CN103826802B - 包括磨料颗粒材料的磨料制品,使用磨料颗粒材料的涂布磨料及其形成方法 - Google Patents
包括磨料颗粒材料的磨料制品,使用磨料颗粒材料的涂布磨料及其形成方法 Download PDFInfo
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Abstract
本发明提供了一种磨料制品,其包括磨料颗粒材料,所述磨料颗粒材料由氧化铝晶体和在所述磨料颗粒材料内浸渍的第一添加剂组合物制得,所述第一添加剂组合物包含Mg和Ca的组合,其中Mg和Ca以约1∶1至约10∶1之间的范围内的添加剂比[Mg∶Ca]存在,且还包含以磨料颗粒材料总重量计至少约0.2wt%的Ca。
Description
技术领域
如下涉及包括磨料颗粒材料的磨料制品,特别地涉及具有特定组成和形状的磨料颗粒材料。
背景技术
高性能磨料材料和部件已长期用于多种工业机械加工应用中,包括精研/碾磨(其中进行本体材料去除)至精抛光(其中处理细微米和亚微米表面不规则)。进行这种机械加工操作的典型的材料包括各种陶瓷、玻璃、玻璃-陶瓷、金属和金属合金。磨料可采取各种形式中的任一者,如自由磨料,其可在浆料中包括磨料颗粒材料。或者,可将这种磨料颗粒材料掺入各种基体结构中以形成固定磨料,如涂布磨料或粘结磨料。涂布磨料通常分类为具有下方基材的磨料部件,磨砂或磨粒通过一系列底胶(make coat)和复胶(size coat)粘附至所述基材。粘结磨料通常不具有下方基材,并由磨砂的一体结构形成,所述磨砂经由基体粘结材料粘结在一起。
工业的特定部分最关注铝土材料,通常是用于磨料应用中的α-氧化铝材料。α-氧化铝可通过通常在大约1000℃至1200℃的温度下转化铝土前体而形成。参见,例如,Harato等人(美国专利No.5,302,368)和Kaisaki等人(美国专利No.6,194,317)。主要含有α-氧化铝的磨料化合物可用于以高的材料去除速率抛光金属表面。α-氧化铝为多晶氧化铝的最硬的相,并提供所需的高的材料去除速率,然而,由于差的选择性和产生不希望的表面缺陷(如划痕和橘皮皱)的趋势,其使用受限于某些应用。
行业持续需要可掺入各种固定磨料制品中的改进的磨料颗粒材料。
发明内容
根据一方面,一种形成磨料制品的方法包括形成多孔氧化铝材料,并用第一添加剂组合物浸渍所述多孔氧化铝材料以形成经浸渍的颗粒材料,所述第一添加剂组合物具有Mg和Ca的组合,其中Mg和Ca以1∶1至约10∶1之间的范围内的添加剂比[Mg∶Ca]存在,且还包含以磨料颗粒材料总重量计至少约0.2wt%的Ca。
根据另一方面,一种磨料制品包括具有成形轮廓的磨料颗粒材料,其中所述磨料颗粒材料具有氧化铝晶体和在所述磨料颗粒材料内浸渍的第一添加剂组合物,所述第一添加剂组合物包含Mg和Ca的组合,其中Mg和Ca以1∶1至约10∶1之间的范围内的添加剂比[Mg∶Ca]存在,且还包含以磨料颗粒材料总重量计至少约0.2wt%的Ca。
在又一方面,一种磨料制品包括基材和磨料颗粒材料,所述磨料颗粒材料包含氧化铝晶体和在所述磨料颗粒材料内浸渍的第一添加剂组合物,所述第一添加剂组合物包含Mg和Ca的组合,其中Mg和Ca以1∶1至约10∶1之间的范围内的添加剂比[Mg∶Ca]存在。
根据又一方面,一种磨料制品包括磨料颗粒材料,所述磨料颗粒材料包含氧化铝晶体和第一添加剂组合物,所述第一添加剂组合物包含第一碱土元素和Ca,其中Ca以不大于所述第一碱土元素的量存在,且其中所述第一添加剂组合物中的大部分优先位于所述氧化铝晶体的晶体边界处。
在一方面,一种磨料制品包括磨料颗粒材料,所述磨料颗粒材料包含氧化铝晶体和第一添加剂组合物,所述第一添加剂组合物包含第一碱土元素和Ca,其中Ca以不大于所述第一碱土元素的量存在,且其中所述磨料颗粒材料包含以磨料颗粒材料总重量计约0.1wt%至约5wt%之间的所述第一添加剂组合物。
根据另一方面,一种磨料制品包括磨料颗粒材料,所述磨料颗粒材料具有氧化铝晶体和在所述磨料颗粒材料内浸渍的第一添加剂组合物,所述第一添加剂组合物包含Mg和Ca的组合,其中Mg和Ca以约1∶1至约10∶1之间的范围内的添加剂比[Mg∶Ca]存在,且还包含以磨料颗粒材料总重量计至少约0.2wt%的Ca。
附图说明
通过参照附图,本公开可更好地得以理解,且本公开的许多特征和优点对于本领域技术人员而言是显而易见的。
图1为示出了根据一个实施例的形成磨料颗粒材料的方法的流程图。
图2A和2B包括磨料颗粒材料的图片,其中图2A包括通过掺杂过程而形成的磨料颗粒材料的图片,图2B包括通过根据一个实施例的浸渍过程而形成的磨料颗粒材料的图片。
图3包括根据一个实施例的磨料颗粒材料的微结构的图示。
图4-9包括根据一个实施例的成形磨粒的图示,所述成形磨粒包括磨料颗粒材料。
图10包括根据一个实施例的掺入磨料颗粒材料的涂布磨料制品的图示。
图11包括使用根据一个实施例的涂布磨料制品和常规涂布磨料制品进行的对比碾磨测试的比碾磨能相比于累积的去除材料的图。
不同图中的相同附图标记的使用表示类似或相同的项目。
具体实施方式
根据一个实施例的磨料颗粒材料的合成可通过获得铝土原料而开始,如在图1的步骤101中所示。尽管某些铝土原料可商业购得,但在其他情况中,可制得铝土原料。例如,铝土原料可根据引晶途径(seeded pathway)加工。在一个实施例中,铝土原料可在悬浮体(或者溶胶或浆料)中包含勃姆石前体和勃姆石晶种,所述悬浮体(或者溶胶或浆料)可被热处理(例如通过水热处理)以将勃姆石前体转化为由粒子或微晶形成的勃姆石颗粒材料。术语“勃姆石”通常在本文用于表示氧化铝水合物,包括矿物勃姆石(通常为Al2O3·H2O,并具有大约15%的水含量),以及拟薄水铝石(具有高于15%的水含量,如20-38重量%)。应注意,勃姆石(包括拟薄水铝石)具有特定且可辨认的晶体结构,并因此具有独特的X射线衍射图案,且同样可区别于其他铝土材料,所述其他铝土材料包括其他水合氧化铝,如ATH(氢氧化铝)(用于制造勃姆石颗粒材料的本文所用的常见前体材料)。
在形成合适的勃姆石颗粒材料之后,可进行热处理过程以完成多晶转变,所述多晶转变去除水,并形成氧化铝材料。根据一方面,勃姆石颗粒材料可具有相对细长的形态,所述相对细长的形态在本文通常以一级(和二级和三级)纵横比描述,并在以下更详细地描述,且勃姆石的形态在原料颗粒材料中极大保持。
一级纵横比定义为最长尺寸与垂直于最长尺寸的下一最长尺寸的比率,并通常不小于2∶1,优选不小于3∶1,4∶1或6∶1。特别参照针状粒子,粒子还可特征在于第二纵横比,所述第二纵横比定义为第二最长尺寸与第三最长尺寸的比率。第二纵横比通常不大于3∶1,通常不大于2∶1,或甚至1.5∶1,时常约1∶1。第二纵横比通常描述在垂直于最长尺寸的平面中的粒子的横截面几何形状。应注意,由于术语纵横比在本文用于表示最长尺寸与下一最长尺寸的比率,其可称为第一纵横比。
或者,勃姆石颗粒材料可具有板状或薄片状轮廓,通常具有细长结构,所述细长结构具有与针状粒子相关的上述一级纵横比。然而,薄片状粒子通常具有相对的主表面,所述相对的主表面通常为平面的,并通常彼此平行。另外,薄片状粒子可特征在于具有比针状粒子的二级纵横比更大的二级纵横比,其通常不小于约3∶1,如不小于约6∶1,或甚至不小于10∶1。
通过引晶过程而形成的勃姆石颗粒材料的形态可具有相对较细的粒子或微晶尺寸。通常,平均勃姆石材料粒度不大于约1000纳米,并落入约100至1000纳米的范围内。其他实施例具有甚至更细的平均粒度(如不大于约800纳米,750纳米,600纳米,500纳米,400纳米),和甚至平均粒度小于300纳米的粒子(表示细颗粒材料)。如本文所用,与高纵横比勃姆石颗粒材料相关的“平均粒度”用于表示粒子的平均最长或长度尺寸。
除了勃姆石颗粒材料的纵横比和平均粒度之外,勃姆石颗粒材料的形态还可以比表面积表征。这里,使用通常可得的BET技术来测量勃姆石颗粒材料的比表面积。根据本文的实施例,勃姆石颗粒材料可具有通常不小于约10m2/g、如不小于约50m2/g、70m2/g或不小于约90m2/g的相对较高的比表面积。由于比表面积随粒子形态以及粒度而变化,通常实施例的比表面积小于约400m2/g,如小于约350或300m2/g。表面积的具体范围为约75m2/g至200m2/g。
转向可制备引晶的勃姆石颗粒材料的过程的细节,通常椭圆形、针状或薄片状勃姆石通过如上述共同所有的专利美国专利4,797,139中通常描述的水热处理由勃姆石前体(通常为铝土材料,包括铁铝氧石矿物)形成。更具体地,勃姆石颗粒材料可通过如下方式形成:在悬浮体中组合勃姆石前体和勃姆石晶种,使所述悬浮体(或者溶胶或浆料)暴露于热处理以引起原料向勃姆石颗粒材料的转化,所述转化还受到悬浮体中提供的勃姆石晶种的影响。加热通常在自生环境中(即在高压釜中)进行,使得高压在加工过程中产生。悬浮体的pH通常选自小于7或大于8的值,且勃姆石晶种材料可具有比约0.5微米更细的粒度。通常,晶种粒子以大于勃姆石前体(计算为Al2O3)的约1重量%的量存在,且加热在大于约120℃(如大于约125℃,或甚至大于约130℃)的温度下和自体产生的压力(通常大约30psi)下进行。
在热处理(如通过水热处理)和勃姆石转化之后,通常例如通过超滤过程或通过用以蒸发剩余液体的热处理而去除液体含量。之后,通常将所得块体压碎至100目。应注意,本文描述的粒度通常描述通过加工而形成的单独的粒子,而不是可在某些实施例中保留的聚集体(例如对于需要聚集材料的那些产品)。
在勃姆石颗粒材料的形成过程中,可改变某些加工变量以获得所需的形态。这些变量包括重量比(即勃姆石前体与勃姆石晶种的比率)、在加工过程中所用的酸或碱的特定类型或物质(species)(以及相对pH水平),和体系的温度(其直接与自生水热环境中的压力成比例)。
合适的酸和碱包括无机酸(如硝酸)、有机酸(如甲酸)、氢卤酸(如盐酸)和酸式盐(如硝酸铝和硫酸镁)。有效的碱包括,例如,胺(包括氨)、碱氢氧化物(如氢氧化钾)、碱土氢氧化物(如氢氧化钙),和碱式盐。
在形成勃姆石颗粒材料之后,过程还可包括热处理勃姆石颗粒材料以形成铝土材料。根据一个特定实施例,热处理可包括在一定温度下煅烧勃姆石颗粒材料,所述温度足以引起向氧化铝的特定相(例如γ、δ、θ、α)的转化或氧化铝的相的组合,从而提供合适的铝土材料。为了阐明的目的,铝土材料为这样的材料,所述材料包含大多数含量(wt%)的氧化铝(Al2O3),优选至少约80wt%,至少90wt%,至少95wt%,或甚至基本上由氧化铝组成。
煅烧温度可部分取决于勃姆石颗粒材料的类型和所需的氧化铝相。通常,煅烧可在至少约500℃、如至少约600℃、至少约700℃、或甚至至少约800℃的温度下进行。而且,根据某些实施例,煅烧可在不大于约1500℃、如不大于约1200℃、或甚至不大于约1000℃的温度下进行。应了解,煅烧可在上述最小温度和最大温度中的任意者之间的范围内的温度下进行。
煅烧可在多种环境(包括受控的气体和压力环境)中进行。由于通常进行煅烧以完成勃姆石颗粒材料中的相变而非化学反应,且由于所得材料主要为氧化物,除了大多数组成和形态受控的氧化铝终产物之外,可能不必应用专门的气体和压力环境。根据一个实施例,煅烧可在环境气氛下进行。某些煅烧操作可在回转窑中进行。
煅烧的合适时间部分取决于勃姆石颗粒材料和氧化铝的所需组成。通常,煅烧进行不大于约5小时、通常在约10分钟至4小时或10分钟至3小时的范围内的持续时间。应了解,上述加工指导方针不是限制性的,而仅仅说明有利于形成铝土材料的可能的步骤。
根据一个实施例,煅烧所得的所形成的铝土材料可特别地为多孔的。例如,铝土材料粒子的平均孔体积可为至少约0.15cm3/g,如至少约0.2cm3/g,至少约0.25cm3/g,至少约0.27cm3/g,或甚至至少约0.3cm3/g。而且,在某些实施例中,铝土材料的平均孔体积可为有限的,如不大于约0.5cm3/g,不大于约0.45cm3/g,或不大于约0.4cm3/g。铝土材料的平均孔体积可在上述最小百分比和最大百分比中的任意者之间的范围内。平均孔体积可经由BET以10℃/min的升温速率直至250℃的浸泡温度和60分钟的浸泡时间而测得。
应了解,在煅烧勃姆石颗粒材料之前,可进行其他中间过程。例如,材料可进行任选的过程,以将含有勃姆石颗粒材料的浆料或溶胶成形为单独的成形粒子。粒子的形状可在整个另外的加工中得以保持,并在本文更详细地描述。合适的成形过程可包括丝网印刷、模制、印花、挤出、浇铸、压制、切削和它们的组合。因此,在成形过程之后,可完成煅烧过程以形成铝土原料的成形粒子。
在步骤101中获得铝土原料之后,可通过用第一添加剂组合物浸渍铝土原料而在步骤102中继续该过程。特别地,可使用浸渍过程以将某些元素、物质和/或组合物渗透至多孔铝土原料内。根据一个实施例,浸渍过程可包括其中浸渍包括混合含有第一添加剂组合物的物质的前体盐材料与多孔氧化铝材料,其中混合包括湿混合包含前体盐材料的溶液与多孔氧化铝材料。
根据一个实施例,浸渍过程可包括混合第一添加剂组合物与多孔氧化铝材料。特别地,混合过程可包括湿混合或干混合过程。例如,浸渍过程可为湿混合过程,其中可使用液体载体而将第一添加剂组合物制备为溶液。某些合适的液体载体材料可包括有机材料和无机材料,和它们的组合。在一个特定情况中,液体载体可为去离子水。此外,可任选地使用相同的液体载体(包括例如去离子水)而将多孔氧化铝材料制备为悬浮体。
在某些情况中,第一添加剂组合物可包含前体盐材料。前体盐材料可为在溶液内提供的材料,其有利于湿混合物和浸渍至多孔氧化铝材料中。在特定情况中,包含前体盐材料的第一添加剂组合物的制备有利于前体盐材料的某些物质(包括例如金属阳离子元素)浸渍至多孔氧化铝材料中。可进一步加工(例如干燥)多孔氧化铝材料,使得前体盐材料的特定物质被包含于多孔氧化铝材料内,由此限定除了氧化铝晶体之外的在磨料颗粒材料内的第一添加剂组合物。在特定情况中,前体盐材料可包括硝酸盐,如金属硝酸盐组合物。其他合适的盐可包括氯化物、碘化物、氟化物、硫酸盐、磷酸盐、草酸盐、乙酸盐、碳酸盐和它们的组合。
通常,第一添加剂组合物可以较少的量存在于混合物内。然而,应了解,浸渍至多孔氧化铝材料中的第一添加剂组合物的量可变化,并可基于最终形成的磨料颗粒材料内的添加剂组合物的所需最终量而计算。在某些情况中,在浸渍过程中混合物内的添加剂组合物的总量以混合物总重量计可小于约20wt%,如小于15wt%,小于12wt%,或甚至小于10wt%。而且,在特定情况中,混合物内的添加剂组合物的量以混合物总重量计可为至少约0.11wt%,如至少约0.5wt%,或甚至至少约1wt%。应了解,混合物内的添加剂组合物的量可在上述最小百分比和最大百分比中的任意者之间的范围内。
在浸渍过程中,多孔氧化铝材料可与含有第一添加剂组合物的溶液混合。在充分混合之后,可允许湿混合物干燥,从而有利于去除液体载体,并产生由用第一添加剂组合物(特别是前体盐材料的阳离子物质)渗透的多孔氧化铝材料制得的经浸渍的颗粒材料。干燥可在大于室温的温度下进行,包括例如至少约50℃、至少约70℃、或甚至至少约85℃的温度。而且,干燥温度可不大于约150℃,如不大于约120℃。应了解,干燥可在上述最小温度和最大温度中的任意者之间的范围内的温度下进行。
干燥气氛可通常为环境气氛。此外,干燥的持续时间可为至少约2小时,至少约4小时,至少约6小时,或甚至至少约10小时。
在步骤102中进行浸渍过程之后,可通过烧结经浸渍的颗粒材料而在步骤103中继续该过程。可进行烧结以将经浸渍的颗粒材料(如适于磨料用途的材料)致密化。根据一个实施例,烧结过程可在大于用于形成多孔铝土材料的煅烧温度的烧结温度下进行。在一个特定情况中,烧结温度可为至少约800℃,至少约900℃,如至少约1000℃,至少约1100℃,或甚至至少约1200℃。而且,根据一个实施例,烧结温度可不大于约1600℃,如不大于约1500℃,不大于1400℃,或甚至不大于约1350℃。应了解,经浸渍的颗粒材料可在烧结温度下烧结,所述烧结温度在上述最小温度和最大温度中的任意者之间的范围内。
烧结可在通常环境气氛下进行,更特别地在回转窑中进行,其中经浸渍的颗粒材料在回转窑中的平均停留时间可限定烧结持续时间。此外,在烧结温度下的烧结持续时间可为至少约2分钟,如至少约5分钟,或甚至至少约8分钟。根据一个特定实施例,烧结过程可具有不大于约60分钟、如小于约45分钟的烧结持续时间。
经浸渍的颗粒材料的烧结可形成磨料颗粒材料。根据一个实施例,磨料颗粒材料可具有比表面积。例如,磨料颗粒材料可具有不大于约0.15m2/g、如不大于约0.13m2/g、不大于约0.1m2/g、或甚至不大于约0.09m2/g的比表面积。
此外,磨料颗粒材料可形成为具有至少3.7g/cm3的平均密度。在其他情况中,磨料颗粒材料的密度可更大,如至少约3.75g/cm3,至少约3.8g/cm3,或甚至至少约3.85g/cm3。而且,磨料颗粒材料可具有不大于约4.00g/cm3、如不大于约3.99g/cm3或甚至不大于3.98g/cm3的平均密度。应了解,本文的实施例的磨料颗粒材料可具有在上述最小密度值和最大密度值中的任意者之间的范围内的密度。
在进一步提及磨料颗粒材料时,应了解这种材料的结晶含量可相对较高。特别地,本文的实施例的过程可有利于形成结晶含量以砂粒中的每一个的总重量计为至少90wt%、如至少约92wt%、至少约95wt%、至少约97wt%、至少约99wt%的磨料颗粒材料的多晶砂。在特定情况中,可形成磨料颗粒材料,使得磨料颗粒材料的总重量中的基本上全部为结晶含量。即,磨料颗粒材料可基本上不含非晶相材料。
另外,磨料颗粒材料可包含由α氧化铝制得的氧化铝晶体。在特定情况中,除了存在于氧化铝晶体内的任何添加剂组合物的含量之外,氧化铝晶体可基本上由α氧化铝组成。
此外,磨料颗粒材料可包含平均晶体尺寸不大于约1微米的氧化铝晶体。本文提及晶体尺寸可与提及晶粒尺寸或磨料颗粒材料的砂粒内的最小单晶结构的平均尺寸相同。在其他情况中,氧化铝晶体的平均晶体尺寸可更小,如不大于约800纳米,不大于约500纳米,如不大于约300纳米或甚至不大于约200纳米。实际上,可将某些氧化铝颗粒材料制造为具有不大于约175纳米、不大于约160纳米或甚至不大于约150纳米的平均氧化铝晶体尺寸。而且,在至少一个实施例中,可形成磨料颗粒材料,如氧化铝晶体具有至少约0.1纳米、如至少约1纳米、至少约5纳米、至少约10纳米、至少约20纳米、至少约30纳米、至少约40纳米、至少约50纳米、或甚至至少约80纳米的平均晶体尺寸。应了解,磨料颗粒材料可由氧化铝晶体制得,所述氧化铝晶体具有在上述最小值和最大值中的任意者之间的范围内的平均晶体尺寸。
磨料颗粒材料可形成为具有可取决于某些加工参数的某个平均粒度。例如,在某些情况中,磨料颗粒材料可形成为具有成形轮廓或复杂形状,其将在本文更详细地描述。在这种情况中,磨料颗粒材料可具有不大于约3毫米、不大于约2.8毫米、不大于约2.5毫米、不大于约2毫米、但可为至少约0.1mm、至少约0.3mm或甚至至少约0.4mm的平均粒度。应了解,平均粒度的提及为具有最大值的粒子的单个尺寸的量度。应了解,磨料颗粒材料可具有在上述最小值和最大值中的任意者之间的范围内的平均粒度。
在某些其他情况中,磨料颗粒材料可制造为具有更细的砂粒尺寸,包括例如不大于约1.5毫米、不大于约1毫米、不大于约500微米、不大于约300微米、不大于约100微米、不大于约50微米、不大于约10微米、不大于约1微米、不大于约0.8微米、或甚至不大于约0.6微米的平均粒度。而且,可形成磨料颗粒材料,使得平均粒度为至少约50纳米,至少约80纳米,至少约100纳米,或甚至至少约150纳米。应了解,磨料颗粒材料可具有在上述最小值和最大值中的任意者之间的范围内的平均粒度。
可形成磨料颗粒材料,使得其具有特定组成。例如,可形成磨料颗粒材料,使得其基本上不含碱金属元素,所述碱金属元素包括例如具有正1(1+)价态的阳离子,更特别地为属于第1族的周期表上的元素(参见IUPAC元素周期表2010)。特别地,磨料颗粒材料可基本上不含包括锂(K)、钠(Na)、钾(K)、铷(Rb)、铯(Ce)和钫(Fr)的碱金属元素。在一个特定情况中,磨料颗粒材料可基本上不含钠,使得磨料颗粒材料内的钠含量不大于杂质量,包括例如以磨料颗粒材料总重量计不大于约0.01wt%。
根据一个实施例,在浸渍过程中,可用特定材料,更特别地用第一添加剂组合物内提供的特定物质浸渍磨料颗粒材料。根据一个实施例,第一添加剂组合物可包含特定碱土元素的组合,其中将碱土元素引入前体盐材料中并浸渍多孔氧化铝材料。合适的碱土元素包括选自元素周期表(参见IUPAC元素周期表2010)的第2族的元素,更特别地包括元素铍(Be)、镁(Mg)、钙(Ca)、锶(Sr)、钡(Ba)和它们的组合。某些磨料颗粒材料可形成为具有碱土元素(包括例如镁和钙)的特定组合。
在一个实施例中,磨料颗粒材料可形成为具有特定的镁和钙的添加剂比(Mg∶Ca),所述添加剂比限定磨料颗粒材料内的镁的重量百分比与钙的重量百分比之间的比率。例如,添加剂比可在约1∶1至约10∶1之间的范围内。在其他实施例中,添加剂比可在约1∶1至约9∶1之间的范围内,如约1∶1至8∶1之间的范围内,或甚至约1∶1至约7∶1之间的范围内,约2∶1至约7∶1之间的范围内,约2∶1至约6∶1之间的范围内,约2∶1至约5∶1之间的范围内,约1∶1至约4∶1之间的范围内,或甚至约2∶1至约4∶1之间的范围内,还在约1∶1至3∶1之间的范围内,或甚至约2∶1至约3∶1之间的范围内。
在特定情况中,磨料颗粒材料可形成为具有某个钙(Ca)含量。例如,磨料颗粒可包含以磨料颗粒材料总重量计不大于约2.0wt%的钙,如不大于约1.8wt%的钙,不大于约1.6wt%的钙,不大于约1.4wt%的钙,不大于约1.2wt%的钙,不大于约1.0wt%的钙,不大于约0.9wt%,不大于约0.8wt%,不大于约0.6wt%。而且,磨料颗粒材料内的钙的量以磨料颗粒材料总重量计可为至少约0.2wt%,或甚至至少约0.25wt%,至少约0.27wt%,至少约0.29wt%,或甚至至少约0.3wt%。应了解,磨料颗粒材料内的钙的量可在上述最小重量百分比和最大重量百分比中的任意者之间的范围内。1.0wt%Ca,以磨料颗粒材料总重量计的Ca。
在又一实施例中,磨料颗粒材料可形成为含有特定量的镁(Mg)。例如,磨料颗粒材料内的镁的量可大于钙的含量。根据一个实施例,镁的量以磨料颗粒材料总重量计可不大于约5.0wt%,如不大于约4.5wt%,不大于约4.0wt%,不大于约3.5wt%,不大于约3.0wt%,不大于约2.0wt%,不大于约1.8wt%,不大于约1.5wt%,不大于约1.2wt%,或甚至不大于约1.0wt%。然而,在特定情况中,可形成磨料颗粒材料,使得其含有最少量的镁,包括例如以磨料颗粒材料总重量计至少约0.1wt%、至少约0.2wt%、至少约0.3wt%、至少约0.4wt%、至少约0.5wt%、至少约0.6wt%、至少约0.7wt%、或甚至至少约0.8wt%的镁。应了解,磨料颗粒材料内的镁的量可在上述最小重量百分比和最大重量百分比中的任意者之间的范围内。
根据另一实施例,磨料颗粒材料可含有一定总量的第一添加剂组合物。例如,可形成磨料颗粒材料,使得其含有不大于约8.0wt%的总添加剂组合物,以磨料颗粒材料总重量计。在其他情况中,可形成磨料颗粒材料,使得其含有不大于约7.0wt%,不大于约6.0wt%,不大于约5.0wt%,如不大于约4.0wt%,不大于约3.0wt%,或甚至不大于约2.0wt%的总添加剂组合物,以磨料颗粒材料总重量计。而且,磨料颗粒材料可含有最少量的第一添加剂组合物。例如,磨料颗粒材料可含有至少约0.4wt%、如至少约0.5wt%、至少约0.7wt%、至少约0.9wt%、至少约1.0wt%、或甚至至少约1.2wt%的第一添加剂组合物,以磨料颗粒材料总重量计。应了解,磨料颗粒材料可含有在上述最小百分比和最大百分比中的任意者之间的范围内的第一添加剂组合物的总量。
对于使用第一添加剂组合物的本文的实施例的某些磨料颗粒材料,更特别地对于包含含有Mg和Ca的第一添加剂组合物的某些磨料颗粒材料,可将第二添加剂组合物浸渍于这种磨料颗粒材料内。某些第二添加剂的存在可有利于磨料颗粒材料的改进的机械和/或化学特性。在某些情况中,磨料颗粒材料可包含第二添加剂组合物,所述第二添加剂组合物包含稀土氧化物材料。在其他情况中,除了第一添加剂组合物的MgO之外,第二添加剂组合物可包含特定的碱土氧化物材料。可选择地或除了其他材料之外,第二添加剂组合物可包含过渡金属氧化物材料。第二添加剂组合物的一些合适的氧化物材料可包括Y2O3、La2O3、BaO、Cr2O3、CoO、Fe2O3、GeO2、HfO2、MnO、NiO、Sc2O3、SrO、TiO2、ZnO、ZrO2和它们的组合。
本文的实施例的磨料颗粒材料可包含特定含量的第二添加剂组合物。在特定情况中,磨料颗粒材料可含有比第一添加剂组合物的量更小的第二添加剂组合物的含量。或者,第二添加剂组合物可以以比第一添加剂组合物的量更大的量存在。例如,磨料颗粒材料可包含以磨料颗粒材料总重量计不大于约5wt%、如不大于约4.5wt%、不大于约4wt%、不大于约3.5wt%、不大于约3wt%、不大于约2.0wt%、不大于约1.8wt%、不大于约1.5wt%、或甚至不大于约1.2wt%的第二添加剂组合物。而且,第二添加剂组合物的量以磨料颗粒材料总重量计可为至少约0.1wt%,如至少约0.2wt%,至少约0.3wt%,至少约0.4wt%,至少约0.5wt%,至少约0.6wt%,或甚至至少约0.7wt%。
根据一个实施例,第一添加剂组合物的材料物质可特别地设置于磨料颗粒材料内的位置。例如,已发现,相比于其他形成方法(包括例如掺杂过程),浸渍过程有可能更好地将特定的元素物质均匀分布于磨料颗粒材料内。对掺杂过程的提及可包括如下的那些过程:添加剂在过程中在初期、通常在氧化铝前体材料(如勃姆石)的初始混合物中提供。由于在进一步的加工(如干燥、煅烧等)过程中添加剂优先分离,这种掺杂过程产生添加剂在最终形成的氧化铝粒子内的非均匀分散。
相比之下,浸渍在稍后的阶段,特别是在形成多孔氧化铝材料之后引入第一添加剂组合物。不希望受限于特定理论,据信不同于掺杂过程,浸渍过程可将第一添加剂组合物的特定元素物质引入多孔氧化铝材料的微结构内的细微颗粒间孔隙中。第一添加剂组合物的物质可在进一步加工过程(其可限制至烧结过程)中牢固保持于微结构内并避免分离。这样,相比于掺杂,浸渍过程的使用可有利于在整个磨料颗粒材料中更均质且更均匀地分散第一添加剂组合物的物质。
作为前述现象的证明,图2A包括通过掺杂过程而形成的磨料颗粒材料的图片,图2B包括根据一个实施例通过浸渍过程而形成的磨料颗粒材料的图片。如图2A所示,包括通过掺杂过程而形成的磨粒的微探针图像,其中设定微探针以检测锆。如图2A清楚显示,如磨粒内的不同颜色所示的锆的浓度非均匀分散。根据设备中的元素映射(elementarymapping)的特定程序,使用电子探针微分析仪JEOL JX8800R产生图2。如所示,磨料颗粒材料包括显示零至少的锆含量的某些磨粒201。相比之下,磨粒203显示明显的锆含量,表明粒子的整个表面可含有锆。此外,磨粒204显示锆在磨粒内的非均匀分散,其中相比于粒子内部的部分,粒子的边缘显示更大的锆浓度。这样,通过掺杂过程形成的图2A的磨料颗粒材料在磨粒内和磨粒之间显示出某些元素物质(例如Zr)的明显分离。
图2B包括通过浸渍过程形成的磨料颗粒材料的图片,所述磨料颗粒材料包括具有添加剂的磨粒。图2B的图片为微探针分析的结果,微探针设定为在与图2A的产生和分析中所用的相同制备和条件下检测锆。如所示,图2B中所示的磨料颗粒材料的磨粒205显示锆在整个磨粒205中和甚至磨粒之间均匀且均质分散。图2B的粒子205中的每一个在粒子的整个体积中显示出均匀的“斑点”,其证明经浸渍的添加剂锆的均匀分布,且锆在粒子边缘很少或无聚集,或很少或不存在在一个粒子中的锆浓度比在另一粒子中明显更大。
根据一个实施例,本文的实施例的磨料颗粒材料可基本上由氧化铝晶体和第一添加剂组合物组成。特别地,第一添加剂组合物可包含一定含量的镁和钙,并可基本上由镁和钙组成。更特别地,磨料颗粒材料内的镁含量可基本上均匀分散于整个磨料颗粒材料中。即,磨料颗粒材料内的镁含量可均匀分散于整个多晶结构中,使得其有可能在氧化铝的晶体晶粒内被辨认,因为其在氧化铝晶体之间的晶体边界处。
根据另一实施例,磨料颗粒材料的微结构可为如下:包含全部元素物质(例如镁和钙)的第一添加剂组合物的大部分可优先位于氧化铝晶体之间的晶体边界处。例如,在考虑第一添加剂组合物内的元素物质的总含量时,相比于位于氧化铝晶体内,这种元素物质更有可能位于氧化铝晶体之间的晶体边界处。特别地,在某些实施例中,第一添加剂组合物可包含钙,所述钙可优先位于氧化铝晶体之间的晶体边界处。即,例如,相比于位于氧化铝晶体内,钙可更有可能存在于晶体边界处。
图3包括根据一个实施例的微结构的图示。如所示,磨料颗粒材料300可具有多晶结构,所述多晶结构由在晶体边界302、303和304处彼此分离的多个氧化铝晶体301限定。如进一步所示,磨粒300可包括第一添加剂组合物307,所述第一添加剂组合物307可以以除了氧化铝晶体301之外的分立的结晶相的形式存在,或者作为包含于另一相(如具有氧化铝晶体的固溶体)内的组分存在。在特定情况中,如所示,含有第一添加剂组合物的物质(例如Ca和Mg)的晶体可位于氧化铝晶体301内和晶体边界302、303和304处。在特定情况中,第一添加剂组合物的总含量可优先位于晶体边界302、303和304处,使得晶体边界302、303和304处的第一添加剂组合物的含量比氧化铝晶体301内更大。
在又一方面,磨料颗粒材料可形成为具有特定形状或轮廓。合适的成型技术可包括挤出、模制、丝网印刷、浇铸、冲压、印花、压制、切削和它们的组合。例如,磨料颗粒材料可具有特定轮廓,如多边形形状,包括例如三角形、矩形、五边形、六边形、锥形、螺旋形、椭圆形和细长形状。磨料颗粒材料可包括这些形状的组合。在一个特定实施例中,磨料颗粒材料可由本体形成,所述本体具有在由纵轴、横轴和垂直轴限定的三个垂直平面中包括3重对称性的复杂三维几何形状。
图4-9包括具有特定轮廓并限定成形磨粒的示例性磨料颗粒材料,其可掺入本文所述的组合物中。如图4所示,成形磨粒400可包括本体401,所述本体401为具有第一端面402和第二端面404的总体棱柱状。此外,成形磨粒400可包括在第一端面402与第二端面404之间延伸的第一侧面410。第二侧面412可与第一侧面410相邻,在第一端面402与第二端面404之间延伸。如所示,成形磨粒400也可包括第三侧面414,所述第三侧面414与第二侧面412和第一侧面410相邻,在第一端面402与第二端面404之间延伸。
如图4所示,成形磨粒400也可包括在第一侧面410与第二侧面412之间的第一边缘420。成形磨粒400也可包括在第二侧面412与第三侧面414之间的第二边缘422。此外,成形磨粒400也可包括在第三侧面414与第一侧面412之间的第三边缘424。
如所示,成形磨粒400的每个端面402、404的形状可为总体三角形。每个侧面410、412、414的形状可为总体矩形。此外,在平行于端面402、404的平面中的成形磨粒400的横截面可为总体三角形。应了解,尽管通过平行于端面402、404的平面的成形磨粒400的横截面形状显示为总体三角形,但其他形状是可能的,包括任意多边形形状,例如四边形、五边形、六边形、七变形、八边形、九边形、十边形等。此外,成形磨粒的横截面形状可为凸状、非凸状、凹状或非凹状。
图5包括根据另一实施例的成形磨粒的图示。如所示,成形磨粒500可包括本体501,所述本体501可包括沿着纵轴504延伸的中心部分502。第一径向臂506可沿着中心部分502的长度从中心部分502向外延伸。第二径向臂508可沿着中心部分502的长度从中心部分502向外延伸。第三径向臂510可沿着中心部分502的长度从中心部分502向外延伸。此外,第四径向臂512可沿着中心部分502的长度从中心部分502向外延伸。径向臂506、508、510、512可围绕成形磨粒500的中心部分502相等间隔。
如图5所示,第一径向臂506可包括总体箭形的远端520。第二径向臂508可包括总体箭形的远端522。第三径向臂510可包括总体箭形的远端524。此外,第四径向臂512可包括总体箭形的远端526。
图5也表明,成形磨粒500可形成为具有第一径向臂506与第二径向臂508之间的第一空隙530。第二空隙532可在第二径向臂508与第三径向臂510之间形成。第三空隙534也可在第三径向臂510与第四径向臂512之间形成。另外,第四空隙536可在第四径向臂512与第一径向臂506之间形成。
如图5所示,成形磨粒可包括长度540、高度542和宽度544。在一个特定方面,长度540大于高度542,且高度542大于宽度544。在一个特定方面,成形磨粒500可限定一级纵横比,所示一级纵横比为长度540与高度542的比率(长度∶宽度)。此外,成形磨粒500可限定第二纵横比,所述第二纵横比为高度542与宽度544的比率(宽度∶高度)。最后,成形磨粒500可限定第三纵横比,所述第三纵横比为长度540与宽度542的比率(长度∶高度)。
根据一个实施例,成形磨粒可具有至少约1∶1、如至少约1.1∶1、至少约1.5∶1、至少约2∶1、至少约2.5∶1、至少约3∶1、至少约3.5∶1、至少4∶1、至少约4.5∶1、至少约5∶1、至少约6∶1、至少约7∶1、至少约8∶1、或甚至至少约10∶1的一级纵横比。
在另一情况中,可形成成形磨粒,使得本体具有至少约0.5∶1、如至少约0.8∶1、至少约1∶1、至少约1.5∶1、至少约2∶1、至少约2.5∶1、至少约3∶1、至少约3.5∶1、至少4∶1、至少约4.5∶1、至少约5∶1、至少约6∶1、至少约7∶1、至少约8∶1、或甚至至少约10∶1的二级纵横比。
此外,某些成形磨粒可具有至少约1∶1、如至少约1.5∶1、至少约2∶1、至少约2.5∶1、至少约3∶1、至少约3.5∶1、至少4∶1、至少约4.5∶1、至少约5∶1、至少约6∶1、至少约7∶1、至少约8∶1、或甚至至少约10∶1的三级纵横比。
成形磨粒500的某些实施例可具有总体矩形的关于一级纵横比的形状,例如平坦或弯曲的。关于二级纵横比的成形磨粒500的形状可为任意多边形形状,例如三角形、方形、矩形、五边形等。关于二级纵横比的成形磨粒500的形状也可为具有任意字母数字字符(例如1、2、3等,A、B、C等)的形状。此外,关于二级纵横比的成形磨粒500的轮廓可为选自希腊字母、现代拉丁字母、古拉丁字母、俄语字母、任何其他字母或它们的任意组合的字符。此外,关于二级纵横比的成形磨粒500的形状可为日本汉字字符。
图6-7表示通常指定为600的成形磨粒的另一实施例。如所示,成形磨粒600可包括具有总体立方体状形状的本体601。应了解,成形磨粒可形成为具有其他多边形形状。本体601可具有第一端面602和第二端面604,在第一端面602与第二端面604之间延伸的第一侧面606,在第一端面602与第二端面604之间延伸的第二侧面608。此外,本体601可具有在第一端面602与第二端面604之间延伸的第三侧面610,在第一端面602与第二端面604之间延伸的第四侧面612。
如所示,第一端面602和第二端面604可彼此平行,并由侧面606、608、610和612分隔,从而提供本体立方体状结构。然而,在一个特定方面,第一端面602可相对于第二端面604旋转,以建立扭转角614。本体601的扭转可沿着一个或多个轴线,并限定特定类型的扭转角。例如,如图7中的本体的俯瞰图所示,所述图7沿着限定本体601的长度的纵轴680俯视平行于由横轴681和垂直轴682限定的平面的端面602,所述横轴681沿着本体601的宽度的尺寸延伸,所述垂直轴682沿着本体601的高度的尺寸延伸。根据一个实施例,本体601可具有限定围绕纵轴的本体601中的扭转的纵向扭转角614,使得端面602和604相对于彼此旋转。如图7所示,扭转角614可作为第一边缘622和第二边缘624的切线之间的角度测得,其中第一边缘622和第二边缘624由共同边缘626结合,并共用共同边缘626,所述共同边缘626在侧面(610和612)中的两个之间纵向延伸。应了解,其他成形磨粒可形成为具有相对于横轴、垂直轴和它们的组合的扭转角。这种扭转角中的任意者可具有如本文所述的值。
在一个特定方面,扭转角614为至少约1°。在其他情况中,扭转角可更大,如至少约2°,至少约5°,至少约8°,至少约10°,至少约12°,至少约15°,至少约18°,至少约20°,至少约25°,至少约30°,至少约40°,至少约50°,至少约60°,至少约70°,至少约80°,或甚至至少约90°。而且,根据某些实施例,扭转角614可不大于约360°,如不大于约330°,如不大于约300°,不大于约270°,不大于约230°,不大于约200°,或甚至不大于约180°。应了解,某些成形磨粒可具有在上述最小角度和最大角度中的任意者之间的范围内的扭转角。
此外,本体可包括沿着纵轴、横轴或垂直轴中的一者延伸通过本体的整个内部的开口。
图8包括成形磨粒的另一实施例的图示。如所示,成形磨粒800可包括本体801,所述本体801具有成形为具有总体三角形底面802的总体角锥体。本体还可包括彼此连接且连接至底面802的侧面816、817和818。应了解,尽管本体801显示为具有角锥体多边形形状,但其他形状是可能的,如本文所述。
根据一个实施例,成形磨粒800可形成为具有孔804(即开口),所述孔804可延伸通过本体801的至少一部分,且更特别地可延伸通过本体801的整个体积。在一个特定方面,孔804可限定穿过孔804的中心的中心轴806。此外,成形磨粒800也可限定穿过成形磨粒800的中心830的中心轴808。应了解,孔804可在成形磨粒800中形成,使得孔804的中心轴806与中心轴808间隔距离810。这样,成形磨粒800的质心可移动至成形磨粒800的几何中点830以下,其中几何中点830可由纵轴809、垂直轴811和中心轴(即横轴)808的交点限定。将质心移动至成形磨粒的几何中点830以下可增加成形磨粒800在下降时落在相同面(例如底面802)上或者沉积于背衬上的可能性,使得成形磨粒800具有预定直立取向。
在一个特定实施例中,质心沿着限定高度的本体802的垂直轴810偏离几何中点830可为至少约0.05高度(h)的距离。在另一实施例中,质心可偏离几何中点830至少约0.1(h)、如至少约0.15(h)、至少约0.18(h)、至少约0.2(h)、至少约0.22(h)、至少约0.25(h)、至少约0.27(h)、至少约0.3(h)、至少约0.32(h)、至少约0.35(h)、或甚至至少约0.38(h)的距离。而且,本体801的质心可偏离几何中点830不大于0.5(h)、如不大于0.49(h)、不大于0.48(h)、不大于0.45(h)、不大于0.43(h)、不大于0.40(h)、不大于0.39(h)、或甚至不大于0.38(h)的距离。应了解,质心与几何中点之间的偏离可在上述最小值和最大值中的任意者之间的范围内。
在特定情况中,质心可偏离几何中点830,使得当成形磨粒800为如图8所示的直立取向时,相比于本体801的顶部,质心更接近本体801的基底,例如底面802。
在另一实施例中,质心可沿着限定宽度的本体801的横轴808偏离几何中点830至少约0.05宽度(w)的距离。在另一方面,质心可偏离几何中点830至少约0.1(w)、如至少约0.15(w)、至少约0.18(w)、至少约0.2(w)、至少约0.22(w)、至少约0.25(w)、至少约0.27(w)、至少约0.3(w)、或甚至至少约0.35(w)的距离。而且,在一个实施例中,质心可偏离几何中点830不大于0.5(w)、如不大于0.49(w)、不大于0.45(w)、不大于0.43(w)、不大于0.40(w)、或甚至不大于0.38(w)的距离。
在另一实施例中,质心可沿着纵轴809偏离几何中点830达距离(Dl),所述距离(Dl)为至少约0.05的本体801的长度(1)。根据一个特定实施例,质心可偏离几何中点至少约0.1(1)、如至少约0.15(1)、至少约0.18(1)、至少约0.2(1)、至少约0.25(1)、至少约0.3(1)、或甚至至少约0.35(1)、或甚至至少约0.38(1)的距离。而且,对于某些磨粒,质心可偏离不大于约0.5(1)、如不大于约0.45(1)、或甚至不大于约0.40(1)的距离。
图9包括根据一个实施例的成形磨粒的图示。成形磨粒900可包括本体901,所述本体901包括底表面902和上表面904,底表面902和上表面904通过一个或多个侧表面910、912和914而彼此间隔。根据一个特定实施例,可形成本体901,使得底表面902具有与上表面904的平面形状不同的平面形状,其中平面形状在由各自的表面限定的平面中观察。例如,如图9的实施例所示,本体901可具有底表面902和上表面904,底表面902通常具有圆形形状,上表面904具有总体三角形形状。应了解,其他变化是可行的,包括底表面902和上表面904处的形状的任意组合。
图10包括根据一个实施例的掺入磨料颗粒材料的涂布磨料制品的横截面图示。如所示,涂布磨料1000可包括基材1001、覆盖基材1001的表面的底胶1003、覆盖并粘合至底胶1003的根据本文实施例中的任意者的磨料颗粒材料1005、和覆盖并粘合至磨料颗粒材料1005的复胶105。
根据一个实施例,基材1001可包括有机材料、无机材料和它们的组合。在某些情况中,基材1001可包括织造材料。然而,基材1001可由非织造材料制得。特别合适的基材材料可包括有机材料,包括聚合物,特别是聚酯、聚氨酯、聚丙烯,聚酰亚胺(如来自杜邦公司(DuPont)的KAPTON)、纸张。一些合适的无机材料可包括金属、金属合金,特别是铜箔、铝箔、钢箔,和它们的组合。
底胶1003可在单个过程中施用至基材1001的表面,或者,磨料颗粒材料1005可与底胶1003材料组合,并作为混合物施用至基材1001的表面。底胶1003的合适的材料可包括有机材料,特别是聚合物材料,包括例如聚酯、环氧树脂、聚氨酯、聚酰胺、聚丙烯酸酯、聚甲基丙烯酸酯、聚氯乙烯、聚乙烯、聚硅氧烷、有机硅、乙酸纤维素、硝酸纤维素、天然橡胶、淀粉、虫胶、和它们的混合物。在一个实施例中,底胶1003可包括聚酯树脂。随后可加热经涂布的基材,以将树脂和磨料颗粒材料固化至基材。通常,在所述固化过程中,将经涂布的基材加热至约100℃至小于约250℃之间的温度。
在充分形成具有包含于其中的磨料颗粒材料1005的底胶1003之后,可形成复胶1007,以覆盖磨料颗粒材料1005并将磨料颗粒材料1005粘合至适当位置。复胶可包括有机材料,可基本上由聚合物材料制得,且特别地可使用聚酯、环氧树脂、聚氨酯、聚酰胺、聚丙烯酸酯、聚甲基丙烯酸酯、聚氯乙烯、聚乙烯、聚硅氧烷、有机硅、乙酸纤维素、硝酸纤维素、天然橡胶、淀粉、虫胶、和它们的混合物。
实例1
将可作为Catapal B购自萨索尔公司(Sasol Corp.)的原料勃姆石掺入包含42%的固体(勃姆石)、1wt%的晶种材料(α氧化铝)(以勃姆石总重量计)和2.5wt%的硝酸(以勃姆石总重量计)的混合物中。所述混合物可为使用水作为液体载体的浆料的形式。浆料在环境条件下胶凝。
在胶凝之后,将浆料丝网印刷,以形成包括勃姆石材料的成形粒子。丝网印刷过程通常描述于美国专利No.6,054,093中。在丝网印刷过程中,连续带形式的印刷丝网经过限定特定的区(包括施用区、脱离区、清洁区和处理区)的一系列四个辊。在施用区中,印刷丝网保持为与连续不锈钢带牢固接触,并将磨料前体粒子的糊剂施用至印刷丝网的内表面。迫使糊剂进入丝网中的孔中,同时印刷丝网与带直接接触。在脱离区中,当印刷丝网与带脱离时,糊剂的分立的形状保持在带的表面上,其中分立的形状具有印刷丝网中的孔的轮廓。所述形状由带传输至干燥区,其中取决于带的速度,形状在环境气氛下在90-95℃下干燥大约5-10分钟。
在成形之后,经干燥的成形粒子在环境气氛下在大约900℃下在旋转炉中煅烧,以形成孔体积为大约0.30cm3/g的多孔铝土材料。
使用由溶解于125g水中的32g硝酸镁六水合物和6g硝酸钙四水合物制得的第一添加剂组合物浸渍大约500g的多孔铝土材料。将第一添加剂组合物与多孔铝土材料混合,以实现前体盐材料的阳离子(即Ca和Mg)的浸渍。经浸渍的材料在95℃下干燥大约12小时。
在用第一添加剂组合物浸渍多孔铝土材料之后,烧结成形的经浸渍的粒子。使用环境气氛在旋转炉中在大约1300℃的温度下进行烧结,以形成经浸渍的磨料颗粒材料。最终形成的磨粒为等边三角形的形式的成形磨料颗粒材料,所述成形磨料颗粒材料具有大约1.5mm的尺寸的边和大约275微米的厚度。磨料颗粒材料为用1.0wt%的Mg和0.3wt%的Ca浸渍的大约98.7%的α氧化铝。
实例2
根据如下过程将实例1的成形磨料颗粒材料成型为涂布磨料样品(CAS1)。经由两种直接涂布方法用甲阶酚醛树脂的底胶涂布平坦织物基材。将成形磨料颗粒材料置于底胶中,以经由静电喷射过程将它们粘着至基材。经由在空气气氛中在175至225F的温度下在烘箱中达到大约1.5小时的持续时间而固化底胶。在形成底胶之后,含有冰晶石的甲阶酚醛树脂的复胶在成形磨料颗粒材料上形成,并经由在空气气氛中在175-225F的温度下在烘箱中达到大约1.5至3小时的持续时间而固化。
使用与用于制备样品CAS1相同的过程制备常规涂布磨料样品。常规样品2(CAC2)使用通过与CAS1相同的过程而形成的成形磨料颗粒材料,不同的是所述材料浸渍为具有大约99.7wt%的α氧化铝和0.3wt%的Ca的组成。常规样品3(CAC3)使用通过与CAS1相同的过程而形成的成形磨料颗粒材料,不同的是所述材料浸渍为具有大约98.7wt%的α氧化铝和1.3wt%的Mg的组成。常规样品4(CAC4)使用通过与CAS1相同的过程而形成的成形磨料颗粒材料,不同的是所述成形磨料颗粒材料不被浸渍,并具有大约100wt%的氧化铝的组成。
根据如下碾磨测试来测试所有样品,以确定碾磨性能:在304不锈钢的工件上以4英寸3/分钟英寸干燥切入式碾磨,其中碾磨间隔进行,以在每次间隔中从工件上去除0.2英寸3的材料。轮速为7500sfpm。
图11包括根据如上详细碾磨测试进行测试的样品(CAS1、CAC2、CAC3和CAC4)的比碾磨能(SGE HP min/in3)相比于累积的去除材料的图。如清楚所示,根据本文实施例而形成的示例性样品显示出碾磨性能的明显改进。如所示,相比于所有常规样品,样品CAS1显示出改进的碾磨性能。在连续使用下,且对于更大含量的累积的去除材料,CAS1显示出更一致的SGE。实际上,CAS1样品显示出相比于最接近样品(CAC3)的大于20%的累积的去除材料的改进,以及相比于CAC2样品的大于40%的改进。此外,相比于常规样品中的任意者,样品CAS1在累积去除材料的基本上全部范围内显示出更低的比碾磨能,表明对于更大量的累积去除材料的改进的材料去除效率。简言之,相比于不具有浸渍的添加剂的粒子以及仅使用Ca或仅使用Mg的成形磨粒,具有作为第一添加剂组分的Mg和Ca的特定组合的示例性样品CAS1显示改进的碾磨能力。
实例3
对于各种样品(包括仅包含Ca或Mg的添加剂的常规材料的样品,和包含受控量的Ca和Mg的示例性样品),测量硬度和韧性。如下表1显示了磨粒的样品的机械特性(包括硬度、韧性和脆性),所述磨粒为三角形二维形状的成形磨粒。表1的数据包括具有受控量的Ca和Mg的根据本文实施例的示例性样品(S1、S2和S3),特别地,样品显示出合适的硬度、韧性和脆性特性。另外且非常出乎意料地,Ca的添加未降低示例性样品的硬度。
硬度经由ASTM1327测得。韧性经由描述于“A Critical Evaluation ofIndentation Techniques for Measuring Fracture Toughness:I,Direct CrackMeasurements(用于测量断裂韧性的压痕技术的决定性评价:I,直接裂纹测量)”,GR.ANSTIS,P.CHANTIKUL,B.R.LAWN和D.B.MARSHALL,J Am.Cer.Soc.第64卷,第533页中的方法测得。
表1
表2
CS1 | CS2 | S4 | S5 | CS3 | CS4 | |
MgO | 1% | 1% | 1% | 0% | ||
CaO | 0.3% | 0.9% | 0.3% | 0.9% | 0% | |
硬度[GPa] | 19.21 | 18.09 | 19.88 | 19.83 | 19.94 | 19.86 |
标准偏差 | 0.51 | 1.24 | 1.28 | 0.58 | 0.49 | 0.91 |
韧性[MPa*m^(0.5)] | 2.44 | 2.77 | 2.35 | 2.46 | 2.22 | 3.22 |
标准偏差 | 0.22 | 0.33 | 0.14 | 0.18 | 0.09 | 0.13 |
表2包括具有受控量的Ca和Mg的根据本文实施例形成的示例性样品(S4和S5)、仅具有Ca添加的常规样品(CS1和CS2)、仅具有Mg添加的常规样品(CS3)和不具有Mg或Ca添加的常规样品CS4。如表2的数据所示,样品CS1和CS2中仅添加Ca导致硬度的立即显著的降低。实际上,相对于样品S5,常规样品CS2具有小大约10%的硬度。
样品S4和S5相对于仅包含Mg的常规样品CS3具有显著更大的韧性,且相对于样品CS3具有可相比的硬度。
非常出乎意料的是,特别是鉴于存在于磨料颗粒材料内的Ca的含量,可获得碾磨性能的这种改进。不希望受限于特定解释,据推理,尽管有工业的一般理解(即使是少量的Ca也应该在氧化铝磨料中避免,因为相比于不包含Ca的组合物(参见例如图11的CAC4),Ca显示出对机械稳定性具有不利效果(参见例如图11,样品CAC2)),但特定比率的Mg和Ca的组合可提供可测的有利效果。
本申请表示了对现有技术的偏离。尽管工业已公认钙可存在于氧化铝磨料内,但通常认为钙的量应该受限,优选限制至小于0.3wt%的量,更实际为0wt%至0.1wt%之间,因为Ca与降低的氧化铝磨料材料的性能相关。参见例如US5,770,145。相比之下,本申请的发明人已出乎意料地发现,钙可在氧化铝磨料中使用,特别是结合本文描述的其他特征,包括例如其他第一添加剂组分(例如Mg)。实际上,非常出乎意料地,这种组合物可有利于改进的碾磨性能。本文描述的磨料颗粒材料使用特征的组合,包括第一添加剂组合物的使用、第二添加剂组合物、第一添加剂组合物物质的比率、特定组合物的最大量和最小量,和特定的形成方法(包括例如浸渍过程,其已显示提供能够具有改进性能的磨料颗粒材料)。
如上公开的主题被认为是说明性的而非限制性的,所附权利要求书旨在涵盖落入本发明的真实范围内的所有这种修改、增强和其他实施例。因此,在法律允许的最大程度内,本发明的范围将由如下权利要求和它们的等同形式的最广允许解释确定,不应由如上具体实施方式限制或限定。
提供说明书摘要以符合专利法,在了解说明书摘要不用于解释或限定权利要求的范围或含义的情况下提交说明书摘要。另外,在如上附图的详细描述中,为了简化本公开,各个特征可在单个实施例中组合在一起或进行描述。本公开不解释为反映如下意图:所要求保护的实施例需要除了在每个权利要求中明确记载之外的更多的特征。相反,如如下权利要求所反映,本发明的主题可涉及比所公开的实施例中的任意者的全部特征更少的特征。因此,如下权利要求引入附图的详细描述,每个权利要求本身分别限定所要求保护的主题。
Claims (34)
1.一种磨料制品,其包括:
磨料颗粒材料,所述磨料颗粒材料基本上由氧化铝晶体和在所述磨料颗粒材料内浸渍的第一添加剂组合物组成,其中所述第一添加剂组合物基本上由Mg和Ca组成,其中Mg和Ca以1:1至10:1之间的范围内的Mg:Ca添加剂比存在,所述Mg:Ca添加剂比限定为磨料颗粒材料内的镁的重量百分比与钙的重量百分比之间的比率,其中所述磨料颗粒材料包含以所述磨料颗粒材料总重量计至少0.1wt%且不大于2wt%的Mg,且还包含以所述磨料颗粒材料总重量计至少0.2wt%的Ca,其中位于氧化铝晶体边界处的所述第一添加剂组合物的重量含量比在所述氧化铝晶体内的所述第一添加剂组合物的重量含量更大。
2.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料基本上不含碱金属元素。
3.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料基本上不含钠。
4.根据权利要求1所述的磨料制品,其中所述氧化铝晶体包括α氧化铝,其中所述氧化铝晶体基本上由α氧化铝组成。
5.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料包含以所述磨料颗粒材料总重量计至少0.25wt%的Ca且不大于2wt%的Ca。
6.根据权利要求5所述的磨料制品,其中所述磨料颗粒材料包含以所述磨料颗粒材料总重量计至少0.3wt%的Ca。
7.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料包含以所述磨料颗粒材料总重量计不大于8wt%的所述第一添加剂组合物。
8.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料包含以所述磨料颗粒材料总重量计至少0.4wt%的所述第一添加剂组合物。
9.根据权利要求1所述的磨料制品,其中所述氧化铝晶体包含不大于1微米的平均晶体尺寸。
10.根据权利要求1所述的磨料制品,其中所述氧化铝晶体包含至少0.1nm的平均晶体尺寸。
11.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料包含不大于3mm的平均粒度。
12.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料包含至少50nm的平均粒度。
13.根据权利要求1所述的磨料制品,其中所述Mg:Ca添加剂比在1:1至9:1之间的范围内。
14.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料包含至少3.7g/cm3且不大于4.00g/cm3的密度。
15.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料包含不大于0.15m2/g的比表面积。
16.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料包含以所述磨料颗粒材料总重量计至少90wt%的结晶度含量。
17.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料包括轮廓且其中所述轮廓包括多边形形状。
18.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料为固定磨料的一部分。
19.根据权利要求18所述的磨料制品,其中所述固定磨料包括粘结磨料制品或涂布磨料制品。
20.根据权利要求18所述的磨料制品,其中所述磨料颗粒材料经由粘结材料粘着至背衬。
21.根据权利要求1所述的磨料制品,其中所述磨料颗粒材料包括选自由以下组成的群组的轮廓:三角形、矩形、五边形、六边形、锥形、螺旋形、椭圆形、细长和它们的组合。
22.一种磨料制品,其包括:
磨料颗粒材料,所述磨料颗粒材料基本上由氧化铝晶体和在所述磨料颗粒材料内浸渍的第一添加剂组合物组成,所述第一添加剂组合物基本上由Mg和Ca的组合组成,其中Mg和Ca以1:1至10:1之间的范围内的Mg:Ca添加剂比存在,所述Mg:Ca添加剂比限定为磨料颗粒材料内的镁的重量百分比与钙的重量百分比之间的比率,其中所述磨料颗粒材料由本体形成,且所述磨料颗粒材料包含以所述磨料颗粒材料总重量计至少0.1wt%且不大于2wt%的Mg,且还包含以所述磨料颗粒材料总重量计至少0.2wt%的Ca。
23.根据权利要求22所述的磨料制品,其中本体包括至少0.5:1的由宽度:高度比定义的第二纵横比。
24.根据权利要求22所述的磨料制品,其中本体包括至少1:1的由长度:高度比定义的第三纵横比。
25.根据权利要求22所述的磨料制品,其中本体包括字符形式的横截面轮廓,所述字符选自希腊字母、拉丁字母或俄语字母。
26.根据权利要求22所述的磨料制品,其中本体包括沿着限定所述本体长度的纵轴的扭转,其中所述沿着纵轴的扭转限定至少1度的所述本体两端之间的纵向扭转角。
27.根据权利要求22所述的磨料制品,其中本体包括沿着限定所述本体宽度的横轴的扭转,其中所述沿着横轴的扭转限定至少1度的所述本体两端之间的横向扭转角。
28.一种形成磨料制品的方法,所述方法包括:
形成多孔氧化铝材料,所述多孔氧化铝材料基本上由氧化铝晶体组成;和
使用第一添加剂组合物浸渍所述多孔氧化铝材料以形成经浸渍的颗粒材料,其中所述第一添加剂组合物基本上由Mg和Ca组成,其中Mg和Ca以1:1至10:1之间的范围内的Mg:Ca添加剂比存在,所述Mg:Ca添加剂比限定为磨料颗粒材料内的镁的重量百分比与钙的重量百分比之间的比率,其中所述磨料颗粒材料包含以所述磨料颗粒材料总重量计至少0.1wt%且不大于2wt%的Mg,且其中位于氧化铝晶体边界处的所述第一添加剂组合物的重量含量比在所述氧化铝晶体内的所述第一添加剂组合物的重量含量更大。
29.根据权利要求28所述的方法,其中形成包括煅烧,其中煅烧在环境气氛下进行,且煅烧在回转窑中进行。
30.根据权利要求29所述的方法,其中煅烧在至少500℃且不大于1500℃的温度下进行。
31.根据权利要求28所述的方法,其中浸渍包括混合含有所述第一添加剂组合物的物质的前体盐材料与所述多孔氧化铝材料,其中混合包括湿混合包含所述前体盐材料的溶液与所述多孔氧化铝材料。
32.根据权利要求31所述的方法,其中所述前体盐材料包括硝酸盐。
33.根据权利要求28所述的方法,其还包括在大于煅烧温度的烧结温度下烧结所述经浸渍的颗粒材料,其中所述烧结温度为至少800℃,且不大于1600℃。
34.根据权利要求28所述的方法,其中所述经浸渍的颗粒材料包含不大于0.15m2/g的比表面积。
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PCT/US2012/057376 WO2013049239A1 (en) | 2011-09-26 | 2012-09-26 | Abrasive articles including abrasive particulate materials, coated abrasives using the abrasive particulate materials and methods of forming |
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2012
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- 2012-09-26 CA CA2850147A patent/CA2850147A1/en not_active Abandoned
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EP2760639A1 (en) | 2014-08-06 |
JP5802336B2 (ja) | 2015-10-28 |
KR20140075720A (ko) | 2014-06-19 |
CA2850147A1 (en) | 2013-04-04 |
WO2013049239A1 (en) | 2013-04-04 |
US20130074418A1 (en) | 2013-03-28 |
EP2760639A4 (en) | 2015-09-30 |
EP2760639B1 (en) | 2021-01-13 |
CN103826802A (zh) | 2014-05-28 |
BR112014007089A2 (pt) | 2017-03-28 |
JP2014526395A (ja) | 2014-10-06 |
KR101704411B1 (ko) | 2017-02-08 |
US9517546B2 (en) | 2016-12-13 |
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