JP7010566B2 - メタルボンド及びガラス質ボンド研磨物品の製造方法、並びに研磨物品前駆体 - Google Patents
メタルボンド及びガラス質ボンド研磨物品の製造方法、並びに研磨物品前駆体 Download PDFInfo
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- C22C32/001—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
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Description
a)逐次的に、
i)固まっていない粉末粒子の層を限定された領域内に堆積させる工程であって、固まっていない粉末粒子が、ガラス質ボンド前駆体粒子、研磨粒子、及び有機化合物粒子を含み、固まっていない粉末粒子の層が、実質的に均一な厚さを有する、堆積させる工程、及び
ii)伝導又は照射によって熱を選択的に適用して、固まっていない粉末粒子の層のエリアを加熱処理する工程、
を含むサブプロセス工程と、
b)工程a)を複数回独立して実施して、結合された粉末粒子と残りの固まっていない粉末粒子とを含む研磨物品プリフォームを生成する工程であって、各工程a)において、固まっていない粉末粒子が独立して選択される、工程と、
c)残りの固まっていない粉末粒子の実質的に全てを研磨物品プリフォームから分離する工程と、
d)研磨物品プリフォームを加熱して、ガラス質ボンド材料中に保持された研磨粒子を含むガラス質ボンド研磨物品を提供する工程と、
の逐次的工程を含む、製造方法である。
a)逐次的に、
i)固まっていない粉末粒子の層を限定された領域内に堆積させる工程であって、固まっていない粉末粒子が、高融点金属粒子、研磨粒子、及び有機化合物粒子を含み、固まっていない粉末粒子の層が、実質的に均一な厚さを有する、堆積させる工程、及び
ii)伝導又は照射によって熱を選択的に適用して、固まっていない粉末粒子の層のエリアを加熱処理する工程、
を含むサブプロセス工程と、
b)工程a)を複数回独立して実施して、結合された粉末粒子と残りの固まっていない粉末粒子とを含む研磨物品プリフォームを生成する工程であって、各工程a)において、固まっていない粉末粒子が独立して選択される、工程と、
c)残りの固まっていない粉末粒子の実質的に全てを研磨物品プリフォームから分離する工程と、
d)研磨物品プリフォームに溶融した低融点金属を注入する工程であって、高融点金属粒子の少なくとも一部が、溶融した低融点金属と接触したときに完全には溶融しない、注入する工程と、
e)溶融した低融点金属を固化して、メタルボンド研磨物品を提供する工程と、
の逐次的工程を含む、製造方法。
a)逐次的に、
i)固まっていない粉末粒子の層を限定された領域内に堆積させる工程であって、固まっていない粉末粒子が、金属粒子、研磨粒子、及び有機化合物粒子を含み、固まっていない粉末粒子の層が、実質的に均一な厚さを有する、堆積させる工程、
ii)伝導又は照射によって熱を選択的に適用して、固まっていない粉末粒子の層のエリアを加熱処理する工程、
を含むサブプロセス工程と、
b)工程a)を複数回独立して実施して、結合された粉末粒子と残りの固まっていない粉末粒子とを含む研磨物品プリフォームを生成する工程であって、研磨物品プリフォームは所定の形状を有し、各工程a)において、固まっていない粉末粒子が独立して選択される、工程と、
c)残りの固まっていない粉末粒子の実質的に全てを研磨物品プリフォームから分離する工程と、
d)研磨物品プリフォームを加熱して、メタルボンド研磨物品を提供する工程と、
の逐次的工程を含む、製造方法である。
混合物重量を基準として、77.3重量%のPDR1、13.6重量%のPDR2、及び9.1重量%のPDR3を混合することによって、印刷材料P1を調製した。粉末混合物を、ガラスジャーに入れ、ローリングバンクミキサ上で約50rpmで15分間回転させた。直線状の金属ブレードを用いて、印刷材料を1枚の紙の上に展延し、1枚の紙をシムとして使用し、得られた第1の粉末層の厚さは約100ミクロンであった。これを、厚さ2mil(50.8マイクロメートル)のPETフィルムで被覆した。はんだごてを約425°F(約218℃)まで加熱し、その高温チップを、所定の約1センチメートル(cm)×1cmのエリア上にゆっくりと動かした。わずかな圧力しか適用されず、PETフィルムはほとんど変形しなかった。その後、PETフィルムを除去し、加熱チップがPETフィルムに接触したエリアにおいて、印刷材料P1が淡灰色から暗灰色に変わったことが観察された。第2層の紙をシムとして使用して、第2の厚さ0.1ミリメートル(mm)の印刷材料の層を、印刷材料の第1層の上に展延した。再びPETフィルムで被覆し、再びはんだごてのチップで同じ1cmx1cmのエリアを加熱した。その後、第3層について、この手順を繰り返した。PETフィルムを除去した後、固まっていない粉末から固形物を抽出した。3つの層は共に溶融してグリーン体を形成したことが観察された。次に、このグリーン体を炉内に入れ、400℃で2時間バーンアウトした後、700℃で4時間焼結して、約1cm×1cmで厚さ0.3mmの寸法の正方形の研磨剤を得た。
次に、このグリーン体を炉内に入れ、400℃で2時間バーンアウトした後、700℃で4時間焼結して、約1.5cm×1.5cmで厚さ0.8mmの寸法の正方形の研磨剤を得た。
実験装置及び製剤
Claims (4)
- 非一時的機械可読媒体から、ガラス質ボンド研磨物品プリフォームの3Dモデルを表すデータを検索することであって、前記ガラス質ボンド研磨物品プリフォームのガラス質ボンド研磨物品前駆体は、
ガラス質ボンド前駆体材料と有機化合物である一時的バインダとによって互いに結合された研磨粒子を含み、前記ガラス質ボンド研磨物品前駆体は、
前記ガラス質ボンド研磨物品前駆体を少なくとも部分的に通って延びる少なくとも1つの蛇行状冷却チャネル;又は
前記ガラス質ボンド研磨物品前駆体を少なくとも部分的に通って延びる少なくとも1つの弓状冷却チャネル;
のうちの少なくとも1つを更に含み、前記有機化合物は、ワックス、糖、250℃以下の融点を有する熱可塑性材料、又は、これらの組み合わせを有する、検索することと、
1又は複数のプロセッサによって、前記データを使用する製造デバイスとインターフェースする3D印刷アプリケーションを実行することと、
前記製造デバイスによって、前記ガラス質ボンド研磨物品プリフォームの物理的オブジェクトを生成することであって、ガラス質ボンド前駆体材料、研磨粒子、及び、有機化合物材料を含む固まっていない粉末粒子の層を堆積することと、前記有機化合物の融点よりも高い温度まで前記固まっていない粉末粒子の層の一部エリアを選択的に加熱することと、前記エリアを変更しながら前記堆積及び前記選択的な加熱を繰り返して、各層の非加熱エリアによって前記少なくとも1つの蛇行状冷却チャネル又は前記少なくとも1つの弓状冷却チャネルを形成することと、を含む前記生成することと、
前記非加熱エリアにおける固まっていない粉末粒子から前記生成された前記ガラス質ボンド研磨物品プリフォームを分離することと、
前記ガラス質ボンド研磨物品プリフォームを540℃から1700℃までの間の温度で焼成することと、
を含む、方法。 - 1又は複数のプロセッサを有する製造デバイスによって、ガラス質ボンド研磨物品前駆体の複数の層を規定するデータを含むデジタルオブジェクトを受信することであって、前記ガラス質ボンド研磨物品前駆体は、
ガラス質ボンド前駆体材料と有機化合物である一時的バインダとによって互いに結合された研磨粒子を含み、前記ガラス質ボンド研磨物品前駆体は、
前記ガラス質ボンド研磨物品前駆体を少なくとも部分的に通って延びる少なくとも1つの蛇行状冷却チャネル;又は
前記ガラス質ボンド研磨物品前駆体を少なくとも部分的に通って延びる少なくとも1つの弓状冷却チャネル;
のうちの少なくとも1つを更に含み、前記有機化合物は、ワックス、糖、250℃以下の融点を有する熱可塑性材料、又は、これらの組み合わせを有する、受信することと、
前記製造デバイスで、付加製造プロセスによって、前記デジタルオブジェクトに基づいてガラス質ボンド研磨物品プリフォームを生成することであって、ガラス質ボンド前駆体材料、研磨粒子、及び、有機化合物材料を含む固まっていない粉末粒子の層を堆積することと、前記有機化合物の融点よりも高い温度まで前記固まっていない粉末粒子の層の一部エリアを選択的に加熱することと、前記エリアを変更しながら前記堆積及び前記選択的な加熱を繰り返して、各層の非加熱エリアによって前記少なくとも1つの蛇行状冷却チャネル又は前記少なくとも1つの弓状冷却チャネルを形成することと、を含む前記生成することと、
前記非加熱エリアにおける固まっていない粉末粒子から前記生成された前記ガラス質ボンド研磨物品プリフォームを分離することと、
前記ガラス質ボンド研磨物品プリフォームを540℃から1700℃までの間の温度で焼成することと、
を含む、方法。 - 前記ワックスは、カルナウバワックス、キャンデリラワックス、酸化フィッシャートロプシュワックス、微結晶性ワックス、ラノリン、ヤマモモワックス、パーム核ワックス、羊脂ワックス、ポリエチレンワックス、ポリエチレンコポリマーワックス、石油由来ワックス、モンタンワックス誘導体、ポリプロピレンワックス、酸化ポリエチレンワックス、及び、これらの組み合わせを有する、請求項1又は2に記載の方法。
- 前記250℃以下の融点を有する熱可塑性材料は、ポリエチレンテレフタレート(PET)、ポリ乳酸(PLA)、ポリ塩化ビニル(PVC)、ポリメチルメタクリレート(PMMA)、ポリプロピレン(PP)、ビスフェノールAポリカーボネート(BPA-PC)、ポリスルホン(PSF)、ポリエーテルイミド(PEI)、及び、これらの組み合わせを有する、請求項1又は2に記載の方法。
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