JP2016521235A - 焼結された研磨粒子、それを作製する方法、及びそれを含む研磨物品 - Google Patents
焼結された研磨粒子、それを作製する方法、及びそれを含む研磨物品 Download PDFInfo
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Abstract
Description
前駆体粒子が焼結された研磨粒子に変換されるような条件下で、前駆体粒子を火炎に通過させることを含み、前駆体粒子はアルファアルミナのか焼された前駆体を含み、前駆体粒子は500マイクロメートル以下の平均粒径を有する。
−100+120、−120+140、−140+170、−170+200、−200+230、−230+270、−270+325、−325+400、
−400+450、−450+500、又は−500+635。
第1の実施形態において、本開示は、焼結された研磨粒子を作製する方法を提供し、該方法は、
前駆体粒子が焼結された研磨粒子に変換されるような条件下で、前駆体粒子を火炎に通過させることを含み、前駆体粒子はアルファアルミナの前駆体を含み、前駆体粒子は500マイクロメートル以下の平均粒径を有する。
ベーマイトゾル−ゲルのサンプルは、以下のレシピを使用して作製した:Sasol North America,Inc.,Houston,TexasからDISPERALとして入手可能な酸化アルミニウム一水和物粉末(1600部)を、水(2400部)及び70重量パーセントの硝酸水溶液(72部)を含有する溶液を11分間高剪断混合によって分散させた。得られたゾル−ゲルを、コーティングの前に少なくとも1時間エージングした。ゾル−ゲルを、100マイクロメートルの側部及び25マイクロメートルの深さの寸法を伴う、等辺三角の成形された型穴を有する、ポピプロピレン生成ツールの中に押し入れた。ゾル−ゲルは、生成ツールの開口部が完全に充填されるように、パテナイフを使用して穴に押し入れた。穴を充填させる前に、離型剤である、1重量パーセントのメタノール中のピーナツ油を使用して、約0.5mg/in2(0.08mg/cm2)のピーナツ油で生成ツールをコーティングした。余分なメタノールは、生成ツールのシートを45℃で5分間、対流式オーブン内に設置することによって除去した。ゾル−ゲルコーティングされた生成ツールを、45℃の対流式オーブン内に少なくとも45分間入れて、乾燥させた。乾燥し成形されたゾル−ゲル粒子は、それに超音波ホーンを通過させることによって、生成ツールから取り出し、次いで、およそ650℃でか焼して、成形されたか焼されたベーマイト粒子をもたらした。
成形されたか焼されたベーマイト粒子の調製(上記)に従って調製した成形されたか焼されたベーマイト粒子を、140+200メッシュ(即ち、106マイクロメートルの開口サイズ〜75マイクロメートルの開口サイズの試験篩で収集される画分)を保持するように、試験篩を使用して分級した。得られたスクリーニングされた粒子を、振動フィーダを使用して、か焼された粒子を加熱する水素/酸素/アルゴン(それぞれ18/15/0の比率で)トーチ火炎を供給するじょうごの中へゆっくりと(約0.5グラム/分)供給し、それらを、得られる焼結された研磨粒子を効果的にクエンチする19リットル(5ガロン)の長方形の金属容器(41センチメートル(cm)×53cm×高さ18cm)に直接移した。トーチは、Bethlehem Apparatus Co.,Hellertown,Pennsylvaniaから得られるBethlehemベンチバーナPM2D Model Bであった。トーチは、中央供給ポート(内径3/16インチ(0.475cm))を有し、そこを通って、供給粒子が、その縦軸に沿ってアルゴンガスとの混合物として、火炎の中へ垂直に下方に導入された。火炎が金属容器に当たる角度は、およそ90°であり、バーナから容器表面までの火炎の長さは、およそ38センチメートル(cm)であった。得られた成形され焼結された研磨粒子を、解析のために収集した。
成形されたか焼されたベーマイト粒子を、トーチ火炎に導入される前に、1200℃のボックスキルン中で1時間加熱したことを除き、実施例1を繰り返した。この燃焼条件を使用して、成形されたか焼されたベーマイト粒子は、最小の高密度化を伴って、アルファアルミナに完全に変換された。その後、この材料を、火炎燃焼手順を使用して燃焼した。得られた燃焼した粒子を収集し、サンプルを取り付け及び研磨した。得られた材料の微細構造には、図6に示されるように、完全に蠕虫状の特徴があった。粒子のセルには、空隙率の特徴があったが、セル境界に沿って割れが無く、実施例1で観察されたものとは完全に反対であった。
気体の混合物を表1に報告されるように調節したことを除き、実施例1を繰り返した。火炎が金属容器に当たる角度は、およそ90°であり、バーナから容器表面までの火炎の長さ(燃焼後の高温気体の尾を含む)は、およそ70センチメートル(cm)であった。得られた成形され焼結された研磨粒子を、解析のために収集した。火炎を出る粒子の温度を測定するための光学的パイロメータ。実施例2〜7に対する代表的な微細構造は、それぞれ図7〜12に示されている。
成形されたか焼されたベーマイト粒子を、1400℃のボックスキルン中で20分間燃焼し、それにより、それらをアルファアルミナに変換したことを除き、比較実施例Bを実施例2と同じように調製した。比較実施例Bの代表的な微細構造を、図13に示す。
トーチが、16部の水素、16部の酸素、及び2部のアルゴンからなる気体混合物を使用したことを除き、実施例1を繰り返した。これは、X線回析解析によって判定される際に、アルファアルミナ粒を成功裏に生成した最も低い温度の火炎を生成したガス流混合物である。成形されたアルファアルミナ研磨粒のサンプルを、取り付け用樹脂(Allied High Tech Products,Rancho Dominguez,Californiaから入手可能なTransparent Thermoplastic Powder 165〜10005)と混合し、10,000倍の倍率の走査電子顕微鏡法(SEM)を使用した後方散乱電子撮像によって、燃焼された粒の断面を評価するために、光学的に平滑な表面になるまでダイアモンドスラリを使用して研磨した。
使用されたトーチ条件が、16部の水素、16部の酸素、及び3部のアルゴンからなる気体混合物を使用するトーチを介して燃焼したことを除き、実施例8を繰り返した。実施例8の空隙率を、実施例8よりも低い火炎温度で燃焼され、かつ実施例8よりも有意により多孔性であった実施例9に対して比較した。2つの実施例の写真を、図14及び15にそれぞれ示す。
Claims (15)
- 焼結された研磨粒子を作製する方法であって、
前駆体粒子が前記焼結された研磨粒子に変換されるような条件下で、前駆体粒子を火炎に通過させることを含み、前記前駆体粒子がアルファアルミナのか焼された前駆体を含み、前記前駆体粒子が500マイクロメートル以下の平均粒径を有する、方法。 - 前記焼結された研磨粒子が、セル微細構造を有するアルファアルミナを含み、前記アルファアルミナが、10,000倍の倍率での断面による画像解析を使用して測定される際、5パーセント以下の面積空隙率を有する、請求項1に記載の方法。
- 前記前駆体粒子が、種粒子を本質的に含まない、請求項1又は2に記載の方法。
- 前記前駆体粒子が、アルファアルミナ粒径調整剤を本質的に含まない、請求項1〜3のいずれか一項に記載の方法。
- 前記前駆体粒子が、前記火炎の縦軸に実質的に沿った重力により、前記火炎を通って加速される、請求項1〜4のいずれか一項に記載の方法。
- 前記焼結された研磨粒子が、成形された研磨粒子を含む、請求項1〜5のいずれか一項に記載の方法。
- 前記前駆体粒子が、該前駆体粒子を成形するために使用される型穴に対応する形状を有する、請求項1〜6のいずれか一項に記載の方法。
- 前記セル微細構造が、アルファアルミナ結晶粒を含み、前記アルファアルミナ結晶粒が、約3マイクロメートル未満の最大寸法を有する、請求項2〜7のいずれか一項に記載の方法。
- 前記焼結された研磨粒子が、アルファアルミナから本質的になる、請求項1〜8のいずれか一項に記載の方法。
- 約3マイクロメートル未満の最大寸法を有するアルファアルミナのアルファアルミナ結晶粒を含むセル微細構造を有し、500マイクロメートル以下の平均粒径を有し、種粒子及びアルファアルミナ粒径調整剤を本質的に含まない、焼結された研磨粒子。
- 前記アルファアルミナが、10,000倍の倍率での断面による画像解析を使用して測定される際、5パーセント以下の面積空隙率を有する、請求項10に記載の焼結された研磨粒子。
- 前記焼結された研磨粒子が、成形された研磨粒子を含む、請求項10又は11に記載のアルファアルミナ研磨粒子。
- 前記焼結された研磨粒子の少なくとも一部分が、角錐台を含む、請求項10〜12のいずれか一項に記載のアルファアルミナ研磨粒子。
- 結合剤及び複数の研磨粒子を含み、前記焼結された研磨粒子の少なくとも一部分が、請求項10〜13のいずれか一項に記載のアルファアルミナ研磨粒子である、研磨物品。
- 結合研磨物品、不織研磨物品、又はコーティングされた研磨物品である、請求項14に記載の研磨物品。
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US8758461B2 (en) | 2010-12-31 | 2014-06-24 | Saint-Gobain Ceramics & Plastics, Inc. | Abrasive particles having particular shapes and methods of forming such particles |
US8840694B2 (en) | 2011-06-30 | 2014-09-23 | Saint-Gobain Ceramics & Plastics, Inc. | Liquid phase sintered silicon carbide abrasive particles |
US8986409B2 (en) | 2011-06-30 | 2015-03-24 | Saint-Gobain Ceramics & Plastics, Inc. | Abrasive articles including abrasive particles of silicon nitride |
EP2760639B1 (en) | 2011-09-26 | 2021-01-13 | Saint-Gobain Ceramics & Plastics, Inc. | Abrasive articles including abrasive particulate materials, coated abrasives using the abrasive particulate materials and methods of forming |
WO2013102177A1 (en) | 2011-12-30 | 2013-07-04 | Saint-Gobain Ceramics & Plastics, Inc. | Shaped abrasive particle and method of forming same |
WO2013102170A1 (en) | 2011-12-30 | 2013-07-04 | Saint-Gobain Ceramics & Plastics, Inc. | Composite shaped abrasive particles and method of forming same |
WO2013106602A1 (en) | 2012-01-10 | 2013-07-18 | Saint-Gobain Ceramics & Plastics, Inc. | Abrasive particles having particular shapes and methods of forming such particles |
BR112014017050B1 (pt) | 2012-01-10 | 2021-05-11 | Saint-Gobain Ceramics & Plastics, Inc. | partícula abrasiva moldada |
US9242346B2 (en) | 2012-03-30 | 2016-01-26 | Saint-Gobain Abrasives, Inc. | Abrasive products having fibrillated fibers |
CN110013795A (zh) | 2012-05-23 | 2019-07-16 | 圣戈本陶瓷及塑料股份有限公司 | 成形磨粒及其形成方法 |
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KR101208896B1 (ko) * | 2012-05-24 | 2012-12-06 | 주식회사 대한세라믹스 | 알루미나계 연마재 지립의 제조방법 및 이에 의해 제조된 알루미나계 연마재 지립 |
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2014
- 2014-03-27 CN CN201480020093.2A patent/CN105102158B/zh active Active
- 2014-03-27 JP JP2016506336A patent/JP6550374B2/ja active Active
- 2014-03-27 WO PCT/US2014/032043 patent/WO2014165390A1/en active Application Filing
- 2014-03-27 EP EP14780310.0A patent/EP2981378B1/en active Active
- 2014-03-27 US US14/782,475 patent/US10400146B2/en active Active
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2019
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JP2021534317A (ja) * | 2018-08-10 | 2021-12-09 | 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Saint−Gobain Ceramics And Plastics, Inc. | 複数の研削粒子を含む組成物およびその使用方法 |
JP7284263B2 (ja) | 2018-08-10 | 2023-05-30 | 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 | 複数の研削粒子を含む組成物およびその使用方法 |
US11674065B2 (en) | 2018-08-10 | 2023-06-13 | Saint-Gobain Ceramics & Plastics, Inc. | Composition including a plurality of abrasive particles and method of using same |
Also Published As
Publication number | Publication date |
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US20160068729A1 (en) | 2016-03-10 |
WO2014165390A1 (en) | 2014-10-09 |
JP6550374B2 (ja) | 2019-07-24 |
EP2981378A1 (en) | 2016-02-10 |
EP2981378A4 (en) | 2016-11-16 |
US10400146B2 (en) | 2019-09-03 |
EP2981378B1 (en) | 2021-06-30 |
JP2019178061A (ja) | 2019-10-17 |
CN105102158A (zh) | 2015-11-25 |
US20190338172A1 (en) | 2019-11-07 |
CN105102158B (zh) | 2018-03-23 |
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