Shaped abrasive particles and method of making same

Abstract

A method of making abrasive particles having a specified shape and abrasive articles containing abrasive particles having a specified shape. The method for preparing such an abrasive particle comprises the steps of: (a) providing a dispersion of comprising particles that can be converted into alpha alumina, preferably particles of alpha alumina monohydrate, in a liquid, which liquid comprises a volatile component, preferably water; (b) providing a mold having a first generally planar surface and a second surface opposed to said first surface, said first surface having an opening to a mold cavity having a specified shape; (c) introducing the dispersion into the mold cavity in such a way that no exposed surface of the dispersion that has been introduced into the mold will extend substantially beyond the plane formed by the first surface of the mold; (d) removing a sufficient portion of the volatile component from the dispersion while the dispersion is in the mold cavity, thereby forming a precursor of an abrasive particle having a shape approximately corresponding to the shape of the mold cavity; (e) removing the precursor of the abrasive particle from the mold cavity; (f) calcining the removed precursor of the abrasive particle; and (g) sintering the calcined precursor to form the desired abrasive particle.

Dependencies are inferred from the claim text.