CN101977877B - 涂覆二氧化硅的熔融颗粒 - Google Patents
涂覆二氧化硅的熔融颗粒 Download PDFInfo
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- CN101977877B CN101977877B CN200980110251.2A CN200980110251A CN101977877B CN 101977877 B CN101977877 B CN 101977877B CN 200980110251 A CN200980110251 A CN 200980110251A CN 101977877 B CN101977877 B CN 101977877B
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 title claims abstract description 116
- 239000000377 silicon dioxide Substances 0.000 title claims abstract description 52
- 238000000576 coating method Methods 0.000 claims abstract description 56
- 239000011248 coating agent Substances 0.000 claims abstract description 55
- 239000002245 particle Substances 0.000 claims description 200
- 238000002844 melting Methods 0.000 claims description 37
- 230000008018 melting Effects 0.000 claims description 36
- 238000000034 method Methods 0.000 claims description 34
- 239000011230 binding agent Substances 0.000 claims description 30
- 239000000203 mixture Substances 0.000 claims description 29
- 229960001866 silicon dioxide Drugs 0.000 claims description 29
- 238000007669 thermal treatment Methods 0.000 claims description 29
- 235000012239 silicon dioxide Nutrition 0.000 claims description 28
- 239000006061 abrasive grain Substances 0.000 claims description 25
- 229910052799 carbon Inorganic materials 0.000 claims description 24
- 238000004519 manufacturing process Methods 0.000 claims description 20
- 239000000395 magnesium oxide Substances 0.000 claims description 18
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 18
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 18
- 238000000227 grinding Methods 0.000 claims description 17
- 239000000126 substance Substances 0.000 claims description 13
- 239000000725 suspension Substances 0.000 claims description 13
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 12
- 238000010438 heat treatment Methods 0.000 claims description 12
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 11
- 238000004458 analytical method Methods 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 7
- 239000000084 colloidal system Substances 0.000 claims description 6
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- 239000012634 fragment Substances 0.000 claims description 3
- 238000009736 wetting Methods 0.000 claims description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 abstract description 5
- 238000012360 testing method Methods 0.000 description 22
- 239000008187 granular material Substances 0.000 description 19
- 235000019580 granularity Nutrition 0.000 description 18
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- 239000000463 material Substances 0.000 description 12
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- 150000001875 compounds Chemical class 0.000 description 9
- 239000000654 additive Substances 0.000 description 8
- 239000000523 sample Substances 0.000 description 8
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 7
- 230000000996 additive effect Effects 0.000 description 7
- VCRLKNZXFXIDSC-UHFFFAOYSA-N aluminum oxygen(2-) zirconium(4+) Chemical compound [O--].[O--].[Al+3].[Zr+4] VCRLKNZXFXIDSC-UHFFFAOYSA-N 0.000 description 7
- 238000010298 pulverizing process Methods 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- 238000001354 calcination Methods 0.000 description 5
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- 239000000292 calcium oxide Substances 0.000 description 4
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 4
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- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
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- 241000588731 Hafnia Species 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 2
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 2
- 229910004298 SiO 2 Inorganic materials 0.000 description 2
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- 238000001033 granulometry Methods 0.000 description 2
- CJNBYAVZURUTKZ-UHFFFAOYSA-N hafnium(IV) oxide Inorganic materials O=[Hf]=O CJNBYAVZURUTKZ-UHFFFAOYSA-N 0.000 description 2
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
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- 229910052700 potassium Inorganic materials 0.000 description 2
- 235000019353 potassium silicate Nutrition 0.000 description 2
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- 239000004576 sand Substances 0.000 description 2
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 2
- 229910001948 sodium oxide Inorganic materials 0.000 description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 2
- 238000003980 solgel method Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 2
- OEPOKWHJYJXUGD-UHFFFAOYSA-N 2-(3-phenylmethoxyphenyl)-1,3-thiazole-4-carbaldehyde Chemical compound O=CC1=CSC(C=2C=C(OCC=3C=CC=CC=3)C=CC=2)=N1 OEPOKWHJYJXUGD-UHFFFAOYSA-N 0.000 description 1
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 229910002016 Aerosil® 200 Inorganic materials 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 229910052684 Cerium Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical group [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910052692 Dysprosium Inorganic materials 0.000 description 1
- 229910052691 Erbium Inorganic materials 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- MBMLMWLHJBBADN-UHFFFAOYSA-N Ferrous sulfide Chemical compound [Fe]=S MBMLMWLHJBBADN-UHFFFAOYSA-N 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical group [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 239000004693 Polybenzimidazole Substances 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 229920001328 Polyvinylidene chloride Polymers 0.000 description 1
- WCUXLLCKKVVCTQ-UHFFFAOYSA-M Potassium chloride Chemical compound [Cl-].[K+] WCUXLLCKKVVCTQ-UHFFFAOYSA-M 0.000 description 1
- 206010063493 Premature ageing Diseases 0.000 description 1
- 208000032038 Premature aging Diseases 0.000 description 1
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 1
- 229910010413 TiO 2 Inorganic materials 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 208000003443 Unconsciousness Diseases 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000005083 Zinc sulfide Substances 0.000 description 1
- CNGGOAOYPQGTLH-UHFFFAOYSA-N [O-2].[O-2].[Mg+2].[Al+3] Chemical compound [O-2].[O-2].[Mg+2].[Al+3] CNGGOAOYPQGTLH-UHFFFAOYSA-N 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
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- 229910052782 aluminium Inorganic materials 0.000 description 1
- 239000005030 aluminium foil Substances 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 229910021502 aluminium hydroxide Inorganic materials 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 238000000498 ball milling Methods 0.000 description 1
- 229910052728 basic metal Inorganic materials 0.000 description 1
- 150000003818 basic metals Chemical class 0.000 description 1
- DUZWNKDFSDMOHT-UHFFFAOYSA-N benzene-1,3-diol;formaldehyde;urea Chemical compound O=C.NC(N)=O.OC1=CC=CC(O)=C1 DUZWNKDFSDMOHT-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
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- 239000006227 byproduct Substances 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- CVXBEEMKQHEXEN-UHFFFAOYSA-N carbaryl Chemical compound C1=CC=C2C(OC(=O)NC)=CC=CC2=C1 CVXBEEMKQHEXEN-UHFFFAOYSA-N 0.000 description 1
- 229960005286 carbaryl Drugs 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- ZMIGMASIKSOYAM-UHFFFAOYSA-N cerium Chemical compound [Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce] ZMIGMASIKSOYAM-UHFFFAOYSA-N 0.000 description 1
- 229910052729 chemical element Inorganic materials 0.000 description 1
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- 239000008139 complexing agent Substances 0.000 description 1
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- 230000007547 defect Effects 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- KBQHZAAAGSGFKK-UHFFFAOYSA-N dysprosium atom Chemical compound [Dy] KBQHZAAAGSGFKK-UHFFFAOYSA-N 0.000 description 1
- 238000010891 electric arc Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- UYAHIZSMUZPPFV-UHFFFAOYSA-N erbium Chemical compound [Er] UYAHIZSMUZPPFV-UHFFFAOYSA-N 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
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- DYDNPESBYVVLBO-UHFFFAOYSA-N formanilide Chemical compound O=CNC1=CC=CC=C1 DYDNPESBYVVLBO-UHFFFAOYSA-N 0.000 description 1
- 229920005546 furfural resin Polymers 0.000 description 1
- 239000005350 fused silica glass Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 229910052735 hafnium Inorganic materials 0.000 description 1
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 1
- 229910052736 halogen Inorganic materials 0.000 description 1
- 150000002367 halogens Chemical class 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 230000002209 hydrophobic effect Effects 0.000 description 1
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 235000011147 magnesium chloride Nutrition 0.000 description 1
- 238000007885 magnetic separation Methods 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000011572 manganese Substances 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000005058 metal casting Methods 0.000 description 1
- 229910000476 molybdenum oxide Inorganic materials 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 239000012766 organic filler Substances 0.000 description 1
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 description 1
- PQQKPALAQIIWST-UHFFFAOYSA-N oxomolybdenum Chemical compound [Mo]=O PQQKPALAQIIWST-UHFFFAOYSA-N 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 239000013034 phenoxy resin Substances 0.000 description 1
- 229920006287 phenoxy resin Polymers 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- 229920002480 polybenzimidazole Polymers 0.000 description 1
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- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- OTYBMLCTZGSZBG-UHFFFAOYSA-L potassium sulfate Chemical compound [K+].[K+].[O-]S([O-])(=O)=O OTYBMLCTZGSZBG-UHFFFAOYSA-L 0.000 description 1
- 229910052939 potassium sulfate Inorganic materials 0.000 description 1
- 235000011151 potassium sulphates Nutrition 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- FDNAPBUWERUEDA-UHFFFAOYSA-N silicon tetrachloride Chemical class Cl[Si](Cl)(Cl)Cl FDNAPBUWERUEDA-UHFFFAOYSA-N 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- -1 sodium aluminum fluoride Chemical compound 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 230000001988 toxicity Effects 0.000 description 1
- 231100000419 toxicity Toxicity 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- DRDVZXDWVBGGMH-UHFFFAOYSA-N zinc;sulfide Chemical compound [S-2].[Zn+2] DRDVZXDWVBGGMH-UHFFFAOYSA-N 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/628—Coating the powders or the macroscopic reinforcing agents
- C04B35/62802—Powder coating materials
- C04B35/62805—Oxide ceramics
- C04B35/62807—Silica or silicates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/628—Coating the powders or the macroscopic reinforcing agents
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/107—Refractories by fusion casting
- C04B35/109—Refractories by fusion casting containing zirconium oxide or zircon (ZrSiO4)
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Abstract
本发明提供一种涂覆颗粒,该颗粒包含采用含二氧化硅涂层至少部分地覆盖的熔融基础颗粒,所述基础颗粒以基于基础颗粒重量的重量百分数计包含大于40%的氧化铝。
Description
技术领域
本发明涉及熔融颗粒,如氧化铝熔融颗粒、氧化铝-氧化锆颗粒或包含氧化镁的熔融颗粒。本发明还涉及包含根据本发明所述颗粒的磨具,以及生产本发明颗粒的方法。
背景技术
磨具通常根据形成构成磨具的陶瓷颗粒模式分类:喷射或无载体的悬浮形式的游离磨料;涂覆磨料,其中所述颗粒固定在布、纸张或聚合物薄膜形式的载体上;以及环形带、棒等形式的粘结磨料。
关于粘结磨料,将研磨颗粒与有机粘结剂如酚醛树脂或玻璃状粘结剂压缩在一起,其中所述玻璃状粘结剂例如为由氧化物构成的粘结剂,特别是硅酸盐粘结剂。关于研磨,所述颗粒本身必须具有良好的机械性质,特别是高刚性和/或硬度,并能够与粘结剂产生良好结合(界面可靠性)。
目前,存在覆盖较宽应用和性能范围的多种研磨颗粒;通过熔化原料而合成的颗粒称作“熔融颗粒”,其提供优异的性质/生产成本的折衷方案。
在本说明书中,除非另外说明,否则颗粒的所有组成均以基于颗粒总重的重量百分数形式给出。
在熔融颗粒范围内,基于氧化铝和氧化锆的材料已经通过US-A-3181939得知。所述颗粒通常由10%-60%的氧化锆、0-10%的添加剂和余量的氧化铝构成。实践中,如专利US-A-3891408中记载,商业产品中氧化锆的量约为25%,即大约为关于氧化铝-氧化锆在约42%(通常在35%-50%)氧化锆下共晶体的值。
US-A-4457767也描述了熔融颗粒。可提及的例子为由供应商Saint-Gobain(法国)出售的商标为的颗粒。所述颗粒典型地包含39重量%氧化锆,和0.8%Y2O3,杂质小于0.5%,余量为氧化铝。所述颗粒的混合物广泛用于涂覆磨料或用于具有有机粘结剂的砂轮,特别是用于除去(粗磨、切割研磨等)特别是位于不锈钢上的大量材料的操作中。
进一步地,EPA 01613709描述了包含多种百分含量的MgO、其余为Al2O3的颗粒。通过熔融所述原料生产所述包含氧化镁的含氧化铝颗粒。然后优选迅速冷却熔融材料,以促进例如采用如在专利US A 3993119中公开的用于在金属薄板间浇铸的装置进行的精细的经定向结构的生产。最后将冷却的材料例如采用滚筒研磨而磨碎,然后筛分并分类成符合例如FEPA精确标准的粒度分布或“粒度(grit)”系列。
US A 5042991描述了由疏水性二氧化硅在非水性液体中的悬浮体得到的涂层。
WO 2006/032982描述了涂覆vitreophilic颗粒的方法。氧化铝不是vitreophilic材料。
为实现研磨颗粒与粘结剂间的更好粘附,已知将涂层涂覆至其表面,例如基于镁或锰的氧化物(US 4,913,708)或基于氧化铝水合物和硅酸钠(EP 0856037)。然而,所述涂层会存在一些缺陷,特别是对氧化锰毒性或由其吸湿性导致水合氧化铝或硅酸钠过早老化的问题。
EP 0417729中还提出了在研磨颗粒表面上二氧化硅的涂覆,但其适用于通过溶胶-凝胶法生产的并用于玻璃化轮的烧结颗粒,而非用于熔融颗粒。
然而,通过涂覆涂层引起的颗粒性能改进根据所述颗粒是熔融或烧结颗粒而差别很大。尽管未能对其作出理论上的解释,但是EP 0417729指出,对含氧化铝研磨颗粒以相同方式采用玻璃质粘结剂实施相同处理,根据所述颗粒是通过溶胶-凝胶法抑或其它方法生产的,导致在粉碎中表现出不同性能的磨具。
进一步地,日本专利申请No.6098299描述了生产基于薄片状二氧化硅涂层的方法。该方法包括:在二氧化硅溶胶中浸渍基础颗粒,除去过量的二氧化硅,然后高温热处理。该专利申请指出,通常难以使用胶体二氧化硅涂覆微粒团聚体形式的研磨颗粒。
最后,用于涂覆熔融颗粒的方法通常复杂而昂贵。
一直需要有表现出与粘结剂(特别是有机粘结剂)具有优异的粘附和/或具有高刚性的新型研磨颗粒。本发明的一个目的在于解决该需求。
还需要以有效方式低成本地生产这类研磨颗粒的新型方法。
发明内容
本发明提出了一种涂覆颗粒,包括至少部分或甚至全部采用含二氧化硅涂层涂覆的熔融基础颗粒,该基础颗粒包括以基于基础颗粒重量的重量百分数计超过40%的氧化铝。
如可在说明书下文中更详细看出,所述二氧化硅涂层使得能够获得良好的冲击强度和破裂强度和/或与粘结剂的良好粘附。
根据本发明的颗粒还可特别地包括一个或多个以下任选的特征:
-所述涂层以基于涂层重量的重量百分数计,包括大于95%的二氧化硅;
-二氧化硅是亲水性的;
-涂层的重量表现出大于0.01%,大于0.1%和/或小于2%,小于0.75%或小于0.3%的基础颗粒重量;
-涂层基本上覆盖所述基础颗粒的所有表面;
-涂层没有裂纹或碎片;
-涂层以不存在分隔所述涂层与所述表面的中间层形式与基础颗粒表面接触;
-基础颗粒以基于基础颗粒重量的百分数计包括至少1%氧化锆、氧化镁、或氧化锆与氧化镁的混合物;
-所述基础颗粒以基于总计100%的重量百分数计具有以下化学分析之一:
Al2O3: 45-65%
ZrO2+HfO2: 35-50%
其它: 0-12%
或
Al2O3: 65-80%
ZrO2+HfO2: 15-30%
其它: 0-12.0%
或
Al2O3: 92.0-98.5%
MgO: 1.5-6.5%
其它: <2.0%
-基础颗粒组成中添加剂的总重小于10%。
本发明还提供一种包含本发明涂覆颗粒的颗粒混合物,所述涂覆颗粒的尺寸大于45μm(微米),大于400μm或大于500μm和/或小于3.35mm或小于2mm或小于600μm。
本发明还提供一种磨具,包括聚集或沉积于载体上的通过粘结剂束缚的研磨颗粒,至少一部分所述研磨颗粒为本发明的颗粒。所述粘结剂特别地可以是有机粘结剂。
本发明还提供一种生产涂覆颗粒的方法,包括以下连续步骤:
1)获得或生产熔融基础颗粒,特别是以基于基础颗粒重量的重量百分数计包含大于40%氧化铝的熔融基础颗粒;
2)采用优选为水性的含二氧化硅的悬浮体至少部分地涂覆所述基础颗粒;
3)任选地,干燥由所述悬浮体润湿的基础颗粒,以形成基于二氧化硅的涂层。
特别地,根据本发明的方法还可包括一个或多个以下任选的特征:
-步骤2)之前,对所述熔融基础颗粒实施热处理步骤,称作“在先”处理,其特别地在大于600℃,或甚至大于800℃,或甚至大于1000℃和/或小于1550℃或小于1350℃或甚至小于1250℃的温度下实施。在先热处理的持续时间可例如大于30分钟,甚至大于1小时,或大于3小时和/或小于10小时。可选地,在步骤2)之前不对熔融基础颗粒实施任何热处理;
-在步骤2)中,将基础颗粒与大于0.5g、大于0.75g或甚至大于1.0g和/或小于5g、小于4g、小于3g或甚至小于2g悬浮体/100g基础树脂量的悬浮体混合。二氧化硅悬浮体可具有小于25%,或甚至小于10%,或甚至小于5%的二氧化硅浓度。
-任选的步骤3)后,所述方法包括热处理步骤4),所述热处理在大于100℃,大于200℃,大于300℃和/或小于1550℃,小于1500℃,小于1350℃,小于1000℃,或甚至小于500℃或小于450℃的温度下实施。所述热处理实施大于30分钟,大于1小时和/或小于24小时或小于10小时的时间。
-熔融基础颗粒在步骤2)和步骤3)或步骤4)之间不经历中间步骤;
-调节所述方法,使得在步骤3)或在适当情况下在步骤4)的末期得到的涂覆颗粒为根据本发明的颗粒。
定义
基于清楚的目的,使用术语“涂覆颗粒”表示包括为熔融材料的“基础颗粒”和至少部分地覆盖所述基础颗粒的含二氧化硅涂层的颗粒。
术语“涂层”是指沿基础颗粒表面延伸的固体材料层。所述涂层可渗透至基础颗粒表面的任意孔中。然而,涂层由与标示化学组成突变的基础颗粒的界面限定。
术语“熔融颗粒”是指采用包括通过冷却使熔融物质凝固的方法得到的颗粒。
“熔融物质”是必须盛放于容器中以保持其形状的物质。熔融物质通常为液态。然而,其可包含固体颗粒,但所述固体颗粒的量不足以使所述物质结构化。
术语“颗粒混合物”是指可浇铸的,即不具有固有刚性的颗粒混合物。对于小尺寸颗粒,常使用术语“粉末”。
本发明的涂覆颗粒可为颗粒混合物形式,特别是易于用作生产磨具用原料的颗粒混合物形式,或所述颗粒相互间固定不动的形式,例如由于将其固定在布上或粘结在一起以形成刚性物质,特别是形成粘结的磨料。
术语“二氧化硅胶体悬浮体”通常是指二氧化硅颗粒在液体(如水性介质)中的悬浮体,取决于所述颗粒是否团聚,所述颗粒具有数纳米至数百纳米的尺寸。
通常,基础颗粒或涂覆颗粒的“尺寸”对应于所述颗粒可通过的标准筛的最小目数。
悬浮体中二氧化硅颗粒的“尺寸”对应于通常由采用激光颗粒测量仪(如供应商HORIBA的Partica LA-950型)实施的粒度分布的表征而给出的尺寸。
粗砂或FEPA标准的参考文献是指FEPA Standard 42-GB-1984参考文献。
如在工业领域常规采用的那样,颗粒的氧化物含量基于以最稳定氧化物形式表达的各相应化学元素的总量;由此,低价氧化物包括和可行的是氮化物、氧氮化物、碳化物、氧碳化物、碳氮化物或甚至上述元素的金属性物质。
当描述熔融基础颗粒的化学组成时,“其它”表示在别处也未明确提及的所有化合物,特别是杂质和“添加剂”。
术语“杂质”表示由原料无意识和必要地引入的或通过与那些组分反应导致的不可避免的组分。杂质是非必要但可容忍的组分。作为例子,构成由钠和其它碱金属、铁、钒和铬的金属性物质、氧化物、氮化物、氧氮化物、碳化物、氧碳化物和碳氮化物形成的组中一部分的化合物为杂质。当期望的产品必须包括氧化锆或氧化锆和氧化铪时,以小于2%的量天然存在于氧化锆原料中的氧化铪不被认为是杂质。剩余的碳表示为C,构成本发明颗粒杂质的一部分。
术语“添加剂”包括用于生产熔融氧化铝或氧化铝-氧化锆颗粒的所有添加剂,特别是氧化锆稳定剂,且特别是氧化钇和氧化钛。还包括镁、钙的氧化物和其它稀土元素的氧化物,特别是钕以及镧、铈、镝和铒的氧化物。术语“添加剂”还包括这些物质的混合物。优选地,基础颗粒组成中添加剂的总量小于10%,或甚至小于5%,3%,1%,0.8%,0.5%或0.2%。
本发明的其它特征和优点通过以下详细描述将变得容易理解。
具体实施方式
所述基础颗粒具有不同组成;特别地,其可由氧化铝、氧化铝-氧化锆、或氧化铝-氧化镁构成,只要其以重量计包含至少40%的氧化铝即可,其中所述氧化铝特别地为α-氧化铝。
基础颗粒可包括以重量计大于45%,或甚至大于65%或甚至大于92%和/或小于98.5%,或甚至小于80%,或甚至小于65%的量的氧化铝。
优选地,基础颗粒包括至少1%的氧化锆、氧化镁、或氧化锆与氧化镁的混合物。
基础颗粒可包括大于15%,大于20%,或甚至大于35%和/或小于50%,或甚至小于30%量的氧化锆(ZrO2+HfO2)。在具体实施方案中,基础颗粒不含氧化锆。
基础颗粒还可包括氧化镁(MgO),氧化镁的重量含量优选大于1.5%,2.2%,2.3%,2.45%和/或小于6.5%,4.0%或甚至2.5%。
特别地,基础颗粒可以是颗粒,例如形成专利申请WO/2004/094554的主题物质的颗粒。
在一个实施方案中,熔融基础颗粒具有以下化学分析;百分数以总计100重量%给出:
Al2O3: 45-65%
ZrO2+HfO2: 35-50%
其它: 0-12.0%。
在另一个实施方案中,熔融基础颗粒具有以下化学分析;百分数以总计100重量%给出:
Al2O3: 65-80%
ZrO2+HfO2: 15-30%
其它: 0-12.0%。
在另一个实施方案中,熔融基础颗粒具有以下化学分析;百分数以总计100重量%给出:
Al2O3: 92.0-98.5%
MgO: 1.5-6.5%
其它: <2.0%。
基础颗粒中杂质的总量优选小于0.5%,或甚至0.4%。优选地,杂质的量小于0.1%。
特别地,已知二氧化硅和氧化钠在熔融基础颗粒中是不利的,其量在基础颗粒中必须被限制至痕量,作为杂质引入至原料中。实际上,二氧化硅的存在导致形成玻璃状表面,该玻璃状表面改进熔融基础颗粒研磨性和硬度。氧化钠的存在,即使量很少,仍然可导致β氧化铝的形成。这些结晶形式的氧化铝降低子颗粒的研磨性。优选地,Na2O<0.1%,或甚至Na2O<0.05%。
基础颗粒中CaO、TiO2、Fe2O3或Cr2O3的量分别优选小于0.5%,更优选小于0.3%。
残余的碳可小于800ppm,小于500ppm,或甚至小于250ppm,或甚至小于200ppm,这与降低的熔融条件相对应。
优选地,熔融基础颗粒通过氦比重测试法测量,具有小于3%的孔隙率。
优选地,涂层的重量以基于基础颗粒的重量百分数计大于0.01%,或甚至大于0.03%,或甚至大于0.1%和/或小于2%,或甚至小于0.75%,或甚至小于0.3%。
所述涂层可包括大于50%,或甚至大于80%,大于90%,或大于95%的二氧化硅。以基于涂层重量的重量百分数计,所述涂层甚至可100%由二氧化硅组成。
非限制性地,优选涂层以充分均匀的方式围绕基础颗粒扩展。在一个具体实施方案中,涂层可充分覆盖基础颗粒的全部表面。
所述涂层可不具有裂纹或碎片,特别是当其按照下述生产方法的步骤2)涂覆时。
现有技术的熔融颗粒可包括与本发明涂覆颗粒中二氧化硅量相当的二氧化硅量作为杂质。然而,本发明的涂覆颗粒与现有技术颗粒的区别在于,其具有的涂层的二氧化硅含量远高于熔融基础颗粒中二氧化硅含量。
在一个实施方案中,所述涂层与基础颗粒的表面接触,即不采用中间层分隔。
二氧化硅优选是亲水性的,即可用水润湿。二氧化硅是天然亲水的,通常需要对其进行特殊处理以赋予其疏水性。
所述涂层的二氧化硅可以是无定形的,部分结晶的或甚至完全结晶的。
本发明还提供一种颗粒混合物,其包括本发明的涂覆颗粒或甚至由本发明的涂覆颗粒构成。
优选地,根据本发明具有颗粒混合物的涂覆颗粒具有大于粒度4(Grit 4),大于粒度12,大于粒度16和/或小于粒度220,小于粒度120或小于粒度80的粒度。
优选地,涂覆颗粒的尺寸大于45μm、150μm、300μm、400μm、500μm和/或小于3.35mm、2.8mm、2mm、1.4mm、1mm、850μm或甚至600μm。
本发明还提供一种磨具,其包括通过粘结剂粘结的研磨颗粒和团聚体,例如为轮形式,或沉积在载体上,例如作为柔性载体上的层沉积,所述磨具特点在于至少一部分或甚至全部所述研磨颗粒为根据本发明的颗粒。
所述磨具特别地可以是砂轮,高精度轮、磨锯齿轮、切割轮、实体加工轮(solid-machining wheel)、修整或粗磨砂轮、调整轮、便携轮、铸造轮、钻子轮、磨头、筒形砂轮、锥形砂轮、盘形砂轮或分割式轮或任意其它类型的轮。
生产这类磨具的方法是公知的。
粘结磨具可通过以研磨颗粒和粘结剂混合物的形式压制而成。
在本发明的磨具中,粘结剂可为玻璃化(例如由氧化物,特别是硅酸盐构成的粘结剂)或有机的。有机粘结剂更加合适并优选。
所述粘结剂特别地可以是热固性树脂。其可选自酚醛树脂、环氧树脂、丙烯酸酯、聚酯、聚酰亚胺、聚苯并咪唑、聚氨酯、苯氧基树脂、苯酚-糠醛树脂、苯胺-甲醛树脂、脲-甲醛树脂、甲酚-醛树脂、间苯二酚-醛树脂、脲醛树脂或三聚氰胺-甲醛树脂及其混合物。
通常,粘结剂占混合物体积的2%-60%,优选20%-40%。
所述粘结剂还可结合有机或无机填料,例如可以是水合物(如氢氧化铝或勃姆石)或非水合物(如氧化钼)的无机填料,冰晶石、卤素、氟石、硫化铁、硫化锌、氧化镁、碳化硅、氯化硅、氯化钾、二氯化镁、氟硼酸钾或锌、氟铝酸钾、氧化钙、硫酸钾、偏二氯乙烯与氯乙烯的共聚物、聚偏二氯乙烯、聚氯乙烯、纤维、硫化物、氯化物、硫酸盐、氟化物及其混合物。所述粘结剂还可包含补强填料如玻璃纤维。
本发明还提供一种生产涂覆颗粒的方法,包括以下连续步骤:
1)获得或生产熔融基础颗粒;
2)采用含二氧化硅悬浮体至少部分地涂覆所述基础颗粒;
3)任选地,干燥由悬浮体润湿的基础颗粒;
4)任选的热处理。
如可在说明书下文中更详细地了解到,该方法意味着本发明的涂覆颗粒可以非常简便的方式生产,且其同时具有良好的冲击强度和良好的与粘结剂的粘附,所述粘结剂特别为有机粘结剂。
在步骤1)中,熔融基础颗粒可采用生产氧化铝或氧化铝-氧化锆熔融颗粒的常规方法生产,特别是在浇铸前采用具有至少1500kWh/吨原料的熔化能的短弧生产。熔融条件可以为使得基础颗粒具有800ppm的最大碳含量。特别地,基础颗粒可采用包含以下连续步骤的方法生产:
a)混合所述原料;
b)常规地在电炉中熔融所述混合原料,直至得到熔化材料;
c)通过急冷冷却所述熔化材料,优选使得熔化材料在不足3分钟内完全凝固,直至得到固体块;
d)粉碎所述固体块,得到熔化基础颗粒,且任选地进行所述基础颗粒的粒度分级。
颗粒的形式可根据应用变化和选择。
在一个实施方案中,在步骤2)之前不向熔融基础颗粒涂覆中间层。
然而,在步骤2)前可洗涤基础颗粒。所述预洗涤可采用水或酸性水溶液如盐酸实施。
在一个实施方案中,熔融基础颗粒在步骤2)前不经历热处理步骤。有利地,从而简化了所述方法。
在一个实施方案中,在涂覆步骤2)结束前的热处理是介于步骤1)和步骤2)之间的唯一操作。
在另一个实施方案中,相反,熔融基础颗粒在步骤2)之前经历热处理步骤。所述在先热处理可特别地在大于600℃,或甚至大于800℃,或甚至大于1000℃和/或小于1550℃或甚至小于1350℃或甚至小于1250℃的温度下实施。
所述热处理可在空气中例如在大气压下实施。
有利地,所述处理可在生产所述涂层前调节基础颗粒的刚性和脆性。在步骤2)中,基础颗粒至少部分地采用含二氧化硅的悬浮体覆盖。
优选地,将基础颗粒与有限量的悬浮体混合,悬浮体的量优选大于0.5g,大于0.75g,或甚至大于1.0g和/或小于5g,小于4g,小于3g,小于2g悬浮体/100g颗粒。如此量的悬浮体可实现二氧化硅悬浮体对基础颗粒的良好覆盖。
如此得到的混合物具有“湿砂”稠度,并可有利地不经中间处理而干燥。同样有利地,干燥后,所述涂覆颗粒不会相互附着,或仅轻度附着以至于无需粉碎即可容易地分离。
所述二氧化硅悬浮体可具有小于25%,或甚至小于10%,或甚至小于5%的二氧化硅浓度。
二氧化硅悬浮体优选以使得基于基础颗粒,可将0.01%、0.03%或0.05%或更高和/或5%、3%、2%、1%、0.75%、0.3%或甚至0.1%或更低重量百分数的二氧化硅沉积在基础颗粒上的比例使用。
所述悬浮体特别地可以是二氧化硅的胶体悬浮体。其可包含添加剂如表面活性剂、润湿剂或络合剂。
优选地,所述胶体悬浮体为纳米级的,即包含2-200纳米尺寸的二氧化硅颗粒。有利地,这意味着存在大量二氧化硅颗粒,从而在较低重量浓度下具有较大的涂覆表面积。
任选地为水性的胶体二氧化硅悬浮体可商购获得,或可以是通过混合熔融二氧化硅和聚乙烯醇(PVA)溶液得到的悬浮体。
所述悬浮体可有利地通过与基础颗粒混合而简单地涂覆。干燥时,特别是在干燥步骤3)期间,或在热处理(步骤4))期间,蒸发除去胶体悬浮体的液相,使二氧化硅保留在颗粒表面上。
在一个实施方案中,生产方法不包括步骤2)和步骤3)或步骤4)之间的中间步骤。特别地,其不包括冲洗或洗涤或化学处理步骤。
在步骤3)中,为使二氧化硅有效附着至熔融基础颗粒上,干燥优选在大于60℃,优选大于80℃和/或小于200℃,优选小于140℃的温度下实施。
可使所述颗粒在优选大于100℃,200℃或甚至300℃或350℃和/或优选小于1550℃,1350℃,1000℃,800℃,600℃或甚至500℃或450℃的温度下,热处理优选大于30分钟,或甚至1小时,或甚至2小时和/或小于24小时,10小时或甚至8小时或6小时的时间。
在大于450℃,大于500℃或大于600℃下的热处理同样是可行的。
优选地,在步骤4)中实施的热处理在游离颗粒粉末上实施,即其中本发明的涂覆颗粒特别地为通过树脂互相粘结的粉末。
约400℃的热处理温度是特别适宜的。从而,本发明的生产方法可通过在相对低温下的热处理产生显著的性能(特别地用于AZ颗粒和用于已经经历在先热处理的Al-MgO颗粒)。
热处理可改进基础颗粒与涂层间界面的质量和粘附。
特别地,基础颗粒可采用专利申请WO/2004/094554中描述的方法生产。在一个方案中,所述方法包括在大于1250℃,或甚至1350℃,1400℃下煅烧优选大于30分钟的步骤。
在本发明生产方法的一个方案中,采用二氧化硅悬浮体覆盖基础颗粒的步骤2)在热处理前实施,特别地对于在专利申请WO/2004/094554中描述的基础颗粒,在所述煅烧步骤前实施。从而,本发明生产方法的步骤4)可有利地起到煅烧步骤的作用。
有利地,煅烧步骤不但如上述专利申请所述可显著改进基础颗粒的性能,而且同时还可改进二氧化硅与基础颗粒表面间的牢固程度。
任选的粉碎后,根据FEPA F标准,可选择具有的粒度在粒度12-粒度220范围内、优选在粒度16-粒度120范围内的涂覆颗粒。已经证实,这些粒度在研磨应用中非常有效。
本发明的生产方法优选调节为使得在步骤3)或步骤4)末期得到的涂覆颗粒为根据本发明的颗粒。
最后,本发明提供采用本发明的生产方法得到的颗粒和颗粒混合物。
实施例
基于阐述本发明目标的目的,给出以下非限制性实施例。
使用的基础颗粒由以下原料生产:
-部分煅烧的、苏打含量小于0.3%的氧化铝;
-氧化锆+铪含量大于98%的氧化锆粉末;
-油焦;
-铝金属箔。
所述基础颗粒采用技术人员已知的常规熔融方法制备。
首先计量出原料使得能够生产基础颗粒。
AZ基础颗粒以重量分数计具有以下化学分析:Al2O3:75.0%、ZrO2+HfO2:24.1%、TiO2:0.1%、SiO2:<0.2%、MgO:0.05%、CaO:0.07%、其它<0.8%。晶体和微结构分析表明,所有氧化锆均以共晶形式与氧化铝结合;其余的氧化铝为α-氧化铝形式。
Al-MgO基础颗粒以重量百分数计具有以下化学分析:Al2O3:95.75%、MgO:3.6%、SiO2:0.02%、CaO:0.07%、其它<0.6%。
根据炉的状态,以基于原料的重量百分数计,将最少1%(最高3%)的油焦和约0.5%-5.5%的铝箔添加至这些原料中。
然后将初始装料在Heroult型单相电弧炉中熔化,所述电弧炉具有石墨电极,0.8m直径炉身、100V-150V电压、1800A-2200A强度和1.8kWh/kg装料-2.5kWh/kg装料的特定供给电能。
然后采用例如专利US-A-3,993,119中公开的薄金属板铸造装置迅速冷却。随后将熔融颗粒粉碎并根据其粒度测量进行分级。选择具有在粒度12-粒度220(FEPA F标准)范围内粒度测量的熔融颗粒。
然后将选择的颗粒水洗并与二氧化硅胶体悬浮体混合,以根据相对于基础颗粒重量的重量百分数计得到颗粒上二氧化硅的百分数PS。使用两种二氧化硅悬浮体:悬浮体A,通过混合由Degussa AG出售的Aerosil 200熔融二氧化硅与聚乙烯醇(PVA)溶液获得;以及悬浮体C,即由Cabot提供的CabOsperse 2020K,包含20%分散于水性介质中的二氧化硅。
然后任选地将该混合物在Thtt温度下热处理(HTT:是/否)两小时。
实施例1B、2B和3B的Al-MgO颗粒在洗涤并与胶体二氧化硅悬浮体混合前,在1500℃下经历4小时的热处理。
为了解颗粒的机械性质,实施下述试验。
试验A:冲击强度和断裂强度的测定
试验A用于测定在钢粉碎碗中施压后剩余的在规定粒度范围内颗粒的比例。该试验能够测定颗粒的动态机械强度。
在试验前,将颗粒混合物在工业标准的型振动筛上筛分,分离1180/1400μm部分(表示根据FEPA标准具有F16数(粒度16)的颗粒),1000/1180μm部分(表示具有F20数(粒度20)的颗粒),710/850μm部分(表示具有F24数(粒度24)的颗粒),以及600/710μm部分(表示具有F30数(粒度30)的颗粒)。
然后使分离的粒度部分通过磁选除铁,以提取由于粉碎而引起的具有污染特征的金属铁。
对于该试验,使用常规用于研磨粉末以对其进行化学分析的Sodemi滚动球磨。该磨被悬挂安装在8个弹簧上,并导致包含试验颗粒的空心圆柱状碗、圆盘和游离滑动环运动。所述圆柱形钢粉碎碗(Z160C 12级)具有以下尺寸:高度50mm、内径139mm。圆盘为实心圆柱体钢(直径75mm、高度45mm),Z200C 12级,重1546克。圆柱形环(内径/外径95/120mm,高度45mm)由相同级别的Z200C 12钢形成,重1464克。
因此,样品的试验A包括以下步骤。
1、采用压缩空气清洗所述碗;
2、在粉碎碗与圆盘间引入在试验产品的粒度范围内的25克样品。在额定速率(1400rpm)下开启Sodemi磨4秒。然后采用刷子(50号)从粉碎碗中取出粉碎的产品,分析粒度分布。然后将产品在一组70mm直径网屏的筛子上筛分3分钟,采用以下网屏Ti:
T1+T2+T3表示由T1、T2和T3网屏(例如具有在1180/1400μm范围内的1180μm、1000μm和500μm孔)阻止的重量之和。以百分数给出的冲击强度(试验A)的值对应于除以参比试样的T1+T2+T3值的试样的T1+T2+T3值。因此,试验A得到的值越高,则冲击强度和破裂强度越好。
参比样品为水洗的样品,其与试样相当,但未经涂覆。因此,参比试验为与基础颗粒混合物基本相同的、经洗涤且未涂覆的试样。
试验B:颗粒与粘结剂间粘附的测定
试验B为测量由与典型有机粘结剂粘结的试验颗粒混合物构成的棒的断裂模量MOR,其中所述组合物模拟砂轮的性质。所述具有100mm×25mm×10mm尺寸棒的MOR采用以下方程通过三点弯曲评价:
MOR(兆帕)=(3FL)/(2e2l),其中
-F:力,以牛顿为单位;
-L:下辊的内轴分离,以mm为单位;
-e:棒的厚度,以mm为单位;
-l:棒的宽度:以mm为单位。
较小的MOR值意味着颗粒/粘结剂界面趋于破裂的趋势和砂轮的脆性;其对应于较差的使用性。
以百分数形式给出的试验B的结果通过用试样的MOR除以相应参比样品的MOR(由用于生产试样的经洗涤但未涂覆的基础颗粒混合物形成的棒的MOR(与有效地用于生产试样的基础颗粒具有相同的组成和尺寸))得到。
结果示于表1中。
表1
表1中,“nd”表示“无法测定”。
结果表明,所试验的本发明产品在试验B中表现出改进的性质,且在试验A中表现出相当的性质或改进的性质。
由表1可见,对Al-MgO基础颗粒的在先加热可以省略:实施例1A的结果与实施例1B的结果相似,且实施例2A与2B以及3A与3B也为类似情况。采用一次热处理得到这些改进的颗粒在经济上是有利的。
然而,对于除Al-MgO以外的基础颗粒,特别是对于氧化铝-氧化锆基础颗粒,热处理是有利的。
表1表明,可能仅存在于两个试验A和B之一上的有利效果通过基础颗粒上极低的二氧化硅百分数PS获得,特别地采用0.03%或更高的PS值。
实施例8表明,为实现颗粒粘附的改进,热处理并非总是必要的。
实施例11-13的对比表明,对于被测验的AZ颗粒,提高热处理温度至超过400℃并不会改进试验B的结果。此外,当该热处理温度升高时,试验A的结果显著变差。小于500℃或甚至小于450℃的热处理似乎是优选的。不期望束缚于该理论,本发明人利用以下情况解释该现象:在过高温度(特别是对于氧化铝-氧化锆颗粒)下的热处理会导致伴随有收缩的二氧化硅涂层烧结以及涂层裂纹的出现和/或氧化锆的相转变,影响颗粒的性质。
对于在涂覆二氧化硅涂层前进行热处理Al-MgO颗粒,并不必须在大于500℃温度下热处理。
明显地,本发明不限于提供作为示例性实施例的实施方案。
Claims (18)
1.一种涂覆研磨颗粒,包含采用获自二氧化硅的胶体悬浮体的涂层至少部分地覆盖的熔融基础颗粒,该涂层以基于涂层重量的重量百分数计包含大于95%的亲水性二氧化硅,该基础颗粒以基于基础颗粒重量的重量百分数计包含大于40%的氧化铝。
2.根据权利要求1所述的涂覆研磨颗粒,其中,所述涂层由水性二氧化硅胶体悬浮体获得。
3.根据权利要求1所述的涂覆研磨颗粒,其中,涂层的重量占基础颗粒重量大于0.01%且小于2%。
4.根据权利要求1所述的涂覆研磨颗粒,其中,涂层重量占基础颗粒重量大于0.1%且小于0.75%。
5.根据权利要求1所述的涂覆研磨颗粒,其中,涂层重量占基础颗粒重量小于0.3%。
6.根据权利要求1所述的涂覆研磨颗粒,其中,涂层不具有裂纹或碎片。
7.根据权利要求1所述的涂覆研磨颗粒,其中,基础颗粒以基于基础颗粒重量的重量百分数计包含至少1%的氧化锆、氧化镁、或氧化锆和氧化镁的混合物。
8.根据权利要求1所述的涂覆研磨颗粒,其中,基础颗粒以总计100%的重量百分数计具有以下化学分析之一:
A12O3: 45-65%
ZrO2+HfO2: 35-50%
其它: 0-12%
或者,
A12O3: 65-80%
ZrO2+HfO2: 15-30%
其它: 0-12.0%
或者,
A12O3: 92.0-98.5%
MgO: 1.5-6.5%
其它: <2.0%。
9.一种包含通过粘结剂粘结的、聚集或沉积在载体上的研磨颗粒的磨具,至少一部分所述研磨颗粒为根据权利要求1-8之一所述的颗粒。
10.一种生产涂覆研磨颗粒的方法,所述涂覆研磨颗粒中的每个为根据权利要求1所述的涂覆研磨颗粒,所述方法包括以下连续步骤:
1)获得或生产熔融基础颗粒,该熔融基础颗粒包含以基于基础颗粒重量的重量百分数计大于40%氧化铝;可选地对所述熔融基础颗粒在大于600℃且小于1550℃温度下进行在先热处理;
2)采用水性的含二氧化硅的胶体悬浮体至少部分地涂覆所述基础颗粒;
3)任选地,干燥由所述悬浮体润湿的基础颗粒,以形成基于二氧化硅的涂层。
11.根据权利要求10所述的方法,在任选的步骤3)后包括热处理步骤4),所述热处理在大于100℃且小于1550℃的温度下实施。
12.根据权利要求11所述的方法,所述热处理步骤在大于300℃且小于500℃的温度下实施。
13.根据权利要求10所述的方法,其中熔融基础颗粒在步骤2)前在大于600℃且小于1550℃温度下经历在先热处理步骤。
14.根据权利要求13所述的方法,所述在先热处理在大于800℃且小于1350℃的温度下实施。
15.根据权利要求10所述的方法,其中熔融基础颗粒在步骤2)前不经历任何热处理步骤。
16.根据权利要求10所述的方法,其中熔融基础颗粒在步骤2)和步骤3)之间不经历任何中间步骤,或者如果所述方法在可选的步骤3)之后包括在大于100℃并且小于1550℃的温度下进行的热处理步骤4),则在步骤2)和步骤4)之间不经历任何中间步骤。
17.根据权利要求10所述的方法,被调节为使得在步骤3)末期得到的涂覆颗粒为根据权利要求1-8中任一项所述的颗粒,或者如果所述方法在可选的步骤3)之后包括在大于100℃并且小于1550℃的温度下进行的热处理步骤4),则被调节为使得在步骤4)末期得到的涂覆颗粒为根据权利要求1-8中任一项所述的颗粒。
18.根据权利要求10所述的方法,其中,在干燥所述颗粒后实施200℃-1550℃温度下的热处理。
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2008
- 2008-03-21 FR FR0851831A patent/FR2928916B1/fr not_active Expired - Fee Related
-
2009
- 2009-03-19 EP EP09733596.2A patent/EP2257509B1/fr not_active Not-in-force
- 2009-03-19 BR BRPI0909500-4A patent/BRPI0909500B1/pt not_active IP Right Cessation
- 2009-03-19 US US12/933,236 patent/US9193631B2/en not_active Expired - Fee Related
- 2009-03-19 KR KR1020107023361A patent/KR101554957B1/ko active IP Right Grant
- 2009-03-19 CA CA2718789A patent/CA2718789A1/fr not_active Abandoned
- 2009-03-19 JP JP2011500275A patent/JP2011517712A/ja active Pending
- 2009-03-19 CN CN200980110251.2A patent/CN101977877B/zh not_active Expired - Fee Related
- 2009-03-19 WO PCT/FR2009/050471 patent/WO2009127796A1/fr active Application Filing
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Also Published As
Publication number | Publication date |
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BRPI0909500A2 (pt) | 2015-12-22 |
JP2011517712A (ja) | 2011-06-16 |
WO2009127796A1 (fr) | 2009-10-22 |
FR2928916B1 (fr) | 2011-11-18 |
US20110053478A1 (en) | 2011-03-03 |
KR101554957B1 (ko) | 2015-09-23 |
CA2718789A1 (fr) | 2009-10-22 |
EP2257509B1 (fr) | 2018-07-18 |
KR20100129323A (ko) | 2010-12-08 |
FR2928916A1 (fr) | 2009-09-25 |
CN101977877A (zh) | 2011-02-16 |
US9193631B2 (en) | 2015-11-24 |
BRPI0909500B1 (pt) | 2020-03-31 |
EP2257509A1 (fr) | 2010-12-08 |
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