Fused abrasive particles, abrasive articles, and methods of making and using the same
Assignee3M Innovative Properties Company
InventorsAnatoly Z. Rosenflanz, Ahmet Celikkaya, Donna W. Bange
Life of this patent
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Abstract
Fused abrasive particles comprising eutectic colonies. The fused abrasive particles can be incorporated into abrasive products such as coated abrasives, bonded abrasives, non-woven abrasives, and abrasive brushes.
Claims35
A plurality of abrasive particles having a specified nominal grade, said plurality of abrasive particle having a particle size distribution ranging from fine to coarse, wherein at least a portion of said abrasive particles is a plurality of fused, crystalline abrasive particles, said fused abrasive particles comprising at least 20 percent by volume, based on the total metal oxide volume of the respective particle, eutectic colonies, said colonies comprising a three-dimensional, interpenetrating network of first and second crystalline metal oxide phases, said first phase comprising at least one of crystalline Al2O3 or a first, crystalline complex Al2O3.metal oxide and said second phase comprising a second, different crystalline complex Al2O3.metal oxide.
A method for by for used, crystalline abrasive particles comprising at least 20 percent by volume, based on the total metal oxide volume of the respective particle, eutectic colonies, said colonies comprising a three-dimensional, interpenetrating network of first and second crystalline metal oxide phases, said first phase comprising at least one of crystalline Al2O3 or a first, crystalline complex Al2O3.metal oxide and said second phase comprising a second, different crystalline complex Al2O3.metal oxide, said method comprising:
- melting at least one Al2O3 source and at least one reactive Al2O3 metal oxide source to provide a melt;
- converting the melt to said fused, crystalline abrasive particles;
- and
- grading said fused, crystalline abrasive particles to provide a plurality of abrasive particles having a specified nominal grade, said plurality of abrasive particles having a particle size distribution ranging from fine to coarse, wherein at least a portion of said plurality of abrasive particles is a plurality of said fused, crystalline abrasive particles.
An abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of said abrasive particles are fused, crystalline abrasive particles comprising at least 20 percent by volume, based on the total metal oxide volume of the respective particle, eutectic colonies, said colonies comprising a three-dimensional, interpenetrating network of first and second crystalline metal oxide phases, said first phase comprising at least one of crystalline Al2O3 or a first, crystalline complex Al2O3.metal oxide and said second phase comprising a second, different crystalline complex Al2O3.metal oxide.
A vitrified bonded abrasive article comprising a plurality of abrasive particles bonded together via vitrified bonding material, wherein at least a portion of said plurality of abrasive particles are fused, crystalline abrasive particles comprising at least 20 percent by volume, based on the total metal oxide volume of the respective particle, eutectic colonies, said colonies comprising a three-dimensional, interpenetrating network of first and second crystalline metal oxide phases, said first phase comprising at least one of crystalline Al2O3 or a first, crystalline complex Al2O3.metal oxide and said second phase comprising a second, different crystalline complex Al2O3.metal oxide.
A method of abrading a surface comprising:
- providing an abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of said abrasive particles are fused, crystalline abrasive particles comprising at least 20 percent by volume, based on the total metal oxide volume of the respective particle, eutectic colonies, said colonies comprising a three-dimensional, interpenetrating network of first and second crystalline metal oxide phases, said first phase comprising at least one of crystalline Al2O3 or a first, crystalline complex Al2O3.metal oxide and said second phase comprising a first, crystalline complex Al2O3.metal oxide;
- contacting at least one of said fused, crystalline abrasive particles with a surface of a workpiece;
- and
- moving at least one of the contacted fused abrasive particles or said surface relative to the other to abrade at least a portion of said surface with the contacted fused abrasive particle.
Dependencies are inferred from the claim text.