Abrasive particles having particular shapes and methods of forming such particles

Abstract

A coated abrasive article comprising a backing, an adhesive layer disposed in a discontinuous distribution on at least a portion of the backing, wherein the discontinuous distribution comprises a plurality of adhesive contact regions and at least one shaped abrasive particle is disposed on a majority of each of the discrete adhesive contact regions, wherein at least 50% of the shaped abrasive particles comprise a predetermined side orientation and have a tilt angle of at least 45 degrees, wherein the shaped abrasive particles comprise a polycrystalline material and are free of binder, wherein the first plurality of discrete adhesive contact regions comprise a predetermined two-dimensional shape as viewed from above, and wherein each of the discrete contact regions comprises a length, a width, or a combination thereof that substantially corresponds to a dimension of the at least one abrasive particle.

What is claimed is: 
     
         1 . A coated abrasive article comprising:
 a backing;   an adhesive layer disposed in a discontinuous distribution on at least a portion of the backing, wherein the discontinuous distribution comprises a first plurality of discrete adhesive contact regions;   at least one shaped abrasive particle disposed on a majority of each of the discrete adhesive contact regions; and   wherein each of the discrete adhesive contact regions comprises a length, a width, or a combination thereof that substantially corresponds to a dimension of the at least one shaped abrasive particle.   
     
     
         2 . The coated abrasive article of  claim 1 , wherein the at least one shaped abrasive particle comprises a predetermined two-dimensional shape selected from a group consisting of a polygon, an ellipsoid, a circle, a numeral, a cross, a multi-armed polygon, a Greek alphabet character, a Latin alphabet character, a Russian alphabet character, an Arabic alphabet character, a rectangle, a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, a nonagon, a decagon, or a combination thereof. 
     
     
         3 . The coated abrasive article of  claim 1 , wherein the at least one shaped abrasive particle comprises a predetermined two-dimensional shape comprising a polygon. 
     
     
         4 . The coated abrasive article of  claim 3 , wherein the polygon is a three-pointed star shape. 
     
     
         5 . The coated abrasive article of  claim 4 , wherein the at least one shaped abrasive particle comprises a polycrystalline material and is free of a binder. 
     
     
         6 . The coated abrasive of  claim 1 , wherein one to three shaped abrasive particles are disposed on the discrete adhesive contact regions. 
     
     
         7 . The coated abrasive of  claim 6 , wherein one shaped abrasive particle is disposed on the discrete adhesive contact regions. 
     
     
         8 . The coated abrasive article of  claim 1 , wherein the discontinuous distribution further comprises an adjacent spacing between the discrete adhesive contact regions that ranges from 0.5 (1) to 10 (1), where (1) is the at least one shaped abrasive particle length. 
     
     
         9 . The coated abrasive article of  claim 8 , wherein the adjacent spacing is in a range of 0.2 mm to 4.0 mm. 
     
     
         10 . The coated abrasive article of  claim 1 , wherein the discontinuous distribution further comprises a longitudinal gap ranging from 1.1 (w) to 10 (w), where (w) is the width of the at least one shaped abrasive particle. 
     
     
         11 . The coated abrasive article of  claim 1 , wherein the number of shaped abrasive particles per cm 2  is in a range of at least 5 particles/cm 2  to not greater than 70 particles/cm 2 . 
     
     
         12 . The coated abrasive article of  claim 1 , further comprising a grain weight of at least 10 lb./ream to 60 lb./ream (148 g/m 2  to 888 g/m 2 ). 
     
     
         13 . The coated abrasive article of  claim 1 , wherein the shaped abrasive particle size is in a range of at least 100 microns to not greater than about 3 mm. 
     
     
         14 . The coated abrasive article of  claim 1 , further comprising a channel region, wherein the channel region comprises a region that is free of the at least one shaped abrasive particle. 
     
     
         15 . The coated abrasive article of  claim 1 , wherein the at least one shaped abrasive particles have a tip, and wherein at least 55% of the abrasive particle tips are upright. 
     
     
         16 . The coated abrasive article of  claim 1 , wherein at least 50% of the shaped abrasive particles comprise a predetermined side orientation and have a tilt angle of at least 45 degrees. 
     
     
         17 . The coated abrasive article of  claim 1 , comprising a ratio of a make weight to a grain weight that is in a range of 1:1 to 1:40. 
     
     
         18 . The coated abrasive article of  claim 1 , wherein the discontinuous distribution comprises a second plurality of discrete adhesive contact regions comprising a predetermined two-dimensional shape as viewed from above. 
     
     
         19 . The coated abrasive article of  claim 18 , wherein the predetermined two-dimensional shape of the second plurality comprises a polygon, an ellipsoid, a circle, a numeral, a cross, a multi-armed polygon, a Greek alphabet character, a Latin alphabet character, a Russian alphabet character, an Arabic alphabet character, a rectangle, a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, a nonagon, a decagon, or a combination thereof. 
     
     
         20 . The coated abrasive article of  claim 19 , wherein the predetermined two-dimensional shape is the same or different than the shape of the first plurality of discrete adhesive contact regions.