CN1072251C - 网印的成形制品 - Google Patents
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Abstract
可如下获得成形的陶瓷制品:由尺寸稳定的陶瓷前体物质的分散体网印出的成形物在一个表面上,干燥如此得到的网印成形物,再将其煅烧产生成形陶瓷制品。
Description
发明的背景
本发明涉及成形陶瓷制品(如具有高度柔性和生产率的磨粒)的形成方法,具体涉及由α氧化铝前体的分散体制得的成形制品。
与将大块磨料粉碎再经分级制得的具有无规形状的磨粒相比,在美国专利5,009,676中披露的晶种溶胶凝胶法制得的丝状氧化铝磨粒业已显示出显著的优点。这种成形磨粒的形成方法披露在美国专利(USPP)5,090,968和5,201,916中。含有这种成形磨粒的涂覆磨具披露在欧洲专利申请0 395 088 A2中。由溶胶凝胶法氧化铝制得的其它类型的成形制品,如盘、刚纸(fibers)和薄片也已有披露。但是,这类方法大都不很适用于制造很小的成形颗粒。
现在已提出了一种新的很灵活的成形氧化铝制品的生产方法,它能由前体材料的分散体快速高效地制造成形氧化铝制品。本发明方法很容易自动化,所以特别适用于制造很细的颗粒。
尽管就制得的成形物的类型而言,本发明相当灵活,但是它特别适用于制造成形的颗粒。
发明的概述
本发明方法是用网印方法制造成形的陶瓷制品,它是穿过一印网向一接受表面施加尺寸稳定的前体物质分散体。
一种较好的方法是将α氧化铝前体物质的分散体施加在支承于接受表面上的多孔印网的表面上,使之填满印网中的许多孔洞,从接受表面上移去印网,随后对留在接受表面上的网印成形物进行干燥、煅烧,形成烧结的α氧化铝成形制品。
所使用的分散体必须是尺寸稳定的,这是指当移去印网后成形物在待下一步干燥和煅烧的一定时间内,用本发明网印方法由分散体形成的简单成形物须能良好地保持其形状。当不能方便地获得前体凝胶时,可使用添加剂获得这种稳定性。如果使用添加剂不能获得形状稳定性,则本发明中分散体的固体含量就是关键因素。当固体含量较低时,可能需要调整粘度以防止移去印网后成形物的形状发生变化,为此可加入粘度调节剂。当分散体是凝胶时,较好的方法是使用酸(如硝酸)产生胶溶作用。但是如果分散体具有太高的固体含量,则难以填满印网的所有孔洞。
在较好的方法中使用的分散体通常是一种勃姆石凝胶,而且该勃姆石凝胶最好含有细分散的、能对氧化铝前体转化成α氧化铝具有成核作用的晶种颗粒。
可以使用任何合适的材料(如不锈钢,塑料如PTFE、EVA、聚酯或尼龙,重级纸纸等)制造多孔的印网。网印是一种众所周知的方法,上述一般适用于制造印网的材料也适用于本发明的用途。
印网的孔洞形状并不关键,可根据制品的性能进行选择。但是需知本方法提供了一种制造大量形状实际上相同的成形物的方法,或者如果需要,本方法还可制造含有各种预定形状不同的成形物的精确混合物的方法。本发明方法宜用于制造成形陶瓷磨粒。这种成形物可以是多角形的或球形的,但最适用的是规则矩形的成形物,其长径比(即长度与最大横截面尺寸之比)约为2∶1-50∶1,最好为约5∶1-25∶1。显然尺寸变化受到印网厚度的限制。如果厚度太大,移去印网时分散体不易从孔洞中脱模,因此如果不使用脱模剂(如硅氧烷类、氟碳类或烃衍生物)对印网进行处理,则网印的最大厚度一般限于约10mm,更经常为3mm或更小,但是,如果要求的是扁平的成形物,则网印的这种厚度限制不是很明显。
发明的详细描述
本发明方法中使用的分散体可以是任何陶瓷前体物质的分散体,这里指的是一种细分散的物质,使用本发明方法以后,该物质成为成形陶瓷制品。前体可以是化学前体,例如,勃姆石是α氧化铝的化学前体;可以是一种形态前体,例如γ氧化铝是α氧化铝的形态前体;也可以是物理前体,其意义是该前体本身已是细粒α氧化铝,用它可以形成一种成形物,烧结后仍保留其形状。
当分散体中含的是物理或形态前体(按本文中使用的意义)时,该前体形态是细粉碎的粉末颗粒,当其烧结在一起时形成陶瓷制品,如在常规粘结磨具和涂覆磨具品中使用的磨粒。这种前体材料一般为平均粒径小于约20微米、宜小于约10微米、最好小于约1微米的粉末颗粒。
物理或形态前体分散体中的固体含量宜约为40-65%,尽管高达约80%固体含量的分散体也可使用。有机化合物常作为悬浮剂或作为临时粘合剂与分散体中细粉碎的颗粒一起使用,其临时粘合作用是在这些颗粒充分干燥之前能保持制品的形状。这种有机化合物可以是常用于该目的的任何已知有机化合物,如聚乙二醇、山梨醇酯等。
通过加热变成最终稳定陶瓷形态的化学前体的固体含量,需要考虑在干燥和煅烧成烧结颗粒的过程中从前体本身中释放的水分。在这种情况下固体含量一般略少一些,例如约75%或更低,最好约为30-50%,更好约30-60%。就勃姆石凝胶而言,最大的固体含量宜约为60%或甚至40%,也可使用固体含量少至20%的胶溶凝胶。
与由加晶种的化学前体制得的制品相比,由物理前体制得的制品需要更高的煅烧温度,例如,在温度低于约1250℃,加晶种的勃姆石凝胶已能形成基本上完全致密的α氧化铝,而由α氧化铝凝胶制得的颗粒则需要高于约1400℃的煅烧温度才能完全致密。
可使用本发明方法制成成形陶瓷物品的材料包括物理前体,如已知陶瓷材料(如α氧化铝、碳化硅、氧化铝/氧化锆和CBN)的细粉碎颗粒;还包括化学和/或形态前体,如氢氧化铝、勃姆石、γ氧化铝和其它过渡型氧化铝及铝矾土。在本发明的上述材料中,最有用的是基于氧化铝的材料及其物理或化学前体。本发明的具体描述是就氧化铝而言的,但是,应该理解本发明不受此限制,能采用许多不同的前体材料。
在某些制造氧化铝基制品的情况下需要的其它组分,包括成核剂,如细粉碎的α氧化铝、氧化铁、氧化铬以及能在前体形态转化成α氧化铝形态的过程中起成核作用的其它材料;氧化镁;氧化钛;氧化锆;氧化钇和稀土金属氧化物。这些添加剂常起晶体生长限制剂或边界相改善剂的作用。这些添加剂在前体中的量通常约小于10%,更宜小于5%(按固体重量计)。
还可将细粉碎α氧化铝本身与有机化合物(该有机化合物使α氧化铝保持悬浮状态并在颗粒被煅烧至基本上完全致密的过程中起临时粘合剂的作用)一起使用来代替α氧化铝的化学或形态前体。在这种情况下,在悬浮体中常可加入煅烧后形成独立相的物质,或在干燥和煅烧过程中或煅烧后有助于成形颗粒保持结构完整性的物质。这种物质也可作为杂质存在。如果例如前体是细粉碎的铝矾土,则会存在有少量玻璃体物质,这种物质在粉末颗粒烧结在一起形成成形制品后它会形成第二相。
用于网印操作的多孔印网可以很容易地适用于不连续操作方式和连续操作方式。当印网的厚度位于其厚度范围的上限(约10mm)时,它的柔性不够,故无法用于采用带状印网的连续操作工艺中。而就许多其它应用而言,最好是用连续操作工艺。在这种自动化的操作方式中,多孔印网通常制成从动带的形式,这意味着网印带上的主要应力是纵向的,即它会有某种程度的拉长。如果在网印带上的孔在其移动方向上成直线排列,则这种拉长不会导致颗粒横截面的明显变形。因此,用于本发明方法的网印带最好具有这个特征。这种形状的其它好处在于它使更多的制带材料在长度方向进行取向,从而使网印带在该方向上的强度达到最佳。
在进行网印时,多孔的网印带通过施加区时与一柔性的带子相接触。因此这个柔性带子最好由抗水分侵蚀的材料制成,使之不受凝胶中水和酸的影响。由于该柔性带子也是被驱动的,所以它最好是较难伸长的。它同时最好是表面上基本光滑的,以免凝胶渗入造成分离困难。许多氧化铝凝胶具有酸性的pH值(特别是用酸进行胶溶的),因此带子应具有足够的抗腐蚀性。符合这些标准的较好材料是不锈钢,但某些情况下可使用其它材料,如镀铬的镍、聚四氟乙烯、含有氟化乙烯单体组分的共聚物以及聚丙烯。
通常还需在多孔网印带的材料上涂上一层防粘涂层,以方便从印网上除去颗粒。防粘涂层可以是例如烘烤上去的氟聚合物,如杜邦公司出售的商标为“Teflon”的商品。或者可在使用前将涂料喷涂上去。这种喷涂上去的涂料含有有机润滑剂,如辛醇、癸烷、十六烷等。当然应该理解,当多孔印网是其它的形态,例如使用于不连续操作方式的简单印网片,上述关于防粘涂层的讨论同样适用于其设计。
由于制造多孔网印带材料的选择是根据许多相同标准的,所以用与其相同的材料制造支承板通常是适宜的。由于多孔网印带和支承板在工艺中所经受环境的需要,选用耐腐蚀金属是较好的选择。
可将烧结成的成形制品即磨粒掺入粘结磨具(如砂轮)或涂覆磨具(如砂盘或砂带)中。
附图描述
图1是适用于连续操作方式的本发明网印方法示意图。
图2是适用于本发明不连续网印操作方式的印网顶面照片。
图3是使用本发明方法和图2所述印网制得的磨粒照片。
本发明具体实施方案的描述
说明书的这一节描述主要集中在使用本发明方法制造成形的颗粒。其所包含的内容适用于制造其它成形物,如平面磨盘、用于球磨的研磨介质等。
现在参考附图对本发明进行描述。这种描述仅出于说明的目的,并不意味着对本发明的基本范围进行任何必要的限制。
印网1以连续带的形式围绕着四个辊2、3、4和5运动。辊2和3之间的区域是施加区6;辊3和4之间的区域是脱离区7;辊4和5之间的区域是清理区8;辊5和2之间的区域是处理区9。
在施加区6中,印网1的外表面与连续的不锈钢带l0紧密地接触,这时这两条带子朝相同的方向以基本相同的速度移动,磨料前体颗粒的分散体则被施加在刮片11前面的印网内表面上(施加机构在图中未显示)。印网带在通过刮片(在该位置,网印带与连续的不锈钢带紧密地接触)时,分散体被压入网印带的孔中。
在脱离区7,网印带与连续的不锈钢带脱离,将网印出的成形物留在不锈钢带10的表面上。不锈钢带将成形物传输至干燥区12,成形物在该区域被除尽水分,水分的除去程度至少应达到将成形物转化成最终具有结构完整性的颗粒所必须的程度。随后经干燥的颗粒从连续的不锈钢带上分离,在一合适的炉子中煅烧,转化成磨粒。如果不锈钢带未经使之具有烘烤上去的防粘层预处理的话,则在不锈钢带进入施加区与网印带接触之前,可对其进行防粘处理(如氟碳物喷涂)。
同时网印带离开脱离区后进入清理区8,网印带在该区域首先经过干燥,随后用一适当导向的刷子、空气鼓风或空气鼓风和刷子并用等方法除去其上面的残留物。
从清理区出来的网印带进入处理区9,在该区域如有必要可向网印带施加防粘剂,为的是方便成形物在脱离区中从网印带上脱离。
附图所述的装置可有种种变化,例如,可在网印带垂直而非水平移动时向其施加分散体。网印带还可构成一个空心圆筒的表面,上述的区6至区9由圆筒周边表面上的不同区域形成。所有这些变化都包括在本发明的基本范围内。
实施例1
本实施例说明本发明不连续操作方法的一种应用。在本方法中,用烃防粘剂喷涂在0.1mm厚的不锈钢平板式网印片(上面有许多1mm长、0.1mm宽的孔,基本如图3所示)上,随后将其放置在一不锈钢平板式支承片上。接着将含有30-35%固体的加晶种的勃姆石凝胶沉积在网印片上,使用刮片将其压入孔中。除去网印片,凝胶成形物留在支承片上。最后将表面上支承有凝胶成形物的支承片置于烘箱中80℃加热5分种,随后再在1325℃煅烧3分钟。得到的磨粒如图3所示。
煅烧后颗粒的密度为3.92g/cc(氦方法测定);用经校正的截距法测出其平均晶体尺寸为0.15微米;硬度为18.3Gpa(50g负载);松散填充密度为0.9g/cc。颗粒的横截面基本上是矩形的,颗粒的最终尺寸:长697微米,横截面的平均边长为79微米,给出长径比约为8.7∶1。磨粒的松散填充密度为0.9,磨粒的等效直径为79微米。
本发明磨粒用于玻璃质粘结的砂轮,证明其磨削效率很高。
实施例2
在另一个与上述实施例相同的操作中,对一块穿有许多孔的不锈钢板(作为印网)进行处理,使之烘烤上一层Teflon FEP氟聚合物涂层。该印网厚0.2mm,孔为矩形,宽约0.2mm,长约6.4mm。使用如上所述的方法(施加、干燥和煅烧步骤)成形出丝状的磨粒,它具有如下性能:
密度(排水法) 3.88-3.93g/cc
晶体尺寸 0.18微米
硬度(维克尔斯,200g负载) 22.5Gpa
等效直径(矩形) 90×135微米
长径比 25∶1
松散填充密度 约0.5
Claims (8)
1.制造成形陶瓷制品的方法,它是将尺寸稳定的α氧化铝前体物质的分散体施加在与支承表面接触的多孔印网的表面上,使之填满印网中的孔,从支承表面移去印网,随后对留在支承表面上的网印成形物进行干燥并煅烧,形成烧结的成形陶瓷制品。
2.如权利要求1所述的方法,其特征在于分散体是勃姆石凝胶。
3.如权利要求2所述的方法,其特征在于凝胶的固体含量为30-60%。
4.如权利要求1所述的方法,其特征在于多孔印网是耐酸和耐水的。
5.如权利要求1所述的方法,其特征在于多孔印网是从动带的形式。
6.如权利要求1所述的方法,其中印网孔具有能形成丝状陶瓷成型磨粒的形状。
7.如权利要求2所述的方法,其特征在于所述分散体还含有以固体重量为基高达10%的添加剂,所述添加剂选自成核剂、氧化镁、氧化锆、氧化钛、氧化钇和稀土金属氧化物。
8.如权利要求7所述的方法,其特征在于使用连续的多孔带来网印颗粒,带上孔尺寸能制造长径比2∶1-50∶1的网印成形物。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/325,744 | 1994-10-19 | ||
US08/325,744 US6054093A (en) | 1994-10-19 | 1994-10-19 | Screen printing shaped articles |
Publications (2)
Publication Number | Publication Date |
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CN1161054A CN1161054A (zh) | 1997-10-01 |
CN1072251C true CN1072251C (zh) | 2001-10-03 |
Family
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Application Number | Title | Priority Date | Filing Date |
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CN95195710A Expired - Lifetime CN1072251C (zh) | 1994-10-19 | 1995-09-12 | 网印的成形制品 |
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US (1) | US6054093A (zh) |
EP (1) | EP0787172B1 (zh) |
JP (1) | JP2937483B2 (zh) |
CN (1) | CN1072251C (zh) |
AT (1) | ATE166916T1 (zh) |
AU (1) | AU683590B2 (zh) |
BR (1) | BR9509407A (zh) |
CA (1) | CA2202670C (zh) |
DE (1) | DE69502837T2 (zh) |
ES (1) | ES2119486T3 (zh) |
NO (1) | NO311695B1 (zh) |
PL (1) | PL179756B1 (zh) |
RU (1) | RU2132349C1 (zh) |
TW (1) | TW363047B (zh) |
WO (1) | WO1996012776A1 (zh) |
ZA (1) | ZA957479B (zh) |
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PL179756B1 (pl) | 2000-10-31 |
CN1161054A (zh) | 1997-10-01 |
MX9702599A (es) | 1998-05-31 |
AU3716895A (en) | 1996-05-15 |
ES2119486T3 (es) | 1998-10-01 |
CA2202670A1 (en) | 1996-05-02 |
NO971803D0 (no) | 1997-04-18 |
DE69502837T2 (de) | 1999-01-14 |
ATE166916T1 (de) | 1998-06-15 |
BR9509407A (pt) | 1998-05-26 |
AU683590B2 (en) | 1997-11-13 |
DE69502837D1 (de) | 1998-07-09 |
ZA957479B (en) | 1996-04-09 |
EP0787172B1 (en) | 1998-06-03 |
RU2132349C1 (ru) | 1999-06-27 |
NO971803L (no) | 1997-04-18 |
JP2937483B2 (ja) | 1999-08-23 |
TW363047B (en) | 1999-07-01 |
NO311695B1 (no) | 2002-01-07 |
JPH10506340A (ja) | 1998-06-23 |
PL319690A1 (en) | 1997-08-18 |
CA2202670C (en) | 2000-08-08 |
EP0787172A1 (en) | 1997-08-06 |
US6054093A (en) | 2000-04-25 |
WO1996012776A1 (en) | 1996-05-02 |
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