Abrasive particles and methods of forming same

Abstract

The invention relates to abrasive particles and methods of forming the same. An abrasive particle has a body including a first major surface, a second major surface opposite the first major surface, and a side surface extending between the first major surface and the second major surface such that a majority of the side surface includes a plurality of microridges.

Description

[0001] This application is a divisional application of the application patent application having application number 201780041719.1 and title "Abrasive Particles and Methods of Forming the Same" and having a filing date of May 10, 2017. TECHNICAL FIELD

[0002] The following relates to abrasive particles, and more particularly, to abrasive particles having certain characteristics and methods of forming such abrasive particles. BACKGROUND

[0003] Abrasive articles incorporating abrasive particles can be used for a variety of material removal operations including grinding, finishing, polishing, and the like. Depending on the type of abrasive, such abrasive particles can be used to shape or grind a variety of materials in the manufacture of goods. To date, certain types of abrasive particles having particular geometries, such as triangular abrasive particles, and abrasive articles incorporating such objects have been formulated. See, for example, U.S. Patent Nos. 5,201,916; 5,366,523; and 5,984,988.

[0004] Previously, three basic techniques have been used to manufacture abrasive particles having particular shapes, namely, melting, sintering, and chemical ceramic. In the melting process, abrasive particles can be shaped by a cooled roll that can or can not be engraved on the surface, a mold into which molten material is poured, or a fin material submerged in an alumina melt. See, for example, U.S. Patent No. 3,377,660. In the sintering process, abrasive particles can be formed from refractory powders having a particle size of up to 10 microns in diameter. A binder can be added to the powder along with a lubricant and a suitable solvent to form a mixture that can be shaped into small pieces or strips having various lengths and diameters. See, for example, U.S. Patent No. 3,079,242. The chemical ceramic technique involves converting a colloidal dispersion or hydrosol (sometimes referred to as a sol) into a gel or any other physical state that restricts the mobility of the components, drying, and firing to obtain a ceramic material. See, for example, U.S. Patent Nos. 4,744,802 and 4,848,041. Additional relevant disclosures regarding abrasive particles and related methods of forming abrasive articles incorporating such particles can be found at http: / / www.abel-ip.com / publications / .

[0005] There is an ongoing need in the industry for improved abrasives and abrasive articles. SUMMARY

[0006] According to one aspect, an abrasive particle comprises a body comprising a first major surface, a second major surface opposite the first major surface, and a side surface extending between the first major surface and the second major surface, wherein the side surface comprises an average anisotropy factor of at least 1.25.

[0007] According to another aspect, an abrasive particle includes a body including a first major surface, a second major surface opposite the first major surface, and a lateral surface extending between the first major surface and the second major surface, wherein the first major surface includes a first protrusion disposed against and extending along at least a portion of a first lateral surface portion of the lateral surface, and further includes a texture-free region extending through a central region of the body, wherein the texture-free region defines a majority of a total surface area of the first major surface.

[0008] In yet another aspect, an abrasive particle includes a body including a first major surface, a second major surface opposite the first major surface, and a lateral surface extending between the first major surface and the second major surface, wherein a majority of the lateral surface includes a plurality of micro-ridges.

[0009] According to yet another aspect, a collection of abrasive particles includes: a first abrasive particle including a body including a first major surface, a second major surface opposite the first major surface, and a lateral surface extending between the first major surface and the second major surface, wherein the body of the first abrasive particle includes a first two-dimensional shape, and wherein the first major surface includes a first protrusion disposed against and extending along at least a portion of a first lateral surface portion of the lateral surface, and wherein the body further includes a texture-free region extending through a central region of the body, wherein the texture-free region defines a majority of a total surface area of the first major surface; and further including a second abrasive particle including a body including a first major surface, a second major surface opposite the first major surface, and a lateral surface extending between the first major surface and the second major surface, wherein the body of the second abrasive particle includes a different two-dimensional shape than the two-dimensional shape of the first abrasive particle.

[0010] In yet another aspect, a collection of abrasive particles includes abrasive particles, wherein each particle in the collection of abrasive particles includes a body having a first major surface, a second major surface opposite the first major surface, and a lateral surface extending between the first major surface and the second major surface; and wherein a majority of the particles in the collection of abrasive particles include a plurality of micro-ridges extending along at least a portion of the lateral surface.

[0011] According to still another aspect, a collection of abrasive particles includes abrasive particles, wherein the particles in the collection of abrasive particles include a body having a first major surface, a second major surface opposite the first major surface, and a lateral surface extending between the first major surface and the second major surface, and wherein the lateral surface includes a plurality of lateral surface portions extending between outer corners of the body, and wherein at least 45% of the lateral surface portions of the body include a plurality of micro-ridges.

[0012] One aspect includes a collection of abrasive particles, wherein each abrasive particle in the collection of abrasive particles includes a body having a first major surface, a second major surface opposite the first major surface, and a lateral surface extending between the first major surface and the second major surface, wherein the first major surface and the second major surface are substantially parallel to each other; and wherein the collection of abrasive particles includes an average non-convexity factor of at least 3.5 and a non-convexity factor standard deviation of at least 2.4.

[0013] Another aspect includes a collection of abrasive particles, wherein each abrasive particle in the collection of abrasive particles includes a body having a first major surface, a second major surface opposite the first major surface, and a lateral surface extending between the first major surface and the second major surface, and wherein the collection of abrasive particles includes an average anisotropy factor of at least 1.25.

[0014] And yet another aspect includes a collection of abrasive particles, wherein each abrasive particle in the collection of abrasive particles includes a body having a first major surface, a second major surface opposite the first major surface, and a lateral surface extending between the first major surface and the second major surface, wherein the body includes a height defined as a distance along the lateral surface between the first major surface and the second major surface, wherein the collection of abrasive particles includes a height standard deviation of no more than 100 microns, and wherein the collection of abrasive particles includes an average non-convexity factor of at least 3.5. BRIEF DESCRIPTION OF DRAWINGS

[0015] The disclosure can be better understood, and its numerous features and advantages can become apparent to those skilled in the art by reading the following specification. The accompanying drawings are also provided to help explain the principles of the disclosure and to present concepts related thereto.

[0016] Figure 1 A schematic diagram including a method of forming abrasive particles according to an embodiment.

[0017] Figure 2A A top view including a system for forming abrasive particles according to an embodiment.

[0018] Figure 2B A cross-sectional view including a portion of a body including a feature according to an embodiment.

[0019] Figure 3A , 3B And 4A through 4L include top and perspective views of a system for modifying a form of a body according to embodiments.

[0020] Figure 5 A perspective view including a shaped abrasive particle.

[0021] Figure 6 A perspective view including a randomly shaped abrasive particle.

[0022] Figure 7APerspective view of a coated abrasive article including controlled height abrasive particles according to an embodiment.

[0023] Figure 7B Perspective view of a coated abrasive article including controlled height abrasive particles according to an embodiment.

[0024] Figure 7C Top view of an abrasive particle including according to an embodiment.

[0025] Figure 7D Side view of a portion of a coated abrasive including according to an embodiment.

[0026] Figure 8A Image of an abrasive particle including according to an embodiment.

[0027] Figure 8B Top-down image of an abrasive particle including according to an embodiment.

[0028] Figure 8C Surface profile plot of a portion of a major surface of an abrasive particle including Figure 8B .

[0029] Figure 8D Surface profile plot of a portion of a major surface of a particle including Figure 8B .

[0030] Figures 9A to 9E Image of an abrasive particle including according to an embodiment.

[0031] Figure 10 Cross-sectional illustration of a coated abrasive article including according to an embodiment.

[0032] Figure 11 Cross-sectional illustration of a bonded abrasive article including according to an embodiment.

[0033] Figures 12A to 12J Top-down image of an abrasive particle from a collection of abrasive particles including according to an embodiment.

[0034] Figures 13A to 13R Top-down image of an abrasive particle from a collection of abrasive particles including according to an embodiment.

[0035] Figures 14A to 14J Top-down image of an abrasive particle from a collection of abrasive particles including according to an embodiment.

[0036] Figure 15A Image of an abrasive particle including according to an embodiment having a plurality of micro-ridges on a side surface.

[0037] Figure 15B Image of a side surface of an abrasive particle including according to an embodiment. Figure 15A ​

[0038] Figure 16 Image of a portion of a side surface of an abrasive particle comprising scale-like microspines according to an embodiment.

[0039] Figure 17 Image of a portion of a side surface of an abrasive particle comprising extended microspines according to an embodiment.

[0040] Figure 18 Side view scanning electron microscope (SEM) image of an abrasive particle according to an embodiment.

[0041] Figure 19 Magnified SEM image of a sidewall of an abrasive particle comprising Figure 18 .

[0042] Figure 20 Side view image of Figure 18 labeled for measuring height of body and second region.

[0043] Figure 21A Scanning electron microscope (SEM) image comprising a portion of a sidewall.

[0044] Figure 21B Image of Figure 21A as analyzed using Fourier transform.

[0045] Figure 22A Top-down X-ray microscope (XRM) image of an abrasive particle according to an embodiment.

[0046] Figure 22B Binary image of Figure 22A .

[0047] Figure 22C Transformed image of Figure 22B using convex hull analysis via imaging processing software.

[0048] Figure 23A Upside-down XRM image of an abrasive particle from sample CS1.

[0049] Figure 23B SEM image of a portion of a side surface of an abrasive particle from sample CS1.

[0050] Figure 24A Top-down image of an abrasive particle from sample CS2.

[0051] Figure 24B SEM image of a portion of a side surface of an abrasive particle from sample CS2.

[0052] Figure 25AAn SEM image from above of abrasive particles comprising abrasive particles from sample CS3.

[0053] Figure 25B An SEM image of a portion of a side surface of an abrasive particle comprising abrasive particles from sample CS1. DETAILED DESCRIPTION

[0054] The following relates to methods of forming abrasive particles and features of such abrasive particles. The abrasive particles can be used in various abrasive articles, including, for example, bonded abrasive articles, coated abrasive articles, and the like. Alternatively, the abrasive particles of the embodiments herein can be used in free abrasive techniques, including, for example, lapping and / or polishing slurries.

[0055] Figure 1 An illustration of a system for forming abrasive particles according to an embodiment. The process of forming abrasive particles can be initiated by forming a mixture 101 comprising a ceramic material and a liquid. In particular, the mixture 101 can be a gel formed from a ceramic powder material and a liquid, where the gel can be characterized as a shape stable material having the ability to maintain a given shape even in a green (i.e., un-fired) state. According to an embodiment, the gel can comprise a powder material that is an integrated network of discrete particles.

[0056] The mixture 101 can be formed to have a particular content of solid material, such as a ceramic powder material. For example, in one embodiment, the mixture 101 can have a solids content in a range of at least 25 wt.% and no greater than 75 wt.% based on the total weight of the mixture 101.

[0057] According to one embodiment, the ceramic powder material can comprise oxides, nitrides, carbides, borides, oxycarbides, oxynitrides, and combinations thereof. In particular cases, the ceramic material can comprise alumina. More particularly, the ceramic material can comprise a boehmite material, which can be a precursor to alpha alumina. The term "boehmite" is used herein generally to refer to hydrated alumina, including the mineral boehmite, which is typically AI2O3-H2O and has a water content of about 15%; and pseudoboehmite, which has a water content higher than 15%, such as 20 wt.% to 38 wt.%. It is noted that boehmite, including pseudoboehmite, has a particular and identifiable crystal structure, and accordingly has a unique X-ray diffraction pattern, and thus, is distinguished from other aluminous materials that include other hydrated aluminas, such as ATH (aluminum trihydrate), which is a common precursor material used in the manufacture of boehmite particulate materials herein.

[0058] Further, mixture 101 can be formed to have a particular content of liquid material. Some suitable liquids can include organic materials. Other suitable materials can include water. According to one embodiment, mixture 101 can be formed to have a liquid content that is less than the solid content of mixture 101. In more particular cases, mixture 101 can have a liquid content in a range of at least about 25 wt.% and no greater than 75 wt.% based on the total weight of mixture 101. The water content of mixture 101 can be controlled to facilitate proper drying upon shrinkage, which can aid in forming abrasive particles according to embodiments herein.

[0059] Further, to facilitate processing and forming abrasive particles according to embodiments herein, mixture 101 can have a particular storage modulus. For example, mixture 101 can have a storage modulus in a range of at least about 1 x 10 4 Pa and no greater than about 1 x 10 7 Pa. The storage modulus can be measured via a parallel plate system using an ARES or AR-G2 rotational rheometer and a Peltier plate temperature control system. To test, mixture 101 can be extruded into the gap between two plates set about 8 millimeters 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 millimeters until mixture 101 completely fills the gap between the plates. After wiping away excess mixture, the gap is reduced by 0.1 millimeters and the test begins. The test is an oscillatory strain sweep test conducted at 6.28 rad.s -1 (1 hertz) with a strain range between 0.1% and 100% of the instrument setting, using 25 millimeter parallel plates and recording 10 points per decade. Within 1 hour of completing the test, the gap is again reduced by 0.1 millimeters and the test is repeated. The test can be repeated at least 6 times. The first test can be different than the second test and the third test. Only the results of the second test and the third test for each sample should be reported. The viscosity can be calculated by dividing the storage modulus value by 6.28 s -1 .

[0060] Further, to facilitate processing and forming abrasive particles according to embodiments herein, mixture 101 can have a particular viscosity, which can facilitate subsequent processing (e.g., modification) and forming of desired abrasive particles. For example, mixture 101 can have a viscosity of at least about 4 x 10 3 Pa-seconds, at least about 5 x 10 3 Pa-seconds, at least about 6 x 10 3 Pa-seconds, at least about 8 x 10 3 Pa-seconds, at least about 10 x 10 3 Pa-seconds, at least about 20 x 10 3 Pa-seconds, at least about 30 x 10 3 Pa-seconds, at least about 40 x 10 3pascal, at least about 50 x 10 3 pascal, at least about 60 x 10 3 pascal, even at least about 65 x 10 3 pascal. In at least one non-limiting embodiment, the mixture 101 can have a viscosity of no greater than about 1 x 10 6 pascal, no greater than about 5 x 10 5 pascal, no greater than about 3 x 10 5 pascal, or even no greater than about 2 x 10 5 pascal. It should be appreciated that the viscosity of the mixture 101 can be within a range between any of the minimum and maximum values described above.

[0061] Further, the mixture 101 can be formed to have a particular content of organic materials, including, for example, organic additives that can be different from the liquid, to facilitate processing and forming abrasive particles according to embodiments herein. Some suitable organic additives can include stabilizers, plasticizers, surfactants, binders, such as sucrose, sucrose, lactose, glucose, UV curable resins, and the like.

[0062] Embodiments herein can use a mixture 101 having a particular content of organic additives. For example, the content of organic materials within the mixture 101, and particularly the content of any of the organic additives described above, can be a small amount compared to other components within the mixture 101. In at least one embodiment, the mixture 101 can have no greater than about 30 wt. % of organic materials, based on the total weight of the mixture 101. In other cases, the amount of organic materials can be less, such as no greater than about 15 wt. %, no greater than about 10 wt. %, or even no greater than about 5 wt. %. Further, in at least one non-limiting embodiment, the amount of organic materials within the mixture 101 can be at least about 0.1 wt. %, such as at least about 0.5 wt. %, based on the total weight of the mixture 101. It should be appreciated that the amount of organic materials in the mixture 101 can be within a range between any of the minimum and maximum values described above.

[0063] Further, the mixture 101 can be formed to have a particular content of acids and / or bases to facilitate processing and forming abrasive particles according to embodiments herein. Some suitable acids or bases can include nitric acid, sulfuric acid, citric acid, chloric acid, tartaric acid, phosphoric acid, ammonium nitrate, ammonium citrate. According to one particular embodiment, using a nitric acid additive, the mixture 101 can have a pH of less than about 5, and more particularly, within a range between about 2 and about 4.

[0064] The process of forming abrasive particles can include forming the mixture 101 into a body. Referring to FIG. 1, the mixture 101 can be formed into a body 102. The body 102 can be formed by any suitable method, such as by molding, casting, or the like. In at least one embodiment, the body 102 can be formed by molding the mixture 101 into a mold. The mold can be any suitable mold, such as a metal mold, a ceramic mold, a plastic mold, or the like. In at least one embodiment, the mold can be a metal mold, such as a steel mold. In at least one embodiment, the mold can be a ceramic mold, such as a ceramic mold having a ceramic material, such as alumina, zirconia, or the like. In at least one embodiment, the mold can be a plastic mold, such as a plastic mold having a plastic material, such as a polymeric material, such as a polyamide, a polyimide, a polyurethane, a polyethylene, a polypropylene, or the like. In at least one embodiment, the mold can be a metal mold, a ceramic mold, and / or a plastic mold having a surface that is coated with a ceramic material, such as alumina, zirconia, or the like. Figure 1, the system 100 can include a mold 103 and define a deposition zone in which the mixture 101 is formed into a body 111. As shown, the mixture 101 can be disposed within an interior of the mold 103 and configured to be extruded through a die 105 located at one end of the mold 103. As further shown, the formation can include applying a force 180 (which can be converted to a pressure) to the mixture 101 to facilitate movement of the mixture 101 through the die 105. According to one embodiment, a particular pressure can be used during extrusion. For example, the pressure can be at least about 10 kiloPascals, such as at least about 500 kiloPascals. Also, in at least one non-limiting embodiment, the pressure used during extrusion can be no greater than about 10 megaPascals or no greater than 5 megaPascals. It should be appreciated that the pressure used to extrude the mixture 101 can be within a range between any of the minimum and maximum values described above.

[0065] In certain systems, the mold 103 can include a die 105 having a particular shape. It should be appreciated that the die 105 can be shaped to impart a particular shape to the mixture 101 and the resulting body 111. Further, the mixture 101 and the resulting body 111 extruded through the die 105 can have substantially the same cross-sectional shape as the die 105. According to one embodiment, the die 105 can have a rectangular shape. In other embodiments, the mold opening 105 can be shaped to create certain features in one or more surfaces of the body 111 as the mixture exits the mold 103. These features can include a controlled feature distribution. Thus, in certain instances, the extrusion of the mixture 101 from the mold 103 and the modification of the body 111 can occur simultaneously. That is, the mixture 101 can exit the mold 103 and be formed into a body 111 having certain features in one or more surfaces such that the body 111 is also modified to include one or more features in one or more surfaces of the body 111 during the formation of the body 111.

[0066] As Figure 1 further shown, the mixture 101 can be extruded onto a substrate. In the illustrated embodiment of Figure 1 , the substrate is in the form of a conveyor belt 109 underneath the mold 103 such that the resulting body 111 is in the form of a layer or sheet of material. Other types of substrates can be used. In certain instances, the mixture 101 can be extruded directly onto the conveyor belt 109, which can facilitate continuous processing.

[0067] According to one particular embodiment, the conveyor belt 109 can be formed to have a film overlaid on a substrate, where the film can be a layer of material configured to facilitate processing and formation of discrete and separate abrasive particles. The process can include providing the mixture 101 directly onto the film of the conveyor belt to form the body 111. In certain instances, the film can include a polymeric material, such as a polyester. In at least one particular embodiment, the film can consist essentially of a polyester.

[0068] In yet another embodiment, the upper surface of the conveyor belt 109 can have a particular roughness, which can aid in forming abrasive particles according to embodiments herein. For example, the roughness of the surface of the conveyor belt 109 can affect the manner in which the bodies 111 are dried and can facilitate controlled cracking of the bodies 111. Various materials can be used for the conveyor belt 109 or as a coating on the surface of the conveyor belt 109. Some suitable materials can include inorganic materials, such as a metal, a metal alloy, a ceramic, a polycrystalline material, an amorphous phase material, a single crystalline material, or any combination thereof. In another embodiment, the conveyor belt 109 or the upper surface of the conveyor belt 109 can include an organic material, such as a polymer, which can include materials such as an epoxy, a resin, a thermoset, a thermoplastic, a polyimide, a polyamide, and combinations thereof. It should be appreciated that the upper surface of the conveyor belt 109 can include one or more features described in embodiments herein, which can be used to form a distribution of features of a portion of the bodies 111, such as a portion of the bodies 111 that is in contact with the upper surface of the conveyor belt 109 having such features. For example, aspects of the conveyor belt 109, such as the surface roughness of the conveyor belt, the material, and the like, can be adapted to particular aspects of the bodies 111 and the forming process to facilitate suitable formation of abrasive particles as described in embodiments herein.

[0069] In some embodiments, the conveyor belt 109 can translate while moving the mixture 101 through the die 105. As shown in the system 100, the mixture 101 can be extruded in a direction 191. The direction of translation 110 of the conveyor belt 109 can be angled relative to the direction of extrusion 191 of the mixture. While the angle between the direction of translation 110 and the direction of extrusion 191 is shown as substantially orthogonal in the system 100, other angles are contemplated, including, for example, acute or obtuse angles. Further, while the mixture 101 is shown as being extruded in a direction 191 that is angled relative to the direction of translation 110 of the conveyor belt 109, in an alternative embodiment, the conveyor belt 109 and the mixture 101 can be extruded in substantially the same direction.

[0070] The conveyor belt 109 can translate at a particular rate to facilitate processing. For certain processes according to embodiments herein, the rate of translation of the conveyor belt 109 can be controlled in comparison to the rate of extrusion of the mixture 101 in the direction 191 to facilitate proper processing. For example, the rate of translation of the conveyor belt 109 can be substantially the same as the rate of extrusion to ensure that suitable bodies 111 are formed.

[0071] For certain embodiments, the mixture 101 can be extruded to form bodies 111 in the form of bodies 111 having a substantially rectangular cross-sectional shape as viewed from a plane defined by the height and width of the bodies 111. While the bodies 111 are shown as flakes, it should be appreciated that the process is not limited thereto and the mixture can be formed into bodies having any desired shape.

[0072] The process of forming the body 111 from the mixture 101 can include controlling certain features and process parameters to facilitate proper formation of abrasive particles having one or more features as provided in embodiments herein. For example, in certain instances, the process of forming the body 111 from the mixture 101 can include forming the body 111 having a particular height. Further, it should be noted that the height 181 of the body 111 can be controlled by varying the distance between the mold 103 and the surface of the conveyor belt 109. Alternatively, the process can use a doctor blade or similar technique to control the height 181 of the body 111. Additionally, forming the mixture 101 into the body 111 can include controlling the size of the body 111 based in part on the viscosity of the mixture 101. In at least one embodiment, the body 111 is formed as a large layer of material having a first major surface having a major surface area of at least 10 square centimeters, such as at least 20 square centimeters, or at least 50 square centimeters, or at least 100 square centimeters, or at least 500 square centimeters, or at least 1 square meter. Notably, the process of forming the body 111 can be performed without the use of a mold or other manufacturing tool to form a plurality of individual and discrete portions of the gel contained within the opening of the manufacturing tool.

[0073] Further, to facilitate processing and forming abrasive particles according to embodiments herein, the body 111 can have a particular viscosity, which can have any of the values noted above for the viscosity of the mixture 101.

[0074] The body 111 can have particular dimensions, including, for example, a length (l), a width (w), and a height (h). According to an embodiment, the body 111 can have a length extending in the direction of the translating conveyor belt 109, which can be greater than the width, where the width of the body 111 is a dimension extending in a direction perpendicular to the length of the conveyor belt 109 and the length of the sheet. The body 111 can have a height 181, where the length and width are greater than the height 181 of the body 111. Thus, according to one embodiment, length > width > height.

[0075] Notably, the height 181 of the body 111 can be a dimension that extends vertically from the surface of the conveyor 109. According to an embodiment, the body 111 can be formed to have a particular size of height 181, where the height can be an average height of the body 111 derived from a plurality of measurements. For example, the height 181 of the body 111 can be at least about 0.1 millimeters, such as at least about 0.5 millimeters. In other examples, the height 181 of the body 111 can be greater, such as at least about 0.8 millimeters, at least about 1 millimeter, at least about 1.2 millimeters, at least about 1.6 millimeters, or even at least about 2 millimeters. Additionally, in one non-limiting embodiment, the height 181 of the body 111 can be no more than about 10 millimeters, no more than about 5 millimeters, or even no more than about 2 millimeters. It will be appreciated that the body 111 can have an average height within a range between any of the minimum values and any of the maximum values noted above.

[0076] After extruding the mixture 101 from the die 103, the body 111 can be translated along the surface of the conveyor 109 in the direction 112. Translation of the body 111 along the conveyor 109 can facilitate further processing. For example, after forming the body 111, the body 111 can be translated to a modification region 120, where at least a portion of the body 111 is modified. The process of modifying the body 111 can include using one or more processes that can facilitate altering stress generation within the body 111 during further processing. For example, the process of modifying the body 111 can include modifying portions of the body 111 such that, after further processing (e.g., drying), the portions of the body 111 associated with the modification can be regions of higher stress concentration compared to those regions that are not modified, such that fracture of the body can be more likely in the regions of higher stress concentration, thus facilitating the formation of shaped precursor particles. For example, the process of modifying the body 111 can locally alter stress generation in the body 111 during drying. In one embodiment, the modification process can include deforming at least a portion of the body 111. Modification of the body 111 can facilitate the formation of at least one crack initiation site in the body 111, such that during later processing (e.g., drying), the initial location of a crack or defect and the direction of crack propagation within the body 111 can be controlled. In one embodiment, the process of modifying the body 111 can include altering physical characteristics of the body 111, such as altering one or more surfaces and / or dimensions of the body 111.

[0077] In yet another embodiment, modifying the body 111 can include changing the chemical composition of at least a portion of the body 111. In certain instances, modifying the body 111 can include changing the rheological properties of the body 111. In certain instances, the process of modifying the body 111 can include applying or providing at least one additive to at least a portion of the body 111 such that the additive can chemically and / or physically change the body 111. The additive can facilitate a change in the body that creates regions of higher stress concentration during further processing, which can facilitate controlled fracture of the body 111. Such modification can facilitate changing the stress within the body 111 such that the body 111 includes regions of higher stress relative to other regions within the body 111 that have lower stress. The distribution of regions of higher stress and lower stress can be controlled by controlling one or more parameters associated with the modification process, including but not limited to controlling the distribution of features formed in the body, controlling the distribution of one or more additives within the body, and the like. Notably, when the process of modifying the body 111 is combined with other processes (e.g., certain drying conditions), it can facilitate the formation of abrasive particles having the features described herein.

[0078] The processes of modifying and drying can have one or more parameters that can be controlled and facilitate the formation of different types of abrasive particles. For example, certain parameters that can affect the characteristics of the abrasive particles ultimately formed can include, but are not limited to, the composition of the upper surface of the conveyor belt 109, the surface roughness of the upper surface of the conveyor belt 109, the distribution of features formed in the body 111 during modification, the shape, size, and / or cross-sectional shape of the distribution of features formed in the body 111 during modification, the distribution and type of one or more additives used during modification, the rheological properties of the body 111 (e.g., viscosity, etc.), the size, shape, and composition of the raw material within the body 111, the height of the body 111, the depth of the features, the drying temperature, the relative humidity, the drying rate, the drying time, the rate of translation through the drying environment, or any combination thereof.

[0079] In one particular embodiment, the process of modifying can include forming a controlled distribution of features in at least a portion of the body. For example, as shown in Figure 1 , a top view of a system including Figure 2A , the upper surface 112 of the body 111 can be deformed such that a series of depressions 121 can be formed in the upper surface 112. As shown in Figure 1 and 2AAs shown in FIG. 1, the recesses 121 can be in the form of lines extending along the width (w) and length of the body 111 and partially through the height 181 of the body 111. It should be appreciated that while the recesses 121 are shown as lines, other shapes and arrangements of the recesses 121 can be used depending on the desired aspects of the abrasive particles ultimately formed. For example, the recesses 121 can be formed to have various shapes or profiles, such as curved, straight, circular dots, and combinations thereof.

[0080] According to one embodiment, the controlled feature distribution can be defined as a pattern or array of features having at least one repeating unit. In another embodiment, the controlled feature distribution can be a random feature distribution such that the arrangement of features lacks discernible short or long range order. Other examples of controlled distributions can include radial patterns, spiral patterns, phyllotactic patterns, asymmetric patterns, self-avoiding random distributions, or any combination thereof.

[0081] The features of the controlled distribution can include various shapes and / or structures. For example, the features can include at least one of protrusions, recesses, interconnected structures, discrete and isolated structures, or any combination thereof. In at least one embodiment, the features can have various cross-sectional shapes including, but not limited to, for example, U-shaped, V-shaped, and the like. In certain instances, at least a portion of the body 111 can be formed to have a controlled feature distribution having an interconnected network of recesses, as shown in FIGS. 1 and 2. In any of the embodiments, the features formed in the body 111 can be identical in shape and size relative to one another. Additionally, in another embodiment, at least two features can differ from one another based on shape, size, profile, cross-sectional shape, and the like. Figure 1 In any of the embodiments, the features formed in the body 111 can be identical in shape and size relative to one another. Additionally, in another embodiment, at least two features can differ from one another based on shape, size, profile, cross-sectional shape, and the like.

[0082] The size, shape, and spacing of the features can be controlled and facilitate the formation of precursor abrasive particles, and thus, the formation of final formed abrasive particles of a desired size. In one particular embodiment, the size, shape, and spacing between features can facilitate the formation of abrasive particles according to the embodiments herein. The desired spacing between features can affect the target average particle size of the abrasive particles to be formed. In at least one embodiment, the features can be formed to have acute angles or small radii of curvature, which can effectively concentrate stress at desired locations within the body 111 and further facilitate controlled breakage to produce abrasive particles of a desired shape and size, which can include those having features of the embodiments herein.

[0083] For at least one aspect, the size of the features of the body 111 can be controlled to facilitate the formation of abrasive particles according to embodiments herein. For example, the features can include at least one feature having a length (Lf), a width (Wf), and a depth (Df). In at least one embodiment, the length can be the longest dimension, the width can be the second longest dimension in the same plane as the length, and the depth can be the shortest dimension of the feature, which can be in a direction perpendicular to the plane defined by the length and the width. Notably, in one embodiment, Lf> Wf> Df. Additionally, in another embodiment, the body can have dimensions based on Lf> Df> Wf.

[0084] According to at least one embodiment, the features can be in the form of recesses formed within the body 111. Figure 2B A cross-sectional illustration of a portion of the body 111 including features formed according to an embodiment. As shown, the features 121 can include recesses 231 formed within the body 111 and extending into the volume of the body. The features 121 can also include protrusions 232 formed within the body 111 and defining a region extending above the upper surface 121 of the body 111. Notably, the recesses 231 can have an average depth 194 (df) defined as the average distance between the lower surface 195 of the recess 231 and the upper surface 112 of the body 111. In at least one embodiment, the recesses 231 can be formed to have an average depth 194 of at least 5% of the average height 181 of the body 111. In other examples, the average depth 194 can be greater, such as at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45%, or at least 50%, or at least 55%, or at least 60%, or at least 65%, or at least 70%, or at least 75%, or at least 80%, or at least 85%, or at least 90%, or at least 95% of the average height 181 of the body 111. Additionally, in one non-limiting embodiment, the average depth 194 can be no greater than 99%, 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 65%, or no greater than 60%, or no greater than 55%, or no greater than 50%, or no greater than 45%, or no greater than 40%, or no greater than 35%, or no greater than 30%, or no greater than 25%, or no greater than 20%, or no greater than 15%, or no greater than 10%, or no greater than 5% of the average height 181 of the body 111. Additionally, it should be appreciated that the average depth 194 can be within a range including any of the minimum and maximum percentages noted above. Controlling the average depth 194 of the recesses 231 can facilitate proper machining and improved formation of abrasive particles having features of embodiments herein. One or more of such features can be present within the ultimately formed abrasive particles.

[0085] In another embodiment, the protrusion 232 may define a region of the body 111 extending above the upper surface 112 of the body 111. The protrusion 232 may have an average height 234 relative to the average height 181 of the body. For example, the protrusion 232 may have an average height of at least 5% of the average height 181 of the body 111. In other examples, the average height 234 of the protrusion 232 may be larger, such as at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45%, or at least 50%, or at least 55%, or at least 60%, or at least 65%, or at least 70%, or at least 75%, or at least 80%, or at least 85%, or at least 90%, or at least 95% of the average height 181 of the body 111. Additionally, in a non-limiting embodiment, the average height 234 may not exceed 99% of the average height 181 of the body 111, such as not exceeding 95%, or not exceeding 90%, or not exceeding 85%, or not exceeding 80%, or not exceeding 75%, or not exceeding 70%, or not exceeding 65%, or not exceeding 60%, or not exceeding 55%, or not exceeding 50%, or not exceeding 45%, or not exceeding 40%, or not exceeding 35%, or not exceeding 30%, or not exceeding 25%, or not exceeding 20%, or not exceeding 15%, or not exceeding 10%, or not exceeding 5%. It should be understood that the average height 234 may be within a range including any of the minimum and maximum percentages mentioned above. Controlling the average height 234 of the protrusions 232 facilitates the appropriate processing and improvement of abrasive particles having the features of the embodiments herein. One or more of these features may be present within the ultimately formed abrasive particles.

[0086] The protrusion 232 can be caused by the modification process. In some examples, when one or more recesses are formed, the mixture of body 111 moves, and the protrusion 232 may form around the recess 231. In other examples, material of body 111 may adhere to a molded part used to modify the surface of body 111, and some material of body 111 may adhere to the molded part when it is pulled away from body 111. This adhesion between the molded part and body 111 can cause the formation of protrusions. In some examples, it may be necessary to limit the formation of protrusions due to adhesion between the molded part and the body during the modification process.

[0087] According to one embodiment, the process of modifying the body 111 may include at least one surface of the modified body 111. For example... Figure 1 As shown, feature 121 may be formed in the upper surface 112 of the body 111. Various mechanisms can be used to form feature 121 in one or more surfaces of the body 111. For example, such as Figure 1As shown in FIG. 1, a shaped member 122 having shaped features 124 can be translated in a direction 123 such that the shaped features 124 contact an upper surface 112 of the body 111 and deform the body 111 according to the shaped features 124. Some examples of such processes can include intaglio roll-pressing or die-pressing. Other suitable processes for deforming a surface of the body 111 can include pressing, stamping, depositing, spraying, and the like.

[0088] In at least one embodiment, features formed in at least a portion of a surface of the body 111, such as the upper surface 112, can be created by contacting a shaped member with the surface of the body 111 to be modified. The shaped member can have one or more features (e.g., protrusions, walls, openings, etc.) that can be used to create corresponding features in the body 111. With reference briefly to FIG. 3, a top view of a shaped member is provided. As shown, in at least one embodiment, the shaped member 300 can be a screen that includes portions 301 connected to one another and defining openings 302 between the portions. The shaped member 300 can be pressed into the upper surface 112 of the body 111 and deform the body 111 in the regions contacted by the portions 301. Notably, the body 111 can be modified by the shaped member 300 such that at least a portion of the upper surface 112 of the body 111 can be deformed to have features corresponding to the features of the shaped member 300. In particular, the portions 301 can be pressed into the body 111 to form depressions, which can be arranged relative to one another in the same arrangement of the portions 301 of the shaped member 300. Further, depending on certain other processing parameters, the formation of the depressions 301 can simultaneously form protrusions, as material from the depressions is pushed aside and displaced, which can result in the formation of protrusions on the upper surface 112 of the body 111. Figure 3B includes Figure 3A a perspective view of a shaped member.

[0089] It should be appreciated that various other shaped members can be used with the process. The shaped members can generally have any combination of features. The shape, size, and arrangement of the features of the shaped member can affect the size and shape of the abrasive particles formed. Further, the features of the shaped member can affect the shape features present in the abrasive particles. Such shape features are described in the embodiments herein. Certain shaped members can utilize a particular arrangement of interconnected protrusions or walls that define openings. Figure 3A 、 3B and 4A-4F include shaped members having interconnected protrusions or walls to define openings. For example, Figure 4A includes a top view of a shaped member according to an embodiment. Figure 4B includes Figure 4A a perspective view of a shaped member. Figure 4A The shaped member of FIG. 4A includes portions 401 in the form of walls connected to one another and defining openings 402 that have a generally quadrilateral, and more specifically, rectangular two-dimensional shape when viewed from above

[0090] Figure 4C Top view of a shaped piece including according to an embodiment. Figure 4D Top view of a shaped piece including Figure 4C Perspective view of a shaped piece including Figure 4C The shaped piece of includes portions 403 in the form of walls connected to one another and defining an opening 404 that has a generally irregular polygonal two-dimensional shape when viewed from above to below.

[0091] Figure 4E Top view of a shaped piece including according to an embodiment. Figure 4F Top view of a shaped piece including Figure 4E Perspective view of a shaped piece including As shown, the shaped piece can have portions 431 connected to one another and defining openings 432 between the portions 431. The openings 432 can have a quadrilateral shape, and more specifically a trapezoidal shape, and even more specifically a right trapezoidal shape, where the shape of the openings 432 includes at least two right angles (i.e., 90 degrees). It should be appreciated that the shaped pieces of embodiments herein can include portions having any combination of shape, size, arrangement, profile, etc. The portions of the shaped piece that define the openings can have a linear shape, an arcuate shape, or any combination thereof. While the shaped piece can include protrusions that are interconnected to define the openings, other shaped pieces that do not necessarily include interconnected protrusions can be used. For example, the protrusions can include one or more discrete and separate features that can be separated from adjacent protrusions by a gap. Figures 4G to 4H Illustration of a shaped piece including protrusions that are not interconnected according to an embodiment.

[0092] Figure 4G Top view of another shaped piece including according to an embodiment. Figure 4H Top view of a shaped piece including Figure 4G Perspective view of a shaped piece including Figure 4G The shaped piece of includes a plate 410 and a plurality of discrete protrusions or pins 411 extending from the plate 410. The pins 411 are spaced apart from one another and can be arranged in any distribution to create a corresponding distribution of discrete and separate recesses in at least a portion of the body 111. The pins 411 are shown as having a generally conical shape. However, it should be appreciated that other shapes can be used, including but not limited to, for example, cylindrical, frustoconical, square conical, frusto square conical, etc.

[0093] While the shaped pieces of embodiments herein have been shown as having a generally planar shape, it should be appreciated that the shaped pieces can have various other shapes. For example, the shaped pieces can be in the shape of a roller configured to be rolled over the body 111 and impart features to the body 111. Shaped pieces having such shapes can be suitable for continuous processing operations.

[0094] Figure 4I Top view of a shaped piece including according to an embodiment. Figure 4J Top view of a shaped piece including Figure 4IA perspective view of the molded part. Figure 4I The molded part comprises a plate 412 and a random arrangement of protrusions 413 extending from the plate 412, the protrusions being used to create corresponding recesses in at least a portion of the surface of the body before drying. The protrusions 413 have random shapes and random spacing relative to other protrusions 413 on the plate 412.

[0095] Figure 4K A top view of a molded part according to one embodiment. Figure 4L Include Figure 4K A perspective view of the molded part. Figure 4K The molded part comprises a plate 414 and a random arrangement of protrusions 415 extending from the plate 414, the protrusions being used to create corresponding recesses in at least a portion of the surface of the body before drying. Figure 4K The formed part includes discrete protrusions 415 having a generally elongated and linear shape. The protrusions 415 have a generally random spacing and orientation relative to other protrusions 415 on the plate 414.

[0096] In addition, such as Figure 4K and 4L As shown, the upper surface of protrusion 415 may have an edge extending between two chamfered surfaces. In other embodiments, the upper surface of the protrusion may generally be flat, such as... Figure 4E As shown in protrusion 431. It should be understood that the upper surface of the protrusion can be given any suitable shape to facilitate appropriate modification of the body and formation of the desired abrasive particles. The upper surface may have a generally planar profile, an edge, a radial or curved profile, or any other shape.

[0097] Any of the molded parts in the embodiments described herein may be made of a particular material. For example, some suitable materials may include inorganic materials, organic materials, synthetic materials, natural materials, or any combination thereof. Some examples of inorganic materials may include metals, metal alloys, glass, ceramics, polycrystalline, monocrystalline, or any combination thereof. Some suitable organic materials may include polymers such as epoxides, resins, thermosets, thermoplastics, polyimides, polyamides, or any combination thereof. The molded part may be a composite material comprising any combination of the materials mentioned herein. The material of the molded part, specifically the material of the protrusions that will contact the body, may be made of a particular material to limit the ability of the mixture to adhere to the molded part. In some examples, the material of the molded part is selected to ensure that the material of the body (i.e., the mixture) will not adhere to the material of the molded part, so that features formed on the surface of the body can be efficiently obtained with appropriate shape and resolution. A molded part that limits adhesion between the body and the molded part can limit unintended deformation of the body during modification and can facilitate improved control of the shape and size of abrasive particles formed by a controlled fracture process.

[0098] In at least one embodiment, the surface of the shaped piece can be coated with a material prior to the shaped piece contacting the body. Such a coating material can be permanent or temporary. The coating material can be an inorganic material, an organic material, a natural material, a synthetic material, or any combination thereof. For example, in one particular embodiment, the coating material can be an oil, such as a lubricant.

[0099] In yet another embodiment, the surface of the shaped piece, and particularly the portion that will contact the body to cause modification, can be coated with a chemical agent that will facilitate proper formation of the features in the body. The chemical agent can be a chemical element or a chemical composition. The chemical agent can be an additive that can help modify the body as described in embodiments herein, including for example, a dopant. The chemical agent can be a permanent or temporary material that is added to the surface of the shaped piece. The chemical agent can be an inorganic material, an organic material, a natural material, a synthetic material, or any combination thereof.

[0100] It should be appreciated that features can be formed in other surfaces. For example, in an alternative embodiment, the surface of the conveyor belt 109 configured to contact the mixture 101 can be formed to have features. Thus, during deposition of the mixture 101 onto the conveyor belt 109, the bodies 111 can be formed and the features on the conveyor belt 109 can impart features to the surface of the bodies 111 that come into contact with the features on the conveyor belt 109. Thus, the process of forming the bodies and modifying the bodies is substantially simultaneous. Such an alternative process can or can not be used with a separate modification zone 120 in which other surfaces of the bodies 111 can be modified as described in embodiments herein. For example, in one embodiment, the upper surface 112 of the bodies 111 that contact the conveyor belt 109 and the lower surface of the bodies 111 can be modified according to any of the techniques described herein.

[0101] In at least one embodiment, the conveyor belt 109 can have an upper surface with a particular surface roughness. The upper surface of the conveyor belt is configured to contact the mixture 101 and the bodies 111. The conveyor belt 109 can not necessarily have any features, but can have a particular surface roughness that can facilitate later processing to form abrasive particles. Notably, it has been observed that certain materials having a certain roughness can facilitate the drying and controlled breakage of the bodies 111 to facilitate the formation of abrasive particles according to embodiments herein. In at least one embodiment, forming the mixture 101 into the bodies 111 includes forming the mixture 101 on a conveyor belt, where the conveyor belt has a controlled surface roughness and surface energy with respect to the mixture 101 to facilitate controlled breakage and formation of a plurality of precursor abrasive particles according to a controlled breakage process.

[0102] As referred to herein, in another embodiment, the process of modifying the bodies 111 can include providing one or more additives to at least a portion of the bodies 111. Such additives can be used to physically or chemically alter the bodies 111 such that, during later processing (e.g., drying), the additives can facilitate controlled breakage of the bodies to form precursor abrasive particles. The one or more additives can be applied to one or more surfaces of the bodies 111, including, for example, any of the outer surfaces of the bodies 111. Some suitable processes for applying the one or more additives can include deposition, spraying, printing, sandblasting, scanning, jetting, heating, and the like. The one or more additives can be added in the form of solid particles, liquids, gases, or combinations thereof. To facilitate processing of the additives and delivery of the additives to the bodies 111, the one or more additives can be added in the form of a portion of an additive composition, which can include the additives and other materials, such as a carrier fluid configured to contain the one or more additives.

[0103] Some suitable additives can include rheology modifiers, dopants, pore formers, volatilizing agents, and the like. Examples of dopants can include, but are not limited to, alkali metal elements, alkaline earth metal elements, rare earth elements, hafnium (Hf), zirconium (Zr), niobium (Nb), tantalum (Ta), molybdenum (Mo), and combinations thereof. In particular cases, the dopants can include elements such as lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), strontium (Sr), barium (Ba), scandium (Sc), yttrium (Y), lanthanum (La), cesium (Ce), praseodymium (Pr), niobium (Nb), hafnium (Hf), zirconium (Zr), tantalum (Ta), molybdenum (Mo), vanadium (V), chromium (Cr), cobalt (Co), iron (Fe), germanium (Ge), manganese (Mn), nickel (Ni), titanium (Ti), zinc (Zn), or any combination thereof. Some suitable examples of rheology modifiers can include organic materials, acids, bases, or any combination thereof. Certain additives, such as dopants, can be added during various stages of processing. For example, dopants can be added during formation of the mixture. Alternatively, dopants can be added to the precursor abrasive particles after some drying and / or some calcination of the precursor abrasive particles.

[0104] It should also be appreciated that the mixture can include seed materials, such as alpha alumina seeds or iron oxide seeds, which can help to form high temperature phases of the material in the final formed and sintered abrasive particles.

[0105] Some suitable examples of pore formers can include hollow particles made from organic or inorganic materials, beads, spheres, glasses, ceramics, glass-ceramics, natural materials, and the like. Some suitable inorganic materials can include oxides or carbon-containing materials, such as graphite; salts, such as sodium chloride, potassium chloride, magnesium chloride, calcium chloride, sodium silicate, sodium carbonate, sodium sulfate, potassium sulfate, magnesium sulfate, or any combination thereof. In certain examples, the pore former can include a material having a low volatilization temperature, such that upon further processing at a suitable temperature, the pore former volatilizes to form a gas, thereby leaving a pore in the body 111. Some example oxide-containing materials can include glasses, glass-ceramics, ceramics, and combinations thereof. Other example organic pore formers can include waxes, seeds, and shells, sulfosuccinates, naphthalenes, vinyl polymers, ketones, polystyrene, polyethylene, polypropylene, acrylic polymers, benzene-containing polymers, alkyd resins, polyalkyd resins, epoxy resins, phenolic resins, acetals, and combinations thereof. Suitable inorganic pore formers can include hollow particles, such as beads, spheres, and the like, made from materials such as glasses, ceramics, glass-ceramics, or combinations thereof.

[0106] Some suitable volatilizing agents can include organic materials, naturally occurring materials, or any combination thereof. The volatilizing agent can be configured to volatilize at a temperature to form a gas phase. Such a volatilizing agent can be suitable for the creation of air pores within the body 111 during later processing, which can facilitate controlled fracture of the body and the formation of abrasive particles having one or more features of embodiments herein.

[0107] One or more additives can also include the use of one or more precursor additives. A precursor additive is one or more elements or compounds that can undergo further processing to form an additive. One or more precursor additives can be mixed to form one or more additives prior to providing the precursor to the body 111. In other examples, one or more precursor additives can be provided to the body 111, and later processing can facilitate the formation of an additive within the body 111 (i.e., in-situ additive formation). For example, one or more precursor additives can be applied to at least a portion of the body 111, which can undergo further processing (e.g., heating), which can facilitate the formation of one or more additives from the one or more precursor additives within the body.

[0108] In one embodiment, the additive can be selectively deposited on at least a portion of the body 111. For example, various techniques can be used to selectively deposit one or more additives (or one or more precursor additives) to a portion of the body 111 such that the affected portion of the body 111 can have treated regions and untreated regions. A treated region is defined as a region to which one or more additives have been applied, and an untreated region is defined as a region of the body 111 to which one or more additives have not yet been applied. The creation of treated and untreated regions on the body can facilitate controlled fracture by later processing and the formation of abrasive particles having one or more features of embodiments herein. It should be appreciated that the portion of the body 111 that can be affected can be any of the portions described in embodiments herein as suitable for modification, including, for example, any of the outer surfaces of the body 111. The additive can be applied to the body such that the treated portion defines a controlled distribution as described in embodiments herein.

[0109] After modifying at least a portion of the body 111, the body 111 can undergo further processing to facilitate the formation of abrasive particles. As Figure 1 As shown in FIGS. 1 and 2, the body 111 can be translated from the modification zone 120 to a drying zone 140. Within the drying zone 140, particular drying conditions can be used to facilitate controlled fracture of the body 111 and the formation of precursor abrasive particles 141. In one embodiment, drying is performed to cause fracture of the body and the formation of a plurality of precursor abrasive particles. According to one embodiment, the drying process can include controlled fracture conditions configured to cause the body to break into a plurality of precursor abrasive particles, where the controlled fracture conditions include controlled crack propagation from at least one crack initiation point.

[0110] The drying process can cause the formation of any one or more features of abrasive particles according to embodiments herein, including but not limited to such features: micro-ridges, protrusions, depressions, and any combination thereof. According to one embodiment, drying the body can include forming micro-ridges on at least a portion of a side surface of at least one of the abrasive particles. In another embodiment, drying the body can include forming micro-ridges on at least a portion of a side surface of a majority of the abrasive particles. In yet another embodiment, drying the body can include forming micro-ridges on a majority of a side surface of a majority of the abrasive particles. For another embodiment, drying the body can include forming micro-ridges on at least a portion of a side surface of each of the abrasive particles.

[0111] As referred to herein, the modification process can define at least one crack initiation point within the body 111, and the drying process can be conducted under certain process parameters to control the initiation of cracks and the direction of crack propagation within the body. The at least one crack initiation point can correspond to one or more features formed within the body 111, including but not limited to, for example, protrusions, recesses, interconnecting structures, discrete and isolated structures, or any combination thereof. In certain examples, the at least one crack initiation point can abut one or more features. Further, the drying can be conducted such that the crack propagation extends along a length of the one or more features, such that the one or more features substantially direct the direction of the crack with respect to at least a portion of the length of the crack. Thus, in certain examples, the fracturing process results in the formation of a precursor abrasive particle having a portion of a controlled feature distribution within the body (e.g., a major surface of the body on which the features are formed). It should be appreciated that the process of modifying the body 111 can also include forming a plurality of crack initiation points, where each of the crack initiation points is associated with a feature formed in the body 111 or the placement of an additive within a particular region of the body 111.

[0112] According to one embodiment, the drying conditions can be related to certain parameters of the modification process to achieve controlled fracturing of the body 111 and the formation of desired abrasive particles. The drying process can facilitate controlled fracturing of the body 111 such that cracks begin and grow in the body, extend through the body 111, and separate the body into smaller pieces that form precursor abrasive particles. Controlled fracturing is a process that is different from conventional processes (e.g., molding, printing, crushing, mechanical segmentation, and agitation or vibration) in that during controlled fracturing, the body 111 is torn and broken under conditions to result in precursor (i.e., green) abrasive particles of a target shape. In at least one embodiment, the process relies only on the modification and drying processes to change the body 111 into precursor abrasive particles. The process does not necessarily require the use of any manufacturing tools (e.g., a screen or a mold) to achieve the formation of abrasive particles and significant abrasive particles of a target size and shape. Such a process represents an efficient mechanism for producing abrasive particles at a high yield in a target particle size and shape. Further, the resulting abrasive particles are characterized by certain unique features (e.g., micro-ridges and / or protrusions and / or recesses on the side surfaces, etc.) as a result of the formation process.

[0113] According to one embodiment, drying can comprise drying the subject in an environment having a drying temperature of at least 20 °C, such as at least 25 °C, or at least 30 °C, or at least 40 °C, or at least 50 °C, or at least 60 °C, or at least 70 °C, or at least 80 °C, or at least 90 °C, or at least 100 °C, or at least 110 °C, or at least 120 °C, or at least 130 °C, or at least 140 °C, or at least 150 °C, or at least 160 °C, or at least 170 °C, or at least 180 °C, or at least 190 °C, or at least 200 °C, or at least 210 °C, or at least 220 °C, or at least 230 °C, or at least 240 °C. Additionally, in another non-limiting embodiment, drying can be performed in an environment having a drying temperature of not greater than 250 °C, such as not greater than 240 °C, or not greater than 230 °C, or not greater than 220 °C, or not greater than 210 °C, or not greater than 200 °C, or not greater than 190 °C, or not greater than 180 °C, or not greater than 170 °C, or not greater than 160 °C, or not greater than 150 °C, or not greater than 140 °C, or not greater than 130 °C, or not greater than 120 °C, or not greater than 110 °C, or not greater than 100 °C, or not greater than 90 °C, or not greater than 80 °C, or not greater than 70 °C, or not greater than 60 °C, or not greater than 50 °C, or not greater than 40 °C, or not greater than 30 °C. It will be appreciated that drying can be performed in an environment having a drying temperature within a range including any of the minimum and maximum temperatures noted above, including, but not limited to, within a range of at least 20 °C and not greater than 250 °C, such as within a range including at least 50 °C and not greater than 150 °C. The temperatures noted above can be an average temperature calculated from a statistically relevant number of random locations within the drying environment.

[0114] In yet another embodiment, drying can comprise drying the subject in an environment having a relative humidity of at least 10%, such as 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%. Additionally, the relative humidity within the environment can be not greater than 90%, such as not greater than 80%, or not greater than 70%, or not greater than 60%, or not greater than 50%, or not greater than 40%, or not greater than 30%, or not greater than 20%. In at least one embodiment, the relative humidity within the environment can be within a range including any of the minimum and maximum percentages noted above, including, for example, at least 10% and not greater than 70%, or within a range of at least 10% and not greater than 70%. The relative humidity noted above can be an average relative humidity calculated from a statistically relevant number of random locations within the drying environment.

[0115] In yet another embodiment, drying can include controlling a flow rate of a gas (e.g., air) within the drying environment. For example, according to one embodiment, the flow rate of the gas through the drying environment can be at least 0.1 meters per second, such as at least 0.2 meters per second, or at least 0.5 meters per second, or at least 0.7 meters per second, or at least 1 meter per second, or at least 1.2 meters per second, or at least 1.5 meters per second, or at least 1.7 meters per second, or at least 2 meters per second, or at least 2.2 meters per second, or at least 2.5 meters per second, or at least 2.7 meters per second, or at least 3 meters per second, or at least 3.2 meters per second, or at least 3.5 meters per second, or at least 3.7 meters per second, or at least 4 meters per second, or at least 4.2 meters per second, or at least 4.5 meters per second. Additionally, in at least one non-limiting embodiment, the flow rate of the gas (e.g., air, inert gas, oxidizing gas, reducing gas, or any combination thereof) can be no greater than 5 meters per second, or no greater than 4.7 meters per second, or no greater than 4.5 meters per second, or no greater than 4.2 meters per second, or no greater than 4 meters per second, or no greater than 3.7 meters per second, or no greater than 3.5 meters per second, or no greater than 3.2 meters per second, or no greater than 3 meters per second, or no greater than 2.7 meters per second, or no greater than 2.5 meters per second, or no greater than 2.2 meters per second, or no greater than 2 meters per second, or no greater than 1.7 meters per second, or no greater than 1.5 meters per second, or no greater than 1.2 meters per second, or no greater than 1 meter per second, or no greater than 0.7 meters per second, or no greater than 0.5 meters per second. It will be appreciated that the flow rate of the gas or gases can be within a range including any of the minimum and maximum values noted above, including, for example, within a range including at least 0.1 meters per second and no greater than 5 meters per second.

[0116] In yet another embodiment, the drying process can include applying radiation to the body 111. The radiation can have a wavelength of at least 0.1 micrometers, or at least 0.5 micrometers, or at least 1 micrometer, or at least 2 micrometers, or at least 3 micrometers, or at least 5 micrometers, or at least 10 micrometers, or at least 20 micrometers, or at least 50 micrometers, or at least 100 micrometers, or at least 200 micrometers, or at least 500 micrometers, or at least 700 micrometers, or at least 1 millimeter. Additionally, in at least one non-limiting embodiment, the radiation can have a wavelength of no greater than 1 meter, such as no greater than 0.8 meters, or no greater than 0.5 meters, or no greater than 0.1 meters, or no greater than 1 centimeter, or no greater than 1 millimeter, or no greater than 500 micrometers, or no greater than 100 micrometers, or no greater than 10 micrometers. It will be appreciated that the radiation can have a wavelength within a range including any of the minimum and maximum values noted above. For example, in one embodiment, the radiation can have a wavelength within a range of at least 0.1 micrometers to no greater than 1 millimeter. Additionally, in other embodiments, the radiation can have a wavelength within a range of at least 1 millimeter to no greater than 1 meter.

[0117] In one embodiment, the process of drying to effect controlled fracture of the body 111 and formation of precursor abrasive particles can be performed without the use of other processes, including but not limited to mechanical devices intended to contact the body and separate the body into smaller pieces (e.g., segmentation devices), ablation processes, vibration processes, acoustic processes, and the like. In at least one embodiment, the process of forming precursor abrasive particles from the body 111 is accomplished using only a drying process and controlling one or more drying conditions, including drying temperature, relative humidity, drying rate, application of radiation, or any combination thereof. In at least one embodiment, the drying process can include breaking the mixture to produce a collection of abrasive particles. The collection of abrasive particles is described in more detail in embodiments herein.

[0118] After the precursor abrasive particles 141 are formed, the precursor abrasive particles 141 can be translated through additional zones for further processing. Alternatively, the precursor abrasive particles 141 can be collected in a bin at the end of the conveyor belt 109 for further processing.

[0119] According to an embodiment, the process of forming abrasive particles can further include a calcination process, in which the precursor abrasive particles are subjected to a particular heating process to remove water and form calcined abrasive particles. In at least one embodiment, the calcination temperature for calcining the precursor abrasive particles can be at least 600°C, such as at least 650°C, or at least 700°C, or at least 750°C, or at least 800°C, or at least 850°C, or at least 900°C, or at least 950°C, or at least 1000°C, or at least 1050°C. In still another non-limiting embodiment, the calcination temperature can be no greater than 1100°C, or no greater than 1050°C, or no greater than 1000°C, or no greater than 950°C, or no greater than 900°C, or no greater than 850°C, or no greater than 800°C, or no greater than 750°C, or no greater than 700°C, or no greater than 650°C. It will be appreciated that the calcination temperature can be within a range including any of the minimum and maximum values noted above, including, for example, within a range including at least 600°C and no greater than 1100°C.

[0120] After calcination, certain optional processes can be applied to the calcined abrasive particles. For example, an impregnation process can be used, in which one or more additives can be applied to the calcined abrasive particles. The additives can include any of the additives described in embodiments herein, including but not limited to one or more dopants.

[0121] After calcination, the calcined abrasive particles can be sintered to form abrasive particles. Sintering of the precursor abrasive particles 141 can serve to densify the particles. In a particular example, the sintering process can facilitate the formation of a high temperature phase of the ceramic material. For example, in one embodiment, the calcined abrasive particles can include alumina, and sintering is performed to form a high temperature phase of alumina (e.g., alpha alumina). In at least one embodiment, sintering can be performed at a sintering temperature including at least 1100 °C to not greater than 2000 °C. The duration of sintering at the sintering temperature can range from including at least 5 minutes to not greater than 10 hours.

[0122] Non-shaped abrasive particles are generally formed by different processes as disclosed herein and generally have different shape attributes. For example, non-shaped abrasive particles are generally formed by a crushing method, where a mass of material is formed, and then crushed and sieved to obtain abrasive particles of a certain size. However, non-shaped abrasive particles will have a generally random surface and edge arrangement, and generally will not have any identifiable two or three-dimensional shape in the surface and edge arrangement around the body. Further, the same group or batch of non-shaped abrasive particles generally do not have a consistent shape relative to one another, such that the surface and edge are randomly arranged when compared to one another. Thus, non-shaped or crushed grains have significantly lower shape fidelity as compared to shaped abrasive particles.

[0123] The abrasive particles formed by the embodiments herein can be controlled height abrasive particles having a controlled two-dimensional shape as viewed from above from the plane of the length and width of the particle. Generally, the abrasive particles of the embodiments herein can have two or more surfaces, such as a first major surface and a second major surface that can be generally parallel to one another and can include features as disclosed in the embodiments herein. Notably, the arrangement of the first and second major surfaces extending parallel to one another and defining the length and width of the body generally provides the particle with a planar shape and a controlled height. The body of the abrasive particle can further include a side surface extending between the first and second major surfaces. The side surface can have various profiles depending on the process conditions used to form the particle. Notably, as described herein, a process can be used to form a batch of abrasive particles, where the batch can include two or more different shaped abrasive particles.

[0124] Figure 5 Perspective view of an abrasive particle including a shaped abrasive particle. Shaped abrasive particles are known to have been made by various prior art processes, including, for example, molding, printing, and the like. The shaped abrasive particle 500 can include a body 501 including a major surface 502, a major surface 503, and a side surface 504 extending between the major surface 502 and the major surface 503. As Figure 5As shown in the middle, the body 501 of the shaped abrasive particle 500 is a thin shaped body having a generally equilateral triangular shape, with major surfaces 502 and 503 being larger than the side surface 504. Further, the body 501 can include an axis 510 extending from a point to the base and through the midpoint 550 on the major surface 502. The axis 510 can define the longest dimension of the major surface extending through the midpoint 550 of the major surface 502, which can be the length or the width of the body, depending on the geometry, but in the illustrated embodiment of an equilateral triangle defines the width. The body 501 can further include an axis 511 defining a dimension of the body 501 that extends generally perpendicular to the axis 510 on the same major surface 502, which in the illustrated embodiment of an equilateral triangle defines the length of the body 501. Finally, as shown, the body 501 can include a vertical axis 512, which in the case of a thin shaped body can define the height (or thickness) of the body 501. For a thin shaped body, the length of the axis 510 is equal to or greater than the vertical axis 512. As shown, the height 512 can extend along the side surface 504 between the major surfaces 502 and 503 and perpendicular to the plane defined by the axes 510 and 511. The shaped abrasive particles are generally formed to remove irregularities from the shape, such that each of the shaped abrasive particles within a batch have substantially the same size and shape relative to one another. Figure 5

[0125] Figure 5 An illustration including shaped abrasive particles having a two-dimensional shape as defined by the plane of the upper major surface 502 or the major surface 503, the shaped abrasive particles having a generally triangular two-dimensional shape, such as an equilateral triangle.

[0126] Figure 6 An illustration including elongated particles, which are non-shaped abrasive particles. The elongated abrasive particles can be non-shaped abrasive particles having a body 651, with a longitudinal axis 652 defining the longest dimension of the particle, a lateral axis 653 extending perpendicular to the longitudinal axis 652 and defining the width of the particle. Further, the elongated abrasive particles can have a height (or thickness) as defined by a vertical axis 654, which can generally extend perpendicular to the plane defined by the combination of the longitudinal axis 652 and the lateral axis 653. As further shown, the body 651 of the elongated, non-shaped abrasive particles can have a generally random arrangement of edges 655 extending along the outer surface of the body 651. Further, the non-shaped abrasive particles do not have an easily identifiable arrangement of one or more surfaces having an easily identifiable shape and / or arrangement relative to one another.

[0127] ​As should be appreciated, the elongated abrasive particle can have a length defined by a longitudinal axis 652, a width defined by a lateral axis 653, and a vertical axis 654 defining a height. As should be appreciated, the body 651 can have a primary aspect ratio of length to width such that the length is greater than the width. Further, the length of the body 651 can be greater than or equal to the height. Further still, the width of the body 651 can be greater than or equal to the height 654.

[0128] Figure 7A Perspective view of a controlled height abrasive particle (CHAP) according to an embodiment. As shown, the CHAP 700 can include a body 701 including a first major surface 702, a second major surface 703, and a side surface 704 extending between the first major surface 702 and the second major surface 703. As Figure 7A shown in the middle, the body 701 can have a thin, relatively planar shape, where the first major surface 702 and the second major surface 703 are greater than the side surface 704 and generally parallel to one another. Further, the body 701 can include an axis 710 that is the longest dimension on the first major surface 710 and defines a length. The body 701 can further include an axis 711 defining a second longest dimension of the body 701 on the first major surface 702, which extends perpendicular to the axis 710 and defines a width of the body 701. Finally, as shown, the body 701 can include a vertical axis 712, which can define a height (or thickness) of the body 701. For thin shaped bodies, the length of the axis 710 can be equal to or greater than the vertical axis 712. As shown, the height defined by the vertical axis 712 can extend along the side surface 704 between the first major surface 702 and the second major surface 703 in a direction generally perpendicular to the plane defined by the axes 710 and 711. As should be appreciated, references herein to length, width, and height of an abrasive particle can refer to an average value obtained from a suitable sample size of abrasive particles from a batch of abrasive particles. The body can further include a midpoint 713 on the first major surface 102 of the body generally defining a point within a center of the first major surface 702.

[0129] As Figure 7AAs further shown, the body 701 can have a side surface 704 that has a generally discernible irregular polygonal (heptagonal) two-dimensional shape as viewed from the plane of the first major surface 702 or the second major surface 703. An irregular polygonal shape is a polygonal shape in which all sides do not have the same length as one another. Notably, the body 701 has six exterior corners 721, 722, 723, 724, 725, and 726 (721-726). The exterior corners 721-726 are portions that would cause a hypothetical rubber band wrapped around the side surface 704 of the body 701 to deflect significantly by at least 10 degrees or more. Notably, while the body 701 has readily identifiable exterior corners 721-726 and seven side surface portions 731, 732, 733, 734, 735, 736, and 737 (731-737) extending between the exterior corners 721-726, the side surface portions 731-737 can have substantial waviness within the profile such that the side surface portions 731-737 are not completely planar. Further, the edges joining the side surface portions 731-737 to the first major surface 702 and the second major surface 703 can have some irregular profile.

[0130] It should be appreciated that CHAPs are not limited to this and can include other two-dimensional shapes. For example, abrasive particles of embodiments herein can include particles having a body with a two-dimensional shape as defined by a major surface of the body from a group of shapes including polygons; irregular polygons; irregular polygons including arcuate or curved sides or portions of sides; complex shapes having combinations of polygonal shapes, star shapes, shapes having arms extending from a central region (e.g., a cruciform body), and combinations thereof. Processes disclosed herein can be used to form shaped abrasive particles having features described herein.

[0131] Figure 7B A perspective view of another abrasive particle including according to an embodiment. Notably, the abrasive particle 750 is a controlled height abrasive particle (CHAP) having a body 751 including a first major surface 752, a second major surface 753, and a side surface 754 extending between the first major surface 752 and the second major surface 753. As Figure 7BAs shown, the body 751 can have a thin, relatively planar shape, with the first major surface 752 and the second major surface 753 being larger than the side surface 754 and generally parallel to each other. Further, the body 751 can include an axis 761 that is the longest dimension on the first major surface 752 and defines a length of the body 751. The body 751 can further include an axis 762 that defines a second longest dimension of the body 701 on the first major surface 702, the axis 762 extending perpendicular to the axis 761 and defining a width of the body 751. Finally, as shown, the body 751 can include a vertical axis 763 that can define a height (or thickness) of the body 701. For a thin shaped body, the length of the axis 761 can be equal to or greater than the vertical axis 763. As shown, the height defined by the vertical axis 763 can extend along the side surface 754 between the first major surface 752 and the second major surface 753 in a direction generally perpendicular to the planes defined by the axes 761 and 762. It should be appreciated that references herein to length, width, and height of an abrasive particle can refer to an average value from a suitable sample size of abrasive particles from a batch of abrasive particles.

[0132] As further shown, the body 751 of the abrasive particle 750 can have a side surface 754 that has an irregular two-dimensional shape, as viewed from the plane of the first major surface 752 or the second major surface 753. An irregular two-dimensional shape is a two-dimensional shape that does not have a recognizable shape, such as a polygonal shape. The irregular two-dimensional shape is characterized by a side surface 754 that can have a random or unpredictable contour. Such an abrasive particle can be formed according to the processes of embodiments herein. The body 751 can have seven external corners 771, 772, 773, 774, 775, 776, and 777 (771-777). The external corners 771-777 are portions that would cause a hypothetical rubber band around the side surface 754 of the body 751 to deflect by at least 10 degrees or more.

[0133] Figure 7C A top view of an abrasive particle including according to an embodiment. Figure 7D A side view of a portion of a coated abrasive including according to an embodiment. As shown, a body 781 of an abrasive particle viewed from above can have a polygonal two-dimensional shape. The body 781 can have a quadrilateral two-dimensional shape, and more specifically, a right trapezoidal two-dimensional shape. The shape of the body 781 includes a side surface portion 782 that is angled from an adjoining side surface portion to create an acute angle 783 and an obtuse angle 784 between the side surface portion 782 and the adjoining side surface portion. As shown, the body 781 can have a first major surface 782 and a second major surface 783 that are generally parallel to each other and larger than the side surface portion 782. The body 781 can have a first axis 784 that is the longest dimension on the first major surface 782 and defines a length of the body 781. The body 781 can further include a second axis 785 that defines a second longest dimension of the body 781 on the first major surface 782, the second axis 785 extending perpendicular to the first axis 784 and defining a width of the body 781. Finally, as shown, the body 781 can include a vertical axis 786 that can define a height (or thickness) of the body 781. For a thin shaped body, the length of the first axis 784 can be equal to or greater than the vertical axis 786. As shown, the height defined by the vertical axis 786 can extend along the side surface portion 782 between the first major surface 782 and the second major surface 783 in a direction generally perpendicular to the planes defined by the first and second axes 784 and 785. It should be appreciated that references herein to length, width, and height of an abrasive particle can refer to an average value from a suitable sample size of abrasive particles from a batch of abrasive particles. Figure 7DAs shown in the middle, the shape of the particles 791 and 792 can be advantageous in the case of coated abrasives because there are multiple orientations in which the point of the particle is pointing away from the backing 794. For example, in the orientation of the abrasive particle 791, the sloped surface 793 of the abrasive particle 791 is farthest from the backing 794 and the base surface 795 is closest to the backing 794. Thus, the point 796 is farthest from the backing 794 and presents a suitable point on the abrasive particle 796 to initiate a material removal operation. With respect to the orientation of the abrasive particle 792, the sloped surface 799 of the abrasive particle 792 is closest to the backing 794 and the base surface 797 is farthest from the backing 794. Thus, the point 798 is farthest from the backing 794 and presents a suitable point on the abrasive particle 792 to initiate a material removal operation.

[0134] According to any of the abrasive particles of the embodiments herein, the body of the abrasive particle can have a primary aspect ratio of length:width that can be at least 1.1 : 1, for example at least 1.2: 1, or at least 1.5: 1, or at least 1.8: 1, or at least 2: 1, or at least 3: 1, or at least 4: 1, or at least 5: 1, or at least 6: 1, or even at least 10: 1. In another non-limiting embodiment, the body can have a primary aspect ratio of length:width that is not greater than 100: 1, for example not greater than 50: 1, or not greater than 10: 1, or not greater than 6: 1, or not greater than 5: 1, or not greater than 4: 1, or not greater than 3: 1, or even not greater than 2: 1. It will be appreciated that the primary aspect ratio of length:width of the body can be within a range including any of the minimum and maximum ratios noted above.

[0135] Further, the body of any of the shaped abrasive particles of the embodiments herein can have a secondary aspect ratio of width:height that can be at least 1.1 : 1, for example at least 1.2: 1, or at least 1.5: 1, or at least 1.8: 1, or at least 2: 1, or at least 3: 1, or at least 4: 1, or at least 5: 1, or at least 8: 1, or even at least 10: 1. Additionally, in another non-limiting embodiment, the secondary aspect ratio of width:height can be not greater than 100: 1, for example not greater than 50: 1, or not greater than 10: 1, or not greater than 8: 1, or not greater than 6: 1, or not greater than 5: 1, or not greater than 4: 1, or not greater than 3: 1, or even not greater than 2: 1. It will be appreciated that the secondary aspect ratio of width:height can be within a range including any of the minimum and maximum ratios noted above.

[0136] In another embodiment, the body of any of the abrasive particles can have a tertiary aspect ratio of length:height that can be at least 1.1 : 1, such as at least 1.2: 1, or at least 1.5: 1, or at least 1.8: 1, or at least 2: 1, or at least 3: 1, or at least 4: 1, or at least 5: 1, or at least 8: 1, or even at least 10: 1. Additionally, in another non-limiting embodiment, the tertiary aspect ratio of length:height can be no greater than 100: 1, such as no greater than 50: 1, or no greater than 10: 1, or no greater than 8: 1, or no greater than 6: 1, or no greater than 5: 1, or no greater than 4: 1, or no greater than 3: 1. It will be appreciated that the tertiary aspect ratio can be within a range including any of the minimum and maximum ratios noted above.

[0137] The abrasive particles of the embodiments herein can have a body that includes a crystalline material, and more specifically a polycrystalline material. Notably, the polycrystalline material can include abrasive grains. In one embodiment, the body of the abrasive particle can be substantially free of organic materials, including for example, binders. In at least one embodiment, the abrasive particle can consist essentially of the polycrystalline material.

[0138] The abrasive grains (i.e., crystallites) contained within the body of the abrasive particle can have an average grain size that is generally no greater than 20 microns, such as no greater than 18 microns, or no greater than 16 microns, or no greater than 14 microns, or no greater than 12 microns, or no greater than 10 microns, or no greater than 8 microns, or no greater than 5 microns, or no greater than 2 microns, or no greater than 1 micron, or no greater than 0.9 microns, or no greater than 0.8 microns, or no greater than 0.7 microns, or even no greater than 0.6 microns. Additionally, the average grain size of the abrasive grains contained within the body of the abrasive particle can 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 average grain size of the abrasive particle can be within a range including any of the minimum and maximum values noted above.

[0139] According to one embodiment, the body of the abrasive particle can have an average particle size of at least 100 microns, as measured according to the largest dimension (i.e., length) that can be measured on the body. Indeed, the body of the abrasive particle can have an average particle size 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. Additionally, the body of the abrasive particle can have an average particle size of not greater than 5 millimeters, such as not greater than 3 millimeters, or not greater than 2 millimeters, or even not greater than 1.5 millimeters. It will be appreciated that the average particle size of the body of the abrasive particle can be within a range including any of the minimum and maximum values noted above.

[0140] In yet another embodiment, the particulate material can have a body with an average particle size that can be selected from a predetermined set of sieve sizes. For example, the average particle size of the body can be not greater than about 5 millimeters, such as not greater than about 3 millimeters, not greater than about 2 millimeters, not greater than about 1 millimeter, or even not greater than about 0.8 millimeters. Additionally, in another embodiment, the average particle size of the body can be at least about 0.1 microns, or at least 1 micron, or at least 0.1 millimeters, or at least 0.5 millimeters. It will be appreciated that the average particle size of the body can be within a range between any of the minimum and maximum values noted above.

[0141] Particles for the abrasive industry are generally graded to a given particle size distribution prior to use. Such distributions typically have a range of particle sizes from coarse to fine particles. In the abrasive art, this range is sometimes referred to as the "coarse," "control," and "fine" fractions. Abrasive particles graded according to accepted grading standards of the abrasive industry specify a particle size distribution for each nominal grade within numerical limit values. Such accepted grading standards of the industry (i.e., nominal grades specified by the abrasive industry) include those known as American National Standards Institute, Inc. (ANSI) standards, Federation of European Producers of Abrasive Products (FEPA) standards, and Japanese Industrial Standard (JIS) standards. ANSI grade designations (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, ANSI 240, ANSI 280, ANSI 320, ANSI 360, ANSI 400, and ANSI 600. FEPA grade designations include P8, P12, P16, P24, P36, P40, P50, P60, P80, P100, P120, P150, P180, P220, P320, P400, P500, P600, P800, P1000, and P1000. JIS grade designations include JIS 8, JIS 12, JIS 16, JIS 24, JIS 36, JIS 46, JIS 54, JIS 60, JIS 80, JIS 100, JIS 150, JIS 180, JIS 220, JIS 240, JIS 280, JIS 320, JIS 360, JIS 400, JIS 600, JIS 800, JIS 1000, JIS 1500, JIS 2500, JIS 4000, JIS 6000, JIS 8000, and JIS 10,000. Alternatively, abrasive particles can be graded to nominal screen size grades using American Standard Test Sieves "Standard Specification for Metal Wire Cloth and Sieves for Testing Purposes" in accordance with ASTM E-11. ASTM E-11 specifies requirements for the design and construction of test sieves using woven wire cloth mounted in frames for the classification of materials according to specified particle sizes.A typical designation can be represented as -18+20, meaning that the particles pass through Test Sieve No. 18, which conforms to the ASTM E-11 specification, and are retained on Test Sieve No. 20, which conforms to the ASTM E-11 specification. In various embodiments, the particulate material can have a nominal screening 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, custom mesh sizes can be used, such as -90+100. The body of the particulate material can be in the form of shaped abrasive particles, as described in greater detail herein.

[0142] Some suitable materials for the body of the abrasive particle can include nitrides, oxides, carbides, borides, oxynitrides, oxoborides, oxocarbides, carbon-based materials, diamond, naturally occurring minerals, rare earth-containing materials, natural minerals, synthetic materials, or any combination thereof. In particular examples, the abrasive particle can include an oxide compound or complex, such as aluminum oxide, zirconium oxide, titanium trioxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, magnesium oxide, rare earth oxides, or any combination thereof. In one particular embodiment, the body can include at least 95 weight percent aluminum oxide, based on the total weight of the body. In at least one embodiment, the body can consist essentially of aluminum oxide. Additionally, in certain examples, the body can include no more than 99.5 weight percent aluminum oxide, based on the total weight of the body. According to an embodiment, the body can consist essentially of alpha aluminum oxide. In certain examples, the body can be formed such that it includes no more than about 1 weight percent of any low temperature aluminum oxide phase. As used herein, a low temperature aluminum oxide phase can include transition phase aluminum oxide, bauxite, or hydrated aluminum oxide, including, for example, gibbsite, boehmite, diaspore, and mixtures containing such compounds and minerals. Certain low temperature aluminum oxide materials can also include a content of iron oxide. Further, the low temperature aluminum oxide phase can include other minerals, such as goethite, hematite, kaolinite, and anatase.

[0143] Further, in particular instances, the body of the abrasive particle can be formed from a seeded sol-gel. In at least one embodiment, the body of any of the abrasive particles of the embodiments herein can be essentially free of iron, rare earth oxides, and combinations thereof. Reference herein to a body having certain characteristics (e.g., composition) will also be understood to refer to a batch of abrasive particles that can have the same characteristics (e.g., composition).

[0144] According to certain embodiments, certain abrasive particles can be a composite of compositions, such that at least two different types of grains are housed within the body of the abrasive particle. It should be appreciated that different types of grains are grains having different compositions with respect to one another. For example, the body of the abrasive particle can be formed such that it includes at least two different types of grains, where the types of grains are selected from the group of: nitrides, oxides, carbides, borides, oxynitrides, oxoborides, oxocarbides, carbon-based materials, diamond, naturally occurring minerals, rare earth-containing materials, natural minerals, synthetic materials, and combinations thereof.

[0145] The body of the abrasive particle can include additives, such as dopants, which can be in the form of an element or a compound (e.g., an oxide). Certain suitable additives can include any of the materials described herein. The body of the abrasive article can include a particular content of one or more additives (e.g., dopants). For example, the body can include no more than about 30 weight percent of additives, based on the total weight of the body. In yet other embodiments, the amount of additives can be lower, such as no more than about 25 weight percent, or no more than about 20 weight percent, or no more than about 18 weight percent, or no more than about 15 weight percent, or no more than about 12 weight percent, or no more than about 10 weight percent, or no more than about 8 weight percent, or no more than 5 weight percent, or no more than 2 weight percent. Additionally, the amount of additives can be at least about 0.5 weight percent, such as at least about 1 weight percent, at least about 2 weight percent, or at least about 3 weight percent, or at least about 4 weight percent, or at least about 5 weight percent, or at least about 8 weight percent, or even at least about 10 weight percent, based on the total weight of the body. It should be appreciated that the amount of additives within the body can be within a range including any of the minimum and maximum percentages noted above.

[0146] The body of the abrasive particle can be particularly dense. For example, the density of the body can be at least about 95% of the theoretical density, such as at least about 96% or even at least about 97% of the theoretical density.

[0147] Figure 8A An image from above of an abrasive particle including according to an embodiment. As shown, the abrasive particle 800 includes a body 801 including a first major surface 802, a second major surface 803, and a side surface 804 extending between the first major surface 802 and the second major surface 803. As shown, the body 801 can have a thin, relatively planar shape, where the first major surface 802 and the second major surface 803 are larger than the side surface 804. From a planar view from above of the first major surface 802, the body 801 can have a generally quadrilateral two-dimensional shape. Figure 8A As shown in FIG. 8A, the body 801 can have a thin, relatively planar shape, where the first major surface 802 and the second major surface 803 are larger than the side surface 804. From a planar view from above of the first major surface 802, the body 801 can have a generally quadrilateral two-dimensional shape.

[0148] The body 801 can have a side surface 804 that can include a plurality of side surface portions separated from one another by outer corners of the body. A first side surface portion 813 can define a portion of the side surface 804 that can be disposed between a first outer corner 815 and a second outer corner 816. As shown and in accordance with an embodiment, the first side surface portion 813 can be a portion of the total length of the side surface 804 that defines a perimeter of the body 801.

[0149] In accordance with an embodiment, the body 801 can include a plurality of side surface portions, where each of the side surface portions has an extension length that is at least 5% of the total length of the body, such as at least 10%, or at least 15%, or at least 20%, or at least 25%. In another non-limiting embodiment, each of the side surface portions can have an extension length that is no greater than 80% of the length of the body, such as no greater than 70%, or no greater than 60%, or no greater than 50%, or no greater than 40%, or no greater than 30%. It will be appreciated that the length of the side surface portions can be within a range that includes any of the minimum and maximum percentages noted above.

[0150] As further shown in Figure 8A The body 801 can include one or more features disposed on the first major surface 802 relative to one or more side surface portions of the side surface 804, as further shown in FIG. 8. As further shown and in accordance with an embodiment, the first major surface 802 can further include a first side surface region 812 disposed between the first side surface portion 813 and the first protrusion 811. The first protrusion 811 can abut the first side surface region 812 and the first side surface portion 813. The first protrusion 811 can extend along the first side surface portion 813 and the first side surface region 812. As shown, the first protrusion 811 can define a raised portion in an upper surface that extends vertically above a height of the first side surface region 812, and / or a non-textured region 850 that extends through a central region 851 of the body 801. The first protrusion 811 can be formed during a modification process. For example, the first protrusion 811 can be a protrusion that can be a result of a mobile mixture to form an adjacent recess during a modification process. Alternatively, the first protrusion 811 can result from adhesion between a shaped piece and a mixture forming the body such that after the shaped piece is removed from the body, a portion of the body adheres to the shaped piece and pulls up to create the first protrusion 811.

[0151] In at least one embodiment, the first protrusion 811 may extend a portion of the total length of the side surface 804 defining the perimeter of the body 801. In one particular embodiment, the first protrusion 811 may extend at least 30% of the total length of the first side surface portion 813, measured as the distance between the first outer angle 815 and the second outer angle 816. In another embodiment, the first protrusion 811 may extend at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or even at least 90% of the total length of the first side surface portion 813. In one particular embodiment, the first protrusions 811 may extend parallel to each other throughout the entire length of the first side surface portion 813. In another non-limiting embodiment, the first protrusion 811 may extend no more than 99% of the total length of the first side surface portion 813, for example, 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%, or no more than 40%, or no more than 30% of the total length of the first side surface portion 813. It should be understood that the extension length of the first protrusion 811 may be within a range including either the minimum or maximum percentage mentioned above.

[0152] According to one embodiment, the first main surface 802 may include a textureless region 850 extending through a central region 851 of the body. The textureless region 850 may include the midpoint 852 of the first main surface 802 of the body 801. Notably, a first protrusion 811 may abut a portion of the textureless region 850.

[0153] It is noteworthy that, in some examples, features (e.g., recesses and protrusions) on the first main surface 802 may be positioned close to the periphery of the body 801, such that the body 801 is included within at least one textureless region 850 in the central region 851 of the body. Additionally, in at least one embodiment, at least a portion of the textureless region 850 may abut against a portion of a side surface (e.g., a fourth side surface portion 843), such that no feature is inserted between the textureless region 850 and at least one portion of the side surface. In another embodiment, a first protrusion 811 may be spaced apart from the textureless region 850 of the first main surface 802.

[0154] In yet another embodiment, the textureless region 850 may have a two-dimensional shape that is substantially the same as the two-dimensional shape of the body 801. For example, such as Figure 8AAs shown in FIG. 8, the body 801 can have a generally quadrilateral shape as defined by the perimeter of the side surface 804, and the untextured region 850 can also have a generally quadrilateral shape. It should be appreciated that in certain examples, the body 801 can have a generally recognizable two-dimensional polygonal shape, and from above looking down from the plane defined by the length and width of the body, the untextured region 850 can have the same generally recognizable two-dimensional polygonal shape. Additionally, in other examples, the two-dimensional shape of the untextured region 850 and the two-dimensional shape of the body 801 can differ from one another.

[0155] In at least one embodiment, the untextured region 850 can define a substantial portion of the first major surface 802, including, for example, at least a majority of the surface area of the first major surface 802. In at least one embodiment, the untextured region 850 can occupy at least 10% of the total surface area of the first major surface, such as at least 20%, or at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or even at least 80%. Such an assessment can be made by viewing the particles (e.g., as shown in FIG. 8) using an optical microscope at a suitable magnification and using imaging analysis software (e.g., ImageJ) to measure the surface area of the first major surface 802 and the surface area of the untextured region 850. In one non-limiting embodiment, the untextured region 850 can occupy no more than 95% of the surface area of the first major surface 802, such as no more than 90%, or no more than 80%, 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%. It should be appreciated that the untextured region 850 can occupy a percentage of the surface area of the first major surface 850 within a range including any of the minimum and maximum values noted above. Figure 8A

[0156] The untextured region 850 can have a substantially different waviness and / or surface roughness. For example, the untextured region 850 can have a waviness (Rw) that is different from the waviness within the region of the first major surface 802 associated with the first recess 811 and the first protrusion 812. Further, in at least one embodiment, the untextured region 850 can have a surface roughness (Ra) that is different from the surface roughness of the first major surface 802 associated with the first protrusion 811.

[0157] In certain examples, any of the features in the first major surface 802 can abut the untextured region 850. For example, the first protrusion 811 can abut the untextured region 850. The untextured region is a region that lacks features (e.g., protrusions and / or recesses) formed in the body during the process of modifying the body. The untextured region 850 can have some surface profile, such as a curvature (e.g., a concave curvature), but generally lacks features formed in the body proximate to the side surface portion. Further, in certain embodiments, the untextured region 850 can have a generally planar profile. ​

[0158] According to another embodiment, the first side surface portion 813 and the first protrusion 811 can have substantially the same profile, viewed from the plane of the first major surface 802. For example, as shown in Figure 8A the first side surface portion 813 and the first protrusion 811 can have a substantially linear shape and extend parallel to one another. In other embodiments, the first side surface portion 813 can have a profile that is significantly different than the profile of the first protrusion 811.

[0159] As further shown in Figure 8A the body 801 can have a second side surface portion 823 that is different than the first side surface portion 813. In particular, the second side surface portion 823 can be separated from the first side surface portion by at least one outer corner, such as a second outer corner 816. The second side surface portion 823 can extend between the second outer corner 816 and a third outer corner 817. As shown in Figure 8A the first side surface portion 813 can be a side that abuts the second outer corner 816, and the second side surface portion 823 can abut the second outer corner 816 opposite the first side surface portion 813. The outer corners can be defined according to an imaginary rubber band test, where an outer corner is any corner on the side surface 804 that would significantly deflect (e.g., define a deflection angle of at least 10 degrees or more) a rubber band if the rubber band were wrapped around the side surface of the body 804.

[0160] In at least one embodiment, any protrusion or recess can intersect one or more side surface portions. For example, the first protrusion 811 can be formed such that it intersects the second side surface portion 823. Further, as shown in Figure 8A the first protrusion 811 can intersect the second outer corner 816.

[0161] The first major surface 802 can include a second protrusion 821 that extends in a direction parallel to the second side surface portion 823. As shown and according to an embodiment, the second side surface portion 823 can be a portion of the total length of the side surface 804 that defines a perimeter of the body 801. As further shown and according to one embodiment, the first major surface 802 can further include a second side surface region 822 disposed between the second side surface portion 823 and the second protrusion 821. The second side surface region 822 can abut and extend along the second side surface portion 823.

[0162] The second protrusion 821 may abut against the second side surface region 822. As shown and according to one embodiment, the second protrusion 821 and the second side surface region 822 may extend parallel to each other and parallel to the second side surface portion 823. In at least one embodiment, the second protrusion 821 and the second side surface region 822 may extend parallel to each other for at least a portion of the second side surface portion 823. The second protrusion 821 and the second side surface region 822 may extend a portion of the total length of the side surface 804 defining the perimeter of the body 801. In a particular embodiment, the second protrusion 821 may extend at least 30% of the total length of the second side surface portion 823, measured as the distance between the second outer angle 816 and the third outer angle 817. In another embodiment, the second protrusion 821 may extend at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or even at least 90% of the total length of the second side surface portion 823. In one particular embodiment, the second protrusion 821 may extend the entire length of the second side surface portion 823. Alternatively, in another non-limiting embodiment, the second protrusion 821 may extend no more than 99% of the total length of the second side surface portion 823, for example, 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%, or no more than 40%, or no more than 30%. It should be understood that the extension length of the second protrusion 821 may be within a range including either the minimum or maximum percentage mentioned above.

[0163] According to another embodiment, viewed from the plane of the first main surface 802, the second side surface portion 823 and the second protrusion 821 may have substantially the same outline relative to each other. For example, as Figure 8A As shown, the second side surface region 822 and the second protrusion 821 may have a generally linear shape and extend parallel to each other along the direction of the second side surface portion 823. In other embodiments, viewed from the plane of the first main surface 802, at least the second protrusion 821 and the second side surface region 822 may have generally different contours. That is, the second side surface portion 823 may have a contour that is significantly different from the contours of the second protrusion 821 and the second side surface region 822.

[0164] According to one embodiment, any of the features on the main surface of the body may intersect each other. For example, such as Figure 8A As shown, the first protrusion 811 may intersect with the second protrusion 821. It is noteworthy that the first protrusion 811 and the second protrusion 821 may intersect each other approximately at their outer corners, such as a second outer corner 816, which separates the first side surface portion 813 from the second side surface portion 823. Figure 8AAs further shown, the second side surface region 822 can intersect and abut the first protrusion 811. Further, according to one embodiment, the first side surface region 812 can intersect and abut the second protrusion 821.

[0165] In at least one embodiment, the first major surface 802 can include a third portion of the side surface 833. The third side surface portion 833 can be distinct from the first side surface portion 813 and the second side surface portion 823. In particular, the third side surface portion 833 can be separated from the first side surface portion 813 and the second side surface portion 823 by at least one exterior angle. According to Figure 8A According to the illustrated embodiment, the third side surface portion 833 can be separated from the first side surface portion by the second exterior angle 816 and the third exterior angle 817. The third side surface portion 833 can be separated from the second side surface portion 823 by the third exterior angle 817. The third side surface portion 833 can extend between the third exterior angle 817 and a fourth exterior angle 818.

[0166] In at least one embodiment, the second protrusion 821 and the second side surface region 822 can intersect the third side surface portion 833 proximate the third exterior angle 817. In particular, the third side surface portion 833 can be distinct from the first and second portions of the side surfaces 813 and 823 because there is no third protrusion extending along the third side surface portion 833. The first major surface 802 does include a third side surface region 832 extending along and abutting the third side surface portion 833. The third side surface region 832 can have any of the features of another side surface region described herein. The third side surface region 832 can be in the form of a ridge line extending vertically above the surface of the untextured region 850 and can have any of the features of the protrusions described in embodiments herein. Further, as shown, the third side surface region 832 can abut the untextured region 850 extending through the central region 851 of the body 801. Additionally, the third side surface region 832 can intersect the second protrusion 821 proximate the third exterior angle 817.

[0167] In at least one embodiment, the first major surface 802 can include a fourth portion of the side surface 843. The fourth side surface portion 843 can be distinct from the first side surface portion 813, the second side surface portion 823, and the third side surface portion 833. In particular, the fourth side surface portion 843 can be separated from the first side surface portion 813, the second side surface portion 823, and the third side surface portion 833 by at least one exterior angle. According to Figure 8AIn the illustrated embodiment, the fourth side surface portion 843 can be separated from the first side surface portion 813 via the first outer angle 815. The fourth side surface portion 843 can be separated from the second side surface portion 823 via all outer angles 815, 816, 817, and 818. The fourth side surface portion 843 can be separated from the third side surface portion 833 via the fourth outer angle 818. The fourth side surface portion 843 can extend between the fourth outer angle 818 and the first outer angle 815.

[0168] In at least one embodiment, the fourth side surface portion 843 may differ from other portions of the side surfaces 813, 823, and 833 because it defines a featureless edge 844. The featureless edge 844 defines the junction between the first main surface 802 and the fourth side surface portion 843 and does not contain any features typically formed during the forming process, such as protrusions and / or recesses. More specifically, in one embodiment, the featureless edge 844 may abut against a textureless region 850 extending through the central region 851 of the first main surface 802 of the body 801. Therefore, there is no intervening feature (e.g., protrusion or recess) between the textureless region 850 of the central region 851 and the fourth side surface portion 843. It should be understood that the abrasive particles of the embodiments herein may include one or more featureless edges that may intersect with one or more featured edges, wherein the featured edges include at least one feature (e.g., protrusion or recess) extending along a portion of the side surface as described in the embodiments herein.

[0169] As further illustrated, certain features from the abutting side surface portion may intersect with the fourth side surface portion 843. For example, the first protrusion 811 may approach the first outer corner 815 and intersect with the fourth side surface portion 843.

[0170] Figure 8B A top-down image of abrasive particles according to one embodiment. Figure 8C Include Figure 8B A surface profile curve of a portion of the main surface of an abrasive particle. Figure 8D Include Figure 8B A surface profile curve of a portion of the main surface of the particles. Obtained using white light chromatic aberration technology with a Nanovea 3D surface profilometer. Figure 8B The image is obtained. For each profile (with X or Y constant), the Y step size is 5.00 μm (with X constant), and the X step size is 5.00 μm (with Y constant). The Z resolution is 7.28 nm. The total probe length depends on the grain size and is measured using a scale bar with line scan capability.

[0171] As shown, the abrasive particle 850 includes a body 851, the body including a first main surface 852, a second main surface (not shown), and a side surface extending between the first main surface 852 and the second main surface. Figure 8B (Not shown in the view). Figure 8B As shown, when viewed from above from the plane of the first main surface 852, the main body 851 has a generally quadrilateral two-dimensional shape.

[0172] like Figure 8B As further shown, the body 851 may include one or more features disposed on a first main surface 852 relative to one or more side surface portions. For example, the first main surface 852 may include a first protrusion 853 extending in a direction parallel to the first side surface portion 854. The first side surface portion 854 may define a portion of a side surface that may be disposed between a first outer corner 855 and a second outer corner 856. As shown and according to one embodiment, the first side surface portion 853 may be a portion of the total length of the side surface defining the perimeter of the body. The first protrusion 853 may abut against and extend along the first side surface portion 854. As shown, the first protrusion 852 may define a raised portion in the first main surface 852 extending vertically above the height of the first main surface 852 and a textureless region 890 extending through the central region 891 of the body 851. The first protrusion 853 may have any of the features of a protrusion described in the embodiments herein. The upper surface 852 may further include a first side surface region 856 disposed between the first protrusion 853 and the first side surface portion 854.

[0173] It is worth noting that, Figure 8C A surface profile curve including the first primary surface 852 along axis 881. The surface profile curve was obtained using a Nanovea 3D surface profilometer with white light chromatic aberration technology. For each profile (with X or Y constant), the Y step size was 5.00 μm (with X constant), and the X step size was 5.00 μm (with Y constant). The Z resolution was 7.28 nm. The total probe length depended on the grain size and was measured using a scale bar with line scan capability.

[0174] As shown in the graph, the first protrusion 853 extends above the first main surface 852. As shown, the first protrusion 853 can directly contact the textureless area 890. The first protrusion 853 can extend along the entire length of the first side surface portion 854 between the first outer corner 855 and the second outer corner 856. Furthermore, viewed from above (as shown...) Figure 8B (As provided in the document), the first protrusion 853 may have a generally similar profile to the first side surface portion 854. The first protrusion 853 and the first side surface portion 854 may have, for example,... Figure 8BThe bow-shaped profile shown is illustrated. It should be noted that not all abrasive particles in the embodiments described herein will contain every single feature depicted in certain abrasive particles, and abrasive particles may contain different combinations of certain features.

[0175] like Figure 8B As further shown and according to one embodiment, the body 851 may further include a second protrusion 863 extending above the first main surface 852. The second protrusion 863 may extend in a direction parallel to the second side surface portion 864. The second side surface portion 864 may define a portion of a side surface that may be disposed between the second outer corner 856 and the third outer corner 857. As shown and according to one embodiment, the second side surface portion 863 may be a portion of the total length of the side surface defining the perimeter of the body 851. The second protrusion 863 may abut against and extend along the second side surface portion 864. As shown, the second protrusion 862 may define a raised portion in the first main surface 852 extending vertically above the height of the first main surface 852 and a textureless region 890 extending through the central region 891 of the body 851. The second protrusion 863 may have any of the features of a protrusion described in the embodiments herein. The upper surface 852 may further include a second side surface region 866 disposed between the second protrusion 863 and the second side surface portion 864.

[0176] It is worth noting that, Figure 8D Includes a surface profile curve of the first main surface 852 along axis 882 and is used for creating Figure 8C The same technique was used to obtain the curve.

[0177] according to Figure 8B In the illustrated embodiment, the second protrusion 863 may extend along the entire length of the second side surface portion 864 between the second outer corner 856 and the third outer corner 857. Furthermore, viewed from above (e.g.) Figure 8B (As provided in the document), the second protrusion 863 may have a generally similar profile to the second side surface portion 864. The second protrusion 863 and the second side surface portion 864 may each have a generally planar profile and, as shown in the document... Figure 8B It extends in a generally linear direction as shown. Figure 8B In the illustrated embodiment, the first protrusion 853 and the second protrusion 863 intersect each other at region 865, which is close to the second outer corner 856.

[0178] The first major surface 852 of the body 851 can further include a first recess 867, which can extend adjacent to the second protrusion 863 and along a majority of the length of the second protrusion 863. The first recess 867 can be located between the second protrusion 863 and the untextured region 890. The first recess 867 can further extend in the direction of the second protrusion 863 and the second side surface portion 864. Further, in Figure 8B In embodiments of the present disclosure, the first recess 867 can extend in a direction parallel to the second protrusion 863 and the second side surface portion 864. Additionally, the second protrusion 863 can be disposed between the second side surface portion 864 and the first recess 867.

[0179] The second protrusion 863 can further abut the first recess 867. As shown and in accordance with one embodiment, the second protrusion 863 and the first recess 867 can extend a portion of the total length of the side surface defining the perimeter of the body 801. In one particular embodiment, the second protrusion 863 and / or the first recess 867 can extend no more than 30% of the total length of the second side surface portion 864, measured as the distance between the outer corner 856 and the outer corner 857. In another embodiment, the second protrusion 863 and / or the first recess 867 can extend at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or even at least 90% of the total length of the second side surface portion 864 parallel to one another. In one particular embodiment, the second protrusion 863 and / or the first recess 867 can extend the entire length of the second side surface portion 864 parallel to one another. Additionally, in another non-limiting embodiment, the second protrusion 863 and / or the first recess 867 can extend no more than 99% of the total length of the second side surface portion 864 parallel to one another, 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%, or no more than 40%, or no more than 30% of the total length of the second side surface portion 864. It will be appreciated that the second protrusion 863 and / or the first recess 867 can extend a length parallel to one another within a range including any of the minimum and maximum percentages noted above.

[0180] It will be appreciated that other abrasive particles can include more than one recess. For example, the particles of the embodiments herein can have one or more recesses on the surface, and such recesses can be associated with and abut more than one other portion of the upper surface of the body, including, for example, one or more protrusions, untextured regions, and the like. One or more protrusions can be disposed between the recess and the side surface portion. Likewise, one or more recesses can be disposed between the protrusion and the untextured region.

[0181] As Figure 8DAs shown in the middle, the first recess 867 can have a significant depth that defines a portion of the first major surface 852 that is positioned vertically below the first major surface associated with the untextured region 890 and below the portion of the first major surface 852 associated with the second protrusion 863. As further shown, the first recess 867 can intersect and abut a portion of the first protrusion 853 in the region 868. Notably, the first recess 867 can terminate at the intersection of the first protrusion 853.

[0182] As Figure 8B As further shown in the middle, the first major surface 852 of the body 851 can include a third side surface portion 874 that extends between a third outer corner 857 and a fourth outer corner 858. The body can further include a fourth side surface portion 884 that extends between the fourth outer corner 858 and the first outer corner 855, such that the body can have a generally quadrilateral shape, with the first side surface portion 854 and the fourth side surface portion 884 having an arcuate profile. The second side surface portion 864 and the third side surface portion 874 can have a generally planar profile and extend in a generally linear direction. It is noted that the second side surface portion 864 and the third side surface portion 874 can have some slight irregularities in the edge profile.

[0183] The first major surface 852 can further include a third protrusion 883 positioned proximate to the fourth outer corner 858. The third protrusion 883 can extend a portion of the length of the fourth side surface portion 884. As Figure 8B As further shown in the middle, the third protrusion 883 can have a more rounded shape as compared to the first protrusion 853 and the second protrusion 863. Further, the third protrusion 883 can abut the untextured region 890.

[0184] Figures 9A to 9E Images including other abrasive particles according to embodiments herein. Figures 9A to 9E Details are provided regarding other features of abrasive particles according to embodiments herein. For example, Figure 9AAn abrasive particle 900 includes a body 901 having a first major surface 902, a second major surface 903, and a side surface 904 extending between the first major surface 902 and the second major surface 903. In particular, in certain embodiments, a feature can intersect a portion of the side surface, the feature extending along the portion. For example, the first major surface 902 includes a first protrusion 911 extending along a portion of a first side surface portion 913. As shown, the first protrusion 911 can intersect the first side surface portion 913. As further shown, the first protrusion 911 can have a different profile as compared to the first side surface portion 913, the profile further facilitating the intersection between the first protrusion 911 and the first side surface portion 913. In particular, the first protrusion 911 can have a generally linear profile, and the first side surface portion 913 can have a curved profile including a concave portion that causes the first side surface portion 913 to intersect the first protrusion 911.

[0185] Figure 9B An abrasive particle 920 includes a body 921 having a first major surface 922, a second major surface 923, and a side surface 924 extending between the first major surface 922 and the second major surface 923. In particular, in certain embodiments, an edge between one of the major surfaces and the side surface can have an irregular profile defining a jagged and sharp region. For example, the second major surface 923 and the side surface 924 can join at an edge 925, the edge characterized by an irregular profile defining a jagged and sharp region.

[0186] Further, in one embodiment, the first major surface 922 can have a first surface area (Al), and the second major surface 923 can have a second surface area (A2). According to one embodiment, the first surface area can be different than the second surface area. Notably, in at least one instance, Al can be less than A2. In a more particular instance, the difference between the first surface area (Al) and the second surface area (A2) can be defined by a ratio (Al / A2), where Al / A2 can be no greater than 1, such as no greater than 0.9, or no greater than 0.8, or no greater than 0.7, or no greater than 0.6, or no greater than 0.5, or no greater than 0.4, or no greater than 0.3, or no greater than 0.3, or no greater than 0.2, or no greater than 0.1. Additionally, in another non-limiting embodiment, the ratio (Al / A2) can be at least 0.01, such as at least 0.05, or at least 0.1, or at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6, or at least 0.7, or at least 0.8, or even at least 0.9. It will be appreciated that the ratio (Al / A2) can be within a range including any of the minimum and maximum values noted above.

[0187] While Figures 8A to 8DAll of the images of abrasive particles of FIGS. 9A-9E have included particles having a generally rectangular two-dimensional shape, but it should be understood that any of the features described in association with these particles can be applied to particles having irregular two-dimensional shapes, such as irregular planar abrasive particles.

[0188] Furthermore, references herein to any dimensional characteristic (e.g., length, width, height, etc.) can refer to the size of an individual particle, a median value, or an average value derived from analysis of a suitable sample of particles. Unless explicitly stated, references herein to a dimensional characteristic can be considered to refer to a median value based on a statistically significant value derived from a random sample of a suitable number of particles. Notably, for certain embodiments herein, a sample size can include at least 10, and more typically, at least 40 particles randomly selected from a batch of particles. A batch of particles can include, but is not necessarily limited to, a set of particles collected from a single process run. In yet another example, a batch of abrasive particles can be a set of abrasive particles of an abrasive article, such as a fixed abrasive article. For example, a batch of particles can include an amount of abrasive particles suitable for forming a commercially available grade of abrasive product, such as at least about 20 pounds of particles.

[0189] Figure 15A An image including a side surface of an abrasive particle according to an embodiment includes a plurality of micro-ridges. As shown, abrasive particle 1500 includes a body 1501 including a first major surface 1502, a second major surface 1503, and a side surface 1504 extending between the first major surface 1502 and the second major surface 1503. The body 1501 can have a thin, relatively planar shape, where the first major surface 1502 and the second major surface 1503 are larger than the side surface 1504.

[0190] According to one embodiment, a majority of the side surface can include a plurality of micro-ridges. For example, as shown in the image of FIG. 15, the side surface 1504 includes a plurality of micro-ridges 1505. Notably, the plurality of micro-ridges 1505 on the side surface 1504 creates a substantially different appearance and texture compared to a surface that contacts a surface represented by the second major surface 1503 (e.g., a molding surface), which has a planar profile and is free of micro-ridges 1505. In certain examples, the plurality of micro-ridges 1505 creates a surface having a jagged surface feature representative of an unpolished ceramic surface. Figure 17

[0191] ​The plurality of microspikes 1505 exhibit a variety of different morphologies or types. A first type of microspike can include a separation microspike 1506, which can be defined by a microspike extending outward from and along a side surface. The separation microspike 1506 can be separated by a generally smooth planar surface. A second type of microspike can include a scalation microspike 1507, which can have a scaled or layered appearance. Another type of microspike includes an expansion microspike, which includes a plurality of microspikes extending outward from a focal region. According to Figure 15A Such microspikes are described. Without wishing to be associated with a particular theory, the plurality of microspikes 1505 appear to be artifacts of the formation process described in embodiments herein. Notably, it is believed that the plurality of microspikes 1505 form during the controlled fracture and breakage of the body used to form the abrasive particles. Thus, the plurality of microspikes 1505 can be characterized as shell-like or sub-shell-like breakage features that form when the body is broken into smaller portions that ultimately form abrasive particles based on the processes as described herein. Further, theoretically, different types of microspikes can be associated with different conditions during processing. Such features appear to be different from the side surfaces of particles formed according to other conventional processes for forming abrasive particles, such as molding, printing, cutting, and the like. Figure 15B A perspective view image of the roughening and irregular features exhibited by the plurality of microspikes is provided by the region 1508 of the side surface 1504 in FIG. 15B.

[0192] In one embodiment, the abrasive particles can have a side surface, where at least 51% of the total surface area of the side surface comprises a plurality of micro-ridges 1505. In another embodiment, a greater percentage of the side surface 1504 can comprise a plurality of micro-ridges 1505, including but not limited to, for example, at least 52%, or at least 54%, or at least 56%, or at least 58%, or at least 60%, or at least 62%, or at least 64%, or at least 66%, or at least 68%, or at least 70%, or at least 72%, or at least 74%, or at least 76%, or at least 78%, or at least 80%, or at least 82%, or at least 84%, or at least 86%, or at least 88%, or at least 90%, or at least 92%, or at least 94%, or at least 96%, or at least 98%, or even at least 99% of the total surface area of the side surface. In another non-limiting embodiment, no greater than 99%, for example, no greater than 98%, or no greater than 96%, or no greater than 94%, or no greater than 92%, or no greater than 90%, or no greater than 88%, or no greater than 86%, or no greater than 84%, or no greater than 82%, or no greater than 80%, or no greater than 78%, or no greater than 76%, or no greater than 74%, or no greater than 72%, or no greater than 70%, or no greater than 68%, or no greater than 66%, or no greater than 64%, or no greater than 62%, or no greater than 60%, or no greater than 58%, or no greater than 56%, or no greater than 54%, or no greater than 52% of the total surface area of the side surface 1504 can comprise a plurality of micro-ridges 1505. It will be appreciated that the total surface area of the side surface covered by the plurality of micro-ridges 1505 can be within a range including any of the minimum and maximum percentages mentioned above.

[0193] As mentioned in other embodiments, the side surface can comprise a plurality of side surface portions, where each side surface portion is defined as a portion of the side surface extending between outer corners of the body. According to one embodiment, at least 45% of the side surface portions of a given abrasive particle can comprise a plurality of micro-ridges. In yet other embodiments, the percentage can be greater, including for example, at least 52%, or at least 54%, or at least 56%, or at least 58%, or at least 60%, or at least 62%, or at least 64%, or at least 66%, or at least 68%, or at least 70%, or at least 72%, or at least 74%, or at least 76%, or at least 78%, or at least 80%, or at least 82%, or at least 84%, or at least 86%, or at least 88%, or at least 90%, or at least 92%, or at least 94%, or at least 96%, or at least 98%, or at least 99% of the side surface portions of the body comprise a plurality of micro-ridges. In at least one embodiment, all of the side surface portions of the side surface of a given abrasive particle can comprise a plurality of micro-ridges.

[0194] While it should be appreciated that the two-dimensional shape of the body as viewed from above should determine the number of side surface portions of the abrasive particle, in at least one embodiment, the body can include at least three side surface portions that include a plurality of micro-ridges. In other embodiments, the number of side surface portions that include a plurality of micro-ridges can be greater, such as at least four, or at least five, or at least six, or at least seven, or at least eight. Additionally, it should be appreciated that, in at least one embodiment, the abrasive particle can be formed such that at least one side surface portion does not include a plurality of micro-ridges.

[0195] Figure 15A An enlarged image of a portion of an abrasive particle including Figure 15B An enlarged image of a portion of an abrasive particle including Figure 15B Two different types of micro-ridges that have been observed on abrasive particles of embodiments herein are depicted more clearly. As depicted, a first type of micro-ridge can include a plurality of discrete micro-ridges, which can include discrete micro-ridges 1506 separated from one another by a smooth planar region 1511. As further shown, the discrete micro-ridges 1506 can extend in an irregular path along the side surface. The path of the discrete micro-ridges 1506 can be irregular but is characterized by a certain coordination when compared to one another. For example, as shown in Figure 15B

[0196] In another embodiment, at least one of the discrete micro-ridges of the plurality of discrete micro-ridges 1506 can be composed of different regions having different shapes. For example, at least one of the discrete micro-ridges can include a head region 1513 and a tail region 1514 connected to and extending from the head region 1513. As depicted and according to one embodiment, the head region 1503 can have a circular shape. The tail region 1514 can have an elongated shape. In at least one embodiment, the discrete micro-ridge can include a series of these regions connected together and separated by one or more gaps 1516. The gaps 1516 can define interruptions in the discrete micro-ridge 1506. The gaps 1516 can define smooth regions located along the irregular path of the one or more discrete micro-ridges 1506. In at least one embodiment, the irregular path of the discrete micro-ridge 1506 can include a plurality of gaps 1516, and thus the discrete micro-ridge can be characterized as a series of discrete micro-ridge portions 1517 extending along the irregular path. Any of the discrete micro-ridge portions can include a head region and a tail region.

[0197] ​The plurality of discrete microspikes 1506 can extend along the side surface a substantial distance. For example, at least one of the discrete microspikes 1506 can extend at least 10% of the average height of the side surface 1504. In other embodiments, the length of one or more discrete microspikes 1506 on the side surface 1504 can be 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 height of the side surface 1504. In still other non-limiting embodiments, the length of one or more discrete microspikes 1506 on the side surface 1504 can be no greater than 99%, or no greater than 90%, or no greater than 80%, or no greater than 70%, or no greater than 60%, or no greater than 50%, or no greater than 40% of the average height of the side surface. It will be appreciated that the length of one or more of the discrete microspikes 1506 along the side surface 1504 can be within a range including any of the minimum and maximum percentages noted above.

[0198] In certain instances, one or more of the plurality of discrete microspikes 1506 can have a total length of at least 100 microns, such as at least 150 microns, or at least 200 microns, or at least 300 microns, or at least 400 microns. Additionally, depending on the height of the abrasive particles, the total length of at least one of the discrete microspikes 1506 can be no greater than 2 millimeters, such as no greater than 1 millimeter, or even no greater than 500 microns.

[0199] The plurality of discrete microspikes 1506 can have a very small thickness, particularly in the trailing region 1514, where the thickness is measured in a direction transverse to the microspike and in a direction defining the length of the microspike. As Figure 15B As depicted in FIG. 15B, the trailing region 1514 of any of the discrete microspikes 1506 can have a thickness of less than 10 microns, such as less than 8 microns, or no greater than 6 microns, or no greater than 4 microns, or no greater than 2 microns. Additionally, it will be apparent that the trailing region 1514 of the discrete microspikes 1506 can have a thickness of at least 0.01 microns or at least 0.1 microns. The thickness of the trailing region 1514 is the maximum thickness measured in the trailing region 1514.

[0200] The plurality of discrete microspikes 1506 can have a thickness in the leading region 1513 that is greater than the thickness in the trailing region 1514. As Figure 15B As depicted in FIG. 15B, the leading region 1513 of any of the discrete microspikes 1506 can have a thickness of less than 50 microns, such as less than 40 microns, or no greater than 30 microns, or no greater than 20 microns. Additionally, it will be apparent that the leading region 1513 of the discrete microspikes 1506 can have a thickness of at least 1 micron or at least 1 micron. The thickness of the leading region 1513 is the maximum thickness measured in the leading region 1513 of a given discrete microspike 1514.

[0201] AsFigure 15B Further depicted therein, at least a portion of the plurality of micro-ridges 1505 can include a plurality of scaly micro-ridges 1507. The plurality of scaly micro-ridges 1507 can have a different morphology as compared to the discrete micro-ridges 1506. As shown, the plurality of scaly micro-ridges 1507 can include a plurality of raised portions having irregular shapes and folds extending between the raised portions. More specifically, the plurality of scaly micro-ridges 1507 can include one or more initial ridges 1521 defining the raised portions and a plurality of folds 1522 extending from the one or more initial ridges 1521. In certain instances, the plurality of folds 1522 can extend between and / or across two or more initial ridges 1521.

[0202] According to one embodiment, and as Figure 15B Further depicted therein, the one or more initial ridges 1521 of the scaly micro-ridges 1507 can extend along the side surface of the body in an irregular path. The irregular path generally includes a random combination of linear and arcuate portions joined together. As further shown, the one or more initial ridges 1521 can be laterally spaced apart from one another but can have some coordination relative to one another such that portions of the initial ridges 1521, including for example those initial ridges abutting one another, can extend in a collectively extending manner similar to the discrete micro-ridges 1506.

[0203] In one aspect, the initial ridges 1521 can have any of the features described with respect to size and orientation according to the discrete micro-ridges. For example, the initial ridges 1521 can extend a substantial distance along the side surface 1504. For example, at least one of the initial ridges 1521 can extend at least 10% of the average height of the side surface 1504. In other embodiments, the length of the one or more initial ridges 1521 on the side surface 1504 can be 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 height of the side surface. In still another non-limiting embodiment, the length of the one or more initial ridges 1521 on the side surface 1504 can be no greater than 99%, or no greater than 90%, or no greater than 80%, or no greater than 70%, or no greater than 60%, or no greater than 50%, or no greater than 40% of the average height of the side surface 1504. It will be appreciated that the length of the one or more initial ridges 1521 along the side surface 1504 can be within a range including any of the minimum and maximum percentages noted above.

[0204] In certain instances, one or more of the initial ridges 1521 can have a total length of at least 100 microns, such as at least 150 microns, or at least 200 microns, or at least 300 microns, or at least 400 microns. Additionally, the total length of at least one of the initial ridges 1521 can be no greater than 2 millimeters, such as no greater than 1 millimeter, or even no greater than 500 microns, depending on the height of the abrasive particles. It will be appreciated that the total length of at least one of the initial ridges 1521 can be within a range including any of the minimum and maximum values noted above.

[0205] As Figure 15B As further depicted in FIG. 15B, the plurality of folds 1522 can extend from one or more of the initial ridges 1521 along the side surface in an irregular path. Generally, at least a substantial portion of the plurality of folds 1522 can extend along a curved path on the side surface of the body. In certain instances, the folds can define grooves that extend along the side surface 1504 in an irregular path. Certain embodiments of the scale-like ridges 1507 can include a greater number of folds 1522 than the number of initial ridges 1521.

[0206] As Figure 16 As further depicted in FIG. 15B and in accordance with one embodiment, the plurality of folds 1522 can extend in a different direction than the one or more initial ridges 1521. For example, the plurality of folds 1522 can extend from, between, and / or across the one or more initial ridges 1521. The plurality of folds 1522 can extend transverse to the length of the initial ridges 1521. The plurality of folds 1522 can be in the shaped piece or in grooves that extend into the body at the side surface.

[0207] In certain embodiments, the plurality of folds 1522 can define a cut through the initial ridge 1521 that can form a gap 1523 or a region of reduced height in the initial ridge 1521. In accordance with one embodiment, one or more of the initial ridges 1521 can include at least one gap 1523 between the elongated portions that define the initial ridge 1521. The gap 1523 can be associated with and / or connected to one or more folds 1522 that extend from the gap 1523.

[0208] As referred to herein, the scale-like micro-ridges 1507 can have a scale-like or scaly appearance. Unlike the discrete micro-ridges 1506, the scale-like micro-ridges 1507 appear to have a greater waviness and / or roughness. Further, a region of the side surface having the scale-like micro-ridges 1507 can define a region of the side surface having a greater roughness than a region of the side surface including the discrete micro-ridges 1506. The scale-like micro-ridges 1506 and the discrete micro-ridges 1507 can also be distinguished from one another based on one or more other surface characteristics, including but not limited to, for example, waviness, maximum surface roughness, and the like.

[0209] As Figure 16 As further depicted in the middle, the scale micro-ridge 1507 can abut the separation micro-ridge 1506. In certain examples, the scale micro-ridge 1507 and the separation micro-ridge 1506 can be coordinated such that the initial ridge 1521 of the scale micro-ridge 1507 and the separation micro-ridge 1506 can have a common extending portion, despite the irregular path across the side surface of the body. Without wishing to be bound to a particular theory, it is believed that the separation micro-ridge 1506 and the scale micro-ridge 1507 can arise from the same process, for example, breaking during formation, but the conditions during formation of the separation micro-ridge 1506 can be slightly different than the conditions during formation of the scale micro-ridge 1507.

[0210] Figure 16 An image of a portion of a side surface including scale micro-ridges according to an embodiment. As depicted, the scale micro-ridge 1607 can include a plurality of initial ridges 1621 extending in an irregular path and a plurality of folds 1622 extending from, between, and / or across the plurality of initial ridges 1621. According to Figure 17 The embodiment depicted in the middle, the scale micro-ridge 1607 can have a layered appearance such that the surface appears to be made of a plurality of layers overlying one another. It should be appreciated that the scale micro-ridge 1607 can not actually include a plurality of layers, but the morphology of the scale micro-ridge 1607 provides such an appearance.

[0211] According to another embodiment, and as shown in the middle, Figure 17 The scale micro-ridge 1607 can include one or more cliff regions 1631. The cliff region 1631 can include a portion of an initial ridge or other raised portion of the scale 1607 that appears to rise sharply away from the side surface and is separated from an underlying region by a shear plane. The cliff region 1631 can include, but is not necessarily required to include, a protrusion or an overhang that can hang in space above the underlying region, similar to a peak of a corrugation. For example, the cliff region 1631 can include a raised portion 1632 extending above an underlying region 1633. The raised portion 1632 and the underlying region 1633 can be separated from one another by a shear plane 1634.

[0212] Figure 18 An image of a side surface including abrasive particles including another type of micro-ridge according to an embodiment. The abrasive particle 1701 can include a side surface 1702 including a plurality of extended micro-ridges 1703. As depicted, the plurality of extended micro-ridges 1703 can be a different type of micro-ridge than the separation and scale micro-ridges in terms of their morphology. For example, as Figure 19As provided, a plurality of extended microridges 1703 extend from the focal region 1704. That is, the plurality of extended microridges 1703 are relatively elongated, extending a considerable distance along the side surface 1702 and extending away from the focal region 1704. The plurality of extended microridges 1703 may comprise microridges that are more tightly packed than those of scaly or separated types. That is, the average distance between adjacent microridges of the extended microridges 1703 may be less than the average distance between separated or scaly microridges, wherein the average distance is measured as the average of the minimum distances between two adjacent ridges. In at least one embodiment, the plurality of extended microridges 1703 may extend from the focal region 1704 in multiple directions. Where it is not desired to be associated with a particular theory, the plurality of extended microridges 1703 may form during a high-energy fracture mode, wherein fracture begins in the focal region 1704 and extends rapidly outward from the focal region 1704 in all directions, thus facilitating the formation of the plurality of extended microridges 1703. Furthermore, the fracture conditions that occur during the formation of multiple extended microridges 1703 may differ from those during the formation of other types of microridges (e.g., detached or squamous microridges).

[0213] In addition to or as an alternative to any of the features described herein, abrasive particles formed by the methods described herein may have specific features that may be associated with a side surface or a portion thereof. Figure 18 A side view image of abrasive particles according to one embodiment. Figure 20 Includes from Figure 18 A magnified image of a portion of the sidewall. Figure 18 Includes markings used to measure the height of the main body and the second zone. Figure 19 A side view image. In one aspect, the body 1801 of the abrasive particle may include a first primary surface 1802, a second primary surface 1803 opposite to the first primary surface 1802, and a side surface 1804 extending between the first primary surface 1802 and the second primary surface 1803. Reference to the primary surface of the abrasive particle herein may refer to surfaces larger than other surfaces of the body. However, it is not necessary that one or more primary surfaces are always the surfaces with the largest area. In one embodiment, the side surface 1804 includes a specific mean anisotropy factor (MAF). The MAF may be associated with a single particle or a collection of particles. The MAF is an analytical technique for measuring the unique fracture characteristics associated with the side surface of a particle formed according to embodiments herein. Without wishing to be associated with a particular theory, it indicates that a combination of parameters of the methods disclosed herein causes the formation of shaped abrasive particles with unique textures on portions of the sidewalls, which can be quantified by the MAF. Clear distinctions are made by analyzing the side surface or portions of the side surface and taking scanning electron micrographs at approximately 1000X magnification using appropriate contrast and resolution.Figure 21A The features provided in the Summary section can be used to measure the MAF. It is important to note that if a portion of the sidewall appears to have more texture than another portion, then the analysis should focus on this region (e.g., as provided in the region 1806 in the Summary section). The image is then analyzed using a Fourier transform according to the equations provided below. Figure 21B

[0214] The definition of the Fourier Transform (FT) is given below:

[0215]

[0216] which implies that "f" is the original image, and (x,y) are its horizontal and vertical axes, and "F" is the Fourier transform of the original image, and (u,v) are its axes in frequency space.

[0217] and where j = V-1 and "N" is the pixel size of the original image.

[0218] By definition, we have FTi (FT(f)) = f. The Fourier transform F of the original image "f" can be written as:

[0219]

[0220] where:

[0221] and

[0222] We call "A" the magnitude of the Fourier transform, and we call the phase of it. To calculate the MAF, we focus on the variable "A", which is actually the magnitude that contains the information of interest.

[0223] Principal Component Analysis (PCA) techniques are then used to evaluate the images analyzed by the Fourier transform. The Fourier transform "F" can be considered as a probability distribution. Therefore, "F" is normalized as follows:

[0224] For

[0225] Now, let We calculate the covariance COV of U:

[0226] COV = E[(U - E(U)) x (U - E(U)) T ]

[0227] where E is defined as:

[0228]

[0229] ​Since F is symmetric, it follows that E(U) = 0. Thus, we get:

[0230] COV = E(UxU T )

[0231] COV is symmetric and positive definite. Thus, it can be written as:

[0232] where MM T = Id

[0233] σ1and σ2are the principal components of F. We define the anisotropy factor γ as:

[0234]

[0235] A suitable programming language, such as Python (version 2.7), can be used to generate the Fourier transform image from the raw image. A computer program can also be used to calculate the anisotropy factor (AF).

[0236] Figure 21A An image containing a portion of the side surface of a particle formed according to an embodiment. Figure 21A An image containing applying a Fourier transform to Figure 21B As can be seen, the surface of Figure 21A contains ridges having a predominant direction in the horizontal (i.e. left to right) direction. Such ridges can be the same as the micro-ridges described in various embodiments herein. The Fourier transform analyzes these features and produces an image of 21B in which the white clouds present denser values in the vertical direction (up and down) compared to the horizontal direction. The PCA technique allows us to analyze and quantify the clouds depicted in Figure 19 .

[0237] The abrasive particles of the embodiments herein can have a particular MAF, such as at least 1.25, or at least 1.30, or at least 1.40, or at least 1.50, or at least 1.60, or at least 1.70, or at least 1.80, or at least 1.90, or at least 2.00, or at least 2.10, or at least 2.20, or at least 2.30, or at least 2.40, or at least 2.50, or at least 2.60, or at least 2.70, or at least 2.80, or at least 2.90, or at least 3.00, or at least 3.10, or at least 3.20, or at least 3.30, or at least 3.40, or at least 3.50, or at least 3.60, or at least 3.70. Additionally, according to one non-limiting embodiment, the abrasive particles can have a MAF of not greater than 20, such as not greater than 15, or not greater than 12, or not greater than 10, or not greater than 8, or not greater than 7, or not greater than 6, or not greater than 5, or not greater than 4. It will be appreciated that the MAF can be within a range including any of the minimum and maximum values noted above. Such values and ranges of values are relevant to a population of abrasive particles formed according to an embodiment.

[0238] In another embodiment, the anisotropy factor (AF) described in the equation above can be plotted against one or more grains to produce a histogram of AF values versus frequency. From the histogram, one can calculate the anisotropy factor standard deviation (i.e., the first standard deviation of the AF histogram). According to one embodiment, the anisotropy factor standard deviation can be at least 0.75, such as at least 0.8, or at least 0.85, or at least 0.90, or at least 1.00, or at least 1.05, or at least 1.10, or at least 1.20. Additionally, in another non-limiting embodiment, the anisotropy factor standard deviation can be not greater than 10, such as not greater than 9, or not greater than 8, or not greater than 7, or not greater than 6, or not greater than 5, or not greater than 4, or not greater than 3, or not greater than 2. It will be appreciated that the anisotropy factor standard deviation can be within a range including any of the minimum and maximum values noted above. Such values and ranges of values are relevant to a population of abrasive particles formed according to an embodiment.

[0239] As referred to herein, MAF and anisotropy factor standard deviation can be generated for a single abrasive particle or a collection of abrasive particles. To quantify MAF and anisotropy factor standard deviation for a single abrasive particle, a suitable number of regions of the side surface should be sampled (e.g., at least 3 different regions) to generate a statistically relevant sample set. MAF and anisotropy factor standard deviation should be measured at those regions that appear to have the greatest texture (e.g., micro-ridges), which for this purpose are sufficiently large for sampling. In some examples, these regions can be associated with controlled fracture during processing. As will be described in the examples herein, MAF and anisotropy factor standard deviation can also be used to analyze a collection of abrasive particles. To calculate these values based on a collection of abrasive particles, at least 8 abrasive particles are randomly selected from the collection and three randomly selected regions of the side surface are analyzed. In view of the fact that certain regions of the side surface exhibit more texture, e.g. Figure 19 As shown in the examples below, these regions can be measured first, assuming they are sufficiently large for analysis.

[0240] According to another aspect, certain abrasive particles of the examples herein can have different regions that can have significantly different MAF and anisotropy factor standard deviation relative to each other. For example, as shown in Figure 20 As shown in the examples below, the side surface 1804 can have a first region 1805 and a second region 1806. The first region 1805 and the second region 1806 can abut each other on the side surface 1804. The first region 1805 can extend from the first major surface 1802 and the second region 1806 can extend from the second major surface 1803. According to one example, the second region can have a MAF that is greater than the MAF of the first region. As will be appreciated, such a comparison requires that the MAF analysis be performed separately on each of the regions 1805 and 1806 and then compared to each other. As will be described in the examples below, the MAF and anisotropy factor standard deviation can be used to analyze a collection of abrasive particles. To calculate these values based on a collection of abrasive particles, at least 8 abrasive particles are randomly selected from the collection and three randomly selected regions of the side surface are analyzed. In view of the fact that certain regions of the side surface exhibit more texture, e.g. Figure 20As mentioned above, the first region 1805 exhibits a smoother texture as compared to the second region 1806. The first region 1805 can be associated with a patterning process. The second region 1806 exhibits a rougher texture as compared to the first region 1806, which can be associated with one or more processing variables including patterning that causes compression and / or controlled fracture. According to one embodiment, the difference in MAF between the first region 1805 and the second region 1806 (i.e., MAF delta = MAF2 / MAF1, where MAF2 is the MAF of the second region 1806 and MAF1 is the MAF of the first region 1805) can be at least 1, such as at least 1.2, or at least 1.4, or at least 1.6, or at least 1.8, or at least 2, or at least 2.2, or at least 2.4, or at least 2.6, or at least 2.8, or at least 3, or at least 3.5, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8. Further, in one non-limiting embodiment, the difference in MAF can be no greater than 1000, or no greater than 500, or no greater than 100, or no greater than 50, or no greater than 10, or no greater than 5. It will be appreciated that the difference in MAF between the first region 1805 and the second region 1806 can be within a range including any of the minimum and maximum values noted above. Such values and ranges of values are relevant to a population of abrasive particles formed in accordance with embodiments herein.

[0241] According to one embodiment, the first region 1805 of the abrasive particle can have a particular MAF. For example, the MAF can be no greater than 1.20, such as no greater than 1.10, or no greater than 1.00, or no greater than 0.90, or no greater than 0.80, or no greater than 0.70, or no greater than 0.60, or no greater than 0.50, or no greater than 0.40, or no greater than 0.30. Further, in one non-limiting embodiment, the MAF of the first region 1805 of the abrasive particle can be at least 0.30, or at least 0.40, or at least 0.50, or at least 0.60, or at least 0.70, or at least 0.80, or at least 0.90, or at least 1.00, or at least 1.10. It will be appreciated that the MAF of the first region 1805 can be within a range including any of the minimum and maximum values noted above. Such values and ranges of values are relevant to a population of abrasive particles formed in accordance with an embodiment.

[0242] In yet another aspect, the second zone 1806 of abrasive particles can have a particular MAF, such as at least 1.30, or at least 1.40, or at least 1.50, or at least 1.60, or at least 1.70, or at least 1.80, or at least 1.90, or at least 2.00, or at least 2.10, or at least 2.20, or at least 2.30, or at least 2.40, or at least 2.50, or at least 2.60, or at least 2.70, or at least 2.80, or at least 2.90, or at least 3.00, or at least 3.10, or at least 3.20, or at least 3.30, or at least 3.40, or at least 3.50, or at least 3.60, or at least 3.70. In another non-limiting example, the MAF of the second zone 1806 of abrasive particles can be no greater than 20, or no greater than 15, or no greater than 12, or no greater than 10, or no greater than 8, or no greater than 7, or no greater than 6, or no greater than 5, or no greater than 4. It will be appreciated that the MAF of the second zone 1806 of abrasive particles can be within a range including any of the minimum and maximum values noted above. Such values and ranges of values are relevant to populations of abrasive particles formed in accordance with an embodiment.

[0243] As noted above, Figure 20 A side view image of an abrasive particle including according to an embodiment including indicia indicating the relative height of the body at three locations and the relative height of the second zone 1806 at the same three locations. The abrasive particles herein are described by length, width, and height. Length is the longest dimension, width is the second longest dimension extending perpendicular to the length and in the same plane as the length, and the height of the body is the shortest dimension extending perpendicular to the length and to the plane of the length and width. Identifying and measuring the length, width, and height of shaped abrasive particles and constant height abrasive particles is straightforward. Identifying and measuring the length, width, and height of crushed or irregularly shaped abrasive particles is not so straightforward. Thus, to measure the height of irregularly shaped abrasive particles, a random sample of abrasive particles is placed on a surface and vibrated. It is assumed that the abrasive particles have aligned with their longest axis parallel to the surface and thus that the height is the dimension extending perpendicular to the surface and the length. After the abrasive particles are vibrated to identify the side surface, the abrasive particle is transferred to an adhesive surface using tweezers such that the side surface is visible from above. The grain is then prepared for imaging analysis (e.g., optical microscopy, SEM, etc.).

[0244] As Figure 20 As shown in FIG. 6, in certain examples, the second zone 1806 can have a particular average height relative to the average height of the body 1801 and relative to the average height of the first zone 1805. For example, in one embodiment, the second zone 1806 can extend a greater percentage of height compared to the first zone 1805. As shown in FIG. 6, the average height of the second zone 1806 can be greater than the average height of the first zone 1805. In another embodiment, the average height of the second zone 1806 can be less than the average height of the first zone 1805. In another embodiment, the average height of the second zone 1806 can be the same as the average height of the first zone 1805. Figure 18The average height of the body 1801 or any region (e.g., the first region 1805 and the second region 1806) is measured using the images shown in the middle and imaging processing software such as ImageJ. A first line 1812 is drawn approximately halfway across the side surface 1804 between the two outer corners 1851 and 1852. A first line 1811 is drawn approximately perpendicular to at least one of the first major surface 1802 and the second major surface 1803. A second line 1811 is drawn to the left of the first line 1812 at a distance approximately halfway between the first outer corner 1851 and the first line 1812. A third line 1813 is drawn to the right of the first line 1812 at a distance approximately halfway between the second outer corner 1852 and the first line 1812. The lengths of the lines 1811, 1812, and 1813 are then averaged to define the average height of the body 1801. The same procedure can be done to measure the average height of the second region 1806 as illustrated by lines 1821, 1822, and 1823.

[0245] According to one embodiment, the average height of the first region 1805 can be no more than 90%, e.g., no more than 80%, 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% of the height of the body 1801. Additionally, in another embodiment, the average height of the first region 1805 can be at least 1%, or at least 2%, or at least 5%, or at least 8%, or at least 10%, or at least 15%, 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% of the height of the body. It will be appreciated that the first region 1805 can have an average height within a range including any of the minimum and maximum percentages noted above. In examples where the side surface clearly has only the first and second regions (e.g., Figures 18 to 20 ), the average height of the first region 1805 can be calculated by subtracting the average height of the second region 1806 from the average height of the body 1801. Alternatively, one can measure the average height of the first region 1805 using the same process described to measure the height of the second region 1806 except taking care to only measure the portion relating to the first region 1805.

[0246] In another embodiment, the average height of the second region 1806 may be no more than 90% of the height of the body 1801, for example, no more than 80%, 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 average height of the second region 1806 may be at least 5%, or at least 8%, or at least 9%, 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% of the height of the body. It should be understood that the second region 1806 may have an average height within a range including any of the minimum and maximum percentages mentioned above. Such values ​​and ranges of values ​​relate to the abrasive particle set according to the embodiments herein.

[0247] In some examples, the abrasive particles in the embodiments described herein may have a specific shape on their side surfaces. For example... Figure 22A and 20 As shown, the sidewall 1804 may have a first region 1805 and a second region 1806 that define stepped areas on the side surface of the body 1801. That is, compared to the first region 1805, the second region 1806 may extend further away from the body, defining a stepped surface 1831 that may have a minimum portion extending generally parallel to the first main surface 1802 and / or the second main surface 1803.

[0248] like Figure 22A As shown in the provided images, the second region 1806 of the side surface 1804 may have a texture that can take the form of multiple microridges as described in other embodiments herein. In some examples, the multiple microridges may extend in substantially the same direction relative to each other. It should be understood that any of the particles in any of the embodiments herein may include one or more of the various features described in any of the embodiments herein.

[0249] As described in more detail herein, any of the features described in the embodiments herein may be associated with an abrasive particle set. Furthermore, it should be understood that various combinations of other features described in the embodiments herein may exist in the abrasive particle set. The abrasive particle set may be multiple, and more precisely, a portion of the abrasive particles present in a fixed abrasive article. The set may, but does not necessarily, be formed according to one embodiment. In some cases, the abrasive particle set may comprise all the particles that constitute a portion of the fixed abrasive. Alternatively, the abrasive particle set may be a portion of free abrasive particles that are not a portion of the fixed abrasive article.

[0250] In one aspect, a collection of abrasive particles can include abrasive particles having a body comprising a first major surface, a second major surface opposite the first major surface, and a side surface extending between the first major surface and the second major surface. The collection of abrasive particles can have a particular average non-convexity factor (MNCF). The MNCF is used to describe the two-dimensional shape of the abrasive particles and is an average value generated from evaluating non-convexity factors, which are calculated from two-dimensional top-down images of the abrasive particles. It is noted that randomly selected abrasive particles are placed on a surface and vibrated. It is assumed that the abrasive particles have aligned with their longest axis parallel to the surface, and the particles are imaged in such positions or carefully transferred to a suitable surface for imaging, noting to maintain the orientation obtained after vibration.

[0251] As an example, Figure 22A , 22B and 22C include a top-down image of a first major surface of an abrasive particle according to an embodiment. The image of Figure 22C was obtained using an X-ray microscope, but one can use other suitable techniques to obtain a clear top-down image of the abrasive particle. After obtaining a suitable image as shown in Figure 10 , a binary image (i.e., only black and white) can be generated by selecting an appropriate threshold gray value that distinguishes black from white and clearly delineates the edges of the particle from the background. Imaging software such as ImageJ can be used. The original area of the abrasive particle is calculated by using the imaging software of the binary image. A convex hull image is generated using the imaging software as shown in Figure 11 . The convex hull defines the largest area of a two-dimensional image by identifying the outer corners and drawing straight lines between those corners. The convex hull area is measured using Figures 12A to 12J . The non-convexity factor (NCF) is then calculated according to the equation NCF = (1 - (original area / convex hull area)) x 100. This process can be repeated for a suitable number of randomly sampled particles in the collection and then plotted as a histogram of non-convexity factor versus frequency. The MNCF can be calculated from the histogram by identifying the average value.

[0252] According to one aspect, the collection of abrasive particles according to an embodiment can have an MNCF of at least 3.5, such as at least 3.75, or at least 4.0, or at least 4.5, or at least 5.0, or at least 5.5, or at least 6.0, or at least 6.5, or at least 7.0, or at least 7.5, or at least 8.0, or at least 8.5, or at least 9.0. Additionally, in another non-limiting embodiment, the MNCF can be no greater than 30, or no greater than 25, or no greater than 20, or no greater than 18, or no greater than 15, or no greater than 14, or no greater than 13, or no greater than 12, or no greater than 11, or no greater than 10.5. The MNCF can be within a range including any of the minimum and maximum values noted above. It is noted that the MNCF of the abrasive particles of the embodiments herein can be significantly different from the MNCF of shaped abrasive particles formed by different processes and generally having a higher degree of shape fidelity and lower MNCF as compared to each other.

[0253] Using the histogram of NCF versus frequency, one can also evaluate the non-convexity factor standard deviation (NCFSD) of the abrasive particles sampled from the collection of abrasive particles. The NCFSD is a first standard deviation measure assuming a Gaussian distribution of the data and can be indicative of the variation in non-convexity values. According to one embodiment, the abrasive particles in the collection can have an NCFSD of at least 2.4, such as at least 2.5, or at least 2.6, or at least 2.7, or at least 2.8, or at least 2.9, or at least 3.0, or at least 3.1, or at least 3.2, or at least 3.3, or at least 3.4, or at least 3.5. Additionally, in one non-limiting embodiment, the abrasive particles in the collection can have an NCFSD of no greater than 30, such as no greater than 25, or no greater than 20, or no greater than 15, or no greater than 10, or no greater than 8, or no greater than 6, or no greater than 4. The NCFSD can be within a range including any of the minimum and maximum values noted above.

[0254] The collection of abrasive particles can have any of the features mentioned in other embodiments, including but not limited to, for example, MAF, anisotropy factor standard deviation, difference in MAF between the first region and the second region of the side surface, average height of the first region, average height of the second region, difference in average height of the first and second regions relative to each other, average height of the first region relative to the average height of the body, average height of the second region relative to the average height of the body, or any combination thereof. The values of any of the features of the embodiments herein can likewise apply to a collection of abrasive particles, where the difference is as opposed to a single abrasive particle, any feature is measured from a suitable sampling of randomly selected abrasive particles.

[0255] According to one embodiment, the collection of abrasive particles can have a particular height standard deviation. Height is measured along a side surface in a direction generally perpendicular to at least one of the first major surface or the second major surface as referred to herein. The forming processes of embodiments herein can facilitate the formation of abrasive particles having controlled height and a particular height standard deviation, for example, no greater than 100 microns, or no greater than 90 microns, or no greater than 85 microns, or no greater than 80 microns, or no greater than 75 microns, or no greater than 70 microns, or no greater than 65 microns, or no greater than 60 microns, or no greater than 55 microns, or no greater than 50 microns, or no greater than 45 microns, or no greater than 40 microns, or no greater than 35 microns. Additionally, in one non-limiting embodiment, the abrasive particles in the collection can have at least 1 micron, for example, at least 5 microns, at least 10 microns, or at least 15 microns, or at least 20 microns, or at least 25 microns, or at least 30 microns, or at least 35 microns. It will be appreciated that the height standard deviation of the collection of abrasive particles can be within a range including any of the minimum and maximum values noted above.

[0256] Figure 12A A cross-sectional view of a coated abrasive article including mixed abrasive particle materials according to one embodiment. Notably, a plurality of abrasive particles on one or more surfaces of the abrasive particles are not shown, but are understood to be present according to embodiments herein. As shown, the coated abrasive 1000 can include a substrate 1001 and a make coat 1003 overlying a surface of the substrate 1001. The coated abrasive 1000 can further include a first type of abrasive particle material 1005 in the form of a first type of abrasive particle (e.g., shaped, CHAP, unshaped, or irregular, etc.), a second type of abrasive particle material 1006 in the form of a second type of abrasive particle (e.g., shaped, CHAP, unshaped, or irregular, etc.), and a third type of abrasive particle material in the form of a dilution abrasive particle, which can have a random shape. The coated abrasive 1000 can further include a primer 1004 overlying and bonded to the abrasive particle materials 1005, 1006, 1007 and the make coat 1004.

[0257] According to one embodiment, the substrate 1001 can include organic materials, inorganic materials, and combinations thereof. In certain instances, the substrate 1001 can include a woven material. However, the substrate 1001 can be made of a non-woven material. Particularly suitable substrate materials can include organic materials, including polymers, and specifically, polyesters; polyurethanes; polypropylenes; polyimides, such as KAPTON from DuPont; paper. Some suitable inorganic materials can include metals, metal alloys, and specifically, foils of copper, aluminum, steel, and combinations thereof.

[0258] The build coat 1003 can be applied to the surface of the substrate 1001 in a single process, or alternatively, the abrasive particulate materials 1005, 1006, 1007 can be combined with the build coat 1003 and applied to the surface of the substrate 1001 in a mixture. Suitable materials for the build coat 1003 can include organic materials, particularly polymeric materials, including, for example, polyesters, epoxies, polyurethanes, polyamides, polyacrylates, polymethacrylates, polyvinylchlorides, polyethylenes, polysiloxanes, silicones, cellulose acetate, nitrocellulose, natural rubber, starch, shellac, and mixtures thereof. In one embodiment, the build coat 1003 can include a polyester resin. The coated substrate can then be heated in order to cure the resin and the abrasive particulate material to the substrate. Generally, during this curing process, the coated substrate 1001 can be heated to a temperature between about 100°C and less than about 250°C.

[0259] Further, it should be appreciated that a coated abrasive article can include one or more sets of different types of abrasive particles, including the abrasive particulate materials 1005, 1006, and 1007, which can represent abrasive particles of embodiments herein. Embodiments herein can include a fixed abrasive article (e.g., a coated abrasive article) having a first set of abrasive particles (e.g., the abrasive particulate material 1005) that represent abrasive particles of embodiments herein. Any fixed abrasive can further employ a second set of abrasive particles therein that can represent another type of abrasive particle according to embodiments herein, which can differ from the abrasive particles in the first set in one or more ways, including but not limited to one or more abrasive characteristics as described herein. The same features can be used for bonded abrasive articles.

[0260] According to embodiments herein, the abrasive particle materials 1005, 1006, and 1007 can comprise different types of abrasive particles. As described in embodiments herein, the different types of abrasive particles can differ from one another in composition, two-dimensional shape, three-dimensional shape, size, and combinations thereof. As shown, the coated abrasive 1000 can comprise a first type of abrasive particle 1005 and a second type of shaped abrasive particle 1006. The coated abrasive 1000 can comprise different amounts of the first type of abrasive particle 1005 and the second type of abrasive particle 1006. It will be appreciated that a coated abrasive can not necessarily comprise different types of abrasive particles and can consist essentially of a single type of abrasive particle. As will be appreciated, the abrasive particles of embodiments herein can be incorporated into a variety of fixed abrasives (e.g., bonded abrasives, coated abrasives, nonwoven abrasives, thin wheels, grinding wheels, reinforced abrasive articles, etc.), including in the form of a blend, which can comprise different types of shaped abrasive particles, shaped abrasive particles with dilution particles, etc. Further, according to certain embodiments, a batch of particle material can be incorporated into a fixed abrasive article in a predetermined orientation, where each of the abrasive particles can have a predetermined orientation relative to one another and relative to a portion of the abrasive article (e.g., a backing of a coated abrasive).

[0261] The abrasive particles 1007 can be dilution particles that are different from the first type of abrasive particle 1005 and the second type of abrasive particle 1006. For example, the dilution particles can differ from the first type of abrasive particle 1005 and the second type of abrasive particle 1006 in composition, two-dimensional shape, three-dimensional shape, size, and combinations thereof. For example, the abrasive particles 1007 can represent conventional, crushed abrasive grits having random shapes. The median particle size of the abrasive particles 1007 can be smaller than the median particle size of the first type of abrasive particle 1005 and the second type of abrasive particle 1006.

[0262] After the construction coating 503 is sufficiently formed with the abrasive particle materials 1005, 1006, 1007 contained therein, a primer 1004 can be formed to overcoat and bond the abrasive particle materials 1005, 1006, 1007 in place. The primer 1004 can comprise an organic material, can consist essentially of a polymeric material, and, notably, a polyester, an epoxy, a polyurethane, a polyamide, a polyacrylate, a polymethacrylate, a polyvinyl chloride, a polyethylene, a polysiloxane, a silicone, a cellulose acetate, a nitrocellulose, a natural rubber, a starch, a shellac, and mixtures thereof can be used.

[0263] Figure 12BAn illustration of a bonded abrasive article including a blend of abrasive grain materials according to an embodiment. As shown, bonded abrasive 1100 can include a bond material 1101, abrasive grain materials 1102 contained in the bond material, and pores 1108 within the bond material 1101. In particular examples, the bond material 1101 can include organic materials, inorganic materials, and combinations thereof. Suitable organic materials can include polymers such as epoxies, resins, thermosets, thermoplastics, polyimides, polyamides, and combinations thereof. Certain suitable inorganic materials can include metals, metal alloys, glassy phase materials, crystalline phase materials, ceramics, and combinations thereof.

[0264] The abrasive grain materials 1102 of the bonded abrasive 1100 can include different types of abrasive particles 1103, 1104, 1105, and 1106, which can have any of the different types of abrasive particle characteristics as described in the embodiments herein (e.g., shaped, CHAP, etc.). Notably, the different types of abrasive particles 1103, 1104, 1105, and 1106 can differ from one another in composition, two-dimensional shape, three-dimensional shape, size, and combinations thereof, as described in the embodiments herein.

[0265] The bonded abrasive 1100 can include a type of abrasive grain material 1107 representing dilution abrasive particles, which can differ from the different types of abrasive particles 1103, 1104, 1105, and 1106 in composition, two-dimensional shape, three-dimensional shape, size, and combinations thereof.

[0266] The pores 1108 of the bonded abrasive 1100 can be open pores, closed pores, and combinations thereof. The pores 1108 can be present in a majority amount (vol.%) based on the total volume of the body of the bonded abrasive 1100. Alternatively, the pores 1108 can be present in a minority amount (vol.%) based on the total volume of the body of the bonded abrasive 1100. The bond material 1101 can be present in a majority amount (vol.%) based on the total volume of the body of the bonded abrasive 1100. Alternatively, the bond material 1101 can be present in a minority amount (vol.%) based on the total volume of the body of the bonded abrasive 1100. Further, the abrasive grain materials 1102 can be present in a majority amount (vol.%) based on the total volume of the body of the bonded abrasive 1100. Alternatively, the abrasive grain materials 1102 can be present in a minority amount (vol.%) based on the total volume of the body of the bonded abrasive 1100.

[0267] Figure 12A An image including abrasive particles formed according to a process herein and defining a set of abrasive particles. The set of abrasive particles can include a group of particles associated with a single abrasive article. In other examples, the set of abrasive particles can include a plurality of particles produced in the same batch according to the same processing conditions.

[0268] According to one embodiment, the set of abrasive particles can include at least first abrasive particles and second abrasive particles, where the first abrasive particles have a different two-dimensional shape compared to the two-dimensional shape of the second abrasive particles. The two-dimensional shape is the shape of the particle as viewed from above from a plane defined by the length and width of the body of the particle. For example, Figures 12C to 12J particles have a different two-dimensional shape compared to the two-dimensional shape of the Figures 12A to 12J particles. Notably, Figures 12A to 12J and 12B the abrasive particles of the set have irregular two-dimensional shapes characterized by side surface portions having a combination of linear and arcuate shapes. Other abrasive particles in the set, some of which are shown in Figures 12A to 12J , can also have the same different two-dimensional shapes relative to each other.

[0269] Further, as shown in Figures 8A to 8B and according to one embodiment, the abrasive particles in the set can include any combination of the features of the other abrasive particles described in the embodiments herein. For example, Figure 3A the abrasive particles of the set can include one or more surface features (e.g., protrusions and / or recesses), a textureless region, a planar surface, a linear or arcuate edge, or any combination thereof. Further, the arrangement of surface features between the particles within the set of abrasive particles can vary. As shown in Figures 13A to 13R each of the particles has a different arrangement of protrusions on the first major surface compared to the other particles in the set.

[0270] The set of abrasive particles can be mixed into a fixed abrasive, such as a coated abrasive, a bonded abrasive, and the like. There can be groups of particles within the set. A group of particles is particles that have the same two-dimensional shape relative to each other. For example, the set of abrasive particles can include a first group of abrasive particles, where each of the first group of particles has substantially the same two-dimensional shape. Referring again to Figures 13A to 13R and 9A-9E, each of the particles in the images shown have a substantially quadrilateral two-dimensional shape and thus can belong to the same group of abrasive particles. The same group of particles can have, but need not have, the same arrangement of surface features (e.g., protrusions, recesses, textureless regions, etc.). Suitable examples of various two-dimensional shapes include any of the two-dimensional shapes mentioned in the embodiments herein, including but not limited to, for example, irregular shapes, polygonal shapes, regular polygonal shapes, irregular polygonal shapes, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, shapes having linear and curved portions, or any combination thereof.

[0271] It will be appreciated that the embodiments herein also include a set of abrasive particles including at least one abrasive particle having a plurality of micro-ridges along a side surface of the body. Reference to micro-ridges herein will be understood to refer to any type of micro-ridge or combination of micro-ridge types. More specifically, in one embodiment, a majority of the abrasive particles in the set of abrasive particles can include a plurality of micro-ridges on at least a portion of the side surface. For example, in at least one aspect, at least 51% of the abrasive particles in the set of abrasive particles, such as at least 52%, or at least 54%, or at least 56%, or at least 58%, or at least 60%, or at least 62%, or at least 64%, or at least 66%, or at least 68%, or at least 70%, or at least 72%, or at least 74%, or at least 76%, or at least 78%, or at least 80%, or at least 82%, or at least 84%, or at least 86%, or at least 88%, or at least 90%, or at least 92%, or at least 94%, or at least 96%, or at least 98%, or at least 99% of the abrasive particles in the set of abrasive particles include a plurality of micro-ridges on at least a portion of the side surface. Additionally, in at least one non-limiting embodiment, no greater than 99% of the abrasive particles in the set of abrasive particles, such as no greater than 98%, or no greater than 96%, or no greater than 94%, or no greater than 92%, or no greater than 90%, or no greater than 88%, or no greater than 86%, or no greater than 84%, or no greater than 82%, or no greater than 80%, or no greater than 78%, or no greater than 76%, or no greater than 74%, or no greater than 72%, or no greater than 70%, or no greater than 68%, or no greater than 66%, or no greater than 64%, or no greater than 62%, or no greater than 60%, or no greater than 58%, or no greater than 56%, or no greater than 54%, or no greater than 52% of the abrasive particles in the set of abrasive particles can include a plurality of micro-ridges on at least a portion of the side surface. It will be appreciated that the percentage of abrasive particles in the set of abrasive particles that include a plurality of micro-ridges on at least a portion of the side surface can be within a range including any of the minimum and maximum percentages noted above.

[0272] In yet another embodiment, a majority of the total surface area of the side surfaces of the abrasive particles in the collection can include a plurality of micro-ridges. For example, at least 51%, or at least 52%, or at least 54%, or at least 56%, or at least 58%, or at least 60%, or at least 62%, or at least 64%, or at least 66%, or at least 68%, or at least 70%, or at least 72%, or at least 74%, or at least 76%, or at least 78%, or at least 80%, or at least 82%, or at least 84%, or at least 86%, or at least 88%, or at least 90%, or at least 92%, or at least 94%, or at least 96%, or at least 98%, or at least 99% of the total surface area of the side surfaces of the abrasive particles in the collection can include a plurality of micro-ridges. In one non-limiting embodiment, no more than 99%, for example, no more than 98%, or no more than 96%, or no more than 94%, or no more than 92%, or no more than 90%, or no more than 88%, or no more than 86%, or no more than 84%, or no more than 82%, or no more than 80%, or no more than 78%, or no more than 76%, or no more than 74%, or no more than 72%, or no more than 70%, or no more than 68%, or no more than 66%, or no more than 64%, or no more than 62%, or no more than 60%, or no more than 58%, or no more than 56%, or no more than 54%, or no more than 52% of the total surface area of the side surfaces of the abrasive particles in the collection can include a plurality of micro-ridges. It will be appreciated that the total surface area of the side surfaces of the abrasive particles in the collection that include a plurality of micro-ridges can be within a range including any of the minimum and maximum percentages noted above.

[0273] In yet another aspect, the side surfaces of the body of the abrasive particles have side surface portions, where each side surface portion is a portion of the side surface extending between an outer corner of the body. Generally, each abrasive particle has at least three side surface portions extending around a peripheral surface of the body between the first major surface and the second major surface. For at least one embodiment, the collection of abrasive particles can be formed such that at least one abrasive particle in the collection has at least 45% of the side surface portions of the body comprising a plurality of micro-ridges. In another embodiment, at least 10% of the abrasive particles in the collection have at least 45% of the side surface portions of the body comprising a plurality of micro-ridges. In other examples, the percentage of abrasive particles in the collection having at least 45% of the side surface portions of the body comprising a plurality of micro-ridges can be greater, such as 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%. It will be appreciated that in one embodiment, each of the abrasive particles in the collection can comprise at least 45% of the side surface portions of the body comprising a plurality of micro-ridges. Further, in one non-limiting embodiment, the percentage of abrasive particles in the collection comprising at least 45% of the side surface portions of the body comprising a plurality of micro-ridges can be no greater than 98%, or no greater than 90%, or 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%. It will be appreciated that the percentage of abrasive particles in the collection having at least 45% of the side surface portions of the body comprising a plurality of micro-ridges can be within a range including any of the minimum and maximum values noted above.

[0274] In yet another embodiment, the set of abrasive particles can include a greater percentage of abrasive particles having side surface portions that include a plurality of micro-ridges. For example, at least 52% of the side surface portions of the body include a plurality of micro-ridges, or at least 54%, or at least 56%, or at least 58%, or at least 60%, or at least 62%, or at least 64%, or at least 66%, or at least 68%, or at least 70%, or at least 72%, or at least 74%, or at least 76%, or at least 78%, or at least 80%, or at least 82%, or at least 84%, or at least 86%, or at least 88%, or at least 90%, or at least 92%, or at least 94%, or at least 96%, or at least 98%, or at least 99% of the side surface portions of the body include a plurality of micro-ridges. It will be appreciated that the percentage of side surface portions that include a plurality of micro-ridges can be combined with any of the foregoing percentages of particles in the set identified as having a plurality of micro-ridges. For example, it is contemplated that in certain embodiments, at least 10% of the abrasive particles in the set can have at least 50% of their side surface portions with a plurality of micro-ridges. In another example, at least 50% of the abrasive particles in the set can have at least 50% of their side surface portions with a plurality of micro-ridges. And as another example, in another embodiment, it can be noted that at least 70% of the abrasive particles in the set can have at least 60% of their side surface portions with a plurality of micro-ridges. In yet another embodiment, however, each of the abrasive particles in the set can have all of their side surface portions include a plurality of micro-ridges.

[0275] The formation of the set of abrasive particles, which can or can not have discrete groups of abrasive particles in the set, can be controlled by one or more process parameters, including but not limited to, the shape of the formed piece used for the modifying mixture, the modifying process, the drying process, and the like. It will be appreciated that the set of abrasive particles can include multiple groups of abrasive particles, and in particular, more than two different groups of abrasive particles.

[0276] Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. As will be appreciated by the skilled artisan, those aspects and embodiments are illustrative only and do not limit the scope of the application. Embodiments can be according to any one or more of the following embodiments.

[0277] Embodiments

[0278] Embodiment 1. An abrasive particle comprising:

[0279] a body including a first major surface, a second major surface opposite the first major surface, and a side surface extending between the first major surface and the second major surface, wherein the side surface comprises an average anisotropy factor of at least 1.25.

[0280] Embodiment 2. An abrasive particle comprising:

[0281] a body comprising a first major surface, a second major surface opposite the first major surface, and a side surface extending between the first major surface and the second major surface, wherein the first major surface includes a first protrusion disposed against and extending along at least a portion of a first side surface portion, and further includes a texture-free region extending through a central region of the body, wherein the texture-free region defines a majority of a total surface area of the first major surface.

[0282] Example 3. An abrasive particle comprising:

[0283] a body comprising a first major surface, a second major surface opposite the first major surface, and a side surface extending between the first major surface and the second major surface, wherein a majority of the side surface comprises a plurality of micro-ridges.

[0284] Example 4. The abrasive particle of any one of examples 2 and 3, wherein the side surface comprises an average anisotropy factor of at least 1.25.

[0285] Example 5. The abrasive particle of any one of examples 1 and 4, wherein the average anisotropy factor is at least 1.30, or at least 1.40, or at least 1.50, or at least 1.60, or at least 1.70, or at least 1.80, or at least 1.90, or at least 2.00, or at least 2.10, or at least 2.20, or at least 2.30, or at least 2.40, or at least 2.50, or at least 2.60, or at least 2.70, or at least 2.80, or at least 2.90, or at least 3.00, or at least 3.10, or at least 3.20, or at least 3.30, or at least 3.40, or at least 3.50, or at least 3.60, or at least 3.70.

[0286] Example 6. The abrasive particle of any one of examples 1 and 4, wherein the average anisotropy factor is not greater than 20, or not greater than 15, or not greater than 12, or not greater than 10, or not greater than 8, or not greater than 7, or not greater than 6, or not greater than 5, or not greater than 4.

[0287] Example 7. The abrasive particle of any one of examples 1, 2, and 3, wherein the side surface comprises an anisotropy factor standard deviation of at least 0.75, or at least 0.8, or at least 0.85, or at least 0.90, or at least 1.00, or at least 1.05, or at least 1.10, or at least 1.20.

[0288] Example 8. The abrasive particle of any one of examples 1, 2, and 3, wherein the side surface comprises an anisotropy factor standard deviation of not greater than 10, or not greater than 9, or not greater than 8, or not greater than 7, or not greater than 6, or not greater than 5, or not greater than 4, or not greater than 3, or not greater than 2.

[0289] Example 9. The abrasive particle of any of examples 1, 2, and 3, wherein the side surface comprises a first region extending from the first major surface and a second region extending from the second major surface, and wherein the first region and the second region abut on the side surface, and wherein the second region comprises a greater average anisotropy factor than the first region.

[0290] Example 10. The abrasive particle of example 9, wherein the second region extends a greater percentage of a height than the first region.

[0291] Example 11. The abrasive particle of example 9, wherein the average height of the first region is no greater than 90%, or 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% of the body height.

[0292] Example 12. The abrasive particle of example 9, wherein the average height of the first region is at least 1%, or at least 2%, or at least 5%, or at least 8%, or at least 10%, or at least 15%, 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% of the body height.

[0293] Example 13. The abrasive particle of example 9, wherein the second region comprises an average height that is no greater than 90%, or 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% of the body height.

[0294] Example 14. The abrasive particle of example 9, wherein the average height of the second region is at least 5%, or at least 8%, or at least 9%, 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% of the body height.

[0295] Example 15. The abrasive particle of example 9, wherein the first region comprises an average anisotropy factor that is no greater than 1.20, or no greater than 1.10, or no greater than 1.00, or no greater than 0.90, or no greater than 0.80, or no greater than 0.70, or no greater than 0.60, or no greater than 0.50, or no greater than 0.40, or no greater than 0.30.

[0296] Example 16. The abrasive particle of Example 9, wherein the average anisotropy factor of the first zone is at least 0.30, or at least 0.40, or at least 0.50, or at least 0.60, or at least 0.70, or at least 0.80, or at least 0.90, or at least 1.00, or at least 1.10.

[0297] Example 17. The abrasive particle of Example 9, wherein the average anisotropy factor of the second zone is at least 1.30, or at least 1.40, or at least 1.50, or at least 1.60, or at least 1.70, or at least 1.80, or at least 1.90, or at least 2.00, or at least 2.10, or at least 2.20, or at least 2.30, or at least 2.40, or at least 2.50, or at least 2.60, or at least 2.70, or at least 2.80, or at least 2.90, or at least 3.00, or at least 3.10, or at least 3.20, or at least 3.30, or at least 3.40, or at least 3.50, or at least 3.60, or at least 3.70.

[0298] Example 18. The abrasive particle of Example 9, wherein the average anisotropy factor of the second zone is not greater than 20, or not greater than 15, or not greater than 12, or not greater than 10, or not greater than 8, or not greater than 7, or not greater than 6, or not greater than 5, or not greater than 4.

[0299] Example 19. The abrasive particle of Example 9, wherein the first zone and the second zone define a stepped zone on the side surface of the body.

[0300] Example 20. The abrasive particle of Example 9, wherein the second zone comprises a plurality of micro-ridges.

[0301] Example 21. The abrasive particle of Example 20, wherein the plurality of micro-ridges extend in substantially the same direction relative to one another.

[0302] Example 22. The abrasive particle of any one of Examples 1, 2, and 3, wherein the first major surface and the second major surface are substantially parallel to one another.

[0303] Example 23. The abrasive particle of any one of Examples 1 and 2, wherein a majority of the side surface comprises a plurality of micro-ridges.

[0304] Example 24. The abrasive particle of any one of Examples 3 and 23, wherein at least a portion of the plurality of micro-ridges comprises a plurality of discrete micro-ridges defined by the micro-ridges extending from the side surface and separated by a substantially smooth planar region.

[0305] Example 25. The abrasive particle of Example 24, wherein the plurality of discrete micro-ridges extend in an irregular path along the side surface.

[0306] Example 26. The abrasive particle of Example 24, wherein at least one of the plurality of discrete micro-ridges comprises a head region and a tail region connected to and extending from the head region, wherein the head region has a circular shape and the tail region has an elongated shape.

[0307] Example 27. The abrasive particle of either of Examples 3 and 23, wherein at least a portion of the plurality of micro-ridges comprises a plurality of scale-like micro-ridges.

[0308] Example 28. The abrasive particle of Example 27, wherein at least a portion of the plurality of scale-like micro-ridges comprises an initial ridge and a plurality of corrugations extending from the initial ridge.

[0309] Example 29. The abrasive particle of Example 28, wherein the initial ridge extends in an irregular path along the side surface.

[0310] Example 30. The abrasive particle of Example 28, wherein at least a portion of the plurality of corrugations extends away from the initial ridge in an irregular path along the side surface.

[0311] Example 31. The abrasive particle of Example 28, wherein the corrugations define a groove that extends in an irregular path along the side surface.

[0312] Example 32. The abrasive particle of Example 28, wherein the corrugations extend along a curved path.

[0313] Example 33. The abrasive particle of Example 28, wherein the plurality of scale-like micro-ridges comprises a greater number of corrugations than the number of initial ridges.

[0314] Example 34. The abrasive particle of Example 28, wherein the corrugations extend in a different direction than one or more initial ridges, and the corrugations extend between two or more initial ridges.

[0315] Example 35. The abrasive particle of Example 28, wherein the initial ridge comprises at least one gap between elongated portions.

[0316] Example 36. The abrasive particle of Example 27, wherein at least a portion of the scale-like micro-ridges has a scale-like appearance.

[0317] Example 37. The abrasive particle of Example 27, wherein at least a portion of the scale-like micro-ridges has a layered appearance.

[0318] Example 38. The abrasive particle of Example 27, wherein at least a portion of the scale-like micro-ridges comprise a plurality of raised portions having irregular shapes and a wrinkle extending between the plurality of raised portions.

[0319] Example 39. The abrasive particle of either of Examples 3 and 23, wherein the plurality of micro-ridges are shell-like fracture features.

[0320] Example 40. The abrasive particle of either of Examples 3 and 23, wherein the plurality of micro-ridges are formed during a controlled fracture of the side surface.

[0321] Example 41. The abrasive particle of either of Examples 3 and 23, wherein the plurality of micro-ridges comprise a cliff region.

[0322] Example 42. The abrasive particle of either of Examples 3 and 23, wherein at least 51%, or at least 52%, or at least 54%, or at least 56%, or at least 58%, or at least 60%, or at least 62%, or at least 64%, or at least 66%, or at least 68%, or at least 70%, or at least 72%, or at least 74%, or at least 76%, or at least 78%, or at least 80%, or at least 82%, or at least 84%, or at least 86%, or at least 88%, or at least 90%, or at least 92%, or at least 94%, or at least 96%, or at least 98%, or at least 99% of the total surface area of the side surface comprises the plurality of micro-ridges.

[0323] Example 43. The abrasive particle of Example 42, wherein no more than 99%, or no more than 98%, or no more than 96%, or no more than 94%, or no more than 92%, or no more than 90%, or no more than 88%, or no more than 86%, or no more than 84%, or no more than 82%, or no more than 80%, or no more than 78%, or no more than 76%, or no more than 74%, or no more than 72%, or no more than 70%, or no more than 68%, or no more than 66%, or no more than 64%, or no more than 62%, or no more than 60%, or no more than 58%, or no more than 56%, or no more than 54%, or no more than 52% of the total surface area of the side surface comprises the plurality of micro-ridges.

[0324] Example 44. The abrasive particle of either of Examples 3 and 23, wherein the side surface of the body comprises side surface portions, and wherein each side surface portion extends between outer corners of the body, and wherein at least 45% of the side surface portions comprise the plurality of micro-ridges.

[0325] Example 45. The abrasive particle of Example 44, wherein the body comprises at least three side surface portions comprising the plurality of micro-ridges.

[0326] Example 46. The abrasive particles according to Example 44, wherein all side surface portions contain multiple microridges.

[0327] Example 47. The abrasive particles according to Example 44, wherein at least 52%, or at least 54%, or at least 56%, or at least 58%, or at least 60%, or at least 62%, or at least 64%, or at least 66%, or at least 68%, or at least 70%, or at least 72%, or at least 74%, or at least 76%, or at least 78%, or at least 80%, or at least 82%, or at least 84%, or at least 86%, or at least 88%, or at least 90%, or at least 92%, or at least 94%, or at least 96%, or at least 98%, or at least 99% of the side surface portion of the body contains a plurality of microridges.

[0328] Example 48. The abrasive particles according to Example 44, wherein the body comprises at least one side surface portion without a plurality of microridges.

[0329] Example 49. The abrasive particle according to any one of Examples 1 and 3 further includes a first protrusion that abuts against a portion of the first side surface and extends along at least a portion of the first side surface.

[0330] Example 50. The abrasive particles according to any one of Examples 2 and 49, wherein the first main surface includes a first recess extending in a direction parallel to the first side surface portion, and wherein a first protrusion is disposed between the first side surface portion and the first recess, the first protrusion abutting against the first side surface portion and extending along at least a portion of the first side surface portion.

[0331] Example 51. The abrasive particles according to any one of Examples 2 and 50, wherein the first protrusion extends at least 30% of the total length of the first side surface portion, or at least 40% of the total length of the first side surface portion, or at least 50% of the total length of the first side surface portion, or at least 60% of the total length of the first side surface portion, or at least 70% of the total length of the first side surface portion, or at least 80% of the total length of the first side surface portion, or at least 90% of the total length of the first side surface portion.

[0332] Example 52. The abrasive particles according to any one of Examples 2 and 50, wherein the first recess extends at least 30% of the total length of the first side surface portion, or at least 40% of the total length of the first side surface portion, or at least 50% of the total length of the first side surface portion, or at least 60% of the total length of the first side surface portion, or at least 70% of the total length of the first side surface portion, or at least 80% of the total length of the first side surface portion, or at least 90% of the total length of the first side surface portion.

[0333] Example 53. The abrasive particles according to any one of Examples 2 and 50, wherein the first side surface portion is defined as a portion of the side surface extending between the two outer corners of the body.

[0334] Example 54. The abrasive particles according to any one of Examples 2 and 50, wherein the first side surface portion is a portion of the total length of the side surface defining the perimeter of the body.

[0335] Example 55. The abrasive particles according to any one of Examples 2 and 50, wherein the first protrusion extends a portion of the total length of the side surface defining the perimeter of the body.

[0336] Example 56. The abrasive particles according to any one of Examples 2 and 50, wherein the first recess extends to define a portion of the total length of the side surface of the periphery of the body.

[0337] Example 57. The abrasive particles according to any one of Examples 2 and 50, wherein the first side surface portion and the first protrusion have substantially the same outline when viewed from the plane of the first main surface.

[0338] Example 58. The abrasive particles according to any one of Examples 2 and 50, wherein the first protrusion intersects with a second side surface portion that is different from the first side surface portion.

[0339] Example 59. The abrasive particles according to any one of Examples 1 and 3 further include a textureless region extending through the central region of the body, wherein the textureless region defines a large portion of the total surface area of ​​the first main surface.

[0340] Example 60. The abrasive particles according to any one of Examples 2 and 59, wherein the textureless region defines at least 55%, or at least 60%, or at least 65%, or at least 70%, or at least 75%, or at least 80%, or at least 85%, or at least 90% of the total surface area of ​​the first primary surface.

[0341] Example 61. The abrasive particles according to any one of Examples 2 and 59, wherein the textureless region defines a total surface area of ​​the first main surface that is not greater than 99%, or not greater than 95%, or not greater than 90%, or not greater than 85%, or not greater than 80%, or not greater than 75%, or not greater than 70%, or not greater than 65%, or not greater than 60%, or not greater than 55%.

[0342] Example 62. The abrasive particles according to any one of Examples 2 and 59, wherein the first protrusion abuts a portion of the textureless region, and wherein the first protrusion is spaced apart from the central region of the body.

[0343] Example 63. The abrasive particles according to any one of Examples 2 and 59, wherein the first protrusion extends above the surface of the textureless region.

[0344] Example 64. Abrasive particles according to any one of Examples 2 and 59, wherein the textureless region abuts a portion of the side surface of the body.

[0345] Example 65. The abrasive particles according to any one of Examples 2 and 59, wherein the textureless region comprises a two-dimensional shape that is substantially the same as the two-dimensional shape of the body.

[0346] Example 66. The abrasive particles according to any one of Examples 2 and 50, wherein the first depression has an average depth of at least 5% and no more than 99% of the average height of the main body.

[0347] Example 67. The abrasive particles according to any one of Examples 2 and 50, wherein the first protrusion has at least 5% and no more than 99% of the average height of the main body.

[0348] Example 68. The abrasive particles according to any one of Examples 2 and 50 further include a second protrusion that abuts against and extends along the second side surface portion.

[0349] Example 69. The abrasive particles according to Example 68, wherein the first main surface includes a second recess extending in a direction parallel to the second side surface portion.

[0350] Example 70. The abrasive particles according to Example 69, wherein the first depression intersects with the second depression.

[0351] Example 71. The abrasive particles according to Example 69, wherein the first depression and the second depression are close to intersecting at the outer angle that separates the first side surface portion from the second side surface portion.

[0352] Example 72. The abrasive particles according to Example 69, wherein the second protrusion abuts against the first depression.

[0353] Example 73. The abrasive particles according to Example 69, wherein the first protrusion abuts against the second depression.

[0354] Example 74. The abrasive particles according to Example 69, wherein the first protrusion abuts against the second protrusion.

[0355] Example 75. The abrasive particles according to any one of Examples 2 and 50 further include a featureless edge extending between a third portion of a first primary surface and a side surface, wherein the third side surface portion is different from the first side surface portion.

[0356] Example 76. The abrasive particles according to Example 75, wherein the third side surface portion and the first side surface portion are separated from each other by at least one outer corner on the side surface.

[0357] Example 77. The abrasive particle according to any one of Examples 2 and 50, wherein the body includes a bottom edge that joins the second main surface and the side surface, wherein at least a portion of the bottom edge has an irregular profile.

[0358] Example 78. The abrasive particles according to any one of Examples 1, 2 and 3, wherein, viewed from a plane defined by the length and width of the body, the body comprises a two-dimensional shape selected from a first group consisting of: regular polygons, irregular polygons, ellipses, numbers, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having combinations of polygonal shapes, shapes having linear and curved portions, and combinations thereof.

[0359] Example 79. The abrasive particles according to any one of Examples 1, 2 and 3, wherein the body comprises an irregular two-dimensional shape when viewed from a plane defined by the length and width of the body.

[0360] Example 80. Abrasive particles according to any one of Examples 1, 2 and 3, wherein the body comprises at least one material from the group consisting of oxides, carbides, nitrides, borides, carbon oxides, nitrogen oxides, boron oxides, natural minerals, synthetic materials, carbon-based materials, and combinations thereof.

[0361] Example 81. Abrasive particles according to any one of Examples 1, 2 and 3, wherein the main body comprises alumina.

[0362] Example 82. Abrasive particles according to any one of Examples 1, 2 and 3, wherein the bulk is substantially composed of alumina.

[0363] Example 83. Abrasive particles according to any one of Examples 1, 2 and 3, wherein the body comprises at least one oxide from the group consisting of: aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, magnesium oxide, rare earth oxides, or any combination thereof.

[0364] Example 84. The abrasive particles according to any one of Examples 1, 2 and 3, further comprising a fixed abrasive containing the abrasive particles.

[0365] Example 85. Abrasive particles according to Example 69, wherein the fixed abrasive is a coated abrasive.

[0366] Example 86. Abrasive particles according to Example 69, wherein the fixed abrasive is a bonded abrasive.

[0367] Example 87. An abrasive particle aggregate comprising:

[0368] The first abrasive particle includes:

[0369] A body comprising a first main surface, a second main surface opposite to the first main surface, and a side surface extending between the first main surface and the second main surface, wherein the body of the first abrasive particle comprises a first two-dimensional shape, and wherein the first main surface comprises at least a portion of a first side surface portion abutting the side surface and extending along said at least a portion, and wherein the body further comprises a textureless region extending through a central region of the body, wherein the textureless region defines a large portion of the total surface area of ​​the first main surface; and

[0370] The second abrasive particle includes:

[0371] The body comprises a first main surface, a second main surface opposite to the first main surface, and a side surface extending between the first main surface and the second main surface, wherein the body of the second abrasive particle comprises a two-dimensional shape that is different from the two-dimensional shape of the first abrasive particle.

[0372] Example 88. An abrasive particle assembly, wherein each abrasive particle in the abrasive particle assembly comprises a body having a first main surface, a second main surface opposite to the first main surface, and a side surface extending between the first main surface and the second main surface, and wherein a majority of the particles in the abrasive particle assembly include a plurality of microridges extending along at least a portion of the side surface.

[0373] Example 89. An abrasive particle set, wherein the abrasive particles in the abrasive particle set comprise:

[0374] A body having a first main surface, a second main surface opposite to the first main surface, and side surfaces extending between the first main surface and the second main surface, wherein the side surfaces include a plurality of side surface portions extending between the outer corners of the body; and

[0375] At least 45% of the side surface portion of the main body contains multiple microridges.

[0376] Example 90. An abrasive particle set, wherein each abrasive particle in the abrasive particle set comprises:

[0377] A body having a first main surface, a second main surface opposite to the first main surface, and a side surface extending between the first main surface and the second main surface, wherein the first main surface and the second main surface are substantially parallel to each other; and

[0378] The abrasive particle set includes an average nonconvexity factor of at least 3.5 and a nonconvexity factor standard deviation of at least 2.4.

[0379] Example 91. An abrasive particle set, wherein each abrasive particle in the abrasive particle set comprises:

[0380] A body having a first main surface, a second main surface opposite to the first main surface, and a side surface extending between the first main surface and the second main surface; and

[0381] The abrasive particle set includes an average anisotropy factor of at least 1.25.

[0382] Example 92. An abrasive particle set, wherein each abrasive particle in the abrasive particle set comprises:

[0383] A body having a first main surface, a second main surface opposite to the first main surface, and a side surface extending between the first main surface and the second main surface, wherein the body includes a height as defined by the distance along the side surface between the first main surface and the second main surface;

[0384] The abrasive particle aggregate described herein includes a height standard deviation of no more than 100; and

[0385] The abrasive particle set mentioned above includes an average nonconvexity factor of at least 3.5.

[0386] Example 93. An abrasive particle set according to any one of Examples 87, 88, 89, 90 and 92, further comprising an average anisotropy factor of at least 1.25.

[0387] Example 94. An abrasive particle set according to any one of Examples 91 and 93, wherein the average anisotropy factor is at least 1.30, or at least 1.40, or at least 1.50, or at least 1.60, or at least 1.70, or at least 1.80, or at least 1.90, or at least 2.00, or at least 2.10, or at least 2.20, or at least 2.30, or at least 2.40, or at least 2.50, or at least 2.60, or at least 2.70, or at least 2.80, or at least 2.90, or at least 3.00, or at least 3.10, or at least 3.20, or at least 3.30, or at least 3.40, or at least 3.50, or at least 3.60, or at least 3.70.

[0388] Example 95. An abrasive particle set according to any one of Examples 91 and 93, wherein the average anisotropy factor is not greater than 20, or not greater than 15, or not greater than 12, or not greater than 10, or not greater than 8, or not greater than 7, or not greater than 6, or not greater than 5, or not greater than 4.

[0389] Example 96. The abrasive particle set according to any one of Examples 87, 88, 89, 90, 91 and 92 further includes an anisotropy factor standard deviation of at least 0.75, or at least 0.8, or at least 0.85, or at least 0.90, or at least 1.00, or at least 1.05, or at least 1.10, or at least 1.20.

[0390] Example 97. An abrasive particle set according to any one of Examples 87, 88, 89, 90, 91 and 92, further having an anisotropy factor standard deviation of no greater than 10, or no greater than 9, or no greater than 8, or no greater than 7, or no greater than 6, or no greater than 5, or no greater than 4, or no greater than 3, or no greater than 2.

[0391] Example 98. An abrasive particle set according to any one of Examples 87, 88, 89, 90, 91 and 92, wherein the side surface includes a first region extending from a first main surface and a second region extending from a second main surface, wherein the first region and the second region abut on the side surface, and wherein the second region includes an average anisotropy factor larger than that of the first region.

[0392] Example 99. An abrasive particle set according to Example 98, wherein the second region extends by a greater percentage of height compared to the first region.

[0393] Example 100. The abrasive particle set according to Example 98, wherein the average height of the first region is no more than 90%, or no more than 80%, 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% of the main body height.

[0394] Example 101. An abrasive particle set according to Example 98, wherein the average height of the first region is at least 1%, or at least 2%, at least 5%, or at least 8%, or at least 10%, or at least 15%, 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% of the body height.

[0395] Example 102. The abrasive particle set according to Example 98, wherein the second region includes an average height of not more than 90%, or not more than 80%, 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%, or not more than 20%, or not more than 10%, or not more than 5% of the main body height.

[0396] Example 103. An abrasive particle set according to Example 98, wherein the average height of the first region is at least 5%, or at least 8%, or at least 9%, 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% of the body height.

[0397] Example 104. The abrasive particle set according to Example 98, wherein the first region includes an average anisotropy factor of not greater than 1.20, or not greater than 1.10, or not greater than 1.00, or not greater than 0.90, or not greater than 0.80, or not greater than 0.70, or not greater than 0.60, or not greater than 0.50, or not greater than 0.40, or not greater than 0.30.

[0398] Example 105. The abrasive particle set according to Example 98, wherein the average anisotropy factor of the first region is at least 0.30, or at least 0.40, or at least 0.50, or at least 0.60, or at least 0.70, or at least 0.80, or at least 0.90, or at least 1.00, or at least 1.10.

[0399] Example 106. The abrasive particle set according to Example 98, wherein the average anisotropy factor of the second region is at least 1.30, or at least 1.40, or at least 1.50, or at least 1.60, or at least 1.70, or at least 1.80, or at least 1.90, or at least 2.00, or at least 2.10, or at least 2.20, or at least 2.30, or at least 2.40, or at least 2.50, or at least 2.60, or at least 2.70, or at least 2.80, or at least 2.90, or at least 3.00, or at least 3.10, or at least 3.20, or at least 3.30, or at least 3.40, or at least 3.50, or at least 3.60, or at least 3.70.

[0400] Example 107. The abrasive particle set according to Example 98, wherein the average anisotropy factor of the second region is not greater than 20, or not greater than 15, or not greater than 12, or not greater than 10, or not greater than 8, or not greater than 7, or not greater than 6, or not greater than 5, or not greater than 4.

[0401] Example 108. An abrasive particle assembly according to Example 98, wherein the first region and the second region define stepped regions on the side surface of the body.

[0402] Example 109. An abrasive particle assembly according to Example 98, wherein the second region includes a plurality of microridges.

[0403] Example 110. An abrasive particle assembly according to Example 98, wherein a plurality of microridges extend in substantially the same direction relative to each other.

[0404] Example 111. An abrasive particle set according to any one of Examples 87, 88, 89, 91 and 92, further comprising an average nonconvexity factor of at least 3.5.

[0405] Example 112. An abrasive particle set according to any one of Examples 90 and 111, wherein the average nonconvexity factor is at least 3.75, or at least 4.0, or at least 4.5, or at least 5.0, or at least 5.5, or at least 6.0, or at least 6.5, or at least 7.0, or at least 7.5, or at least 8.0, or at least 8.5, or at least 9.0.

[0406] Example 113. An abrasive particle set according to any one of Examples 90 and 111, wherein the average nonconvexity factor is not greater than 30, or not greater than 25, or not greater than 20, or not greater than 18, or not greater than 15, or not greater than 14, or not greater than 13, or not greater than 12, or not greater than 11, or not greater than 10.5.

[0407] Example 114. An abrasive particle set according to any one of Examples 87, 88, 89, 91 and 92, further comprising a nonconvexity factor standard deviation of at least 2.4.

[0408] Example 115. An abrasive particle set according to any one of Examples 90 and 114, wherein the standard deviation of the nonconvexity factor is at least 2.5, or at least 2.6, or at least 2.7, or at least 2.8, or at least 2.9, or at least 3.0, or at least 3.1, or at least 3.2, or at least 3.3, or at least 3.4, or at least 3.5.

[0409] Example 116. An abrasive particle set according to any one of Examples 90 and 114, wherein the standard deviation of the nonconvexity factor is not greater than 30, or not greater than 25, or not greater than 20, or not greater than 15, or not greater than 10, or not greater than 8, or not greater than 6, or not greater than 4.

[0410] Example 117. An abrasive particle set according to any one of Examples 87, 88, 89, 90 and 91, further comprising a height standard deviation of not more than 100 micrometers and an average nonconvexity factor of at least 3.5.

[0411] Example 118. An abrasive particle set according to any one of Examples 91 and 117, wherein the height standard deviation is not greater than 90 micrometers, or not greater than 85 micrometers, or not greater than 80 micrometers, or not greater than 75 micrometers, or not greater than 70 micrometers, or not greater than 65 micrometers, or not greater than 60 micrometers, or not greater than 55 micrometers, or not greater than 50 micrometers, or not greater than 45 micrometers, or not greater than 40 micrometers, or not greater than 35 micrometers.

[0412] Example 119. An abrasive particle set according to any one of Examples 91 and 117, wherein the height standard deviation is at least 1 micrometer, or at least 5 micrometers, or at least 10 micrometers, or at least 15 micrometers, or at least 20 micrometers, or at least 25 micrometers, or at least 30 micrometers, or at least 35 micrometers.

[0413] Example 120. The abrasive particle set according to any one of Examples 87, 88, 89, 90, 91 and 92 further includes at least one feature from the group consisting of:

[0414] At least a mean nonconvexity factor of 3.5;

[0415] At least 2.4 standard deviations of the nonconvexity factor;

[0416] At least a mean anisotropy factor of 1.25;

[0417] The height standard deviation is no greater than 100 micrometers;

[0418] Or any combination thereof.

[0419] Example 121. An abrasive particle set according to any one of Examples 87, 88, 89, 90, 91 and 92, wherein the first primary surface and the second primary surface are substantially parallel to each other.

[0420] Example 122. The abrasive particle set according to any one of Examples 87, 88, 89, 90, 91 and 92, further comprising a fixed abrasive containing the abrasive particle set.

[0421] Example 123. According to the abrasive particle set described in Example 122, the fixed abrasive is a coated abrasive.

[0422] Example 124. An abrasive particle assembly according to Example 122, wherein the fixed abrasive is a bonded abrasive.

[0423] Example 125. The abrasive particle set according to any one of Examples 87, 88, 89, 90, 91 and 92, further comprising a first group of abrasive particles, each of the abrasive particles in the first group being a first abrasive particle.

[0424] Example 126. The abrasive particle set according to Example 125 further includes a second group of abrasive particles, each of the abrasive particles in the second group being a second abrasive particle.

[0425] Example 127. The abrasive particle set according to Example 126, wherein, viewed from a plane defined by the length and width of the body, the two-dimensional shape of the body of the first abrasive particle is selected from a first group consisting of: regular polygons, irregular polygons, numbers, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having combinations of polygonal shapes, shapes having linear and curved portions, and combinations thereof.

[0426] Example 128. An abrasive particle assembly according to Example 126, wherein, viewed from a plane defined by the length and width of the body, the body of the first abrasive particle comprises a two-dimensional shape of an irregular polygonal shape.

[0427] Example 129. The abrasive particle set according to Example 126, wherein, viewed from a plane defined by the length and width of the body, the two-dimensional shape of the body of the second abrasive particle is selected from a first group consisting of: regular polygons, irregular polygons, numbers, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having combinations of polygonal shapes, shapes having linear and curved portions, and combinations thereof.

[0428] Example 130. An abrasive particle assembly according to Example 126, wherein, viewed from a plane defined by the length and width of the body, the body of the first abrasive particle comprises a two-dimensional shape of an irregular polygonal shape, and wherein, viewed from a plane defined by the length and width of the body, the body of the second abrasive particle comprises a two-dimensional shape, said two-dimensional shape being an irregular polygonal shape different from the irregular polygonal shape of the body of the first abrasive particle.

[0429] Example 131. An abrasive particle assembly according to Example 126, wherein the body of the first abrasive particle comprises a plurality of side surface portions and most of the side surface portions are substantially planar.

[0430] Example 132. The abrasive particle assembly according to Example 131, wherein all side surface portions of the body of the first abrasive particle are generally planar.

[0431] Example 133. An abrasive particle assembly according to Example 131, wherein the first side surface portion has a curved profile.

[0432] Example 134. An abrasive particle assembly according to Example 131, wherein the first side surface portion has an irregular profile.

[0433] Example 135. An abrasive particle assembly according to Example 131, wherein the body of the first abrasive particle comprises a plurality of side surface portions, and the extension length of each of the side surface portions is at least 5%, or at least 10%, or at least 15%, or at least 20%, or at least 25% of the body length.

[0434] Example 136. The abrasive particle set according to Example 131, wherein the extension length of each of the side surface portions of the body of the first abrasive particle is not greater than 50%, or not greater than 40%, or not greater than 30% of the body length.

[0435] Example 137. An abrasive particle assembly according to Example 126, further comprising a third abrasive particle, the third abrasive particle comprising a body comprising a first main surface, a second main surface opposite to the first main surface, and a side surface extending between the first main surface and the second main surface, wherein the body of the second abrasive particle comprises a two-dimensional shape different from the two-dimensional shape of the body of the first abrasive particle and the two-dimensional shape of the body of the second abrasive particle.

[0436] Example 138. An abrasive particle assembly according to any one of Examples 87, 88, 89, 90, 91, and 92, wherein the body includes a first side surface portion extending from at least a portion of the distance between two outer corners of the body, and further includes a first protrusion extending from the side surface portion of the first side surface portion for 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% of the total length of the first side surface portion.

[0437] Example 139. The abrasive particle assembly according to Example 138, wherein the first side surface portion is defined as a portion of the side surface extending between the two outer corners of the body.

[0438] Example 140. An abrasive particle assembly according to Example 138, wherein the first side surface portion is a portion of the total length of the side surface defining the perimeter of the body.

[0439] Example 141. An abrasive particle assembly according to Example 138, wherein a first protrusion extends to define a portion of the total length of the side surface of the perimeter of the body.

[0440] Example 142. An abrasive particle assembly according to Example 138, wherein, viewed from the plane of the first main surface, the first side surface portion and the first protrusion have substantially the same profile.

[0441] Example 143. An abrasive particle assembly according to Example 138, wherein the first protrusion intersects with a second side surface portion that is different from the first side surface portion.

[0442] Example 144. The abrasive particle assembly according to Example 138 further includes a first recess extending in a direction parallel to a first side surface portion of the side surface.

[0443] Example 145. The abrasive particle assembly according to Example 144 further includes a second recess extending in a direction parallel to the second side surface portion, and further includes a second protrusion disposed between the second side surface and the second recess, the second protrusion abutting against the second side surface portion and extending along the second side surface portion.

[0444] Example 146. The abrasive particle assembly according to Example 138 further includes a featureless edge extending between a first main surface and a third side surface portion, wherein the third side surface portion is different from the first side surface portion.

[0445] Example 147. An abrasive particle assembly according to Example 146, wherein the third side surface portion and the first side surface portion are separated from each other by at least one outer corner on the side surface.

[0446] Example 148. An abrasive particle assembly according to any one of Examples 87, 88, 89, 90, 91 and 92, wherein the body includes a bottom edge that joins a second main surface and a side surface, wherein at least a portion of the bottom edge has an irregular profile.

[0447] Example 149. An abrasive particle set according to any one of Examples 87, 88, 89, 90, 91 and 92, wherein the main body comprises at least one material from the group consisting of oxides, carbides, nitrides, borides, carbon oxides, nitrogen oxides, boron oxides, natural minerals, synthetic materials, carbon-based materials, and combinations thereof.

[0448] Example 150. An abrasive particle set according to any one of Examples 87, 88, 89, 90, 91 and 92, wherein it further comprises:

[0449] The first group of abrasive particles, each of the abrasive particles in the first group is the first abrasive particle; and

[0450] The second group of abrasive particles, each of the abrasive particles in the second group is a second abrasive particle; and

[0451] The body of the first abrasive particle comprises at least one material from the group consisting of oxides, carbides, nitrides, borides, carbon oxides, nitrogen oxides, boron oxides, natural minerals, synthetic materials, carbon-based materials, and combinations thereof.

[0452] Example 151. An abrasive particle set according to any one of Examples 149 and 150, wherein the main body comprises alumina.

[0453] Example 152. An abrasive particle assembly according to Example 151, wherein the main body is substantially composed of alumina.

[0454] Example 153. An abrasive particle set according to any one of Examples 87, 88, 89, 90, 91 and 92, wherein the main body comprises at least one oxide from the group consisting of: aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, magnesium oxide, rare earth oxides, or any combination thereof.

[0455] Example 154. The abrasive particle assembly according to Example 150, wherein the body of the second abrasive particle includes a generally planar side surface portion.

[0456] Example 155. The abrasive particle assembly according to Example 150, wherein the body of the second abrasive particle includes a plurality of side surface portions, and wherein most of the side surface portions are generally planar.

[0457] Example 156. The abrasive particle assembly according to Example 155, wherein all side surface portions of the body of the second abrasive particle are substantially planar.

[0458] Example 157. An abrasive particle assembly according to Example 155, wherein the body of the second abrasive particle includes a side surface portion having a curved profile.

[0459] Example 158. An abrasive particle assembly according to Example 155, wherein the body of the second abrasive particle includes a side surface portion having an irregular profile.

[0460] Example 159. An abrasive particle assembly according to Example 150, wherein the body of the first abrasive particle comprises a plurality of side surface portions, and the extension length of each of the side surface portions is at least 5%, or at least 10%, or at least 15%, or at least 20%, or at least 25% of the body length.

[0461] Example 160. The abrasive particle set according to Example 159, wherein the extension length of each of the side surface portions of the body of the first abrasive particle is no more than 80%, 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 body length.

[0462] Example 161. An abrasive particle assembly according to Example 150, wherein the first main surface of the body of the second abrasive particle includes a first protrusion that abuts against a portion of the first side surface and extends along the portion of the first side surface.

[0463] Example 162. The abrasive particle assembly according to Example 161, wherein the first main surface of the body of the second abrasive particle includes a first recess extending in a direction parallel to the first side surface portion.

[0464] Example 163. The abrasive particle assembly according to Example 161, wherein the first protrusion extends at least 30% of the total length of the first side surface portion, or at least 40% of the total length of the first side surface portion, or at least 50% of the total length of the first side surface portion, or at least 60% of the total length of the first side surface portion, or at least 70% of the total length of the first side surface portion, or at least 80% of the total length of the first side surface portion, or at least 90% of the total length of the first side surface portion.

[0465] Example 164. The abrasive particle assembly according to Example 161, wherein the first side surface portion is defined as a portion of the side surface extending between the two outer corners of the body.

[0466] Example 165. An abrasive particle assembly according to Example 161, wherein the first side surface portion is a portion of the total length of the side surface defining the perimeter of the body.

[0467] Example 166. An abrasive particle assembly according to Example 161, wherein the first protrusion extends to define a portion of the total length of the side surface of the perimeter of the body.

[0468] Example 167. An abrasive particle assembly according to Example 161, wherein, viewed from the plane of the first main surface, the first side surface portion and the first protrusion have substantially the same profile.

[0469] Example 168. An abrasive particle assembly according to Example 161, wherein the first protrusion intersects with a second side surface portion that is different from the first side surface portion.

[0470] Example 169. An abrasive particle set according to any one of Examples 87, 89, 90, 91 and 92, wherein most of the abrasive particles in the abrasive particle set include a plurality of microridges along at least a portion of the side surface of the body.

[0471] Example 170. An abrasive particle set according to any one of Examples 88 and 169, wherein at least 51% of the abrasive particles in the abrasive particle set, or at least 52%, or at least 54%, or at least 56%, or at least 58%, or at least 60%, or at least 62%, or at least 64%, or at least 66%, or at least 68%, or at least 70%, or at least 72%, or at least 74%, or at least 76%, or at least 78%, or at least 80%, or at least 82%, or at least 84%, or at least 86%, or at least 88%, or at least 90%, or at least 92%, or at least 94%, or at least 96%, or at least 98%, or at least 99% comprises a plurality of microridges.

[0472] Example 171. An abrasive particle set according to any one of Examples 88 and 169, wherein no more than 99% of the abrasive particles in the abrasive particle set, or no more than 98%, or no more than 96%, or no more than 94%, or no more than 92%, or no more than 90%, or no more than 88%, or no more than 86%, or no more than 84%, or no more than 82%, or no more than 80%, or no more than 78%, or no more than 76%, or no more than 74%, or no more than 72%, or no more than 70%, or no more than 68%, or no more than 66%, or no more than 64%, or no more than 62%, or no more than 60%, or no more than 58%, or no more than 56%, or no more than 54%, or no more than 52% comprises a plurality of microridges.

[0473] Example 172. An abrasive particle set according to any one of Examples 88 and 169, wherein a large portion of the total surface area of ​​the side surfaces of the abrasive particles in the abrasive particle set comprises multiple microridges.

[0474] Example 173. An abrasive particle assembly according to Example 172, wherein at least 51%, or at least 52%, or at least 54%, or at least 56%, or at least 58%, or at least 60%, or at least 62%, or at least 64%, or at least 66%, or at least 68%, or at least 70%, or at least 72%, or at least 74%, or at least 76%, or at least 78%, or at least 80%, or at least 82%, or at least 84%, or at least 86%, or at least 88%, or at least 90%, or at least 92%, or at least 94%, or at least 96%, or at least 98%, or at least 99% of the total surface area of ​​the side surfaces of the abrasive particles in the assembly contains a plurality of microridges.

[0475] Example 174. An abrasive particle set according to Example 172, wherein the total surface area of ​​the side surfaces of the abrasive particles in the set is not greater than 99%, or not greater than 98%, or not greater than 96%, or not greater than 94%, or not greater than 92%, or not greater than 90%, or not greater than 88%, or not greater than 86%, or not greater than 84%, or not greater than 82%, or not greater than 80%, or not greater than 78%, or not greater than 76%, or not greater than 74%, or not greater than 72%, or not greater than 70%, or not greater than 68%, or not greater than 66%, or not greater than 64%, or not greater than 62%, or not greater than 60%, or not greater than 58%, or not greater than 56%, or not greater than 54%, or not greater than 52%, and contains a plurality of microridges.

[0476] Example 175. An abrasive particle assembly according to any one of Examples 88 and 169, wherein at least a portion of the plurality of microridges comprises a plurality of separate microridges defined by microridges extending from the side surface and separated by generally smooth planes.

[0477] Example 176. An abrasive particle assembly according to Example 175, wherein multiple separated microridges extend along the side surface in an irregular path.

[0478] Example 177. An abrasive particle assembly according to Example 175, wherein at least one of the plurality of separated microridges includes a head region and a tail region connected to and extending from the head region, wherein the head region has a circular shape and the tail region has an elongated shape.

[0479] Example 178. An abrasive particle set according to any one of Examples 88 and 169, wherein at least a portion of the plurality of microridges comprises a plurality of scaly microridges.

[0480] Example 179. An abrasive particle assembly according to Example 178, wherein at least a portion of the scaly microridges of the plurality of scaly microridges includes an initial ridge and a plurality of folds extending from the initial ridge.

[0481] Example 180. An abrasive particle assembly according to Example 179, wherein the initial ridges extend along the side surface in an irregular path.

[0482] Example 181. An abrasive particle assembly according to Example 179, wherein at least a portion of a plurality of folds extends away from the initial ridge along an irregular path along the side surface.

[0483] Example 182. An abrasive particle assembly according to Example 179, wherein the folds define grooves extending along an irregular path along the side surface.

[0484] Example 183. An abrasive particle assembly according to Example 179, wherein the folds extend along a curved path.

[0485] Example 184. An abrasive particle assembly according to Example 179, wherein a plurality of scaly microridges contain a larger number of folds than the number of initial ridges.

[0486] Example 185. The abrasive particles according to Example 179, wherein the folds extend in a different direction than one or more initial ridges, and the folds extend between two or more initial ridges.

[0487] Example 186. An abrasive particle assembly according to Example 179, wherein the initial ridge comprises at least one gap between elongated portions.

[0488] Example 187. The abrasive particle assembly according to Example 178, wherein at least a portion of the scaly microridges has a scaly appearance.

[0489] Example 188. An abrasive particle assembly according to Example 178, wherein at least a portion of the scaly microridges has a layered appearance.

[0490] Example 189. An abrasive particle assembly according to Example 178, wherein at least a portion of the scaly microridges comprises a plurality of protrusions having an irregular shape and folds extending between the plurality of protrusions.

[0491] Example 190. An abrasive particle set according to any one of Examples 88 and 169, wherein multiple microridges are conchoidal fracture features.

[0492] Example 191. An abrasive particle assembly according to any one of Examples 88 and 169, wherein multiple microridges are formed during fracture of the side surfaces.

[0493] Example 192. An abrasive particle set according to any one of Examples 88 and 169, wherein a plurality of microridges comprise cliff regions.

[0494] Example 193. An abrasive particle set according to any one of Examples 87, 88, 89, 90, 91 and 92, wherein the side surface of the body includes side surface portions, and wherein each side surface portion extends between the outer corners of the body, and wherein at least 45% of the side surface portion includes a plurality of microridges.

[0495] Example 194. An abrasive particle assembly according to Example 193, wherein the main body comprises at least three side surface portions containing a plurality of microridges.

[0496] Example 195. An abrasive particle assembly according to Example 193, wherein all side surface portions contain multiple microridges.

[0497] Example 196. An abrasive particle set according to Example 193, wherein at least 52%, or at least 54%, or at least 56%, or at least 58%, or at least 60%, or at least 62%, or at least 64%, or at least 66%, or at least 68%, or at least 70%, or at least 72%, or at least 74%, or at least 76%, or at least 78%, or at least 80%, or at least 82%, or at least 84%, or at least 86%, or at least 88%, or at least 90%, or at least 92%, or at least 94%, or at least 96%, or at least 98%, or at least 99% of the side surface portion of the body contains a plurality of microridges.

[0498] Example 197. An abrasive particle assembly according to Example 193, wherein the body comprises at least one side surface portion without a plurality of microridges.

[0499] Example 198. An abrasive particle assembly according to Example 193, wherein at least 10% of the abrasive particles in the assembly have at least 45% of their side surface portions comprising a plurality of microridges.

[0500] Example 199. An abrasive particle assembly according to Example 193, wherein each of the abrasive particles in the assembly comprises at least 45% of a side surface portion containing a plurality of microridges.

[0501] Example

[0502] Various abrasive particles are prepared under the following conditions.

[0503] The first sample, sample S1, was initially formed from a mixture comprising approximately 37 to 43 wt% boehmite, water, and nitric acid. Commercially available boehmite, such as Disperal from Sasol, could be used. The nitric acid to boehmite ratio was approximately 0.035. The boehmite was mixed and seeded with 1% α-alumina seed crystals relative to the total alumina content of the mixture. The α-alumina seed crystals were prepared by milling alumina using conventional techniques, such as those described in US 4,623,364. The components were mixed in a conventionally designed planetary mixer and mixed under reduced pressure to remove gaseous elements (e.g., foam) from the mixture.

[0504] The mixture is then poured onto a conveyor belt using an extruder. The mixture forms a layer with a width of approximately 8 cm and a height of approximately 0.4 mm. The surface of the conveyor belt in contact with the mixture is Invar 36. The extrusion and layering of the mixture are carried out under standard environmental conditions of temperature, pressure, and atmosphere.

[0505] After the mixture is formed, various modifications are performed to produce different samples of abrasive particles. Specifically, the layers are shaped using various different forms with different characteristics.

[0506] Example 1

[0507] The mixture is formed as a layer as described above, and uses a molded part with a square opening, for example... Figures 13A to 13F and 3B The upper surface of the modified layer of the molded part is shown. Each square opening has four sides defining the opening, and each side is approximately 1.7 mm in length. The molded part is made of silicone and is pressed (manually) into the upper surface of the body on a conveyor belt. Sufficient force is applied to create lines in the upper surface of the body corresponding to the arrangement of features on the molded part.

[0508] The modified body is conveyed to a drying zone containing two 4000-watt IR lamps, which are mounted in parallel and side-by-side above the upper surface of the modified body. Each lamp is 40 inches long and 2.5 inches wide, and operates at 35% of its maximum power (i.e., 1400 watts). The drying temperature within the drying zone is set to 70°C, controlled by a thermocouple placed approximately 1 cm above the upper surface of the modified body. Air with approximately 50% (+15%) relative humidity flows into the drying zone at a flow rate of approximately 1.5 m / s. The drying zone is partially enclosed, with openings at opposite ends to allow airflow through the housing. The housing is 2 meters long, 0.5 meters high, and 0.5 meters wide.

[0509] Drying is performed under the conditions mentioned above to achieve controlled fracture of the substrate and formation of precursor abrasive particles. That is, after modifying the substrate using a molded part, the drying conditions are sufficient to cause the modified substrate to fracture in a manner that generates multiple precursor abrasive particles from the substrate. The nature of the pattern created by the molded part in the substrate influences the fracture behavior during the drying process to facilitate the formation of precursor abrasive particles.

[0510] Next, the dried abrasive particles were sintered for 10 minutes at a sintering temperature of approximately 1400°C in a rotary tube furnace under standard atmospheric pressure and air atmospheric pressure.

[0511] Figures 13G to 13L Provides a top-down image of the particles generated according to the method in Example 1. (Source: [Original Source Name]) Figures 13M to 13R The images include those acquired using a Nanovae microscope, where chromatic aberration represents height differences along the particle surface. Notably, some feature segments within the particles are not formed during the modification process, and signs of these features are present within these abrasive particles (e.g., Figure 15A Other particles exhibit characteristic fractures that occurred during the modification process (e.g., Figure 4CThese abrasive particles have a two-dimensional shape that substantially corresponds to the opening shape in the molded part used for patterning the body. These abrasive particles also have a size that substantially corresponds to the opening size in the molded part used for patterning the body (providing a certain degree of wear during calcination and sintering). Other abrasive particles (e.g., Figures 12A to 12J The image contains images of abrasive grains formed according to Example 1, where the grains exhibit fractures near features already formed in the body, but some traces of the features (e.g., protrusions or grooves) remain within the abrasive grain. Such features are typically located near the sidewalls of the abrasive grain. Furthermore, Figure 4G , 15B The features described and depicted in 16 and 17 represent abrasive particles made from Example 1.

[0512] Example 2

[0513] In addition to using, such as Figures 14A to 14J and 4D In addition to the modified body of the molded part depicted herein, abrasive particles are formed using the mixture-generating process mentioned above and the conditions provided in Example 1. The molded part is a 3D printed object. Sufficient force is used to press the molded part (manually) against the mixture on a conveyor belt to create a pattern in the upper surface of the body corresponding to features (e.g., recesses) of the feature pattern in the molded part. Figures 18 to 20 Image containing abrasive particles formed according to Example 2.

[0514] Example 3

[0515] In addition to using, such as Figure 23A and 4H In addition to the modified body of the molded part depicted herein, abrasive particles are formed using the process of generating the mixture as mentioned above and the conditions outlined in Example 1. The molded part is a 3D printed object. Sufficient force is used to press the molded part (manually) against the mixture on a conveyor belt to create a pattern in the upper surface of the body corresponding to features (e.g., recesses) of the feature pattern in the molded part. Figure 23B Image containing abrasive particles formed according to Example 3.

[0516] Example 4

[0517] The abrasive particles were formed using the process of Example 1, except that the mixture was patterned using a shaped part made of PEEK, and the shaped part was pressed against the surface of the mixture by a motor-driven roller. These abrasive particles of this sample form an assembly and are referred to herein as sample S4. Representative images of the abrasive particles from the assembly are provided. Figure 24AThe abrasive particle aggregate has a mean non-convexity factor (MAF) of approximately 3.80, an anisotropy factor standard deviation of approximately 1.14, a MAF difference between the first and second zones greater than 3, a mean non-convexity factor of 9.28, a non-convexity factor standard deviation of 3.54, a bulk average height of 228 micrometers, a height standard deviation of approximately 46 micrometers, a first zone average height of 68 micrometers, and a second zone average height of 172 micrometers.

[0518] Analysis was performed on other types of conventional abrasive particles to assess the differences between these particles and the representative particles of sample S4. The first conventional set of particles, sample CS1, was obtained and indicated as triangularly shaped abrasive particles of Cubitron II purchased from 3M. Figure 24B A top-down image containing abrasive particles from sample CS1. Figure 25A An image containing a portion of the side surface of an abrasive particle from sample CS1.

[0519] The second set of conventional particles, sample CS2, was obtained and represents conventional crushed abrasive particles. Figure 25B A top-down image of the particles containing sample CS2. Figure 25B Image of a portion of the side surface of an abrasive particle containing sample CS2. These particles were available as Cerpass 24Grit from Saint-Gobain.

[0520] Finally, the third set of conventional abrasive particles, sample CS3, was obtained and represents the particles cast into a layer of material to be cut later by a blade. ​ A top-down image of the particles containing sample CS3. ​ An image of a portion of the side surface of the abrasive particles in sample CS2.

[0521] The abrasive particles of sample CS1 have an MAF of approximately 0.64, an anisotropy factor standard deviation of approximately 0.49, an average nonconvexity factor of 3.32, a nonconvexity factor standard deviation of 0.73, and a bulk average height of 290 micrometers. Since the abrasive particles of sample CS1 are presumably shaped abrasive particles produced through a molding process, the sidewalls of the particles do not exhibit significantly different regions, such as a first region and a second region, as indicated by the representative abrasive particles of sample S4.

[0522] The abrasive particle ensemble of sample CS2 has an MAF of approximately 1.21, an anisotropy factor standard deviation of approximately 0.72, an average nonconvexity factor of 12.9, a nonconvexity factor standard deviation of 3.65, a bulk average height of 514 μm, and a height standard deviation of approximately 106 μm. Because the abrasive particles in sample CS2 are crushed abrasive particles, the particle sidewalls do not exhibit significantly different regions, such as a first and a second region, as indicated by representative abrasive particles from sample S4.

[0523] The abrasive particle set of sample CS3 has a mean nonconvexity factor (MAF) of 9.40 and a standard deviation of MAF of 2.33. The MAF was not measured, but given the values ​​provided in the image, most of the sidewall region will likely have a smaller MAF than the representative abrasive particles of sample S4. The same is expected for the standard deviation of the anisotropy factor. ​ As shown, the abrasive particles of sample CS3 generally have sidewalls comprising a first region 2502 and a second region 2503. The average height of the main body is approximately 289 micrometers, with a standard deviation of approximately 57 micrometers. The second region 2503 is significantly smaller in height compared to the first region 2502. The second region 2503 has an average height of 18 micrometers, while the first region 2502 has an average height of approximately 271 micrometers. The height of the second region 2503 is approximately 6% of the height of the main body 2501. The first region 2502 has a significantly smoother and lower textured surface compared to the second region 2503.

[0524] This application represents a departure from current state-of-the-art technology. While it is recognized in the industry that abrasive particles can be formed through processes such as molding and screen printing, the processes used in the embodiments herein differ from these processes. Notably, the embodiments herein utilize a combination of process features that facilitate the formation of abrasive particles with one or more unique characteristics. Such features may include, but are not limited to, the shape, size, features in one or more main surfaces, composition, etc., as described in the embodiments herein. Furthermore, the processes in the embodiments herein facilitate the formation of shaped abrasive particles or batches of abrasive particles having one or more characteristics, comprising one or more combinations of abrasive particle features. Certain abrasive particles and batches containing the abrasive particles of the embodiments herein may have features that achieve enhanced performance in the case of fixed abrasive articles.

[0525] The subject matter disclosed above should be considered illustrative rather than restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments that fall within the true scope of the invention. Therefore, to the fullest extent permitted by law, the scope of the invention is determined by the broadest permissible interpretation of the following claims and their equivalents, and should not be construed as limited by the foregoing embodiments.

[0526] This summary of the disclosure is provided to comply with patent law and should be understood not to be construed as limiting the scope or meaning of the claims. Additionally, in the foregoing embodiments, various features may be grouped together or described in a single embodiment for the purpose of simplification. This disclosure should not be construed as reflecting an intention that the claimed embodiments require more features than expressly recited in each claim. Rather, as reflected in the following claims, the subject matter of the invention may relate to fewer than all the features of any of the disclosed embodiments. Therefore, the appended claims are incorporated into the detailed description, wherein each claim, in itself, represents a separately defined subject matter.

Claims

1. An abrasive particle comprising: The body includes a first main surface, a second main surface opposite to the first main surface, and a side surface extending between the first main surface and the second main surface, wherein the side surface includes an average anisotropy factor of at least 1.

25.

2. The abrasive particles according to claim 1, wherein the average anisotropy factor is at least 1.30 and not greater than 20.

3. The abrasive particles according to claim 1, wherein the side surface comprises an anisotropy factor standard deviation of at least 0.75 and not greater than 10.

4. The abrasive particle of claim 1, wherein the side surface comprises a first region extending from the first main surface and a second region extending from the second main surface, wherein the first region and the second region abut on the side surface, and wherein the second region comprises an average anisotropy factor greater than that of the first region.

5. The abrasive particles of claim 4, wherein the second region extends by a greater percentage of height compared to the first region.

6. The abrasive particles according to claim 4, wherein the average height of the first region is not greater than 90% of the height of the body.

7. The abrasive particles according to claim 4, wherein the second region comprises an average height of not more than 90%, or not more than 80%, 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%, or not more than 20%, or not more than 10%, or not more than 5% of the height of the main body.

8. The abrasive particles according to claim 4, wherein the first region comprises an average anisotropy factor of not more than 1.

20.

9. The abrasive particles of claim 4, wherein the average anisotropy factor of the second region is at least 1.

30.

10. The abrasive particles according to claim 4, wherein the average anisotropy factor of the second region is not greater than 20, or not greater than 15, or not greater than 12, or not greater than 10, or not greater than 8, or not greater than 7, or not greater than 6, or not greater than 5, or not greater than 4.

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