# US 9,039,797 B2 · Shaped abrasive particles and method of making

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- Number: US 9,039,797 B2
- Document ID: US9039797B2
- Status: Granted
- Kind: B2
- Application number: 13/818,365
- Filed: 2011-10-19
- Published: 2013-10-10
- Granted: 2015-05-26
- Earliest claimed: 2010-11-01
- Assignees: 3M Innovative Properties Company
- Applicants: Dwight D. Erickson
- Inventors: Dwight D. Erickson
- Web page: https://patentgrep.com/patent/US9039797B2

## CPC

- C09K 3/1418: {obtained by division of a mass agglomerated by sintering}
- B24D 3/008: {Abrasive bodies without external bonding agent}
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11)

## Abstract

A method of making shaped abrasive particles including forming an abrasive flake comprising a plurality of precursor shaped abrasive particles and a frangible support joining the precursor shaped abrasive particles together; transporting the abrasive flake through a rotary kiln to sinter the abrasive flake; and breaking the sintered abrasive flake into individual shaped abrasive particles. The method is useful to make small shaped abrasive particles having insufficient mass to be efficiently individually sintered in a rotary kiln without joining two or more of the shaped abrasive particles together.

## Claims

### Claim 1

A method of making shaped abrasive particles comprising:
forming an abrasive flake comprising a plurality of precursor shaped abrasive particles and a frangible support joining the precursor shaped abrasive particles together;
transporting the abrasive flake through a rotary kiln to sinter the abrasive flake; and
breaking the sintered abrasive flake into individual shaped abrasive particles.

### Claim 2 (depends on 1)

The method of claim 1 wherein the frangible support comprises a continuous web.

### Claim 3 (depends on 2)

The method of claim 2 wherein the continuous web of the abrasive flake comprises a thickness from 0.005 to 0.25 mm.

### Claim 4 (depends on 1)

The method of claim 1 wherein the abrasive flake comprises the plurality of precursor shaped abrasive particles and a plurality of bond posts joining the precursor shaped abrasive particles together.

### Claim 5 (depends on 4)

The method of claim 4 wherein the precursor shaped abrasive particles comprise side edges and vertices, and the bond posts are located along the side edges and not at the vertices.

### Claim 6 (depends on 4)

The method of claim 4 wherein each of the precursor shaped abrasive particles in the plurality of precursor shaped abrasive particles comprises 2 to 20 bond posts.

### Claim 7 (depends on 4)

The method of claim 4 wherein the bond posts of the abrasive flake have a thickness and the thickness is from 0.005 to 0.25 mm.

### Claim 8 (depends on 1)

The method of claim 1 wherein the abrasive flake comprises a largest dimension and the largest dimension is greater than 0.50 mm.

### Claim 9 (depends on 1)

The method of claim 1 wherein the abrasive flake comprises a largest dimension of the largest dimension is greater than 0.70 mm and less than 2 cm.

### Claim 10 (depends on 9)

The method of claim 9 wherein the sintered abrasive flake comprises from 2 to 1000 shaped abrasive particles.

### Claim 11 (depends on 1)

The method of claim 1 wherein the sintered abrasive flake comprises alpha alumina particles made from a dispersion of at least one of aluminum oxide hydroxide and aluminum monohydrate.

### Claim 12 (depends on 1)

The method of claim 1 wherein after separation from the frangible support, the shaped abrasive particles comprises a flange extending from the edge of the shaped abrasive particles, and further wherein the flange includes a fractured surface.

### Claim 13 (depends on 1)

The method of claim 1 wherein the abrasive particles of the abrasive flake are spaced to form a gap, and further wherein the frangible support extends across the gap.