soak temperature of 100 to 120° C., where the sample was maintained for about 20 to 30 minutes. It should be understood that the size layer was formed so that the sum of the components provided in Table 3 equaled 100%.

[0424] Table 3: Seam layer formulations

[0425] Components of adhesive preparation percentage dye 2-4wt% Solmod Tamol 165A 0.5-2wt% FillerSyn Cryolite K 40-45wt% Resin single component 94-908 50-55wt% DF70 Defoamer 0.1-0.2wt% water 2-4wt%

[0426] The samples were then placed in an oven for heat treatment. The oven temperature was set to a final soak temperature of about 110 to 120°C, where the samples were kept for about 10 to 12 hours.

[0427] A supersize layer having the formulation provided below in Table 4 was then applied to the sample and processed in the same manner as the size layer. It should be understood that the supersize layer was formed such that the sum of the components provided in Table 4 equaled 100%.

[0428] Table 4: Top coat formulation

[0429] Top glue preparation components percentage dye 1-3wt% Solmod Cabosil 0.05-3wt% Solmod DAXAD 11 1-4wt% Packing Type A 63-67wt% Resin PF Prefere 80-5080A 20-25wt% DF70 Defoamer 0.1-0.2wt% water 6-10wt%

[0430] Each sample was tested according to the standard grinding test using the conditions summarized in Table 5. It is worth noting that two samples of coated abrasives were tested in each case to derive the results.

[0431] Table 5

[0432]

[0433] Fig.16 A graph of specific grinding energy versus cumulative material removal for the above samples is included. As described above, samples CaS3 and CaS4 removed more material and generally had lower SGE than samples CaS1 and CaC2. The subject matter disclosed above should be construed as illustrative and not restrictive, and it is intended that the appended claims cover all such modifications, enhancements, and other embodiments that fall within the spirit and scope of the invention. Therefore, to the maximum extent permitted by law, the scope of the present invention is defined by the broadest permissible interpretation of the appended claims and their equivalents, and is not restricted or limited by the above-described specific embodiments.

[0434] The Abstract of the present disclosure is provided to comply with patent law and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the above-described detailed description, various features may be grouped together or described in a single embodiment for the purpose of simplifying the present disclosure. The present disclosure should not be construed as embodying such an intention: the embodiments protected by the claims require more features than those expressly listed in each claim. Rather, as reflected in the following claims, the inventive subject matter may involve less than all the features of any of the embodiments disclosed herein. Therefore, the following claims are incorporated into the detailed description, with each claim independently defining a separately claimed subject matter.

Claims

1. A coated abrasive article, comprising: substrate; as well as A plurality of abrasive particles, each of the plurality of abrasive particles having a body including a length, a width, and a thickness, wherein the plurality of abrasive particles have an average first-stage batch aspect ratio [B(length / width)] in the range of at least 1.1 and not more than 4.7 and a first-stage batch aspect ratio standard deviation [STDEV-B(length / width)] of at least 0.05 and not more than 0.

55.

2. The coated abrasive article of claim 1, wherein the plurality of abrasive particles comprises pyramidal abrasive particles.

3. A coated abrasive article according to claim 2, wherein each of the conical abrasive particles comprises a body, the body comprising: a tip region comprising a tip of the body, a base region comprising a base of the body, wherein the base region is at an opposite end of the body relative to the tip region along the length of the body.

4. The coated abrasive article of claim 1, wherein the plurality of abrasive particles comprises tapered abrasive particles having a taper fraction standard deviation of at least 0.025 and no greater than 0.

090.

5. The coated abrasive article of claim 2, wherein each of the conical abrasive particles comprises a body having a length, a width, and a thickness, wherein length>width≥thickness.

6. The coated abrasive article of claim 2, wherein the tip region is defined by a taper comprising a reduction in width or thickness of the body along the length of the tip region.

7. The coated abrasive article of claim 2, wherein the tip region comprises an asymmetric taper including a first surface and a second surface, wherein the first surface has a different profile than the second surface.

8. A coated abrasive article according to claim 2, wherein the base includes a protrusion extending from the body, wherein the protrusion extends at an angle relative to the longitudinal axis of the body, and wherein the base region includes a base angle of at least 91 degrees and no greater than 180 degrees.

9. The coated abrasive article of claim 2, wherein the base comprises a base surface comprising peaks and valleys.

10. The coated abrasive article of claim 2, wherein the base comprises a base surface having a plurality of peaks, wherein at least one peak of the plurality of peaks has a tip radius that is smaller than a tip radius of the tip of the body.

11. The coated abrasive article of claim 2, wherein the abrasive article further comprises an elongated region extending between the tip region and the base region.

12. The coated abrasive article of claim 11, wherein the elongated region defines a region having a width variation or a thickness variation of no more than 10% over the length of the elongated region.

13. The coated abrasive article of claim 1, wherein the tapered abrasive particles comprise an average Solidity of at least 0.

87.

14. The coated abrasive article of claim 2, wherein the plurality of abrasive particles have a predetermined lateral position, a predetermined longitudinal position, a predetermined radial position, a predetermined rotational orientation, a predetermined tilt angle, or any combination thereof.

15. The coated abrasive article of claim 2, wherein the tapered abrasive particles comprise an average elongation fraction value of at least 0.2.

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