JP2021000721A - 成形研磨材粒子、その製造方法、及びそれを含む研磨材物品 - Google Patents
成形研磨材粒子、その製造方法、及びそれを含む研磨材物品 Download PDFInfo
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Abstract
Description
非コロイド固体粒子及び液体ビヒクルを含むスラリーを提供する工程であって、少なくともいくつかの非コロイド固体粒子は、αアルミナ又はαアルミナ前駆体のうちの少なくとも1つを含み、非コロイド固体粒子は、スラリーの少なくとも30体積%を構成する、工程と、
スラリーの少なくとも一部を、基材と接触する成形体に形成する工程であって、成形体は規定形状に実質的にしたがって形成される、工程と、
成形体を少なくとも部分的に乾燥させて、成形研磨材前駆体粒子を得る工程と、
基材から成形研磨材前駆体粒子の少なくとも一部を分離する工程と、
成形研磨材前駆体粒子の少なくとも一部を成形研磨材粒子に変換する工程であって、成形研磨材粒子はαアルミナを含み、αアルミナは、0.8〜8マイクロメートルの平均結晶粒径を有し、αアルミナは、少なくとも真密度の92%である見かけ密度を有し、各成形研磨材粒子は、それぞれが複数の辺及び少なくとも4つの頂点を含む表面を有し、成形研磨材粒子は、公称の規定形状に一致する、工程と、を含む。
用語「見かけ密度」は、材料の質量をその見かけ体積で割る(すなわち、内部の空隙を含む体積)を指し、
用語「コロイド」は、約10〜10,000オングストロームの寸法である超微粒子状粒子が、これらが容易に濾過されるか又は迅速に沈降するのを防ぐような方法で、連続液体媒体内に分散される系を指し、
用語「結晶粒」は、個別の結晶における結晶格子が連続し、結晶粒界を内部に含まずにその端部まで破壊されていな単一結晶又は単結晶物質における個別の結晶を指し、
用語「結晶粒界」は、多結晶材料において、2つの結晶粒又は結晶子の間に境界面を形成する結晶粒の結晶構造における欠損を指し、
粒径に関して使用される用語「メッシュ」は、別途記載のない限り、米国メッシュサイズを指し、
用語「非コロイド状」は、コロイドの特性を有さないことを意味し、
用語「成形(された)」は、製造中、規定形状にしたがって意図的に成形した結果の形状を意味し、
表面に関する用語「滑らか」は、表面に不規則性、粗さ、又は突起部、それを作製するのに使用される製造プロセスに起因する不規則性によってもたらされ得るもの以外を含まないことを意味し、
用語「真密度」は、所定の圧力及び温度(例えば、大気圧及び25℃の温度)において測定される、物質の任意の内部空隙を除いた所定の物質の密度を指し、
語句「成形研磨材粒子は、公称の規定形状に一致する」とは、成形研磨材粒子の形状が、意図された(規定の)公称形状に一致することを意味し、これは、乾燥中、焼成中、及び焼結中の縮小、及びプロセスの変動性によって起こり得る無作為な偏差(例えば、若干の反り又は欠陥)を考慮に入れて、それらが作製される方法(例えば、成形、押出し、又はスクリーン印刷)によって判断される。
第1の実施形態において、本開示は、研磨材粒子の作製方法を提供し、その方法は、
非コロイド固体粒子及び液体ビヒクルを含むスラリーを提供する工程であって、少なくともいくつかの非コロイド固体粒子は、αアルミナ又はαアルミナ前駆体のうちの少なくとも1つを含み、非コロイド固体粒子は、スラリーの少なくとも30体積%を構成する、工程と、
スラリーの少なくとも一部を、基材と接触する成形体に形成する工程であって、成形体は規定形状に実質的にしたがって形成される、工程と、
成形体を少なくとも部分的に乾燥させて、成形研磨材前駆体粒子を得る工程と、
基材から成形研磨材前駆体粒子の少なくとも一部を分離する工程と、
成形研磨材前駆体粒子の少なくとも一部を成形研磨材粒子に変換する工程であって、成形研磨材粒子はαアルミナを含み、αアルミナは、0.8〜8マイクロメートルの平均結晶粒径、及び少なくとも真密度の92%である見かけ密度を有し、各成形研磨材粒子は、それぞれが複数の辺及び少なくとも4つの頂点を含む表面を有する、工程と、を含む。
成形研磨材前駆体粒子を焼結して成形研磨材粒子を得る工程を含む。
成形研磨材前駆体粒子を焼成して焼成された成形研磨材前駆体粒子を得る工程と、
焼成された成形研磨材前駆体粒子を焼結し、成形研磨材粒子を得る工程と、を含む。
成形研磨材前駆体粒子を金属塩溶液に含浸して、含浸された成形研磨材前駆体粒子を得る工程と、
含浸された成形研磨材前駆体粒子を焼結して成形研磨材粒子を得る工程と、を含む。
成形研磨材前駆体粒子を焼成して焼成された成形研磨材前駆体粒子を得る工程と、
焼成された成形研磨材前駆体粒子を金属塩溶液に含浸して含浸焼成された成形研磨材前駆体粒子を得る工程と、
含浸焼成された成形研磨材前駆体粒子を焼結して成形研磨材粒子を得る工程と、を含む。
裏材と、
裏材の主表面に固定されたメイクコートであって、成形研磨材粒子はメイクコートに接触する、メイクコートと、
メイクコートの少なくとも一部及び成形研磨材粒子の少なくとも一部上に配設されるサイズコートと、を更に含む。
裏材と、
裏材の主表面に固定されたメイクコートであって、成形研磨材粒子はメイクコートに接触する、メイクコートと、
メイクコートの少なくとも一部及び成形研磨材粒子の少なくとも一部上に配設されるサイズコートと、を更に含む。
ポリエチレンライニングボールミルジャーに、100グラム(g)の脱イオン水、0.5gのクエン酸アンモニウム分散剤、400gの様々な酸化アルミニウム粉末(表1で報告されており、表2には原料の供給源を報告している)を投入した。約700グラムのアルミナ粉砕媒体(直径:10mm、99.9%アルミナ、Union Process,Akron,Ohioから入手)をボトルに加え、混合物を120rpmで24時間粉砕した。粉砕後、粉砕媒体を取り除き、デシケータージャー中に載置し、機械式ポンプを使用して真空にかけて(真空下で約10分間保持)スラリーを脱気した。生じたスラリーを、約0.4mmの側長、0.1mmの深さを有する切頭三角錐の複製パターンを含み、5重量%のエタノール溶液から乾燥して残留した鉱油の局所コーティングを有するポリエチレンシートに注入した。スキージを使用して、スラリーをシートの約400cm2の領域に広げて被覆させた。次に、セラミックスラリーを含有するシートをヒートガンで乾燥させた。乾燥後、シートを激しく振って、その時には切頭三角錐の形状になっていた生じた成形研磨材前駆体粒子を取り除いた。
約17グラムの生じた成形研磨材粒子を研磨布紙ディスクに組み込んだ。従来の手順にしたがって研磨布紙ディスクを作製した。成形研磨材粒子を、従来の炭酸カルシウムを充填したフェノール性のメイクレジン(make resin)(48%のレゾール型樹脂及び52%の炭酸カルシウムを水及びグリコールエーテルで81%固体分に希釈したもの)、及び従来のクライオライトを充填したフェノール性のサイズレジン(size resin)(32%のレゾール型樹脂、2%の酸化鉄、66%のクライオライトを水及びグリコールエーテルで78%固体分に希釈したもの)を使用して17.8cmの直径及び0.8mm厚のバルカンファイバー裏材(直径2.2cmの中央穴を有する)に結合した。湿ったメイクレジンの重量は、約185g/m2であった。メイクコートを適用した直後、成形研磨材粒子を静電塗装した。メイクレジンを120分間88℃で加熱した。次に、メイクコート及び研磨材粒子にクライオライトを充填したフェノール性のサイズコートをコーティングした。湿ったサイズの重量は、約850g/m2であった。サイズレジンを12時間99℃で加熱した。研磨布紙ディスクを試験前に屈曲させた。
手順を数回繰り返して、より大量の材料を生成する以外は、実施例2に記載されるようにして、実施例8a〜8eの成形研磨材粒子を調製した。続けて、焼成された成形粒子を結晶粒成長させ、室温から最高着火温度(表4で報告)までにおける25℃/分の傾斜率を含む熱処理を誘導する。実施例8a〜8eの材料は、熱処理に使用される最高着火温度が異なる。
低温で様々な焼成添加剤を導入して緻密化を促進する以外は、実施例1に記載されるようにして実施例9〜13を調製した。焼成添加剤及び96%の理論密度を達成するのに必要な最低着火温度を以下の表5にまとめた。
テフロンライニングアトライターミルジャーに、250gの脱イオン水、4gの硝酸(70%濃縮)、190gの水酸化アルミニウムSH−20(Dadco Aluminium and Chemicals,Lausanne,Switzerlandから入手)を投入した。この粉末は、約0.25重量%のNa2Oを含有していた。約700グラムのアルミナ粉砕媒体(直径:5mm、99.9%アルミナ、Union Processから入手)をジャーに加え、混合物を500rpmで24時間粉砕した。粉砕後、粉砕媒体を取り除き、デシケータージャー中に載置し、31gの硝酸マグネシウム水酸化物(Mg(NO3)2・6H2O)(Sigma−Aldrich Co.,Saint Louis,Missouri)をスラリーに加え、空気駆動の撹拌装備を用いて均質化した。生じたスラリーを、約0.4mmの側長、0.1mmの深さを有する切頭三角錐の複製パターンを含み、5重量%のエタノール溶液から乾燥して残留した鉱油の局所コーティングを有するポリエチレンシートに注入し、スキージを使用して、スラリーをシートの約400cm2の領域に広げて被覆した。次に、スラリーを含有するシートをヒートガンで乾燥させた。乾燥後、ウェブを激しく振って、その時には切頭三角錐の形状になっている生じた成形研磨材前駆体粒子を取り除いた。
Claims (38)
- 研磨材粒子を作製する方法であって、
非コロイド固体粒子及び液体ビヒクルを含むスラリーを提供する工程であって、少なくともいくつかの前記非コロイド固体粒子は、αアルミナ又はαアルミナ前駆体のうちの少なくとも1つを含み、前記非コロイド固体粒子は、前記スラリーの少なくとも30体積%を構成する、工程と、
前記スラリーの少なくとも一部を、基材と接触する成形体に形成する工程であって、前記成形体は規定形状に実質的にしたがって形成される、工程と、
前記成形体を少なくとも部分的に乾燥させて、成形研磨材前駆体粒子を得る工程と、
前記基材から前記成形研磨材前駆体粒子の少なくとも一部を分離する工程と、
前記成形研磨材前駆体粒子の少なくとも一部を成形研磨材粒子に変換する工程であって、前記成形研磨材粒子はαアルミナを含み、前記αアルミナは、0.8〜8マイクロメートルの平均結晶粒径、及び少なくとも真密度の92%である見かけ密度を有し、各成形研磨材粒子は、それぞれが複数の辺及び少なくとも4つの頂点を含む表面を有する、工程と、を含む方法。 - 前記基材はその表面にキャビティを有し、前記スラリーを、前記基材と接触する成形研磨材前駆体粒子に形成する前記工程は、前記スラリーを前記キャビティの少なくとも一部に押入する工程を含む、請求項1に記載の方法。
- 前記スラリーを成形する工程は、前記スラリーをスクリーンを通して前記基材に押入する工程を含む、請求項1又は2に記載の方法。
- 前記非コロイドαアルミナ前駆体粒子は、等量ベースで、前記成形研磨材前駆体粒子の総重量に対して、少なくとも0.03重量%の酸化ナトリウムを含有する、請求項1〜3のうちのいずれか一項に記載の方法。
- 前記成形研磨材前駆体粒子の少なくとも一部を前記成形研磨材粒子に変換する前記工程は、
前記成形研磨材前駆体粒子を焼結して前記成形研磨材粒子をもたらす工程を含む、請求項1〜4のうちのいずれか一項に記載の方法。 - 前記成形研磨材前駆体粒子の少なくとも一部を前記成形研磨材粒子に変換する前記工程は、
前記成形研磨材前駆体粒子を焼成して焼成された成形研磨材前駆体粒子をもたらす工程と、
前記焼成された成形研磨材前駆体粒子を焼結して前記成形研磨材粒子をもたらす工程と、を含む、請求項1〜4のうちのいずれか一項に記載の方法。 - 前記成形研磨材前駆体粒子の少なくとも一部を前記成形研磨材粒子に変換する前記工程は、
前記成形研磨材前駆体粒子を金属塩溶液に含浸して含浸された成形研磨材前駆体粒子を得る工程と、
前記含浸された成形研磨材前駆体粒子を焼結して前記成形研磨材粒子を得る工程と、を含む、請求項1〜6のうちのいずれか一項に記載の方法。 - 前記成形研磨材前駆体粒子の少なくとも一部を前記成形研磨材粒子に変換する前記工程は、
前記成形研磨材前駆体粒子を焼成して焼成された成形研磨材前駆体粒子を得る工程と、
前記焼成された成形研磨材前駆体粒子を金属塩溶液に含浸して含浸焼成された成形研磨材前駆体粒子を得る工程と、
前記含浸焼成された成形研磨材前駆体粒子を焼結して成形研磨材粒子を得る工程と、を含む、請求項1〜6のうちのいずれか一項に記載の方法。 - 前記非コロイドαアルミナ前駆体粒子は、酸化アルミニウム粉末を含む、請求項1〜8のうちのいずれか一項に記載の方法。
- 前記非コロイドαアルミナ前駆体粒子は、粉砕したアルミニウム三水和物粒子を含む、請求項1〜9のうちのいずれか一項に記載の方法。
- 前記非コロイドαアルミナ前駆体粒子は、等量ベースで、前記成形研磨材前駆体粒子の総重量に対して、0.03〜0.25%の酸化ナトリウムを含有する、請求項1〜10のうちのいずれか一項に記載の方法。
- 前記非コロイドαアルミナ前駆体粒子は、少なくとも0.2マイクロメートルの平均粒径を有する、請求項1〜10のうちのいずれか一項に記載の方法。
- 前記スラリーは増粘剤を更に含む、請求項1〜12のうちのいずれか一項に記載の方法。
- 前記増粘剤はコロイド状ベーマイトを含む、請求項13に記載の方法。
- 前記増粘剤は有機増粘剤を含む、請求項13に記載の方法。
- 前記成形研磨材粒子は20メッシュより大きい平均粒径を有する、請求項1〜15のうちのいずれか一項に記載の方法。
- 前記非コロイドαアルミナ前駆体粒子は、前記スラリーの少なくとも40体積%を構成する、請求項1〜16のうちのいずれか一項に記載の方法。
- 請求項1〜17のうちのいずれか一項に記載の方法により作製される、成形研磨材粒子。
- バインダーに保持された、請求項18に記載の成形研磨材粒子を含む研磨材物品であって、前記成形研磨材粒子はαアルミナを含み、前記αアルミナは、0.8〜8マイクロメートルの平均結晶粒径を有し、前記αアルミナは、少なくとも真密度の92%である見かけ密度を有し、前記成形研磨材粒子は、公称の規定形状に一致する、研磨材物品。
- 前記研磨材物品が、
裏材と、
前記裏材の主表面に固定されたメイクコートであって、前記成形研磨材粒子は前記メイクコートに接触している、メイクコートと、
前記メイクコートの少なくとも一部及び前記成形研磨材粒子の少なくとも一部上に配設されているサイズコートと、を更に含む、請求項19に記載の研磨材物品。 - 前記研磨材粒子は、裏材及び前記裏材の主表面と接触する研磨層を更に含み、前記研磨層は、前記バインダー及び前記成形研磨材粒子を含む、請求項19又は20に記載の研磨材物品。
- 前記研磨材物品は嵩高な開放型の繊維ウェブを更に含む、請求項19に記載の研磨材物品。
- 前記研磨材物品は結合研磨ホイールを含む、請求項19に記載の研磨材物品。
- 請求項19〜23のうちのいずれか一項に記載の研磨材物品に含まれる少なくとも1つの成形研磨材粒子と工作物とを接触させる工程と、研磨材物品又は前記工作物のうちの少なくとも1つを他方に対して動かして前記工作物の少なくとも一部を研磨する工程と、を含む、工作物の研磨方法。
- αアルミナを含む成形研磨材粒子であって、前記αアルミナは、0.8〜8マイクロメートルの平均結晶粒径を有し、前記αアルミナは、少なくとも真密度の92%である見かけ密度を有し、各成形研磨材粒子は、それぞれが複数の辺及び少なくとも4つの頂点を含む表面を有し、前記成形研磨材粒子は、公称の規定形状に一致する、成形研磨材粒子。
- 各表面はそれぞれが少なくとも4つの縁部を更に含み、各縁部の平均幅は、約5〜20マイクロメートルの範囲であり、平均結晶粒径に対する各縁部の平均幅の比率は、1〜25の範囲である、請求項25に記載の成形研磨材粒子。
- 各成形研磨材粒子は、それぞれが複数の側壁に当接する底面を含み、前記底面は少なくとも3つの頂点を含む、請求項25又は26に記載の成形研磨材粒子。
- 各成形研磨材粒子は、それぞれが前記複数の側壁に当接する上面を更に含み、前記上面及び前記底面は互いに接触しない、請求項27に記載の成形研磨材粒子。
- 前記側壁は、前記底面から内側に向かって細くなっている、請求項27又は28に記載の成形研磨材粒子。
- 前記成形研磨材粒子は、等量ベースで、前記成形研磨材粒子の総重量に対して、少なくとも0.03重量%の酸化ナトリウムを含有する、請求項25〜29のうちのいずれか一項に記載の成形研磨材粒子。
- 前記成形研磨材粒子は、前記成形研磨材粒子の総重量に対して、0.03〜0.25%の酸化ナトリウムを含有する、請求項25〜29のうちのいずれか一項に記載の成形研磨材粒子。
- 前記成形研磨材粒子は、6〜80の範囲の米国メッシュサイズと一致する平均粒径を有する、請求項25〜31のうちのいずれか一項に記載の成形研磨材粒子。
- バインダーに保持された成形研磨材粒子を含む研磨材物品であって、前記成形研磨材粒子はαアルミナを含み、前記αアルミナは、0.8〜8マイクロメートルの平均結晶粒径を有し、前記αアルミナは、少なくとも真密度の92%である見かけ密度を有し、前記成形研磨材粒子は、公称の規定形状に一致する、研磨材物品。
- 前記研磨材物品が、
裏材と、
前記裏材の主表面に固定されたメイクコートであって、前記成形研磨材粒子は前記メイクコートに接触している、メイクコートと、
前記メイクコートの少なくとも一部及び前記成形研磨材粒子の少なくとも一部上に配設されているサイズコートと、を更に含む、請求項33に記載の研磨材物品。 - 前記研磨材物品は、裏材及び前記裏材の主表面と接触する研磨層を更に含み、前記研磨層は、前記バインダー及び前記成形研磨材粒子を含む、請求項33に記載の研磨材物品。
- 前記研磨材物品は嵩高な開放型の繊維ウェブを更に含む、請求項33に記載の研磨材物品。
- 前記研磨材物品は結合研磨ホイールを含む、請求項33に記載の研磨材物品。
- 請求項33〜37のうちのいずれか一項に記載の研磨材物品と前記工作物とを接触させる工程と、研磨材物品又は前記工作物のうちの少なくとも1つを他方に対して動かして前記工作物の少なくとも一部を研磨する工程と、を含む、工作物の研磨方法。
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JP2018090311A Active JP6960373B2 (ja) | 2012-10-31 | 2018-05-09 | 成形研磨材粒子、その製造方法、及びそれを含む研磨材物品 |
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EP (1) | EP2914402B1 (ja) |
JP (3) | JP6550335B2 (ja) |
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CN (1) | CN104768710B (ja) |
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CA (1) | CA2888733A1 (ja) |
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US11530345B2 (en) | 2022-12-20 |
PL2914402T3 (pl) | 2021-09-27 |
EP2914402B1 (en) | 2021-04-28 |
JP7076890B2 (ja) | 2022-05-30 |
RU2015114083A (ru) | 2016-12-20 |
US20150267097A1 (en) | 2015-09-24 |
CA2888733A1 (en) | 2014-05-08 |
EP2914402A1 (en) | 2015-09-09 |
CN104768710B (zh) | 2017-09-22 |
JP6550335B2 (ja) | 2019-07-24 |
RU2616464C9 (ru) | 2018-05-21 |
JP2018134733A (ja) | 2018-08-30 |
KR102146313B1 (ko) | 2020-08-21 |
JP2016500581A (ja) | 2016-01-14 |
US10696883B2 (en) | 2020-06-30 |
CN104768710A (zh) | 2015-07-08 |
KR20150081313A (ko) | 2015-07-13 |
JP6960373B2 (ja) | 2021-11-05 |
US20200277522A1 (en) | 2020-09-03 |
RU2616464C2 (ru) | 2017-04-17 |
BR112015009886A2 (pt) | 2017-07-11 |
MX2015005167A (es) | 2015-09-04 |
BR112015009886B1 (pt) | 2021-06-08 |
WO2014070468A1 (en) | 2014-05-08 |
EP2914402A4 (en) | 2016-07-20 |
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