JP2012520181A - Abrasive elements, architectural elements, and methods of forming such elements - Google Patents

Abstract

  The abrasive or building element consists essentially of a glass material that is at least partially devitrified. A method of forming an abrasive element or building element includes providing a plurality of pieces of glass material, and heat treating the pieces of glass material, thereby forming a solid molded member having at least a portion that includes a devitrified material. Including the steps of:

Description

  The present invention relates to material processing media and methods of forming processing media.

  It is known to use material processing media to remove burrs from mass produced articles and to smooth the surfaces of those articles. Burrs may be present in articles for a variety of reasons. In particular, the surfaces of parts made by metal casting, machining, and general processing often have burrs and roughness that are unacceptable in the final product.

  The finishing treatment of the article includes removal of burrs from the article and reduction of the surface roughness of the article.

  In some cases, the article to be finished, together with the elements of the finish treatment medium, is a vibratory finisher such as a barrel polisher or rolling polisher, a vibrating bowl or bowl, a centrifugal finisher or a drag finisher. It may be put inside. An abrasive or a degreasing agent may be added.

  When deburring an article, the finish media typically has a relatively rough surface, but when polishing an article, the finish media typically has a relatively smooth surface. Have.

  During the finishing process described above, the finishing media is agitated and the elements of the media will impact the article to be finished. One or more compounds, such as liquid soaps, degreasing agents, polishes, etc. may be supplied with the finishing medium.

  Many different types of finishing equipment are known. One such form is a tumbling mill. The tumbling mill is configured to finish the article by the “tumbling” action of the elements of the finishing media on the article.

  The finishing medium itself may have sharp edges or sharp corners. Alternatively or additionally, the media may have particles of abrasive material embedded therein. Some finishing materials are in the form of calcined clay with embedded aluminum oxide particles. In the case of a finishing material in the form of a plastic material, quartz particles may be included.

  During the finishing process, sharp tips or sharp corners and / or embedded particles exposed on the surface of the media will enter the grooves and gaps in the article, thereby smoothing the article. In some cases, the finishing media may have a cleaning effect instead of or in addition to the smoothing effect.

  There is a problem during the finishing process that sharp edges, sharp edges, or sharp corners of the elements of the finishing media are rapidly worn and worn. As a result, these elements can no longer reach into the grooves and gaps in order to finish the article efficiently.

  Patent Document 1 discloses a finishing tumbling medium in the form of a triangular or star-shaped plate having an opening formed therethrough. The opening is formed near the apex of the plate. A sharp edge is provided at the top of the media to facilitate the finishing process. In order to extend the useful life of the finishing media, the media is configured to crush when worn to a certain degree during use. The media is configured to break in the area of the opening, thereby providing a new sharp edge for the finishing process.

  Disclosed are media formed from either substantially 100% inorganic ceramic, or a combination of ceramic abrasive particles and a vitreous or plastic resin binder that bonds the particles together.

  Ceramic media have the disadvantages of high manufacturing costs and the need to add abrasives to provide a cutting action.

  U.S. Patent No. 6,053,077 discloses a finishing medium in the form of an article having a star-shaped cross section and a length greater than the maximum diameter of the star-shaped cross section. The medium is disclosed as being formed from either a zinc-based die cast material, steel, aluminum, brass, or a ceramic material.

  Ceramic materials have the disadvantage that once worn, such materials are not easy to reuse and must be discarded. On the other hand, metallic materials can often be reformed by melting or recasting.

  However, when metal finishing media are used to finish metal workpieces, the media tends to lose its sharp edges relatively quickly compared to harder materials such as ceramics. As a result, metallic vibration finishing media tend to be carbide based. Carbide-based materials have the disadvantage of relatively high manufacturing costs.

  A further disadvantage of metal finishing media is the fact that such media are relatively difficult to mass produce by machining. These materials also tend to corrode rapidly in wet processing environments, particularly in environments where acid compounds are used.

  As a result, in some cases, the finishing media may not be useful at all. Rather, the part will be placed under a “self-processing” state. In other words, these parts will themselves move relative to each other in a vibration finishing process environment with no finishing media added. Such a condition is normally only used for deflashing, i.e. for large quantities of low quality parts that require little deburring. The self-finishing process can damage the part during the finishing process.

  Patent Document 3 discloses a blasting medium made of thermoplastically processable polymer particles filled with a finely divided metal. The metal particles are coated with an adhesion promoter. Polymeric vibration media have the disadvantage of providing a non-negligible “carbon footprint”, relatively difficult to manufacture, and not easy to recycle.

Patent Document 4, comprises Al ₂ O ₃ and SiO _2, glass and glass - discloses a process for producing a ceramic, glass - discloses that ceramic particles useful as abrasive particles. This document discloses a method of embedding glass-ceramic particles in a base material to form an abrasive article such as an abrasive wheel. In one embodiment, the particles are bound to a fiber mat provided on the substrate by a binder.

  Further, the finishing media element may be formed as a separate component that need not be supported by a substrate such as the fiber mat of US Pat.

  It is also known to use an abrasive wheel to finish the article. In some cases, the article may be pressed against a rotating abrasive wheel.

US Pat. No. 3,375,615 British Patent No. 1130923 US Pat. No. 5,373,047 US Patent Application Publication No. 2004/0148966

  In a first aspect of the invention, there is provided an abrasive element consisting essentially of a glass material that is at least partially devitrified.

  The term “glass material” means a portion formed from an amorphous or glassy material.

  Embodiments in which the elements are formed essentially or exclusively from a glass material have advantages over prior art media consisting in particular of a green element in which abrasive particles such as aluminum oxide are embedded. . This is because prior art elements tend to drop off their abrasive particles during use, forming a slurry consisting of abrasive particles, substrate elements, and shavings from the article to be finished. This slurry can cause environmental problems for some abrasive particles and may require further expensive processing before the slurry is discarded. In contrast, embodiments of the present invention drop out only glass particles, which can be easily discarded or recycled.

  The term “devitrified” means a material that has a crystalline structure and originally has an amorphous (glassy) structure. The term “amorphous structure” means a material that does not have a long-range crystal structure as measured by X-ray diffraction. The term “glass or vitreous” means an amorphous material that exhibits a glass transition temperature.

  “Abrasive media” according to the present invention (also referred to herein as “finishing media”) have the advantage that they can be produced from relatively low cost starting materials by a relatively low cost method. . An “abrasive element” (sometimes referred to as a “finishing media element”) according to one or more embodiments of the invention can also be made from recycled glass material.

  Raw materials for obtaining ceramics (such as porcelain clay) are usually obtained by mining operations, with the result that there are environmental problems with the use of this material. However, the use of recycled material has the advantage that it does not require the destruction of the landscape by mining operations.

  In particular, green (or gray) glass is usually not recycled. Thus, embodiments of the present invention will provide excellent utilization of this material that is discarded in landfills or other dumping facilities.

  In a second aspect of the invention, there is provided a building element consisting essentially of a glass material that is at least partially devitrified.

  The building element is preferably in the form of a building brick.

  The element may have a portion that includes a substantially amorphous material.

  The presence of amorphous glass will have the effect of increasing the toughness of the element. In other words, the presence of the amorphous glass material can reduce the tendency of the material to shatter.

  Preferably, the element contains or encloses a plurality of voids created, for example, by bubbles, preferably air bubbles.

  The voids, when exposed on the surface area of the element, will result in sharp edges having a good size for cutting, deburring, and finishing processes. The exposed air gap can also serve as a reservoir for the fluid finishing media used in the vibration finishing process.

  The voids are preferably distributed substantially uniformly within the element.

  More preferably, the void is provided at least in the surface of the element.

  Even more preferably, the voids are exposed in the surface layer, thereby providing a sharp edge on the surface.

  The voids may be exposed on the surface, thereby providing a reservoir for the fluid finishing media used in the finishing process.

  Preferably, the air gap has a nominal diameter in the range of about 50 nm to about 5 mm, preferably about 1 μm to about 1 mm, more preferably about 10 μm to about 500 μm, and even more preferably about 100 μm to about 500 μm. ing.

  The volume of the element in the form of devitrified material may be in the range of about 1% to about 100%.

  The volume of the element in the form of devitrified material may be in the range of about 20% to about 80%, and optionally about 50%.

  Preferably, the element has a longest dimension in the range of about 5 mm to about 80 mm.

  The element may have a longest dimension in the range of about 5 mm to about 50 mm.

  Elements having dimensions within these ranges have been found to be particularly suitable for finishing articles over various size ranges. Further, the size of the element may be selected such that the element can impact all necessary surfaces of the article without remaining in the recess, gap, or other feature of the article.

  Preferably, the element has a minimum dimension in the range of about 10 mm to about 40 mm.

  The element may comprise a plurality of regions of crystalline material in the free surface of the element.

  The element preferably consists essentially of an amorphous glass material and a crystallized glass material.

  The element may consist essentially of an amorphous glass material and a crystallized glass material.

  The crystallized glass material may be provided in the form of particles dispersed in the amorphous glass material.

  The amorphous glass material may be provided in the form of particles dispersed in the crystallized glass material.

  Preferably, the element consists essentially of at least partially devitrified material, preferably devitrified glass material.

  The devitrification material may include at least a part having a needle-like shape.

  The element may include silica.

  The element may have a hardness value of about 5.5 on a morscale.

  If the hardness is too high, the finishing element may break during use. If it is too soft, the element can lose its effectiveness by rounding the edges of the element.

  The shape of the element is at least one selected from a cube, an ellipsoid, a prism, a cone, a tetrahedron, a pyramid, a polyhedron, a sphere, a triangular structure, a disk or a disk-like structure, and a segment of a disk and a disk-like structure. It may be one.

  The element may be provided in the form of a disc suitable for use as a grinding wheel or polishing wheel.

  The element may comprise at least one support element arranged to prevent the disc from breaking.

  The support element may have at least a portion embedded in the disc.

  In a third aspect of the present invention there is provided a grinding wheel or abrasive wheel comprising an element according to the first aspect of the present invention.

  Preferably, the grindstone has a plurality of elements, each in the form of a disc or segment of a disk-like structure, these elements being connected together thereby A whetstone is formed.

  These elements may be connected together by a hub element.

  In a fourth aspect of the invention, in a method of forming an abrasive element, providing a plurality of pieces of glass material, and subjecting the pieces of glass material to a heat treatment, thereby including at least a portion comprising a devitrifying material. Forming a solid molded member having a method.

  According to a fifth aspect of the present invention, in a method of forming a building element, the steps of providing a plurality of pieces of glass material, and heat treating the pieces of glass material, thereby providing at least one devitrifying material. Forming a solid molded member having a portion.

  The building element may be in the form of a building brick.

  Preferably, the molding member is formed so as to include a plurality of voids.

  The method may include placing a piece of glass material into the mold.

  The method may further include injecting a piece of glass material into the mold.

  The method may include the step of consolidating the glass material fragments in a mold.

  Providing a plurality of pieces of glass material may further comprise providing a plurality of pieces of filler material arranged to thermally decompose during the heat treatment, thereby providing a plurality of voids.

  Preferably, the filler comprises at least one selected from plant material shells, crushed eggshells, and polymeric materials.

  The filler debris may have a size in the range of about 500 μm or less, and optionally about 250 μm or less.

  The method may include mixing a plurality of pieces of glass material and a plurality of pieces of filler material.

  The method may further comprise placing glass material fragments and filler material into the mold.

  Preferably, the piece of glass material is glass waste or contains glass waste.

  Preferably, the plurality of material pieces are selected from about 4 mm or less, about 4 mm to about 2 mm, about 3 mm to about 1 mm, about 1.5 mm to about 0.75 mm, about 1.5 mm to about 500 μm, and about 100 μm or less. Have an average dimension within the range.

  In general, it has been found that the smaller the average size of the debris from which the finishing element is made, the smoother the surface of the finished article. Elements made from debris having an average value at the lower end of the above range are particularly suitable for finishing an article so that the finished article has a relatively low surface roughness.

  The molded member preferably comprises an amorphous glass material.

  The method may further include the step of cutting the molded member, thereby forming a plurality of finishing media elements.

  The present invention forms a molded member so as to have a shape that is at least one selected from a cube, an ellipsoid, a prism, a cone, a tetrahedron, a pyramid, a polyhedron, a sphere, and a disc or disc shape. Step may be included.

  Preferably, the polishing element is formed in the shape of a cone having a cone angle in the range of about 30 ° to 120 °.

  Preferably, the polishing element is formed to have one cone angle selected from 30 °, 60 °, 90 ° and 120 °.

  The polishing element may be formed to have a disk or disk-like shape, and may include a support member having at least a portion embedded in the element.

  The support member may be arranged to prevent the disc from being crushed.

  The heat treatment may include heating to a temperature in the range of about 700 ° C. to about 1100 ° C., optionally, about 750 ° C. to about 950 ° C.

  The heat treatment may further comprise heating to a temperature in the range of about 800 ° C. to about 1000 ° C., optionally to about 975 ° C.

  Preferably, the heat treatment comprises heating to a temperature in the range of about 850 ° C. to about 950 ° C., preferably about 900 ° C. to about 920 ° C., more preferably about 900 ° C.

  The heat treatment is performed at a temperature in the range of about 700 ° C. to about 1100 ° C., preferably about 700 ° C. to about 950 ° C., more preferably about 900 ° C. to about 920 ° C. for about 1 hour to about 3 hours, More preferably, it may include heating to about 900 ° C.

  The heat treatment is performed at a temperature in the range of about 700 ° C. to about 1100 ° C., preferably about 700 ° C. to about 950 ° C., more preferably about 900 ° C. to about 920 ° C. for about 2 hours, even more preferably, Heating to about 900 ° C. may be included.

  The heat treatment heat treats at least one piece, thereby melting at least a portion of the at least one piece and subsequently cooling to form a solid molded member having at least a portion that includes devitrified material. Steps may be included.

  The method may be configured to provide an abrasive element having a hardness value of about 5.5 Mohs.

  In a sixth aspect of the present invention, in a method for reshaping at least one abrasive element, the method comprises providing at least one abrasive element according to the first aspect, performing a heat treatment, followed by a devitrifying material. Cooling to form a solid molded member.

  This has the advantage that exhausted finishing elements can be reshaped and new finishing elements can be made. Thus, it is not necessary to dispose of exhausted finishing elements in landfills or other dumping facilities.

  Providing at least one abrasive element further includes crushing at least one abrasive element, thereby forming a plurality of pieces of material.

  Preferably, the step of crushing at least one abrasive element is followed by a step of placing a plurality of pieces of the crushed element into a mold.

  In a seventh aspect of the present invention there is provided an abrasive element according to the first aspect of the present invention in combination with a degreasing agent and / or an abrasive.

  According to an eighth aspect of the present invention, in a method for finishing an article, the step of providing a plurality of finishing media according to the first aspect and impinging the abrasive element on the article, thereby reducing the surface roughness of the article. A method comprising: reducing.

  The method may further include providing at least one selected from a degreasing agent, a cleaning agent, or an abrasive, thereby increasing the reduction in surface roughness of the article.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

4 is a plot of temperature as a function of time for heat treatment according to the first and second embodiments of the present invention. It is a figure which shows the prism-shaped finishing process medium element by the 1st Embodiment of this invention. FIG. 6 shows a substantially conical finishing media element according to a second embodiment of the invention. FIG. 4 shows a mold suitable for forming a plurality of finishing media elements according to a second embodiment of the invention. FIG. 6 shows a plurality of conical shaped finishing media having a cone angle in the range of about 15 ° to about 90 °. It is sectional drawing of the finishing element which has a bubble structure. FIG. 3 is a cross-sectional view of a finishing element showing the presence of crystalline material (devitrified material) on the free surface of the element. FIG. 8B is a perspective view (8a) of a grinding wheel or polishing wheel according to an embodiment of the present invention, and FIG. ). 1 shows a grinding wheel or polishing wheel according to an embodiment of the invention having a support element embedded in a disc-shaped polishing element. FIG. 1 shows a grinding wheel or polishing wheel according to an embodiment of the invention having an abrasive material in the form of a disc segment. FIG.

  According to a first embodiment of the invention, the polishing element (or “finishing media element”) is formed from a partially recrystallized silica glass material. Other glass materials are also useful.

  Amorphous silica glass is widely used as a daily necessities material that is relatively inexpensive compared to metal materials. For example, amorphous silica glass is utilized in the form of recycled beverage bottles and other recycled articles.

  In one embodiment of the invention, the starting material in the form of amorphous silica glass is crushed into strips. In some embodiments of the invention, these fragments have a diameter of about 4 mm. The term “diameter” means the maximum diameter of a piece of material. Other sizes are also useful.

  In some embodiments, gradient mixed glass cullets are used, including fragments with a maximum diameter of about 4 mm.

  In some embodiments, debris having a larger diameter is used. For example, debris having a diameter up to about 5 mm may be used.

  In some embodiments, debris having a diameter of a few μm to about 5 mm is used.

  According to the first embodiment, the debris is placed in a mold and subjected to heat treatment. The heat treatment is cooled to at least partially melt the debris and then form a material having at least a portion comprising devitrified silica material (also referred to as a “cast member”). Devitrified silica is relatively hard and has the property of being resistant to abrasion due to abrasion.

  The debris may be subjected to a consolidation process in the mold to reduce the porosity of the molded member. The decrease in the porosity will reduce the number and / or size of the voids in the molded member.

  Examples of consolidation include mold swaying and / or application of pressure to the debris. Other consolidation processes are also useful.

  The cooled material has both a region of amorphous material and a region of devitrified, ie crystallized silica material. On the other hand, the starting crushed glass is typically almost entirely composed of an amorphous silica material.

  A plot of temperature as a function of time for a heat treatment process according to an embodiment of the invention is shown schematically in FIG.

  The debris is heated to a temperature T1 of about 700 ° to 1400 °. The debris is held at this temperature for a time t1, which is in the range of about 1 to 6 hours.

  In a preferred embodiment of the invention, the debris is heated at a temperature T1 of about 900 ° C. for a period t1 of about 2 hours. In some embodiments, the debris is heated to a temperature T1 of about 925 ° C.

  The degree of recrystallization that occurs in the glass material during cooling from the high temperature T1 will determine the substantial range of hardness of the resulting finish media. The time t1 and temperature T1 used will affect the proportion of crystalline material contained in the finishing medium. It has been found that higher proportions of crystalline material typically result in higher hardness finishing media.

  Also, polishing media that contain a higher proportion of crystalline material exhibit higher brittleness and may fracture during use. Thus, to obtain an abrasive material that has sufficient hardness to not cause excessively high wear rates during the finishing process and sufficient toughness not to cause excessively easy crushing An acceptable balance must be achieved between the relative blending ratios of the and the crystalline material.

  In some embodiments, the element comprises up to about 75-80% by volume crystalline material.

  Once the partially recrystallized glass material is cooled to room temperature, it will be cut to form elements of a shape and size suitable for use as a finishing medium. Cutting is generally performed using a conventional circular saw blade with a diamond tip.

  In some embodiments of the invention, the cutting is performed by water jet or laser. Other cutting means are also useful.

  In accordance with one embodiment of the present invention, the material is cut to form a prismatic finishing media suitable for use in a vibration finishing process as shown generally at 110 in FIG. Has been. According to one embodiment, the length of the side of the base of each prism is in the range of about 5 mm to about 50 mm. In some embodiments, this range is between about 10 mm to about 40 mm.

  The size of the medium is selected according to the size and shape of the article to be finished. The size is selected to avoid the problem of clogging the finishing media elements within the recesses or other structures of the article to be finished.

  According to one embodiment of the present invention, the finishing medium is in the form of a solid prism piece formed by cutting from a block of partially devitrified material.

  In alternative embodiments, the material forms various shapes, for example, cubes, parallelepipeds, ellipsoids, shapes with cross sections or other parts in the form of a star shape, or any other suitable shape. To be cut off.

  According to yet another embodiment of the present invention, the finishing media melts the crushed silica glass particles in individual molds to directly form the final required finishing media. Is formed. Thus, it is not necessary to cut the solidified melt to form the finish media element.

  FIG. 3 is a schematic view of a finishing media element 210 having a substantially conical shape formed directly from a mold. A suitable mold for forming such an element 210 is shown in FIG. The mold is provided with a plurality of well elements 310 having a shape corresponding to the shape of the conical finishing media element 210.

  Conical shaped finishing media have the advantage that they can be easily released once the molding material has cooled. Accordingly, these finish media elements can be made quickly and conveniently.

  In some embodiments, the mold is formed by removing a portion of the material from a solid block of mold material.

  By using a mold, various complex shaped abrasive elements can be formed relatively quickly and efficiently. At least part of this is because it is not necessary to perform a cutting operation after the melt has cooled.

  When finishing media elements according to embodiments of the present invention are used up, such as when the media element size is worn or reduced to an extent that effectiveness is no longer acceptable, these media elements are It should be understood that it can be recycled to form a finish media element.

  In this way, depleted elements can be heated and cooled to form new abrasive elements. In some embodiments, depleted elements are crushed to form particles that are heat treated. In some embodiments, these particles will be placed in a mold as shown in FIG. 4 and subjected to a heat treatment similar to that described above.

  The recycling of disposable elements has the advantage of reducing material disposal, thereby reducing the burden on the dumping facility for processes using abrasive elements. The fact that the raw material for forming the finishing element is derived from silica glass material recycled in the first stage also has significant advantages in reducing the environmental impact of the process.

  FIG. 5 illustrates a series of finish media elements according to embodiments of the present invention having a cone angle in the range of about 15 ° to about 90 °. Conical angles up to about 120 ° are also useful.

  FIG. 6 shows the internal structure of the element 410 formed to have a porous structure or a bubble structure. That is, element 410 includes a plurality of pores or voids 450. Such a structure has the advantage that an element 410 having a free surface 411 in which a plurality of sharp edges 415 are present is conveniently obtained without binding the particles to the substrate. In addition, it should be understood that as the abrasive element wears during use, new voids are exposed to the free surface. Thus, when the element wears, a new sharp surface is exposed.

  Furthermore, as the element wears, any piece of material that breaks from the element has a relatively small size compared to the size of the element itself. Thus, there is less risk of debris clogging associated fluid treatment devices such as filters and vibration finishing tools compared to some known finishing media elements and abrasive materials.

  The cell structure may be controlled by changing the degree to which the compaction of the glass pieces is performed prior to heating to form the molded member. As the debris is consolidated more strongly, the porosity of the molded member becomes smaller. Further, in some embodiments, particles of packing media such as ground wheat shells or other organic materials may be used, or crushed egg shells may be used. Other filler materials are also useful.

  Consolidation may be performed by agitating the mold in which the debris is placed and / or by applying pressure to the debris.

  In some embodiments of the present invention, the finish media element comprises a crystalline material exposed on the surface of the element that provides an abrasive surface for the article to be finished. In some embodiments, the crystalline material of the element is in the form of elongated crystals that protrude from the outer surface of the element. FIG. 7 is a cross-sectional view of a portion of a finishing element 510 having a free surface 511. Crystalline (devitrified) materials 520, 525 are present on the free surface 511. In some embodiments, some of the crystalline material is in the form of elongated crystals 520 that protrude from the free surface 511. There may also be voids (or pores) 550 in element 510.

  It should be understood that the size of the crystals present in the finishing element depends on the heat treatment applied to the starting glass. Longer annealing at higher temperatures usually results in larger crystals.

  In some embodiments, the devitrified material is present in combination with the substrate of the vitreous material 530 such that the crystalline material 520, 525 is effectively “embedded” within the vitreous material 530. I want you to understand more. Thus, the process of heat treating the glass results in the formation of a particle / substrate structure without mixing particles and substrate materials from separate material sources. This greatly simplifies the cost and complexity of the manufacturing process.

  Thus, in some embodiments of the present invention, at least three features of the polishing element will be related to abrasion or polishing of the article in contact with the element. These are: (i) the size of the glass debris used to form the abrasive element, (ii) the size of the crystals of material present in the element as determined by the time / temperature profile of the heat treatment applied to the glass debris. And (iii) to the extent that the element has pores formed therein.

  Larger pieces of glass debris are injected into the mold and then heat treated, thereby firing the glass debris, forming an abrasive element and at least partially devitrifying the smaller pieces of glass debris. It has been found that elements with a rougher surface morphology are obtained than in the case of use. Accordingly, larger pieces of glass debris will generally result in elements having a rougher surface finish than smaller pieces of glass debris.

  Thus, using larger pieces of glass debris results in a more granular structure, and the surface of this element has longer scale irregularities than if smaller pieces of glass debris are used.

  The crystal size of the material present in the polishing element is highly dependent on the temperature profile of a given heat treatment (ie, the temperature of the element as a function of time during the heat treatment). It should be understood that larger crystals exposed on the free surface of the polishing element typically result in elements having a rougher surface morphology than in elements exposed on the free surface.

  In some embodiments, the polishing element is provided in the form of a grinding wheel or polishing wheel. FIG. 8 (a) shows such an element which is a grindstone element 610. The grindstone element 610 has an opening 611 defined by the inner peripheral surface 612 of the grindstone element 610, and the inner peripheral surface 612 is concentric with the rotational axis of the element 610.

  FIG. 8B shows a hub element 620 that is an element configured to be provided in the opening 611 of the grindstone element 610. In some embodiments, the grindstone element 610 is configured to be formed around the hub element 620. That is, the heat treatment for heating the glass waste to form the molded member is performed on-site using the hub element 620. In some embodiments, the hub element 620 is adapted to be coupled to the grindstone element 610 after the grindstone element is heat treated to form a molded member.

  In some embodiments, the hub element 620 is shaped to have a concave outer peripheral surface 622. The concave outer peripheral surface 622 is configured to cooperate with the corresponding inner peripheral surface of the grindstone element 610 to reduce the risk of the grindstone element 610 and the hub element 620 being separated from each other. Other shapes for the outer peripheral surface 622 are also useful.

  FIG. 9 shows a grindstone element 710 according to an embodiment of the present invention having a support member 730 embedded in the grindstone element 710 (shown in dotted lines). The support member 730 is disposed in order to increase resistance to crushing of the grindstone element 710. In some embodiments, the support member 730 is provided outside the grindstone element 710. That is, the support member 730 is not embedded in the grindstone element 710. In some embodiments, the support member 730 is partially embedded within the grindstone element 710.

  In the embodiment of FIG. 9, the support member 730 includes a plurality of radial spoke elements 731 and one or more concentric ring elements 732. In some embodiments, either a spoke element 731 or one or more ring elements 732 are provided. Other support member configurations are also useful.

  FIG. 10 illustrates an embodiment in which the grindstone element 810 includes a plurality of uniform wedge-shaped segments 815. Other configurations are also useful. The segments 815 may be connected to each other by an adhesive. Alternatively or additionally, the segments 815 may be connected to each other by one or more connecting elements.

  In some embodiments, the grindstone element is formed by heating glass scrap or crushed abrasive elements (eg, discarded or used elements) at a temperature of about 850 ° C. for about 4 hours.

  In one embodiment of the present invention, an architectural element for use in building a building is provided. These elements may be in the form of brick elements that are used in place of clay fired bricks or any other building bricks.

  These elements have the advantage of strength, i.e. damage resistance, and the ability to be easily recycled and reshaped when the building reaches its lifetime.

  In some embodiments, the building element is used to allow the building elements to be substantially connected to each other using mortar, as in the case of conventional construction practices using clay bricks. The mating surfaces are formed to have a sufficient porosity.

  The use of such building elements has the advantage that raw materials are obtained from a single source of material (recycled glass) and are processed relatively directly to form building elements. . There is no need to introduce additional media such as binding media.

  In some embodiments, to increase the porosity of the building element, a filler material is used that is adapted to pyrolyze upon heating, similar to that described above for the abrasive / finishing media element. May be. The foregoing description regarding the processing and heat treatment of glass materials to form abrasive / finishing media elements may be applied to the formation of building elements.

  Throughout the description and claims of this specification, “comprise” and “contain” and variations of these terms, eg, “comprising” and “comprises” Means, but is not limited to, and is not intended to exclude (and does not exclude) other parts, appendages, components, whole bodies, or steps. Not).

  Throughout this description and the claims, the singular forms also include the plural unless the context requires otherwise. It is to be understood that this specification considers the singular as well as the plural unless the context requires otherwise, particularly where non-limiting articles are used.

  Any feature, completeness, property, compound, chemical moiety or chemical group described in connection with a particular aspect, embodiment or example of the present invention, unless stated otherwise, It should be understood that other aspects, embodiments, or examples are applicable.

Claims (72)

  An abrasive element consisting essentially of a glass material that is at least partially devitrified.   An architectural element consisting essentially of a glass material that is at least partially devitrified.   The building element according to claim 2, wherein the building element is in the form of a building brick.   An element according to any preceding claim, characterized in that it has a part comprising a substantially amorphous material.   An element according to any preceding claim, characterized in that it comprises or incorporates a plurality of voids formed by, for example, bubbles, preferably air bubbles.   The element of claim 5, wherein the voids are substantially uniformly distributed within the element.   The element according to claim 5, wherein the void is provided in at least a surface layer of the element.   8. Element according to any one of claims 5 to 7, characterized in that voids are exposed on the surface layer, thereby providing a sharp edge on the surface.   9. The method of any one of claims 5 to 8, wherein the void is exposed on the surface, thereby providing a reservoir for a fluid finishing media used in a finishing process. Listed elements.   The void has a nominal diameter in the range of about 50 nm to about 5 mm, preferably 1 μm to about 1 mm, more preferably about 10 μm to about 500 μm, and even more preferably about 100 μm to about 500 μm. 10. An element according to any one of claims 5-9.   An element according to any preceding claim, wherein the volume of the element in the form of devitrified material is in the range of about 1% to about 100%.   The volume of the element in the form of devitrified material is in the range of about 20% to about 80%, and optionally about 50%, according to any preceding claim. Elements.   An element according to any preceding claim, having a maximum dimension in the range of about 5 mm to about 80 mm.   An element according to any preceding claim, having a maximum dimension in the range of about 5 mm to about 50 mm.   An element according to any preceding claim, having a maximum dimension in the range of about 10 mm to about 40 mm.   An element according to any preceding claim, characterized in that it comprises a plurality of regions of crystallized glass material on the free surface of the element.   An element according to any preceding claim characterized in that it consists essentially of an amorphous glass material and a crystallized glass material.   An element according to any preceding claim, characterized in that it consists of an amorphous glass material and a crystallized glass material.   The element according to claim 16, wherein the crystallized glass material is provided in the form of particles dispersed in the amorphous glass material.   20. The element according to any one of claims 16 to 19, wherein the amorphous glass material is provided in the form of particles dispersed in the crystalline glass material.   Element according to any preceding claim, characterized in that it consists essentially of a material that is at least partially devitrified, preferably a glass material that is devitrified.   An element according to any preceding claim, wherein the devitrifying material comprises at least a part having a needle-like form.   An element according to any preceding claim, characterized in that it comprises silica.   An element according to any preceding claim, characterized in that it has a hardness value of about 5.5 on a morscale.   Be in at least one shape selected from a cube, an ellipsoid, a prism, a cone, a tetrahedron, a pyramid, a polyhedron, a sphere, a triangular structure, a disk or disk-shaped structure, and a segment of a disk or disk-shaped structure An element according to any preceding claim characterized by:   26. Element according to claim 25, subordinate to claim 1, characterized in that it is in the form of a disc suitable for use as a grinding wheel or a grinding wheel.   27. The element of claim 26, comprising at least one support member arranged to prevent crushing of the disc.   28. The element of claim 27, wherein the support member has at least a portion embedded in the disc.   A grinding wheel or polishing wheel comprising an element according to any one of claims 23 to 26, which ultimately depends on claim 1.   Comprising a plurality of elements, each in the form of a disc or segment of a disc-like structure, the segments being connected together, thereby forming the grinding wheel The grindstone according to claim 29.   The grindstone according to claim 30, wherein the segments are connected together by a hub member. In a method of forming an abrasive element,
Providing a plurality of pieces of glass material;
Heat-treating the plurality of glass material fragments, thereby forming a solid molded member having at least a portion including a devitrifying material;
A method comprising the steps of: In a method of forming an architectural element,
Providing a plurality of pieces of glass material;
Heat-treating the plurality of glass material fragments, thereby forming a solid molded member having at least a portion including a devitrifying material;
A method comprising the steps of:   34. The method of claim 33, wherein the building element is in the form of a building brick.   35. A method according to any one of claims 32-34, comprising forming the molded member to comprise a plurality of voids.   36. A method according to any one of claims 32 to 35, comprising the step of placing the glass material fragments into a mold.   37. The method of claim 36, comprising injecting the glass material fragments into the mold.   38. A method according to claim 36 or 37, comprising the step of consolidating the glass material fragments in the mold.   The step of providing a plurality of pieces of glass material further comprises providing a plurality of pieces of filler material that are pyrolyzed during the heat treatment, thereby providing the plurality of voids. The method according to any one of claims 32 to 38.   40. The method of claim 39, wherein the filler material comprises at least one selected from plant material shells, crushed eggshells, and polymeric materials.   41. A method according to claim 39 or 40, wherein the filler material debris has a size in the range of about 500 [mu] m or less, and optionally about 250 [mu] m or less.   42. The method of any one of claims 39 to 41, comprising mixing the plurality of pieces of glass material and the plurality of pieces of filler material.   43. A method according to any one of claims 39 to 42, comprising placing the glass material fragments and the filler material into the mold.   44. A method as claimed in any one of claims 32 to 43, wherein the pieces of glass material comprise glass debris.   The plurality of material debris is within a range selected from about 4 mm or less, about 4 mm to about 2 mm, about 3 mm to about 1 mm, about 1.5 mm to 0.75 mm, about 1.5 mm to 500 μm, and about 100 μm or less. 45. A method as claimed in any one of claims 32 to 44, having an average size of.   46. A method according to any one of claims 32-45, wherein the molded member comprises an amorphous glass material.   47. The method of any one of claims 32-46, further comprising cutting the molded member, thereby forming a plurality of finishing media elements. Forming the molded member so as to have a shape that is at least one selected from a cube, an ellipsoid, a prism, a cone, a tetrahedron, a pyramid, a polyhedron, a sphere, and a disc and a disc-like shape. 48. A method according to any one of claims 32-47, comprising:   49. The method of claim 48, wherein the polishing element is formed in the shape of a cone having a cone angle in the range of about 30 [deg.] To about 120 [deg.].   50. The method of claim 49, wherein the polishing element is formed to have one cone angle selected from 30 [deg.], 60 [deg.], 90 [deg.], And 120 [deg.].   The polishing element is formed to have a disc shape or a disc shape, and the element includes a support member having at least a part embedded in the element. Item 49. The method according to Item 48.   52. The method of claim 51, wherein the support member is arranged to prevent the disc from being crushed.   53. Any one of claims 32-52, wherein the heat treatment comprises heating to a temperature in the range of about 700 ° C to about 1100 ° C, and optionally about 750 ° C to about 950 ° C. The method described in 1.   53. The method of any one of claims 32-52, wherein the heat treatment comprises heating to a temperature in the range of about 800 ° C to about 1000 ° C, optionally to about 9750 ° C. .   33. The heat treatment includes heating to a temperature in the range of about 850 ° C. to about 950 ° C., preferably about 900 ° C. to about 920 ° C., more preferably about 900 ° C. 53. The method according to any one of 52.   The heat treatment is performed at a temperature in the range of about 700 ° C. to about 1100 ° C., preferably about 700 ° C. to about 950 ° C., more preferably about 900 ° C. to about 920 ° C. for about 1 hour to about 3 hours; 53. The method of any one of claims 32-52, further preferably comprising heating to about 900C.   The heat treatment is performed at a temperature in the range of about 700 ° C. to about 1100 ° C., preferably about 700 ° C. to about 950 ° C., more preferably about 900 ° C. to about 920 ° C., even more preferably for about 2 hours. 53. The method of any one of claims 32-52, comprising heating to about 900 <0> C. The heat treatment heat-treats the at least one piece, thereby melting at least a portion of the at least one piece;
58. A method according to any one of claims 32 to 57, comprising cooling to form a solid molded member having at least a portion comprising devitrified material.   59. The method of any one of claims 30-58, wherein the method is configured to provide an abrasive element having a hardness value of about 5.5 Mohs. In a method of reshaping at least one abrasive element,
Providing at least one polishing element according to any one of claims 1 to 31, and performing a heat treatment;
Subsequently, cooling to form a solid molded member containing the devitrification material;
A method comprising the steps of:   61. The method of claim 60, wherein providing the at least one polishing element further comprises crushing the at least one polishing element, thereby forming a plurality of material pieces.   62. The method of claim 61, wherein the step of crushing the at least one abrasive element includes the step of placing a plurality of pieces of the crushed element into a mold.   32. Abrasive element according to any one of claims 1 to 31 in combination with a degreasing agent and / or an abrasive. In a method for finishing an article,
Providing a plurality of abrasive elements according to any one of claims 1-31;
Impacting the abrasive element to the article, thereby reducing the surface roughness of the article;
A method comprising the steps of:   The method of claim 64, further comprising providing at least one selected from a degreasing agent, a cleaning agent, or an abrasive, thereby promoting a reduction in surface roughness of the article.   An abrasive element substantially as herein described with reference to the accompanying drawings.   A method of forming an abrasive element as substantially described herein with reference to the accompanying drawings.   A method of reshaping at least one abrasive element substantially as described herein with reference to the accompanying drawings.   Method for finishing an article substantially as herein described with reference to the accompanying drawings   An architectural element substantially as described in the specification with reference to the accompanying drawings.   A method of forming a building element as substantially described herein with reference to the accompanying drawings.   64. The brick according to claim 62, having a portion containing a substantially amorphous material.

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