Shaped abrasive particles and method of forming the same

Abstract

To provide composite shaped abrasive particles that may be used in various abrasive articles, including bonded abrasive articles, coated abrasive articles, and the like.SOLUTION: An abrasive particle includes a shaped abrasive particle 600 including a body 601. The body includes an upper major surface, a bottom major surface opposite to the upper major surface, and a side surface extending between the upper major surface and the bottom major surface. The body has a shape index of 0.5 or less. Each body has at least one surface with surface roughness greater than the surface roughness of another surface of the body.SELECTED DRAWING: Figure 6A

Description

Technical Field

[0001] The following relates to shaped abrasive particles, and more particularly, composite shaped abrasive particles having specific characteristics, and methods of forming such composite shaped abrasive particles.

Background Art

[0002] Abrasive articles incorporating abrasive particles are useful in a variety of material removal operations including grinding, finishing, polishing, etc. Depending on the type of abrasive material, such abrasive particles can be useful for shaping or grinding various materials in the manufacture of articles. Certain types of abrasive particles having specific geometries, such as triangular shaped abrasive particles and abrasive articles incorporating such objects, have been incorporated to date. See, for example, U.S. Pat. Nos. 5,201,916, 5,366,523, and 5,984,988.

[0003] Previously, abrasive particles having a specified shape were manufactured using three basic techniques: fusion, sintering, and chemical ceramics. In the fusion process, the abrasive particles can be formed by a chill roll, a mold into which the molten material is poured, or a heat sink material immersed in an aluminum oxide melt, whether or not the surface is engraved. See, for example, U.S. Pat. No. 3,3 77,660. In the sintering process, the abrasive particles can be formed from refractory powders having a particle size of up to 10 μm 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 plates or rods of various lengths and diameters. See, for example, U.S. Pat. No. 3,079,242. The chemical ceramic technique involves using a colloidal dispersion or hydrosol (sometimes referred to as a sol) to obtain a ceramic material. A process for converting a liquid phase (called a sol) into a gel or any other physical state that retains the mobility of the components. The process includes the steps of: 2 and 4,848,041. The method, as well as other relevant disclosures of abrasive articles incorporating such particles, can be found at http: / / www.abstract.com / articles / 201302311. Available at www.abel-ip.com / publications / .

[0004] Industry continues to demand improvements in abrasive materials and abrasive articles. Summary of the Invention

[0005] According to a first aspect, a method of forming an abrasive particle includes forming a mixture and applying a plurality of abrasive particles to the mixture. applying abrasive particles to at least one surface of the mixture; forming a shaped abrasive particle having a plurality of abrasive particles bonded to a surface thereof. .

[0006] In yet another aspect, the abrasive article comprises a bond material and a first layer of abrasive particles bonded to the bond material. a first aggregate, each particle in the first aggregate having a body and at least one of the bodies of the shaped abrasive particle and a plurality of abrasive particles bonded to a surface of the shaped abrasive particle.

[0007] In another aspect, the abrasive particles include shaped abrasive particles comprising a body and at least one of the bodies of the shaped abrasive particles. and a plurality of abrasive particles bonded to a surface thereof. [Brief description of the drawings]

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

[0009]

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DETAILED DESCRIPTION OF THE INVENTION

[0010] The following relates to shaped abrasive particles, and more particularly, to a method of forming composite shaped abrasive particles including shaped abrasive particles and a plurality of abrasive particles covering at least one surface of the body of the shaped abrasive particles. The abrasive particles of the embodiments herein can be used in various abrasive articles, including, for example, bonded abrasive articles, polishing cloth paper articles, etc. Alternatively, the shaped abrasive particle fraction of the embodiments herein can be utilized in free abrasive techniques including, for example, grinding slurries and / or polishing slurries. at least one surface of the shaped abrasive particles. The abrasive particles of the embodiments herein can be used in various abrasive articles, including, for example, bonded abrasive articles, polishing cloth paper articles, etc. Alternatively, the shaped abrasive particle fraction of the embodiments herein can be utilized in free abrasive techniques including, for example, grinding slurries and / or polishing slurries. This specification relates to a method of forming composite shaped abrasive particles including shaped abrasive particles and a plurality of abrasive particles covering at least one surface of the body of the shaped abrasive particles. The abrasive particles of the embodiments herein can be used in various abrasive articles, including, for example, bonded abrasive articles, polishing cloth paper articles, etc. Alternatively, the shaped abrasive particle fraction of the embodiments herein can be utilized in free abrasive techniques including, for example, grinding slurries and / or polishing slurries. variety of abrasive articles. Alternatively, the shaped abrasive particle fraction of the embodiments herein can be utilized in free abrasive techniques including, for example, grinding slurries and / or polishing slurries. For example, it can be used in free abrasive techniques including grinding slurries and / or polishing slurries.

[0011] The abrasive particles of the embodiments herein may be formed by, but are not limited to, printing, molding, pressing, Stamping, casting, extruding, cutting, crushing, heating, cooling, crystallizing, rolling, embossing Various processing methods including deposition, etching, scoring, drying, and combinations thereof. The particular method for forming the shaped abrasive particles may be by using a manufacturing tool (e.g., a slab). A sol-gel mixture is molded into an opening in a cleaning or mold and formed into precursor shaped abrasive particles. The screen printing method for forming shaped abrasive particles is generally known in the art. No. 8,753,558. Molded abrasive particles by conventional molding processes A suitable method for forming is described in US Pat. No. 5,201,916.

[0012] According to one particular embodiment, the process for forming the shaped abrasive particles is a screen printing process. FIG. 1A illustrates a composite shaped abrasive particle according to one non-limiting embodiment. 1 is a diagram of a system 150 for making composite shaped abrasive particles. The process can begin by forming a mixture 101 that includes a tetradecane material and a liquid. In particular, the mixture 101 may be a gel formed from a ceramic powder material and a liquid. In addition, the gel has the ability to substantially retain a given shape even in the green (i.e., unfired) state. According to one embodiment, the gel can be characterized as a shape-stable material having a high strength. may be formed from ceramic powder materials as a network of individual particles interconnected.

[0013] The mixture 101 has suitable rheological properties for use in the processes detailed herein. It can contain a specific content of solid materials, liquid materials, and additives. That is, in some cases the mixture can have a certain viscosity, and more specifically, rheological properties suitable for forming a shape-stable phase of the material formed by the method described herein can be formed. The dimensionally stable phase of the material can be formed to have a specific shape and is a material that can substantially maintain the shape for at least part of the post-forming processing. In some cases the shape can be maintained through subsequent processing such that the shape initially provided in the forming process is present in the finally formed object.

[0014] Mixture 101 can be formed to have a specific content of solid materials such as ceramic powder materials. For example, in one embodiment, mixture 101 can have a solid content of at least about 25 wt% based on the total weight of mixture 101, and can be, for example, at least about 3 5 wt%, or even at least about 38 wt%. Further, in at least one non-limiting embodiment, the solid content of mixture 101 is about 75 wt% or less, such as about 7 0 wt% or less, about 65 wt% or less, about 55 wt% or less, about 45 wt% or less, or about 42 wt% or less. It will be understood that the content of the solid material in mixture 101 is within the range between any of the above minimum percentages and maximum percentages.

[0015] According to one embodiment, the ceramic powder material can include oxides, nitrides, carbides, borides, oxycarbides, oxynitrides, and combinations thereof. In a specific example, the ceramic material can include alumina. More specifically, the ceramic material is a precursor of α-alumina It may include a boehmite material that can do something. The term "boehmite" generally in this specification is typically Al2O3·H2O and has a water content of about 15% Mineral boehmite having, and pseudo-boehmite having a water content higher than 15% by weight, for example, 20 to 38% by weight Is used to indicate an alumina hydrate containing. (Including pseudo-boehmite Note that) Boehmite has a specific and identifiable crystal structure and thus has a unique X-ray diffraction pattern Turn. As such, boehmite is distinguished from ATH (aluminum trihydroxide), a common precursor used in this specification for the production of other aluminous substances, such as other alumina-containing substances containing hydrated alumina, for example, boehmite particulate material In this specification Is.

[0016] Furthermore, the mixture 101 can be formed to have a specific content of liquid material. Some Suitable liquids may include water. In a more specific example, the mixture 101 can have a liquid content of at least about 25% by weight based on the total weight of the mixture 101 In other examples, the amount of liquid in the mixture 101 is more, for example, at least about 35% by weight, at least At least about 45% by weight, at least about 50% by weight, or even at least about 58% by weight Can be. Furthermore, in at least one non-limiting embodiment, the liquid content of the mixture can be about 75% by weight Or less, for example, about 70% by weight or less, about 65% by weight or less, about 62% by weight or less Or even about 60% by weight or less. It will be understood that the content of the liquid in the mixture 101 is within the range between any of the above Minimum percentage and maximum percentage.

[0017] Furthermore, in order to easily process and form the shaped abrasive particles according to the embodiments of this specification, mixing​​ The article 101 may have a specific storage modulus. For example, the mixture 101 may have a storage modulus of at least about 1×1 0 4 Pa, and for example, at least about 4×10 4 Pa, or even at least about 5×10 Pa. However, in at least one non-limiting embodiment 4 , the mixture 101 may have a storage modulus of about 1×10 Pa or less, for example, about 2×10 7 Pa or less. It will be understood that the storage modulus of the mixture 101 is within the range between any of the above minimum and maximum values 6 . The storage modulus can be measured via a parallel plate system using an ARES or AR- G2 rotational rheometer equipped with a Peltier plate temperature control system. For the test

[0018] , the mixture 101 can be extruded into the gap between two plates placed approximately 8 mm apart from each other . After extruding the gel into the gap, the distance between the two plates defining the gap is reduced to 2 mm until the mixture 101 completely fills the gap between the plates . After wiping off the excess mixture , the gap is reduced by 0.1 mm and the test is started. This test is performed using 25 mm parallel flat plates, recording 10 points per decade, at 6.28 rad / s (1 Hz), and is an oscillatory strain sweep test performed with the device set in the strain range of 0.01% to 100% . Within one hour after the test is completed, the gap is lowered by 0.1 mm again and the test is repeated . The test can be repeated at least 6 times. The first test may be different from the second and third tests . Only the results from each test piece of the second and third tests should be reported .

[0019] ​Furthermore, to facilitate the processing and formation of the shaped abrasive particles according to the embodiments of the present specification, a mixture 101 may have a specific viscosity. For example, the mixture 101 may have a viscosity of at least about 4×10 3 P a·s, at least about 5×10 3 Pa·s, at least about 6×10 3 Pa·s, at least also about 8×10 3 Pa·s, at least about 10×10 3 Pa·s, at least about 20×10 3 Pa·s, at least about 30×10 3 Pa·s, at least about 40×10 3 Pa·s, at least about 50×10 3 Pa·s, at least about 60×10 3 Pa·s, or at least also about 65×10 3 Pa·s. In one non-limiting embodiment, the mixture 1 01 can have a viscosity of about 100×10 3 Pa·s or less, for example, about 95×10 3 Pa·s or less, about 90×10 3 Pa·s or less, or even about 85x10 3 Pa·s or less. It will be understood that the viscosity of the mixture 101 is within the range between any of the above minimum and maximum values. The viscosity can be measured in the same manner as the storage modulus described above.

[0020] Furthermore, the mixture 101 may be formed to have a specific content of an organic material, for example, an organic additive different from a liquid, in order to facilitate the processing and formation of the shaped abrasive particles according to the embodiments of the present specification. Some suitable organic additives may include binders such as stabilizers, fructose, sucrose, lactose, glucose, UV curable resins, and the like.

[0021] In particular, the embodiments of this specification may utilize a mixture 101 that can be different from the slurries used in conventional forming operations. For example, the content of the organic material in the mixture 101, particularly any of the above organic additives, may be a small amount compared to other components in the mixture 101. In at least one embodiment, the mixture 101 may be formed to have an organic material of about 30 wt% or less based on the total weight of the mixture 101. In other examples, the amount of the organic material may be even less, for example, about 15 wt% or less, about 10 wt% or less, or even about 5 wt% or less. Further, in at least one non-limiting embodiment, the amount of the organic material in the mixture 101 may be at least about 0.01 wt%, for example, at least about 0.5 wt% based on the total weight of the mixture 101. It will be understood that the amount of the organic material in the mixture 101 is within the range between any of the above minimum values and maximum values. Moreover, the mixture 101 may be formed to have a specific content of an acid or a base different from the liquid content in order to facilitate the processing and formation of the shaped abrasive particles according to the embodiments of this specification. Some suitable acids or bases may include nitric acid, sulfuric acid, citric acid, chloric acid, tartaric acid, phosphoric acid, ammonium nitrate, and ammonium citrate. According to a specific embodiment where a nitric acid additive is used, the mixture 101 may have a pH of less than about 5, and more specifically, may have a pH within the range of about 2 to about 4. The system 150 of FIG. 1A may include a mold 103. As illustrated, the mixture 101 is supplied into the interior of the mold 103 and extruded through a mold opening 105 disposed at one end of the mold 103.

[0022]

[0023] ​​​​​​​​​​​​​​​It can be configured to be. Further, by way of example, the extrusion process applies a force (such as pressure) 180 to the mixture 101 to easily extrude the mixture 101 through the mold opening 105 The process may include. During extrusion within the coating zone 183, the manufacturing tool or manufacturing tool 15 1 can be in direct contact with a part of the belt 109. The screen printing process may include the step of extruding the mixture 101 from the mold 103 through the mold opening 105 in the direction 191 . In particular, the screen printing process can extrude the mixture 101 into the opening 152 of the manufacturing tool 151 when extruding the mixture 101 through the mold opening 105 So that the manufacturing tool 151 can be utilized.

[0024] According to one embodiment, a specific pressure can be utilized during extrusion. For example, the pressure Can be at least about 10 kPa, for example at least about 500 kPa. Further , In at least one non-limiting embodiment, the pressure utilized during extrusion can be about 4 MPa or less. It will be understood that the pressure used to extrude the mixture 101 is within the range between any of the above Minimum and maximum values. In a specific example The consistency of the pressure delivered by the piston 199 can easily process and Form. In particular, by applying a controlled pressure consistently across the entire mixture 101 and across the width of the mold 103 Improved process control and improved dimensional characteristics of the shaped abrasive particles can be promoted.

[0025] Briefly referring to FIG. 1B, a part of the manufacturing tool (e.g., screen) 151 is illustrated As shown, the manufacturing tool 151 has an opening 152, more specifically, The manufacturing tool 151 may include a number of openings 152 extending through its thickness. According to the method, the opening 152 has a planar dimension defined by the length (L) and width (W) of the screen. When viewed from the surface, it can have a two-dimensional shape. The two-dimensional shape can be various shapes, such as , polygons, ovals, numbers, Greek letters, Latin alphabet letters, Russian Alphabet letters Examples of shapes include complex shapes including combinations of alphabets, polygons, and combinations of these. In specific examples, the openings 152 may be triangular, rectangular, quadrilateral, pentagonal, hexagonal, or It has two-dimensional polygons such as pentagons, heptagons, octagons, nonagons, decagons, and combinations of these. It is possible.

[0026] As further illustrated, the manufacturing tool 151 may have apertures oriented in a particular manner relative to each other. As illustrated, according to one embodiment, each opening 152 may have a , are substantially the same orientation relative to each other and are substantially the same relative to the surface of the manufacturing tool 151. For example, each of the openings 152 may be aligned along a transverse axis 152 of the manufacturing tool 151. 8 defines a first plane 155 of a first row 156 of openings 152 extending laterally across The manufacturing tool 151 may have a first end 154 that is aligned with a longitudinal axis of the manufacturing tool 151. 157. However, in other examples, the opening It will be appreciated that the mouths 152 do not necessarily have to be oriented in the same direction relative to one another.

[0027] Additionally, the first row 156 of openings 152 allows the shaped abrasive particles to be easily and specifically processed and controlled. For a given formation, it can be oriented with respect to the direction of movement. For example, the first plane 155 of the first column 156 defines an angle with respect to the direction of movement 171, and the opening 152 can be placed on the manufacturing tool 151. As illustrated, the first plane 155 can define an angle that is substantially orthogonal to the direction of movement 171. Further, in one embodiment, it will be understood that the first plane 155 of the first column 156 can be placed on the manufacturing tool 151 such that it defines a different angle with respect to the direction of movement, for example, an acute or obtuse angle. Further, it will also be understood that the openings 152 need not necessarily be arranged in a columnar fashion. The openings 152 can be arranged on the manufacturing tool 151 in various specific regular distributions relative to each other, such as in the form of a two-dimensional pattern. Also, the openings can be randomly arranged on the manufacturing tool 151. For example, the first plane 155 of the first column 156 defines an angle with respect to the direction of movement 171, and the opening 152 can be placed on the manufacturing tool 151. As illustrated, the first plane 155 can define an angle that is substantially orthogonal to the direction of movement 171. Further, in one embodiment, it will be understood that the first plane 155 of the first column 156 can be placed on the manufacturing tool 151 such that it defines a different angle with respect to the direction of movement, for example, an acute or obtuse angle. Further, in one embodiment, it will be understood that the first plane 155 of the first column 156 can be placed on the manufacturing tool 151 such that it defines a different angle with respect to the direction of movement, for example, an acute or obtuse angle. Further, it will also be understood that the openings 152 need not necessarily be arranged in a columnar fashion. The openings 152 can be arranged on the manufacturing tool 151 in various specific regular distributions relative to each other, such as in the form of a two-dimensional pattern. Also, the openings can be randomly arranged on the manufacturing tool 151. Referring back to FIG. 1A, after extruding a portion of the mixture 101 through the mold opening 105 and through the opening 152 of the manufacturing tool 151, one or more precursor formed abrasive particles 123 can be printed onto the belt 109 placed under the manufacturing tool 151. According to a particular embodiment, the precursor formed abrasive particles 123 can have a shape generally determined by the shape and forming process of the opening 152. In particular, the mixture 101 can be passed quickly through the manufacturing tool 151 such that the average residence time of the mixture 101 within the opening 152 is less than about 2 minutes, and can even be less than about 1 minute, less than about 40 seconds, or less than about 20 seconds. In a specific non-limiting embodiment, since the mixture 101 moves through the screen opening 152, it does not substantially change during printing, and as a result, there is no change in the amount of components from the original mixture. Referring back to FIG. 1A, after extruding a portion of the mixture 101 through the mold opening 105 and through the opening 152 of the manufacturing tool 151, one or more precursor formed abrasive particles 123 can be printed onto the belt 109 placed under the manufacturing tool 151. According to a particular embodiment, the precursor formed abrasive particles 123 can have a shape generally determined by the shape and forming process of the opening 152.

[0028] Referring back to FIG. 1A, after extruding a portion of the mixture 101 through the mold opening 105 and through the opening 152 of the manufacturing tool 151, one or more precursor formed abrasive particles 123 can be printed onto the belt 109 placed under the manufacturing tool 151. According to a particular embodiment, the precursor formed abrasive particles 123 can have a shape generally determined by the shape and forming process of the opening 152. In particular, the mixture 101 can be passed quickly through the manufacturing tool 151 such that the average residence time of the mixture 101 within the opening 152 is less than about 2 minutes, and can even be less than about 1 minute, less than about 40 seconds, or less than about 20 seconds. In a specific non-limiting embodiment, since the mixture 101 moves through the screen opening 152, it does not substantially change during printing, and as a result, there is no change in the amount of components from the original mixture. In particular, the mixture 101 can be passed quickly through the manufacturing tool 151 such that the average residence time of the mixture 101 within the opening 152 is less than about 2 minutes, and can even be less than about 1 minute, less than about 40 seconds, or less than about 20 seconds. In a specific non-limiting embodiment, since the mixture 101 moves through the screen opening 152, it does not substantially change during printing, and as a result, there is no change in the amount of components from the original mixture. In a specific non-limiting embodiment, since the mixture 101 moves through the screen opening 152, it does not substantially change during printing, and as a result, there is no change in the amount of components from the original mixture. In a specific non-limiting embodiment, since the mixture 101 moves through the screen opening 152, it does not substantially change during printing, and as a result, there is no change in the amount of components from the original mixture. In a specific non-limiting embodiment, since the mixture 101 moves through the screen opening 152, it does not substantially change during printing, and as a result, there is no change in the amount of components from the original mixture. nor can it be subjected to enough drying to be recognizable within the opening 152 of the manufacturing tool 151. Further in other examples, the mixture 101 can be subjected to some drying at the opening 152, easily released from the opening 152, and can easily form a specific shaped form of the shaped abrasive grains.

[0029] Furthermore, the system 151 can include a bottom stage 198 within the application zone 183. During the process of forming the shaped abrasive grains, the belt 109 can move over the bottom stage 198 that can provide a substrate suitable for forming the mixture 101.

[0030] During operation of the system 150, the manufacturing tool 151 is moved in the direction 153, and the belt 109 is moved in a direction 110 that is substantially the same as the direction 153, at least within the application zone 183, to continuously and easily perform a printing operation. Thus, the precursor shaped abrasive grains 123 are printed on the belt 109 and moved along the belt 109 to undergo further processing. Such further processing can include, for example, shaping, application of other materials (such as a plurality of abrasive grains), drying, sintering, etc., and can include the processes described in the embodiments of this specification.

[0031] In some embodiments, the belt 109 and / or the manufacturing tool 151 can be moved while extruding the mixture 101 through the die opening 105. As shown in the system 100, the mixture 101 can be extruded in the direction 191. The moving direction 110 of the belt 109 and / or the manufacturing tool 151 is at an angle with respect to the extrusion direction 191 of the mixture 101. can be attached. The angle between the moving direction 110 and the extrusion direction 191 is illustrated to be substantially orthogonal in the system 100, but other angles, for example, including acute or obtuse angles, are conceivable.

[0032] To facilitate processing, the belt 109 and / or the manufacturing tool 151 can be moved at a specific speed. For example, the belt 109 and / or the manufacturing tool 151 can be moved at a speed of at least about 3 cm / second. In other embodiments, the moving speed of the belt 109 and / or the manufacturing tool 151 can be faster, for example, at least about 4 c m / second, at least about 6 cm / second, at least about 8 cm / second, or even at least about 10 cm / second. Further, in at least one non-limiting embodiment, the belt 109 and / or the manufacturing tool 151 can be moved in the direction 110 at a speed of about 5 m / second or less, and can even be about 1 m / second or less, or about 0.5 m / second or less. The belt 109 and / or the manufacturing tool 151 can be moved at a speed within the range between any of the above minimum and maximum values, and it will be understood that they can also be moved at substantially the same speed as each other. Furthermore, in a specific process according to the embodiments herein, the moving speed of the belt 109 is controlled compared to the extrusion speed of the mixture 101 in the direction 191, and appropriate processing can be easily performed.

[0033] After the mixture 101 is extruded through the mold opening 105, the mixture 101 can be moved along the belt 109 under the knife edge 107 attached to the surface of the mold 103. The knife edge 107 can define a region in front of the mold 103 that facilitates the movement of the mixture 101 into the opening 152 of the manufacturing tool 151. ​​​​

[0034] Certain processing parameters can be controlled to produce the precursor shaped abrasive particles 123 and ultimately the The specific shape of the subsequently formed shaped abrasive particles can be easily formed. Some exemplary process parameters include the release distance 197, the viscosity of the mixture, the temperature of the mixture, and the like. storage modulus of the lower stage, mechanical properties of the lower stage, geometric or dimensional properties of the lower stage, thickness of the manufacturing tool, manufacturing tool stiffness, solids content of the mixture, carrier content of the mixture, release angle, travel speed, temperature , release agent content, pressure applied to the mixture, belt speed, drying speed, drying time, drying temperature and combinations thereof.

[0035] According to one embodiment, one particular process parameter is the time between the fill position and the release position. In particular, the release distance 197 can include controlling the release distance 197 of the end of the mold 103. and the movement of the belt 109 between the initial point of separation between the manufacturing tool 151 and the belt 109. It may be the distance measured along the direction 110.

[0036] After the mixture 101 is extruded into the opening 152 of the manufacturing tool 151, the belt 109 and 185 to move the belt 109 and the manufacturing tool 151 to the release zone 185. 1 can be easily separated to form precursor shaped abrasive particles 123. 1, the manufacturing tool 151 and belt 109 are then rotated within the release zone 185 at a particular release angle. can be separated from each other.

[0037] The precursor shaped abrasive particles 123 are then placed in a series of optional tubes on which various treatment processes may be performed. Some suitable exemplary treatment processes include: Then, drying, heating, curing, reacting, irradiating, mixing, stirring, flattening, calcining, sintering, powder crushing, sieving, doping, impregnating, humidifying, applying another abrasive particle to the body of the precursor formed abrasive particle and combinations thereof can be mentioned. According to one embodiment, the precursor formed abrasive particles 123 can be moved through the shaping zone 113 as necessary, and at least one outer surface of the particles can be shaped as described in the embodiments of this specification. Furthermore, the precursor formed abrasive particles 123 can be moved through the application zone 131 as necessary, and as described in the embodiments of this specification, a dopant material and / or a plurality of abrasive particles and other materials can be applied to at least one outer surface of the precursor formed abrasive particles 123. It can be done.

[0038] After forming the precursor formed abrasive particles 123, the particles can be moved through any post-forming zone 125. Various processes including the treatment of the precursor formed abrasive particles 123 can be carried out in the post-forming zone 125. In one embodiment, the post-forming zone 125 can include a heating process that can dry the precursor formed abrasive particles 123. The drying process can include removing specific contents of substances containing volatile substances such as water. According to one embodiment, the drying process can be carried out at a drying temperature of about 300 °C or lower, for example, about 280 °C or lower, or even about 250 °C or lower. Furthermore, in one non-limiting embodiment, the drying process can be carried out at a drying temperature of at least about 50 °C. It will be understood that the drying temperature is within the range between any of the above-mentioned minimum and maximum temperatures. Furthermore, the precursor formed abrasive particles 123 can be at a specific speed, for example, at least about 0.2 feet / minute, and about 8 feet / minute, etc. It can be moved through the post-formation zone 125 at a speed of less than / minute.

[0039] Furthermore, the drying process can be carried out for a specific time. For example, the drying process can be for about 6 hours or less and, for example, can even be about 5 hours or less, about 4 hours or less, about 2 hours or less, or about 1 hour or less. Furthermore, the drying process can be at least about 1 minute, for example at least about 15 minutes or at least about 30 minutes. It will be understood that the drying time is within the range between any of the above minimum and maximum temperatures. For example, in at least one embodiment, the precursor-formed abrasive particles can be dried for 1 to 10 minutes and can be easily and intentionally crushed along a predetermined stress concentration point and a predetermined stress concentration vector. After moving the precursor-formed abrasive particles 123 through the post-formation zone 125, the precursor-formed abrasive particles 123 can be removed from the belt 109. For further processing, the precursor-formed abrasive particles 123 can be collected in the bin 127.

[0040] According to one embodiment, the process of forming the shaped abrasive particles can further include a sintering process. In a specific process of the embodiments herein, sintering can be carried out after collecting the precursor-formed abrasive particles 123 from the belt 109. Alternatively, sintering can be a process carried out while the precursor-formed abrasive particles 123 are on the belt 109. Sintering of the precursor-formed abrasive particles 123 can generally be utilized to densify the particles in the green state.

[0041] In a specific example, the sintering process can easily form a high-temperature phase of the ceramic material. For example in one embodiment, the high-temperature phase of alumina such as α-alumina is formed so that the precursor is sintered after being collected from the belt 109. Alternatively, sintering can be a process carried out while the precursor-formed abrasive particles 123 are on the belt 109. Sintering of the precursor-formed abrasive particles 123 can generally be utilized to densify the particles in the green state. Sintering of the precursor-formed abrasive particles 123 can generally be utilized to densify the particles in the green state. In a specific example, the sintering process can easily form a high-temperature phase of the ceramic material. For example in one embodiment, the high-temperature phase of alumina such as α-alumina is formed so that the precursor The shaped abrasive particles 123 can be sintered. In one example, the shaped abrasive particles can include at least about 90 wt% α-alumina based on the total weight of the particles. In other examples, the α-alumina content can be higher such that the shaped abrasive particles consist essentially of α-alumina. In some cases, another post-formation process can include applying moisture to one or more surfaces of the gel mixture while the gel mixture is present in the opening 152, or

[0042] after the formation of the precursor shaped abrasive particles 123 (i.e., after the mixture is removed from the opening of the manufacturing tool). The application of moisture, referred to as humidification, can be done to facilitate the application of a plurality of particles to one or more surfaces of the mixture 101 and / or the precursor shaped abrasive particles 123. In at least one embodiment, the application of moisture can include depositing moisture onto one or more surfaces of the mixture and / or onto the precursor shaped abrasive particles 123 while the mixture is present in the opening 152 of the manufacturing tool 151. In another example, the step of applying moisture can include wetting at least one surface of the mixture 101 and / or the precursor shaped abrasive particles 123 for a sufficient time to change the viscosity of an outer region of at least one surface compared to the viscosity in an inner region spaced from the outer region. Further, it should be noted that the application of moisture promotes gelation and makes the surfaces of the mixture 101 and / or the precursor shaped abrasive particles 123 more readily bondable to a plurality of abrasive particles. According to one embodiment, a plurality of abrasive particles can be applied to the surfaces of the mixture 101 and / or the precursor shaped abrasive particles 123, and the water on the surface promotes gelation of the material of the abrasive particles, and the wetted surfaces promote improved bonding. References herein to a plurality of abrasive particles include green or unsintered abrasive particles, sintered abrasive particles, or a combination thereof. It should be noted that the application of moisture can include depositing moisture onto one or more surfaces of the mixture and / or onto the precursor shaped abrasive particles 123 while the mixture is present in the opening of the manufacturing tool. In another example, the step of applying moisture can include wetting at least one surface of the mixture and / or the precursor shaped abrasive particles for a sufficient time to change the viscosity of an outer region of at least one surface compared to the viscosity in an inner region spaced from the outer region. Further, the application of moisture promotes gelation and makes the surfaces of the mixture and / or the precursor shaped abrasive particles more readily bondable to a plurality of abrasive particles. According to one embodiment, a plurality of abrasive particles can be applied to the surfaces of the mixture and / or the precursor shaped abrasive particles, and the water on the surface promotes gelation of the material of the abrasive particles, and the wetted surfaces promote improved bonding. References herein to a plurality of abrasive particles include green or unsintered abrasive particles, sintered abrasive particles, or a combination thereof. Referring to various types of particles including, but not limited to, abrasive particles and the like.

[0043] The application of moisture can be selective such that it is applied to at least one surface of the mixture 101 and / or the precursor shaped abrasive particles 123, but it is not necessarily required that another surface of the mixture 101 and / or the precursor shaped abrasive particles 123 be coated. In one embodiment, the application of moisture can be accomplished by deposition of moisture, for example, by spraying moisture onto one or more surfaces of the mixture 101 and / or the precursor shaped abrasive particles 123. In one embodiment, the application of moisture can include moving the mixture and / or the precursor shaped abrasive particles 123 through an environment having a specific moisture content. The humidity and temperature within the environment, and the rate at which the mixture 101 and / or the precursor shaped abrasive particles 123 are moved through the environment can be controlled to produce a specific amount of moisture on at least one surface of the mixture 101 and / or the precursor shaped abrasive particles 123. For example, the step of applying moisture to at least one surface of the mixture 101 and / or the precursor shaped abrasive particles 123 can include directing a gas towards one

[0044] or more surfaces of the mixture 101 and / or the precursor shaped abrasive particles 123. In a more specific example, the process of applying moisture can include directing water vapor and / or steam towards at least one surface of the mixture 101 and / or the It may contact one or more surfaces of the object 101 and / or the precursor shaped abrasive particles 123.

[0045] Furthermore, in another embodiment, another post-formation process is to change the viscosity of the mixture 101 and / or the precursor shaped abrasive particles 123 to facilitate the attachment of a plurality of abrasive particles to at least one surface. The step of changing the viscosity of the mixture includes depositing a second material on the surface of the mixture 101 and / or the precursor shaped abrasive particles 123, or using a process to change the viscosity of the mixture 101 and / or the precursor shaped abrasive particles 123 in an external region. For example, in some cases, changing the viscosity may include applying an adhesive material such as an organic or inorganic adhesive material. By selectively depositing one or more of such materials on one or more surfaces of the mixture 101 and / or the precursor shaped abrasive particles 123, a plurality of abrasive particles can be easily applied to the surface.

[0046] In another embodiment, changing the viscosity can include applying one or more viscosity modifiers to increase or decrease the viscosity of the external region of the mixture 101 and / or the precursor shaped abrasive particles 123 compared to the internal region of the mixture 101 and / or the precursor shaped abrasive particles 123 that are spaced apart from the outer region and not treated with a viscosity modifier. Such a change in viscosity may be suitable for the attachment of a plurality of abrasive particles.

[0047] According to one embodiment, the process of forming abrasive particles includes forming the mixture 101 and / or the precursor shaped abrasive particles 123, and attaching a plurality of abrasive particles to at least one surface of the mixture 101 and / or at least one surface of the body of the precursor shaped abrasive particles 123. It includes. In some cases, the adhesion process is performed in the application zone 131, and one or more coating heads 132 can promote the deposition of a plurality of abrasive particles on the main outer surface (e.g., the upper surface) of the precursor shaped abrasive particles 123. Various suitable processes for attaching a plurality of abrasive particles include deposition processes such as blasting, spraying, pressing, gravity coating, forming, stamping, and combinations thereof, etc. Further, it will be understood that the coating can be performed while the mixture 101 is present within the manufacturing tool 151.

[0048] According to one embodiment, the process of attaching a plurality of abrasive particles includes forcibly spraying a plurality of abrasive particle mixtures 101 and / or onto at least one surface of the precursor shaped abrasive particles 123. The reference in this specification to attaching a plurality of abrasive particles to at least one surface may include the step of attaching a plurality of abrasive particles to the surface of the mixture 101 while the mixture is held in a manufacturing tool 151 (e.g., a mold or a screen), or after the mixture 101 is removed from the manufacturing tool 151 and the precursor shaped abrasive particles 12 3 are formed. It will be understood that part or all of the mixture 101 and / or the precursor shaped abrasive particles 123 can have a plurality of abrasive particles attached thereto. In at least one embodiment, the step of forcibly spraying a plurality of abrasive particles onto the mixture 101 or the precursor shaped abrasive particles 123 includes applying a controlled force to a deposition material containing a carrier and a plurality of abrasive particles, and embedding at least a part of the plurality of abrasive particles into the surface of the mixture 101 or the precursor shaped abrasive particles 123. For example, the deposition material can include a carrier that may be a gas. Suitable gaseous materials include applying a controlled force to a deposition material containing a carrier and a plurality of abrasive particles, and embedding at least a part of the plurality of abrasive particles into the surface of the mixture 101 or the precursor shaped abrasive particles 123. For example, the deposition material can include a carrier that may be a gas. Suitable gaseous materials can include a carrier that may be a gas. Suitable gaseous materials may include water vapor, steam, an inert gas, air, or a combination thereof.

[0049] In at least one embodiment, humidification of one or more surfaces of the mixture 101 and / or the precursor shaped abrasive particles 123 and deposition of the abrasive particles may be performed separately, and more specifically the humidification process may be performed prior to the deposition process. In yet another embodiment, the humidification process and the deposition process are performed simultaneously as a mixture of water vapor and / or steam, and the plurality of abrasive particles are directed to at least one surface of the mixture 101 and / or the precursor shaped abrasive particles 123.

[0050] The force or pressure used to spray the carrier gas and the plurality of abrasive particles is adjusted so that the abrasive particles can be properly adhered to the surface of the mixture 101 and / or the precursor shaped abrasive particles 123. In particular, the force or pressure is not limited, but the viscosity of the surface of the mixture 101 and / or the precursor shaped abrasive particles 123, the median particle size of the plurality of abrasive particles, the content (weight or volume) of the plurality of abrasive particles sprayed per unit time, the humidity of the environment during spraying, the temperature during spraying the moving speed of the manufacturing tool or gel, the desired coating rate level by the plurality of abrasive particles, or a combination thereof, and may be configured based on one or more process parameters.

[0051] In at least one embodiment, the process of attaching the plurality of abrasive particles to the body of the precursor shaped abrasive particles can be performed before substantially drying the body. In particular, in some cases some moisture in the precursor shaped abrasive particles can allow the plurality of abrasive particles to adhere properly. According to one embodiment, the moisture content of the precursor shaped abrasive particles during attachment (i.e., the weight percentage of the liquid) When the mixture 101 is disposed in the manufacturing tool 151, the adhesion process can occur such that the moisture content of the mixture 101 has a difference of about 70% or less. The percentage difference can be calculated according to the formula [(Mc1 - Mc2) / Mc1]×100%. In the formula, Mc1 is the moisture content of the mixture 101 while it is disposed in the manufacturing tool 151, and Mc2 is the moisture content of the precursor formed abrasive particles during adhesion. In other examples, the moisture content of the precursor formed abrasive particles during adhesion can have a difference of about 60% or less, for example, about 50% or less, about 40% or less, about 30% or less, about 20% or less, or about 10% or less, from the moisture content of the mixture 101 when the mixture 101 is disposed in the manufacturing tool 151. Further, in at least one non-limiting embodiment, the moisture content of the precursor formed abrasive particles during adhesion can be substantially the same as, or exactly the same as, the moisture content when the mixture 101 is disposed in the manufacturing tool 151. In at least one embodiment, the process of attaching a plurality of abrasive particles to the body of the precursor formed abrasive particles can include a step of humidifying the surface of the precursor formed abrasive particles before attaching the abrasive particles. For example, the moisture content of the surface of the precursor formed abrasive

[0052] particles can be increased before the adhesion process such that it is approximately the same as, or greater than, the moisture content of the mixture 101 when the mixture 101 is disposed in the manufacturing tool 151. According to another embodiment, the process of attaching a plurality of abrasive particles to the body of the mixture 101 and / or the precursor formed abrasive particles 123 can be to mix on a layer of abrasive particles including a plurality of formed abrasive particles.

[0053] ​​It may include a step of depositing the object 101. For example, the manufacturing tool can be prepared to include a layer of abrasive particles on the surface above the mixture 101, and the mixture 101 is deposited on the layer of abrasive particles so as to be directly adhered onto a plurality of abrasive particles, forming the precursor shaped abrasive particles. In such a case, the process of shaping the mixture 101 into the precursor shaped abrasive particles 123 and the adhesion of a plurality of abrasive particles can be completed simultaneously. For example, the upper surface of the belt 109 can be manufactured to include a layer of abrasive particles, and the mixture 101 can be extruded into the opening 152 of the manufacturing tool 151 and onto the layer of abrasive particles on the upper surface of the belt 109. Next, the manufacturing tool 151 can be removed from the belt 109, and the precursor shaped abrasive particles 123 can have a plurality of abrasive particles adhered to the bottom surface that was in contact with the belt 109. By using additional processes, a plurality of abrasive particles can be adhered to other surfaces, and it will be understood that the process includes a deposition process of adhering a plurality of abrasive particles onto the upper surface of the mixture 101 and / or the precursor shaped abrasive particles 123. One or more processes can be used to adhere a plurality of abrasive particles to one or more surfaces of the mixture 101 and / or to one or more surfaces of the body of the precursor shaped abrasive particles 123, including the bottom surface, upper surface, and side surfaces of the body of the precursor shaped abrasive particles 123, although it is not limited thereto. It can be prepared to include a layer of abrasive particles, and the mixture 101 is deposited on the layer of abrasive particles so as to be directly adhered onto a plurality of abrasive particles. Deposit the mixture 101 on the abrasive particle layer to form the precursor shaped abrasive particles. In such a case, the process of shaping the mixture 101 into the precursor shaped abrasive particles 123 and the adhesion of a plurality of abrasive particles can be completed simultaneously. For example, the upper surface of the belt 109 can be manufactured to include a layer of abrasive particles. The mixture 101 can be extruded into the opening 152 of the manufacturing tool 151 and onto the layer of abrasive particles on the upper surface of the belt 109. Then, the manufacturing tool 151 can be removed from the belt 109. The precursor shaped abrasive particles 123 can have a plurality of abrasive particles adhered to the bottom surface that was in contact with the belt 109. By using additional processes, a plurality of abrasive particles can be adhered to other surfaces. The process includes a deposition process of adhering a plurality of abrasive particles onto the upper surface of the mixture 101 and / or the precursor shaped abrasive particles 123. One or more processes can be used to adhere a plurality of abrasive particles to one or more surfaces of the mixture 101 and / or to one or more surfaces of the body of the precursor shaped abrasive particles 123. It is considered that a plurality of abrasive particles can be adhered to one or more surfaces of the mixture 101 and / or the precursor shaped abrasive particles 123, including the bottom surface, upper surface, and side surfaces of the body of the precursor shaped abrasive particles 123, although it is not limited thereto. Using one or more processes, a plurality of abrasive particles can be adhered to one or more surfaces of the mixture 101 and / or to one or more surfaces of the body of the precursor shaped abrasive particles 123. The body of the precursor shaped abrasive particles 123 includes the bottom surface, upper surface, and side surfaces of the body of the precursor shaped abrasive particles 123. It is considered that a plurality of abrasive particles can be adhered to one or more surfaces of the mixture 101 and / or the precursor shaped abrasive particles 123, although it is not limited thereto. That is not all.

[0054] In yet another embodiment, the mixture 101 and / or the precursor shaped abrasive particles 123 can be disposed within a manufacturing tool that moves over a substrate, and a plurality of abrasive particles cover the surface of the substrate. The substrate, the manufacturing tool, and one side of the mixture 101 and / or the precursor shaped abrasive particles 123. A plurality of abrasive particles cover the surface of the substrate. Stamp it so that a plurality of polishing particles are deposited and at least partially embedded in the mixture 101 and / or embedded in the precursor formed polishing particles 123.

[0055] According to one embodiment, the plurality of polishing particles can be applied or bonded to at least one surface of the body of the mixture 101 and / or the precursor formed polishing particles that are unsintered particles. That is , the plurality of polishing particles can be further processed with the mixture 101 and / or the precursor formed polishing particles to become a raw material for forming sintered polishing particles on the surface of the body of the formed polishing particles. , for example, the plurality of polishing particles can include a raw material containing at least one material from the group of oxides, nitrides, carbides, borides, oxycarbides, oxynitrides, or combinations thereof. Specifically , in a specific example, the plurality of polishing particles can include boehmite or pseudo-boehmite materials and the materials as described above. , the boehmite or pseudo-boehmite materials can be processed in the same manner as a mixture containing additives such as seed materials, pinning agents, and other additives. In a specific embodiment, the plurality of polishing particles include the same materials as those contained in the mixture used to form the body of the formed polishing particles.

[0056] In one embodiment, after attaching the plurality of polishing particles to the precursor formed polishing particles, the process can include drying the precursor formed polishing particles and the plurality of polishing particles. Further, optionally , it will be understood that the process can include calcining the precursor formed polishing particles and the plurality of polishing particles after attaching the plurality of polishing particles to the precursor formed polishing particles. Further , it will be understood that this process can include sintering the precursor formed polishing particles and the plurality of polishing particles to form composite formed polishing particles after bonding the plurality of polishing particles to the precursor formed polishing particles.

[0057] Figure 2 illustrates a part of the system used in forming shaped abrasive grains according to one embodiment. Specifically, the system 150 of FIG. 2 includes some of the same components as the system 150 of FIG. 1A, but does not include the belt 109 under the tool 151. In particular, the tool 151 of FIG. 2 may be in the form of a screen as illustrated in FIG. 1A, and the cavity 152 extends through the entire thickness of the tool 151. Further, the tool 151 of FIG. 2 is formed such that the cavity 152 extends into a part of the entire thickness of the tool 151 and has a bottom surface, and the volume of the space configured to hold and shape the mixture 10 1 is defined by the bottom surface and the side surfaces, as will be understood. All processes described herein in other embodiments are utilized with the system illustrated in FIG. 2 and include, but are not limited to, a drying operation that can easily remove the mixture 101 from the cavity 152 to form precursor shaped abrasive grains. That is, the mixture 101 can be dried slightly while being contained in the cavity 152 of the tool 151. Further, while the mixture 101 is present in the cavity or after being removed from the cavity 152, a process of attaching a plurality of abrasive grains to one or more surfaces of the mixture 101 (i.e., on the surface of the precursor shaped abrasive grains) can be utilized with the system 150 of FIG. 2. The system of FIG. 2 may include one or more components described in U.S. Patent No. 9,200,187. For example, the system 150 may include a backing plate that is under and adjacent to the tool 151 while extruding the mixture into the cavity 152 of the tool 151. By the backing plate, the cavity 152 can be filled with the mixture 101. The mixture 101 is placed in the cavity 152 of the tool 151, it can be dried to a barely perceptible extent. Further, while the mixture 101 is present in the cavity or after being removed from the cavity 152, a process of attaching a plurality of abrasive grains to one or more surfaces of the mixture 101 (i.e., on the surface of the precursor shaped abrasive grains) can be utilized with the system 150 of FIG. 2. After being removed from the cavity 152, a process of attaching a plurality of abrasive grains to one or more surfaces of the mixture 101 (i.e., on the surface of the precursor shaped abrasive grains) can be utilized with the system 150 of FIG. 2.

[0058] The system of FIG. 2 may include one or more components described in U.S. Patent No. 9,200,187. For example, the system 150 may include a backing plate that is under and adjacent to the tool 151 while extruding the mixture into the cavity 152 of the tool 151. By the backing plate, the cavity 152 can be filled with the mixture 101. While extruding the mixture 101 into the cavity 152 of the tool 151, the system 150 may include a backing plate that is under and adjacent to the tool 151. The backing plate allows the cavity 152 to be filled with the mixture 101. The mixture 101 is placed in the cavity When depositing within 152, the tool abuts against the backing plate within the deposition zone such that the tool 151 can be moved over the backing plate, and the tool 151 moves away from the deposition zone, so the tool 151 moves away from the backing plate in such a manner.

[0059] The tool can be moved to the discharge zone, and at least one discharge assembly guides discharge material to the mixture 101 contained within the cavity 152 and discharges the mixture 101 from the cavity to form precursor shaped abrasive particles. The discharge material can include an aerosol containing a gas phase component, a liquid phase component , a solid phase component, and combinations thereof.

[0060] Figure 3 is an image of abrasive particles according to one embodiment. The abrasive particles can include composite shaped abrasive particles 300 having a body 301 and at least one surface 303, such as a plurality of abrasive particles 302 attached to the main surface of the body 301 of the shaped abrasive particle. As shown in the illustration, the shaped abrasive particle can have a two-dimensional triangular shape when viewed in the plane defined by the length (L) and width (W) of the body 301. However, it will be understood that the shaped abrasive particle can have other two-dimensional shapes including, but not limited to polygons, ellipses , numbers, Greek letters, Latin alphabet letters, Russian alphabet letters, complex shapes having combinations of polygons , and combinations thereof.

[0061] According to one embodiment, the shaped abrasive particle can include a first main surface 303, a second main surface (e.g., a bottom surface) opposite the first main surface, and side surfaces extending between the first and second main surfaces . ​​can be. A plurality of abrasive particles 302 can be bonded to any surface of the main body, for example, including the first main surface 303 of the main body 301. In other examples, a plurality of abrasive particles 302 can be bonded to at least two surfaces of the main body. For example, a plurality of abrasive particles 302 can be bonded to at least two main surfaces of the main body 301, for example, the first and second main surfaces, and can be bonded to the surface having the largest surface area among all the surfaces of the main body 301 within the particle shown in FIG. 3. In still other embodiments, a plurality of abrasive particles 302 can be bonded to at least two surfaces of the main body 301 that may include one or more side surfaces. For example, a plurality of abrasive particles 302 can be bonded to the upper surface and the side surface of the main body 301. Alternatively, a plurality of abrasive particles 302 can be bonded to the bottom surface and the side surface of the main body 301. In at least one embodiment, it will be understood that a plurality of abrasive particles 302 can adhere to all of the surfaces of the main body 301 of the shaped abrasive particles. Furthermore, in some embodiments, a selective arrangement of abrasive particles is utilized to attach a plurality of abrasive particles to some surfaces (e.g., one or more main surfaces of the main body 301), while one or more other surfaces (e.g., the side surfaces of the main body 301) may essentially not contain a plurality of abrasive particles. A surface that essentially does not contain abrasive particles can include a small number of abrasive particles that may accidentally deposit or bond to the surface, but the abrasive particles do not completely cover the entire surface. For example, the surface can include 10 or fewer abrasive particles and can be considered to essentially not contain abrasive particles. In yet another example, the surface has no abrasive particles bonded to it and can essentially not contain abrasive particles. These abrasive particles including shaped abrasive particles, and a plurality of abrasive particles attached to one or more surfaces, can be referred to as composite abrasive particles.

[0062] ​​​​​​In some cases, by controlling the coverage rate of a plurality of abrasive grains on the body of the shaped abrasive grains, it is possible to easily improve the formation, arrangement, and / or performance of the abrasive grains. In some of the abrasive grains of the embodiments of the present specification, the plurality of abrasive grains 302 can cover at least about 1% of the total surface area of the body 301 of the shaped abrasive grains. In other examples, the plurality of abrasive grains 302 covering the outer surface of the body 301 of the shaped abrasive grains are wider, for example, at least about 5%, at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 7 0%, at least 80%, at least 90%, at least 95%, or even at least 99% of the total surface area of the body 301 of the shaped abrasive grains. Further, in at least one embodiment, the plurality of abrasive grains 302 can cover 99% or less of the total surface area of the body 301 of the shaped abrasive grains, for example 95% or less , 90% or less, 85% or less, 80% or less, 70% or less, 60% or less, 50% or less, 40% or less, 30% or less, 20% or less, or even 10% or less. It will be understood that the plurality of abrasive grains 302 can cover a percentage of the total surface area of the body 301 of the shaped abrasive grains within a range

[0063] including any of the above minimum and maximum percentages. For some of the abrasive grains of the embodiments of the present specification, by controlling the coverage rate of the plurality of grains on one surface of the body of the shaped abrasive grains, the formation, arrangement, and / or performance of the abrasive grains can be easily improved. For example, the plurality of abrasive grains 302 It is possible. In other examples, the coverage rate of a plurality of abrasive particles on a predetermined surface of the main body of the shaped abrasive particles is higher, for example, at least about 5%, at least 10%, at least 20%, at least 30%, at least 40%, at least 5 0%, at least 60%, at least 70%, at least 80%, at least 90%, or even at least 95%, or even at least 99%, or even further at least 100% can be achieved. Further, in at least one embodiment, the plurality of abrasive particles 302 can cover 100% or less of the total surface area of the main body 301 of the shaped abrasive particles, for example, 99% or less or 95% or less, 90% or less, 85% or less, 80% or more, 70% or less, 60% or less, 50 % or less, 40% or less, 30% or less, 20% or less, or even 10% or less. It will be understood that the plurality of abrasive particles 302 can cover a percentage of the total surface area of the main body 301 of the shaped abrasive particles within a range including any of the above minimum and maximum percentages. For example the plurality of abrasive particles can cover at least 1% and 99% or less of the total surface area of the first main surface. In yet another embodiment, the plurality of abrasive particles can cover at least 30% and 99% or less of the total surface area of the first main surface. In yet another embodiment, the plurality of abrasive particles can cover at least 40% and 99% or less of the total surface area of the first main surface. According to another aspect, the plurality of abrasive particles can cover at least 8 0% and 99% or less of the total surface area of the first main surface. For some of the abrasive particles of the embodiments herein, the coverage rate of a plurality of particles on one surface of the main body of the shaped abrasive particles is controlled to facilitate the formation, arrangement and / or performance of the abrasive particles to be directed easily towards

[0064] For some of the abrasive particles of the embodiments herein, the coverage rate of a plurality of particles on one surface of the main body of the shaped abrasive particles is controlled to facilitate the formation, arrangement and / or performance of the abrasive particles towards It can be done. For example, in one embodiment, the abrasive particles may include at least 10 particles of a plurality of abrasive particles on the main surface of the body of the shaped abrasive particles. In still other examples, the number of particles of the plurality of abrasive particles on the first main surface of the body may be greater, for example, at least 12, or at least 15, or at least 18, or at least 20, or at least 22, or at least 25, or at least 27, or at least 30. Further, depending on the formation conditions, the average number of particles on the first main surface of the body can be 500 or less, for example 400 or less, or 300 or less, or 200 or less, or 100 or less, 80 or less, or 60 or less, or 50 or less. It will be understood that the average number of abrasive particles on the first main surface of the body of the shaped abrasive particles is within the range including any of the above minimum and maximum values. For example the average number of abrasive particles can be at least 10 and 500 or less, for example at least 10 and 200 or less, or at least 15 and 200 or less, or at least 2 0 and 100 or less. Further, it will be understood that such an average number can be true for any other surface of the body of the shaped abrasive particles. According to one embodiment, the plurality of abrasive particles 302 can account for at least 1% by weight of the total weight of the abrasive particles 300, for example, at least 2% by weight, at least 3% by weight, at least

[0065] 4% by weight, at least 5% by weight, at least 6% by weight, at least 7% by weight, at least 8% by weight, at least 9% by weight, at least 10% by weight, at least about 20% by weight at least about 30% by weight, at least about 40% by weight, or at least about 50% by weight. ​​It is possible. Further, in a non-limiting embodiment, the plurality of abrasive particles 302 can be about 80 wt% or less of the total weight of the abrasive particles 300 For example, it can be about 60 wt% or less, about 40 wt % or less, about 30 wt%, or even about 20 wt% or less, 10 wt% or less, 8 wt% or less, 6 wt% or less, 5 wt% or less, or 4 wt% or less, or even 3 wt% or less. The plurality of abrasive particles 302 can occupy a specific wt% of the total weight of the abrasive particles within a range including any of the above minimum and maximum percentages, as will be understood. Such percentages can represent the average value calculated for a plurality of abrasive particles, and each abrasive particle includes a shaped abrasive particle having a plurality of abrasive particles bonded to at least one surface of the body of the shaped abrasive particle It will also be understood. Such an average value is calculated from a random and statistically valid sample size of the abrasive particles. The wt% of the plurality of abrasive particles can be calculated by obtaining a first sample of particles containing at least 300 mg of abrasive particles having a plurality of abrasive particles bonded to at least one surface. Measure the mass (M1) of the particles. The particles are spread on a flat surface that provides a contrast suitable for accurately counting the number of particles (N). Take a picture of the particles using a camera and count the number of coated particles ( N1) using appropriate imaging software (e.g., imageJ). The average mass per particle (Mg1) of the abrasive grains having a plurality of abrasive particles is calculated according to the formula Mg1 = M1 / N1.

[0066] For a sample of particles that do not contain a plurality of abrasive particles (i.e., uncoated abrasive particles), the same procedure is followed. Measure the mass of the particles. The particles are spread on a flat surface that provides a contrast suitable for accurately counting the number of particles. Take a picture of the particles using a camera and count the number of particles using appropriate imaging software. The average mass per particle of the abrasive grains having a plurality of abrasive particles is calculated according to the formula Mg1 = M1 / N1. For a sample of particles that do not contain a plurality of abrasive particles (i.e., uncoated abrasive particles), the same procedure is followed. is calculated according to the formula Mg1 = M1 / N1.

[0067] For a sample of particles that do not contain a plurality of abrasive particles (i.e., uncoated abrasive particles), the same Perform the process. Calculate the average mass per particle (Mg2) of the uncoated sample. Next, calculate the average weight percentage of the plurality of abrasive particles according to the formula 100×[(Mg2 - Mg1) / Mg1]. Calculate the percentage.

[0068] The plurality of abrasive particles 302 can be selected from certain types of materials to facilitate the proper formation of the composite-shaped abrasive particles. Examples of the plurality of abrasive particles 302 include, for example, oxides, carbides, nitrides, borides, oxycarbides, oxynitrides, oxyborides, natural minerals, synthetic substances, carbon-based substances, and substances from the group of combinations thereof. In one particular embodiment, the plurality of abrasive particles can include alumina, and more specifically, can consist essentially of α-alumina.

[0069] In at least one embodiment, the plurality of abrasive particles 302 can include a material having a specific coefficient of thermal expansion (CTE) relative to the CTE of the body 301 that can easily improve the formation, arrangement, and / or performance of the abrasive particles. For example, the plurality of abrasive particles 302 can have a CTE that is about 50% or less different from the CTE of the body 301 of the shaped abrasive particles according to the formula [(CTE1 - CTE2) / CTE1]×100%, where CTE1 represents a higher CTE value compared to CTE2. In some cases, the plurality of abrasive particles 302 can have a CTE that is smaller than the CTE of the body 301. In another embodiment, the plurality of abrasive particles 302 can have a CTE that is larger than the CTE of the body 301. Further, the plurality of abrasive particles 302 can have a CTE that is about 40% or less different, about 30% or less different, about 20% or less different, or even about 10% or less different compared to the CTE of the body 301. Further, in one non-limiting embodiment, the plurality of abrasive particles 3 ​​​​​​​​​​​​​The CTE of the body 302 can be essentially the same as the CTE of the body 301. In the embodiment, the CTE of the plurality of abrasive particles 302 is at least as large as the CTE of the body 301. It may differ by about 0.5%, by at least about 1%, or by at least about 3%. The abrasive particles have a CTE within a range including any minimum and maximum values ​​above with respect to the CTE of the body. It will be understood that there may be a difference in E. The CTE may be measured on the final formed abrasive particle after sintering.

[0070] According to one embodiment, the plurality of abrasive particles 302 may be crushed abrasive grains, irregularly shaped abrasive grains, or the like. , elongated grains, weak agglomerates, strong agglomerates, finely molded abrasive particles, flakes, and combinations thereof. In one particular example, the plurality of abrasive particles is selected from the group consisting of a generally irregular The flakes consist essentially of ground abrasive grains that may have a regular shape. The abrasive grains may be elongated or non-elongated having a very small thickness.

[0071] The shaped abrasive particles can be formed by molding, printing, casting, pressing, or the like, as described herein. The material may be formed by a specific process, including annealing, etc., as further described herein. In at least one embodiment, at least a portion of the plurality of abrasive particles 302 is a shaped abrasive. The abrasive particles 301 may include shaped abrasive particles of a significantly finer size than the body 301 of the abrasive particles 301. The shaped abrasive particles included in the plurality of abrasive particles 302 covering the body 301 of the shaped abrasive particles are The shaped abrasive particles may have any of the characteristics of the shaped abrasive particles defined in the embodiments herein.

[0072] The body 301 of the shaped abrasive particle can have a length (L), a width (W) and a height (H). k, L≧W≧H. The length can define the longest dimension of the main body 301, and in some cases, it may be equal to the dimension that defines the width. In one embodiment, the width can generally define the second longest dimension of the main body 301, but in some cases, the width may have the same value as the length. The height can generally define the shortest dimension of the main body and can extend in a direction perpendicular to the plane defined by the length and width of the main body 301. According to one specific embodiment, the width may be greater than or equal to the height. According to one embodiment, the main body 301 of the shaped abrasive particles can have an average particle diameter of at least about 100 micrometers as measured by the maximum dimension (i.e., length) measurable on the main body 301. In fact, the main body 301 of the shaped abrasive particles can have an average particle diameter of at least about 150 micrometers, for example, at least about 200 micrometers, at least about 300 micrometers, at least about 400 micrometers, at least about 500 micrometers, at least about 500 micrometers, at least about 600 micrometers, at least about 800 micrometers, or even at least about 900 micrometers. Further, the abrasive particles can have an average particle diameter of about 5 mm or less, for example, about 3 mm or less, about 2 mm or less, or even about 1.5 mm or less. It is understood that the abrasive particles can have an average particle diameter within the range between any of the above minimum and maximum values. The abrasive grains (i.e., crystallites) or a plurality of abrasive particles contained within the main body of the shaped abrasive particles can generally have an average particle diameter of about 100 micrometers or less. In other embodiments, The abrasive grains (i.e., crystallites) or a plurality of abrasive particles contained within the main body of the shaped abrasive particles can generally have an average particle diameter of about 100 micrometers or less. In other embodiments, The abrasive grains (i.e., crystallites) or a plurality of abrasive particles contained within the main body of the shaped abrasive particles can generally have an average particle diameter of about 100 micrometers or less. In other embodiments,

[0073] According to one embodiment, the main body 301 of the shaped abrasive particles can have an average particle diameter of at least about 100 micrometers as measured by the maximum dimension (i.e., length) measurable on the main body 301. In fact, the main body 301 of the shaped abrasive particles can have an average particle diameter of at least about 150 micrometers, for example, at least about 200 micrometers, at least about 300 micrometers, at least about 400 micrometers, at least about 500 micrometers, at least about 500 micrometers, at least about 600 micrometers, at least about 800 micrometers, or even at least about 900 micrometers. Further, the abrasive particles can have an average particle diameter of about 5 mm or less, for example, about 3 mm or less, about 2 mm or less, or even about 1.5 mm or less. It is understood that the abrasive particles can have an average particle diameter within the range between any of the above minimum and maximum values. The abrasive grains (i.e., crystallites) or a plurality of abrasive particles contained within the main body of the shaped abrasive particles can generally have an average particle diameter of about 100 micrometers or less. In other embodiments, The abrasive grains (i.e., crystallites) or a plurality of abrasive particles contained within the main body of the shaped abrasive particles can generally have an average particle diameter of about 100 micrometers or less. In other embodiments, The abrasive grains (i.e., crystallites) or a plurality of abrasive particles contained within the main body of the shaped abrasive particles can generally have an average particle diameter of about 100 micrometers or less. In other embodiments, The abrasive grains (i.e., crystallites) or a plurality of abrasive particles contained within the main body of the shaped abrasive particles can generally have an average particle diameter of about 100 micrometers or less. In other embodiments, The abrasive grains (i.e., crystallites) or a plurality of abrasive particles contained within the main body of the shaped abrasive particles can generally have an average particle diameter of about 100 micrometers or less. In other embodiments, The abrasive grains (i.e., crystallites) or a plurality of abrasive particles contained within the main body of the shaped abrasive particles can generally have an average particle diameter of about 100 micrometers or less. In other embodiments, The abrasive grains (i.e., crystallites) or a plurality of abrasive particles contained within the main body of the shaped abrasive particles can generally have an average particle diameter of about 100 micrometers or less. In other embodiments,

[0074] The abrasive grains (i.e., crystallites) or a plurality of abrasive particles contained within the main body of the shaped abrasive particles can generally have an average particle diameter of about 100 micrometers or less. In other embodiments, The average particle size is smaller, for example, about 80 micrometers or less, about 50 micrometers or less, about 30 micrometers or less, about 20 micrometers or less, about 10 micrometers or less, about 1 micrometer or less, about 0.9 micrometer or less, about 0.8 micrometer or less, about 0.7 micrometer or less, or about 0.6 micrometer or less and can even be. Further, the average particle size of the abrasive grains contained in the main body of the polishing particles is at least about 0.01 micrometer, and can be, for example, at least about 0.05 micrometer , at least about 0.06 micrometer, at least about 0.07 micrometer , at least about 0.08 micrometer, at least about 0.09 micrometer, , at least about 0.1 micrometer, at least about 0.12 micrometer, at least about 0.15 micrometer, at least about 0.17 micrometer, at least about 0.2 micrometer, or even at least about 0.5 micrometer. It will be understood that the abrasive grains can have an average particle size within the range between any of the above minimum and maximum values.

[0075] The plurality of polishing particles 302 can have a specific median particle size with respect to one or more dimensions of the main body 301 of the shaped polishing particles. For example, the plurality of polishing particles 302 can have a median particle size (D50) that is less than or equal to the length (L) of the main body 301 of the shaped polishing particles. More specifically, the plurality of polishing particles 302 can have a median particle size (D50) that is about 90% or less of the length (L) of the main body 301, and can be, for example, about 80% or less of the length, about 70% or less of the length, about 60 % or less of the length, about 50% or less of the length, about 40% or less of the length, about 30% or less of the length, about 25 % or less of the length, etc. % Hereinafter, about 20% or less of the length, about 18% or less of the length, about 15% or less of the length, about 12 % or less of the length, about 10% or less of the length, about 8% or less of the length, about 6% or less of the length, or about 5% of the length may even be less. In yet another non-limiting embodiment, the plurality of abrasive particles 302 have a median particle size (D50) of at least about 0.1% of the length (L) of the body 301, and can be, for example, at least about 0.5% of the length, at least about 1% of the length, or at least about 2% of the length, at least about 3% of the length, at least about 4% of the length, at least about 5% of the length, at least about 6% of the length, at least about 7% of the length, at least about 8% of the length, at least about 9% of the length, at least about 10% of the length, at least about 12% of the length, at least about 15% of the length, at least about 18% of the length, at least about 20% of the length, at least about 25% of the length, or even at least about 30% of the length. The plurality of abrasive particles 302 have a median particle size (D50) within a range including any of the above minimum and maximum percentages and it will be understood that they can have such a size. According to one particular embodiment, the plurality of abrasive particles 302 have a median particle size (D50) of at least 0.1% and about 90% or less of the length (L) of the body of the shaped abrasive particle, and can be calculated by [(D50) / (L)]×100%. In another embodiment the plurality of abrasive particles 302 can have a median particle size (D50) of at least 0.1% and about 50% or less of the length of the body, for example, at least 0.1% and about 20% or less of the length of the body of the shaped abrasive particle, or at least 0.1% and about 10% or less of the length of the body, or at least

[0076] According to one particular embodiment, the plurality of abrasive particles 302 have a median particle size (D50) of at least 0.1% and about 90% or less of the length (L) of the body of the shaped abrasive particle and can be calculated by [(D50) / (L)]×100%. In another embodiment the plurality of abrasive particles 302 can have a median particle size (D50) of at least 0.1% and about 50% or less of the length of the body, for example, at least 0.1% and about 20% or less of the length of the body of the shaped abrasive particle, or at least 0.1% and about 10% or less of the length of the body, or at least 0.1% and about 20% or less, or at least 0.1% and about 10% or less, or at least 0.1% and about 50% or less of the median particle size (D50) of the length of the body, for example, at least 0.1% and about 20% or less of the length of the body of the shaped abrasive particle, or at least 0.1% and about 10% or less of the length of the body, or at least 0.1% and about 20% or less, or at least 0.1% and about 10% or less, or at least It can also be at least 0.1% and about 8% or less, or at least 0.1% and about 6% or less, or at least 0 .1% and about 5% or less, or even at least 1% and 5% or less. Further, in some cases it has been pointed out that the relative median particle size (D5 0) of the plurality of abrasive particles 302 compared to the length of the main body can affect the coverage rate of the abrasive particles on the main body.

[0077] In another embodiment, the plurality of abrasive particles 302 can have a median particle size (D50) of about 90% or less of the width (W) of the main body 301, for example, about 80% or less of the width, 70% or less of the width, about 60% or less of the width, about 50% or less of the width, about 40% or less of the width, about 30% or less of the width, 25% or less of the width, about 20% or less of the width, about 18% or less of the width, about 15% or less of the width, about 12% or less of the width, 10% or less of the width, 8% or less of the width, 6% or less of the width, or even 5% or less of the width. In yet another non - limiting embodiment, the plurality of abrasive particles 302 can have a median particle size (D50) of at least about 0.1% of the width (W ) of the main body 301, for example, at least about 0.5% of the width, at least about 1% of the width, at least about 2% of the width, at least about 3% of the width, at least about 4% of the width, at least about 5% of the width, at least about 6% of the width, at least about 7% of the width, at least about 8% of the width, at least about 9% of the width, at least about 1 0% of the width, at least about 12% of the width, at least about 15% of the width, at least about 18% of the width, at least about 20% of the width, at least about 25% of the width, at least about 30% of the width. The plurality of abrasive particles 302 can be understood to have a median particle size (D50) within a range including any of the above - mentioned minimum and maximum percentages. It will be understood that the plurality of abrasive particles 302 can have a median particle size (D50) within a range including any of the above - mentioned minimum and maximum percentages. of abrasive particles 302 can have a median particle size (D50) within a range including any of the above - mentioned minimum and maximum percentages. It will be understood that the plurality of abrasive particles 302 can have a median particle size (D50) within a range including any of the above - mentioned minimum and maximum percentages.

[0078] According to one particular embodiment, the plurality of abrasive particles 302 can have a median particle size (D50) of from 0.1% to about 90% of the width of the body of the shaped abrasive particles, and can be calculated by [(D50) / ( W)]×100%. In another embodiment, the plurality of abrasive particles 302 can have a median particle size (D50) of at least 0.1% and about 50% or less of the width of the body, for example, at least 0.1% and about 20% or less, or at least 0.1% and about 10% or less, or at least 0.1% and about 8% or less, or at least 0.1% and about 6% or less, or at least 1% and about 6% or less, or at least 1% and about 4% or less of the width of the body of the shaped abrasive particles. Further, in some cases, it has been pointed out that the relative median particle size (D50) of the plurality of abrasive particles 302 compared to the width of the body can affect the coverage rate of the abrasive particles on the body.

[0079] In another embodiment, the plurality of abrasive particles 302 can have a median particle size (D50) of about 90% or less of the height of the body 301, for example, about 80% or less of the height, about 70 % or less of the height, about 60% or less of the height, about 50% or less of the height, about 40% or less of the height, about 30 % or less of the height, about 25% or less of the height, about 20% or less of the height, about 18% or less of the height, about 15 % or less of the height, about 12% or less of the height, about 10% or less of the height, about 8% or less of the height, about 6% or less of the height, or about 5% of the height. In yet another non-limiting embodiment, the plurality of abrasive particles 3 02 can have a median particle size (D50) of at least about 0.1% of the height, for example, at least about 0.5% of the height of the body 301, at least about 1% of the height, at least about 2% of the height, at least about 3% of the height, at least about 4% of the height, at least about 4% of the height of the body 301. at least about 5%, at least about 6% of the height, at least about 7% of the height, at least about 8% of the height, at least about 9% of the height, at least about 10% of the height, at least about 12% of the height, height at least about 15% of the height, at least about 18% of the height, at least about 20% of the height, of the height at least about 25% of the height, at least about 30% of the height. The plurality of abrasive particles 302 are the above may have a median particle size (D50) within a range including any minimum percentage and maximum percentage of as will be understood.

[0080] According to one particular embodiment, the plurality of abrasive particles 302 can have a median particle size (D50) of at least 0.1% and up to about 90% of the height of the body of the shaped abrasive particles and can be calculated by [(D50) / (H)]×100%. In another embodiment, the plurality of abrasive particles 302 can have a median particle size (D50) of at least 0.1% and up to about 50% of the height of the body, for example, at least 0. 1% and up to about 20% of the height of the body of the shaped abrasive particles, or at least 1% and up to about 18% of the height of the body, or at least 5% and up to about 18% of the height of the body, or at least 8% and up to about 16 of the height of the body. Further, in some cases, it has been pointed out that the relative median particle size (D50) of the plurality of abrasive particles 302 compared to the height of the body can affect the coverage rate of the abrasive particles on the body. It has been pointed out that it can affect the coverage rate of the abrasive particles on the body.

[0081] According to one embodiment, the plurality of abrasive particles 302 can have a median particle size (D5 0) of about 1 mm or less, for example, about 800 micrometers or less, about 500 micrometers or less, or 300 micrometers or less, or 200 micrometers or less, or ​​​​​​​​​100 micrometers or less, or 90 micrometers or less, or 80 micrometers or less, or 70 micrometers or less, or 65 micrometers or less, or 60 micrometers or less, or 50 micrometers or less, or 40 micrometers or less It can be made. Further, in one non-limiting embodiment, the plurality of polishing particles 302 can have a median particle size (D50) of at least about 0.1 micrometer, for example at least about 0.5 micrometer, 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 15 micrometers, or at least 20 micrometers, or at least 25 micrometers, or at least 30 micrometers. It will be understood that the polishing particles can have a median particle size within the range between any of the above minimum and maximum values. For example, the plurality of polishing particles can have a median particle size (D50) of at least 0.1 micrometer and 500 micrometers or less, or at least 0.5 micrometer and 100 micrometers or less, or at least 1 micrometer and 65 micrometers or less. In some cases, it has been pointed out that the median particle size (D50) of the plurality of polishing particles 302 can affect the formation, arrangement, and / or performance of the polishing particles. In at least one embodiment, at least a portion of the plurality of polishing particles can be at least partially embedded in at least one surface of the body 301 of the shaped polishing particle. Further

[0082] ​​​​​​​​​​​​In some cases, that portion may include a majority of abrasive particles 302 that can be at least partially embedded in at least one surface of the body 301 of the shaped abrasive particles 。According to another embodiment, some of the plurality of abrasive particles can be a minority of the plurality of abrasive particles at least partially embedded within at least one surface of the body 301 。In contrast to particles that cover the surface of the body 301 but do not embed and extend within the volume of the body 301 (e.g., particles applied as a type of coating), it will be understood that the embedded particles can extend within the volume of the body below the outer surface of the body 301 。Furthermore, the shape of the embedded abrasive particles is different from the shape of the patterned surface, e.g., grooves or round protrusions, etc. The abrasive particles are embedded in the volume of the body of the shaped abrasive particles, and the plurality of abrasive particles have sharp irregular corners that protrude from the surface (e.g., in the case of crushed irregular shaped abrasive particles). Without wishing to be bound by a particular theory, the sharp irregular surfaces of the plurality of abrasive particles and the random distribution of the abrasive particles on the surface of the shaped abrasive particles affect the self-sharpening behavior of the composite abrasive particles, and as a result, it is considered that the performance of the abrasive particles and related abrasive articles can be improved. The plurality of abrasive particles can also be easily improved in retention within a specific bonded matrix material, such as within the bonding layer of abrasive cloth paper or within the three-dimensional volume of the binder within the bonded abrasive article 。In contrast to particles that cover the surface of the body 301 but do not embed and extend within the volume of the body 301 (e.g., particles applied as a type of coating), it will be understood that the embedded particles can extend within the volume of the body below the outer surface of the body 301 。Furthermore, the shape of the embedded abrasive particles is different from the shape of the patterned surface, e.g., grooves or round protrusions, etc. The abrasive particles are embedded in the volume of the body of the shaped abrasive particles, and the plurality of abrasive particles have sharp irregular corners that protrude from the surface (e.g., in the case of crushed irregular shaped abrasive particles). Without wishing to be bound by a particular theory, the sharp irregular surfaces of the plurality of abrasive particles and the random distribution of the abrasive particles on the surface of the shaped abrasive particles affect the self-sharpening behavior of the composite abrasive particles, and as a result, it is considered that the performance of the abrasive particles and related abrasive articles can be improved. The plurality of abrasive particles can also be easily improved in retention within a specific bonded matrix material, such as within the bonding layer of abrasive cloth paper or within the three-dimensional volume of the binder within the bonded abrasive article 。In contrast to particles that cover the surface of the body 301 but do not embed and extend within the volume of the body 301 (e.g., particles applied as a type of coating), it will be understood that the embedded particles can extend within the volume of the body below the outer surface of the body 301 。Furthermore, the shape of the embedded abrasive particles is different from the shape of the patterned surface, e.g., grooves or round protrusions, etc. The abrasive particles are embedded in the volume of the body of the shaped abrasive particles, and the plurality of abrasive particles have sharp irregular corners that protrude from the surface (e.g., in the case of crushed irregular shaped abrasive particles). Without wishing to be bound by a particular theory, the sharp irregular surfaces of the plurality of abrasive particles and the random distribution of the abrasive particles on the surface of the shaped abrasive particles affect the self-sharpening behavior of the composite abrasive particles, and as a result, it is considered that the performance of the abrasive particles and related abrasive articles can be improved. The plurality of abrasive particles can also be easily improved in retention within a specific bonded matrix material, such as within the bonding layer of abrasive cloth paper or within the three-dimensional volume of the binder within the bonded abrasive article 。Furthermore, the shape of the embedded abrasive particles is different from the shape of the patterned surface, e.g., grooves or round protrusions, etc. The abrasive particles are embedded in the volume of the body of the shaped abrasive particles, and the plurality of abrasive particles have sharp irregular corners that protrude from the surface (e.g., in the case of crushed irregular shaped abrasive particles). Without wishing to be bound by a particular theory, the sharp irregular surfaces of the plurality of abrasive particles and the random distribution of the abrasive particles on the surface of the shaped abrasive particles affect the self-sharpening behavior of the composite abrasive particles, and as a result, it is considered that the performance of the abrasive particles and related abrasive articles can be improved. The plurality of abrasive particles can also be easily improved in retention within a specific bonded matrix material, such as within the bonding layer of abrasive cloth paper or within the three-dimensional volume of the binder within the bonded abrasive article 。Furthermore, the shape of the embedded abrasive particles is different from the shape of the patterned surface, e.g., grooves or round protrusions, etc. The abrasive particles are embedded in the volume of the body of the shaped abrasive particles, and the plurality of abrasive particles have sharp irregular corners that protrude from the surface (e.g., in the case of crushed irregular shaped abrasive particles). Without wishing to be bound by a particular theory, the sharp irregular surfaces of the plurality of abrasive particles and the random distribution of the abrasive particles on the surface of the shaped abrasive particles affect the self-sharpening behavior of the composite abrasive particles, and as a result, it is considered that the performance of the abrasive particles and related abrasive articles can be improved. The plurality of abrasive particles can also be easily improved in retention within a specific bonded matrix material, such as within the bonding layer of abrasive cloth paper or within the three-dimensional volume of the binder within the bonded abrasive article 。Without wishing to be bound by a particular theory, the sharp irregular surfaces of the plurality of abrasive particles and the random distribution of the abrasive particles on the surface of the shaped abrasive particles affect the self-sharpening behavior of the composite abrasive particles, and as a result, it is considered that the performance of the abrasive particles and related abrasive articles can be improved. The plurality of abrasive particles can also be easily improved in retention within a specific bonded matrix material, such as within the bonding layer of abrasive cloth paper or within the three-dimensional volume of the binder within the bonded abrasive article 。Without wishing to be bound by a particular theory, the sharp irregular surfaces of the plurality of abrasive particles and the random distribution of the abrasive particles on the surface of the shaped abrasive particles affect the self-sharpening behavior of the composite abrasive particles, and as a result, it is considered that the performance of the abrasive particles and related abrasive articles can be improved. The plurality of abrasive particles can also be easily improved in retention within a specific bonded matrix material, such as within the bonding layer of abrasive cloth paper or within the three-dimensional volume of the binder within the bonded abrasive article 。Without wishing to be bound by a particular theory, the sharp irregular surfaces of the plurality of abrasive particles and the random distribution of the abrasive particles on the surface of the shaped abrasive particles affect the self-sharpening behavior of the composite abrasive particles, and as a result, it is considered that the performance of the abrasive particles and related abrasive articles can be improved. The plurality of abrasive particles can also be easily improved in retention within a specific bonded matrix material, such as within the bonding layer of abrasive cloth paper or within the three-dimensional volume of the binder within the bonded abrasive article 。According to one embodiment, at least one of the abrasive particles of the plurality of abrasive particles can be attached to the surface of the body of the shaped abrasive particles and can define an acute contact angle. In particular, the process of this specification 。According to one embodiment, at least one of the abrasive particles of the plurality of abrasive particles can be attached to the surface of the body of the shaped abrasive particles and can define an acute contact angle. In particular, the process of this specification 。According to one embodiment, at least one of the abrasive particles of the plurality of abrasive particles can be attached to the surface of the body of the shaped abrasive particles and can define an acute contact angle. In particular, the process of this specification

[0083] 。According to one embodiment, at least one of the abrasive particles of the plurality of abrasive particles can be attached to the surface of the body of the shaped abrasive particles and can define an acute contact angle. In particular, the process of this specification 。According to one embodiment, at least one of the abrasive particles of the plurality of abrasive particles can be attached to the surface of the body of the shaped abrasive particles and can define an acute contact angle. In particular, the process of this specification By providing a plurality of abrasive particles, so as to define an acute angle, the one or more abrasive particles can easily adhere to the body. A random sample of abrasive particles can be obtained . Each abrasive particle can be cut perpendicular to the longitudinal axis passing through the central half of the body or ground. When an appropriate view of the cross-section as illustrated in FIG. 10 is obtained, the body of the shaped abrasive particle 10 01 is clearly shown, and a plurality of abrasive grains 1002 attached to at least one main surface 1004 can also be seen. Each of the abrasive particles can be fixed in a cured and solidified epoxy resin . After fixing each abrasive particle in the epoxy resin, using a wafer slicing saw , when each of the abrasive particles and a part of the epoxy surrounding each of the abrasive particles are cut out, an individual sample is formed, and the sample can include the entire abrasive particle surrounded by a mass of epoxy. Next, each sample is polished to remove a part of the abrasive grains, and a cross-section is exposed for use in evaluating the contact area of the exposed abrasive grains . The cross-section must be smooth so that the perimeter of the resulting cross-section is well defined . If necessary, the surface of the obtained cross-section can be polished to a uniform height .

[0084] After completing the preparation of the sample, each abrasive particle is placed and can be evaluated at a magnification of 10 times with a field of view of 2 mm using an optical microscope (e.g., Olympus DSX500). Using an optical microscope , an image of the cross-section of each abrasive particle as shown in FIG. 11 is obtained. Using an appropriate imaging program such as ImageJ (available from the National Institute of Health), the contact angle generated by bringing the surface of the abrasive particle into contact with the surface of the body is measured .

[0085] Referring to FIG. 11, the polishing particles 1101 can form a contact angle 102 with the main surface 1103 of the main body 1104. In particular, at least a part of the polishing particles forms a contact angle with the main body of less than 90 degrees. For example, the contact angle of the polishing particles is less than 88 degrees, such as less than 85 degrees, or less than 80 degrees, or less than 75 degrees, or less than 70 degrees, or less than 65 degrees, or less than 60 degrees, or less than 55 degrees, or less than 50 degrees, or less than 45 degrees, or less than 40 degrees, or less than 35 degrees, or less than 30 degrees, or less than 25 degrees, or less than 20 degrees, or less than 15 degrees, or less than 10 degrees, or less than 5 degrees. In yet another embodiment, the contact angle of the polishing particles can be at least 1 degree, or at least 5 degrees, or at least 10 degrees, or at least 15 degrees, or at least 20 degrees, or at least 25 degrees, or at least 30 degrees, or at least 35 degrees, or at least 40 degrees. It will be understood that the contact angle of the polishing particles is within a range including any of the above minimum and maximum values.

[0086] In another embodiment, at least a part of the plurality of polishing particles 302 can be directly bonded to at least one surface of the main body 301 of the shaped polishing particle. More specifically, at least a part of the plurality of polishing particles 302 can be sintered and bonded to at least one surface of the main body 301 of the shaped polishing particle. In at least one embodiment, all of the polishing particles of the plurality of polishing particles 302 can be sintered and bonded to at least one surface of the main body 301 of the shaped polishing particle.

[0087] FIG. 4 is a three-dimensional image of the upper surface of the polishing particles according to one embodiment. As illustrated, the polishing particles 400 include a main body 401 having an upper surface 402 to which a plurality of polishing particles are attached. The three-dimensional map As illustrated in the peppering image, the plurality of abrasive particles form an upper surface having a rough outer shape with a plurality of randomly arranged peaks and valleys. Such a rough outer shape can facilitate the bonding of abrasive particles in various fixed abrasive articles as compared to formed abrasive particles having a smooth surface. Further, the rough and varying outer shape of the upper surface 402 has more sharp abrasive surfaces than conventional formed abrasive particles with a smooth surface, so the abrasiveness in various fixed abrasives can be easily improved. In some cases, the presence of a rough outer shape can generally limit the need to orient abrasive particles in a particular orientation, which is a desirable approach for conventional formed abrasive particles, especially in abrasive cloth articles. Further, in other embodiments, it is advantageous to orient abrasive particles in a particular orientation in a fixed abrasive, and one or more surfaces including a plurality of abrasive particles have a controlled orientation with respect to one or more reference axes within the fixed abrasive article. According to one embodiment, a plurality of abrasive particles can be attached to a first major surface, and the first

[0088] major surface can have a surface roughness greater than that of another surface (e.g., a side surface) of the body to which fewer abrasive particles are adhered. In one particular embodiment, the first major surface can include a plurality of abrasive particles bonded thereto, and the body may essentially not include abrasive particles bonded to the side surface. In such a case, the surface roughness of the first major surface is significantly greater than that of the side surface. The surface roughness can be measured using any suitable technique, including, for example, optical measurement techniques. In yet another embodiment, the first major surface can include a plurality of abrasive particles bonded thereto, and the body may essentially not include abrasive particles bonded to a second major surface. In such a case, the body may essentially not include abrasive particles bonded to the second major surface. In such a case, the surface roughness of the first main surface is significantly greater than that of the second main surface.

[0089] 5 is a perspective view of a shaped abrasive particle according to one embodiment. The face 502 includes a major surface 503 and a side surface 504 extending between the major surfaces 502 and 503. As illustrated in FIG. 5, the body 501 of the shaped abrasive particle 500 may include a main surface. The body 501 is a thin body with faces 502 and 503 larger than the side faces 504. The surface 502 may include an axis 510 extending from the top to the bottom and passing through a midpoint 550. 0 may define the longest dimension of the major surface that extends through the midpoint 550 of the major surface 502. It may be the length or width of the body depending on the geometry, but in the exemplary embodiment of FIG. The form defines the width. The body 501 defines the dimensions of the body 501 and has a same major surface 502. 510 of the body 501 in the illustrated equilateral triangular embodiment. Finally, as illustrated, the body 501 may further include an axis 511 defining a length. In the case of a feature, it may include a longitudinal axis 512 that may define the height (or thickness) of the body 501. For thin compacts, the length of axis 510 is equal to or greater than longitudinal axis 512. As illustrated, height 512 is along side 504 between major surfaces 502 and 503. The length of the abrasive particles herein may extend perpendicular to the plane defined by 10 and 511. References to width and height are taken from an appropriate sampling size of abrasive particles for a batch of abrasive particles. It will be understood that reference may be made to average values ​​obtained.

[0090] The shaped abrasive particles may include any of the features of the abrasive particles of the embodiments herein. For example, The shaped abrasive particles can include a crystalline material, more particularly, a polycrystalline material. In particular, the polycrystalline material can include abrasive grains. In one embodiment, for example, the body of the abrasive particles including shaped abrasive particles may not essentially include an organic material including a binder. In at least one embodiment, the abrasive particles can essentially consist of a polycrystalline material. In one embodiment, for example, the body of the abrasive particles can essentially not include an organic material including a binder. In at least one embodiment, the abrasive particles can essentially consist of a polycrystalline material. In at least one embodiment, the abrasive particles can essentially consist of a polycrystalline material. can consist essentially of a polycrystalline material.

[0091] Materials suitable for use as abrasive particles can include nitrides, oxides, carbides, borides, oxynitrides, oxyborides, diamond, carbon-containing substances, and combinations thereof. can include nitrides, oxides, carbides, borides, oxynitrides, oxyborides, diamond, carbon-containing substances, and combinations thereof. In specific examples, examples of the abrasive particles can include oxide compounds or complexes such as aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, magnesium oxide, rare earth oxides, and combinations thereof. In one specific embodiment, the abrasive particles can include at least 95 wt% alumina based on the total weight of the body. In at least one embodiment, the abrasive particles can essentially consist of alumina. In at least one embodiment, the abrasive particles can essentially consist of alumina. In one specific embodiment, the abrasive particles can include at least 95 wt% alumina based on the total weight of the body. In at least one embodiment, the abrasive particles can essentially consist of alumina. In at least one embodiment, the abrasive particles can essentially consist of alumina. In at least one embodiment, the abrasive particles can essentially consist of alumina. Further, in some cases, the abrasive particles can include up to 99.5 wt% alumina based on the total weight of the body. Further, in some cases, the abrasive particles can include up to 99.5 wt% alumina based on the total weight of the body. Further, in some cases, the shaped abrasive particles can be formed from a seed-added sol-gel. In at least one embodiment, the abrasive particles of the embodiments herein can essentially not include iron, rare earth oxides, and combinations thereof. can essentially not include iron, rare earth oxides, and combinations thereof.

[0092] According to some embodiments, some abrasive particles can be a composite product including at least two different types of abrasive grains within the body of the shaped abrasive particles or within the body of the abrasive particles of a plurality of abrasive particles. According to some embodiments, some abrasive particles can be a composite product including at least two different types of abrasive grains within the body of the shaped abrasive particles or within the body of the abrasive particles of a plurality of abrasive particles. The different types of abrasive grains are abrasive grains having different compositions from each other. will be understood. For example, two different types of abrasive grains may be nitrides, oxides, carbides, borides, oxynitrides, oxyborides, carbon-based materials, diamond, naturally occurring minerals, rare earth-containing materials, and combinations thereof, and at least two different types of abrasive grains may be included to form the body of the shaped abrasive particles.

[0093] FIG. 5 is a view of shaped abrasive particles having a secondary shape as defined by a plane of the upper major surface 502 or the major surface 503, and the shaped abrasive particles have a substantially triangular two-dimensional shape such as an equilateral triangle. The shaped abrasive particles of the embodiments herein are not limited thereto, and it will be understood that other two-dimensional shapes may be included. For example, the shaped abrasive particles of the embodiments herein include polygons, irregular polygons, bow-shaped or curved sides or parts of sides of irregular polygons, ellipses, numbers, Greek letters, Latin alphabet letters, Russian alphabet letters, Chinese characters, complex shapes having combinations of polygons, stars, shapes having arms extending from a central region (e.g., a cross-shaped body), and particles having a two-dimensional shaped body defined by the major surface of a shape group including combinations thereof.

[0094] The shaped abrasive particles are not necessarily limited to a thin shape defined only by the two-dimensional shape of the major surface, and it will also be understood that three-dimensional shapes may be included. For example, the body may be a polyhedron, pyramid, ellipsoid, sphere, prism, cylinder, cone, tetrahedron, cube, cuboid, rhombohedron, truncated pyramid, truncated ellipsoid, truncated sphere, truncated cone, pentahedron, hexahedron, heptahedron, octahedron, enneahedron It may have a three-dimensional shape selected from the group consisting of Chinese characters, complex polygonal shapes, outlines of irregular shapes, volcanic shapes, monostatic shapes, and combinations thereof. The monostatic shape is a shape having a single stable stationary position. Thus, the shaped abrasive particles having a monostatic shape can be applied to a substrate and, since they have one or no stable stationary position, can be consistently oriented at the same position. For example, the shaped abrasive particles having a monostatic shape may be suitable for attaching the particles to the backing by gravity coating which can be used in the formation of abrasive cloth paper products. More specifically, the shaped abrasive particles can be a mono-monostatic shape which is an unstable three-dimensional object having only one center of balance. According to a particular embodiment, the shaped abrasive particles can have the shape of a gomboc. In another embodiment, the shaped abrasive particles are a monostatic polyhedron having at least four surfaces. and can have a three-dimensional shape selected from the group consisting of Chinese characters, complex polygonal shapes, outlines of irregular shapes, volcanic shapes, monostatic shapes, and combinations thereof. The monostatic shape is a shape having a single stable stationary position. Thus, the shaped abrasive particles having a monostatic shape can be applied to a substrate and, since they have one or no stable stationary position, can be consistently oriented at the same position. For example, the shaped abrasive particles having a monostatic shape may be suitable for attaching the particles to the backing by gravity coating which can be used in the formation of abrasive cloth paper products. More specifically, the shaped abrasive particles can be a mono-monostatic shape which is an unstable three-dimensional object having only one center of balance. According to a particular embodiment, the shaped abrasive particles can have the shape of a gomboc. In another embodiment, the shaped abrasive particles are a monostatic polyhedron having at least four surfaces. shape is a shape having a single stable stationary position. Thus, the shaped abrasive particles having a monostatic shape can be applied to a substrate and, since they have one or no stable stationary position, can be consistently oriented at the same position. For example, the shaped abrasive particles having a monostatic shape may be suitable for attaching the particles to the backing by gravity coating which can be used in the formation of abrasive cloth paper products. More specifically, the shaped abrasive particles can be a mono-monostatic shape which is an unstable three-dimensional object having only one center of balance. According to a particular embodiment, the shaped abrasive particles can have the shape of a gomboc. In another embodiment, the shaped abrasive particles are a monostatic polyhedron having at least four surfaces. shape can be applied to a substrate and, since they have one or no stable stationary position, can be consistently oriented at the same position. For example, the shaped abrasive particles having a monostatic shape may be suitable for attaching the particles to the backing by gravity coating which can be used in the formation of abrasive cloth paper products. More specifically, the shaped abrasive particles can be a mono-monostatic shape which is an unstable three-dimensional object having only one center of balance. According to a particular embodiment, the shaped abrasive particles can have the shape of a gomboc. In another embodiment, the shaped abrasive particles are a monostatic polyhedron having at least four surfaces. shape can be applied to a substrate and, since they have one or no stable stationary position, can be consistently oriented at the same position. For example, the shaped abrasive particles having a monostatic shape may be suitable for attaching the particles to the backing by gravity coating which can be used in the formation of abrasive cloth paper products. More specifically, the shaped abrasive particles can be a mono-monostatic shape which is an unstable three-dimensional object having only one center of balance. According to a particular embodiment, the shaped abrasive particles can have the shape of a gomboc. In another embodiment, the shaped abrasive particles are a monostatic polyhedron having at least four surfaces. shape may be suitable for attaching the particles to the backing by gravity coating which can be used in the formation of abrasive cloth paper products. More specifically, the shaped abrasive particles can be a mono-monostatic shape which is an unstable three-dimensional object having only one center of balance. According to a particular embodiment, the shaped abrasive particles can have the shape of a gomboc. In another embodiment, the shaped abrasive particles are a monostatic polyhedron having at least four surfaces. shape may be suitable for attaching the particles to the backing by gravity coating which can be used in the formation of abrasive cloth paper products. More specifically, the shaped abrasive particles can be a mono-monostatic shape which is an unstable three-dimensional object having only one center of balance. According to a particular embodiment, the shaped abrasive particles can have the shape of a gomboc. In another embodiment, the shaped abrasive particles are a monostatic polyhedron having at least four surfaces. shape can be a mono-monostatic shape which is an unstable three-dimensional object having only one center of balance. According to a particular embodiment, the shaped abrasive particles can have the shape of a gomboc. In another embodiment, the shaped abrasive particles are a monostatic polyhedron having at least four surfaces. shape can be a mono-monostatic shape which is an unstable three-dimensional object having only one center of balance. According to a particular embodiment, the shaped abrasive particles can have the shape of a gomboc. In another embodiment, the shaped abrasive particles are a monostatic polyhedron having at least four surfaces. shape can have the shape of a gomboc. In another embodiment, the shaped abrasive particles are a monostatic polyhedron having at least four surfaces. In another embodiment, the shaped abrasive particles are a monostatic polyhedron having at least four surfaces.

[0095] FIG. 6A is a perspective view of shaped abrasive particles according to one embodiment. In particular, the shaped abrasive particles 600 can include a body 601 including a surface 602 and a surface 603, and can be called end faces 602 and 603. The body can further include surfaces 604, 605, 606, 607 that extend between and are coupled to the end faces 602 and 603. The shaped abrasive particles of FIG. 6A are elongated abrasive particles having a longitudinal axis 610 that extends along the surface 605 and passes through an intermediate point 640 between the end faces 602 and 603. Since the body 601 has a generally square cross-sectional outer shape as defined by the end faces 602 and 603, it will be understood that the surface 605 is selected to show the longitudinal axis 610. Thus, the surfaces 604, 605, can include a body 601 including a surface 602 and a surface 603, and can be called end faces 602 and 603. The body can further include surfaces 604, 605, 606, 607 that extend between and are coupled to the end faces 602 and 603. The shaped abrasive particles of FIG. 6A are elongated abrasive particles having a longitudinal axis 610 that extends along the surface 605 and passes through an intermediate point 640 between the end faces 602 and 603. Since the body 601 has a generally square cross-sectional outer shape as defined by the end faces 602 and 603, it will be understood that the surface 605 is selected to show the longitudinal axis 610. Thus, the surfaces 604, 605, and can be called end faces 602 and 603. The body can further include surfaces 604, 605, 606, 607 that extend between and are coupled to the end faces 602 and 603. The shaped abrasive particles of FIG. 6A are elongated abrasive particles having a longitudinal axis 610 that extends along the surface 605 and passes through an intermediate point 640 between the end faces 602 and 603. Since the body 601 has a generally square cross-sectional outer shape as defined by the end faces 602 and 603, it will be understood that the surface 605 is selected to show the longitudinal axis 610. Thus, the surfaces 604, 605, and 603. The body can further include surfaces 604, 605, 606, 607 that extend between and are coupled to the end faces 602 and 603. The shaped abrasive particles of FIG. 6A are elongated abrasive particles having a longitudinal axis 610 that extends along the surface 605 and passes through an intermediate point 640 between the end faces 602 and 603. Since the body 601 has a generally square cross-sectional outer shape as defined by the end faces 602 and 603, it will be understood that the surface 605 is selected to show the longitudinal axis 610. Thus, the surfaces 604, 605, The abrasive particles of FIG. 6A are elongated abrasive particles having a longitudinal axis 610 that extends along the surface 605 and passes through an intermediate point 640 between the end faces 602 and 603. Since the body 601 has a generally square cross-sectional outer shape as defined by the end faces 602 and 603, it will be understood that the surface 605 is selected to show the longitudinal axis 610. Thus, the surfaces 604, 605, The abrasive particles of FIG. 6A are elongated abrasive particles having a longitudinal axis 610 that extends along the surface 605 and passes through an intermediate point 640 between the end faces 602 and 603. Since the body 601 has a generally square cross-sectional outer shape as defined by the end faces 602 and 603, it will be understood that the surface 605 is selected to show the longitudinal axis 610. Thus, the surfaces 604, 605, 603, the body 601 has a generally square cross-sectional outer shape as defined by the end faces 602 and 603, it will be understood that the surface 605 is selected to show the longitudinal axis 610. Thus, the surfaces 604, 605, 606, 607 606 and 607 have approximately the same size as each other. However, surfaces 602 and 603 define different shapes, for example, a rectangle, and if one of surfaces 604, 605, 606, and 607 is a larger, elongated abrasive particle relative to the others, the largest surface of those surfaces defines the major surface, and thus its longitudinal axis extends along the largest surface of those surfaces Furthermore, by way of further illustration, body 601 may include a transverse axis 611 that extends perpendicular to longitudinal axis 610 within the same plane defined by surface 605. By way of further illustration body 601 may further include a longitudinal axis 612 that defines the height of the abrasive particle, and longitudinal axis 612 may extend perpendicular to the plane defined by longitudinal axis 610 and transverse axis 611 of surface 605 As with the thin shaped abrasive particles of FIG. 5, it will be understood that the elongated shaped abrasive particles of FIG. 6A can have various two-dimensional shapes as defined with respect to the shaped abrasive particles of FIG. 5 The two-dimensional shape of body 601 can be defined by the shape around end faces 602 and 603 The elongated shaped abrasive particle 600 can have any of the characteristics of the shaped abrasive particles of the embodiments herein

[0096] As with the thin shaped abrasive particles of FIG. 5, it will be understood that the elongated shaped abrasive particles of FIG. 6A can have various two-dimensional shapes as defined with respect to the shaped abrasive particles of FIG. 5 The two-dimensional shape of body 601 can be defined by the shape around end faces 602 and 603 The elongated shaped abrasive particle 600 can have any of the characteristics of the shaped abrasive particles of the embodiments herein

[0097] FIG. 6B is a view of an elongated particle that is a non-shaped abrasive particle. Shaped abrasive particles can be formed by specific processes including shaping, printing , casting, extrusion, etc. Shaped abrasive particles are formed such that each particle has a substantially the same surface and end arrangement relative to other shaped abrasive particles having the same two-dimensional and three-dimensional shapes Thus, shaped abrasive particles have a surface and end arrangement relative to other shaped abrasive particles of a group having the same two-dimensional and three-dimensional shapes ​​​​​ In a configuration, it can have high shape fidelity and consistency. In contrast, non-shaped abrasive particles are formed by different processes and can have different shape characteristics. For example, non-shaped abrasive particles typically form a mass of material, which is then crushed and screened to obtain abrasive particles of a certain size by a crushing process. However, non-shaped abrasive particles generally have a random arrangement of surfaces and edges, and generally lack a recognizable two-dimensional or three-dimensional shape in the arrangement of the surfaces and edges around the body. Furthermore, non-shaped abrasive particles of the same group or batch generally lack a consistent shape with each other, and the surfaces and edges are randomly arranged compared to each other. Therefore, non-shaped abrasive grains or crushed abrasive grains have significantly lower shape fidelity than shaped abrasive particles.

[0098] Furthermore, as illustrated in FIG. 6B, an elongated abrasive article has a body 651, a longitudinal axis 652 that defines the longest dimension of the particles, and a transverse axis 653 that extends perpendicular to the longitudinal axis 652 and defines the width of the particles and is a non-shaped abrasive particle. Furthermore, the elongated abrasive particle can have a height (or thickness) defined by a longitudinal axis 654 that extends substantially perpendicular to the plane defined by the combination of the longitudinal axis 65 2 and the transverse axis 653. As further illustrated, the body 651 of the elongated non- shaped abrasive particle can have a generally random arrangement of edges 655 that extend along the outer surface of the body 651.

[0099] As understood, the elongated abrasive particle can have a length defined by the longitudinal axis 652, a width defined by the transverse axis 653, and a longitudinal axis 654 that defines the height. As understood, the body 651 has a length:width primary aspect ratio such that the length is greater than the width ​ This can be done. Further, the length of the main body 651 can be greater than or equal to the height. Finally, the width of the main body 651 can be greater than or equal to the height 654. According to one embodiment, the length:width primary aspect ratio can be at least 1.1:1, at least 1.2:1 , at least 1.5:1, at least 1.8:1, at least 2:1, at least 3:1 , at least 4:1, at least 5:1, at least 6:1, or even at least 10:1 can be achieved. In another non-limiting embodiment, the main body 651 of the elongated shaped abrasive particles can have a length:width primary aspect ratio of 100:1 or less, 50:1 or less, 10:1 or less, 6:1 or less, 5:1 or less, 4:1 or less, 3:1 or less, or even 2:1 or less. It will be understood that the primary aspect ratio of the main body 651 is within the range including any of the above minimum and maximum ratios . It will be understood that not all non-shaped abrasive particles are elongated abrasive particles, and some non-shaped abrasive particles can be substantially equiaxial, with any combination of length, width, and height being substantially the same. The non-shaped abrasive particles can be used as a plurality of abrasive particles bonded to cover the surface of the shaped abrasive particles . It will be understood that the non-shaped abrasive particles can be used as the main body of the abrasive particles to which the plurality of abrasive particles are bonded . . . .

[0100] Furthermore, the main body 651 of the elongated abrasive particles 650 can include a secondary width:height aspect ratio of at least 1.1:1, for example, at least 1.2:1, at least 1.5:1 , at least 1.8:1, at least 2:1, at least 3:1, at least 4:1, at least , at least 1.8:1, at least 2:1, at least 3:1, at least 4:1, at least can be at least 5:1, at least 8:1, or even at least 10:1. In yet another non-limiting embodiment, the secondary aspect ratio of the width:height of the body 651 is 100:1 or less and may be, for example, 50:1 or less, 10:1 or less, 8:1 or less, 6:1 or less, 5:1 or less, 4:1 or less, 3:1 or less, or even 2:1 or less. It is understood that the width:height secondary aspect ratio is within a range including any of the minimum and maximum ratios described above.

[0101] In another embodiment, the body 651 of the elongated abrasive particle 650 can have a tertiary aspect ratio of length:height of at least 1.1:1, for example, at least 1.2:1, at least 1.5:1, at least 1.8:1, at least 2:1, at least 3:1, at least 4:1, at least 5:1, at least 8:1, or even at least 10:1. In yet another non-limiting embodiment, the tertiary aspect ratio of the body 651, length:height can be 100:1 or less and may be, for example, 50:1 or less, 10:1 or less, 8:1 or less, 6:1 or less, 5:1 or less, 4:1 or less, 3:1 or less. It is understood that the tertiary aspect ratio of the body 651 is within a range including any of the minimum and maximum ratios described above.

[0102] The elongated abrasive particle 650 can have certain characteristics of other abrasive particles described in the embodiments herein, including, for example, but not limited to, composition, microstructural features ( e.g., average particle size / crystallite size), hardness, porosity, etc.

[0103] FIG. 7A is a top view of a shaped abrasive particle according to one embodiment. In particular, the shaped abrasive particle 700 may include a body 701 having the shape of other shaped abrasive particles of the embodiments of the present specification , and includes an upper main surface 703 and a bottom main surface (not shown) facing the upper main surface 703. The upper main surface 703 and the lower main surface may include at least one side surface portion and may be separated from each other by at least one side surface 705. For example, it includes a first portion 706 of the side surface 705, a second portion 707 of the side surface 705, and a third portion 708 of the side surface 705. Specifically, the first portion 706 of the side surface 705 may extend between a first corner 709 and a second corner 710. The second portion 707 of the side surface 705 may extend between the second corner 710 and a third corner 711. In particular, the second corner 710 may be a protruding corner that joins two portions of the side surface 705. The second corner 710 and the third corner 711 are also protruding corners and are adjacent to each other, and no other protruding corners are arranged between them. Also, the third portion 708 of the side surface 705 may extend between the third corner 71 1 and the first corner 709, and these corners are adjacent to each other, and no other protruding corners are arranged between them. As an example, the body 701 may include a first portion 706 including a first curved portion 742 disposed between a first straight portion 741 and a second straight portion 743 and between the protruding corners 709 and 710. The second portion 707 is separated from the first portion 706 of the side surface 705 by the protruding corner 710. The second portion 707 of the side surface 705 may include a second curved portion 752 that joins a third straight portion 751 and a fourth straight portion 753. Further, the body 701 may include a third portion 708 separated from the first portion 706 of the side surface 705 by the protruding corner 709 and separated from the second portion 70 7 by the protruding corner 711. The third portion 708 of the side surface 705 may include a fifth No other protruding corners are arranged between them.

[0104] As illustrated, the body 701 may include a first portion 706 including a first curved portion 742 disposed between a first straight portion 741 and a second straight portion 743 and between the protruding corners 709 and 710. The second portion 707 is separated from the first portion 706 of the side surface 705 by the protruding corner 710. The second portion 707 of the side surface 705 may include a second curved portion 752 that joins a third straight portion 751 and a fourth straight portion 753. Further, the body 701 may include a third portion 708 separated from the first portion 706 of the side surface 705 by the protruding corner 709 and separated from the second portion 70 7 by the protruding corner 711. The third portion 708 of the side surface 705 may include a fifth 753. Further, the body 701 may include a third portion 708 separated from the first portion 706 of the side surface 705 by the protruding corner 709 and separated from the second portion 70 7 by the protruding corner 711. The third portion 708 of the side surface 705 may include a fifth portion 708 of the side surface 705 may include a fifth It may include a third curved portion 762 that joins the straight portion 761 and the sixth straight portion 763.

[0105] FIG. 7B is a top view of the shaped abrasive particles 730 according to one embodiment. The tip sharpness of the shaped abrasive particles, which may be the average tip sharpness, can be measured by determining the radius of the best-fit circle on the chamfer 731 of the body 732. For example, referring to FIG. 7B, a top view of the upper main surface 733 of the body 732 is provided. At the chamfer 731, the best-fit circle is superimposed on the image of the body 732 of the shaped abrasive particle 730, and the radius of the best-fit circle with respect to the curvature of the chamfer 731 defines the value of the tip sharpness of the chamfer 731. To determine the individual average tip sharpness of a single shaped abrasive particle 730, the measurement can be reproduced for each chamfer of the body 732. Further, to obtain the average batch tip sharpness, the measurement can be reproduced with an appropriate sample size of the shaped abrasive particles in a batch of shaped abrasive particles. Any suitable computer program, such as ImageJ, can be used with an image at an appropriate magnification (e.g., an SEM image or an optical microscope image) to accurately measure the best-fit circle and the tip sharpness. The tip sharpness of the shaped abrasive particles, which may be the average tip sharpness, can be measured by determining the radius of the best-fit circle on the chamfer 731 of the body 732. For example, referring to FIG. 7B, a top view of the upper main surface 733 of the body 732 is provided. At the chamfer 731, the best-fit circle is superimposed on the image of the body 732 of the shaped abrasive particle 730, and the radius of the best-fit circle with respect to the curvature of the chamfer 731 defines the value of the tip sharpness of the chamfer 731. To determine the individual average tip sharpness of a single shaped abrasive particle 730, the measurement can be reproduced for each chamfer of the body 732. Further, to obtain the average batch tip sharpness, the measurement can be reproduced with an appropriate sample size of the shaped abrasive particles in a batch of shaped abrasive particles. Any suitable computer program, such as ImageJ, can be used with an image at an appropriate magnification (e.g., an SEM image or an optical microscope image) to accurately measure the best-fit circle and the tip sharpness. The shaped abrasive particles of the embodiments herein can have a specific tip sharpness that can promote appropriate performance in the fixed abrasive articles of the embodiments herein. For example, the body of the shaped abrasive particle can have a tip sharpness of 80 micrometers or less, for example, 70 micrometers or less, 60 micrometers or less, 50 micrometers or less, 40 micrometers or less, 30 micrometers or less, 20 micrometers or less, or even 10 micrometers. In yet another non-limiting embodiment, the tip sharpness is

[0106] The shaped abrasive particles of the embodiments herein can have a specific tip sharpness that can promote appropriate performance in the fixed abrasive articles of the embodiments herein. For example, the body of the shaped abrasive particle can have a tip sharpness of 80 micrometers or less, for example, 70 micrometers or less, 60 micrometers or less, 50 micrometers or less, 40 micrometers or less, 30 micrometers or less, 20 micrometers or less, or even 10 micrometers. In yet another non-limiting embodiment, the tip sharpness is For example, the body of the shaped abrasive particle can have a tip sharpness of 80 micrometers or less, for example, It can be at least 2 micrometers, for example, at least 4 micrometers, at least 10 micrometers, at least 20 micrometers, at least 3 0 micrometers, at least 40 micrometers, at least 50 micrometers, at least 6 0 micrometers, at least 60 micrometers, or even at least 70 micrometers. It will be understood that the body can have a tip sharpness within the range between any of the above minimum and maximum values.

[0107] Another particle characteristic of the shaped abrasive particles is the shape index. The shape index of the body of the shaped abrasive particles can be represented as the value obtained by comparing the outer diameter of the best-fit circumcircle superimposed on the body when viewed on a two-dimensional plane of the length and width of the body (for example, the upper main surface or the lower main surface) with the inner diameter of the largest best-fit incircle that perfectly fits within the body when the length and width are viewed in the same plane. For example, referring to FIG. 7C, the shaped abrasive particle 770 is given two circles superimposed on the figure to demonstrate the calculation of the shape index. The first circle is the best-fit circumcircle representing the smallest circle that can be used to fit the entire circumference of the body 770 within its boundary. The outer circle has a radius (Ro). In the case of a shape as illustrated in FIG. 7C, the outer circle can intersect the perimeter of the body at each of the three protruding corners. However, in the case of some irregular or complex shapes, it may not be possible for the body to fit evenly within the circle such that each protruding corner intersects the circumference at equal intervals, but it will be understood that the best-fit circumcircle can be formed. Any suitable computer program, such as Image J, can be used with an image at an appropriate magnification (for example, an SEM image or an optical microscope image) to create the outer circle and measure the radius (Ro). ​​​​​​​​​​​​​It is possible.

[0108] As illustrated in FIG. 7C, the second inner circle, when viewed in the plane of the length and width of the body 770, is the best-fit circle representing the largest circle that can be completely disposed within the outer periphery of the body 770. The second inner circle can be superimposed on the body 77 0. The inner circle can have a radius (Ri). In some cases of irregular shapes or complex shapes, as shown for the shape of FIG. 7C, it is understood that the inner circle may not fit uniformly within the body such that the circumference of the circle contacts the portion of the body at equal intervals . However, a best-fit inner circle can be further formed. Any suitable computer program such as ImageJ can be used together with an image at an appropriate magnification (e.g., an SEM image or an optical microscope image) to create the inner circle and measure the radius (Ri).

[0109] The shape index can be calculated by dividing the outer radius by the inner radius (i.e., shape index = Ri / Ro). For example, the body 770 of the shaped abrasive particle has a shape index of about 0.35. Further, an equilateral triangle generally has a shape index of about 0.5, while other polygons such as hexagons or pentagons have shape index values greater than 0 .5. According to one embodiment, the shaped abrasive particles herein can have a shape index of at least 0.15, at least 0.20, at least 0 .25, at least 0.30, at least 0.35, at least 0.40, at least 0 .45, at least about 0.5, at least about 0.55, at least 0.60, at least .65, at least 0.70, at least 0.75, at least 0.80, at least .85, at least 0.90, at least 0.95. In yet another non-limiting embodiment , the shaped abrasive particles can have a shape index of 1 or less, for example, 0.98 ​ Hereinafter, it may be 0.95 or less, 0.90 or less, 0.85 or less, 0.80 or less, 0.75 or less, 0. 70 or less, 0.65 or less, 0.60 or less, 0.55 or less, 0.50 or less, 0.45 or less, 40 or less, 0.35 or less, 0.30 or less, 0.25 or less, 0.20 or less, or even 0.1 5 or less. It will be understood that the shaped abrasive particles can have a shape factor within the range between any of the above minimum and maximum values.

[0110] FIG. 7D is a top view of shaped abrasive particles according to another embodiment. The shaped abrasive particles 780 can have a body 781 having the shape of other shaped abrasive particles of the embodiments of the present specification, including an upper major surface 783 and a lower major surface (not shown) facing the upper major surface 783. The upper major surface 78 3 and the lower major surface can be separated from each other by at least one side surface 7 84 that can include one or more distinct side portions. According to one embodiment, the body 781 can have an irregular hexagonal two-dimensional shape (i.e., having six sides) when viewed in a plane of the length and width of the body 781, and can be defined as an irregular hexagon, and at least two side surfaces such as side surfaces 785 and 786 have different lengths from each other. In particular, the longest dimension along one of the side surfaces means the width of the body 7 81, and the length of the body is the longest dimension extending from one side of the body through the midpoint of the body 781 to the other side (e.g., from a corner to the corner on the opposite flat side) as understood herein. Further, as illustrated, none of the sides are parallel to each other. Further although not illustrated, any of the side surfaces may have a curvature including a concave curvature in which the side surface curves inwardly toward the inside of the body 781. is understood herein. Further, as illustrated, none of the sides are parallel to each other. Further moreover, although not illustrated, any of the side surfaces may have a curvature including a concave curvature in which the side surface curves inwardly toward the inside of the body 781.

[0111] ​​​​​​FIG. 8 is a cross-sectional view of a part of abrasive particles according to an embodiment. As shown in the figure, the abrasive particles are , as seen in the cross-sectional view, a body 801 including a first main surface 802, a second main surface 803, and side surfaces 804 and 805 extending between the first main surface 802 and the second main surface 803. The abrasive particles 800 may include shaped abrasive particles. The abrasive particles 800 may further include a plurality of abrasive particles bonded to some surfaces of the body 801 of the shaped abrasive particles. The plurality of abrasive particles may include one or more portions of particles distinguishable as an abrasive particle group, and different groups may have at least one different abrasive characteristic from each other. The abrasive characteristics include, but are not limited to, average particle size, average crystallite size, hardness, toughness, two-dimensional shape, three-dimensional shape, shaped abrasive particles, non-shaped abrasive particles, composition, standing angle, orientation, and combinations thereof. By using different groups, the abrasive particles can be easily adjusted for a given application. Further, different groups may or may not be bonded to different surfaces of the body 801 of the shaped abrasive particles. That is, in one embodiment, the same single surface of the body 801 may include a plurality of groups of abrasive particles. In still other embodiments, the body 801 of the shaped abrasive particles may have different groups of abrasive particles bonded to different surfaces of the body 801. In particular, the abrasive particles 800 may include a plurality of abrasive particles including a first group of abrasive particles 810 attached to a part of the first main surface 802. The first group of abrasive particles 810 may include fine shaped abrasive particles 811 having an average particle size significantly smaller than the average particle size of the body 801 of the shaped abrasive particles. The fine shaped abrasive particles may have any characteristics of other shaped abrasive particles as described in the embodiments of the present specification. In one particular embodiment, the fine shaped abrasive particles are shaped abrasive particles. By using different groups, the abrasive particles can be easily adjusted for a given application. Further, different groups may or may not be bonded to different surfaces of the body 801 of the shaped abrasive particles. That is, in one embodiment, the same single surface of the body 801 may include a plurality of groups of abrasive particles. In still other embodiments, the body 801 of the shaped abrasive particles may have different groups of abrasive particles bonded to different surfaces of the body 801. In particular, the abrasive particles 800 may include a plurality of abrasive particles including a first group of abrasive particles 810 attached to a part of the first main surface 802. The first group of abrasive particles 810 may include fine shaped abrasive particles 811 having an average particle size significantly smaller than the average particle size of the body 801 of the shaped abrasive particles. The fine shaped abrasive particles may have any characteristics of other shaped abrasive particles as described in the embodiments of the present specification. In one particular embodiment, the fine shaped abrasive particles are shaped abrasive particles. groups of abrasive particles bonded to different surfaces of the body 801.

[0112] In particular, the abrasive particles 800 may include a plurality of abrasive particles including a first group of abrasive particles 810 attached to a part of the first main surface 802. The first group of abrasive particles 810 may include fine shaped abrasive particles 811 having an average particle size significantly smaller than the average particle size of the body 801 of the shaped abrasive particles. The fine shaped abrasive particles may have any characteristics of other shaped abrasive particles as described in the embodiments of the present specification. In one particular embodiment, the fine shaped abrasive particles are shaped abrasive particles. The first group of abrasive particles 810 may include fine shaped abrasive particles 811 having an average particle size significantly smaller than the average particle size of the body 801 of the shaped abrasive particles. The fine shaped abrasive particles may have any characteristics of other shaped abrasive particles as described in the embodiments of the present specification. In one particular embodiment, the fine shaped abrasive particles are shaped abrasive particles. particles. In yet another embodiment, the particle may have a two-dimensional shape that is substantially the same as the two-dimensional shape of the body of the particle. The micro-shaped abrasive particles may have a two-dimensional shape that is different from the two-dimensional shape of the body of the shaped abrasive particle. The micromolded abrasive particles may have any three-dimensional shape as described herein. It will also be understood that

[0113] In particular, the finely molded abrasive particles may be formed to have a median diameter for the length, width, and / or height of the body 801. When the plurality of abrasive particles includes fine molded abrasive particles, the molded abrasive particles may have a particle size. The present invention relates to the median particle size of a plurality of abrasive particles relative to the length, width, or height of the body of the particle. The same relationships as stated in the subsection apply. The micromolded abrasive particles have length≦width≦height, and the micromolded The average length of the shaped abrasive particle is less than the length of the body of the shaped abrasive particle.

[0114] For example, the fine shaped abrasive particles 810 may be about 90% or less of the length of the body 801 of the shaped abrasive particle. For example, the average length of the or about 60% or less of the length, or about 50% or less of the length, or about 40% or less of the length About 30% or less of the length, or about 25% or less of the length, or about 20% or less of the length, or about 18% or less of the length % or less, or about 15% or less of the length, or about 12% or less of the length, or about 10% or less of the length, Or 8% or less of the length, or 6% or less of the length, or 5% or less of the length. In one embodiment, the fine shaped abrasive particles 811 are spaced apart along the length of the body 801 of the shaped abrasive particle. It may have an average length of at least about 0.1%, or at least about 0.5% of the length , or at least about 1% of the length, or at least about 2% of the length, or at least about 3%, or at least about 4% of the length, or at least about 5% of the length, or at least about 6% of the length, or at least about 7% of the length, or at least about 8% of the length, or at least about 9% of the length, or at least about 10% of the length, or at least about 12% of the length, or at least about 15% of the length, or at least about 18% of the length, or at least about 20 %, or at least about 25% of the length, or at least about 30%. It is understood that the average length of the fine shaped abrasive particles is within the range between any of the above minimum and maximum percentages.

[0115] Furthermore, the fine shaped abrasive particles can have a specific average width that is shorter than the length of the body 801 of the shaped abrasive particles. According to one embodiment, the fine shaped abrasive particles 811 can have an average width that is about 90% or less of the length of the body 801, for example, about 80% or less of the length of the body of the shaped abrasive particles, or about 70% or less of the length, or about 60% or less of the length, or about 50% or less of the length, or about 40% or less of the length, or about 30% or less of the length, or about 25% or less of the length, or about 20% or less of the length, or about 18% or less of the length, or about 15% or less of the length, or about 12% or less of the length, or about 10% or less of the length, or about 8% or less of the length, or about 6% or less of the length, or about 5% or less of the length. In yet another embodiment, the fine shaped abrasive particles 811 can have an average width that is at least about 0.1% of the length of the body 801, for example, at least about 0.5% of the length of the body of the shaped abrasive particles, or at least about 1% of the length, or at least about 2% of the length, or at least about 3% of the length, or at least about 4% of the length, or at least about 5% of the length, or at least about 6% of the length, or at least about 7% of the length, or at least about 8% of the length, or at least about 9% of the length, or at least about 10% of the length, or at least about 12% of the length, or at least about 15% of the length, or at least about 18% of the length, or at least about 20 %, or at least about 25% of the length, or at least about 30% of the length. ​At least about 8%, or at least about 9%, or at least about 10%, or At least about 12% of the length, or at least about 15% of the length, or at least about 18% of the length %, or at least about 20% of the length, or at least about 25% of the length, or at least about The average width of the micromolded abrasive particles is within any of the minimum and maximum percentages listed above. It will be understood that the range is between 100 and 200.

[0116] In yet another embodiment, the fine shaped abrasive particles 811 are spaced apart along the length of the body 801 of the shaped abrasive particle. For example, the micro-molded abrasive particles 811 may have an average height less than the length of the body 801. 801 of the shaped abrasive particle body 801. About 80% or less of the length, or about 70% or less of the length, or about 60% or less of the length, or about 50% or less of the length 0% or less, or about 40% or less of the length, or about 30% or less of the length, or about 25% or less of the length or about 20% or less of the length, or about 18% or less of the length, or about 15% or less of the length About 12% or less of the length, or about 10% or less of the length, or about 8% or less of the length, or about 6% of the length or less than about 5% of the length. The shaped abrasive particles 811 have an average height of at least about 0.01% of the length of the body 801. For example, at least about 0.5% of the length of the body 801 of the shaped abrasive particle, or at least about 1% of the length, or at least about 2% of the length, or at least about 3% of the length, or at least about 4% of the length, or at least about 5% of the length, or at least about 6% of the length; or at least about 7% of the length, or at least about 8% of the length, or at least about 9% of the length %, or at least about 10% of the length, or at least about 12% of the length, or at least at least 15% of the length, or at least about 18% of the length, or at least about 20% of the length or at least about 25% of the length, or at least about 30% of the length. The average height of the micro-formed abrasive particles is understood to be within the range between any of the above minimum and maximum percentages. It will be.

[0117] Referring to FIG. 8, it will be understood that most of the plurality of abrasive particles covering the body 801 can be micro-formed abrasive particles. Furthermore, in some cases, all of the plurality of abrasive particles covering the body 801 can be essentially micro-formed abrasive particles.

[0118] The composite-formed abrasive particle 800 may further include a second group of abrasive particles 812 attached to the first main surface 802 of the body 801. The second group of abrasive particles 812 may be non-formed abrasive particles 813. According to one embodiment, as illustrated in FIG. 8, at least one surface of the body 801, such as the first main surface 802 of the abrasive particle 800, may have a mixture of two different types of abrasive particles. The first group of abrasive particles 810 and the second group of abrasive particles 812 may be disposed on the first main surface 802 using any of the techniques described herein. The first group of abrasive particles 810 and the second group of abrasive particles 812 may be deposited on the first main surface 802 simultaneously or separately.

[0119] Furthermore, the first group of abrasive particles 810 may have a first average particle size that can be defined by the average length in the case of micro-formed abrasive particles. And the second group of abrasive particles 812 may have a second average particle size that can be defined by the average length in the case of micro-formed abrasive particles. In some cases, Therefore, the first and second average particle sizes may be different from each other. In yet another embodiment the first and second average particle sizes may be substantially the same. The relative sizes of the abrasive particles 811 of the first abrasive particle group 810 and the abrasive particles 813 of the second abrasive particle group 812 can be adjusted according to the desired use of the abrasive particles.

[0120] Furthermore, as another example, the abrasive particles 800 may include a third abrasive particle group 817 that can be bonded to the second main surface 803 of the body 801. The third abrasive particle group 817 may include fine shaped abrasive particles 818 that may have an average particle size significantly smaller than that of the body 801 of the shaped abrasive particles. The fine shaped abrasive particles 818 may have a different two-dimensional shape compared to the shaped abrasive particles 811 of the first abrasive particle group 810.

[0121] Furthermore, at least a part of the fine shaped abrasive particles 818 may be oriented in a standing position with respect to the surface 803 of the body 801 of the shaped abrasive particles. Although the abrasive particle group 817 is exemplified as shaped abrasive particles, it may also include elongated abrasive particles that may be shaped or non-shaped and may be oriented in a standing position with respect to the surface 803 of the body 801. It will be understood that this is the case. According to one embodiment the standing orientation may be defined by the maximum surface (i.e., the main surface) of the body of the fine shaped abrasive particles disposed at an interval from the surface of the body of the shaped abrasive particles. Furthermore, the standing orientation of the fine shaped abrasive particles 818 can be defined by the standing angle 820 between the longitudinal axis 819 of the fine shaped abrasive particles 820 (or shaped or non-shaped elongated abrasive particles) and the main surface 803 of the body 801. The standing angle 820 is at least 5 degrees, for example at least 10 degrees, at least At least 20 degrees, at least 30 degrees, or at least 40 degrees, or at least 50 degrees, or at least 60 degrees, or at least 70 degrees, or at least 80 degrees, or at least 85 degrees. In at least one embodiment, the micro - formed abrasive particles 818 are in a standing orientation with respect to the surface 803 of the body 801 and define a substantially vertical standing angle 820 as illustrated in FIG. 8. In at least one embodiment, the micro - formed abrasive particles 818 are in a standing orientation with respect to the surface 803 of the body 801 and define a substantially vertical standing angle 820 as illustrated in FIG. 8. To define.

[0122] Furthermore, in another embodiment, the abrasive particle group 817 may include a part of the flat - arranged abrasive particles 830. In the flat - arranged orientation, the longitudinal axis of the abrasive particle 831 can be substantially parallel to the surface 803 of the body 801. Furthermore, in another embodiment, the abrasive particle group 817 may include a part of the flat - arranged abrasive particles 830. In the flat - arranged orientation, the longitudinal axis of the abrasive particle 831 can be substantially parallel to the surface 803 of the body 801. To be substantially parallel.

[0123] FIG. 9 is a top view of abrasive particles according to one embodiment. As illustrated, the abrasive particles 900 may include a formed abrasive particle having a body 901 and a plurality of abrasive particles 940 bonded to cover the main surface 905 of the body 901. To have a formed abrasive particle having a body 901 and a plurality of abrasive particles 940 bonded to cover the main surface 905 of the body 901. According to one embodiment, as illustrated, the plurality of abrasive particles 940 may be arranged in one or more distributions on one or more surfaces of the body 901. According to one embodiment, as illustrated, the plurality of abrasive particles 940 may be arranged in one or more distributions on one or more surfaces of the body 901.

[0124] As illustrated, in one embodiment, the plurality of abrasive particles 940 may include different groups. For example, the plurality of abrasive particles 940 may include a first abrasive particle group 902 that may include micro - formed abrasive particles 903 arranged in a controlled distribution on the surface 905 of the body 901. The micro - formed abrasive particles 903 may be arranged flat with respect to the surface 905 of the body 905. To include a first abrasive particle group 902 that may include micro - formed abrasive particles 903 arranged in a controlled distribution on the surface 905 of the body 901. The micro - formed abrasive particles 903 may be arranged flat with respect to the surface 905 of the body 905. The micro - formed abrasive particles 903 may be arranged in a pattern defined by a plurality of repeating units, and each repeating unit of the plurality of repeating units is substantially the same as each other. As illustrated in this embodiment, The micro - formed abrasive particles 903 may be arranged in a pattern defined by a plurality of repeating units, and each repeating unit of the plurality of repeating units is substantially the same as each other. As illustrated in this embodiment, Each repeating unit of the plurality of repeating units is substantially the same as each other. As illustrated in this embodiment, As shown, the fine-shaped abrasive particles 903 are arranged in a pattern defined by a substantially triangular repeating unit as indicated by the dotted line. In at least one embodiment, the abrasive particles 900 are formed such that, as shown, the fine abrasive particles 903 extend over a majority or substantially the entire surface 905 of the body 901 in a controlled distribution. This will be understood to apply to any of the abrasive particle groups exemplified herein. Further, in some cases, one or more abrasive particle groups may bond to cover the same surface of the body 901 and define different distributions and / or orientations with respect to each other.

[0125] According to another embodiment, the plurality of abrasive particles 940 may include a second abrasive particle group 910 that may include fine-shaped abrasive particles 911 that may be arranged on the surface 905 of the body 901 in a random distribution. The fine-shaped abrasive particles 911 can be in an upright orientation with respect to the surface 905 of the body 905. The fine-shaped abrasive particles 911 have no recognizable repeating unit and are thus arranged in a substantially random distribution when compared to each other. It will be understood that other types of abrasive particles can be used and other orientations of the abrasive particles can be employed. In at least one embodiment, the abrasive particles 900 are formed such that, as exemplified, the fine abrasive particles 911 extend over a majority or substantially the entire surface 905 of the body 901 in a random distribution.

[0126] In yet another embodiment, the plurality of abrasive particles 940 may include a third abrasive particle group 920 that may include fine-shaped abrasive particles 921 that may be arranged on the surface 905 of the body 901 in a controlled distribution. The fine-shaped abrasive particles 921 can be in an upright orientation with respect to the surface 905 of the body 905. It is possible. As exemplified in this embodiment, the fine-machining abrasive particles 921 can be arranged in a pattern defined by a substantially rectangular repeating unit as shown by the dotted line. In at least one embodiment, the abrasive particles 900 can be formed such that, as exemplified, the fine abrasive particles 903 extend over most or substantially the entire surface 905 of the main body 901 in a controlled distribution. In at least one embodiment, the abrasive particles 900 can be formed such that, as exemplified, the fine abrasive particles 903 extend over most or substantially the entire surface 905 of the main body 901 in a controlled distribution. It can be formed so as to extend. Other types of abrasive particles can be used, and other orientations of the abrasive particles can be used, as will be understood. It can be formed so as to extend. Other types of abrasive particles can be used, and other orientations of the abrasive particles can be used, as will be understood. In yet another embodiment, the plurality of abrasive particles 940 can include a fourth group of abrasive particles 930 that can include non-shaped abrasive particles 931 that can be arranged on the surface 905 of the main body 901 in a random distribution. The non-shaped abrasive particles 931 can be arranged substantially randomly with respect to each other. In at least one embodiment, the abrasive particles 900 can be formed such that, as exemplified, the non-shaped abrasive particles 931 extend over most or substantially the entire surface 905 of the main body 901 in a random distribution.

[0127] In yet another embodiment, the plurality of abrasive particles 940 can include a fourth group of abrasive particles 930 that can include non-shaped abrasive particles 931 that can be arranged on the surface 905 of the main body 901 in a random distribution. The non-shaped abrasive particles 931 can be arranged substantially randomly with respect to each other. In at least one embodiment, the abrasive particles 900 can be formed such that, as exemplified, the non-shaped abrasive particles 931 extend over most or substantially the entire surface 905 of the main body 901 in a random distribution. In yet another embodiment, the plurality of abrasive particles 940 can include a fourth group of abrasive particles 930 that can include non-shaped abrasive particles 931 that can be arranged on the surface 905 of the main body 901 in a random distribution. The non-shaped abrasive particles 931 can be arranged substantially randomly with respect to each other. In at least one embodiment, the abrasive particles 900 can be formed such that, as exemplified, the non-shaped abrasive particles 931 extend over most or substantially the entire surface 905 of the main body 901 in a random distribution. In yet another embodiment, the plurality of abrasive particles 940 can include a fourth group of abrasive particles 930 that can include non-shaped abrasive particles 931 that can be arranged on the surface 905 of the main body 901 in a random distribution. The non-shaped abrasive particles 931 can be arranged substantially randomly with respect to each other. In at least one embodiment, the abrasive particles 900 can be formed such that, as exemplified, the non-shaped abrasive particles 931 extend over most or substantially the entire surface 905 of the main body 901 in a random distribution. In at least one embodiment, the abrasive particles 900 can be formed such that, as exemplified, the non-shaped abrasive particles 931 extend over most or substantially the entire surface 905 of the main body 901 in a random distribution. In at least one embodiment, the abrasive particles 900 can be formed such that, as exemplified, the non-shaped abrasive particles 931 extend over most or substantially the entire surface 905 of the main body 901 in a random distribution. It can be formed so as to extend. Other types of abrasive particles can be used, and other orientations of the abrasive particles can be used, as will be understood.

[0128] In at least one embodiment, at least some of the plurality of abrasive particles can have a coating that covers at least a portion of the outer surface of the abrasive particles. The coating can include a material selected from the group consisting of inorganic, organic, amorphous, crystalline, polycrystalline, ceramic, metal, resin, epoxy, polymer, oxide, carbide, nitride, boride, carbon-based materials, and combinations thereof. In at least one embodiment, at least some of the plurality of abrasive particles can have a coating that covers at least a portion of the outer surface of the abrasive particles. The coating can include a material selected from the group consisting of inorganic, organic, amorphous, crystalline, polycrystalline, ceramic, metal, resin, epoxy, polymer, oxide, carbide, nitride, boride, carbon-based materials, and combinations thereof. In at least one embodiment, at least some of the plurality of abrasive particles can have a coating that covers at least a portion of the outer surface of the abrasive particles. The coating can include a material selected from the group consisting of inorganic, organic, amorphous, crystalline, polycrystalline, ceramic, metal, resin, epoxy, polymer, oxide, carbide, nitride, boride, carbon-based materials, and combinations thereof. In at least one embodiment, at least some of the plurality of abrasive particles can have a coating that covers at least a portion of the outer surface of the abrasive particles. The coating can include a material selected from the group consisting of inorganic, organic, amorphous, crystalline, polycrystalline, ceramic, metal, resin, epoxy, polymer, oxide, carbide, nitride, boride, carbon-based materials, and combinations thereof. In at least one embodiment, at least some of the plurality of abrasive particles can have a coating that covers at least a portion of the outer surface of the abrasive particles. The coating can include a material selected from the group consisting of inorganic, organic, amorphous, crystalline, polycrystalline, ceramic, metal, resin, epoxy, polymer, oxide, carbide, nitride, boride, carbon-based materials, and combinations thereof.

[0129] According to one embodiment, the abrasive particles of the embodiments herein can have a particularly rough, jagged surface. Abrasive particles having a smooth surface and sharp edges provide the best performance. According to one embodiment, the abrasive particles of the embodiments herein can have a particularly rough, jagged surface. Abrasive particles having a smooth surface and sharp edges provide the best performance. It has been noted by some in the industry. However, surprisingly, abrasive grains having a rough surface with a plurality of abrasive particles attached thereto may have improved functionality compared to abrasive grains having no particles (i.e., abrasive grains having a smoother surface) attached to one or more surfaces wherein a plurality of particles are not attached. The applicant of the present disclosure has discovered this.

[0130] In at least one particular embodiment, the abrasive particles can include a body of shaped abrasive particles having a first major surface and a second major surface separated from the first major surface by a side surface wherein a plurality of abrasive particles are attached to at least the first major surface or the second major surface and the side surface essentially does not include a plurality of abrasive particles. In yet another example, the abrasive particles can include a body of shaped abrasive particles having a first major surface and a second major surface separated from the first major surface by a side surface wherein a plurality of abrasive particles are attached to the first major surface and the second major surface and the side surface essentially does not include a plurality of abrasive particles. Further, it will be understood that a plurality of abrasive particles can be attached covering one or more side surfaces of the body of the shaped abrasive particles . FIG. 12A is a cross-sectional view of an abrasive paper article incorporating an abrasive particulate material according to one embodiment

[0131] . In particular, a plurality of abrasive particles on one or more surfaces of the abrasive particles are not shown but will be understood to be present in accordance with the embodiments of the present specification. By way of example, abrasive paper 1 200 can include a substrate 1201 and a make coat layer 1203 covering the surface of the substrate 1201 . Abrasive paper 1200 can include a first type of abrasive particulate material 1205 in the form of a first type of shaped abrasive particles, a second type of abrasive particulate material 1206 in the form of a second type of shaped abrasive particles . ​​and diluent abrasive particles having random shapes, not necessarily shaped abrasive particles. The coated abrasive 1200 may further include a third type of abrasive particulate material in the form of a size coat layer 1204 that covers and bonds the particulate materials 1205, 1206, 1207; and a make coat layer 1204.

[0132] According to one embodiment, the substrate 1201 can be made of organic materials, inorganic materials, and combinations thereof. In some cases, the substrate 1201 may include a woven material. 1 may be made from a non-woven material. Particularly suitable substrate materials are polymers, especially poly Polyester, polyurethane, polypropylene, polypropylene such as KAPTON from DuPont Some suitable inorganic materials include metals, gold, Metal alloys, and in particular copper foil, aluminum foil, steel foil, and combinations thereof. I can see it.

[0133] The make coat layer 1203 may be applied to the surface of the substrate 1201 in a single step, or alternatively, In addition, the abrasive particles 1205, 1206, and 1207 are combined with the make coat layer 1203 material. The make coat layer 1201 can be applied to the surface of the substrate 1201 as a mixture. Suitable materials for 203 include organic materials, especially polymeric materials, such as polyester, epoxy, etc. Resin, polyurethane, polyamide, polyacrylate, polymethacrylate, polyvinyl chloride Nyl, polyethylene, polysiloxane, silicone, cellulose acetate, nitrocellulose In one embodiment, the composition may include cellulose, natural gum, starch, shellac, and mixtures thereof. In the embodiment, the make coat layer 1203 may include a polyester resin. can then be heated to cure the resin and abrasive particulate material onto the substrate. Generally, the coated substrate 1201 can be heated to a temperature between about 100 °C and less than about 250 °C during this curing process.

[0134] Furthermore, the abrasive sheet article can include one or more aggregates of various types of abrasive particles, which exhibit the abrasive particles of the embodiments herein, such as abrasive particulate materials 1205, 1206, and 1207. It will be understood that the embodiments herein can include a fixed abrasive article (e.g., an abrasive sheet article) having a first aggregate of abrasive particles that exhibit the abrasive particles of the embodiments herein (e.g., abrasive particulate material 1205). Any fixed abrasive can further use a second aggregate of abrasive particles that can exhibit different types of abrasive particles according to the embodiments herein. The second aggregate of abrasive particles differs from the abrasive particles of the first aggregate in one or more respects and includes, but is not limited to, one or more of the abrasive characteristics described herein. The same features may be utilized for a combined abrasive article.

[0135] Abrasive particulate materials 1205, 1206, and 1207 can include different types of shaped abrasive particles according to the embodiments herein. Different types of shaped abrasive particles can differ from each other in composition, two-dimensional shape, three-dimensional shape, size, and combinations thereof, as described in the embodiments herein. As an illustration, abrasive sheet 1200 can include a first type of shaped abrasive particle 1205 having a generally triangular two-dimensional shape and a second type of shaped abrasive particle 1206 having a quadrilateral two-dimensional shape. Abrasive sheet 1200 can include different amounts of the first type of shaped abrasive particle 1205 and the second type of shaped abrasive particle 1206. The abrasive sheet does not necessarily ​​​​​​​​​ It is not necessary to include different types of shaped abrasive particles, and it can be understood that it can consist essentially of a single type of shaped abrasive particle. As will be understood, the shaped abrasive particles of the embodiments herein can be in a mixed form including different types of shaped abrasive particles, and include various fixed abrasives (e.g., bonded abrasives, abrasive cloth papers, non-woven abrasives, thin wheels, cutoff wheels, reinforced abrasive articles, etc.) including shaped abrasive particles having diluent particles. Further, according to some embodiments, a batch of particulate material can be incorporated into a fixed abrasive article in a predetermined orientation, and each of the shaped abrasive particles can have a predetermined orientation with respect to each other and with respect to a portion of the abrasive article (e.g., the backing of the abrasive cloth paper).

[0136] The abrasive particles 1207 can be diluent particles different from the first type of shaped abrasive particles 1205 and the second type of shaped abrasive particles 1206. For example, the diluent particles can be different from the first type of shaped abrasive particles 1205 and the second type of shaped abrasive particles 1206 in terms of composition, two-dimensional shape, three-dimensional shape, size, and combinations thereof. For example, the abrasive particles 1207 can represent conventional crushed abrasive grains having a random shape. The abrasive particles 1207 can have a median particle diameter smaller than the median particle diameters of the first type of shaped abrasive particles 1205 and the second type of shaped abrasive particles 1206.

[0137] After sufficiently forming the make coat layer 503 together with the abrasive fine particle materials 1205, 1206, and 1207 contained therein, the size coat layer 1204 can be formed to cover the abrasive fine particle material 1205 and bond it to a predetermined position. The size coat layer 1204 contains an organic material. ​​​​​​​​​​​​​​​and can be substantially composed of a polymer material, particularly, polyester, epoxy resin, po lyurethane, polyamide, polyacrylate, polymethacrylate, polyvinyl chloride, po lyethylene, polysiloxane, silicone, cellulose acetate, nitrocellulose, natural rubber, starch, shellac, and mixtures thereof can be used.

[0138] FIG. 12B is a perspective view of a portion of a polishing cloth article including abrasive particles according to one embodiment. In particular, the exemplary embodiment of FIG. 12B includes a polishing article 1230, and the polishing article 1230 includes abrasive particles 1231. The abrasive particles 1231 include shaped abrasive particles 1232, and the shaped abrasive particles 12 32 have a body including a plurality of abrasive particles 1234 bonded to a first major surface 1235 of the body of the shaped abrasive particles. In particular, the polishing cloth article includes a backing 1236 having a longitudinal axis 1237 and a transverse axis 1238. In one embodiment, the abrasive particles 1231 are disposed on the backing 1236 and can be bonded to the backing 1236 in a specific orientation using one or more adhesive layers (e.g., make coat layer, size coat layer, etc.) as shown herein. In some examples, the orientation of the first major surface 1235 of the abrasive particles 1231, which includes a plurality of shaped abrasive particles 1234, can be controlled on the backing 1236 such that it has a specific orientation with respect to the longitudinal axis 1237 and / or the transverse axis 1238 of the backing 1236. For example, in some cases, the first major surface 1235 including the plurality of abrasive particles 1234, as in the case of the abrasive particles 1232, can be oriented substantially perpendicular to the longitudinal axis 1237 and substantially parallel to the transverse axis 1238. In some other examples, other arrangements can be disposed on the backing 1236 in a controlled orientation such that the orientation of the first major surface 1235 of the abrasive particles 1231 has a specific orientation with respect to the longitudinal axis 1237 and / or the transverse axis 1238 of the backing 1236. For example, in some cases, the first major surface 1235 including the plurality of abrasive particles 1234, as in the case of the abrasive particles 1232, can be oriented substantially perpendicular to the longitudinal axis 1237 and substantially parallel to the transverse axis 1238. In some other examples, other arrangements can be made. For example, in some cases, the first major surface 1235 including the plurality of abrasive particles 1234 can be oriented substantially perpendicular to the longitudinal axis 1237 and substantially parallel to the transverse axis 1238. In some other examples, other arrangements An orientation may be desirable, for example, the first major surface 1243 of the body of the shaped abrasive particles 1244 includes abrasive particles 1241 having a plurality of abrasive particles 1242 adhered thereto, and the particles are perpendicular to the horizontal axis 1 238 and have a first major surface 1 that is substantially parallel to the longitudinal axis 1237 243 and has a controlled orientation. The abrasive particles may have other controlled orientations such that the orientation of one or more abrasive particles on the backing defines a controlled angle with respect to the horizontal axis 1238 and / or the longitudinal axis 1237, as will be understood . Further, the orientation of the abrasive particles may be controlled depending on the number and / or type of the surface of the coated shaped abrasive particles (i.e., the first major surface and / or the second major surface and / or the side surface). Further, the abrasive cloth article may include one or more groups of abrasive particles on the backing 1236 , and each group of abrasive particles may have at least one abrasive characteristic similar to each other. Suitable examples of some types of abrasive characteristics include the type of coating of a plurality of abrasive particles, the size of a plurality of abrasive particles , the shape of the body of the shaped abrasive particles, the composition of the shaped abrasive particles and / or a plurality of abrasive particles , orientation, tilt angle, and any other features of the embodiments detailed herein. Further, the abrasive particles from different groups on the backing may differ in at least one of the abrasive characteristics described herein . . FIG. 13A is a view of a bonded abrasive article incorporating an abrasive particulate material according to one embodiment . As an illustration, the bonded abrasive 1300 may include a binder 1301, an abrasive particulate material 1302 contained in the binder

[0139] , and pores 1308 in the binder 1301. In a specific example, the binder material 1301 may include organic materials, inorganic materials, and combinations thereof. Suitable organic materials include organic materials, inorganic materials, and combinations thereof. Suitable organic materials include organic materials, inorganic materials, and combinations thereof. Suitable organic materials The material may include polymers such as epoxy, resin, thermosetting resin, thermoplastic resin, polyimide, polyamide, and combinations thereof. Some suitable inorganic materials may include metals, metal alloys, glass phase materials, crystalline phase materials, ceramics, and combinations thereof. .

[0140] The abrasive grains material 1302 of the bonded abrasive 1300 can have any characteristics of different types of formed abrasive grains, different types of formed abrasive grains 1303, 1304, 1305, and 1306 as described in the embodiments of this specification. Particularly, different types of formed abrasive grains 1303, 1304, 1305, and 1306 can have different compositions, two-dimensional shapes, three-dimensional shapes, sizes, and combinations thereof as described in the embodiments of this specification. That is, they can be different from each other.

[0141] The bonded abrasive 1300 includes one type of abrasive grains material 1307 representing diluent abrasive grains. The diluent abrasive grains can have different compositions, two-dimensional shapes, three-dimensional shapes, sizes, and combinations thereof from different types of formed abrasive grains 1303, 1304, 1305, and 1306.

[0142] The pores 1308 of the bonded abrasive 1300 can be open pores, closed pores, or combinations thereof. The pores 1308 can be present in a majority amount (volume %) relative to the total volume of the body of the bonded abrasive 1300. Alternatively, the pores 1308 can be present in a small amount (volume %) based on the total volume of the body of the bonded abrasive 1300. The bonding material 1301 can be present in a majority amount (volume %) relative to the total volume of the body of the bonded abrasive 1300. Alternatively, the bonding material can be present in a majority amount (volume %) relative to the total volume of the body of the bonded abrasive 1300. The material 1301 may be present in a small amount (volume %) with respect to the total volume of the body of the bonded abrasive 1300. Furthermore, the abrasive particulate material 1302 may be present in a majority amount (volume %) with respect to the total volume of the body of the bonded abrasive 1300. Alternatively, the abrasive particulate material 1302 may be present in a small amount (volume %) based on the total volume of the body of the bonded abrasive 1300.

[0143] FIG. 13B is an illustration of a bonded abrasive article including abrasive particles of an embodiment of the present specification. As illustrated, the bonded abrasive 1350 may include a body 1351 including abrasive particles 1360 and 1370 included within a bonding matrix material 1352 of the body 1351. The abrasive particle 1 360 may include a shaped abrasive particle 1361 and a plurality of abrasive particles 1362 bonded to at least a first major surface 1363 of the body of the shaped abrasive particle 1361. In particular, the abrasive particle 13 60 may have a specific position within the three-dimensional volume of the body 1351 of the bonded abrasive 1350. Further more, the abrasive particle 1360 may have a predetermined orientation controlled with respect to the radial axis 1381 and / or the transverse axis 1382 of the body 1351. According to one embodiment, the first major surface 1363 of the body of the shaped abrasive particle 1361 is substantially parallel to the radial axis 1381 or is substantially parallel to the major surfaces 1354 and 1355 of the body 1351 of the bonded abrasive 1350 such that the abrasive particle 1360 may have an orientation that is considered to be flatly disposed within the body 1351. Further, the first major surface 1363 of the shaped abrasive particle 1361 may be substantially perpendicular to the transverse axis 1382. In some cases, the bonded abrasive may include a portion of abrasive particles having an orientation similar to that of the abrasive particle 1360 within the body, which can easily improve the formation of the bonded particles and / or may easily improve the performance of the bonded abrasive.

[0144] Still by way of example, the abrasive particles 1370 include formed abrasive particles 1371 and a plurality of abrasive particles 1372 bonded to at least a first main surface 1373 of the body of the formed abrasive particles 13 71. In particular, the abrasive particles 1370 may have a specific position within the three-dimensional body of the bonded abrasive 1350's body 1351. Further, the abrasive particles 1370 may have a predetermined orientation controlled with respect to the radial axis 1 381 and / or the transverse axis 1382 of the body 1351. According to one embodiment, the first main surface 1373 of the body of the formed abrasive particles 1371 is substantially parallel to the transverse axis 1382, and the abrasive particles 1360 may have an orientation such that they stand upright within the body 1351 and are substantially perpendicular to the main surfaces 1354 and 1355 of the body 1351 of the bonded abrasive 1350. Further, the first main surface 137 3 of the formed abrasive particles 1371 can be substantially perpendicular to the radial axis 1381. In other examples, the abrasive particles 1370 can be inclined with respect to the transverse axis and oriented within the body 1351 so as to define a controlled tilt angle. In such a situation, the abrasive particles 13 71 may have a first main surface that is neither substantially perpendicular to the radial axis 1381 nor substantially parallel to the transverse axis. Such a controlled tilt angle can include any angle between 5 degrees and 85 degrees. As used herein, references to substantially parallel or substantially perpendicular orientations refer to a difference of 5 degrees or less between the axis or plane and the reference axis. Further, as will be understood, the abrasive particles can have various rotational orientations around the transverse axis 1382 and the radial axis 1381. Referring to the tilt angle, the radial axis 1381 and the component with the largest dimension in the radial direction are considered. The abrasive particles 1370 can be inclined with respect to the transverse axis and oriented within the body 1351 so as to define a controlled tilt angle. In such a situation, the abrasive particles 13 370 can be oriented within the body 1351. In such a situation, the abrasive particles 13 71 may have a first main surface that is neither substantially perpendicular to the radial axis 1381 nor substantially parallel to the transverse axis. Such a controlled tilt angle can include any angle between 5 degrees and 85 degrees. As used herein, references to substantially parallel or substantially perpendicular orientations refer to a difference of 5 degrees or less between the axis or plane and the reference axis. Further, as will be understood, the abrasive particles can have various rotational orientations around the transverse axis 1382 and the radial axis 1381. Referring to the tilt angle, the radial axis 1381 and the component with the largest dimension in the radial direction are considered. References to substantially parallel or substantially perpendicular orientations refer to a difference of 5 degrees or less between the axis or plane and the reference axis. Further, as will be understood, the abrasive particles can have various rotational orientations around the transverse axis 1382 and the radial axis 1381. Referring to the tilt angle, the radial axis 1381 and the component with the largest dimension in the radial direction are considered. The abrasive particles can have various rotational orientations around the transverse axis 1382 and the radial axis 1381. Referring to the tilt angle, the radial axis 1381 and the component with the largest dimension in the radial direction Defined as the minimum angle formed with the radial vector defining the direction of the main surface it has It will be understood that a radial tilt angle may exist. The horizontal axis 1382 and the horizontal axis The minimum formed between the vector defining the direction of the main surface having the largest component in the direction A lateral tilt angle defined as an angle may also exist.

[0145] Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, those skilled in the art will understand that those aspects and embodiments are merely illustrative and do not limit the scope of the present invention. Embodiments may conform to one or more of the items listed below.

[0146] Item Item 1: Abrasive particles comprising a shaped abrasive particle having a body and a plurality of abrasive particles bonded to at least one surface of the body of the shaped abrasive particle

[0147] Item 2: The abrasive particle according to item 1, wherein the body of the shaped abrasive particle has a two-dimensional shape when viewed in a plane defined by the length and width of the body selected from the group consisting of a polygon, an ellipse, a number, a Greek letter, a Latin alphabet letter, a Cyrillic alphabet letter, a combination of polygons, and combinations thereof

[0148] Item 3: The abrasive particle according to item 1, wherein a plurality of abrasive particles are bonded to the main surface of the body, or a plurality of abrasive particles are bonded to at least two surfaces of the body, or a plurality of abrasive particles are bonded to at least two main surfaces of the body

[0149] ​​​​​​​Item 4: A portion of the particles of the plurality of abrasive particles is embedded within the volume of the body of the shaped abrasive particle. or a portion of the abrasive particles of the plurality of abrasive particles is embedded within at least one surface of the body. The abrasive particles are sintered to at least one surface of the body of the shaped abrasive particle. A portion of the abrasive particles of the bonded or multi-part abrasive particles is at least part of the body of the shaped abrasive particle. 2. The abrasive particles according to claim 1, wherein the abrasive particles are sinter-bonded to one surface of the abrasive particles.

[0150] Item 5: Some include a small number of particles of a plurality of abrasive particles, or some include a small number of particles of a plurality of abrasive particles. 5. The abrasive particles according to item 4, comprising a majority of the particles.

[0151] Item 6: A plurality of abrasive particles occupy at least 1%, or at least 5%, or is at least 10%, or at least 20%, or at least 30%, or at least 4 0%, or at least 50%, or at least 60%, or at least about 70%, or less At least about 80%, or at least about 90%, or at least 95% coverage, and Abrasive particles occupy 95% or less of the total surface area of ​​the body, or 90% or less, or 80% or less, or 60% or less % or less, or 50% or less, or 40% or less, or 30% or less of the polishing material according to item 1. particle.

[0152] Item 7: The body has a first main surface and a second main surface, and a plurality of abrasive particles are bonded to the first major surface and the side surface extends between the first major surface and the side surface extends between the second major surface and the 2. The abrasive particles of claim 1, which are essentially free of a few abrasive particles.

[0153] Item 8: The surface of the body containing a plurality of abrasive particles is a plurality of runs of abrasive particles on the main surface of the body. The abrasive particles according to item 1, having a dam arrangement and the side surface of the main body essentially containing no plurality of abrasive particles. abrasive particles.

[0154] Item 9: The main body includes a first main surface and a second main surface separated from the first main surface by a side surface, and a plurality of abrasive particles are attached to the first main surface, and the first main surface has a surface roughness greater than the surface roughness of the side surface. The abrasive particles of item 1. The main body includes a first main surface and a second main surface separated from the first main surface by a side surface, and a plurality of abrasive particles are attached to the first main surface, and the first main surface has a surface roughness greater than the surface roughness of the side surface. The abrasive particles of item 1. The abrasive particles of item 1.

[0155] Item 10: The plurality of abrasive particles are selected from the group consisting of oxides, carbides, nitrides, borides, oxycarbides, oxynitrides, oxyborides, natural minerals, synthetic substances, carbon-based substances, and combinations thereof. The abrasive particles according to item 1. The plurality of abrasive particles are selected from the group consisting of oxides, carbides, nitrides, borides, oxycarbides, oxynitrides, oxyborides, natural minerals, synthetic substances, carbon-based substances, and combinations thereof. The abrasive particles according to item 1. The abrasive particles according to item 1.

[0156] Item 11: The plurality of abrasive particles are selected from the group consisting of crushed abrasive grains, abrasive grains of irregular shape, elongated abrasive grains, weak aggregates, strong aggregates, and combinations thereof. The abrasive particles according to item 1. The plurality of abrasive particles are selected from the group consisting of crushed abrasive grains, abrasive grains of irregular shape, elongated abrasive grains, weak aggregates, strong aggregates, and combinations thereof. The abrasive particles according to item 1. The abrasive particles according to item 1.

[0157] Item 12: The main body of the shaped abrasive particles has a length ≧ width ≧ height, and the plurality of shaped abrasive particles have a median particle diameter (D50), and the median particle diameter (D50) is less than or equal to the length of the main body of the shaped abrasive particles, or the median particle diameter (D50) is less than or equal to the width of the main body of the shaped abrasive particles, or the median particle diameter (D50) is less than or equal to the height of the main body of the shaped abrasive particles. The abrasive particles according to item 1. The main body of the shaped abrasive particles has a length ≧ width ≧ height, and the plurality of shaped abrasive particles have a median particle diameter (D50), and the median particle diameter (D50) is less than or equal to the length of the main body of the shaped abrasive particles, or the median particle diameter (D50) is less than or equal to the width of the main body of the shaped abrasive particles, or the median particle diameter (D50) is less than or equal to the height of the main body of the shaped abrasive particles. The abrasive particles according to item 1. The main body of the shaped abrasive particles has a length ≧ width ≧ height, and the plurality of shaped abrasive particles have a median particle diameter (D50), and the median particle diameter (D50) is less than or equal to the length of the main body of the shaped abrasive particles, or the median particle diameter (D50) is less than or equal to the width of the main body of the shaped abrasive particles, or the median particle diameter (D50) is less than or equal to the height of the main body of the shaped abrasive particles. The abrasive particles according to item 1. The main body of the shaped abrasive particles has a length ≧ width ≧ height, and the plurality of shaped abrasive particles have a median particle diameter (D50), and the median particle diameter (D50) is less than or equal to the length of the main body of the shaped abrasive particles, or the median particle diameter (D50) is less than or equal to the width of the main body of the shaped abrasive particles, or the median particle diameter (D50) is less than or equal to the height of the main body of the shaped abrasive particles. The abrasive particles according to item 1. The abrasive particles according to item 1.

[0158] Item 13: The plurality of abrasive particles have a median particle diameter (D50) that is about 90% or less of the length of the main body, or at least about 0.1% of the length of the main body. The abrasive particles of item 12. Item 13: The plurality of abrasive particles have a median particle diameter (D50) that is about 90% or less of the length of the main body, or at least about 0.1% of the length of the main body. The abrasive particles of item 12.

[0159] Item 14: The plurality of abrasive particles comprises at least 1% by weight of the total weight of the abrasive particles, or The plurality of abrasive particles comprises about 80% by weight or less of the total weight of the abrasive particles, the abrasive particles of Item 1.

[0160] Item 15: The median particle size (D50) is less than or equal to the width of the body of the shaped abrasive particle, or a plurality of the abrasive particles has a median particle size (D50) of about 90% or less of the width of the body or at least about 0.1% of the width of the body, the abrasive particles of Item 12. Item 16: The plurality of abrasive particles comprises a material having a coefficient of thermal expansion (CTE) with a difference of about 50% or less from the CTE of the body of the shaped abrasive particle, the abrasive particles of Item 1.

[0161] Item 17: The median particle size (D50) is less than or equal to the height of the body of the shaped abrasive particle, or a plurality of the abrasive particles has a median particle size (D50) of about 90% or less of the height of the body or at least about 0.1% of the height of the body, the abrasive particles of Item 15.

[0162] Item 18: At least a part of the plurality of abrasive particles comprises fine shaped abrasive particles, or all of the plurality of the abrasive particles essentially comprises fine shaped abrasive particles, the abrasive particles of Item 1. Item 19: The fine shaped abrasive particles have a length ≤ width ≤ height, and the average length

[0163] of the fine shaped abrasive particles is shorter than the length of the body of the shaped abrasive particle, the abrasive particles of Item 18. Item 20: The fine shaped abrasive particles have an average length of about 90% or less of the length of the body, or at least about 0.1% of the length of the body of the shaped abrasive particle, the abrasive particles of Item 19.

[0164] Item 21: The fine shaped abrasive particles have an average width shorter than the length of the body of the shaped abrasive particle, and the average width of the fine shaped abrasive particles is shorter than the length of the body of the shaped abrasive particle, the abrasive particles of Item 19.

[0165] Item 22: The fine shaped abrasive particles have an average width of about 90% or less of the length of the body, or at least about 0.1% of the length of the body of the shaped abrasive particle, the abrasive particles of Item 21. Item 23: The fine shaped abrasive particles have an average height shorter than the length of the body of the shaped abrasive particle,

[0166] and the average height of the fine shaped abrasive particles is shorter than the length of the body of the shaped abrasive particle, the abrasive particles of Item 21. Or, the fine shaped abrasive particles have an average height shorter than the length of the body of the shaped abrasive particles, item 19 abrasive particles.

[0167] Item 22: Part of the fine shaped abrasive particles are arranged in a standing orientation with respect to the surface of the body of the shaped abrasive particles of the abrasive particles of item 19.

[0168] Item 23: A plurality of abrasive particles are arranged in a random distribution on the surface of the body, item 1 of the abrasive particles.

[0169] Item 24: A plurality of abrasive particles are arranged in a controlled distribution on the surface of the body, item 1 of the abrasive particles.

[0170] Item 25: The controlled distribution includes a pattern defined by a plurality of repeating units and each repeating unit of the plurality of repeating units is substantially the same as each other, the abrasive particles of item 24.

[0171] Item 26: Part of the abrasive particles of the plurality of abrasive particles are coated with a material selected from the group consisting of inorganic, organic, amorphous, crystalline, polycrystalline, ceramic, metal, resin, epoxy, polymer, oxide, carbide, nitride, boride, carbon-based materials, or combinations thereof, item 1 of the abrasive particles. including.

[0172] Item 27: The surface of the body including the plurality of abrasive particles has a random arrangement of the plurality of abrasive particles on the main surface of the body, and the side surface of the body is essentially free of the plurality of abrasive particles, item 1 of the abrasive particles. .

[0173] Item 28: The body has a first main surface and a second having a main surface, with a plurality of abrasive particles adhered to at least the first main surface or the second main surface, and the side surface essentially not containing a plurality of abrasive particles, the abrasive particles of item 1. wherein the side surface essentially does not contain a plurality of abrasive particles, the abrasive particles of item 1.

[0174] Item 29: The body has a first main surface and a second main surface separated from the first main surface by the side surface, with a plurality of abrasive particles adhered to the first main surface and the second main surface, and the side surface essentially not containing a plurality of abrasive particles, the abrasive particles of item 1. wherein a plurality of abrasive particles are adhered to the first main surface and the second main surface, and the side surface essentially does not contain a plurality of abrasive particles, the abrasive particles of item 1. wherein the side surface essentially does not contain a plurality of abrasive particles, the abrasive particles of item 1.

[0175] Item 30: The abrasive particles of item 1, wherein the abrasive particles are incorporated into a fixed abrasive article.

[0176] Item 31: Further comprising an abrasive paper article including a substrate and abrasive particles covering the substrate, wherein the abrasive particles have a predetermined orientation on an abrasive paper defined by the orientation of at least one surface including a plurality of abrasive particles with respect to the longitudinal axis or the transverse axis of the substrate, the abrasive particles of item 1. wherein the abrasive particles have a predetermined orientation on an abrasive paper defined by the orientation of at least one surface including a plurality of abrasive particles with respect to the longitudinal axis or the transverse axis of the substrate. the abrasive particles of item 1.

[0177] Item 32: Further comprising bonded abrasive particles including a body containing a bonding matrix material, wherein the abrasive particles have a predetermined position and orientation in the body defined by the predetermined position and orientation of at least one surface including a plurality of abrasive particles with respect to the longitudinal axis or the transverse axis of the body, the abrasive particles of item 1. wherein the abrasive particles have a predetermined position and orientation in the body defined by the predetermined position and orientation of at least one surface including a plurality of abrasive particles with respect to the longitudinal axis or the transverse axis of the body. the abrasive particles of item 1.

[0178] Item 33: Comprising a bonding material and a first aggregate of abrasive particles bonded to the bonding material, wherein each particle in the first aggregate comprises a shaped abrasive particle including a body and a plurality of abrasive particles bonded to at least one surface of the body of the shaped abrasive particle, an abrasive substance. wherein each particle in the first aggregate comprises a shaped abrasive particle including a body and a plurality of abrasive particles bonded to at least one surface of the body of the shaped abrasive particle. the abrasive particles of item 1.

[0179] Item 34: A step of forming a mixture, and a plurality of abrasive particles on at least one surface of the mixture ​a step of attaching to, and a plurality of abrasive grains bonded to the main body and at least one surface of the main body a step of forming shaped abrasive grains having, a method of forming abrasive grains, comprising:

[0180] Item 35: The step of forming the mixture comprises at least one selected from the group consisting of printing, molding, casting, cutting, excision, pan ting, drying, crushing, sintering, humidifying, and combinations thereof at least one process, the method of item 34.

[0181] Item 36: The step of forming the mixture includes a step of forming precursor shaped abrasive grains and a step of attaching a plurality of abrasive grains to at least one surface of the precursor shaped abrasive grains, item 34 method. 34 method.

[0182] Item 37: The step of forming the mixture includes depositing the mixture within an opening of a manufacturing tool and attaching a plurality of abrasive grains to at least one surface of the mixture within the opening of the production tool a step of, the method of item 34. a step of, the method of item 34.

[0183] Item 38: The method according to item 34, wherein the plurality of abrasive grains are attached to the main body of the mixture prior to substantially drying the main body. Item 34.

[0184] Item 39: The step of attaching the plurality of abrasive grains includes depositing the plurality of abrasive grains on the surface of the main body, and the depositing step includes processes selected from the group consisting of blasting, spraying, pressing, gravity coating ing, molding, stamping, and combinations thereof, the method of item 34. ing, molding, stamping, and combinations thereof, the method of item 34. Item 34.

[0185] Item 40: The mixture is formed on a manufacturing tool including a layer of abrasive grains including a plurality of abrasive grains Item 34 method.

[0186] Item 41: The method of item 34, wherein the process further includes a step of applying moisture to at least one surface of the mixture before attaching a plurality of polishing particles.

[0187] Item 42: The method of item 34, wherein the step of attaching a plurality of polishing particles includes a step of directing a deposition material towards at least one surface, and the deposition material includes a plurality of

[0188] polishing particles and a carrier gas. Item 43: The method of item 42, wherein the carrier gas may include water vapor, steam, an inert gas element,

[0189] and combinations thereof. Item 44: The method of item 34, wherein the mixture is formed on a manufacturing tool including a layer of

[0190] polishing particles including a plurality of polishing particles. Item 45: The method of item 34, wherein the process further includes a step of providing moisture to at least one

[0191] surface of the mixture before attaching a plurality of polishing particles. Item 46: The method of item 45, wherein the step of applying moisture includes a step of directing a gas

[0192] towards at least one surface of the mixture before attaching a plurality of polishing particles. Item 47: The method of item 45, wherein the step of applying moisture includes a step of directing steam

[0193] towards at least one surface of the mixture within the manufacturing tool. Item 48: The method of item 45, wherein the step of applying moisture includes wetting at least one surface of the mixture for a sufficient time to change the viscosity of an outer region of the at least one surface

[0194] Item 49: The process is at least with respect to the viscosity of the internal region of the mixture spaced from the external region changing the viscosity of the external region of the body including at least one surface, and attaching a plurality of abrasive particles to the external region of the mixture, the method of item 34 further comprising.

Example

[0195] Example 1 Three samples of shaped abrasive particles were prepared and tested for performance comparison. The first comparative sample ( CS1) was a conventional shaped abrasive particle commercially available as 3M984F from 3M Corporation. The average width of the body was 1400 micrometers and the height was about 300 micrometers meters. The shaped abrasive particles of sample CS1 had a rare earth element doped α-alumina composition, an average tip sharpness of about 20 micrometers, an average strength of about 606 MPa and an average cross-sectional shape factor of about 0 .15. Figure 14 is a cross-sectional image of the shaped abrasive particles of sample CS1.

[0196] Two samples (sample S1 and sample S2) representing the embodiments herein were formed from a gel mixture containing about 45-50 wt % boehmite. Boehmite was obtained as Catapal B from Sasol Corp . and was modified by high-pressure heating with 30 wt% of Catapal B mixture together with deionized water and nitric acid. The nitric acid to boehmite ratio was about 0.025. The mixture was then placed in an autoclave and treated at 100 °C to 250 °C for 5 minutes to 24 hours. The autoclaved Catapal B sol was dried by conventional means. Another boehmite commercially available as DISPERAL from Sasol Corp. can also be used. Mix the boehmite and the total alumina content of the mixture ​​​​​​ It was seeded with 1% α-alumina seeds with respect to the amount. The α-alumina seeds were produced by crushing corundum using the prior art described in, for example, U.S. Patent No. 4, 623,364. This mixture also contained 45-50 wt% water and 2.5-4 wt% additional nitric acid and was used to form a gel mixture. The components were mixed with a conventionally designed planetary stirrer and mixed under reduced pressure to remove gaseous components (such as bubbles) from the mixture.

[0197] A gel was deposited in the opening of a stainless steel manufacturing tool to manually form sample S1 . Holes were opened on both sides of the manufacturing tool such that the opening extended through the entire thickness of the manufacturing tool. The cavity or opening of the manufacturing tool had a two-dimensional shape of an equilateral triangle when viewed from above, with a length of about 2.77 mm, a width of about 2.4 mm, and a depth of about 0.59 mm. The surface of the opening of the manufacturing tool was coated with a lubricant of oleo oil to easily remove the precursor forming abrasive particles from the manufacturing tool.

[0198] After depositing the gel and while it was placed in the cavity of the manufacturing tool, the first surface of the mixture was wetted with a sponge. A plurality of dry un-sintered particles of the same gel mixture used to form the mixture in the manufacturing tool were deposited on the wetted surface of the mixture present in the cavity of the manufacturing tool. The plurality of un-sintered particles were sieved using 100 US mesh (ASTM E-11 having an opening of 150 micrometers), and the maximum particle size of the plurality of un-sintered particles was less than 100 US mesh. The plurality of abrasive particles had an absorption water content of about 10-15% with respect to the total weight of the particles.

[0199] Next, the manufacturing tool was inverted, and while it was placed inside the cavity of the manufacturing tool, the opposite side of the gel mixture was wetted with a sponge. Next, a plurality of abrasive particles were applied to the wetted surface, and both main surfaces of the exposed gel mixture inside the cavity of the manufacturing tool were coated with the plurality of abrasive particles. Excess abrasive particles were removed, and the mixture and the plurality of abrasive particles were dried inside the cavity at about 50 °C for 10 minutes using an IR lamp and a fan to form precursor abrasive particles. The precursor abrasive particles were taken out of the manufacturing tool and sintered at about 1325 °C for about 10 minutes to achieve at least 98% of the theoretical density. The obtained abrasive particles had a body including a two-dimensional triangular shape with a length of about 1550 micrometers, a width of about 1350 micrometers, and a height of about 300 micrometers. Figures 11A and 11B are diagrams showing cross-sectional images of representative abrasive particles of sample S1. The abrasive particles of sample S1 had an average strength of about 847 MPa, an average tip sharpness of 20 micrometers, a shape index of about 0.5, and an average cross-sectional shape coefficient of about 29%. Sample S2 was formed using the same gel mixture as sample S1 above. The gel mixture was put into a mold and extruded into the opening of a PEEK manufacturing tool that was moved under the mold as described in the embodiments herein. The opening of the manufacturing tool was the same as the manufacturing tool used in sample S1 described above, except that the manufacturing tool had a thickness of about 0.54 mm. In the first batch of sample S2 (sample batch S2B1), while the gel mixture was inside the cavity of the manufacturing tool, a plurality of abrasive particles were deposited on a single surface of the gel mixture by gravity. The plurality of abrasive particles were the same as those used in sample S1. Figure 15 is a top view and a side view of representative abrasive particles of sample batch S2B1.

[0200] ​​​​​​​​​​​​​​​​​

[0201] In the second batch of sample S2 (sample batch S2B2), while the mixture was in the cavity of the manufacturing tool, a plurality of abrasive particles were deposited on both major surfaces of the mixture. On the first major surface, a plurality of abrasive particles were deposited via gravity (e.g., by spraying the particles onto the manufacturing tool in the cavity and onto the gel mixture). On the opposite major surface, while the gel mixture was present in the cavity, a plurality of abrasive particles were accommodated on the surface of the bottom of the manufacturing tool that was repeatedly pressurized, and the abrasive particles were attached to the bottom surface of the gel mixture. Thus, while the gel mixture was present in the cavity, a plurality of abrasive particles were attached to both major surfaces of the gel mixture. The plurality of abrasive particles were the same as those described for sample S1. FIG. 16 is a top view image and a side view image of the abrasive particles of sample batch S2B2.

[0202] In both batches of sample S2, while the gel mixture was present in the cavity, the manufacturing tool was moved by a set of rollers that applied pressure to the upper and bottom surfaces of the manufacturing tool to help embed the abrasive particles into the gel mixture.

[0203] For both batches of sample S2, the mixture was dried at about 50 - 55 °C for about 5 minutes using an IR lamp and a fan. For both batches of sample S2, the samples were removed from the manufacturing tool and sintered according to the conditions shown for sample S1. The abrasive particles of sample batch S1B1 had an average tip sharpness of 20 micrometers, a shape index of about 0.5, and an average cross-sectional shape factor of about 21%. The abrasive particles of sample batch S1B2 had an average tip sharpness of 20 micrometers, a shape index of about 0.5, and an average cross-sectional shape factor of about 30%.

[0204] Samples CS1 and S1 were tested in the major surface orientation and the side surface orientation by a single-grit grinding test (SGGT). was tested. When performing SGGT, a single shaped abrasive particle is held by an epoxy bonding material to a particle holder. The shaped abrasive particle is fixed in a desired orientation (i.e., main surface orientation or side surface orientation), and using a wheel speed of 22 m / sec and an initial scratch depth of 30 micrometers, it is moved over a workpiece of 304 stainless steel with a scratch length of 8 inches. A groove having a cross-sectional area (AR) is formed on the workpiece by the shaped abrasive particle. For each sample set, each shaped abrasive particle is passed 15 times over a length of 8 inches, 10 individual particles for each orientation are tested, and the results are analyzed. By the test, the tangential force applied by the particle to the workpiece in the direction parallel to the surface of the workpiece and in the direction of the groove is measured, and the net change in the cross-sectional area of the groove from the beginning to the end of the scratch length is measured to determine the wear of the shaped abrasive particle. The net change in the cross-sectional area of the groove for each pass may be measured. For SGGT, the net cross-sectional area of the groove is defined by the difference between the cross-sectional area of the groove under the surface and the cross-sectional area of the material displaced above the surface. The property (Ft / A) is defined as the ratio of the tangential force to the net cross-sectional area of the groove.

[0205] SGGT is performed on the workpiece using shaped abrasive particles in two different orientations. SG GT is performed with a first sample set of shaped abrasive particles in the main surface orientation, and the main surface of each shaped abrasive particle is oriented perpendicular to the grinding direction such that the main surface starts grinding on the workpiece. From the results of SGGT using the sample set of shaped abrasive particles in the main surface orientation, it becomes possible to measure the grinding efficiency of the shaped abrasive particles in the main surface orientation.

[0206] SGGT is also performed with a second sample set of shaped abrasive particles in the side surface orientation, and for each shaped abrasive particle ​​​​​​The side surfaces are oriented perpendicular to the grinding direction such that grinding of the workpiece is initiated thereby. The results of SGGT tests using a sample set of shaped abrasive grains in side surface orientation enable measurement of the grinding efficiency of the shaped abrasive grains in side surface orientation.

[0207] FIG. 17 includes plots of the force per total area removed from the workpiece for the front surface orientation (left bar) and side surface orientation (right bar) of sample CS1 and sample S1. The force per total area removed is a measure of the grinding efficiency of the shaped abrasive grains, and the smaller the force per total area removed, the more efficient the grinding ability. As illustrated, sample S1 showed substantially equivalent performance compared to sample CS1. Those skilled in the art have previously recognized that the most efficient cutting action of the abrasive grains may be due to particles having a high form accuracy characterized by sharp edges and smooth surfaces (i.e., like a chisel). Considering this, this result is quite remarkable. See, for example, U.S. Pat. Nos. 4,261,706 and 5,603,738, and U.S. Patent Application Publication No. 2010 / 0319269. However, the abrasive grains of the embodiments herein show a significant performance difference from conventional abrasive grains when compared to the conventional abrasive grains, from the perspective of the significant differences between the abrasive grains and conventional abrasive grains having relatively smooth side surfaces and sharp edges. In particular, the abrasive grains herein have a surface characterized by an irregular outer shape including protrusions and valleys randomly disposed on one or more surfaces of the shaped abrasive grains. This is in contrast to the prior art teachings suggesting that the surface of the shaped abrasive grains should be made smooth and the edges sharpened to achieve the highest performance.

[0208] The abrasive particle sample batch S2B1 was formed into an abrasive paper article having the following structure. One continuous batch of 18-pound finish paper backing was obtained and coated with a makeup formulation containing phenol formaldehyde as shown in Table 1. Then, an electrostatic film-forming process was used to attach 40 pounds of abrasive particles per continuous batch from the sample batch S2B1 to the web having the makeup coat layer. Next, this partial structure of the web with the attached makeup coat layer and abrasive grains was dried in an oven at 80 °C for 2 hours.

[0209]

Table 1

[0210] Next, the abrasive paper structure was coated with a 14-pound-per-continuous-batch phenol formaldehyde size coat layer. The detailed composition of the size coat layer is shown in Table 2. The web was passed through a dryer with a dry bulb temperature set at 120 °C for 2 hours.

[0211]

Table 2

[0212] Next, the abrasive paper sample was placed in a convection oven and a post-curing step was performed at an oven temperature of 125 °C for 12 hours.

[0213] A sample S3, which is a third sample of the abrasive paper, was also prepared. The abrasive particles of sample S3 were prepared according to the process used to produce the abrasive particles of sample batch S2B1, but multiple abrasive particles were not deposited on the shaped abrasive grains. The configuration of the abrasive paper of sample S3 was the same as that of the abrasive paper containing the particles of sample batch S2 B1. The particles of sample CS1 were from 3M Corp B1.​​ It was tested as a conventional abrasive paper article commercially available from 984F from oration.

[0214] Each of three different abrasive paper samples was tested according to the conditions summarized in Table 3. In particular two sample abrasive papers were tested in each case to obtain results.

[0215]

Table 3

[0216] Figure 18 is a plot of specific grinding energy versus the cumulative material removed (at a material removal 3 rate of 4 inches per minute per inch) for each of the samples. The abrasive paper using the abrasive grains of sample batch S2B1 is superior in performance to the abrasive paper containing the abrasive grains of sample S3, and it is worth noting that it has essentially the same performance as the abrasive paper sample containing the abrasive grains of sample CS1.

[0217] Example 2 A new abrasive grain sample (sample S4) was formed. The shaped abrasive grains of sample S4 were formed from a gel mixture containing about 45 - 5 0 wt% boehmite. The boehmite was obtained as Catapal B from Sasol Co rp. and was modified by high-pressure heating a 30 wt% mixture of Catapal B with deionized water and nitric acid. The nitric acid-boehmite ratio was about 0.025 in an autoclave and was treated at 100 °C to 250 °C for 5 minutes to 24 hours. The autoclave-treated Catapal B sol was dried by conventional means. The boehmite was mixed and seeded with 1% α-alumina seeds based on the total alumina content of the mixture. The α-alumina seeds are described, for example, in U.S. Patent No. 4,623,364. It was produced by crushing corundum using conventional techniques. This mixture also contained 45 - 50 weight % water and 2.5 - 4 weight % additional nitric acid and was used to form a gel mixture. The components were mixed in a planetary mixer of conventional design and mixed under reduced pressure to remove gaseous components (e.g., air bubbles) from the mixture.

[0218] Next, the gel was placed in a mold and extruded into the opening of a manufacturing tool that was moved under the mold at a rate appropriate to the deposition rate so that the opening was fully filled. Holes were opened on both sides of the manufacturing tool such that the opening extended through the entire thickness of the manufacturing tool. The holes or openings in the manufacturing tool had a two - dimensional shape of an equilateral triangle when viewed from above, with a length of about 2.77 mm, a width of about 2.4 mm, and a depth of about 0.60 mm. The thickness of the manufacturing tool was about 0.60 mm. The surface of the opening of the manufacturing tool was coated with a lubricant of

[0219] cannola oil to facilitate removal of the precursor - formed abrasive particles from the manufacturing tool. After depositing the gel into the opening of the manufacturing tool, a plurality of dry unsintered particles of the same gel material deposited within the opening were sprayed onto the surface of the gel within the manufacturing tool. A plurality of abrasive particles were forcedly discharged towards the gel within the manufacturing tool using air as a carrier material at a pressure of about 40 psi. The process of attaching the plurality of abrasive particles was completed within a container where a large portion of the excess or un - bonded abrasive particles could be Sieved to make the maximum particle size of the plurality of green particles less than 100 US mesh. The plurality of abrasive particles had an absorption moisture content of about 10-15% based on the total weight of the particles. Approximately 70% of the precursor abrasive particles had a suitable high coverage rate of the plurality of dry green particles on the first main surface .

[0220] Excess dry green particles were removed, and the mixture and the plurality of abrasive particles were dried in the cavity at about 50 °C for 30 seconds using an IR lamp and a fan to form precursor abrasive particles. The precursor abrasive particles were taken out of the manufacturing tool and pre-sintered at about 800 °C and sintered at about 1320 °C for about 15 minutes to achieve at least 98% of the theoretical density. The resulting abrasive particles had a body including a two-dimensional triangular shape with a length of about 1550 micrometers, a width of about 1350 micrometers, and a height of about 300 micrometers . The abrasive particles of sample S4 had an average strength of about 20.3 MPa, an average tip sharpness of 30 micrometers, and a shape index of about 0.5 . Another sample of abrasive particles (sample CS4) was formed in the same manner as sample S4 above, except that the abrasive particles did not contain a plurality of abrasive particles on the surface of the shaped abrasive particles (i.e., unmodified abrasive particles).

[0221] Two samples of abrasive paper articles were formed from the abrasive particles of samples S4 and CS4 to create abrasive paper samples CAS4 and CACS4, respectively. The abrasive paper samples CAS4 and CACS4 were formed in the same manner as used to form the abrasive paper samples of Example 1 using sample CS1 and sample batch S2B1.

[0222]

[0223] Each abrasive paper sample was tested according to the tests outlined in Table 4 below. In each case, Two samples of abrasive paper were tested and results obtained.

[0224]

Table 4

[0225] Figure 19 is a plot of specific grinding energy versus the cumulative material removed from the workpiece. As shown, sample CAS4 shows improved cumulative material removed and a decrease in specific grinding energy, especially near the end of the test, compared to sample CACS4. .

[0226] Example 3 To investigate the effect of the median particle size of a plurality of abrasive particles on the coverage rate of abrasive particles on at least one surface of the shaped abrasive particles, five samples of abrasive particles (S5-1, S5- 2, S5-3, S5-4, and S5-5) were formed. Table 5 below summarizes the effect of the median particle size of a plurality of abrasive particles on the coverage rate of a plurality of abrasive particles on the first major surface of shaped abrasive particles having a substantially triangular two-dimensional shape with a length of about 1550 μ m, a width of about 1350 μm, and a height of about 320 μm. The abrasive particles were formed in the same way as used to form sample S4 of Example 2, except that the surface of the gel of the manufacturing tool was humidified before applying a plurality of dry un-sintered abrasive grains. The humidification process utilized vapor (i.e., a mixture of gaseous water and suspension particles) directed towards the surface of the gel within the manufacturing tool.

[0227]

Table 5

[0228] Figures 20A to 20E are images of abrasive grains of samples S5-1, S5-2, S5-3, S5-4, and S5- 5, respectively. In particular, the average median particle size of a plurality of abrasive grains with respect to the particle size of the shaped abrasive grains affected the coverage rate of a plurality of abrasive grains on the surface of the shaped abrasive grains.

[0229] Example 6 Four samples of abrasive grains (sample S6-1, sample S6-2, CS1, and sample S6-3) were tested according to the single-grain grinding test described in Example 1. Sample S6-1 has an average of 32 abrasive grains bonded to the main surface of the body of the shaped abrasive grains, and sample S6 -2 has an average of 7 abrasive grains bonded to the main surface of the body of the shaped abrasive grains Except for this, samples S6-1, S6-2, and S6-3 were formed in the same manner as sample S4 of Example 2. Sample S6-3 had no plurality of abrasive grains bonded to the surface of the shaped abrasive grains.

[0230] Figure 21 is a plot of the force per total area removed from the workpiece for the front orientation (left bar) and side orientation (right bar) of samples S6-1, S6-2, S6-3, and (the same as given in Example 1 ) sample CS1. Surprisingly, sample S6-2 showed a greater variation in cutting efficiency in the front orientation compared to sample S6-1. Sample S6- 1 also showed a lower variation in cutting efficiency compared to samples S6-3 and CS1 in the front orientation.

[0231] Example 7 Two samples of abrasive grains were prepared. Sample S7-1, the first sample, was the same as Example 2 except that the surface of the gel of the manufacturing tool was humidified before depositing a plurality of dry green abrasive grains. ​​​​​It was formed in the same manner as that used to form sample S4. The humidification process utilized vapor directed towards the surface of the gel within the manufacturing tool. The plurality of abrasive particles adhered to the first major surface of the shaped abrasive particles of sample S7-1 were neither calcined nor sintered. In a second sample a certain sample S7-2 was formed in the same manner as that used to form sample S7-1, except that sintered α-alumina abrasive grains were used for the plurality of abrasive particles adhered to the first major surface of the shaped abrasive particles. Sample S7-1 exhibited significantly better coverage compared to sample S7-2, with 90 - 95% of the particles being properly covered by the plurality of abrasive particles. However, sample S7-2 had only 60 - 70% of the total abrasive particles properly covered on the first major surface of the shaped abrasive particles. The sintered abrasive particles adhered to the surface of the precursor shaped abrasive particles of sample S7-2 were not well-bonded to the surface, but the dry particles could be re-gelled on the humidified surface of the gel before further processing, resulting in improved bonding for the green unsintered particles adhered to the surface of sample S7-1.

[0232] Example 8 Two samples of abrasive particles were fabricated. A first sample, sample S8-1, was formed in the same manner as that used to form sample S4 of Example 2. The plurality of abrasive particles adhered to the first major surface of the shaped abrasive particles of sample S8-1 were neither calcined nor sintered. A second sample a certain sample S8-2 was formed in the same manner as that used to form sample S8-1, except that the abrasive particles were not deposited on the surface of the gel or the resulting shaped abrasive particles.

[0233] Next, using the abrasive particles of samples S8-1 and S8-2, in the form of disks with a diameter of 7 inches A lapping cloth paper article was fabricated, and samples CAS8-1 and CAS8-2 were fabricated respectively. The following Samples CAS8-1 and CAS8-2 were formed according to the following

[0234] A fiber backing material having an average thickness of 0.95 mm available from Sachsenroder was coated with the make coat layer formulation shown in Table 6 below. The wet laydown weight of the make coat layer was 9 pounds / ream ± 0.3 pounds, and it was applied using a two-roll coating method with a steel roll on a hard rubber roll of 65 ~72 Shore A durometer.

[0235]

Table 6

[0236] The viscosity of the formulation was adjusted to the range of 9500 - 10500 cps at 100°F using water. After applying the make coat layer, the abrasive particles of samples S8-1 and S8-2 were silanized and adhered to the make coat layer by electrostatic deposition. The target particle weight for each sample was 55 pounds / ream ± 3 pounds. The particles of each sample were preheated before deposition.

[0237] After depositing the particles on the make coat layer and the backing, the make coat layer was cured using the following process in a festoon oven. Step 1) 42 minutes at 150°F, Step 2 ) 42 minutes at 170°F, Step 3) 38 minutes at 200°F, Step 4) 43 minutes at 215°F, Step ) 23 minutes at 230°F.

[0238] After curing the make coat layer, a size coat layer having the formulation shown in Table 7 was applied to the surface of the particles and the make coat layer was cured. ​​​​​​

[0239]

Table 7

[0240] The formulation of the size coat layer was adjusted to a viscosity range of 5400 - 5600 cps at 100°F using water. The size coat layer was applied using the same machine as was used to apply the make coat layer. The sizing was visually controlled against a known standard of setting the gap of the two - roll coater at 0.045 inches. After the size coat layer was applied, the material was cured in a festoon oven using the following process: Step 1) 20 minutes at 130°F and 45% RH, Step 2) 20 minutes at 170°F, Step 3) 20 minutes at 190°F, Step 4) 20 minutes at 210°F, Step 5) 30 minutes at 235°F. Next, the material was wound up and cured in a post - cure oven at 250°F for 12 hours.

[0241] After the size coat layer was applied, the material was cured in a festoon oven using the following process: Step 1) 20 minutes at 130°F and 45% RH, Step 2) 20 minutes at 170°F, Step 3) 20 minutes at 190°F, Step 4) 20 minutes at 210°F, Step 5) 30 minutes at 235°F. Next, the material was wound up and cured in a post - cure oven at 250°F for 12 hours. Step 3) 20 minutes at 190°F, Step 4) 20 minutes at 210°F, Step 5) 30 minutes at 235°F. Next, the material was wound up and cured in a post - cure oven at 250°F for 12 hours.

[0242] When the roll was removed from the post - cure oven, the backing was bent and water was applied to re - wet it.

[0243] Each abrasive paper sample was tested according to the conditions summarized in Table 8.

[0244]

Table 8

[0245] Figure 22 is a plot of the relative performance (% material removed) of samples CAS8 - 1 and CAS8 - 2 against sample CACS8 - 3, a conventional abrasive paper sample available as 982C from 3M Corporation. As illustrated, sample CAS8 - 1 is a conventional abrasive paper paper sample. ​ had essentially the same performance as the sample. In contrast, sample CAS8-2 showed a relative performance that was approximately 20% lower compared to sample CAS8-1, which is a conventional sample.

[0246] All values, ratios, percentages, and / or quantitative data provided herein regarding the abrasive particles of any embodiment can also be an average derived from a random and statistically valid sample size of representative abrasive particles. For example, regarding the coverage rate of a plurality of abrasive particles on the body, such percentages can also be calculated from a random and statistically valid sample size of a batch of abrasive particles. The sample size can vary depending on the batch size.

[0247] In particular, herein, references to a composition "free of" other materials (e.g., material Z) can be interpreted as a composition that may have a trace or impurity content of material Z, provided that such content does not substantially affect the properties of the composition. For example, a material may be "free of" a particular type, and such type may be present in an amount of 0.1% or less or 0.01% or less or 0.001% or less. This paragraph is not intended to limit other disclosures in the foregoing embodiments, but is only intended to define these examples using the term "free of". Further, when a particular type is not expressly specified, the applicant reserves the right to further define the material as being free of said particular type. However, unless the term "free of" is expressly recited, such term cannot be construed to narrow these embodiments or claims using inclusive terms such as "comprising", "having", "including", etc.

[0248] The subject matter disclosed above should be regarded as illustrative and not as limiting. The appended claims are intended to cover all appropriate modifications, enhancements and other embodiments that fall within the true scope of the invention. Accordingly, to the fullest extent permitted by law, the scope of the invention should be determined by the broadest permissible interpretation of the following claims and their equivalents, and should not be limited or restricted by the foregoing detailed description.

[0249] The abstract of the disclosure is provided to comply with the patent law and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Further, in the embodiments for carrying out the above invention, various features may be grouped together or described in a single embodiment for the purpose of simplifying the disclosure. The disclosure should not be construed as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as reflected by the following claims, the subject matter of the invention may be directed to less than all of the features of any of the disclosed embodiments. Accordingly, the following claims are incorporated into the embodiments for carrying out the invention, and each claim stands on its own as defining separately claimed subject matter. ​

Claims

1. a shaped abrasive particle having a body; a plurality of abrasive particles bonded to at least one surface of the body of the shaped abrasive particle; The abrasive particles include

2. The body of the shaped abrasive particle may be in the shape of a regular polygon, an irregular polygon, an oval, a number, a Greek number, Letters, Latin alphabet letters, Russian alphabet letters, polygonal combination Complex shapes having straight and curved parts, and combinations thereof, When viewed in a plane defined by the length and width of the body, the first group consisting of 10. The abrasive particle of claim 1, comprising a two-dimensional shape.

3. 10. The abrasive grain of claim 1, wherein the plurality of abrasive particles are bonded to a major surface of the body. child.

4. 10. The method of claim 1, wherein the plurality of abrasive particles are bonded to at least two surfaces of the body. The abrasive particles according to claim 1.

5. The body has a first major surface and a second major surface, and and a side extending between said first major surface and said second major surface, 10. The abrasive grain of claim 1, wherein the side surface is essentially free of abrasive particles of the plurality of abrasive particles. child.

6. A portion of the abrasive particles of the plurality of abrasive particles are embedded within at least one surface of the body. The abrasive particle of claim 1 which is embedded.

7. A portion of the abrasive particles of the plurality of abrasive particles contact the at least one surface of the body. The abrasive particle of claim 1 which is directly bonded.

8. A portion of the abrasive particles of the plurality of abrasive particles are attached to the minor portion of the body of the shaped abrasive particle.

2. The abrasive particle of claim 1, wherein at least one surface of the abrasive particle is sinter bonded.

9. The plurality of abrasive particles may be selected from the group consisting of oxides, carbides, nitrides, borides, oxycarbides, oxynitrides, oxysilicates, and oxynitrides. From the group consisting of oxyborides, natural minerals, synthetic materials, carbon-based materials, and combinations thereof.

2. The abrasive particle of claim 1, selected from the group consisting of:

10. the body of the shaped abrasive particle having a length ≧ width ≧ height, and the plurality of shaped abrasive particles The median particle size (D50) is a diameter of the body. at least 0.1% and no more than about 20% of the length of the body, at least 0.1% and no more than about 20% of the width of the body about 20% or less, at least 0.1% and about 20% or less of the height of the body. Item 2. The abrasive particles according to item 1.

11. The plurality of abrasive particles have a mean diameter of 0.1 micrometers and 80 micrometers or less. The abrasive particles according to claim 1 , having an Anne particle size (D50).

12. The surface of the body containing the plurality of abrasive particles is provided with the plurality of abrasive particles on a major surface of the body. a random arrangement of abrasive particles, the side surface of the body being essentially free of the plurality of abrasive particles. The abrasive particles according to claim 1.

13. The abrasive particle of claim 1 , wherein the abrasive particle is incorporated into a fixed abrasive article.

14. Abrasive particles comprising: A binder material; a first mass of abrasive particles bonded to the bond material; The particles in the first collection are a shaped abrasive particle having a body; The plurality of abrasives bonded to at least one surface of the body of the shaped abrasive particles. and a particle.

15. 1. A method of forming an abrasive particle, comprising: forming a mixture; depositing a plurality of abrasive particles on at least one surface of the mixture; a body and a plurality of abrasive particles bonded to at least one surface of the body. forming shaped abrasive particles.

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