Coated abrasive articles

Abstract

An abrasive article is presented that includes a first set of shaped abrasive particles with a majority of the first set of shaped abrasive particles are oriented with respect to a backing in a first orientation. The abrasive article also includes a second set of shaped abrasive particles with a majority of the second set of shaped abrasive particles are oriented with respect to the backing in a second orientation, and wherein the second orientation differs from the first orientation. The first and second set of shaped abrasive particles are embedded within a coating layer on the baking.

1 . An abrasive article comprising:
 a first set of shaped abrasive particles, wherein a majority of the first set of shaped abrasive particles are oriented with respect to a backing in a first orientation;   a second set of shaped abrasive particles, wherein a majority of the second set of shaped abrasive particles are oriented with respect to the backing in a second orientation, and wherein the second orientation differs from the first orientation; and   wherein the first and second set of shaped abrasive particles are embedded within a make coat layer on the backing.   
     
     
         2 . The abrasive article of  claim 1 , wherein each of the first set of shaped abrasive particles includes a base portion and an abrading portion, and wherein the base portion is embedded within the make coat layer and the abrading portion faces away from the backing. 
     
     
         3 . The abrasive article of  claim 1 , wherein some of the second set of shaped abrasive particles are oriented at least 90° with respect to the majority of the first set of shaped abrasive particles. 
     
     
         4 . The abrasive article of  claim 1 , wherein the majority of the second set of shaped abrasive particles are oriented up to 180° with respect to the majority of the first set of shaped abrasive particles. 
     
     
         5 . The abrasive article of  claim 1 , and further comprising a third set of abrasive particles forming a closed coat on the backing. 
     
     
         6 . The abrasive article  claim 1 , wherein the first set of shaped abrasive particles are oriented with respect to each other, such that faces of adjacent abrasive particles are parallel. 
     
     
         7 . The abrasive article of  claim 6 , wherein the second set of shaped abrasive particles is at least 5% by weight of the first and second sets of shaped abrasive particles. 
     
     
         8 . The abrasive article of  claim 1 , wherein one of the first and second sets of abrasive particles are magnetically responsive. 
     
     
         9 . The abrasive article of  claim 1 , wherein the first set of shaped abrasive particles comprise:
 a shape selected from the group consisting of: rods, tetrahedrons, right angle triangular prisms, isosceles triangular prisms, equilateral triangular prisms, scalene triangular prisms, trapezoidal prisms, crescents, stars, cubes, dual tapered, irregular polygonal faces, shape-on-shape, variable cross-sectional area; or   a feature selected from the group consisting of: a sloping sidewall, a groove, a recess, a facet, a fractured surface, a cavity, more than one vertex, sharp edges, a non-shaped portion, a notch, a rake angle and / or a low roundness factor.   
     
     
         10 . A method of making a coated abrasive article, the method comprising:
 coating a backing with a coating precursor layer;   embedding a first set of abrasive particles within the make coat precursor, wherein a majority of the first set of abrasive particles have a first orientation with respect to the backing and are oriented such that faces of adjacent particles are parallel to each other;   embedding a second set of abrasive particles within the coating precursor layer, wherein a majority of the second set of abrasive particles have a second orientation with respect to the backing; and   curing the coating precursor layer.   
     
     
         11 . The method of  claim 10 , wherein the coating precursor layer is a make coat, and wherein the method also comprises applying a size coat over at least one of the first and second sets of abrasive particles. 
     
     
         12 . The method of  claim 10 , wherein the coating precursor layer is a size coat, and wherein the method also includes applying a make coat to the backing. 
     
     
         13 . The method of  claim 12 , wherein the first set of abrasive particles are embedded within the make coat, and wherein the second set of abrasive particles are embedded within the size coat. 
     
     
         14 . The method of  claim 10 , and further comprising embedding a third set of abrasive particles within the make coat precursor. 
     
     
         15 . The method of  claim 14 , and wherein the third set of abrasive particles are crushed abrasive particles. 
     
     
         16 . The method of  claim 10 , and further comprising:
 filling an alignment tool with the first set of abrasive particles such that a plurality of cavities within the alignment tool receive one of the first set of abrasive particles; and   positioning the alignment tool such that each of the first set of abrasive particles move out of the plurality of cavities and embed within the make coat.   
     
     
         17 . The method of  claim 10 , wherein the first set of abrasive particles are magnetically responsive, and wherein embedding the first set of abrasive particles within the make coat precursor comprises exposing the first set of abrasive particles to a magnetic field such that the first set of abrasive particles move into the first orientation. 
     
     
         18 . The method of  claim 10 , wherein embedding the second set of abrasive particles within the make coat precursor comprises drop coating the second set of abrasive particles, wherein the first orientation comprises the first set of abrasive particles aligned in rows on the backing, and wherein the second orientation comprises each of the second set of abrasive particles embedding into the make coat in a space between a first row and a second row of the first set of abrasive particles. 
     
     
         19 . The method of  claim 10 , wherein the first set of abrasive particles are shaped as one of: triangular prisms, rods, tetrahedrons, crescents, stars, cubes, rectangular prisms, or another regular polygonal prism. 
     
     
         20 . An abrasive article comprising:
 a backing;   a coating layer applied to the backing;   a first set of shaped abrasive particles, each of the first set of shaped abrasive particles comprising a first base edge and a first cutting portion, wherein the first set of shaped abrasive particles are in a first orientation comprising the first base edge embedded within the coating layer and the first cutting portion oriented away from the backing; and   a second set of shaped abrasive particles, each of the second set of shaped abrasive particles comprising a second base edge and a second cutting portion, wherein the second set of shaped abrasive particles are in a second orientation comprising the second cutting portion embedded within the coating layer and the first base edge facing away from the backing.   
     
     
         21 - 37 . (canceled)