Process for the manufacture of filamentary abrasive particles

Claim 2

A process for producing filamentary abrasive particles of substantially constant aspect ratio and a diameter less than 600 microns which comprises (i) forcing by means of a forcing means an aqueous dispersion of an abrasive material at a fixed rate through an orifice and through a multiplicity of perforations in a belt which moves across and in tight registry with said orifice to form filamentary particles which are sufficiently sticky as to cause the particles to stick together if brought into contact with one another and remain attached to said belt, (ii) treating said filamentary particles to render them non-sticky while they remain attached to said belt, (iii) thereafter firing the treated filamentary particles at a temperature that is sufficient to form sintered filamentary abrasive particles.

Claim 3

The process of claim 1, wherein the belt moves at a speed such that the perforations therein are in register with said orifice for essentially the same period of time so as to produce filamentary particles of essentially the same length.

Claim 4

The process of claim 2, wherein the period of time is sufficiently short that the filamentary particles produced are of a length wherein further length reduction is not done.

Claim 5

The process of claim 2, wherein the perforations each have essentially the same size so as to produce filamentary particles having a substantially constant aspect ratio.

Claim 6

The process of claim 4, wherein the abrasive filaments have an aspect ratio of from about 1:1 to about 1:25.

Claim 7

The process of claim 1, wherein the treating to render non-sticky comprises at least partially drying the filamentary particles.

Claim 8

The process of claim 1, wherein the treating to render non-sticky comprises coating the surfaces of the filamentary particles with a powder.

Claim 9

The process of claim 1, wherein the aqueous dispersion is a gel.

Claim 10

The process of claim 8, wherein the gel has a solids content of about 40 to 55%.

Claim 11

The process of claim 8, wherein the gel comprises alumina.

Claim 12

The process of claim 1, wherein the treated filamentary particles are removed from the belt loop prior to firing using a removing mean while the belt is in motion.

Claim 13

The process of claim 1, wherein the belt is a continuous belt loop.

Claim 14

The process of claim 1, wherein the filamentary abrasive particles after firing have a diameter of about 45 to about 400 microns.

Claim 15

The process of claim 1, wherein the belt moves at a velocity of from about 0.5 to about 10 feet per minute.

Claim 16

The process of claim 1, wherein the belt is a continuous loop and, after passing by the removing means, passes through a cleaning means for cleaning any remaining abrasive material from the belt loop.

Claim 17

The process of claim 1, wherein the forcing means is an extruder.

Claim 18

The process of claim 16, wherein the extruder is a horizontal piston extruder.

Claim 19

The process of claim 16, wherein the extruder is operated at a pressure of about 2 to about 500 psi.

Claim 20

A process for producing filamentary abrasive particles which comprises the steps of (i) forcing by means of a forcing means a gel of an aqueous dispersion of an abrasive material through an orifice and through a multiplicity of perforations in a continuous belt loop which moves across and in tight register with said orifice at a substantially constant rate to form filamentary particles which are sufficiently sticky that the particles would stick together if brought in contact with each other and remain attached to said belt loop and move with the belt loop, (ii) treating said filamentary particles while adhered to the belt loop to render them non-sticky to each other, (iii) removing the treated filamentary particles from the belt loop, and (iv) firing the treated filamentary particles to form filamentary abrasive particles, and wherein the portion of the belt loop from which the dried filamentary particles are removed thereafter passing through a cleaning means for removing any abrasive material from the belt loop before that portion of the belt loop again passes by the forcing means.

Claim 21

A process for producing filamentary abrasive particles which comprises the steps of (i) forcing by means of a forcing means a gel of an aqueous dispersion of an abrasive material through an orifice and through a multiplicity of perforations in a continuous belt loop which moves across and in tight register with said orifice at a substantially constant rate to form filamentary particles which are sufficiently sticky that the particles would stick together if brought in contact with each other and remain attached to said belt loop and move with the belt loop, (ii) treating said filamentary particles while adhered to the belt loop to render them non-sticky to each other, (iii) removing the treated filamentary particles from the belt loop, and (iv) firing the treated filamentary particles to form filamentary abrasive particles, and wherein the portion of the belt loop from which the dried filamentary particles are removed thereafter passing through a cleaning means for removing any abrasive material from the belt loop before that portion of the belt loop again passes by the forcing means.

Claim 22

The process of claim 19, wherein (i) the perforations each have essentially the same size and the belt moves at a speed such that the perforations therein are in register with said orifice for essentially the same period of time so as to produce filamentary particles of essentially the same length and having a substantially constant aspect ratio, (ii) the period of time is sufficiently short that the filamentary particles produced are of a length wherein further length reduction is not done, and (iii) the treating to render non- sticky is at least partially drying.