KR20210002524A - Abrasive article with shaped abrasive particles having a predetermined rake angle - Google Patents

Abstract

The present invention provides an abrasive article 10. The abrasive article 10 has a direction of use, a y axis, and a z axis perpendicular to the y axis and the direction of use. The abrasive article 10 further includes a backing 12 and shaped abrasive particles attached to the backing. About 5% to about 100% of the shaped abrasive particles 14 independently comprise the first side surface 16,
A second side surface 18 opposite the first side surface 16, connected to the first side surface 16 at the first edge 24 and to the second side surface 18 at the second edge 26. Connected tip surface (20),
A rake angle 30 between the backing 12 and the leading surface 20 within a range of about 10 degrees to about 110 degrees, and
The z-direction rotation angle between the line 52 intersecting the first edge 16 and the second edge 18 and the direction of use 22 of the abrasive article 10 within a range of about 10 degrees to about 170 degrees ( 50).

Description

Abrasive article with shaped abrasive particles having a predetermined rake angle

Abrasive particles and abrasive articles comprising the abrasive particles are useful for polishing, finishing or grinding a wide range of materials and surfaces in the manufacture of goods. As such, there continues to be a need for an improvement in the cost, performance or longevity of abrasive particles or abrasive articles.

The present invention provides an abrasive article. The abrasive article has a direction of use, a y axis, and a z axis orthogonal to the y axis and the direction of use. The abrasive article further includes a backing and shaped abrasive particles attached to the backing. About 5% to about 100% of the shaped abrasive particles independently comprise a first side surface; A second side surface opposite the first side surface; A leading surface connected at the first edge to the first side surface and connected at the second edge to the second side surface; A rake angle between the backing and the leading surface, in the range of about 10 degrees to about 110 degrees; And a z-direction rotation angle between a direction of use of the abrasive article and a line intersecting the first and second edges, within a range of about 10 degrees to about 170 degrees.

The present invention further includes an abrasive article having a first direction of use. The abrasive article includes abrasive particles attached to a backing. Under the same test conditions, the amount of material removed from the workpiece in contact with the abrasive article is greater than the amount of material of the workpiece removed when the abrasive article is moved in a second direction different from the first direction of use.

The present invention further includes an abrasive article having a first direction of use. The abrasive article includes abrasive particles that adhere to the backing. Under the same test conditions, the surface roughness of the work piece in contact with the abrasive article is greater than the surface roughness of the work piece when the abrasive article is moved in a second direction different from the first direction of use.

The present invention further provides a method of making an abrasive article. The method includes orienting the shaped abrasive particles, and attaching the shaped abrasive particles to a backing. About 5% to about 100% of the abrasive particles are shaped and independently a first side surface; A second side surface opposite the first side surface; A leading surface connected to the first side surface at a first edge and connected to the second side surface at a second edge; A rake angle between the backing and the leading surface, in the range of about 10 degrees to about 110 degrees; And a z-direction rotation angle between a direction of use of the abrasive article and a line intersecting the first and second edges, within a range of about 10 degrees to about 170 degrees.

The present invention further includes a method of using an abrasive article. The method includes contacting the shaped abrasive particles with a workpiece; Moving the abrasive article relative to the workpiece in the direction of use; And removing a portion of the work piece. About 5% to about 100% of the abrasive particles are shaped and independently a first side surface; A second side surface opposite the first side surface; A leading surface connected to the first side surface at a first edge and connected to the second side surface at a second edge; A rake angle between the backing and the leading surface, in the range of about 10 degrees to about 110 degrees; And a z-direction rotation angle between a direction of use of the abrasive article and a line intersecting the first and second edges, within a range of about 10 degrees to about 170 degrees.

In drawings that are not necessarily drawn to scale, like reference numerals designate substantially similar elements throughout several figures. Similar reference numbers with different letter suffixes indicate different instances of substantially similar elements. The drawings generally illustrate the various embodiments discussed herein by way of example and not by way of limitation.
1A is a side view of an abrasive belt in accordance with various embodiments.
1B is a front view of an abrasive belt in accordance with various embodiments.
1C is a bottom view of an abrasive belt in accordance with various embodiments.
2 is a side view of an abrasive belt having shaped abrasive particles, in accordance with various embodiments.
3 is a bottom view of an abrasive disk in accordance with various embodiments.
4 is a schematic diagram illustrating a method of manufacturing an abrasive article, in accordance with various embodiments.
5 is a schematic diagram illustrating the orientation of shaped abrasive particles according to the method of FIG. 4, in accordance with various embodiments.
6 is a schematic diagram illustrating the orientation of shaped abrasive particles according to the method of FIG. 4, in accordance with various embodiments.
7 is a schematic diagram illustrating the orientation of shaped abrasive particles according to the method of FIG. 4, in accordance with various embodiments.
8 is a plot of data from grinding procedure A, according to various embodiments.
9 is a plot of data from grinding procedure B, according to various embodiments.
10 is a plot of data from grinding procedure C, in accordance with various embodiments.
11 is a 2D color contour height map of a substrate of a surface analysis procedure D polished in a reverse direction, in accordance with various embodiments.
12 is a 2D color contour height map of a substrate of a forward polished surface analysis procedure D, in accordance with various embodiments.
13 is a 3D image of a substrate of reversely polished surface analysis procedure D, in accordance with various embodiments.
14 is a 3D image of a substrate of forwardly polished surface analysis procedure D, in accordance with various embodiments.

Reference will now be made in detail to certain embodiments of the disclosed subject matter, examples of which are partially illustrated in the accompanying drawings. While the disclosed subject matter will be described in connection with the enumerated claims, it will be understood that the illustrated subject matter is not intended to limit the claims to the disclosed subject matter.

Throughout this specification, values expressed in range form not only include the numerical values expressly stated as limits of such ranges, but also all individual numerical values or subranges included within such ranges, as if each Numerical values and subranges are to be interpreted in a flexible manner as inclusive as if explicitly stated. For example, a range of "about 0.1% to about 5%" or "about 0.1% to 5%" is only about 0.1% to about 5%, as well as individual values within the indicated range (e.g., 1%, 2%, 3%, and 4%) and subranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%). Unless otherwise indicated, reference to “about X to Y” has the same meaning as “about X to about Y”. Likewise, unless otherwise indicated, reference to “about X, Y, or about Z” has the same meaning as “about X, about Y, or about Z”.

In this specification, the terms "a", "an", or "the" are used to include one or more than one, unless the context clearly indicates otherwise. The term “or” is used to refer to a non-exclusive “or” unless otherwise indicated. Reference to “at least one of A and B” has the same meaning as “A, B, or A and B”. Moreover, it should be understood that phrases or terms used herein and not otherwise defined are for the purpose of description only and not limitation. Any use of section headings is intended to aid the understanding of the document and should not be construed as limiting; Information related to the section title may be within or outside that particular section.

In the methods described herein, actions may be performed in any order without departing from the principles of the present invention, except when a temporal sequence or a task sequence is explicitly stated. Moreover, specified actions may be performed concurrently, unless the explicit expression of the claims states that they will be performed individually. For example, the claimed action to do X and the claimed action to do Y can be performed simultaneously within a single task, and the resulting process will fall within the literal scope of the claimed process.

As used herein, the term "about" refers to the degree of variability in a value or range, for example within 10%, within 5%, or within 1% of the stated value or stated range limit. And the exact values or ranges mentioned are included.

As used herein, the term “substantially” means at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9 %, 99.99%, or at least about 99.999% or more, or the majority or majority, as in 100%.

According to various embodiments of the present invention, an abrasive article is disclosed. The abrasive article can be selected from many different abrasive articles such as an abrasive belt, an abrasive sheet or an abrasive disc. 1A-1C are various views of an abrasive belt 10. 1A is a side view of the belt 10, FIG. 1B is a front view of the belt 10, and FIG. 1C is a bottom view of the belt 10. 1A-1C show many of the same features and will be discussed simultaneously. 1A to 1C, the abrasive belt 10 has a z-axis and a y-axis orthogonal to the z-axis. The use direction 22 for the abrasive belt 10 extends in one direction along the x axis orthogonal to both the z axis and the y axis. With respect to Fig. 1A, the direction of use 22 is from left to right; With respect to Fig. 1B, the direction of use 22 is towards the reader out of the page; With respect to Fig. 1C, the usage direction 22 is from the bottom of the page to the top of the page.

The abrasive belt 10 includes a backing 12 to which shaped abrasive particles 14 are attached. The backing 12 can have any desired degree of flexibility. Backing 12 may comprise any suitable material. For example, the backing 12 may be made of a polymer film, a metal foil, a woven fabric, a knitted fabric, paper, a vulcanized fiber, a nonwoven fabric, a foam, a screen, a laminate, or a combination thereof. Can include. The backing 12 may further include various additive(s). Examples of suitable additives include colorants, processing aids, reinforcing fibers, heat stabilizers, UV stabilizers and antioxidants. Examples of useful fillers include clay, calcium carbonate, glass beads, talc, clay, mica, wood flour and carbon black.

As shown, the edge of the at least one shaped abrasive particle 14 substantially contacts the backing 12. In a further embodiment, it may be possible that the edge or portions of the edge do not contact the backing 12.

The shaped abrasive particles 14 are any abrasive particles in which at least a portion of the abrasive particles have a predetermined shape. The predetermined shape can be replicated, for example, from a mold cavity used to form the shaped precursor abrasive particles. In embodiments in which the shaped abrasive particles 14 are formed in the mold cavity, the predetermined geometric shape may substantially replicate the mold cavity used to form the shaped abrasive particles 14. The shaped abrasive particles 14 can also replicate the shape of a die in an example in which the shaped abrasive particles are formed through extrusion. The shaped abrasive particles 14 can also be programmed, for example, computer-aided-design (CAD), when the shaped abrasive particles 14 or abrasive articles are formed through an additive manufacturing process. ) You can duplicate the shape found in the program. The shaped abrasive particles 14 do not refer to shredded abrasive particles of random size formed by, for example, mechanical shredding operations.

The shaped abrasive particles 14 contain many geometric features. For example, as shown in FIGS. 1A-1C, the shaped abrasive particles 14 have a first side surface 16, a second side surface 18, a leading surface 20, and a trailing end. Includes surface 28. The surfaces of the shaped abrasive particles 14 are connected at the edges. For example, the leading surface 20 is connected to the first side surface 16 at the edge 24 and also to the second side surface 18 at the edge 26. In operation, the leading surface 20 is the leading surface of the shaped abrasive particles 14 with respect to the direction of use 22, and the trailing surface 28 is disposed opposite to the leading surface 20. In some embodiments, the leading surface 20, the trailing surface 28, or any of both may be an edge formed at the intersection of the two surfaces.

The first side surface 16, the second side surface 18, the leading surface 20, and the trailing surface 28 may have any suitable shape. For example, the first side surface 16, the second side surface 18, the leading surface 20, and the rear end surface 28 may have a polygonal shape, which may be a regular polygon or an irregular polygon. In some embodiments, the polygonal shape may substantially conform to a triangular shape, a square shape, a pentagonal shape, a hexagonal shape, a heptagonal shape, or an octagonal shape. Other higher-order polygonal shapes are within the scope of the present invention. In embodiments where the polygonal shape substantially follows the square shape, the square shape may be, for example, square, rectangular, or trapezoidal. In embodiments where the polygonal shape substantially conforms to the triangular shape, the triangular shape may be, for example, a right triangle, an equilateral triangle, an isosceles triangle, an acute triangle, or an obtuse triangle. In some embodiments, the triangular shape is not an equilateral triangle.

The first side surface 16, the second side surface 18, the leading surface 20, and the rear end surface 28 may have the same shape or may have different shapes. Additionally, the first side surface 16 and the second side surface 18 are of substantially the same size, or are substantially the same size based on at least one of a surface area, a maximum length dimension, a maximum width dimension, or any combination thereof. It can be of different sizes. Each of the leading surface 20 and the trailing surface 28 is based on at least one of a surface area, a maximum length dimension, a maximum width dimension, or any combination thereof, each of the first side surface 16 and the second side surface ( May be smaller than 18).

Any of the first side surface 16, the second side surface 18, the leading surface 20, and the trailing surface 28 may or may not be substantially flat. Additionally, any of the first side surface 16, the second side surface 18, the leading surface 20, and the trailing surface 28 may extend substantially parallel or non-parallel to each other. have. In embodiments in which any of the first side surface 16, the second side surface 18, the leading surface 20, and the trailing surface 28 are not flat, these surfaces will have a substantially concave or convex shape. I can. In some embodiments, a portion of any of the first side surface 16, the second side surface 18, the leading surface 20, and the trailing surface 28 may be substantially planar and of the same surface. Other parts may not be flat. In a further embodiment, a portion of any of the first side surface 16, the second side surface 18, the leading surface 20, and the trailing surface 28 may be substantially convex and the same surface Other parts of the can be substantially concave.

Depending on the shape or profile of any of the first side surface 16, the second side surface 18, the leading surface 20, and the trailing surface 28, any of the edges 24, 26 The edges can be straight, tapered or curved. The edges connecting one surface to other surfaces can have the same length or different lengths. For example, as shown in Fig. 1B, the edges 24 and 26 are parallel and have the same length in the z direction. This causes the cutting tips 31 of the shaped abrasive particles 14 to extend parallel to the x-y plane. The cutting tip 31 is understood to refer to the point of inflection along the leading surface 20 and the trailing surface 28. In another embodiment, the edges 24 and 26 are of different lengths and the cutting tip 31 is inclined so as not to be parallel to the x-y plane. The cutting tip 31 may have a radius of curvature of about 60 micrometers or more, about 70 micrometers or more, about 80 micrometers or more, about 90 micrometers or more, or about 100 micrometers or more without a sharp tip.

Any of the first side surface 16, the second side surface 18, the leading surface 20, and the trailing surface 28 may be an opening, a concave surface, a convex surface, a groove, a ridge, a fractured surface. Additional shape features such as a surface, a low roundness factor, or a perimeter that includes one or more corner points with sharp tips.

Shaped abrasive particles 14 can be positioned against backing 12 to achieve some performance characteristics of abrasive belt 10. The positioning of the shaped abrasive particles 14 can be characterized by a variety of different angles of the shaped abrasive particles 14 relative to the backing 12.

For example, the rake angle 30 may be characterized by the angle measured between the backing 12 and the leading surface 20 or cutting tip 31. 1A, the rake angle 30 is about 90 degrees. However, in other embodiments, the rake angle 30 is a value within the range of about 10 degrees to about 170 degrees, about 80 degrees to about 100 degrees, about 85 degrees to about 95 degrees, or about 10 degrees, 15, 20, 25 degrees. , 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150 , 155, 160, 165, or a value less than or equal to or greater than about 170 degrees. The value of the rake angle 30 can be selected for the intended purpose of the abrasive belt 10. For example, if the rake angle 30 is 90 degrees or less, the abrasive article is used to remove material from the workpiece, to achieve deep cuts within the workpiece, or to remove large pieces of swarf from the workpiece. Can be very suitable for Conversely, if the rake angle 30 is greater than 90 degrees, the abrasive belt 10 may still have some of the previously described properties, but may additionally be more suitable for finishing the surface of the work piece.

In some embodiments of the abrasive belt 10, it may be desirable for a certain percentage of the shaped abrasive particles 14 to have substantially the same rake angle 30. For example, in some embodiments, about 50% to about 100%, or about 90% to about 100%, or about 50%, 55, 60, 65, 70, 75, 80, 85 of the shaped abrasive particles. The rake angle 30 of the shaped abrasive particles less than or equal to or greater than 90, 95, or 100% is substantially the same. Having the abrasive particles 14 or 100% of the abrasive belt 10 share the same rake angle 30 may be desirable to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the abrasive belt 10, it may be desirable to have different rake angles. For example, some embodiments of the abrasive belt 10 may include a plurality of rows of abrasive particles 14. With respect to FIG. 1A, three rows 40, 42, 44 are shown, although other embodiments of the abrasive belt 10 may include fewer or more rows. As shown, each of the rows 40, 42, 44 extends in the y direction, and adjacent rows (eg, 40 and 42 as well as 42 and 44) are spaced from each other in the x direction. In embodiments comprising multiple rows, it is possible for each abrasive particle 14 in the row to have the same rake angle 30. For example, each of the shaped abrasive particles 14 in the row 44 may have the same rake angle 30. Further, each of the shaped abrasive particles 14 of the row 42 may have the same rake angle 30, but this rake angle 30 is the rake angle of the shaped abrasive particles 14 of the row 42 Can be different. In addition, each of the shaped abrasive particles 14 of the row 44 may have the same rake angle 30, but this rake angle 30 is the shape of the shaped abrasive particles 14 of the rows 42 and 40. It can be different from the rake angle. In this way, a gradient of rake angles 30 can be created in the abrasive belt 10.

The relief angle 46 is characterized by the angle measured between the backing 12 and the cutting tip 31 at the inflection point of the trailing surface 28. 1A, the clearance angle 46 is measured between the backing 12 and the cutting tip 30 along the trailing surface 28. In various embodiments, the clearance angle 46 may be in the range of about 90 degrees to about 180 degrees, about 120 degrees to about 140 degrees, or about 90 degrees, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, or less than, equal to, or greater than about 180 degrees. In some embodiments, the difference between the rake angle 30 and the clearance angle 46 may be in a range of about 5 degrees to about 50 degrees, about 10 degrees to about 40 degrees, or about 5 degrees, 10, 15, 20 degrees. , 25, 30, 35, 40, 45, or less than or equal to or greater than about 50 degrees. The value of the relief angle 46 can be selected for the intended purpose of the abrasive belt 10. For example, as the clearance angle 46 approaches a higher value, the polishing belt 10 may finish the surface (eg, when the direction of use 22 is reversed to the second direction of use). Additionally, when the clearance angle 46 is a higher value, it is possible for the material removed from the workpiece to be released, which can help to prevent clogging of the abrasive belt 10. However, in some embodiments, having a lower relief angle 46 value may help enhance the adhesion of the abrasive particles 14 to the backing when a force is applied to the abrasive belt 10 during operation. .

In some embodiments of the abrasive belt 10, it may be desirable for a certain percentage of the shaped abrasive particles 14 to have substantially the same relief angle 46. For example, in some embodiments, about 50% to about 100%, or about 90% to about 100%, or about 50%, 55, 60, 65, 70, 75, 80, 85 of the shaped abrasive particles. The relief angle 46 of the shaped abrasive particles less than or equal to or greater than 90, 95, or 100% is substantially the same. It may be desirable to have the abrasive particles 14 or 100% of the abrasive belt 10 share the same clearance angle 46 to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the abrasive belt 10 it may be desirable to have different relief angles 46. For example, each of the shaped abrasive particles 14 in the row 44 may have the same relief angle 46. In addition, each of the shaped abrasive particles 14 of the row 42 may have the same clearance angle 46, but this clearance angle 46 is equal to the clearance angle of the shaped abrasive particles 14 of the row 42 Is different. In addition, each of the shaped abrasive particles 14 in the row 44 may have the same clearance angle 46, but this clearance angle 46 is the same as that of the shaped abrasive particles 14 in the rows 42 and 40. It is different from the clearance angle. In this way, a gradient of clearance angles 46 can be created in the abrasive belt 10.

The draft angle (α) 48 is characterized by the angle measured between the backing 12 and any of the first side surface 16 and the second side surface 18. As shown in Fig. 1B, the draft angle (α) 48 is about 90 degrees. However, in other embodiments, the draft angle (α) 48 may be in the range of about 90 degrees to about 130 degrees, about 95 degrees to about 120 degrees, or about 90 degrees, 100, 105, 110, 115, 120 , 125, or less than or equal to or greater than about 130 degrees. In some embodiments of the abrasive belt 10, it may be desirable for a certain percentage of the shaped abrasive particles 14 to have substantially the same draft angle (α) 48. For example, in some embodiments, about 50% to about 100%, or about 90% to about 100%, or about 50%, 55, 60, 65, 70, 75, 80, 85 of the shaped abrasive particles. , The draft angle (α) 48 of the shaped abrasive particles less than or equal to or greater than 90, 95, or 100% is substantially the same. Having the abrasive particles 14 or 100% of the abrasive belt 10 share the same draft angle (α) 48 may be desirable to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the abrasive belt 10, it may be desirable to have a different draft angle (α) 48. For example, each of the shaped abrasive particles 14 in the row 44 may have the same draft angle (α) (48). Further, each of the shaped abrasive particles 14 of the row 42 may have the same draft angle (α) 48, but this draft angle 48 is the shaped abrasive particles 14 of the row 42 It may be different from their draft angle. In addition, each of the shaped abrasive particles 14 of the row 44 may have the same draft angle (α) 48, but this draft angle 48 is the shaped abrasive particles of the rows 42 and 40 ( It is different from the draft angle of 14). In this way, a gradient of the draft angle α 48 can be created in the abrasive belt 10. Alternatively, the draft angles (α) 48 of adjacent shaped abrasive particles in the same row can be different to create a gradient in the y direction.

An additional angle to characterize the shaped abrasive particles 14 may be the z-direction rotation angle 50. As shown in FIG. 1C, the z-direction rotation angle 50 may be defined between the use direction 22 and the line 52 intersecting the first edge 24 and the second edge 26. The z-direction rotation angle 50 may be in the range of about 10 degrees to about 170 degrees, about 80 degrees to about 100 degrees, about 85 degrees to about 95 degrees, or about 10 degrees, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, It may be less than, equal to or greater than 160, 165, or about 170 degrees.

In some embodiments of the abrasive belt 10, it may be desirable for a certain percentage of the shaped abrasive particles 14 to have substantially the same z-direction rotation angle 50. For example, in some embodiments, about 50% to about 100%, or about 90% to about 100%, or about 50%, 55, 60, 65, 70, 75, 80, 85 of the shaped abrasive particles. The z-direction rotation angle 50 of the shaped abrasive particles less than or equal to or greater than 90, 95, or 100% is substantially the same. Having the abrasive particles 14 or 100% of the abrasive belt 10 share the same z-direction rotation angle 50 may be desirable to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the abrasive belt 10 it may be desirable to have different z-direction rotation angles 50. For example, each of the shaped abrasive particles 14 in row 44 may have the same z-direction rotation angle 50. In addition, each of the shaped abrasive particles 14 of the row 42 may have the same z-direction rotation angle 50, but this z-direction rotation angle 50 is the shaped abrasive particles of the row 42 (14) may be different from the z-direction rotation angle. In addition, each of the shaped abrasive particles 14 of the row 44 may have the same z-direction rotation angle 50, but this z-direction rotation angle 50 is the shape of the rows 42 and 40. It is different from the z-direction rotation angle of the abrasive particles 14. In this way, a gradient of the z-direction rotation angles 50 can be created in the abrasive belt 10. Alternatively, the z-direction rotation angle 50 of adjacent shaped abrasive particles within the same row can be different to create a gradient in the y direction.

1A to 1C show the abrasive particles 14 as having a generally triangular shape following the shape of a right triangle. However, in light of the foregoing, it is possible for any shaped abrasive particles 14 of abrasive belt 10 to have one of many other suitable shapes. As an example, FIG. 2 shows a side view of an abrasive belt 10A comprising shaped abrasive particles 14A. As shown, the shaped abrasive particles 14A have a generally triangular shape, but the tip surface 20A has both a convex portion 32 and a concave portion 34. In embodiments such as this embodiment where the tip surface 20A is non-linear, the rake angle 30 can be determined by measuring the angle between the backing 12 and the line 54. Line 54 is a line abutting the cutting tip 31.

1A-1C and 2 illustrate embodiments in which the abrasive article is an abrasive belt or abrasive sheet configured for linear movement. However, in other embodiments, the abrasive article may be an abrasive disc configured for rotational movement. 3 is a bottom view of the polishing disk 60. The polishing disk 60 is configured for rotational movement about a central axis 62. The use rotation direction 22A may be determined as a line in contact with the outer peripheral portion 64 of the polishing disk 60.

In the abrasive disk 60, the shaped abrasive particles 14 may retain the same properties as those of the abrasive belt 10. For example, the shaped abrasive particles have the same rake angle 30, draft angle (α) 48, relief angle 46, and z-direction described herein with respect to FIGS. 1A-1C and 2 Rotation angle 50 may have characteristics. Each of the rake angle 30, the draft angle α 48, and the clearance angle 46 may be measured and determined in a manner consistent with the manner described above with respect to FIGS. 1A-1C and 2. In order to measure the z-direction rotation angle 50 of each shaped abrasive particle 14 in the abrasive disc 60, the center of mass 66 of the individual shaped abrasive particle 14 is determined. A line 68 is drawn from the central axis 62 through the center of mass 66 to the outer periphery 64. At the intersection between the line 68 and the outer periphery 64, the line in contact with the outer periphery 64, indicating the direction of use 22A, is shaped to pass through the center of mass 66 and the tip surface 20 It is applied on the abrasive particles 14. Then, the z-direction rotation angle 50 is measured between the overlapped tangent line 22A and line 52.

The shaped abrasive particles 14 can make up 100% by weight of the abrasive particles in any abrasive article. Alternatively, the shaped abrasive particles 14 may be part of a blend of abrasive particles distributed on the backing 12. When present as part of the blend, the shaped abrasive particles 14 are in the range of about 5% to about 95%, about 10% to about 80%, about 30% to about 50% by weight of the blend. May be, or about 5%, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or about 95% by weight of the blend It may be less than, equal to or greater than. In the blend, the balance of the abrasive particles may include conventional crushed abrasive particles. The crushed abrasive particles are generally formed through a mechanical crushing operation and do not have a duplicated shape. The balance of the abrasive particles may also include other shaped abrasive particles that may, for example, comprise an equilateral triangle shape (e.g., flat triangular shaped abrasive particles or tetrahedral shaped abrasive particles in which each side of the tetrahedron is an equilateral triangle). have.

Any abrasive article, such as abrasive belt 10 or abrasive disc 60, is used to attach the shaped abrasive particles 14, or a blend of shaped abrasive particles 14 and crushed abrasive particles to the backing 12. It may include a make coat. The abrasive article may further comprise a size coat that adheres the shaped abrasive particles to the make coat. Make coat, size coat, or both can be any suitable such as phenol resin, epoxy resin, urea formaldehyde resin, acrylate resin, aminoplast resin, melamine resin, acrylate epoxy resin, urethane resin, or mixtures thereof. It may contain resin. Additionally, the make coat, size coat, or both may include fillers, grinding aids, wetting agents, surfactants, dyes, pigments, coupling agents, adhesion promoters, or mixtures thereof. Examples of fillers may include calcium carbonate, silica, talc, clay, calcium metasilicate, dolomite, aluminum sulfate, or mixtures thereof.

The shaped abrasive particles 14 can be formed in a number of suitable ways, for example the shaped abrasive particles 14 can be manufactured according to a multiple working process. This process can be performed using any material or precursor dispersion material. Briefly, for embodiments in which the shaped abrasive particles are monolithic ceramic particles, the process can be converted to a seeded or non-seed precursor dispersion (e.g., alpha alumina) which can be converted to the corresponding one. Boehmite sol-gel); Filling one or more mold cavities having a desired outer shape of the shaped abrasive particles 14 with a precursor dispersion; Drying the precursor dispersion to form shaped precursor abrasive particles; Removing the shaped precursor abrasive particles 14 from the mold cavity; Calcining the shaped precursor abrasive particles 14 to form calcined shaped precursor abrasive particles 14; And then sintering the calcined shaped precursor abrasive particles 14 to form the shaped abrasive particles 14. The process will now be described in more detail with respect to the alpha-alumina-containing shaped abrasive particles 14. In another embodiment, the mold cavity may be filled with melamine to form shaped melamine abrasive particles.

This process may include providing a seeded or non-seed dispersion of a precursor that can be converted to a ceramic. In an example in which the precursor is seeded, the precursor may be seeded with an oxide of iron (eg, FeO). The precursor dispersion may contain a liquid that is often a volatile component. In one example, the volatile component is water. The dispersion may contain a sufficient amount of liquid so that the viscosity of the dispersion is low enough to allow for filling of the mold cavity and replicating of the mold surface, but there is so much liquid that subsequent removal of the liquid from the mold cavity is prohibitively expensive. Cannot contain In one example, the precursor dispersion comprises from 2% to 90% by weight of particles that can be converted to ceramic, such as particles of aluminum oxide monohydrate (boehmite), and at least 10% by weight, or from 50% to 70% or 50% by weight. Volatile components such as water from weight percent to 60 weight percent. Conversely, the precursor dispersion contains 30% to 50% or 40% to 50% by weight solids in some embodiments.

Examples of suitable precursor dispersions include zirconium oxide sol, vanadium oxide sol, cerium oxide sol, aluminum oxide sol and combinations thereof. Suitable aluminum oxide dispersions include, for example, boehmite dispersions and other aluminum oxide hydrate dispersions. Boehmite can be prepared by known techniques or can be obtained commercially. Examples of commercially available boehmite are the trade names "DISPERAL" and "DISPAL", both available from Sasol North America, Inc. or from BASF Corporation. Includes products having the commercially available trade name "HIQ-40". These aluminum oxide monohydrates are relatively pure; That is, they contain a relatively small hydrate phase, if present, in addition to the monohydrate and have a large surface area.

The physical properties of the resulting shaped abrasive particles 14 can generally depend on the type of material used in the precursor dispersion. As used herein, a “gel” is a three-dimensional network of solids dispersed in a liquid.

The precursor dispersion may contain a modifying additive or a precursor of a modifying additive. The modifying additive may function to enhance some desirable properties of the abrasive particles or increase the effectiveness of the subsequent sintering step. The modifying additive or precursor of the modifying additive may be in the form of a soluble salt, for example a water soluble salt. These may include metal-containing compounds, magnesium, zinc, iron, silicon, cobalt, nickel, zirconium, hafnium, chromium, yttrium, praseodymium, samarium, ytterbium, neodymium, lanthanum, gadolinium, cerium, dysprosium, erbium, titanium. And a precursor of an oxide of a mixture thereof. The specific concentration of these additives that may be present in the precursor dispersion may vary.

The introduction of the modifying additive or the precursor of the modifying additive can cause the precursor dispersion to gel. In addition, the precursor dispersion can be induced into a gel by the application of heat over a period of time to reduce the liquid content in the dispersion through evaporation. The precursor dispersion may also contain a nucleating agent. Nucleating agents suitable for the present invention may include fine particles of alpha alumina, alpha iron oxide or precursors thereof, titanium oxide and titanates, chromium oxide or any other material that will nucleate the transformation. If used, the amount of nucleating agent should be sufficient to effect the conversion of alpha alumina.

A peptizing agent may be added to the precursor dispersion to prepare a more stable hydrosol or colloidal precursor dispersion. Suitable peptizing agents are monoprotic acids or acid compounds such as acetic acid, hydrochloric acid, formic acid and nitric acid. Multiprotic acids can also be used, but this can quickly gel the precursor dispersion, making it difficult to handle or introduce additional ingredients. Some commercial sources of boehmite contain acid titers (eg, absorbed formic or nitric acid) that will help form stable precursor dispersions.

The precursor dispersion can be formed by any suitable means, for example, in the case of a sol-gel alumina precursor, it is simply by mixing the aluminum oxide monohydrate with water containing a peptizing agent, or by adding a peptizing agent. It can be formed by forming an aluminum oxide monohydrate slurry.

Defoamers or other suitable chemicals may be added to reduce the tendency to form bubbles or entrain air during mixing. If necessary, additional chemicals may be added such as wetting agents, alcohols or coupling agents.

Further operations may include providing a mold having one or more mold cavities or a plurality of cavities formed within one or more major surfaces of the mold. In some examples, the mold is formed as a manufacturing tool, which may be, for example, a belt, sheet, continuous web, coating roll such as a rotogravure roll, a sleeve mounted on a coating roll, or a die. In one example, the manufacturing tool may comprise a polymeric material. Examples of suitable polymeric materials include polyester, polycarbonate, poly(ether sulfone), poly(methyl methacrylate), polyurethane, polyvinylchloride, polyolefin, polystyrene, polypropylene, polyethylene or combinations thereof. It includes a thermoplastic material or a thermosetting material. In one example, the entire tool is made of a polymeric or thermoplastic material. In another example, the surface of the tool that contacts the precursor dispersion while the precursor dispersion is drying, such as the surface of a plurality of cavities, comprises a polymeric or thermoplastic material, and other portions of the tool may be made of other materials. As an example, a suitable polymeric coating can be applied to a metal tool to change its surface tension properties.

Polymeric or thermoplastic manufacturing tools can be replicated from metal master tools. The master tool can have an inverse pattern of the pattern required for the manufacturing tool. The master tool can be manufactured in the same way as the manufacturing tool. In one example, the master tool is made of metal (eg, nickel) and diamond turned. In one example, the master tool is formed at least in part using stereolithography. The polymeric sheet material can be heated with the master tool so that the polymeric material is embossed into the master tool pattern by pressing the two together. Polymeric or thermoplastic materials can also be extruded or cast onto a master tool and then pressed. The thermoplastic material cools to solidify and creates a manufacturing tool. When a thermoplastic manufacturing tool is used, care must be taken not to generate excessive heat that may distort the thermoplastic manufacturing tool and limit its life.

Access to the cavity can be made from an opening in the upper or lower surface of the mold. In some examples, the cavity may extend over the entire thickness of the mold. Alternatively, the cavity may extend over only a portion of the thickness of the mold. In one example, the top surface is substantially parallel to the bottom surface of the mold, with the cavity having a substantially uniform depth. At least one side of the mold, that is, the side in which the cavity is formed, may remain exposed to the surrounding atmosphere during the step of removing volatile components.

The cavities have a specific three-dimensional shape to make the shaped abrasive particles 14. The depth dimension is equal to the vertical distance from the top surface to the lowest point on the bottom surface. The depth of a given cavity may be uniform or may vary along its length and/or width. The cavities of a given mold may have the same shape or may have different shapes.

Further work entails filling the cavity of the mold with a precursor dispersion (eg, by prior art). In some examples, a knife roll coater or vacuum slot die coater may be used. If desired, a mold release agent may be used to assist in removing the particles from the mold. Examples of mold release agents include oils such as peanut oil or mineral oil, fish oil, silicone, polytetrafluoroethylene, zinc stearate and graphite. In general, when a mold release agent is required, about 0.1 mg/in ² (0.6 mg/cm 2) to about 3.0 mg/in ² (20 mg/cm 2 ), or about 0.1 mg/in ² (0.6 mg/cm 2) per unit area of the mold. Cm2) to about 5.0 mg/in ² (30 mg/cm 2) of the mold release agent is applied to the surface of the manufacturing tool in contact with the precursor dispersion, in a liquid such as water or alcohol, for example peanut oil. . In some embodiments, the top surface of the mold is coated with a precursor dispersion. The precursor dispersion can be pumped onto the upper surface.

In a further operation, a scraper or leveler bar can be used to push the precursor dispersion completely into the cavity of the mold. The remaining portion of the precursor dispersion that has not entered the cavity can be removed from the upper surface of the mold and recycled. In some examples, a small portion of the precursor dispersion may remain on the top surface, while in other examples the top surface is substantially free of dispersion. The pressure exerted by the scraper or leveler bar may be less than 100 psi (0.6 MPa), less than 50 psi (0.3 MPa), or even less than 10 psi (60 kPa). In some examples, the exposed surface of the precursor dispersion does not extend substantially beyond the top surface.

In these examples where it is desired to form the exposed surface of the cavity on the flat side of the shaped ceramic abrasive particles, it may be desirable to overfill the cavity (e.g., using a micronozzle array) and slowly dry the precursor dispersion.

Further work entails drying the dispersion by removing the volatile components. Volatile components can be removed by fast evaporation rates. In some instances, removal of a volatile component by evaporation occurs at a temperature above the boiling point of the volatile component. The upper limit on the drying temperature often depends on the material from which the mold is made. For polypropylene tools, this temperature should be below the melting point of the plastic. In one example, in the case of an aqueous dispersion of about 40 to 50% solids and a polypropylene mold, the drying temperature may be about 90°C to about 165°C, or about 105°C to about 150°C, or about 105°C to about 120°C. . Higher temperatures can lead to improved manufacturing rates, but can also lead to degradation of the polypropylene tool, which limits its useful life as a mold.

During drying, the precursor dispersion shrinks, often causing retraction from the cavity walls. For example, if the cavity has a flat wall, the subsequently obtained shaped abrasive particles 14 may tend to have at least three concave major surfaces. It has now been discovered that it is possible to obtain shaped abrasive particles 14 having at least three substantially flat major surfaces by making the cavity walls concave (and thereby increasing the cavity volume). The degree of concavity generally depends on the solids content of the precursor dispersion.

A further operation involves removing the resulting shaped precursor abrasive particles 14 from the mold cavity. The shaped precursor abrasive particles 14 can be removed from the cavity by using the following processes alone or in combination in the mold: gravity, vibration, ultrasonic vibration, vacuum or pressurized air to remove the particles from the mold cavity.

The shaped precursor abrasive particles 14 may be further dried outside of the mold. If the precursor dispersion is dried to the desired level in the mold, this additional drying step is not necessary. However, in some cases it can be economical to use this additional drying step to minimize the time the precursor dispersion remains in the mold. The shaped precursor abrasive particles 14 will be dried at a temperature of 50° C. to 160° C. or 120° C. to 150° C. for 10 minutes to 480 minutes or 120 minutes to 400 minutes.

A further operation involves calcining the shaped precursor abrasive particles 14. During calcination, essentially all volatile materials are removed and the various components present in the precursor dispersion are converted to metal oxides. The shaped precursor abrasive particles 14 are generally heated to a temperature of 400° C. to 800° C. and within this temperature range until free water and more than 90% by weight of any bound volatile material are removed. maintain. In an optional step, it may be desirable to introduce modifying additives by means of an impregnation process. A water-soluble salt may be introduced into the pores of the calcined shaped precursor abrasive particles 14 by impregnation. Then, the shaped precursor abrasive particles 14 are pre-fired again.

Further operations may involve sintering the calcined shaped precursor abrasive particles 14 to form the particles. However, in some instances where the precursor comprises a rare earth metal, sintering may not be necessary. Prior to sintering, the calcined shaped precursor abrasive particles 14 are not fully densified and thus lack the hardness required to be used as shaped abrasive particles 14. Sintering takes place by heating the calcined shaped precursor abrasive particles 14 to a temperature of 1000° C. to 1650° C. The period during which the calcined shaped precursor abrasive particles 14 can be exposed to the sintering temperature to achieve this level of conversion varies depending on various factors, but is possible from 5 seconds to 48 hours.

In another embodiment, the duration of the sintering step is in the range of 1 minute to 90 minutes. After sintering, the shaped abrasive particles 14 may have a Vickers hardness of 10 GPa (giga Pascals), 16 GPa, 18 GPa, 20 GPa, or more.

To modify the described process, additional operations can be used, such as, for example, rapidly heating the material from the calcination temperature to the sintering temperature and centrifuging the precursor dispersion to remove sludge and/or waste. In addition, the process can be modified by combining two or more of the process steps if desired.

The shaped abrasive particles 14 can be independently sized according to the abrasive industry recognized standard nominal grade. The abrasive industry recognized grade standards include those published by the American National Standards Institute (ANSI), the Federation of European Producers of Abrasives (FEPA), and the Japanese Industrial Standard (JIS). ANSI class designations (i.e., regulatory nominal classes) are for example ANSI 4, ANSI 6, ANSI 8, ANSI 16, ANSI 24, ANSI 36, ANSI 46, ANSI 54, ANSI 60, ANSI 70, ANSI 80, ANSI 90, It includes ANSI 100, ANSI 120, ANSI 150, ANSI 180, ANSI 220, ANSI 240, ANSI 280, ANSI 320, ANSI 360, ANSI 400, and ANSI 600. FEPA class designations are F4, F5, F6, F7, F8, F10, F12, F14, F16, F18, F20, F22, F24, F30, F36, F40, F46, F54, F60, F70, F80, F90, F100, F120, F150, F180, F220, F230, F240, F280, F320, F360, F400, F500, F600, F800, F1000, F1200, F1500, and F2000. JIS grade names are JIS8, JIS12, JIS16, JIS24, JIS36, JIS46, JIS54, JIS60, JIS80, JIS100, JIS150, JIS180, JIS220, JIS240, JIS280, JIS320, JIS360, JIS400, JIS600, JIS800, JIS1000, JIS1500, JIS2500, It includes JIS4000, JIS6000, JIS8000, and JIS10,000.

In addition to the materials already described, at least one magnetic material may be contained within or coated on the individually shaped abrasive particles 14. Examples of magnetic materials include iron; cobalt; nickel; Various alloys of nickel and iron marketed as Permalloy in various grades; Various alloys of iron, nickel, and cobalt sold as Fernico, Kovar, Pernico I, or Pernico II; Various alloys of iron, aluminum, nickel, cobalt and sometimes also copper and/or titanium, marketed as Alnico in various grades; Alloys of iron, silicon, and aluminum (about 85:9:6 by weight) commercially available as Sendust alloys; Heusler alloy (eg, Cu ₂ MnSn); Manganese bismuth (also known as Bismanol); Rare earth magnetizable materials such as gadolinium, dysprosium, holmium, europium oxide, neodymium, alloys of iron and boron (eg, Nd ₂ Fe ₁₄ B), and alloys of samarium and cobalt (eg, SmCo ₅ ); MnSb; MnOFe ₂ O ₃ ; Y ₃ Fe ₅ O ₁₂ ; CrO ₂ ; MnAs; Ferrites such as ferrite and magnetite; Zinc ferrite; Nickel ferrite; Cobalt ferrite, magnesium ferrite, barium ferrite, and strontium ferrite; Yttrium iron garnet; And combinations thereof. In some embodiments, the magnetizable material contains 8 to 12 weight percent (wt %) aluminum, 15 to 26 weight percent nickel, 5 to 24 weight percent cobalt, up to 6 weight percent copper, up to 1% titanium. Containing alloy, where the balance of the material added up to 100% by weight is iron. In some other embodiments, a magnetizable coating may be deposited on the abrasive particles 14 using a deposition technique such as physical vapor deposition (PVD) including magnetron sputtering.

Including these magnetizable materials can cause the shaped abrasive particles 14 to respond to a magnetic field. Any of the shaped abrasive particles 14 may comprise the same material or may comprise different materials. Additionally, if present, the shaped abrasive particles 14 and the crushed abrasive particles may comprise the same or different materials.

The abrasive articles described herein can be made according to a number of suitable methods. The method described herein may allow precise placement of at least some of the shaped abrasive particles 14 on the backing 12. This may allow precise and predetermined alignment of the sub-surface 20. This may also allow a variety of predetermined patterns of shaped abrasive particles 14 to be formed. For example, in the abrasive belt 10, the z-direction rotation angle 50 of the shaped abrasive particles 14 will be positioned so that the pattern formed by the shaped abrasive particles 14 includes a plurality of parallel lines. I can. As a further example, in the abrasive disc 60, the z-direction rotation angle 50 of the shaped abrasive particles 14 will be positioned so that the pattern formed by the shaped abrasive particles 14 includes a plurality of circles. I can.

The abrasive articles described herein can be made according to any suitable method. Generally speaking, the abrasive article has a backing 12 to achieve at least one of a rake angle 30, a z-direction rotation angle 50, a clearance angle 46, a draft angle (α) 48, or a combination thereof. ) Can be formed by orienting at least a portion of the shaped abrasive particles 14 on. The method may further include attaching the shaped abrasive particles 14 to the backing 12.

Orienting the abrasive particles 14 can be achieved, for example, by including one or more cavities within the backing 12. The cavities are individually shaped such that at least one of the rake angle (30), z-direction rotation angle (50), clearance angle (46), draft angle (α) (48), or a combination thereof achieves a predetermined value. The particles 14 can be shaped in such a way that they are located on the backing 12.

The inclusion of cavities within the backing 12 may cause the abrasive particles 14 to be either a drop coating or an electrostatic coating on the backing 12 while achieving the intended orientation. As generally understood, in the drop coating technique, a large feed of abrasive particles 14 is fed through a hopper, falls under gravity onto the backing 12, and settles in the cavities. Without cavities, the spatial orientation of the abrasive particles 14 when contacting the backing 12 would be completely random in all directions. However, the cavities eliminate random spatial orientation.

In other embodiments, precise orientation of the shaped abrasive particles 14 can be achieved using a dispensing tool or screen. The dispensing tool or screen may include one or more slots defined by a plurality of walls. The slot can be opened at two ends. One end may be configured to receive the shaped abrasive particles 14 and the other end may contact the backing 12. Backing 12 may optionally have a make coat distributed over the backing. Slots are individually shaped such that at least one of the rake angle (30), z-direction rotation angle (50), clearance angle (46), draft angle (α) (48), or a combination thereof achieves a predetermined value. The particles 14 are designed to be located on the backing 12. Particles that do not properly enter the cavity may be wiped out of the dispensing tool, and additional particles may contact the dispensing tool and enter the empty slots.

The dispensing tool comprising the shaped abrasive particles 14 may be left in contact with the backing 12 for any suitable amount of time when the shaped abrasive particles 14 are attached to the make coat. After sufficient time has elapsed for good adhesion between the shaped abrasive particles 14 and the make coat, the manufacturing tool is removed and a size coat is optionally placed over the shaped abrasive particles 14.

In another embodiment, precise orientation of the shaped abrasive particles 14 can be achieved using a rotary manufacturing tool. The rotary manufacturing tool is circular and includes a plurality of cavities on the outer surface. Each of the cavities is designed to receive the shaped abrasive particles 14 in a specific orientation. To increase the probability that each cavity will be filled, extra shaped abrasive particles 14 are contacted with the manufacturing tool. The shaped abrasive particles 14 that do not enter the cavity are collected for later use. Once set in the cavity, the shaped abrasive particles 14 are brought into contact with the backing 12, which can be supplied as a web. The backing 12 has a pre-placed make coat on top so that upon contact, the shaped abrasive particles 14 adhere to the backing 12 and are removed from the manufacturing tool.

In another embodiment, precise orientation of the shaped abrasive particles 14 may be achieved using shaped abrasive particles comprising at least some magnetic material. Shaped abrasive particles comprising magnetic material may be randomly arranged on the backing 12. Subsequently, in the shaped abrasive particles 14, the shaped abrasive particles 14 are at least one of a rake angle 30, a z-direction rotation angle 50, a clearance angle 46, and a draft angle (α) 48. Can be exposed to the magnetic field in a manner that is rotated and aligned to achieve Once properly oriented, the shaped abrasive particles 14 can be attached to the backing 12 in a make coat and optionally a size coat. As a result of this process, at least one of the rake angle 30, the z-direction rotation angle 50, the clearance angle 46, the draft angle (α) 48, or a combination thereof, to achieve a predetermined value. Individually shaped abrasive particles 14 are placed on the backing 12. Examples of such processes are described in further detail below with respect to FIGS. 4 to 7.

4 shows a web 110 including a backing 115 having a make layer precursor 120 disposed thereon, moving in a web downstream direction 114 (e.g., machine direction) along a web path 112 do. The web 110 has a web transverse direction (not shown) that is perpendicular to the web downstream direction 114. The make layer precursor 120 includes a first curable binder precursor (not shown). Magnetizable particles 132 (having a structure corresponding to the shaped abrasive particles 14) fall onto the make layer precursor 120 through a portion of the applied magnetic field 140. At least some of the magnetizable particles 132 are abrasive particles. Magnetizable particles 132 are primarily deposited on the web 110 after moving downward along the downwardly inclined distribution surface 185 fed from the hopper 175. While moving downward along the downwardly inclined distribution surface 185, the longest side of the magnetizable abrasive particles tends to align with the applied magnetic field 140. Various web handling components 180 (eg, rollers, conveyor belts, feed rolls, and take-up rolls) handle web 110.

Throughout this method, at least until the transfer of the magnetizable abrasive particles to the make precursor layer, the magnetizable particles are applied with their longest axis aligned substantially parallel (or antiparallel) to the magnetic field line 165. Oriented continuously by a magnetic field. Once delivered, the applied magnetic field can continue to influence the orientation on the magnetizable abrasive particles, but this is not a requirement.

In general, the applied magnetic field used in the practice of the present invention has a magnetic field strength of at least about 10 Gauss (1 mT) in the region where the magnetizable particles are affected (e.g., attracted and/or oriented), and about 100 Gauss ( 10 mT) or more, or about 1000 Gauss (0.1 T) or more, but this is not a requirement.

The applied magnetic field may be provided, for example, by one or more permanent magnets and/or electromagnet(s), or a combination of magnets and ferromagnetic members. Suitable permanent magnets include rare earth magnets comprising magnetizable materials as described above. The applied magnetic field can be static or variable (eg, oscillating). The upper and/or lower magnet members 152, 154, each having an N and S pole, may be monolithic, or they consist of, for example, a plurality of component magnets 154a, 154b and/or a magnetizable body. Can be. When comprised of multiple magnets, multiple magnets within a given magnet member may be adjacent and/or co-aligned (eg, at least substantially parallel) to their magnetic field lines where the component magnets approach each other closest. Stainless steel retainers 156, 158a, 158b hold the magnets in place. Stainless steel 304 or equivalent is suitable due to its non-magnetic properties, but magnetizable materials can also be used. Mild steel mounts 162 and 164 support stainless steel retainers 156, 158a, 158b, respectively. Although steel mounts are shown in FIG. 4, the mounts can be made of any dimensionally stable material(s), whether magnetizable or not.

The downwardly inclined distributing surface can be inclined at any suitable angle, provided that the magnetizable particles can move downwards along the surface and distribute onto the web. Suitable angles may be in the range of 15 to 60 degrees, but other angles may also be used. In some cases, for example, it may be desirable to vibrate the downwardly sloped distribution surface to facilitate particle movement.

The downwardly sloping distribution surface may be constructed of any dimensionally stable material that may not be magnetizable. Examples include metals such as aluminum; wood; And plastics.

5-7 show the magnetizable particles 132 at the transfer position from the downwardly inclined distribution surface 185 onto the web 110 according to the position of the downwardly inclined distribution surface 185 within the applied magnetic field 140. Shows the general process of Figure 4 showing alignment.

For example, in the configuration shown in FIG. 5, the magnetizable shaped abrasive particles 132 are magnetic field lines 165 such that they obtain an orientation in which their long edges slope upward from right to left when transferred to the web. ) Is distributed onto the web 110 where it forms a web downstream angle α with the web 100 of less than 90 degrees. As shown, the magnetizable shaped abrasive particles 132 slide downward along the downwardly inclined distribution surface 185 and begin to be oriented with their longest edges aligned with the magnetic field lines 165. As the magnetizable shaped abrasive particles 132 contact the make layer precursor 120 of the web 110, they are tilting in a direction downstream of the web. The gravity and/or lower magnetic element causes the magnetic shaped abrasive particles to settle onto the make layer precursor 120, and after curing they are subsequently attached to the backing 115. Most of the magnetizable shaped abrasive particles 132 have a nominal rake angle of about 90 degrees in the web upweb direction (e.g., the tip of the magnetizable shaped abrasive particles in a indicated direction (e.g., upstream or downstream of the web). The angle between the edge and the backing).

Referring now to the configuration shown in FIG. 6, the magnetizable shaped abrasive particles 132, when transferred to the web 110, have their longest edges inclined upward from right to left or from left to right. Aligned to obtain orientation. The magnetizable shaped abrasive particles 132 slide downward along the downwardly inclined distribution surface 185 and begin to oriented with their longest edges aligned with the magnetic field lines 165. Magnetizable shaped abrasive particles 132 are distributed onto web 110 where magnetic field lines 165 are approximately perpendicular to web 110. The magnetizable shaped abrasive particles 132 are placed onto the web 110 with their longest edges approximately perpendicular to the backing. This causes the particles to rotate around their longest edge. The lower magnetic element and/or gravity causes the magnetizable shaped abrasive particles 132 to settle onto the make layer precursor 120 and after curing they are subsequently attached to the backing 115. An approximately equal percentage of the magnetizable shaped abrasive particles have a nominal 90 degree rake angle towards the web downstream direction as they face the web upstream direction.

In the configuration shown in FIG. 7, the magnetizable shaped abrasive particles 132 are aligned so that they obtain an orientation in which their long edges slope upwardly from left to right when transferred to the web. As the magnetizable shaped abrasive particles 132 slide downward along the downwardly inclined distribution surface 185, they begin to be oriented with their longest edges aligned with the magnetic field lines 165. Magnetizable shaped abrasive particles 132 are distributed on the backing where magnetic field lines 165 form a web downstream angle β with the web 100 greater than 90 degrees. As the particles contact the web, they are tilting forward in the direction downstream of the web. The lower magnetic element and/or gravity causes the magnetizable shaped abrasive particles 132 to settle onto the make layer precursor 120 and after curing they are subsequently attached to the backing 115. Most of the magnetizable shaped abrasive particles 132 are attached to the web 110 at a rake angle of about 90 degrees in a direction downstream of the web.

Once the magnetizable particles are coated onto the curable binder precursor, they are at least partially cured in a first curing station (not shown) to firmly hold the magnetizable particles in place. In some embodiments, additional magnetizable and/or non-magnetizable particles (eg, filler abrasive particles and/or grinding aid particles) may be applied to the make layer precursor prior to curing.

In the case of coated abrasive articles, the curable binder precursor comprises a make layer precursor, and the magnetizable particles comprise magnetizable abrasive particles. A size layer precursor may be applied over the at least partially cured make layer precursor and the magnetizable abrasive particles, but this is not a requirement. If present, the size layer precursor is then at least partially cured in a second curing station, optionally with further curing of the at least partially cured make layer precursor. In some embodiments, a supersize layer is disposed on the at least partially cured size layer precursor.

According to various embodiments, a method of using an abrasive article such as an abrasive belt 10 or an abrasive disc 60 includes contacting the shaped abrasive particles 14 with a workpiece or substrate. The work piece or substrate may comprise many different materials such as steel, steel alloy, aluminum, plastic, wood, or combinations thereof. Upon contact, one of the abrasive article and the workpiece is moved in the direction of use 22 relative to each other, and a portion of the workpiece is removed.

According to various embodiments, the depth of cut into the substrate or workpiece may be about 10 μm or more, about 20 μm or more, about 30 μm or more, about 40 μm or more, about 50 μm or more, or about 60 μm or more. A portion of the substrate or work piece is removed as debris by the abrasive article. The maximum average dimension or length of debris taken from the set of debris after a grinding cycle is about 1200 μm or more, about 1250 μm or more, about 1300 μm or more, about 1350 μm or more, about 1400 μm or more, about 1450 μm or more, about 1500 μm or more , About 1500 μm or more, about 1550 μm or more, about 1600 μm or more, or about 1650 μm or more.

According to various embodiments, the cutting speed of the abrasive article is at least about 100 m/min, at least about 110 m/min, at least about 120 m/min, at least about 130 m/min, at least about 140 m/min, about 150 m. At least about 160 m/min, at least about 170 m/min, at least about 180 m/min, at least about 190 m/min, at least about 200 m/min, at least about 300 m/min, about 400 m/min Min or more, about 500 m/min or more, about 1000 m/min or more, about 1500 m/min or more, about 2000 m/min or more, about 2500 m/min or more, about 3000 m/min or more, or about 4000 m/min It can be more than a minute.

The direction of use 22 is a first direction indicated as shown in FIGS. 1A to 1C, 2 and 3. It is possible for the abrasive article to be moved in a second direction different from the direction of use 22. The second direction is about 1 degree to about 360 degrees, about 160 degrees to about 200 degrees, about 1 degree, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50 with respect to the direction of use 22 , 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175 , 180, 185, 190, 195, 200, 205, 210, 215, 220, 230, 240, 250, 260, 265, 270, 275, 280, 285, 290, 295, 300, 305, 310, 315, 320 , 325, 330, 335, 340, 350, 355, or less than or equal to about 360 degrees, or a direction rotated by more than or equal to it.

According to various embodiments, the abrasive articles described herein may have several advantages when moved in the direction of use 22 as opposed to any other direction of use. For example, the amount of material removed from the work piece, the length of debris removed from the work piece, the depth of cut into the work piece, the surface finish of the work piece, or a combination thereof, at the same application force, cutting speed, or a combination thereof. Is greater in the first direction than in any other second direction.

For example, about 10% or more, about 15% or more, about 35% or more, about 40% or more, about 45% or more, about 50% or more, about 55% or more, about 60% or more, about 65% or more, about 70% or more, about 75% or more, about 80% or more, about 85% or more, about 90% or more, about 95% or more, about 100% or more, about 120% or more, about 130% or more, about 140% or more, about At least 150% more material is removed from the substrate or work piece in the first direction of use. In some embodiments, about 15% to about 500%, or about 30% to about 70%, or about 40% to about 60%, or about 15%, 20%, 25%, 30%, 35%, 40% , 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 105%, 110%, 115%, 120%, 125 %, 130%, 135%, 140%, 145%, 150%, 155%, 160%, 165%, 170%, 175%, 180%, 185%, 190%, 195%, 200%, 205%, 210%, 215%, 220%, 225%, 230%, 235%, 240%, 245%, 250%, 255%, 260%, 265%, 270%, 275%, 280%, 285%, 290% , 295%, 300%, 305%, 310%, 315%, 320%, 325%, 330%, 335%, 340%, 345%, 350%, 355%, 360%, 365%, 370%, 375 %, 380%, 385%, 390%, 395%, 400%, 405%, 410%, 415%, 420%, 425%, 430%, 435%, 440%, 445%, 450%, 455%, Less than 460%, 465%, 470%, 475%, 480%, 485%, 490%, 495%, or about 500% less, equal to, or more than 500% of the material is removed in the first direction of use. The amount of material removed may be related to an initial cut amount (eg, an initial cut amount in a cutting cycle) or a total cut amount (eg, the sum of the amount of material removed over a set number of cutting cycles).

The procedure for grinding the workpiece is described herein in examples of grinding procedure A and grinding procedure B. (When the abrasive article is operated in the direction of use) The initial cut amount of the workpiece measured according to grinding procedure A is about 9 grams or more, about 9.5 grams or more, about 10 grams or more, about 10.5 grams or more, about 11 grams or more, about 11.5 About 12.5 grams or more, about 13 grams or more, about 13.5 grams or more, about 14 grams or more, about 14.5 grams or more, about 15 grams or more, about 15.5 grams or more, about 16 grams or more, about 16.5 grams or more Gram or more, about 17 grams or more, about 17.5 grams or more, about 17.8 grams or more, about 18 grams or more, about 18.5 grams or more, about 19 grams or more, about 19.5 grams or more, about 20 grams or more, about 20.5 grams or more, about 21 At least about 21.5 grams, at least about 22 grams, at least about 22.5 grams, at least about 23 grams, at least about 23.5 grams, at least about 24 grams, at least about 25.5 grams, or at least about 25 grams. (When the abrasive article is operated in the direction of use) The total cut amount of the workpiece measured according to grinding procedure A is about 65 grams or more, about 70 grams or more, about 75 grams or more, about 80 grams or more, about 85 grams or more, about 90 It may be at least about 95 grams, at least about 100 grams, at least about 105 grams, at least about 110 grams, at least about 115 grams, at least about 118.37 grams, at least about 120 grams, or at least about 125 grams. (When the abrasive article is operated in the direction of use) The initial cutting amount of the workpiece measured according to grinding procedure B is about 9 mm or more, about 9.5 mm or more, about 10 mm or more, about 10.5 mm or more, about 11 mm or more, about 11.5 mm or more, about 12 mm or more, about 12.5 mm or more, about 13 mm or more, about 13.5 mm or more, about 14 mm or more, about 14.5 mm or more, about 15 mm or more, about 15.5 mm or more, about 16 mm or more, about 16.5 mm or more, about 17 mm or more, about 17.5 mm or more, about 18 mm or more, about 18.47 mm or more, about 19 mm or more, about 19.5 mm or more, about 20 mm or more, about 20.5 mm or more, about 21 mm or more, about 21.5 mm or more, about 22 mm or more, about 22.5 mm or more, about 23 mm or more, about 23.5 mm or more, about 24 mm or more, about 25.5 mm or more, or about 25 mm or more. (When the abrasive article is operated in the direction of use) The total cutting amount of the workpiece measured according to grinding procedure B is about 172 mm or more, about 180 mm or more, about 190 mm or more, about 200 mm or more, about 210 mm or more, about 220 mm or more, about 230 mm or more, about 240 mm or more, about 250 mm or more, about 260 mm or more, about 270 mm or more, about 280 mm or more, about 290 mm or more, about 300 mm or more, about 310 mm or more, about 320 mm or more, about 330 mm or more, about 340 mm or more, about 350 mm or more, about 360 mm or more, about 370 mm or more, about 380 mm or more, about 390 mm or more, about 400 mm or more, about 410 mm or more, about 420 mm or more, about 430 mm or more, about 440 mm or more, about 450 mm or more, about 460 mm or more, about 470 mm or more, about 480 mm or more, about 485.29 mm or more, about 490 mm or more, about 500 mm or more, about 510 mm or more, about 520 mm or more, about 530 mm or more, about 540 mm or more, about 550 mm or more, about 560 mm or more, about 570 mm or more, about 580 mm or more, about 590 mm or more, or about 600 mm or more .

As a further example, the depth of cut into the substrate or workpiece is at least about 10%, or at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, in the first direction of use, About 55% or more, about 60% or more, about 65% or more, about 70% or more, about 75% or more, about 80% or more, about 85% or more, about 90% or more, about 95% or more, about 100% or more, It may be about 120% or more, about 130% or more, about 140% or more, about 150% or more deeper. In some embodiments, about 10% to about 500%, or about 30% to about 70%, or about 40% to about 60%, or about 15%, 20%, 25%, 30%, in the first direction of use, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 105%, 110%, 115% , 120%, 125%, 130%, 135%, 140%, 145%, 150%, 155%, 160%, 165%, 170%, 175%, 180%, 185%, 190%, 195%, 200 %, 205%, 210%, 215%, 220%, 225%, 230%, 235%, 240%, 245%, 250%, 255%, 260%, 265%, 270%, 275%, 280%, 285%, 290%, 295%, 300%, 305%, 310%, 315%, 320%, 325%, 330%, 335%, 340%, 345%, 350%, 355%, 360%, 365% , 370%, 375%, 380%, 385%, 390%, 395%, 400%, 405%, 410%, 415%, 420%, 425%, 430%, 435%, 440%, 445%, 450 %, 455%, 460%, 465%, 470%, 475%, 480%, 485%, 490%, 495%, or less than or about 500% deeper than or equal to it.

As a further example, the arithmetic mean roughness value (Sa) of the workpiece or substrate cut by moving the abrasive article in the first direction of use 22 is the corresponding substrate or operation cut under exactly the same conditions but in the second direction of movement. May be higher than water. For example, the surface roughness may be about 30% more, or about 40% more, about 50% more, about 60% more, about 70% more, about 80% more when the work piece or substrate is cut in the first direction, About 90% more, about 100% more, about 110% more, about 120% more, about 130% more, about 140% more, about 150% more, about 160% more, about 170% more, about 180% more, About 190% more, about 200% more, about 210% more, about 220% more, about 230% more, about 240% more, about 250% more, about 260% more, about 270% more, about 280% more, About 290% more, about 300% more, about 310% more, about 320% more, about 330% more, about 340% more, about 350% more, about 360% more, about 370% more, about 380% more, About 390% more, about 400% more, about 410% more, about 420% more, about 430% more, about 440% more, about 450% more, about 460% more, about 470% more, about 480% more, It can be about 490% more, or about 500% more. The arithmetic mean roughness value may be in the range of about 1000 to about 2000, about 1000 to about 1100, or about 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, 1500, 1550, 1600, 1650, 1700, 1750, 1800, 1850, 1900, 1950, or less than about 2000, or equal to or greater than.

While it may be desirable to move the abrasive article in the first direction of use 22, there are several reasons for moving the abrasive article in a second direction of movement other than the first direction of use 22. For example, contacting the substrate or workpiece with the abrasive article and moving the abrasive article in a second direction can be beneficial in finishing the substrate or workpiece. While not intending to be bound by any particular theory, the inventors believe that movement in the second direction will expose the substrate or workpiece to a relief angle 46 that has a different value than the rake angle 30 more suitable for finishing applications. I assume you can.

Example

Assembly of the magnetic device (MA1)

The upper magnet assembly (UM1) was magnetized through a thickness of a grade N52 magnetic material (from SM Magnetics, Pelham, Alabama), each 10.16 cm wide × 7.62 cm deep × 5.08 cm thick, 3 Formed from two identical rectangular magnets. These three magnets were arranged to form a 15.08 cm wide × 7.62 cm deep × 5.08 cm thick magnet assembly, with the same poles in the same plane, and the magnetic poles of each magnet were oriented in the same direction. This magnet array was attached to a plate of 1018 steel (110.16 cm wide × 12.7 cm deep × 7.62 cm thick) using epoxy resin (DP460, 3M Company, St. Paul, Minnesota), and 0.476 of 304 stainless steel. Covered with a cm thick sheet.

The first lower magnet assembly LM1 was formed in the same manner as the UM, except that the opposite poles were directed away from the steel plate.

A second lower magnet assembly (LM2) was magnetized through a thickness of a grade N52 magnetic material (from SM Magnetics, Pelham, Alabama, USA) through a thickness of three identical, each 10.16 cm wide × 15.24 cm deep × 5.08 cm thick. It was formed from a rectangular magnet. These three magnets were arranged to form a 15.08 cm wide × 15.24 cm deep × 5.08 cm thick magnet assembly, with the same poles in the same plane, and the magnetic poles of each magnet were oriented in the same direction as LM1. This magnet array was attached to a plate of 1018 steel (110.16 cm wide × 20.32 cm deep × 7.62 cm thick) using epoxy resin (DP460, 3M Company, St. Paul, Minnesota), and made a 0.47625 cm thick sheet of 304 stainless steel. Covered.

A composite lower magnet assembly LM3 was formed by combining LM1 and LM2. The LM1 and LM2 were arranged to form a magnet assembly 15.08 cm wide × 22.86 cm deep × 5.08 cm thick, with the same poles in the same plane, touching the 30.48 cm × 5.08 cm magnet faces and placing the respective magnets in contact with them. The stimuli were oriented in the same direction. Both LM1 and LM2 were bolted to a plate of 1018 steel (110.16 cm wide x 27.94 cm deep x 2.54 cm thick) to create LM3.

The LM3 was placed parallel to the upper magnet (UM) with a gap of 15.24 cm with both trailing edges aligned. UM1 and LM3 had opposite poles facing each other to create a magnetic device (MA1).

Preparation of magnetizable abrasive particles (MAP1)

AP1 was coated with 304 stainless steel using physical vapor deposition using magnetron sputtering. Thin Solid Films, 1979, vol. 63, pp. 143-150], a 304 stainless steel sputter target described by Barbee et al. was deposited as a magnetic ferrite body-centered cubic shape. An apparatus for use in the manufacture of 304 stainless steel film coated abrasive particles (eg, magnetizable abrasive particles) is disclosed in US Pat. No. 8,698,394 (McCutcheon et al.). Physical vapor deposition was performed on 51.94 grams of AP1 at 1.0 kilowatts of argon sputtering gas pressure of 10 millitorr (1.33 pascals) for 4 hours. The weight percentage of the metal coating in coated AP1 was approximately 0.65%, and the coating thickness was approximately 1 micrometer.

Preparation of magnetizable abrasive particles (MAP2)

AP2 was coated with 304 stainless steel using physical vapor deposition using magnetron sputtering. Thin Solid Films, 1979, vol. 63, pp. 143-150], a 304 stainless steel sputter target described by Bobby et al. was deposited as a magnetic ferrite body core cubic shape. An apparatus for use in the manufacture of 304 stainless steel film coated abrasive particles (ie, magnetizable abrasive particles) is disclosed in US Pat. No. 8,698,394 (McKerchen et al.). Physical vapor deposition was performed on 51.94 grams of AP2 at 1.0 kilowatts of argon sputtering gas pressure of 10 millitorr (1.33 pascals) for 4 hours. The weight percentage of the metal coating in coated AP2 was approximately 0.65%, and the coating thickness was approximately 1 micrometer.

Example 1

Untreated polyester cloth having a basis weight of 300 to 400 g/m ² , obtained from Milliken & Company of Spartanburg, SC, under the trade name "POWERSTRAIT", was prepared. , 75 parts of epoxy resin (bisphenol A diglycidyl ether available from Resolution Performance Products of Houston, Texas under the trade name "EPON 828"), 10 parts of trimethylolpropane triacrylate (Obtained under the trade name "TMPTA" from Cytec Industrial Inc. of Woodland Park, NJ), 8 parts dicyandiamide hardener (Air Products & Chemicals, Allentown, PA, USA) Products and Chemicals) under the trade name “DICYANEX 1400B”), 5 parts novolac resin (Momentive Specialty Chemicals Inc., Columbus, Ohio, USA) under the trade name “Ruta Obtained as "RUTAPHEN 8656"), 1 part 2,2-dimethoxy-2-phenylaceto-phenone (from BASF Corporation, Florum Park, NJ, trade name "IRGACURE"). ) 651" obtained as a photoinitiator), and 0.75 parts of 2-propylimidazole (available from Synthron, Morganton, North Carolina, USA under the trade name "ACTIRON NXJ-60 Liquid (LIQUID)" It was pre-sized to a basis weight of 113 g/m ² .

The cloth backing is from 1.5:1 to 52 parts resol phenol-formaldehyde resin (75% by weight in water) (1-5% metal hydroxide catalyzed by 1-5% metal hydroxide and obtained from Georgia-Pacific, Atlanta, GA). 2.1:1 (formaldehyde:phenol) condensate), 45 parts calcium metasilicate (obtained from NYCO Company, Wilsboro, NY under the trade name "M400 WOLLASTOCOAT"), and It was coated with 209 g/m ² of a phenol make resin containing 2.5 parts of water.

As shown in FIG. 4, as the backing passed through the magnetic device MA1, the abrasive particles MAP1 were distributed to the make resin-coated backing through an inclined distribution ramp. As shown in Fig. 4, the end of the inclined dispensing ramp was 1.27 cm from the surface of the backing and 15.87 cm from the bottom trailing corner of the upper magnet. The coating weight of MAP1 was 480 grams/m ² . Immediately after coating the abrasive particles (MAP1) on the backing, the abrasive particles (AP3) were coated onto the backing with a coating weight of 376 grams/m ² .

The abrasive coated backing was placed in an oven at 90° C. for 1.5 hours to partially cure the make resin. 45.76 parts resol phenol-formaldehyde resin (75% by weight in water) (1.5:1 to 2.1:1 (formaldehyde:phenol) catalyzed by 1 to 5% metal hydroxide and available from Georgia-Pacific, Atlanta, GA, USA. ) Condensates), 4.24 parts water, 24.13 parts cryolite (Solvay Fluorides, LLC, Houston, TX, USA), 24.13 parts calcium metasilicate (from the Naico Company, Wilsboro, NY, USA) Obtained under the trade name "M400 Wollastocoat"), and a size resin consisting of 1.75 parts of red iron oxide were applied to each strip of backing material with a basis weight of 712 g/m ² , and the coated strip was placed in an oven at 90° C. For hours, then at 102° C. for 8 hours. After curing, the strip of coated abrasive was converted into a belt as known in the art.

Comparative Example A

Untreated polyester fabric having a basis weight of 300 to 400 g/m ² , obtained from Milliken & Company of Spartanburg, South Carolina under the trade name "PowerStraight", was prepared with 75 parts of epoxy resin (Houston, TX, USA). Bisphenol A diglycidyl ether, obtained from Resolution Performance Products under the trade name "EPON 828"), 10 parts trimethylolpropane triacrylate (obtained from Cytec Industrial Inc., Woodland Park, NJ, under the trade name "TMPTA") ), 8 parts dicyandiamide hardener (obtained from Air Products & Chemicals, Allentown, Pa. under the trade name "Dicianex 1400B"), 5 parts novolac resin (Momentive Specialty, Columbus, Ohio, USA) Obtained from Chemicals Inc. under the trade name "Rutafen 8656"), 1 part 2,2-dimethoxy-2-phenylaceto-phenone (trade name "Irgacure 651 from BASF Corporation, Florum Park, NJ, USA" 113 g of a composition consisting of "obtained as a photoinitiator), and 0.75 parts of 2-propylimidazole (obtained from Synthron, Morganton, North Carolina, under the trade name "Actyron NXJ-60 Liquid") It was pre-sized to a basis weight of /m ² .

The cloth backing was made up of 52 parts resol phenol-formaldehyde resin (75% by weight in water) (1.5:1 to 2.1:1 (form) catalyzed by 1 to 5% metal hydroxide and obtained from Georgia-Pacific, Atlanta, GA, USA. Aldehyde: phenol) condensate), 45 parts of calcium metasilicate (obtained under the trade name "M400 Wollastocoat" from the Naico Company, Willsboro, NY), and 209 g/m ^{2 of a} phenol make resin consisting of 2.5 parts of water Coated with.

As shown in Fig. 4, as the backing passed through the magnetic device MA1, abrasive particles MAP2 were distributed to the make resin coated backing. As shown in Fig. 4, the end of the inclined dispensing ramp was 1.27 cm from the surface of the backing and 15.87 cm from the bottom trailing corner of the upper magnet. The coating weight of MAP1 was 480 grams/m ² . Immediately after coating the abrasive particles (MAP1) on the backing, the abrasive particles (AP3) were coated onto the backing with a coating weight of 376 grams/m ² .

The abrasive coated backing was placed in an oven at 90° C. for 1.5 hours to partially cure the make resin. 45.76 parts resol phenol-formaldehyde resin (75% by weight in water) (1.5:1 to 2.1:1 (formaldehyde:phenol) catalyzed by 1 to 5% metal hydroxide and available from Georgia-Pacific, Atlanta, GA, USA. ) Condensates), 4.24 parts water, 24.13 parts cryolite (Solvay Fluorides, LLC, Houston, TX, USA), 24.13 parts calcium metasilicate (from the Naico Company, Wilsboro, NY, USA) Obtained under the trade name "M400 Wollastocoat"), and a size resin having 1.75 parts of red iron oxide were applied to each strip of backing material with a basis weight of 712 g/m ² , and the coated strip was placed in an oven at 90° C. For hours, then at 102° C. for 8 hours. After curing, the strip of coated abrasive was converted into a belt as known in the art.

Comparative Example B

Comparative Example B is an abrasive grinding belt obtained from 3M Company, St. Paul, Minnesota, under the trade name CUBITRON II CLOTH BELT 991FZ, grade 36+.

Comparative Example C

Comparative Example B is an abrasive grinding belt obtained from 3M Company, St. Paul, Minnesota, under the trade name Qubitron II Cloth Belt 984F, Grade 36+.

Grinding test procedure A

The grinding test procedure A was used to evaluate the effects of the abrasive belt of Example 1, the abrasive belt of Comparative Example A, and the abrasive belt of Comparative Example C. The work piece was an aluminum 6061 bar given to the polishing belt along 5.08 cm by 91.44 cm of the polishing belt. A 20.3 cm diameter, 70 durometer Shore A, serrated (1:1 land to groove ratio) rubber contact disk was used. The belt was run at 5500 surface feet per minute. The workpiece was pressed against the central portion of the belt with a combination of 10 to 15 pounds (4.53 to 6.8 kg) of normal forces. The test involved measuring the weight loss of the workpiece after 15 seconds of grinding (1 cycle). The workpiece was then cooled and tested again. The test was terminated after 15 test cycles. Cycle 1 is referred to as the initial cut of each embodiment. In the case of Example 1 and Comparative Example C, the tests were performed in the forward direction in the first direction of use and in the reverse direction in the opposite second direction of use. The amount of cut in grams was recorded after each cycle.

The results from grinding procedure A (aluminum) are presented in Table 1 herein. A plot of the data is also provided in FIG. 8.

[Table 1]

Grinding Test procedure B (wood)

A 40.6 cm long × 30.48 cm × 1.6 cm thick particle board work obtained from Collins Co. of Portland, Oregon under the trade name COLLINS PINE PARTICLE BOARD, each 5.08 cm × 91.44 It was fixed to the test fixture at the position to be polished on its 30.48 cm edge by the abrasive belts of Example A and Comparative Example B, which are endless abrasive belts with dimensions of cm. In each test, the abrasive belt was supported by a platen covered with graphite. In each test, the board was pressed into the abrasive belt as the belt was moving at a feed rate of 5500 surface feet per minute. A force of 15 pounds of total force was applied to the board and the board was left in contact with the abrasive belt for a grinding time of 10 seconds. The board was removed from the belt and the amount of material removed from the board was measured. This process was repeated for a total of 25 cycles. Cycle 1 is referred to as the initial cut of each embodiment. In the case of Example 1 and Comparative Example B, the tests were carried out in the forward direction in the first direction of use and in the reverse direction in the opposite second direction of use. The amount of material in mm of the particle board removed was recorded after each cycle. The results from grinding procedure B (Particle Board) are presented in Table 2 herein. A plot of the data is also provided in FIG. 9.

[Table 2]

Belt Force Data Procedure C

The polishing belt of Example, the polishing belt of Comparative Example A, and the polishing belt of Comparative Example B. The test belts were endless belts each having a dimension of 5.08 cm by 91.44 cm. The abrasive belts were mounted on a belt sander equipped with a 20.6 cm steel contact wheel. Collins Fine Particleboard, a 40.6 cm long×30.48 cm×1.6 cm thick particle board workpiece (Collin's Company, Portland, Oregon, USA) was fixed to the test fixture at the position to be polished on its edge by an endless polishing belt. The test fixture was adjusted to provide a 10 mm interference between the proximal surface of the edge of the workpiece and the surface of the abrasive belt. The belt sander was activated at a surface speed of 1753 m/min and the workpiece was traversed along the 40.6 cm dimension at a speed of 150 mm/sec. In the case of Example 1 and Comparative Example B, the tests were carried out in the forward direction in the first direction of use and in the reverse direction in the opposite second direction of use. In the case of Comparative Example B, the test was carried out in the reverse direction in the second direction of use. The amount of cut in grams was recorded after each cycle.

The normal force at the abrasive belt/workpiece interface was measured when a specified volume of wood was polished off. After this first pass, the edge of the particle board was retracted from the polishing belt, returned to its starting position, adjusted to provide an additional 10 mm interference, and traversed during a further polishing pass. This process was repeated for a total of 25 passes. The results from grinding procedure C are presented herein in Table 3. A plot of the data is also provided in FIG. 10.

[Table 3]

Workpiece Surface Analysis Procedure D

A portion of the work piece of Example 1 operated in the forward direction, as well as the work piece of Example 1 operated in the reverse direction from the grinding procedure A, are available from Keyence Corporation of America (Itasca, Ill.). Analysis was performed using a microscope used with a Keyence VK-X250 laser confocal microscope (LASER CONFOCAL MICROSCOPE). A 10 magnification objective lens was used. The 10 magnification objective lens has a field of view of 1 mm x 1.43 mm. To analyze a larger area, images were created by stitching together a 3×3 array of individual images. This produced a field of view of 2.9 mm x 3.9 mm for the final image.

Then, the stitched images were analyzed using a Keyence Multi-file Analyzer. A 2D color contour height map is shown in FIGS. 11 and 12. FIG. 11 shows the substrate of Example 1 operated in the reverse direction, and FIG. 12 shows the substrate of Example 1 operated in the forward direction. A 3D image of each surface was also created to show the difference between the samples. 13 shows a 3D image of the substrate of Example 1 operated in the reverse direction, and FIG. 14 shows the substrate of Example 1 operated in the forward direction. Additionally, the surface finish metric for each surface was recorded, which is shown in Table 4.

The parameters mentioned include the arithmetic mean height Sa. Sa is the extension of Ra to the surface (the arithmetic mean height of the line). This is expressed as an absolute value, and the difference in height of each point is compared to the arithmetic mean of the surface. These parameters are commonly used to evaluate the surface roughness.

Skewness (Ssk) was also measured, and the Ssk value represents the degree of bias of the roughness shape. Ssk greater than zero means that the height distribution is skewed over the average plane (peak); Ssk equal to zero means that the height distribution (peak and pit) is symmetric about the average plane; An Ssk of less than 0 means that the height distribution is skewed below the average plane (feet).

The maximum peak height (Sp) was also measured. Sp is the height of the highest peak within the defined area. The maximum pit height (Sv) was also measured. Sv is the absolute value of the height of the maximum pit within the limited area. Each of Sa, Ssk, Sp, and Sv was measured according to the standard known as ISO 25178.

[Table 4]

Workpiece debris analysis procedure E

A portion of the debris was collected from the work of Example 1 running in the forward direction. A portion of the debris was also collected from the work of Comparative Example C running in the forward direction.

The respective debris portions were analyzed using scanning electron microscopy (SEM). Image of debris was captured using a field emission scanning electron microscope available under the trade name JSM-7600F Field Emission Scanning Electron Microscope, available from JEOL Ltd (Tokyo, Japan) I did. Images using the GEOL JSM-7600 were photographed at 33 magnification with a 45 degree inclination, and stitched into a 2x2 composite.

The average length of debris collected from Example 1 and Comparative Example C was determined using a microscope available under the trade name Keyence 5000 digital microscope, available from Keyence Corporation of America (Itasca, Illinois, USA). The average length was measured using binary image analysis to calculate the maximum diagonal length.

Analysis showed that the average length for 78 pieces of debris collected from Example 1 was 1772 μm. Further analysis showed that the average length for 89 pieces of debris collected from Comparative Example C was 1109 μm.

Additional embodiment

The following exemplary embodiments are provided, and their numbering should not be construed as indicating a level of importance:

Embodiment 1 is an abrasive article having a direction of use, a y axis, and a z axis orthogonal to the y axis and the direction of use,

Backing;

Comprising shaped abrasive particles attached to the backing,

About 5% to about 100% of the shaped abrasive particles are independently,

First side surface,

A second side surface opposite the first side surface,

A leading surface connected at the first edge to the first side surface and at the second edge to the second side surface,

A rake angle between the backing and the leading surface within the range of about 10 degrees to about 110 degrees, and

An abrasive article is provided, comprising a z-direction angle of rotation between a direction of use of the abrasive article and a line intersecting the first and second edges within a range of about 10 degrees to about 170 degrees.

Embodiment 2 is an abrasive article having a first direction of use,

The amount of material of the workpiece that contains abrasive particles attached to the backing and is removed from the workpiece in contact with the abrasive article under the same test conditions is the material of the workpiece that is removed when the abrasive article is moved in a second direction different from the first direction of use. Provides more than the amount of, abrasive articles.

Embodiment 3 provides the abrasive article of Embodiment 2, wherein at least 15% more material is removed in the first direction of use.

Embodiment 4 provides the abrasive article of Embodiment 2 or 3, wherein at least 50% more material is removed in the first direction of use.

Embodiment 5 provides the abrasive article of Embodiment 2, wherein about 10% to about 500% more material is removed in the first direction of use.

Embodiment 6 provides the abrasive article of Embodiment 1 or Embodiment 5, wherein about 30% to about 70% more material is removed in the first direction of use.

Embodiment 7 provides the abrasive article of Embodiment 1 or any one of Embodiments 5 and 6, wherein about 40% to about 60% more material is removed in the first direction of use.

Embodiment 8 is an abrasive article according to any one of Embodiments 2 to 7, wherein about 5% to about 100% of the abrasive particles are,

First side surface,

A second side surface opposite the first side surface,

A leading surface connected at the first edge to the first side surface and at the second edge to the second side surface,

A rake angle between the backing and the leading surface within the range of about 10 degrees to about 110 degrees, and

An abrasive article is provided, wherein the abrasive article is shaped abrasive particles that independently comprise a z-direction angle of rotation between a direction of use of the abrasive article and a line intersecting the first and second edges, within a range of about 10 degrees to about 170 degrees.

Embodiment 9 provides the abrasive article of any one of Embodiments 2-8, wherein material is removed according to at least one of grinding procedure A and grinding procedure B.

Embodiment 10 provides the abrasive article of Embodiment 9, wherein the initial cut amount of the workpiece when the abrasive article is operated in the direction of use according to grinding procedure A is 9 grams or more.

Embodiment 11 provides the abrasive article of Embodiment 9 or Embodiment 10, wherein the initial cut amount of the workpiece when the abrasive article is operated in the direction of use according to grinding procedure A is 11 grams or more.

Embodiment 12 provides an abrasive article according to any one of Embodiments 9-11, wherein the initial cut amount of the workpiece when the abrasive article is operated in the direction of use according to grinding procedure A is 17.8 grams or more. .

Example 13 is the abrasive article of any one of Embodiments 9 to 12, wherein the total cutting amount of the workpiece after 15 cycles when the abrasive article is operated in the direction of use according to the grinding procedure A is 65 grams or more. Provide supplies.

Example 14 is the abrasive article of any one of Embodiments 9 to 13, wherein the total cut amount of the workpiece after 15 cycles when the abrasive article is operated in the direction of use according to the grinding procedure A is 118.37 grams or more. Provide supplies.

Example 15 is the abrasive article of any one of Embodiments 9 to 14, wherein the total cutting amount of the workpiece after 15 cycles when the abrasive article is operated in the direction of use according to the grinding procedure A is 120 grams or more. Provide supplies.

Embodiment 16 provides the abrasive article of Embodiment 9, wherein the initial cut amount of the workpiece when the abrasive article is operated in the direction of use according to grinding procedure B is 9 mm or more.

Embodiment 17 provides the abrasive article of Embodiment 9 or Embodiment 16, wherein the initial cutting amount of the workpiece when the abrasive article is operated in the direction of use according to grinding procedure B is 11 mm or more.

Embodiment 18 is the abrasive article of any one of Embodiment 9, Embodiment 16, or Embodiment 17, wherein the initial cut amount of the workpiece when the abrasive article is operated in the direction of use according to the grinding procedure B is 18.47 mm or more. Provide supplies.

Example 19 is the abrasive article of any one of Embodiment 9 or Embodiment 16 to Embodiment 19, wherein the total cut amount of the workpiece after 25 cycles when the abrasive article is operated in the direction of use according to the grinding procedure B is 180 mm or more, an abrasive article is provided.

Example 20 is the abrasive article of any one of Embodiment 9 or Embodiments 16 to 19, wherein the total cut amount of the workpiece after 25 cycles when the abrasive article is operated in the direction of use according to grinding procedure B is 187 mm or more, an abrasive article is provided.

Example 21 is the abrasive article of any one of Embodiment 9 or Embodiment 16 to Embodiment 20, wherein the total cut amount of the workpiece after 25 cycles when the abrasive article is operated in the direction of use according to grinding procedure B is 485.29 mm or more, an abrasive article is provided.

Embodiment 22 is an abrasive article having a first direction of use,

The average surface roughness of the work piece that includes abrasive particles attached to the backing and is polished by the abrasive article under the same test conditions is the average of the work piece that is polished when the abrasive article is moved in a second direction of use different from the first direction of use It provides an abrasive article that is greater than the surface roughness.

Embodiment 23 provides the abrasive article of embodiment 22, wherein the average surface roughness is at least 90% greater in the first direction of use.

Embodiment 24 provides the abrasive article of embodiment 22 or embodiment 23, wherein the average surface roughness is at least 105% greater in the first direction of use.

Embodiment 25 provides the abrasive article of embodiment 22, wherein the average surface roughness is about 10% to about 500% greater in the first direction of use.

Embodiment 26 is the abrasive article according to any one of Embodiments 22-25, wherein about 5% to about 100% of the abrasive particles are,

First side surface,

A second side surface opposite the first side surface,

A leading surface connected at the first edge to the first side surface and at the second edge to the second side surface,

A rake angle between the backing and the leading surface within the range of about 10 degrees to about 110 degrees, and

An abrasive article is provided, wherein the abrasive article is shaped abrasive particles that independently comprise a z-direction angle of rotation between a direction of use of the abrasive article and a line intersecting the first and second edges, within a range of about 10 degrees to about 170 degrees.

Embodiment 27 provides the abrasive article of any one of embodiments 9-26, wherein the work piece is polished according to at least one of grinding procedure A and grinding procedure B.

Embodiment 28 is the abrasive article of any one of Embodiments 1-27, wherein about 25% to about 100% is a first side surface, a second side surface, a leading surface, a rake angle, and a z-direction rotation. An abrasive article is provided that includes an angle.

Embodiment 29 is the abrasive article of any one of Embodiments 1-28, wherein about 50% to about 100% is a first side surface, a second side surface, a leading surface, a rake angle, and a z-direction rotation. An abrasive article is provided that includes an angle.

Embodiment 30 is the abrasive article of any one of Embodiments 1 to 29, wherein the backing is a polymer film, metal foil, fabric, knitted fabric, paper, cured fiber, nonwoven fabric, foam, screen, laminate, or a combination thereof. It provides an abrasive article, which is a flexible backing comprising a.

Embodiment 31 provides an abrasive article of any one of Embodiments 1 to 30, wherein at least one of the shaped abrasive particles is a shaped ceramic abrasive particle.

Embodiment 32 is the abrasive article of any one of Embodiments 1-31, wherein the shaped abrasive particles independently comprise alpha alumina, sol-gel derived alpha alumina, or a mixture thereof. to provide.

Embodiment 33 is the abrasive article of any one of Embodiments 1-32, wherein the shaped abrasive particles are independently molten aluminum oxide, heat-treated aluminum oxide, ceramic aluminum oxide, sintered aluminum oxide, silicon carbide material, Abrasive articles are provided, comprising titanium diboride, boron carbide, tungsten carbide, titanium carbide, diamond, cubic boron nitride, garnet, molten alumina-zirconia, cerium oxide, zirconium oxide, titanium oxide, or combinations thereof.

Embodiment 34 is the abrasive article of any one of Embodiments 1-33, wherein the first side surface and the second side surface of at least one of the shaped abrasive particles comprise a polygonal shape. , Provide abrasive supplies.

Embodiment 35 provides the abrasive article of embodiment 34, wherein the polygonal shapes of the first side surface and the second side surface are independently regular polygons or irregular polygons.

Embodiment 36 provides the abrasive article of embodiment 33 or embodiment 34, wherein the polygonal shapes of the first side surface and the second side surface are independently triangular or rectangular in shape.

Embodiment 37 provides the abrasive article of embodiment 36, wherein the polygonal shape is a square shape.

Embodiment 38 provides the abrasive article of embodiment 37, wherein the square shape comprises a trapezoid, square, or rectangle.

Embodiment 39 provides the abrasive article of embodiment 36, wherein the polygonal shape is a triangular shape.

Embodiment 40 provides the abrasive article of embodiment 39, wherein the triangular shape comprises a right triangle, an equilateral triangle, an isosceles triangle, an acute triangle, or an obtuse triangle.

Embodiment 41 provides the abrasive article of embodiment 39 or embodiment 40, wherein the triangular shape is free of equilateral triangles.

Embodiment 42 is the abrasive article of any one of Embodiments 39-41, wherein at least one of the shaped abrasive particles further comprises a third side surface having a triangular shape,

The tip surface has a triangular shape,

The shaped abrasive particles provide an abrasive article, which is a tetrahedron.

Embodiment 43 is the abrasive article of any one of Embodiments 1-42, wherein the clearance angle between the backing and the trailing surface at the cutting tip of at least one of the shaped abrasive particles is An abrasive article is provided that is in the range of about 90 degrees to about 180 degrees.

Embodiment 44 is the abrasive article of any one of Embodiments 1-43, wherein the clearance angle between the backing and the trailing surface at the cutting tip of at least one of the shaped abrasive particles is An abrasive article is provided that is in the range of about 120 degrees to about 140 degrees.

Embodiment 45 is the abrasive article of any one of embodiments 1-44, wherein the first side surface and the second side surface of at least one of the shaped abrasive particles are a surface area, a maximum length dimension , And substantially the same size based on at least one of a maximum width dimension.

Embodiment 46 is the abrasive article of any one of embodiments 1 to 45, wherein the first side surface and the second side surface of at least one of the shaped abrasive particles are a surface area, a maximum length dimension , And different sizes based on at least one of a maximum width dimension.

Embodiment 47 is the abrasive article of any one of Embodiments 1-46, wherein the first side surface, the second side surface, and the tip surface of at least one of the shaped abrasive particles are substantially Provides a flat, abrasive article.

Embodiment 48 is the abrasive article of any one of Embodiments 1-46, wherein at least one of a first side surface, a second side surface, and a tip surface of at least one of the shaped abrasive particles. One provides an abrasive article that is not substantially flat.

Embodiment 49 is the abrasive article of any one of Embodiments 1-46, wherein a first side surface, a second side surface, and a tip surface of at least one of the shaped abrasive particles are each other. A substantially parallel, abrasive article is provided.

Embodiment 50 is the abrasive article of any one of Embodiments 1-46, wherein the first side surface, the second side surface, and the tip surface of at least one of the shaped abrasive particles are each other. A substantially non-parallel, abrasive article is provided.

Embodiment 51 is the abrasive article of any one of Embodiments 1-46, wherein at least one of a first side surface, a second side surface, and a tip surface of at least one of the shaped abrasive particles. One provides an abrasive article having a concave shape.

Embodiment 52 is the abrasive article of embodiment 46, wherein for the shaped abrasive particles of at least one of the shaped abrasive particles,

The first side surface has a concave shape and the second side surface is substantially flat;

The first side surface has a convex shape and the second side surface has a concave shape; or

A first side surface is shaped inwardly and a second side surface is shaped inwardly, providing an abrasive article.

Embodiment 53 is the abrasive article of any one of Embodiments 1-28, wherein at least one of the shaped abrasive particles comprises an opening, a concave surface, a convex surface, a groove, a ridge, a ruptured surface. , A low roundness factor, or at least one shape feature including a perimeter comprising one or more corner points having a sharp tip.

Embodiment 54 provides the abrasive article of any one of embodiments 1-53, wherein at least one of the shaped abrasive particles comprises an opening.

Embodiment 55 is the abrasive article of any one of embodiments 1-54, wherein the first edge and the second edge of at least one of the shaped abrasive particles are substantially parallel. Provides.

Embodiment 56 provides the abrasive article of any one of embodiments 1-55, wherein the first edge and the second edge of at least one of the shaped abrasive particles are tapered. do.

Embodiment 57 provides an abrasive article of any one of embodiments 1-55, wherein the first edge and the second edge of at least one of the shaped abrasive particles are curved. do.

Embodiment 58 is the abrasive article of any one of Embodiments 1 to 55, wherein the draft angle (α) between the second side surface and the tip surface of at least one of the shaped abrasive particles is An abrasive article is provided that is in the range of about 95 degrees to about 130 degrees.

Embodiment 59 provides the abrasive article of any one of embodiments 1-58, wherein a cutting tip of at least one of the shaped abrasive particles is substantially aligned with the y direction. do.

Embodiment 60 is the abrasive article of any one of Embodiments 1-59, wherein the rake angle of at least one of the shaped abrasive particles is in the range of about 80 degrees to about 100 degrees. Provides.

Embodiment 61 is the abrasive article of any one of embodiments 1 to 60, wherein the rake angle of at least one of the shaped abrasive particles is in the range of about 85 degrees to about 95 degrees. Provides.

Embodiment 62 is the abrasive article of any one of Embodiments 1-61, wherein the z-direction rotation angle of at least one of the shaped abrasive particles is in the range of about 80 degrees to about 100 degrees. , Provide abrasive supplies.

Embodiment 63 is the abrasive article of any one of Embodiments 1-62, wherein the z-direction rotation angle of at least one of the shaped abrasive particles is in the range of about 85 degrees to about 95 degrees. , Provide abrasive supplies.

Embodiment 64 is the abrasive article of any one of Embodiments 1-63, wherein for at least one shaped abrasive particle of the shaped abrasive particles,

The first side surface and the second side surface comprise a triangular shape without an equilateral triangle shape,

The first edge and the second edge are substantially parallel,

The rake angle ranges from about 80 degrees to about 110 degrees,

The z-direction rotation angle ranges from about 80 degrees to about 110 degrees.

Embodiment 65 provides the abrasive article of embodiment 64, wherein the triangular shape is a right triangle.

Embodiment 66 is the abrasive article of any one of embodiments 1-65, wherein an edge of at least one of the shaped abrasive particles is substantially aligned with the backing in the xy plane. to provide.

Embodiment 67 provides the abrasive article of any one of embodiments 1-66, wherein at least one of the shaped abrasive particles is responsive to a magnetic field.

Embodiment 68 provides the abrasive article of any one of embodiments 1-67, wherein at least one of the shaped abrasive particles comprises a magnetic material.

Embodiment 69 provides the abrasive article of embodiment 68, wherein the magnetic material at least partially coats the surface of the shaped abrasive particles.

Embodiment 70 provides the abrasive article of embodiment 69, wherein at least one of the shaped abrasive particles is a monolithic abrasive particle.

Embodiment 71 provides an abrasive article of any one of embodiments 1-70, wherein the rake angle of about 50% to about 100% of the shaped abrasive particles is substantially the same.

Embodiment 72 provides the abrasive article of any one of Embodiments 1-71, wherein the rake angle of about 90% to about 100% of the shaped abrasive particles is substantially the same.

Embodiment 73 provides the abrasive article of any one of embodiments 1-72, wherein the z-direction rotation angle of about 50% to about 100% of the shaped abrasive particles is substantially the same. .

Embodiment 74 provides the abrasive article of any one of Embodiments 1-73, wherein the z-direction rotation angle of about 90% to about 100% of the shaped abrasive particles is substantially the same. .

Embodiment 75 provides the abrasive article of any one of embodiments 1-74, further comprising crushed abrasive particles.

Embodiment 76 provides the abrasive article of embodiment 75, wherein the crushed abrasive particles and the shaped abrasive particles comprise different materials.

Embodiment 77 is the abrasive article of embodiment 75 or embodiment 76, wherein the shaped abrasive particles comprise from about 5% to about 95% by weight of a blend of shaped abrasive particles and crushed abrasive particles. Provides.

Embodiment 78 provides the abrasive article of any one of Embodiments 1-77, wherein the abrasive article comprises a belt, disk, or sheet.

Embodiment 79 provides the abrasive article of any one of Embodiments 1-78, further comprising a make coat that adheres the shaped abrasive particles to the backing.

Embodiment 80 provides the abrasive article of embodiment 79, further comprising a size coat that adheres the shaped abrasive particles to the make coat.

Embodiment 81 is the abrasive article of Embodiment 79 or Embodiment 80, wherein at least one of the make coat and the size coat is a phenol resin, an epoxy resin, a urea-formaldehyde resin, an acrylate resin, an aminoplast resin, a melamine resin, and an acrylic. Abrasive articles are provided, comprising a rate epoxy resin, a urethane resin, or mixtures thereof.

Embodiment 82 is the abrasive article of any one of Embodiments 78 to 81, wherein at least one of a make coat and a size coat is a filler, a grinding aid, a wetting agent, a surfactant, a dye, a pigment, a coupling agent, an adhesion promoter, Or a mixture thereof.

Embodiment 83 provides the abrasive article of embodiment 82, wherein the filler comprises calcium carbonate, silica, talc, clay, calcium metasilicate, dolomite, aluminum sulfate, or mixtures thereof.

Embodiment 84 is the abrasive article of any one of Embodiments 1-83, wherein the abrasive article comprises a disk, and the z-direction angle of rotation circumferentially locates the tip surface, and is applied to the shaped abrasive particles. The pattern created by provides an abrasive article comprising a plurality of circles.

Embodiment 85 is the abrasive article of any one of Embodiments 1-84, wherein the abrasive article comprises a sheet or belt, and the z-direction rotation angle is a pattern created by the shaped abrasive particles. An abrasive article is provided for positioning a substantially flat surface at an angle to include parallel lines.

Embodiment 86 is a method of manufacturing the abrasive article of any one of Embodiments 1 to 85, comprising:

Orienting the shaped abrasive particles; And

Attaching the shaped abrasive particles to the backing

It provides a method comprising a.

Embodiment 87 is the method of embodiment 87, wherein the step of orienting the shaped abrasive particles comprises at least one of the shaped abrasive particles within the cavity of the shaped backing such that at least one shaped abrasive particle having a z-direction rotational orientation is obtained. A method comprising placing one shaped abrasive particle is provided.

Embodiment 88 is the method of embodiment 87, wherein the step of orienting the shaped abrasive particles comprises at least one shaping having a z-direction rotational orientation by passing at least one of the shaped abrasive particles through a screen. It provides a method comprising the step of obtaining a polished abrasive particle.

Embodiment 89 is the method of embodiment 88, wherein the step of orienting the at least one shaped abrasive particle comprises disposing the at least one shaped abrasive particle into a separate cavity of the delivery tool, and the at least one shaped abrasive particle And contacting the backing to obtain at least one shaped abrasive particle having a z-direction rotational orientation.

Embodiment 90 provides the method of embodiment 89, wherein the step of orienting the at least one shaped abrasive particle comprises exposing the at least one shaped abrasive particle to a magnetic field.

Embodiment 91 provides the method of embodiment 90, further comprising rotating at least one shaped abrasive particle within a magnetic field.

Embodiment 92 is the method of any one of embodiments 87-91, wherein attaching the shaped abrasive particles to the backing comprises contacting the shaped abrasive particles with a make coat disposed over at least a portion of the backing. , Provide a way.

Embodiment 93 is the method of embodiment 92, wherein attaching the shaped abrasive particles to the backing further comprises disposing a size coat over at least a portion of the shaped abrasive particles and at least one of a make coat and a backing. Provides.

Embodiment 94 is a method of using an abrasive article prepared according to any one of embodiments 1 to 85 or according to the method of any one of embodiments 86 to 93,

Contacting the shaped abrasive particles with the workpiece;

Moving at least one of the abrasive article and the workpiece relative to each other in a direction of use; And

Removing part of the work piece

It provides a method comprising a.

Embodiment 95 provides the method of embodiment 94, wherein a cutting tip of at least one of the shaped abrasive particles is in contact with a workpiece.

Embodiment 96 provides the method of embodiment 95, wherein the cutting tip is free of sharp tips with a radius of curvature of at least 60 microns.

Embodiment 97 provides the method of any one of embodiments 94 to 96, wherein the depth of cut into the work piece is 10 μm or more.

Embodiment 98 provides the method of any one of Embodiments 94 to 97, wherein the depth of cut into the workpiece is 30 μm or more.

Embodiment 99 provides the method of any one of embodiments 94-98, wherein the cutting speed of the abrasive article is at least 100 m/min.

Embodiment 100 provides the method of any one of embodiments 94-99, wherein the abrasive article has a cutting speed of at least 300 m/min.

Embodiment 101 provides the method of any one of embodiments 94-100, wherein at least a portion of the workpiece is removed as debris by the abrasive article.

Embodiment 102 provides the method of embodiment 101, wherein the longest average dimension of individual debris produced in one grinding cycle is at least 1200 μm millimeters.

Embodiment 103 provides the method of embodiment 101 or embodiment 102, wherein the longest average dimension of individual debris produced in one grinding cycle is at least 1772 μm.

Embodiment 104 provides the method of embodiment 102 or 103, wherein the debris comprises low carbon steel.

Embodiment 105 is the method of any one of Embodiments 94 to 104, wherein the direction of use is a first direction, and under the same test conditions, the amount of material removed from the work piece is a second direction different from the first direction. Provides a way, more in the first direction than in.

Embodiment 106 is the method of any one of Embodiments 94 to 105, wherein the direction of use is the first direction, and under the same test conditions, the amount of force required to remove the same amount of material from the work piece is used. When the direction is in a second direction different from the first direction, a method is provided which is less than the amount of force required to remove the same amount of material at the same feed rate.

Embodiment 107 provides the method of embodiment 106, wherein the workpiece feed rate is from about 110 mm/s to about 200 mm/s.

Embodiment 108 provides the method of embodiment 106 or 107, wherein the workpiece feed rate is from about 140 mm/s to about 160 mm/s.

Embodiment 109 provides the method of embodiment 105, wherein the article is moved in a second direction to finish the workpiece.

Embodiment 110 provides the method of any one of embodiments 98 to 109, wherein the usage direction is a linear direction or a rotation direction.

Embodiment 111 provides the method of embodiment 110, wherein the usage direction is a rotation direction, and a z-direction rotation angle is between a line intersecting the first edge and the second edge and a line tangent to the rotation direction.

Embodiment 112 provides the method of embodiment 111, wherein the abrasive article is a belt or sheet, and the directions of use are along the y axis and the x axis orthogonal to the z axis.

Embodiment 113 provides the method of any one of embodiments 94-112, wherein the workpiece comprises steel, aluminum, alloys thereof, wood, or mixtures thereof.

Embodiment 114 is the method of any one of embodiments 94-113, wherein the amount of work material removed in a force applied to the abrasive article comprises shaped abrasive particles comprising equilateral triangles. Greater than, provide a way.

Embodiment 115 is the method of any one of embodiments 94-114, wherein the arithmetic mean roughness value of the workpiece material is in the range of about 1000 to about 2000 when the abrasive article is moved in the first direction of use. to provide.

Embodiment 116 is the method of any one of embodiments 94-115, wherein the arithmetic mean roughness value of the workpiece material is in the range of about 1000 to about 1100 when the abrasive article is moved in the first direction of use. to provide.

Embodiment 117 is the method of any one of embodiments 94 to 116, wherein the arithmetic mean roughness value of the workpiece material is moved in the first direction of use than when the abrasive article is moved in the second direction of use. When it becomes bigger, it provides a way.

The terms and expressions used are used in a manner of description and not limitation, and there is no intention to exclude any equivalents of features or portions thereof presented and described in the use of these terms and expressions, and various modifications may be made to the present invention. It is recognized that it is possible within the scope of the embodiment. Accordingly, although the present invention has been specifically disclosed by specific embodiments and optional features, modifications and variations of the concepts disclosed in the present specification may be made by those skilled in the art, and such modifications and variations fall within the scope of the embodiments of the present invention. It should be understood that it is considered to be.

Claims (20)

An abrasive article having a first direction of use, comprising:
Including abrasive particles attached to a backing,
Under the same test conditions, the amount of material of the work piece removed when the abrasive article is moved in a second direction different from the first direction of use is greater than the amount of material of the work piece removed. The abrasive article of claim 2, wherein at least 15% more material is removed in the first direction of use. The abrasive article of claim 1 or 2, wherein at least 50% more material is removed in the first direction of use. 4. The abrasive article of any of the preceding claims, wherein the material is removed according to at least one of grinding procedure A and grinding procedure B. An abrasive article having a direction of use, a y axis, and a z axis orthogonal to the y axis and the direction of use,
Backing;
Shaped abrasive particles attached to the backing
Including,
About 5% to about 100% of the shaped abrasive particles are independently,
First side surface,
A second side surface opposite the first side surface,
A leading surface connected at the first edge to the first side surface and connected at the second edge to the second side surface,
A rake angle between the backing and the leading surface within the range of about 10 degrees to about 110 degrees, and
Z-direction rotation angle between the direction of use of the abrasive article and the line intersecting the first and second edges, in the range of about 10 degrees to about 170 degrees
Containing, abrasive article. The abrasive article of claim 5, wherein at least one of the shaped abrasive particles is a shaped ceramic abrasive particle. The abrasive article of claim 5 or 6, wherein the rake angle of at least one of the shaped abrasive particles is in the range of about 80 degrees to about 100 degrees. The abrasive article of claim 5, wherein the rake angle of at least one of the shaped abrasive particles is in the range of about 85 degrees to about 95 degrees. 9. The abrasive article of any of claims 5 to 8, wherein the z-direction rotation angle of at least one of the shaped abrasive particles is in the range of about 80 degrees to about 100 degrees. 10. The abrasive article of any of claims 5 to 9, wherein the z-direction rotation angle of at least one of the shaped abrasive particles is in the range of about 85 degrees to about 95 degrees. The relief angle between the edge and the backing or trailing surface at the cutting tip of at least one of the shaped abrasive particles according to any one of claims 5 to 10. angle) in the range of about 90 degrees to about 180 degrees. 12. The abrasive article of any of claims 5 to 11, wherein an edge of at least one of the shaped abrasive particles is substantially aligned with the backing in the x-y plane. 13. The abrasive article of any of claims 5-12, wherein the rake angle of about 50% to about 100% of the shaped abrasive particles is substantially the same. 14. The abrasive article of any one of claims 5-13, wherein the z-direction rotation angle of about 90% to about 100% of the shaped abrasive particles is substantially the same. 15. The abrasive article of any of claims 5-14, further comprising crushed abrasive particles. A method of using an abrasive article according to any one of claims 5 to 15, comprising:
Contacting the shaped abrasive particles with the workpiece;
Moving at least one of the abrasive article and the workpiece relative to each other in a direction of use; And
Removing a portion of the material of the workpiece
Containing, method. The method of claim 16, wherein the direction of use is a first direction, and under the same test conditions, the portion of material removed from the work piece is more in the first direction than in a second direction different from the first direction. The method of claim 16 or 17, wherein the article is moved in a second direction to finish the work. The method according to any one of claims 16 to 18, wherein the direction of use is a linear direction or a rotational direction. 20. The method of any of claims 16-19, wherein the work piece comprises steel, aluminum, alloys thereof, wood, or mixtures thereof.

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