CN106660872A - 用于高压高温压机的合成垫片材料 - Google Patents

用于高压高温压机的合成垫片材料 Download PDF

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Publication number
CN106660872A
CN106660872A CN201580018418.8A CN201580018418A CN106660872A CN 106660872 A CN106660872 A CN 106660872A CN 201580018418 A CN201580018418 A CN 201580018418A CN 106660872 A CN106660872 A CN 106660872A
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Prior art keywords
gasket material
weight
adhesive
clay mineral
hard material
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CN201580018418.8A
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Inventor
R·克拉克
G·哈兰德
M·帕沃尼
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Morgan Advanced Ceramics Inc
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Morgan Advanced Ceramics Inc
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Publication of CN106660872A publication Critical patent/CN106660872A/zh
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Abstract

用于高压高温压机的垫片材料，其包含：‑一定比例的粘土矿物‑一定比例的硬质材料，用于提高粘土矿物的粘度‑一定比例的粘合剂，选自硼酸盐粘合剂、磷酸盐粘合剂及其混合物。

Description

用于高压高温压机的合成垫片材料
本发明涉及用于高压高温(HPHT)压机的合成垫片材料，并且涵盖由这种材料制成的垫片。
HPHT压机被应用于若干应用中，但是其中的一个主要应用在于合成金刚石的制造或生长。在这样的应用中，需要使垫片材料可以耐受所涉及的高压和高温(例如约1500℃的温度和6GPa的压力或者更大)。
典型地，这样的垫片可以具有不同的形式(例如但不限于立方形、圆柱形或者更加复杂的形式，以适应压机的几何形状)。
这样的垫片材料及其制备方法公开于US5858525和US6338754，其内容在本文通过引用而被引入。
US5858525公开了在垫片组合物中使用粘合剂，所述粘合剂包括“包括硅酸钠、丙烯酸共聚物、阿拉伯胶、波特兰水泥等的材料组”。US6338754使用硅酸钠粘合剂。本申请人提出改进的粘合剂体系。
本发明包括垫片材料，其包含：
·一定比例的粘土矿物
·一定比例的硬质材料，用于提高粘土矿物的粘度
·一定比例的粘合剂，选自硼酸盐粘合剂、磷酸盐粘合剂及其混合物。
粘土矿物是指细小粒度的硅酸盐材料。粘土矿物的非穷举列表在US5858525中提供，其中所列出的通过引用而被引入。
粘土矿物与硬质材料的比例可以(但并不必须)位于1-10∶10-1的相应比率中。
粘合剂与粘土矿物和硬质材料的组合量的比例可以(但并不必须)位于1∶1-100的相应比率中。
粘土矿物、硬质材料和粘合剂的总量可以占垫片材料的70-100重量％范围。
粘土矿物可以(但并不必须)是选自由镁黄长石、硅铍石(bertandite)、高岭石、叶蜡石、葡萄石、镁铝榴石、钙沸石、蛇纹岩、滑石、黝帘石及其混合物构成的组的粘土。
硬质材料可以(但并不必须)是选自由二氧化硅、锆、石榴石、碳化硅、碳化硼、氧化铝、氧化锆、蓝晶石、多铝红柱石及其混合物构成的组。
硼酸盐粘合剂体系可以(但并不必须)是硼酸和水的溶液，包括液体和固体两种形式。由这样的混合物形成的溶液可以是过饱和的形式，加热至高于室温，并在高温下与其它成分结合。
磷酸盐粘合剂可以(但并不必须)是通过使磷酸与贫溶氧化物或氧化物矿物的反应来形成的。磷酸盐粘合剂可以包含固体和液体两种组分，但是便利地，可以使用仅包含固体组分的粘合剂。典型的磷酸盐粘合剂包括磷酸镁和磷酸铝，但是可以使用其它的磷酸盐粘合剂。
与硅酸钠相比，硼酸盐和磷酸盐粘合剂的一个优点在于设备清洁能力，一旦硅酸钠凝固，其就需要被切除。使用硼酸盐粘合剂例如硼酸，或者磷酸盐粘合剂，热水就可以清除设备的未凝固材料。
垫片材料的制造可以包括分散固体组分、使其共混和压制的步骤。
固体组分可被分散于溶液(例如硼酸/硼砂的水溶液)中，并喷雾干燥以提供分散的并充分混合的材料，其将在压力下流动。一旦粘合剂凝固，将避免这样的易于流动。
固体组分可被粒化以确保分布的一致性和改善的压制性能。
压制可以包括单轴压制或者等压压制，或者在压制产品中提供需要的密度的任何形式的压制。
典型的组成可以是：
粘土矿物60-90重量％
硬质材料5-35重量％
粘合剂5-25重量％
并且例如可以包含：
粘土矿物65±4重量％
硬质材料15±5重量％
粘合剂5-25重量％。
粘土矿物和硬质材料的典型组合包括但不限于：
·滑石和石榴石
·叶蜡石和石榴石
·滑石和锆
·叶腊石和锆
然而，如下的组合通常应当被认为是落入本发明的范围内：
·每种粘土矿物或其组合；与
·每种硬质材料及其组合；与
·每种硼酸盐或磷酸盐粘合剂及其组合。
粘土和硬质材料可以具有细小粒度，例如-200目或者-230目或者-270目或者-325目或者甚至更小。然而，更加粗糙的粒度并未被排除。
实施例
在下文的实施例中：
·滑石被用作粘土矿物[商用等级“Nicron554”，购自Emerys。其为-325目材料，平均粒度为3微米]；
·使用-220目碳化硅，尽管更小的材料为优选的；
·实施例#1至#3为预言的实施例。
下文示出的实施例#2、#4和#5的粉末通过使用热水来制造以溶解硼酸，随后添加其它成分，之后干燥以形成粉末。
随后在实验室单轴Carver压机中将这种粉末压制到约103MPa(15,000psi)的压力，从而形成用于进行评价的试样盘。
发现所制备的盘为固结的。
通过在研钵和碾槌中压碎回到可压制粉末来评估盘的脆性，其显示出更高的粘土含量(在这些例子的情况中为滑石)改善了材料，实施例#4和#5与实施例#2相比表现得更加易碎。
#1 #2 #3 #4 #5
滑石 65％ 65％ 45％ 45％ 60％
B4C 15％ 0％ 25％ 0％ 0％
SiC 0％ 15％ 0％ 25％ 20％
硼酸 20％ 20％ 30％ 30％ 20％
总计： 100％ 100％ 100％ 100％ 100％
对于磷酸盐粘合剂，预期的实施方案包括：
这些实施例和预期的实施方案指示根据本发明可以制备的材料，并且本发明不限于此。
权利要求书(按照条约第19条的修改)
1.用于高压高温压机的垫片材料，其包含：
i.一定比例的粘土矿物
ii.一定比例的硬质材料，用于提高粘土矿物的粘度
iii.一定比例的粘合剂，选自硼酸盐粘合剂、硼酸盐粘合剂和磷酸盐粘合剂的混合物。
2.如权利要求1所述的垫片材料，其中粘土矿物与硬质材料的比例位于1-10∶10-1的相应比率中。
3.如权利要求1或2所述的垫片材料，其中粘合剂与粘土矿物和硬质材料的组合量的比例位于1∶1-100的相应比率中。
4.如权利要求1至3任一项所述的垫片材料，其中粘土矿物、硬质材料和粘合剂的总量占垫片材料的70-100重量％范围。
5.如权利要求1至4任一项所述的垫片材料，其包含：
粘土矿物60-90重量％
硬质材料5-35重量％
粘合剂5-25重量％。
6.如权利要求5所述的垫片材料，其包含61重量％或更多的粘土矿物。
7.如权利要求6所述的垫片材料，其包含：
粘土矿物65±4重量％
硬质材料15±5重量％
粘合剂5-25重量％。
8.如权利要求1至7任一项所述的垫片材料，其中粘土矿物选自由镁黄长石、硅铍石、高岭石、叶蜡石、葡萄石、镁铝榴石、钙沸石、蛇纹岩、滑石、黝帘石及其混合物构成的组。
9.如权利要求1至8任一项所述的垫片材料，其中硬质材料选自由二氧化硅、锆、石榴石、碳化硅、碳化硼、氧化铝、氧化锆、蓝晶石、多铝红柱石及其混合物构成的组。
10.制备如权利要求1至9任一项所述的垫片材料的方法，包括分散固体组分、使其共混和压制的步骤。
11.如权利要求10所述的方法，其中分散和共混固体组分包括将固体组分分散至溶液中以形成悬浮液，并喷雾干燥所述悬浮液。
12.如权利要求10或11所述的方法，其中固体组分被粒化。
13.由权利要求1至9任一项的垫片材料形成的垫片。

Claims (13)

1.用于高压高温压机的垫片材料，其包含：
i.一定比例的粘土矿物
ii.一定比例的硬质材料，用于提高粘土矿物的粘度
iii.一定比例的粘合剂，选自硼酸盐粘合剂、磷酸盐粘合剂及其混合物。
2.如权利要求1所述的垫片材料，其中粘土矿物与硬质材料的比例位于1-10∶10-1的相应比率中。
3.如权利要求1或2所述的垫片材料，其中粘合剂与粘土矿物和硬质材料的组合量的比例位于1∶1-100的相应比率中。
4.如权利要求1至3任一项所述的垫片材料，其中粘土矿物、硬质材料和粘合剂的总量占垫片材料的70-100重量％范围。
5.如权利要求1至4任一项所述的垫片材料，其包含：
粘土矿物60-90重量％
硬质材料5-35重量％
粘合剂5-25重量％。
6.如权利要求5所述的垫片材料，其包含61重量％或更多的粘土矿物。
7.如权利要求6所述的垫片材料，其包含：
粘土矿物65±4重量％
硬质材料15±5重量％
粘合剂5-25重量％。
8.如权利要求1至7任一项所述的垫片材料，其中粘土矿物选自由镁黄长石、硅铍石、高岭石、叶蜡石、葡萄石、镁铝榴石、钙沸石、蛇纹岩、滑石、黝帘石及其混合物构成的组。
9.如权利要求1至8任一项所述的垫片材料，其中硬质材料选自由二氧化硅、锆、石榴石、碳化硅、碳化硼、氧化铝、氧化锆、蓝晶石、多铝红柱石及其混合物构成的组。
10.制备如权利要求1至9任一项所述的垫片材料的方法，包括分散固体组分、使其共混和压制的步骤。
11.如权利要求10所述的方法，其中分散和共混固体组分包括将固体组分分散至溶液中以形成悬浮液，并喷雾干燥所述悬浮液。
12.如权利要求10或11所述的方法，其中固体组分被粒化。
13.由权利要求1至9任一项的垫片材料形成的垫片。
CN201580018418.8A 2014-04-02 2015-04-01 用于高压高温压机的合成垫片材料 Pending CN106660872A (zh)

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