• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
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  • 优先权
    • 专利摘要:
    ABRASIVE PARTICLES WITH FORMAT AND PRODUCTION METHOD. The present invention relates to a method of producing abrasive shaped particles including the formation of an abrasive flake that comprises a plurality of shaped abrasive precursor particles and a frangible support that joins the shaped abrasive precursor particles; transports the abrasive flake through a rotating furnace to sinter the abrasive flake; and breaks the sintered abrasive flake into individual shaped abrasive particles. The method is useful for making small shaped abrasive particles with insufficient mass to be individually sintered efficiently in a rotary furnace, without joining two or more shaped abrasive particles.
    公开号:BR112013009469B1
    申请号:R112013009469-9
    申请日:2011-10-19
    公开日:2020-08-25
    发明作者:Dwight D. Erickson
    申请人:3M Innovative Properties Company；
    IPC主号:
    专利说明:

    [0001] Abrasive particles and abrasive articles produced from abrasive particles are useful for abrasion, finishing or crushing a wide variety of materials and surfaces in the manufacture of goods. As such, there remains a need to improve the cost, performance or life of the abrasive particle and / or the abrasive article.
    [0002] Abrasive particles with triangular shape and abrasive articles using triangular shape abrasive particles are disclosed in U.S. Patent No. 5,201,916 to Berg; 5,366,523 to Rowenhorst (Re. 35,570); and 5,984,988 to Berg. In one embodiment, the shape of the abrasive particles comprises an equilateral triangle. Abrasive particles with triangular shape are useful in the manufacture of abrasive articles that have high cutting rates. summary
    [0003] Shaped abrasive particles can, in general, outperform randomly crushed abrasive particles. By controlling the abrasive particle shape, it is possible to control the performance resulting from the abrasive article. In order to reduce the cutting rate and optimize the finish when using abrasive shaped particles to abrasion parts, smaller shaped abrasive particles are required. Typically, shaped abrasive particles that are produced in commercial quantities are calcined and sintered in a rotary furnace, instead of an oven, to economically produce large quantities during the manufacture of the shaped abrasive particles. Rotary furnaces often have a counterflow current of hot air relative to the downward movement of the abrasive particle from the tilted slope of the rotary furnace. As the shaped abrasive particle becomes smaller and smaller, the air currents inside the rotating furnace can impede its progress through the rotating furnace, decreasing the normal residence time inside the rotating furnace or even catching and expelling the abrasive particles shaped with the gaseous volatiles produced during sintering. As the shaped abrasive particle becomes very small, at the end none of the shaped abrasive particles leave the rotating furnace and all remain inside the furnace or are expelled with the gaseous volatiles.
    [0004] The inventor determined that to solve this problem it is necessary to temporarily connect the shaped abrasive particles to each other with a frangible support to form larger abrasive flakes containing the individually shaped abrasive particles. These larger abrasive flakes can readily pass through the rotary furnace due to their size without the problems described above and can then be mechanically manipulated to break up the sintered abrasive flakes within the individual shaped abrasive particles. The frangible support can be a substantially continuous and thin layer of material surrounding the shaped abrasive particle or discontinuous bonding rods connecting each shaped abrasive particle to the next shaped abrasive particle. By controlling the thickness of the frangible support, its fracture resistance can be controlled to allow the sintered abrasive flake to fracture into individual shaped abrasive particles.
    [0005] Therefore, in one embodiment, the invention resides in a method for producing abrasive particles with a shape that comprises: forming an abrasive flake that comprises a plurality of abrasive precursor particles with a shape and a frangible support joining the abrasive precursor particles with a shape; transport the abrasive flake through a rotary furnace to sinter the abrasive flake; and breaking the sintered abrasive flake into individual shaped abrasive particles.
    [0006] In another embodiment, the invention resides in a sintered abrasive flake that comprises a plurality of shaped abrasive particles and a frangible support joining the shaped abrasive particles.
    [0007] In another embodiment, the invention resides in a plurality of shaped abrasive particles having a rated grade or examined rated grade specified in the abrasive industry each shaped abrasive particle comprising a fractured surface of a frangible support fixed to the shaped abrasive particle . Brief description of the drawings
    [0008] It should be understood by the person skilled in the art that the present discussion is a description of exemplary modalities only and is not intended to limit the broader aspects of the present description, whose broader aspects are incorporated into the exemplary construction.
    [0009] Figure 1 is a photomicrograph of sintered abrasive flakes that comprise abrasive particles with a shape and a frangible support.
    [0010] Figure 2 is an illustration of a sintered abrasive flake comprising shaped abrasive particles and a frangible support.
    [0011] Figure 3 is a photograph of individual shaped abrasive particles resting on a canvas after mechanical breakage of the frangible support.
    [0012] Figure 4 is a photograph of a shaped abrasive particle and with a portion of the remaining frangible support attached to the shaped abrasive particle.
    [0013] Figures 5A and 5B are illustrations of another modality of shaped abrasive particles.
    [0014] The repeated use of reference characters in the specification and drawings is intended to represent the same or similar characteristics or elements of the description. Definitions
    [0015] For use in the present invention, the forms of the words "understand", "have" and "include" are legally equivalent and are not limiting. Therefore, the additional elements, functions, steps or limitations not mentioned may be present in addition to the elements, functions, steps, or limitations mentioned.
    [0016] For use in the present invention, the term "abrasive dispersion" means an alpha alumina precursor that can be converted to alpha alumina, which is introduced into a mold cavity. The composition is called an abrasive dispersion until sufficient volatile components are removed to cause the abrasive dispersion to solidify.
    [0017] For use in the present invention, "abrasive flake" refers to the non-sintered structure of a plurality of shaped abrasive precursor particles joined by a frangible support while "sintered abrasive flake" refers to the structure after being sintered which comprises a plurality abrasive particles shaped by a frangible support.
    [0018] For use in the present invention, the term "shaped abrasive precursor particle" means the unsintered particle produced by removing a sufficient amount of the volatile component from the abrasive dispersion, when it is in the mold cavity, to form a solidified body that it can be removed from the mold cavity and substantially retains its molded shape in subsequent processing operations.
    [0019] For use in the present invention, the term "shaped abrasive particle" means a ceramic abrasive particle with at least a portion of the abrasive particle having a predetermined shape. The shape is often reproduced from a mold cavity used to form the shaped abrasive precursor particle. Except in the case of abrasive fragments (for example, as described in US patent application 12/336877), the shaped abrasive particle will generally have a predetermined geometric shape that substantially reproduces the mold cavity that was used to form the particle abrasive with shape. The mold cavity can reside on the surface of a embossing roller or be contained in a flexible conveyor or production tool. Alternatively, the shaped abrasive particles can be precisely cut out of a sol-gel blade dried by a laser beam in the desired geometric shape. Detailed Description Sintered abrasive flakes
    [0020] Referring to Figure 1, sintered abrasive flakes 10 comprising abrasive particles shaped 12 and a frangible support 14 are illustrated. The sintered abrasive flakes, the shaped abrasive particles, and the frangible support comprise a ceramic. In one embodiment, the ceramic may comprise alpha alumina particles produced from a dispersion of aluminum hydroxide oxide or aluminum monohydrate that is gelled, shaped into a specific shape and dried to form abrasive flakes containing abrasive shaped, calcined particles , and then sintered as discussed in this document earlier.
    [0021] In order to process the abrasive flakes effectively through the rotary furnace, the largest dimension of the sintered abrasive flakes should be greater than or equal to 0.50, 0.60, or 0.70 mm. As the size of the abrasive flake becomes larger, it is more easily processed through the rotating furnace without the undue influence of drafts in the furnace or even sticking inside the furnace due to the abrasive flake having a very small mass. However, large abrasive flakes are prone to cracking by sol-gel (cracking by desiccation) and are thus somewhat self-limiting at their maximum size. In some embodiments, the sintered abrasive flakes have a maximum dimension of 2 cm or less. In embodiments of the invention, the size of the sintered abrasive flakes may be such that they do not pass through a US standard sieve in accordance with ASTM E-11, with a weft size of 18, 16, 14, or smaller sieve and are retained in the sieve.
    [0022] In other embodiments of the invention, the average mass of the sintered abrasive flakes can be greater than or equal to 7 x 103 grams, greater than or equal to 9 x 10 '3 grams, or greater than or equal to 11 x 10-3 grams. The average mass of the sintered abrasive flakes can be determined by weighing 100 individual sintered abrasive flakes and averaging the result. The inventors determined that by making individual shaped abrasive particles with an average mass of less than 9 x 10-3 grams, the efficiency of the process begins to decrease and the loss of shaped abrasive particles when sintering in a rotary furnace begins to occur .
    [0023] The method of processing the abrasive flakes through the rotating furnace is especially effective when the overall size (defined as the minimum size that passes through a screen) of the shaped abrasive particles after being separated from the frangible support is less than or equal to 0.70, 0.60, or 0.50 mm and greater than 0.0 mm. As the size of the shaped abrasive particle becomes larger, it is not necessary to interconnect multiple particles to efficiently sinter the particles in a rotary furnace. When the size is large enough to sinter individual particles, it is easier to do it directly without the additional processing steps of interconnecting the abrasive precursor particles with a shape prior to sintering and then separating the abrasive particles with shape after sintering. In embodiments of the invention, the size of the shaped abrasive flakes, after being separated, passes through the US standard test sieve in accordance with ASTM E-11, with a weft size of 18, 20, 25 or greater number of sieve and are retained in the sieve.
    [0024] In other embodiments of the invention, the average mass of the shaped abrasive particles, after being separated, may be less than or equal to 5 x 10-3 grams, less than or equal to 7 x 10-3 grams, or less than or equal to 9 x 10-3 grams. The average mass of the shaped abrasive particles can be determined by weighing 100 individual shaped abrasive particles and averaging the result. In the embodiment illustrated in figures 3 and 4, the shaped abrasive particles had an average mass of 9 x 10-5 grams.
    [0025] Based on the size variations above, in general each abrasive flake or sintered abrasive flake will contain approximately 2 to 1000, or 5 to 100, or 5 to 50 abrasive precursor shaped particles or abrasive shaped particles held together by the frangible support. In many embodiments, the frangible support will comprise a continuous mat or flange connecting the edges of each shaped abrasive particle to the next, as best seen in figure 1. In order to avoid separating the shaped abrasive particles during sintering, but still allowing the particles to be readily separated after sintering, the thickness of the continuous mat should be controlled. In particular, the thickness of the continuous mat connecting individual shaped abrasive precursor particles or shaped abrasive particles should be 0.03 to 0.15 mm, or 0.01 to 0.20 mm, or 0.005 to 0.25 mm (as measured in the state does not burn prior to calcination or sintering, or 2 to 150 μm, 5 to 100 μm, or 10 to 50 μm after sintering. If the thickness is very small, then the abrasive flakes can prematurely separate into abrasive precursor shaped particles during handling If the thickness is too thick, then the abrasive shaped particles may be damaged or fractured when attempting to separate them from the continuous mat or be extremely difficult to separate from the frangible support.
    [0026] In some embodiments, the frangible support will comprise one or more connecting rods 16 connecting adjacent shaped abrasive particles 12 to each other, so that the abrasive flake 10 comprises a plurality of shaped abrasive particles connected to each other by a plurality of connecting rods, as seen in figure 2. While the connecting rods can be located anywhere on the shaped abrasive particle, they will typically be located along the edges of the shaped abrasive particles and not on the vertices where the edges intersect, as shown in figure 2. Locating the connecting rods at the apex can have an effect on the crushing performance, since the apex of the shaped abrasive particle is often the initial cutoff point during use. As such, it is desirable to mold it to a specific cutting profile and not have an uncontrolled and fractured surface present in this location. In general, each shaped abrasive particle or abrasive precursor particle shaped in the sintered abrasive flake or abrasive flake will comprise 2 to 20 bonding rods, or 2 to 10 bonding rods joining the shaped abrasive particle to the shaped abrasive particles surrounding the abrasive flake.
    [0027] Often, the thickness of the connecting rods will be greater than that of the continuous mat since the area of the frangible support contiguous to the individual particles is reduced; however, this is not a requirement. The greater thickness of the connecting rod at the different locations of the connecting rod can help keep the abrasive shaped particles attached to each other while being transported through the furnace. In particular, the thickness of the connecting rods can be from 0.03 to 0.15 mm, or from 0.01 to 0.20 mm, or from 0.005 to 0.25 mm (as measured in the non-burning state prior to calcination or sintering), or 2 to 150 μm, 5 to 100 μm, or 10 to 50 μm after sintering. If the thickness is too thin, then the abrasive flakes can prematurely separate into abrasive precursor shaped particles during handling. If the thickness is too thick, then the shaped abrasive particles can be damaged or fractured when trying to separate them from the connecting rods.
    [0028] The width of the connecting rods along the edge can vary significantly, as when they become wider they approach a continuous blanket while a connecting rod almost touches the next adjacent connecting rod. However, in general, the connecting rods will have a percentage of coverage (calculated as the total distance for all connecting rods along a side edge divided by the length of the side edge times 100) that is, equal to or less than 50 %, 40%, 30%, 20%, or 10%. Reducing the width of the individual connecting rods allows for a cleaner edge with less fractured surface area when shaped abrasive particles are separated after sintering. This will often produce an abrasive particle with a sharper shape. In some embodiments, the connecting rods can interfere with the finish when very small shaped abrasive particles are produced and the connecting rods do not clearly fracture the edge of the shaped abrasive particles. Abrasive shaped particles
    [0029] With reference to figures 5A and 5b, in one embodiment, the abrasive particles shaped after separation of the frangible support may comprise thin bodies that have a first main surface 24, and a second main surface 26 and have a thickness T. In some embodiments , the thickness T ranges from about 5 micrometers to about 1 millimeter. The shaped abrasive particles can comprise a uniform thickness or the thickness of the shaped abrasive particles can decrease or vary. In some embodiments, the first main surface 24 and the second main surface 26 are connected to each other by at least one side wall 22, which can be an inclined side wall, which has an outlet angle α between the second main surface 26 and the sidewall 22 that is different from 90 degrees In some embodiments, more than one inclined sidewall 22 may be present and the slope or angle for each inclined sidewall 22 may be the same or different as more fully described in the pending patent application US serial number 12 / 337,075, filed December 17, 2008 entitled “Shaped Abrasive Particles With A Sloping Sidewall”. In other embodiments, the side wall 22 can cross the first main surface 24 and the second main surface 26 at a 90 degree angle.
    [0030] The first and second main surfaces (24 and 26) comprise a geometric shape selected as a circle, an oval shape, a triangle, a quadrilateral (rectangle, square, trapezoid, rhombus, rhomboid, kite, superelipse), or another geometric shape with various edges (pentagon, hexagon, octagon, etc.). Alternatively, the first and second main surfaces (24 and 26) can comprise an irregularly repeatable shape (replicated by the mold cavity) or a shape that combines line segments and arcuate segments to form the contour or perimeter. Depending on the exit angle a, the areas of the first and second main surfaces of each shaped abrasive particle can be the same or different. In many embodiments, the shaped abrasive particles comprise a prism (90 degree exit angle) or a truncated pyramid (other than 90 degree exit angle) such as a triangular prism, a truncated triangular pyramid, a rhomboid prism or a rhomboid pyramid truncated, to name a few possibilities.
    [0031] In various embodiments of the invention, the angle of departure α may be between approximately 90 degrees to approximately 135 degrees, or between 95 degrees to approximately 130 degrees, or between about 95 degrees to about 125 degrees or between about 95 degrees to about 120 degrees or between about 95 degrees to about 115 degrees or between about 95 degrees to about 110 degrees or between about 95 degrees to about 105 degrees or between about 95 degrees to about 100 degrees. As discussed in US Patent Application Serial No. 12 / 337,075, entitled “Shaped Abrasive Particles With A Sloping Sidewal” filed on December 17, 2008, specific variations for the α angle of departure have been revealed to produce surprising increases in the performance of crushing coated abrasive articles produced from abrasive particles shaped with a sloping sidewall. In particular, the 98-degree, 120-degree or 135-degree exit angles were revealed to have improved crushing performance over a 90-degree exit angle. The improvement in shredding performance is particularly pronounced at the exit angles of 98 degrees or 120 degrees, as seen in Figures 6 and 7 of US Patent Application Serial No. 12 / 337,075.
    [0032] In various embodiments of the invention, abrasive particles shaped 20 may include additional features. In some embodiments, the first main surface 24 is substantially flat, the second main surface 26 is substantially flat, or both are substantially flat. Alternatively, one side may be concave or recessed, as discussed in more detail in copending patent application serial number US 12 / 336,961 entitled “Dish-Shaped Abrasive Particles With A Recessed Surface”, filed December 17, 2008. A surface concave or recessed can be created by selecting sun-gel drying conditions, while remaining in the mold cavity that forms a meniscus in the sol-gel that tends to shift the edges of the sun-gel up the sides of the mold, as discussed in US Patent Application Serial No. 12 / 336,961. A concave surface can help increase cutting performance in some applications similar to a hollow crushed chisel blade.
    [0033] Additionally, one or more openings that pass through the first main surface 24 and the second main surface 26 may be present in the shaped abrasive particles, as discussed in more detail in US copending patent application serial number 12 / 337,112 entitled “Shaped Abrasive Particles With An Opening ”, deposited on December 17, 2008. An opening through shaped abrasive particles can reduce the apparent density of shaped abrasive particles, thus increasing the porosity of the resulting abrasive article in some applications, such as a wheel. crushing, where increased porosity is often desired. Alternatively, the opening can reduce the carcass by anchoring the particle in the more firmly sized coating or the opening can act as a reservoir to aid in crushing. An opening can be formed in the shaped abrasive particle by selecting drying conditions that exaggerate the meniscus phenomenon discussed above, or by producing a mold that has one or more rods extending from the mold surface. Methods for preparing abrasive particles with an aperture shape are discussed in US Patent Application Serial No. 12 / 337,112.
    [0034] In addition, shaped abrasive particles may have a plurality of grooves on the first or second main surface, as described in US Patent Application Serial No. 12 / 627,567, entitled Shaped Abrasive Particles With Grooves, filed on November 30 de 2009. The grooves are formed by a plurality of ridges on the surface of the mold cavity that have been shown to facilitate the removal of abrasive precursor particles shaped from the mold. It is believed that a crest with a triangular-shaped cross section acts as a wedge, lifting the shaped abrasive precursor particle out of the bottom surface of the mold, under drying conditions that promote sun-gel shrinkage while remaining in the mold. mold cavity.
    [0035] Another appropriately shaped abrasive particle is presented in the provisional patent application under serial number 61 / 266,000, entitled “Dual Tapered Shaped Abrasive Particles”, deposited on December 2, 2009. These shaped abrasive particles comprise a first side, a second side, a maximum length along a longitudinal axis and a maximum width transverse to the longitudinal axis. The first side comprises a quadrilateral that has four edges and four vertices, with the quadrilateral selected from the group consisting of a rhombus, a rhomboid, a kite or a superelipse. The second side comprises a vertex and four facets forming a pyramid. The ratio of the representation of the maximum length to the maximum width is 1.3 or greater. An example of such a shaped abrasive particle is shown in figure 4.
    [0036] Referring to figure 4, the shaped abrasive particles, after separating the frangible support, comprise a fractured surface. In the embodiment shown in figure 4, the fractured surface is located on a flange or flare extending from the edge of the shaped abrasive particle. In order to avoid the separation of the shaped abrasive particles during sintering, but still allow the particles to be readily separated after sintering, the thick flange or flare should be controlled. In particular, the flange or flare thickness should be 0.03 to 0.15 mm, or 0.01 to 0.20 mm, or 0.005 to 0.25 mm (as measured in the previous non-firing state calcination or sintering), or 2 to 150 μm, 5 to 100 μm, or 10 to 50 μm after sintering.
    [0037] Abrasive 20-shaped particles can also have a surface coating. Surface coatings are known to optimize the adhesion between abrasive grains and binder in abrasive articles, or can be used to assist in electrostatic deposition of 20-shaped abrasive particles. Such surface coatings are described in US Patent No. 5,213,591 , 5,011,508, 1,910,444, 3,041,156, 5,009,675, 5,085,671, 4,997,461 and 5,042,991. In one embodiment, surface coatings, as described in U.S. Patent No. 5,352,254 in an amount of 0.1% to 2% inorganic to the weight of the shaped abrasive particle, were used. Additionally, the surface coating can prevent the shaped abrasive particle from forming a "capping". “Capping” is the term used to describe the phenomenon where metal particles from the part being roughed are welded to the top of the shaped abrasive particles. Surface coatings for performing the above functions are known to those skilled in the art.
    [0038] In another embodiment, a plurality of shaped abrasive particles having a nominal grade or an examined rated grade specified in the abrasive industry, with each shaped abrasive particle comprising a fractured surface of a frangible support fixed to the shaped abrasive particle. provided. Shaped abrasive particles produced in accordance with the present description can be incorporated into an abrasive article selected from the group consisting of a coated abrasive article, a binding abrasive article, a non-woven abrasive article or an abrasive brush, a chipboard, or used loosely (abrasive polishing of aqueous paste). Abrasive particles are, in general, classified for a given particle size distribution before use. Such distributions typically have a range of particle sizes, from rough particles to fine particles. In abrasive technique, this band is sometimes called "rough", "control" and "thin" fractions. The abrasive particles classified, according to the classification standards accepted by the abrasives industry, specify the particle size distribution for each nominal classification within numerical limits. Such industry-accepted classification standards (that is, nominal rating specified by the abrasives industry) include those known as the American National Standards Institute, Inc. (ANSI) standards, standards of the Federation of European Producers of Abrasive Products (FEPA) and Japanese Industrial Standard (JIS) standards.
    [0039] ANSI classification designations (that is, specified nominal ratings) include: ANSI 4, ANSI 6, ANSI 8, ANSI 16, ANSI 24, ANSI 36, ANSI 40, ANSI 50, ANSI 60, ANSI 80, ANSI 100, ANSI 120, ANSI 150, ANSI 180, ANSI 220, ANSI 240, ANSI 280, ANSI 320, ANSI 360, ANSI 400 and ANSI 600. FEPA classification designations include P8, P12, P16, P24, P36, P40, P50, P60, P80, P100, P120, P150, P180, P220, P320, P400, P500, P600, P800, P1000 and P1200. JIS classification designations include JIS8, JIS12, JIS16, JIS24, JIS36, JIS46, JIS54, JIS60, JIS80, JIS100, JIS150, JIS180, JIS220, JIS240, JIS280, JIS320, JIS360, JIS400, JIS600, JIS800, JIS800, JIS800 , JIS2500, JIS4000, JIS6000, JIS8000 and JIS10,000.
    [0040] Alternatively, shaped abrasive particles can be classified to a nominal grade examined using the USA Standard Test Sieves, in accordance with ASTM E-11 “Standard Specification for Wire Cloth and Sieves for Testing Purposes”. ASTM E-11 outlines requirements for the design and construction of test sieves using a woven wire cloth medium mounted on a frame for the classification of materials, according to a designated particle size. A typical designation can be represented as -18 + 20, which means that the formatted abrasive particles pass through a test sieve that meets the E-11 specifications for the number 18 sieve and are retained on a test sieve that meets ASTM E-11 specifications for number 20 sieve. In one embodiment, shaped abrasive particles have a particle size such that most particles pass through a 14 mesh test sieve and are retained in a 16, 18, 20, 25, 30, 35, 40, 45 or 50 mesh test sieve. In various embodiments of the invention, shaped abrasive particles can have an examined nominal grade comprising: -18 + 20, -20 / + 25, -25 + 30, -30 + 35, -35 + 40, -40 + 45, -45 + 50, -50 + 60, -60 + 70, -70 / + 80, -80 + 100, -100 + 120, -120 + 140, -140 + 170, -170 + 200, -200 + 230, -230 + 270, -270 + 325, -325 + 400, -400 + 450, -450 + 500 or -500 + 635. Alternatively, an adapted network size could be used as -90 + 100. Manufacturing Method of Abrasive Flakes and Abrasive Shaped Particles
    [0041] Materials that can be produced as shaped ceramic objects using the process of the invention include physical precursors, such as finely divided particles of ceramic materials known as alpha alumina, silicon carbide, alumina / zirconia and CBN. Also included are chemical and / or morphological precursors, such as aluminum trihydrate, bohemite, gamma alumina and other transition alumines, and bauxite.
    [0042] The most useful of the above are typically based on alumina and its physical or chemical precursors. It should be understood, however, that the invention is not limited to this, but can be adapted for use with a plurality of different precursor materials.
    [0043] Other components that were desirable in certain circumstances for the production of alumina-based particles include nucleating agents such as finely divided alpha alumina, ferric oxide, chromium oxide and other materials capable of nuclear transformation of precursor forms to the form of alpha alumina ; magnesia; titanium oxide; zirconia; yttria; and rare earth metal oxides. Such additives often act as crystal growth limiters or borderline phase modifiers. The amount of such additives in the precursor is generally less than about 10% and often less than 5% by weight (based on solids).
    [0044] It is also possible to use, instead of a chemical or morphological precursor of alpha alumina, a finely divided strip of alpha alumina together with an organic compound that will keep it in suspension and act as a temporary binder while the particle is being burned up essentially complete densification. In these cases, it is often possible to include in the suspension materials that will form a separate phase upon burning or that can act as an aid in maintaining the structural integrity of the shaped particles during drying and burning or after burning. Such materials can be present as impurities. If, for example, the precursor is finely divided bauxite, there will be a small proportion of glassy material present that will form a second phase after the powder grains are sintered together to form the shaped particle.
    [0045] The dispersion that is employed in the process of the invention can be any dispersion of a ceramic precursor, such as a finely dispersed material that, after being subjected to the process of the invention, is in the form of a shaped ceramic article. The dispersion can be chemically a precursor, as an example, bohemite is a precursor chemical of alpha alumina; a morphological precursor such as the gamma alumina is a morphological precursor to alpha alumina; as well as (or alternatively), physically a precursor in the sense that a finely divided form of alpha alumina can be formed into one shape and sintered to retain that shape.
    [0046] When the dispersion comprises a physical or morphological precursor, according to the term used in this document, the precursor is in the form of finely divided powder grains that, when sintered, form a ceramic article, as an abrasive particle useful in abrasive applications. conventional coated and bonded. Such materials generally comprise powder grains with an average size of less than about 20 microns, preferably less than about 10 microns and, most preferably, less than about one micron.
    [0047] The dispersion used in a preferred process is most conveniently a bohemian sol-gel. The sol-gel can be a sol-gel in seed that comprises finely dispersed seed particles capable of nuclear conversion of alumina precursors to alpha alumina or a sol-gel in non-seed that turns into alpha alumina when sintered.
    [0048] The solids content of the dispersion of a physical or morphological precursor is preferably about 40% to 65%, although higher solids contents of up to about 80% can be used. An organic compound is often used together with finely divided grains in such dispersions as a suspending agent or perhaps a temporary binder, until the formed particle has been sufficiently dried to maintain its shape. This can be any of those commonly known for such purposes, such as polyethylene glycol, sorbitan esters and the like.
    [0049] The solids content of a precursor that changes to the final stable ceramic form upon firing may need to take into account the water that can be released from the precursor during drying and firing to sinter the abrasive particles. In these cases, the solids content is typically slightly less, about 75% or less and more preferably between about 30% and about 50%. With a bohemian sol-gel, a maximum solids content of about 60% or even 40% can be used and a sol-gel with a minimum peptized solids content of about 20% can also be used.
    [0050] Abrasive particles produced from physical precursors will typically need to be burned at higher temperatures than those formed from a chemical seed precursor. For example, while the particles of a seed bohemian sol-gel form an alpha alumina essentially and fully densified at temperatures below about 1250 degrees Celsius, particles produced from non-seed bohemian sol-gels may require a firing temperature above about 1400 degrees Celsius for complete densification.
    [0051] In a way of producing the abrasive particles with shape, the following process steps can be used. The first step in the process involves providing both an abrasive dispersion in seed and non-seed that can be converted to alpha alumina. The precursor composition of alpha alumina often comprises a liquid that is a volatile component. In one embodiment, the volatile component is water. The abrasive dispersion must comprise a sufficient amount of liquid so that the viscosity of the abrasive dispersion is sufficiently low, allowing to fill the mold cavities and replicate the mold surfaces, but not so much liquid as to cause the subsequent removal of the liquid from the mold cavity, becoming prohibitively expensive. In one embodiment, the abrasive dispersion comprises from 2 percent to 90 percent by weight of particles that can be converted to alpha alumina, such as aluminum oxide monohydrate (bohemite) particles, and at least 10 percent by weight, or 50 percent to 70 percent, or 50 percent to 60 percent, by weight, of a volatile component such as water. Adversely, the abrasive dispersion, in some embodiments, contains 30 percent to 50 percent, or 40 percent to 50 percent, by weight, of solids.
    [0052] Aluminum oxide hydrates in addition to bohemian can also be used. Bohemite can be prepared by known techniques or it can be commercially obtained. Examples of commercially available bohemians include products bearing the trademarks "DISPERAL" and "DISPAL", both available from Sasol North America, Inc. or "HiQ-40" available from BASF Corporation. These aluminum oxide monohydrates are relatively pure, that is, they include relatively few, if any, hydrate phases in addition to monohydrates and have a high surface area. The physical properties of the resulting 20 shaped abrasive particles will, in general, depend on the type of material used in the abrasive dispersion.
    [0053] In one embodiment, the abrasive dispersion is in a gel state. For use in the present invention, a "gel" is a three-dimensional network of solids dispersed in a liquid. The abrasive dispersion may contain a modifying additive or precursor to a modifying additive. The modifying additive can work to improve some desirable properties of the abrasive particles or to increase the effectiveness of the subsequent sintering step. Modification additives or modification additive precursors can be in the form of soluble salts, typically water-soluble salts. They typically consist of a metal-containing compound and can be a precursor to magnesium oxide, zinc, iron, silicon, cobalt, nickel, zirconium, hafnium, chromium, yttrium, praseodymium, samarium, ytterbium, neodymium, lanthan, gadolinium, cerium, dysprosium, erbium, titanium and mixtures thereof. The particular concentrations of these additives that may be present in the abrasive dispersion, can be varied based on those skilled in the art. Typically, the introduction of a modifying additive or precursor to a modifying additive will induce abrasive dispersion to gel. Abrasive dispersion can also be induced to gel through the application of heat over a period of time.
    [0054] The abrasive dispersion may also contain a nucleating agent (seeding) to enhance the transformation from calcined or hydrated aluminum oxide to alpha alumina. Nucleating agents suitable for this description include fine particles of alpha alumina, ferric oxide alpha or its precursor, titanium and titanate oxides, chromium oxides or any other material that will nuclear the transformation. The amount of nucleating agent, if used, must be sufficient to effect the transformation of alpha alumina. Nucleation as abrasive dispersions is disclosed in U.S. Patent No. 4,744,802 to Schwabel.
    [0055] A peptizing agent can be added to the abrasive dispersion to produce a more stable hydrosol or colloidal abrasive dispersion. Suitable peptizing agents are monoprotic acids or acid compounds such as acetic acid, hydrochloric acid, formic acid and nitric acid. Multiprotic acids can also be used, but they can quickly make the dispersion abrasive in gel, making it difficult to handle or introduce additional components into it. Some commercial bohemian sources contain an acidic titration (such as absorbed formic acid or nitric acid) that will assist in the formation of a stable abrasive dispersion.
    [0056] The abrasive dispersion may be formed by any suitable means, such as, for example, simply by mixing aluminum oxide monohydrate with water containing a peptizing agent or by forming an aqueous paste of aluminum oxide monohydrate to which the peptization is added. Foam eliminators or other suitable chemicals can be added to reduce the tendency for bubbles or air to enter under mixing. Additional chemicals such as wetting agents, alcohols or binding agents can be added if desired. The abrasive grain of alpha alumina may contain silica and iron oxide, as presented in US Patent No. 5,645,619, to Erickson et al., On July 8, 1997. The abrasive grain of alpha alumina may contain zirconia, as shown in US Patent No. 5,551,963, to Larmie, on September 3, 1996. Alternatively, the abrasive grain of alpha alumina has a microstructure or additives as presented in US Patent No. 6,277,161, to Castro, on August 21 2001.
    [0057] The second step of the process involves providing a mold that has at least one mold cavity, and preferably a plurality of cavities. The cavity has a specific three-dimensional shape to produce the shaped abrasive particles, illustrated in figures 1 to 5. In general, the shape of the cavity adjacent to the upper surface of the mold forms the perimeter of the first main surface 24. The perimeter of the mold cavity at the bottom it forms the perimeter of the second main surface 26.
    [0058] The plurality of cavities can be formed in a production tool. The production tool can be a mat, a blade, a continuous mat, a coating cylinder such as a gravure cylinder, a cover mounted on a embossing roller or die. In one embodiment, the production tool comprises polymeric material. Examples of suitable polymeric materials include thermoplastics such as polyesters, polycarbonates, poly (sulfone ether), poly (methyl methacrylate), polyurethanes, polyvinyl chloride, polyolefin, polystyrene, polypropylene, polyethylene or combinations thereof, or heat-cured materials. In one embodiment, all tools are made of polymeric or thermoplastic material. In another embodiment, the tooling surfaces in contact with the sol-gel under drying, such as the surfaces of the plurality of cavities, comprise polymeric or thermoplastic materials and other portions of the tooling can be produced from other materials. A suitable polymeric coating can be applied to metal tooling to change its surface tension properties as an example.
    [0059] A polymeric or thermoplastic tool can be copied from a metal master tool. The master tool will have a pattern opposite to that desired for the production tool. The master tool can be produced in the same way as the production tool. In one embodiment, the master tool is made of metal, for example, nickel and is turned by diamond. The polymeric blade material can be heated together with the master tool in such a way that the polymeric material is embossed with the standard master tool by pressing both. A polymeric or thermoplastic material can also be extruded or molded on the master tool and then pressed. The thermoplastic material is cooled to solidify and produce the production tool. If a thermoplastic production tool is used, care must be taken not to generate excessive heat that could distort the thermoplastic production tool, limiting its life. More information regarding the design and manufacture of production tools or master tools can be found in U.S. Patent No. 5,152,917 (Pieper et al.); 5,435,816 (Spurgeon et al.); 5,672,097 (Hoopman et al.); 5,946,991 (Hoopman et al.); 5,975,987 (Hoopman et al.); and 6,129,540 (Hoopman et al.).
    [0060] Access to the cavities can be from an opening in the top surface. In one embodiment, the top surface is substantially parallel to the bottom surface of the mold, with the cavities having a substantially uniform depth. One side of the mold, that is, the side on which the cavity is formed, can remain exposed to the surrounding atmosphere during the step in which the volatile component is removed.
    [0061] The third step of the process involves filling the cavities in the mold with the abrasive dispersion using any conventional technique. In some embodiments, a knife-type coating applicator or vacuum crack matrix coating applicator may be used. A mold release can be used to assist in removing particles from the mold, if desired. Typical mold release agents include oils, such as peanut oil or mineral oil, fish oil, silicones, polytetrafluoro ethylene, zinc stearate, and graphite. In general, between about 0.1% and about 5%, by weight of mold release agent, such as peanut oil, in a liquid such as water or alcohol, is applied to the surfaces of the production tooling in contact with the sol-gel, such that between about 0.016 mg / cm2 to about 0.47 mg / cm2 (about 0.1 mg / in2 to about 3.0 mg / in2), or between about 0.016 mg / cm2 to about 0.78 mg / cm2 (about 0.1 mg / in2 to about 5.0 mg / in2 of the mold release agent are present per unit area of the mold when a mold release is desired In one embodiment, the top surface of the mold is coated with the abrasive dispersion. The abrasive dispersion can be pumped or applied over the top surface. Then, a scraper or leveling bar can be used to force the abrasive dispersion fully to inside the mold cavity. The remaining portion of the abrasive dispersion that does not enter the cavity forms the frangible support that adjoins the adjacent particles shaped vests. Alternatively, a blade of the abrasive dispersion or precursor ceramic material can be embossed or shaped by a cylinder into a plurality of shaped structures joined by a frangible support, which can then be separated into shaped abrasive particles. See U.S. patent number 3,859,407 (Blanding et al.) As an example.
    [0062] The fourth step in the process involves removing the volatile component to dry the dispersion. Desirably, the volatile component is removed by rapid evaporation rates. In some embodiments, the removal of the volatile component through evaporation occurs at temperatures above the boiling point of the volatile component. An upper limit for the drying temperature often depends on the material from which the mold is made. For polypropylene tooling, the temperature must be lower than the melting point of the plastic.
    [0063] In one embodiment, for a water dispersion between about 40 to 50 percent solids and a polypropylene mold, drying temperatures can be between about 90 degrees Celsius to about 165 degrees Celsius, or between about 105 degrees Celsius at about 150 degrees Celsius, or between about 105 degrees Celsius at about 120 degrees Celsius. Higher temperatures can lead to improved production speeds, but they can also lead to degradation of the polypropylene tooling that limits its useful life as a mold.
    [0064] Abrasive flakes can be formed by allowing the sol-gel to be dried at room temperature or at elevated temperatures while the abrasive precursor particles reside in the tooling used to mold the shaped abrasive precursor particles. As the sol-gel dries, there is a propensity for sol-gel cracking (desiccation cracking similar to cracking that forms in dry mud puddles) and will form a plurality of abrasive flakes of various sizes while supported by the tooling. Alternatively, a rotary die cutter can be used to cut abrasive flakes with specific dimensions while the sol-gel resides in the tooling prior to the start of the desiccation cracking installation.
    [0065] In another embodiment, a laser can be used to cut a dry blade of sol-gel into a plurality of abrasive precursor shaped particles joined by a frangible support. The laser can be used to partially cut the thickness of the sol-gel by forming the edges of the abrasive precursor shaped particles or the laser can cut the abrasive precursor shaped particle leaving one or more connecting rods securing the abrasive precursor particle shaped to a or more other shaped abrasive precursor particles. After cutting with the laser and, optionally drying, the blade can be divided into appropriately sized abrasive flakes, or the laser can completely cut the blade in selected areas to make different abrasive flakes which are then sintered. Alternatively, the laser can be used to cut appropriately sized abrasive flakes while the precursor abrasive particles reside in the tooling used to shape them. More information regarding laser-cut abrasive particles can be found in US pending patent application with Lawyer Precedent No. 65473US002 and serial number US 61/408813, entitled “Laser Method For Making Shaped Ceramic Abrasive Particles, Shaped Ceramic Abrasive Particles, And Abrasive Articles ”, filed on the same date as this patent application.
    [0066] The fifth processing step involves the removal of abrasive flakes and abrasive precursor particles shaped from the mold cavities. Abrasive flakes can be removed from the cavities using the following processes alone or in combination in the mold: gravity, vibration, ultrasonic vibration, vacuum or pressurized air to remove particles from the mold cavities.
    [0067] Abrasive flakes and precursor abrasive particles can be additionally dried out of the mold. If the abrasive dispersion is dried to the desired level in the mold, this additional drying step is not necessary. However, in some cases, it may be more economical to employ this additional drying step in order to minimize the time that the abrasive dispersion remains in the mold. Typically, shaped abrasive precursor particles will be dry for 10 to 480 minutes, or 120 to 400 minutes, at a temperature of 50 degrees C to 160 degrees C, or 120 degrees C to 150 degrees C.
    [0068] The sixth stage of the process involves the calcination of the abrasive flakes in an oven or rotary furnace. During calcination, essentially all the volatile material is removed and the various components that are present in the abrasive dispersion are transformed into metal oxides. Abrasive flakes are, in general, heated to a temperature of 400 degrees Celcius to 800 degrees Celcius and kept within this temperature range until free water and more than 90 weight percent of any bound volatile material are removed. In an additional step, it may be desirable to introduce the modifying additive through an impregnation process. A water-soluble salt can be introduced by impregnating the pores of the calcined abrasive flakes. Then the abrasive flakes are calcined again. This option is further described in European Patent Application No. 293,163.
    [0069] The seventh stage of the process involves sintering the abrasive flakes calcined in a rotating furnace to form particles of alpha alumina. Before sintering, the calcined abrasive flakes are not completely densified and therefore do not contain the desired hardness content to be used as abrasive particles. Sintering takes place by heating the calcined abrasive flakes to a temperature of 1,000 degrees Celcius to 1,650 degrees Celcius and keeping them within that temperature range until substantially all of the alpha alumina monohydrate (or equivalent) is converted to alpha alumina and the porosity is reduced to less than 15% by volume. The amount of time that the calcined abrasive flakes must be exposed to the sintering temperature to achieve this level of conversion depends on several factors, but is typically from five seconds to 48 hours, typically. In another modality, the duration for the sintering step is in the range of one minute to 90 minutes. After sintering, shaped abrasive particles can have a Vickers hardness content of 10 GPa, 16 GPa, 18 GPa, 20 GPa, or more.
    [0070] The eighth stage of the process involves mechanically separating the shaped abrasive particles from the sintered abrasive flake. Suitable methods include a crushing off-set cylinder, holding the sintered abrasive flakes on a support surface and using a cylinder on them, passing the sintered abrasive flakes through a contact line between two rotating cylinders with at least one of the cylinders with a deformable elastomeric cover or other means that are flexible, instead of crushing the sintered abrasive flakes to induce rupture along the frangible support. Examples
    [0071] The objectives and advantages of this description are further illustrated by the following non-limiting examples. The specific materials and the quantities of them recited in these examples, as well as other conditions and details, should not be interpreted to unduly limit this description. Unless otherwise specified, all parts, percentages, proportions, etc., in the examples and the rest of the specification are expressed in weight.
    [0072] A 5% solution of peanut oil in methanol was brushed over a micro-replicated polypropylene tooling that has a set of correct rhombic pyramidal cavities. The rhombic base had a representation ratio greater than 2: 1 (main axis: minor axis). The dimensions of the cavity were designed to produce abrasive particles with a shape that would pass through a 50 mesh sieve but will be retained in a 60 mesh sieve (ie particles between 250 micrometers and 350 micrometers. A bohemian sol-gel approximately 30% solids were subsequently spread over the polypropylene matrix and forced into the cavities using a spatula Care was taken to ensure that the cavities were completely filled with gel, so that the resulting abrasive precursor shaped particles remained interconnected by a frangible support that comprises a continuous mat when the sol-gel has dried, the sol-gel has been air-dried and the abrasive precursor shaped particles have been agitated in the micro-applied tooling which has resulted in a collection of abrasive flakes of different sizes. abrasive flakes were calcined at 650 degrees Celcius, impregnated with a solution of oxide of rare earth (OTR) comprising 1.4% MgO, 1.7% Y2O3, 5.7% La2O3 and 0.07% CoO., dried and calcined again at 650 degrees Celcius and sintered at 1400 degrees Celcius , resulting in the abrasive flakes shown in figure 1.
    [0073] A portion of the abrasive flakes was then placed on a glass slide and was gently undone using a hard plastic roller on top of the abrasive flakes to separate the individual abrasive particles shaped from the abrasive flakes. The shaped abrasive particles were screened to separate the individual shaped abrasive particles from the abrasive flakes that required additional treatment with the rigid plastic roller. Abrasive shaped particles collected on the screen with +300 micrometers are shown in figure 3. The abrasive shaped particles made by this process had a residual frangible support, as shown in figure 4.
    [0074] Other modifications and variations of the present description can be practiced by those skilled in the art without departing from the spirit and scope of the present description, which is more particularly presented in the appended claims. It is understood that aspects of the various modalities can be changed in whole or in part or can be combined with other aspects of the various modalities. All cited references, patents or patent applications in the above application for patent authorization are hereby incorporated by reference in their entirety in a consistent manner. In the event of inconsistencies or contradictions between the portions of the incorporated references and this order, the information in the previous description will prevail. The preceding description, given for the purpose of allowing one of ordinary skill in the art to practice the claimed description, should not be construed as limiting the scope of the description, which is defined by the claims and all equivalents thereto.
    权利要求:
    Claims (10)
    [0001]
    Method for producing abrasive particles with a CHARACTERIZED format because it comprises: forming an abrasive flake comprising a plurality of shaped abrasive precursor particles and a frangible support comprising a plurality of connecting rods joining the shaped abrasive precursor particles; transport the abrasive flake through a rotary furnace to sinter the abrasive flake; and break the sintered abrasive flake into individual shaped abrasive particles.
    [0002]
    Method according to claim 1, CHARACTERIZED by the fact that the abrasive flake comprises a larger dimension and the larger dimension is greater than 0.50 mm.
    [0003]
    Method, according to claim 1 or 2, CHARACTERIZED by the fact that the abrasive flake comprises a larger dimension of the larger dimension is greater than 0.70 mm and less than 2 cm.
    [0004]
    Method according to any one of claims 1 to 3, CHARACTERIZED by the fact that the sintered abrasive flake comprises from 2 to 1000 shaped abrasive particles.
    [0005]
    Sintered abrasive flake CHARACTERIZED by the fact that it comprises a plurality of shaped abrasive particles and a frangible support that comprises a plurality of connecting rods joining the shaped abrasive particles.
    [0006]
    Sintered abrasive flake, according to claim 5, CHARACTERIZED by the fact that the sintered abrasive flake comprises from 2 to 1000 shaped abrasive particles.
    [0007]
    Plurality of shaped abrasive particles with an examined nominal grade or specified grade specified in the abrasive industry CHARACTERIZED by the fact that each of the shaped abrasive particles comprises a fractured surface of a frangible support fixed to the shaped abrasive particle, the frangible support comprises a plurality of connecting rods that joined the shaped abrasive particles prior to the formation of the fractured surface of the frangible support.
    [0008]
    Plurality of shaped abrasive particles according to claim 7, CHARACTERIZED by the fact that the fractured surface resides in the flare that extends from the shaped abrasive particle.
    [0009]
    Plurality of shaped abrasive particles according to claim 8, CHARACTERIZED by the fact that the flare has a thickness of 2 to 150 μm.
    [0010]
    Plurality of shaped abrasive particles according to any of claims 7 to 9, CHARACTERIZED by the fact that the specified nominal grade of the abrasive industry is equal to or less than ANSI 60.
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    法律状态:
    2018-04-03| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2019-05-21| B06T| Formal requirements before examination|
    2020-04-07| B09A| Decision: intention to grant|
    2020-08-25| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 19/10/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US40878810P| true| 2010-11-01|2010-11-01|
    US61/408,788|2010-11-01|
    PCT/US2011/056833|WO2012061016A1|2010-11-01|2011-10-19|Shaped abrasive particles and method of making|
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