JP5525546B2 - 溝を有する成形された研磨粒子 - Google Patents
溝を有する成形された研磨粒子 Download PDFInfo
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- JP5525546B2 JP5525546B2 JP2011542205A JP2011542205A JP5525546B2 JP 5525546 B2 JP5525546 B2 JP 5525546B2 JP 2011542205 A JP2011542205 A JP 2011542205A JP 2011542205 A JP2011542205 A JP 2011542205A JP 5525546 B2 JP5525546 B2 JP 5525546B2
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K3/00—Materials not provided for elsewhere
- C09K3/14—Anti-slip materials; Abrasives
- C09K3/1409—Abrasive particles per se
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
- B24D18/0009—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
- B24D5/10—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor with cooling provisions, e.g. with radial slots
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09G—POLISHING COMPOSITIONS; SKI WAXES
- C09G1/00—Polishing compositions
- C09G1/02—Polishing compositions containing abrasives or grinding agents
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K3/00—Materials not provided for elsewhere
- C09K3/14—Anti-slip materials; Abrasives
-
- 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
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24364—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.] with transparent or protective coating
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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
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/256—Heavy metal or aluminum or compound thereof
- Y10T428/257—Iron oxide or aluminum oxide
-
- 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
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
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- Manufacturing & Machinery (AREA)
- Inorganic Chemistry (AREA)
- Polishing Bodies And Polishing Tools (AREA)
Description
本明細書で使用されているように、「含む」、「有する」、及び「包含する」という単語の形態は、法律的に同意義でありかつ制約されない。それゆえ、列挙されている要素、機能、工程又は制限に加えて、列挙されていない付加的な要素、機能、工程又は制限が存在し得る。
図1を参照すると、複数の成形型の空洞102を有する生産工具100の一部が示されている。明確にするために、単一の成形型の空洞102が図示される。成形型の空洞102は、成形型の側壁104と成形型の底面106とを含む。一実施形態において、成形型の底面及び成形型の側壁は高分子材料を含んだ。成形型の底面の外辺部を形成する成形型の側壁104の幾何学的形状は様々であってよい。一実施形態において幾何学的形状には、成形型の空洞が3つの対向する成形型の側壁を有するように、生産工具内の各成形型の空洞の上から見たときに正三角形が選択された。本明細書で後述するように、成形型の空洞の他の幾何学的形状も使用できる。成形型の側壁104は、成形型の底面106と所定の角度αで交差する。本明細書で後述するように、成形された研磨粒子20の研削性能は、角度αが約95度〜約130度になるように選択することによって改善できる。しかし所定の角度αは、90度又は90度よりも若干小さくてもよい。これは、成形型の空洞102内で形成される成形された研磨粒子の前駆体が乾燥中に収縮することがあり、したがって成形された研磨粒子の前駆体は閉じ込められるのではなく、それでもなお成形型の空洞から取り出されるからである。
図6A、6B、及び6Cを参照すると、例示の傾斜側壁22を有する成形された研磨粒子20が図示されている。以下の説明において、傾斜側壁(90度を超える抜き勾配α)を有する成形された研磨粒子のいずれの実施形態も上述の溝116を有する成形された研磨粒子のいずれかの実施形態と組み合わせることができる。傾斜側壁22を有する成形された研磨粒子20が作製される材料は、αアルミナを含む。αアルミナ粒子は、本明細書で後述するように、ゲル化され、型で成形され、その形を維持するために乾燥され、か焼され、次に焼結された、酸化アルミニウム一水和物の分散により作製されてよい。
図1C、4C、及び5Cを参照すると、被覆された研磨物品40は、裏材42の第1の主表面41に塗布される結合剤の第1の層(以下、メークコート44と呼ぶ)を有する裏材42を含む。メークコート44に取り付けられる又は部分的に埋め込まれるのは、傾斜側壁22及び/又は溝116を有する複数の成形された研磨粒子20であり、研磨層を形成する。傾斜側壁22を有する成形された研磨粒子20には、結合剤の第2の層(以下、サイズコート46と呼ぶ)が塗布される。メークコート44の目的は、傾斜側壁22を有する成形された研磨粒子20を裏材42に固定することであり、サイズコート46の目的は、傾斜側壁22を有する成形された研磨粒子20を補強することである。傾斜側壁22を有する成形された研磨粒子20の大部分は、先端48又は頂点が裏材42から離れる方向を向くように配向され、成形された研磨粒子は、傾斜側壁22上に存在し、示されるように先細になるか又は傾斜している。
第1のプロセス工程は、αアルミナに転換可能な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。αアルミナ前駆体組成物は、揮発性成分である液体を含むことが多い。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。一実施形態において、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。
次の配合を使用してベーマイトゾルゲルの試料を作製した。つまり、水(2400部)及び70%の含水硝酸(72部)を含有する溶液を11分間高せん断混合することによって、商品名「DISPERAL」を有する酸化アルミニウム一水和物粉末(1600部)を分散させた。結果として生じるゾルゲルは、少なくとも1時間置いてから塗布した。ゾルゲルは、28ミル(0.71mm)の深さ及び両側110ミル(2.79mm)の三角形の成形型の空洞を有する生産工具に押し入れた。成形型の側壁と成形型の底面との間の抜き勾配αは、生産工具ごとに異なっていた。抜き勾配αは、第1の工具では90度、第2の工具では98度、第3の工具では120度、最後の工具では135度であった。抜き勾配が98度の生産工具は、成形型の空洞の50%が、三角形の一辺と90度の角度で交差する空洞の底面から立ち上がる8つの平行の隆起部を有し、残りの空洞が平滑な成形型底面を有するように製造した。上述のように、平行な隆起部は0.277mmごとに離隔され、隆起部の横断面は、高さ0.0127mmで、それぞれの隆起部の側部が先端となす角度が45度の三角形であった。ゾルゲルは、生産工具の開口部が完全に埋まるように、パテナイフを使用して空洞に押し入れた。離型剤(メタノール中1%のピーナッツオイル)を使用して生産工具を被覆し、生産工具に約0.5mg/in2(0.078mg/cm2)のピーナッツオイルを塗布した。過剰なメタノールは、生産工具のシートを空気対流炉に45℃で5分間配置することにより除去した。ゾルゲルで被覆された生産工具は、45℃の空気対流炉に少なくとも45分間配置して乾燥させた。超音波ホーンを通過させることにより、成形された研磨粒子の前駆体を生産工具から取り出した。成形された研磨粒子の前駆体を約650℃でか焼し、次に、(酸化物として報告された)濃度がそれぞれ1.8%のMgO、Y2O3、Nd2O3及びLa2O3硝酸混合液で飽和した。過剰な酢酸溶液を除去し、飽和した、開口部を有する成形された研磨粒子の前駆体を乾燥させ、その後粒子を650℃で再か焼し、約1400℃で焼結した。か焼及び焼結のいずれも、回転管状窯を使用して実行した。
Claims (4)
- それぞれが側壁を有する成形された複数の研磨粒子を含み、前記成形された複数の研磨粒子のそれぞれがαアルミナを含み、前記側壁によって分けられた第1の面及び第2の面を有し、並びに最大厚さTを有し、
前記第1の面の外辺部及び前記第2の面の外辺部が三角形を含み、
前記成形された複数の研磨粒子が前記第2の面上に複数の溝を更に含み、
前記第2の面と前記側壁との間の抜き勾配αを含み、前記抜き勾配αが95度〜130度である、複数の研磨粒子。 - 前記複数の溝の断面形状が三角形又は切頭三角形を含む、請求項1に記載の複数の研磨粒子。
- 前記複数の溝のそれぞれが深さDを含み、D/Tのパーセント比が0.1〜10%である、請求項1又は2に記載の複数の研磨粒子。
- 請求項1〜3のいずれか一項に記載の複数の研磨粒子と、裏材の第1の主表面上のメークコートと、前記側壁によって前記メークコートに接着され、研磨層を形成する前記成形された複数の研磨粒子のブレンドと、サイズコートで被覆された前記研磨層とを含み、前記成形された複数の研磨粒子のブレンドが、前記複数の溝を有する成形された複数の研磨粒子と、前記複数の溝を有さない成形された複数の研磨粒子とを含む、被覆された研磨物品。
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US13826808P | 2008-12-17 | 2008-12-17 | |
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PCT/US2009/066099 WO2010077509A1 (en) | 2008-12-17 | 2009-11-30 | Shaped abrasive particles with grooves |
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JP2012512046A JP2012512046A (ja) | 2012-05-31 |
JP2012512046A5 JP2012512046A5 (ja) | 2012-12-20 |
JP5525546B2 true JP5525546B2 (ja) | 2014-06-18 |
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JP2011542205A Active JP5525546B2 (ja) | 2008-12-17 | 2009-11-30 | 溝を有する成形された研磨粒子 |
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PL (1) | PL2370232T3 (ja) |
RU (1) | RU2506152C2 (ja) |
WO (1) | WO2010077509A1 (ja) |
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US20140237907A1 (en) | 2014-08-28 |
US20140239148A1 (en) | 2014-08-28 |
RU2506152C2 (ru) | 2014-02-10 |
US20240010893A1 (en) | 2024-01-11 |
CA2746932C (en) | 2018-09-11 |
JP2012512046A (ja) | 2012-05-31 |
CA2746932A1 (en) | 2010-07-08 |
US9938439B2 (en) | 2018-04-10 |
US20190092991A1 (en) | 2019-03-28 |
US9890309B2 (en) | 2018-02-13 |
US20100146867A1 (en) | 2010-06-17 |
WO2010077509A1 (en) | 2010-07-08 |
RU2011123660A (ru) | 2013-01-27 |
US8764865B2 (en) | 2014-07-01 |
BRPI0922318A2 (pt) | 2016-01-12 |
EP2370232A4 (en) | 2013-02-20 |
BRPI0922318B1 (pt) | 2020-09-15 |
CA3012625C (en) | 2020-07-07 |
CA3081239C (en) | 2022-09-20 |
US20190092990A1 (en) | 2019-03-28 |
CA3012625A1 (en) | 2010-07-08 |
US11767454B2 (en) | 2023-09-26 |
CN102317038A (zh) | 2012-01-11 |
EP2370232A1 (en) | 2011-10-05 |
KR101691240B1 (ko) | 2016-12-29 |
EP2370232B1 (en) | 2015-04-08 |
PL2370232T3 (pl) | 2015-09-30 |
KR20110093947A (ko) | 2011-08-18 |
US20180223145A1 (en) | 2018-08-09 |
CN102317038B (zh) | 2014-02-05 |
CA3081239A1 (en) | 2010-07-08 |
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