Shaped abrasive particles and methods of forming same

1. A shaped abrasive particle having a body comprising an arrowhead shape, wherein the body comprises a tortuous contour.

2. The shaped abrasive particle of claim 1 , wherein the body comprises a first major surface, a second major surface, and a first surface joining the first major surface and second major surface, wherein at least a portion of the side surface comprises a concave curvature.

3. The shaped abrasive particle of claim 2 , wherein the body comprises a length, a width, and a height, wherein the length is a longest dimension of any side of the shaped abrasive particle, wherein the width is a longest dimension of the shaped abrasive particle through a midpoint of the shaped abrasive particle, wherein the thickness is the shortest dimension of the shaped abrasive particle extending in a direction perpendicular to the length and width, wherein the body comprises a primary aspect ratio of at least 1.2:1, wherein the primary aspect ratio is a ratio of length:width, wherein the body comprises a secondary aspect ratio of at least 3:1, wherein the secondary aspect ratio is a ratio of length:height.

4. The shaped abrasive particle of claim 1 , wherein the body comprises a percent flashing of not greater than about 10%.

5. The shaped abrasive particle of claim 4 , wherein a side surface of the body comprises a fractured region.

6. A method comprising:

forming a precursor shaped abrasive particle in less than about 18 minutes, wherein forming comprises:

applying a mixture into a shaping assembly within an application zone; and

removing the mixture from the shaping assembly to form a precursor shaped abrasive particle.

7. The method of claim 6 , wherein the mixture comprises a gel comprising a ceramic powder material as an integrated network of discrete particles.

8. The method of claim 6 , wherein the mixture comprises at least 0.5 wt % and not greater than about 30 wt % organic materials for the total weight of the mixture.

9. The method of claim 6 , wherein the mixture comprises a storage modulus of at least about 20×10 4 Pa and not greater than 80×10 4 Pa.

10. The method of claim 6 , wherein the mixture comprises a viscosity of at least about 30×10 3 Pa s and not greater than 100×10 3 Pa s.

11. The method of claim 6 , wherein applying comprises extruding the mixture through a die opening and into the shaping assembly, and wherein extruding is conducted at a pressure of at least 500 kPa and not greater than 10,000 kPa.

12. The method of claim 6 , wherein the shaping assembly comprises an opening configured to receive the mixture and defined by at least three surfaces.

13. The method of claim 6 , wherein the shaping assembly comprises a first portion comprising a screen and a second portion comprising a backing plate, wherein the first portion and the second portion are adjacent to each other in the application zone.

14. The method of claim 6 , wherein the mixture has an average residence time in the shaping assembly of at least 1 second and not greater than 10 minutes.

15. The method of claim 6 , wherein the mixture comprises a change in weight of less than about 5% for a total weight of the mixture for a duration the mixture is in an opening of the shaping assembly.

16. The method of claim 6 , wherein applying the mixture comprises extruding the mixture through a die opening and into an opening in the shaping assembly, wherein during extrusion into the opening, the mixture flows into a first portion of the shaping assembly and abuts a surface of a second portion of the shaping assembly.

17. The method of claim 6 , further comprising translating at least a portion of the shaping assembly from the application zone to an ejection zone.

18. The method of claim 6 , further comprising removing the mixture from at least one surface of a portion of the shaping assembly prior to removing the mixture from the shaping assembly.

19. The method of claim 6 , wherein removing the mixture comprises directing an ejection material at the mixture in the shaping assembly under a predetermined force of at least 12 N and not greater than 20 N, removing the mixture from the shaping assembly and forming a precursor shaped abrasive particle.

20. The method of claim 19 , wherein the ejection material directly contacts an exposed major surface of the mixture in an opening of the shaping assembly.

21. The shaped abrasive particle of claim 1 , wherein the tortuous contour extends along at least a portion of a first major surface, wherein the tortuous contour comprises a first curved portion, a second curved portion, and a planar portion joining the first curved portion and the second curved portion.

22. The method of claim 6 , wherein during applying the mixture has a solids content of at least 42 wt % and not greater than 65 wt %.

23. The method of claim 6 , further comprising a batch productivity of at least 0.2 kg/min/m 2 of shaping surface.

24. The method of claim 13 , wherein the backing plate of the second portion is coated with a fluoropolymer.

25. The method of claim 13 , further comprising forming a batch of precursor shaped abrasive particles having a weight of at least 1 kg in not greater than 30 minutes.

26. The method of claim 16 , wherein the second portion is stationary relative to the first portion, and wherein the second portion terminates prior to removing the mixture.

27. The method of claim 20 , wherein the method further comprises drying, wherein drying is conducted at a temperature of at least 10° C. and not greater than 300° C., and wherein drying comprises removing a portion of the water content of the mixture.

28. The method of claim 6 , wherein the mixture comprises a coil value of at least 2000 N and not greater than 6000 N.