CN106458760A - 陶瓷刚玉干燥、制粒和成型的生产工艺 - Google Patents

陶瓷刚玉干燥、制粒和成型的生产工艺 Download PDF

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CN106458760A
CN106458760A CN201480078517.0A CN201480078517A CN106458760A CN 106458760 A CN106458760 A CN 106458760A CN 201480078517 A CN201480078517 A CN 201480078517A CN 106458760 A CN106458760 A CN 106458760A
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王胜国
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Abstract

发明了一种大规模生产溶胶‑凝胶法磨料的新型干燥和成型方法和设备，极大地提高了生产效率和有效产出。单水氢氧化铝溶胶通过辊涂、刀涂或者挤出涂层等方法涂到载体背基上，在连续性干燥机如涂附磨具行业或者其它行业常用的布基处理烘箱，悬挂式烘箱或者转鼓干燥机上干燥到高固含量的凝胶状态，通过网纹辊或者丝网或者涂附磨具行业用的其它成型和制粒方法来成型和制粒。成型的凝胶进一步干燥、煅烧、浸渍和烧结成微晶陶瓷氧化铝磨料。

Description

陶瓷刚玉干燥、制粒和成型的生产工艺
技术领域
本发明涉及生产溶胶-凝胶法刚玉磨料的新型的方法和设备，可以极大地提高生产效率和可用大小的粒度，同时保持或者提高磨削性能。
背景技术
今天的磨料行业主要的焦点是研发低压和高压力应用下磨削速度高使用寿命长的更有效的磨料。众所周知，现在的氧化铝磨料包括如棕刚玉、白刚玉、单晶刚玉和半脆刚玉等电熔刚玉磨料和溶胶-凝胶法烧结刚玉磨料。电熔刚玉磨料在倾倒炉中熔化，倒入成块，块体大小适合设计的冷却速度和晶体尺寸。由于大批量生产和廉价的原材料，电熔刚玉的成本很低，广泛应用于涂附和固结磨具中，但是其磨削性能包括磨削速度和总磨削量或者磨削比是有限的。
从1980年代早期开始，溶胶-凝胶技术开始用于提高氧化铝磨料的性能，对涂附磨具和固结磨具行业产生了冲击性的影响。溶胶-凝胶法工艺使得氧化铝显微结构的控制程度比电熔法工艺大的多。所以溶胶-凝胶法磨料的晶体尺寸比电熔法小几个数量级，从而韧性提高，磨削性能也得以提高。
在过去的几十年中，大量的工作用于如何提高溶胶-凝胶法磨料的磨削性能。这些工作包括探索如改性剂和烧结助剂和晶种的添加剂和优化成型和烧结工艺等生产过程。这些工作在这些专利里都有说明，如美国专利号US 4,314,827，US 4,518,397，US 4,623,364，US 4,770,671，4,799,938，4,848,041，US 4,881,951，US 4,964,883，US 5,034,360，US 5,090,968，US 5,106,791，US 5,190,567，US 5,194,073，US 5,227,104，US 5,244,477，US 5,431,704，US 5,453,104，US 5,489,204，US 5,531,799，US 5,660,604，US 5,984,988，US 6,258,141，US 6,802,878等。从2009年以来，3M开发了第2代Cubitron II溶胶-凝胶法磨料，通过成型技术革命性地提高了磨削性能。
传统的溶胶-凝胶法氧化铝磨料生产工艺（如引用专利所描述）包括下述步骤：
（1）分散溶胶制备：通常需要30-60分钟（2）分散液凝胶：10-30分钟，（3）干燥或者破碎或者成型：对于传统的干燥/破素工艺，溶胶或者凝胶在托盘里70-100摄氏度干燥24-48小时，对于美国专利号US 5,372,620描述的挤出条干燥工艺，是在75-80度干燥24-72小时。（4）煅烧：500-800摄氏度煅烧10～60分钟。（5）烧结：1300-1500度烧结5～120分钟。其它可选择的工艺包括抽真空，离心分离和浸渍等。
我们可以轻易地看出，溶胶-凝胶法磨料的生产过程是间歇式生产，工艺瓶颈是干燥过程。干燥步骤占了总生产时间的80-90％以上。如果我们可以减少干燥时间，溶胶-凝胶法磨料就适合大规模生产，制造成本可以大大降低。
在溶胶-凝胶法磨料的传统生产工艺中，干燥步骤是很关键的。干燥温度越低，烧结磨料的密度越高。对于托盘干燥工艺，因为溶胶和凝胶的厚度是几厘米，干燥温度和时间要非常小心地控制以避免产生气泡或者泡沫，这回影响烧结密度和磨削性能。所以托盘干燥温度低，通常为70-90摄氏度，干燥时间长，24-48小时。所以生产效率很低。托盘干燥通常也需要破碎步骤，在破碎过程中会产生一些细粒度磨料（细于P120或F120），而磨料粒度细于P120或F120，溶胶-凝胶法磨料相对于电熔法磨料优势不明显。所以这些细磨料必须回收或者丢弃，而这会增加生产成本。
美国专利申请US 2009/0165394描述了一种丝网印刷工艺来对凝胶成型和干燥。干燥时间缩短到几分钟，但是干燥烘箱很短，如专利申请里面所写，只有27英尺，包括2个区域，不是悬挂式烘箱或多层带式干燥机那样生产效率高，所以涂胶/干燥速度很慢，同时涂胶厚度很薄，小于1毫米，所以产量有限，不适合大规模生产。
在过去30年间，很少有努力花在如何降低溶胶-凝胶法磨料的成本和改进溶胶-凝胶法磨料的生产工艺使之适合大规模生产。所以溶胶-凝胶法磨料的成本很高，比电熔法刚玉昂贵很多，比如在中国市场，电熔棕刚玉或者白刚玉磨料的售价大约是1美元/公斤，而溶胶-凝胶法磨料的售价约20-30美元/公斤，这限制了溶胶-凝胶法磨料的应用，只适合成本/效益合理的场合。溶胶-凝胶法磨料的典型应用包括不锈钢、高镍合金钢和热敏感金属。自从1981年发明溶胶-凝胶法磨料以来，全世界溶胶-凝胶法磨料的总年产量小于1万吨，而全世界传统电熔刚玉磨料的年产量超过100万吨。
所以，很有必要降低溶胶-凝胶法磨料的原材料成本，在陶瓷刚玉磨料生产过程中提高生产效率和可用粒度磨料的产率，同时保持或者提高其磨料性能，使得我们可以使其和传统电熔刚玉磨料相比更有竞争性。在本发明中，我们侧重如何提高生产效率和可用粒度磨料的产率，同时保持或者提高其磨料性能。如何降低原材料成本由另外一个发明来解决。
发明内容
本发明的目的之一是提供一种干燥和成型方法与/或设备来提高溶胶-凝胶法磨料生产过程中的生产效率和可用粒度范围内磨料的产率。溶胶-凝胶法磨料的生产过程瓶颈是干燥步骤，而溶胶-凝胶法磨料的成型可以根据磨削压力、磨削速度和金属类型等来调整磨削性能。
在本发明中，溶胶-凝胶法磨料的干燥、成型和制粒工艺得以改进。发明的溶胶-凝胶法磨料的生产工艺说明如下：
单水氢氧化铝溶胶或者凝胶（通过刀涂、辊涂或挤出）涂胶到载体背基如聚四氟乙烯或者聚丙烯、涤纶或者其它耐热的塑料薄膜背基或者有离型涂层的纸基上（这些背基在涂附磨具行业很常用），然后在连续式干燥机如广泛用于涂附磨具行业的悬挂式烘箱上干燥到高固含量凝胶状态，再通过涂附磨具行业常用的网纹辊制粒或者成型，在第2段悬挂式烘箱里，凝胶干燥到不太粘状态，但是也不是太干以致失去粘结力从载体背基上掉下来。然后部分干燥的凝胶在对流烘箱包括但不限于布基处理烘箱或者多层带式干燥机上进一步干燥。干燥时间大大减少使得溶胶-凝胶法磨料的大规模生产成为可能，同时因为在高固含量凝胶态时进行制粒和成型，使得可用粒度范围的磨料产量提高。另外，磨料的磨削性能也可用网纹辊和丝网来控制溶胶-凝胶法磨料的长度、宽度和厚度来调整不同磨削应用如磨削压力，速度和金属类型等条件下时磨料的磨削性能。
附图说明
图1是生产溶胶-凝胶法磨料的制造工艺。
图2是生产溶胶-凝胶法磨料的制造工艺。
图3是溶胶-凝胶法磨料的成型和制粒的网纹辊。
图4是溶胶-凝胶法磨料的成型和制粒的网纹辊/压花辊。
图5是溶胶-凝胶法磨料的成型和制粒的网纹辊。
图6是溶胶-凝胶法磨料的成型和制粒的网纹辊。
图7是溶胶-凝胶法磨料的成型和制粒的网纹辊/压花辊。
图8是成型和制粒用的涂覆聚四氟乙烯的玻璃纤维网。
具体实施方式
溶胶-凝胶法磨料的整个生产过程如图1和2所示。具体的工艺步骤表述如下：
（1）溶胶制备：溶胶分散体通过混合去离子水、高度分散的单水氢氧化铝、硝酸、亚微米尺寸的alpha氧化铝晶种和其它如稀土等可以改变烧结性能和显微结构的助剂制备。混合设备可以是高剪切搅拌机或球磨机或砂磨机。固含量最好在25％～30％.。
（2）在砂带生产线底胶台将溶胶涂胶到载体背基上：根据溶胶的粘度，将步骤（1）制备的溶胶用刀涂、辊涂或者挤出方法涂到比如塑料薄膜背基上，这些背基包括但不限于聚四氟乙烯、涤纶或者聚丙烯或者有离型涂层的纸基上。涂布宽度通常是1.4-1.6米，在涂附磨具行业很普遍。涂胶厚度根据溶胶粘度、粒度大小、生产效率/产量、干燥温度和时间和磨削性能等条件而不同，涂胶厚度范围通常是0.2-5毫米。比如对于P36目，对于磨削性能较好的涂胶厚度是0.4-0.8毫米。通常薄的涂胶更适合低压力磨削应用，比如钢纸磨片，百叶片和木材加工，而厚的涂胶更适合高磨削压力应用和高生产效率/产量。
（3）第1节悬挂式烘箱干燥到高固含量凝胶状态：干燥温度和时间根据不同的涂胶厚度和产品而不同。砂带生产线的第1节悬挂式烘箱，通常有2-3个加热区。温度可设在70-120度，干燥时间是30-120分钟。干燥温度和时间的调整的标准是避免在干燥过程中产生气泡或者泡沫。通常干燥温度低干燥时间长，磨料烧结的密度更高，磨削性能越好。在第1节悬挂式烘箱中，溶胶胶干燥到高固含量凝胶态，有点粘，可以通过网纹辊、丝网和挤出成型。在第1节悬挂式烘箱干燥后，固体含量最好控制在40-65％，取决于下1步的加工要求。
（4）网纹辊对溶胶-凝胶法磨料成型和制粒：经过砂带生产线第1节悬挂式烘箱干燥后，高固含量凝胶进入砂带生产线复胶涂胶台。网纹辊对凝胶挤压，对磨料进行成型和制粒，和金字塔砂带生产过程的成型类似。中国市场可以买到的网纹辊和压花辊如图3到图7所示。所有的图片都只是举例，并不是特指，任何涂附磨具或者其它行业用的网纹辊/压花辊都可在本发明应用。成型和制粒也可通过将图8所示的涂覆聚四氟乙烯的玻璃纤维网布压入高固含量凝胶涂层来加工。网布中长方形的大小不指定，长/宽比可从1到2或3，取决于应用条件，厚度取决于磨削应用条件和生产效率。其它成型和制粒方法如模切也适合用于生产过程。成型和制粒后，凝胶进入砂带生产线第2节悬挂式烘箱以便进一步干燥。干燥状态控制到有点粘，但不是特别干到失去粘结力一致从载体布基上掉落下来，在传统砂带生产线的绕卷平台，载体背基上干燥的成型凝胶与下1道干燥设备相连。
（5）在多层带式干燥机或其它水平对流烘箱进一步干燥或成型：砂带生产线第2节悬挂式烘箱干燥后的载体上的凝胶进入对流烘箱如涂附磨具行业用的布处理烘箱，或多层带式干燥机或转鼓式干燥机，使凝胶干燥成固体颗粒。干燥温度可从70到130摄氏度，干燥时间是2-20分钟。干燥后，干燥的颗粒可从载体背基上刮下来，以备下一道工序如煅烧，浸渍和烧结。
整个干燥和成型工艺也可在转鼓式干燥机或多层带式干燥机上生产。转鼓干燥机占地更小，生产效率差不多，但是如果加热蒸汽压力高了，有在溶胶中产生气泡或泡沫的风险，转鼓温度应控制在不在溶胶或者凝胶中产生泡沫。网纹辊或丝网也可在多层带式或者转鼓式干燥工艺中用于成型和制粒。
（6）煅烧：干燥的凝胶在回转炉里进一步煅烧来出去残余水分和其他挥发物。较好的煅烧温度是500～850℃，煅烧时间是10～60分钟。
（7）烧结：煅烧颗粒加到碳化硅管的旋转炉中烧结来使颗粒致密化。较好的烧结温度是1300～1500℃，较好的烧结时间是5-120分钟。

Claims (11)

1.一种溶胶-凝胶法氧化铝磨料，其特征在于，在生产过程中，勃姆石溶胶或者凝胶涂胶到载体背基上，在连续式干燥机包括但不限于砂带生产线悬挂式烘箱或其它涂附磨具行业或者其它行业常用的如布处理烘箱，转鼓干燥机和多层带式干燥机上干燥到高固含量凝胶状态，然后用网纹辊、压花辊或者涂附磨具或者其它行业常用的成型、制粒和切割设备成型或制粒，再在水平对流烘箱或者多层带式干燥机上进一步干燥。
2.根据权利要求1所述的溶胶-凝胶法氧化铝磨料，其特征在于，其中的载体背基包括但不限于如聚四氟乙烯、聚酯，聚丙烯或有机硅塑料薄膜，或者带有离型涂层的纸基。
3.根据权利要求1所述的溶胶-凝胶法氧化铝磨料，其特征在于，整个干燥、成型和制粒过程在转鼓式干燥机上进行。
4.根据权利要求1所述的溶胶-凝胶法氧化铝磨料，其特征在于，整个干燥、成型和制粒过程在多层带式干燥机上进行。
5.根据权利要求1所述的溶胶-凝胶法氧化铝磨料，其特征在于，干燥过程在砂带生产线悬挂式烘箱或者水平对流烘箱或者转鼓式干燥机或者多层带式干燥机或者其它连续式干燥机上进行，溶胶或者凝胶涂胶到载体背基上用网纹辊或者丝网或者其它成型/制粒技术来成型。
6.根据权利要求1所述的溶胶-凝胶法氧化铝磨料，其特征在于，整个干燥、成型和制粒过程在悬挂式烘箱、转鼓式干燥机、多层带式干燥机、涂胶和挤出设备和如网纹辊和丝网等成型和制粒设备组合而成的设备上进行。
7.根据权利要求1所述的溶胶-凝胶法氧化铝磨料，其特征在于，成型和制粒是用网纹辊、压花辊和丝网进行加工的。
8.一种具有不同形状和大小的溶胶凝胶法氧化铝磨料，其特征在于，干燥和成型工艺如权利要求1到7所描述。
9.一种通过氧化铝粉烧结而成的磨料，特征在于磨料通过根据权利要求1到7的干燥、成型和制粒方法生产而得。
10.一种固结磨具产品，特征在于，它的磨料根据权利要求1到9的方法生产而得。
11.一种涂附磨具产品，特征在于，它的磨料根据权利要求1到9的方法生产而得。
CN201480078517.0A 2014-05-02 2014-05-02 陶瓷刚玉干燥、制粒和成型的生产工艺 Pending CN106458760A (zh)

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