JP2011507718A - 成形され断裂された研磨粒子及びこの研磨粒子を使用する研磨物品、並びにそれらの作製方法 - Google Patents
成形され断裂された研磨粒子及びこの研磨粒子を使用する研磨物品、並びにそれらの作製方法 Download PDFInfo
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- JP2011507718A JP2011507718A JP2010540790A JP2010540790A JP2011507718A JP 2011507718 A JP2011507718 A JP 2011507718A JP 2010540790 A JP2010540790 A JP 2010540790A JP 2010540790 A JP2010540790 A JP 2010540790A JP 2011507718 A JP2011507718 A JP 2011507718A
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
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- C—CHEMISTRY; METALLURGY
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
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- Y10T428/24372—Particulate matter
- Y10T428/24413—Metal or metal compound
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
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Abstract
【選択図】 図4
Description
三角形の研磨粒子及びこれらの三角形の研磨粒子を使用する研磨物品は、米国特許第5,201,916号(バーグ(Berg))、同第5,366,523号(ローウェンホースト(Rowenhorst))、及び同第5,984,988号(バーグ(Berg))に開示されている。一実施形態において、この研磨粒子の形は正三角形を含む。三角形の研磨粒子は、優れた削り取りレートを有する研磨物品の製造に有用である。
本明細書で使用される「含む/備える/具備する(comprise)」、「有する(have)」、及び「含む(include)」という言葉の形態は、法的に同等かつ非限定的である。したがって、記載された要素、機能、工程、又は制限に加えて、記載されていない追加的な要素、機能、工程、又は制限が存在する場合がある。
図4及び5を参照すると、研磨粒子20が図示されている。研磨粒子20は、複数のαアルミナ研磨破片21に成形される断裂したαアルミナ研磨粒子を含む。図1を参照すると、成形型34内の前駆体研磨粒子23が図示されている。それぞれのαアルミナ研磨破片21は、少なくとも第1の正確に成形された面22と、第1の正確に成形された面と既定の角度αで交差する第2の正確に成形された面24と、この第1の正確に成形された面22と対向する第3の表面26と、断裂表面28と、を含む。第1の正確に成形された面22は、成形型34内の空洞32の底面30との接触によって形成され得る。図1では、成形型34の空洞32の一部分のみが断面で示されている。典型的には、成形型34は、αアルミナ研磨破片21を経済的に製造するために複数の空洞を有する。第1の正確に成形された面22は、空洞32の底面30の表面の仕上げ及び形を実質的に複製する。
第一のプロセス工程は、αアルミナに転換可能な粒子を含有するシードされた又はシードされていない研磨材分散液のいずれかを提供する工程を伴う。これらの粒子は揮発性成分を含む液体中に分散される。一実施形態において、揮発性成分は水である。研磨材分散液は、成形型の空洞を充填して成形型表面を複製することを可能にするために研磨材分散液の粘性を十分に低くするために十分な量でありながらも、後に成形型の空洞から液体を除去することを実現不可能なほど高価にしない程度の量の液体を含まなくてはならない。研磨材分散液は、αアルミナに転換可能な、酸化アルミニウム一水和物(ベーマイト)のような粒子を2重量%〜90重量%、及び水のような揮発性成分を少なくとも10重量%、又は50重量%〜70重量%、又は50重量%〜60重量%含む。逆に、いくつかの実施形態における研磨材分散液は、固体を30重量%〜50重量%、又は40重量%〜50重量%含有する。
別の観点において、本開示は、結合剤と複数の研磨粒子とを含む研磨物品を提供し、研磨粒子の少なくとも一部分は本開示に従って作製されたαアルミナ研磨破片である。代表的な研磨材物品としては、被覆された研磨物品、結合研磨材物品(例えばホイール)、不織研磨材物品、及び研磨ブラシが挙げられる。被覆された研磨物品は、典型的に、第1主表面と、反対側の第2主表面とを有する裏材を含み、結合剤(メークコート)と複数の研磨粒子が、前記第1主表面の少なくとも一部分の上に研磨層を形成する。いくつかの実施形態では、研磨物品中の研磨粒子の総重量に対して、少なくとも5重量%、10重量%、15重量%、20重量%、25重量%、30重量%、35重量%、40重量%、45重量%、50重量%、55重量%、60重量%、65重量%、70重量%、75重量%、80重量%、85重量%、90重量%、95重量%、あるいは100重量%さえもの研磨物品中の研磨粒子が本開示によるαアルミナ研磨破片である。
次の手順を用いて研磨ディスクを試験した。評価用の直径17.8cm(7インチ)の研磨ディスクを、17.8cm(7インチ)のリブ付きディスクパッド平面皿(3Mカンパニー(3M Company)(ミネソタ州セントポール)から入手した(「80514エクストラハードレッド(80514 Extra Hard Red)」)を装備した回転研削盤に取り付けた。次に、研削盤を稼動して、44.5N(10ポンド)の荷重下の、1.9×1.9cm(0.75×0.75インチ)の予め計量された1045スチールバーの末端面を付勢した。この荷重下でのこの加工対象物に対する研削盤の結果的な回転速度は5000rpmであった。この加工対象物を、これらの条件下で合計36回20秒研削インターバル(パス)で研磨した。それぞれの20秒インターバルの後、加工対象物を室温まで冷却させ、計量して、研磨動作による削り取りを測定した。試験結果は、それぞれのインターバルでのインクリメンタルな削り取り、及び取り除かれた合計削り取りとして報告した。所望により、好適な設備を用いて試験を自動化することができる。
Claims (37)
- 複数の空洞を有する成形型を提供する工程と、
前記複数の空洞を研磨材分散液で充填する工程であり、前記研磨材分散液が、αアルミナに転換可能な液体中の粒子を含み、前記液体が揮発性成分を含む、工程と、
前記研磨材分散液が前記複数の空洞の中にあるうちに前記研磨材分散液から前記揮発性成分の少なくとも一部分を除去することによって、既定のサイズを有する複数の前駆体研磨粒子を形成する工程と、
前記複数の前駆体研磨粒子が複数の空洞の中にあるうちに前記複数の前駆体研磨粒子の少なくとも過半数を少なくとも2つの片に断裂することによって、複数の断裂した前駆体研磨粒子を形成する工程と、を含む、方法。 - 前記複数の断裂した前駆体研磨粒子を前記複数の空洞から取り出す工程と、前記断裂した複数の前駆体研磨粒子をか焼することによって、か焼された断裂した複数の前駆体研磨粒子を形成する工程と、前記か焼された断裂した複数の前駆体研磨粒子を焼結することによって、複数のαアルミナ研磨破片を形成する工程と、を含む、請求項1に記載の方法。
- 前記複数のαアルミナ研磨破片を研磨工業規格公称等級に等級分けする工程を含む、請求項2に記載の方法。
- 前記複数のαアルミナ研磨破片を公称スクリーニング等級にスクリーニングする工程を含む、請求項2に記載の方法。
- 前記断裂する工程が、前記揮発性成分の沸点を越す温度で乾燥することを含む、請求項1に記載の方法。
- 前記揮発性成分が水を含み、前記温度が約105℃〜約150℃である、請求項5に記載の方法。
- 前記断裂する工程が、前記複数の前駆体研磨粒子の75%〜100%を少なくとも2つの片に断裂することを含む、請求項6に記載の方法。
- 前記断裂する工程が、前記複数の前駆体研磨粒子の75%〜100%を少なくとも2つの片に断裂することを含む、請求項1に記載の方法。
- 前記断裂する工程が、約90℃〜約165℃の温度で乾燥することを含む、請求項1に記載の方法。
- 前記成形型がポリプロピレンを含み、前記成形型の前記複数の空洞に離型剤が適用されない、請求項1に記載の方法。
- 前記複数の空洞が濡れ張力を備え、前記濡れ張力が約33ダイン/cm未満である、請求項10に記載の方法。
- 前記断裂する工程が、約105℃〜約120℃の温度で乾燥することを含む、請求項11に記載の方法。
- 前記複数の空洞が正三角形を含む、請求項12に記載の方法。
- 前記複数の空洞が正三角形を含む、請求項1に記載の方法。
- 前記断裂する工程が、前記複数の空洞のそれぞれに約2〜4の断裂した複数の前駆体研磨粒子を生成する、請求項14に記載の方法。
- 前記断裂する工程が、一対のニップロールを通して前記成形型を移動することを含む、請求項1に記載の方法。
- 前記成形型がポリプロピレンを含み、前記断裂する工程が前記成形型を曲げることを含む、請求項1に記載の方法。
- 前記複数の空洞のそれぞれが濡れ張力を備え、前記濡れ張力が約33ダイン/cm未満である、請求項1に記載の方法。
- 前記成形型がポリプロピレンを含み、前記成形型の前記複数の空洞に離型剤が適用されない、請求項1に記載の方法。
- 前記複数の空洞が濡れ張力を備え、前記濡れ張力が約33ダイン/cm未満である、請求項19に記載の方法。
- 研磨材であって、研磨工業規格公称等級又は公称スクリーニング等級を有する複数のαアルミナ研磨破片を含み、前記複数のαアルミナ研磨破片が第1の正確に成形された面と、前記第1の正確に成形された面と既定の角度αで交差する第2の正確に成形された面と、前記第1の正確に成形された面と対向する第3の面と、断裂した面と、を備える、研磨材。
- 研磨工業規格公称等級が、ANSI 4、ANSI 6、ANSI 8、ANSI 16、ANSI 24、ANSI 36、ANSI 40、ANSI 50、ANSI 60、ANSI 80、ANSI 100、ANSI 120、ANSI 150、ANSI 180、ANSI 220、ANSI 240、ANSI 280、ANSI 320、ANSI 360、ANSI 400、及びANSI 600からなる群から選択される、請求項21に記載の研磨材。
- 前記公称スクリーニング等級が、−18+20、−20+25、−25+30、−30+35、−35+40、−40+45、−45+50、及び−50+60からなる群から選択される、請求項21に記載の研磨材。
- 結合された研磨物品、被覆された研磨物品、不織研磨物品、及び研磨ブラシからなる群から選択される研磨物品を形成する結合剤を含む、請求項21に記載の研磨材。
- 前記複数のαアルミナ研磨破片が、複数の三角形の空洞を有する成形型内で形成される、請求項24に記載の研磨材。
- 前記複数の三角形の空洞のそれぞれが正三角形を含む、請求項25に記載の研磨材。
- 約2〜4のαアルミナ研磨破片が前記複数の三角形の空洞のそれぞれに形成される、請求項24に記載の研磨物品。
- 裏材の第1の主表面にあるメークコートを含み、前記複数のαアルミナ研磨破片が前記メークコートに部分的に埋め込まれて研磨層を形成し、サイズコートが前記研磨層を被覆するものであり、前記研磨層が前記複数のαアルミナ研磨破片を少なくとも5重量%含む、請求項21に記載の研磨材。
- 前記研磨層が前記複数のαアルミナ研磨破片を約60〜100重量%含む、請求項28に記載の研磨材。
- 前記研磨層が前記複数のαアルミナ研磨破片を約100重量%含む、請求項28に記載の研磨材。
- 前記複数のαアルミナ研磨破片が、複数の三角形の空洞を有する成形型内で形成される、請求項28に記載の研磨材。
- 前記複数の三角形の空洞のそれぞれが正三角形を含む、請求項31に記載の研磨材。
- 前記複数のαアルミナ研磨破片が、ANSI 4、ANSI 6、ANSI 8、ANSI 16、ANSI 24、ANSI 36、ANSI 40、ANSI 50、ANSI 60、ANSI 80、ANSI 100、ANSI 120、ANSI 150、 ANSI 180、ANSI 220、ANSI 240、ANSI 280、ANSI 320、ANSI 360、ANSI 400、及びANSI 600からなる群から選択される研磨工業規格公称等級を備える、請求項28に記載の研磨材。
- 前記研磨層が前記複数のαアルミナ研磨破片を約60〜100重量%含む、請求項33に記載の研磨材。
- 前記研磨層が前記複数のαアルミナ研磨破片を約100重量%含む、請求項33に記載の研磨材。
- 前記既定の角度αが約91度〜約120度である、請求項21に記載の研磨材。
- 前記既定の角度αが約95度〜約100度である、請求項21に記載の研磨材。
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JP2015503463A (ja) * | 2011-12-30 | 2015-02-02 | サン−ゴバン セラミックス アンド プラスティクス,インコーポレイティド | 成形研磨粒子および同粒子を形成する方法 |
JP2017071051A (ja) * | 2011-12-30 | 2017-04-13 | サン−ゴバン セラミックス アンド プラスティクス,インコーポレイティド | 成形研磨粒子および同粒子を形成する方法 |
US9765249B2 (en) | 2011-12-30 | 2017-09-19 | Saint-Gobain Ceramics & Plastics, Inc. | Shaped abrasive particle and method of forming same |
US10428255B2 (en) | 2011-12-30 | 2019-10-01 | Saint-Gobain Ceramics & Plastics, Inc. | Shaped abrasive particle and method of forming same |
Also Published As
Publication number | Publication date |
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KR20100105692A (ko) | 2010-09-29 |
US20090169816A1 (en) | 2009-07-02 |
BRPI0821437B1 (pt) | 2019-01-22 |
EP2242618B1 (en) | 2020-09-23 |
US20110314746A1 (en) | 2011-12-29 |
WO2009085841A9 (en) | 2010-11-11 |
US9446502B2 (en) | 2016-09-20 |
KR101563381B1 (ko) | 2015-10-26 |
EP2242618A4 (en) | 2013-01-23 |
US8034137B2 (en) | 2011-10-11 |
JP5414694B2 (ja) | 2014-02-12 |
WO2009085841A3 (en) | 2009-10-22 |
BRPI0821437A2 (pt) | 2015-06-16 |
CN101909823A (zh) | 2010-12-08 |
EP2242618A2 (en) | 2010-10-27 |
WO2009085841A2 (en) | 2009-07-09 |
CN101909823B (zh) | 2012-11-21 |
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