CN109890930B - 可磁化磨料颗粒及其制备方法 - Google Patents
可磁化磨料颗粒及其制备方法 Download PDFInfo
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- CN109890930B CN109890930B CN201780065829.1A CN201780065829A CN109890930B CN 109890930 B CN109890930 B CN 109890930B CN 201780065829 A CN201780065829 A CN 201780065829A CN 109890930 B CN109890930 B CN 109890930B
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- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
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- C09K3/1436—Composite particles, e.g. coated particles
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/111—Fine ceramics
- C04B35/1115—Minute sintered entities, e.g. sintered abrasive grains or shaped particles such as platelets
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- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/62876—Coating fibres with metals
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Abstract
本发明提出了一种制备可磁化磨料颗粒的方法,所述方法包括:用水玻璃润湿陶瓷颗粒的外表面以提供润湿的陶瓷颗粒。使可磁化颗粒与所述润湿的陶瓷颗粒接触,以提供涂有粉末的陶瓷颗粒。将所述涂有粉末的陶瓷颗粒加热到至少足以使所述涂有粉末的陶瓷颗粒的所述可磁化颗粒粘结至相应的所述陶瓷颗粒的温度,从而提供所述可磁化磨料颗粒。每个可磁化磨料颗粒在各自的基础上包括相应陶瓷颗粒,所述相应陶瓷颗粒具有粘结至其上的可磁化颗粒。
Description
技术领域
本公开广义上涉及磨料颗粒、磨料制品及其制备方法。
背景技术
本领域中已知各种类型的磨料制品。例如,带涂层的磨料制品通常具有通过树脂粘结剂材料粘附到背衬的磨料颗粒。示例包括砂纸和具有粘附到背衬的精确成形的磨料复合物的结构化磨料。磨料复合物通常包含磨料颗粒和树脂粘结剂。
粘结的磨料颗粒包括保留在粘结剂基质中的磨料颗粒,该粘结剂基质可为树脂的或玻璃质的。示例包括磨石、切割轮、细磨刀石和磨石。
磨料颗粒在磨料制品诸如(例如)带涂层的磨料制品和粘结的磨料制品中的精确布置和取向已成为多年连续关注来源。
例如,已使用诸如磨料颗粒的静电涂覆技术制备带涂层的磨料制品,以用于将粉碎的磨料颗粒与垂直于背衬的纵向轴线对准。同样,成形磨料颗粒已通过如美国专利申请公布2013/0344786 A1(Keipert)中所公开的机械方法对准。
磨料颗粒在粘结的磨料制品中的精确布置和取向已描述于专利文献中。例如,美国专利1,930,788(Buckner)描述了使用磁通量来确定具有薄铁粉涂层的磨粒在粘结的磨料制品中的取向。同样,英国(GB)专利396,231(Buckner)描述了使用磁场来确定具有薄铁粉或钢粉涂层的磨粒的取向,以确定磨粒在粘结的磨料制品中的取向。使用该技术,磨料颗粒在粘结轮中径向地取向。
美国专利申请公布2008/0289262 A1(Gao)公开了用于制备均匀分布、阵列模式和优选取向的磨料颗粒的设备。使用电流形成磁场致使针状软磁性金属棒吸收或释放镀有软磁性材料的磨料颗粒。
一直需要用于将磁性材料粘结至磨料颗粒的新材料和方法。
发明内容
有利地,本公开提供了使用水玻璃将可磁化颗粒粘结至磨料颗粒的新方法。
本发明人意外地发现,该方法也可有效地将磨料颗粒选择性地粘结至一些磨料颗粒的某些部分上。虽然使用本体技术诸如溶液涂覆、粉末涂覆或蒸汽涂覆将一层可磁化材料沉积到磨料颗粒上通常为相对直接的方法,但在磨料颗粒表面的仅一部分上将可磁化材料沉积在精确位置处十分困难。当考虑到诸如重现性、生产率和成本因素时,问题变得更加复杂。有利地,本发明的制备可磁化磨料颗粒的方法在某些实施方案中克服了这些问题。
在一个方面,本公开提供了一种制备可磁化磨料颗粒的方法,该方法包括以下步骤:
a)提供陶瓷颗粒,每个陶瓷颗粒具有相应的外表面;
b)用水玻璃润湿陶瓷颗粒的外表面以提供润湿的陶瓷颗粒;以及
c)使可磁化颗粒与润湿的陶瓷颗粒接触,以提供涂有粉末的陶瓷颗粒;以及
d)将涂有粉末的陶瓷颗粒加热到至少足以使涂有粉末的陶瓷颗粒的可磁化颗粒粘结至其涂覆的相应陶瓷颗粒的温度,从而提供可磁化磨料颗粒,其中每个可磁化磨料颗粒在各自的基础上包括相应陶瓷颗粒,所述相应陶瓷颗粒具有粘结至其上的至少一些可磁化颗粒。
如本文所用:
术语“陶瓷”是指由至少一种金属元素(其可包括硅)与氧、碳、氮或硫组合制成的各种硬质、易碎、耐热和耐腐蚀材料中的任一种。陶瓷可以为例如结晶的或多晶的。
术语“铁磁体”是指表现出铁氧体磁性的材料。铁氧体磁性是在固体中出现的一种类型的永磁性,其中与单个原子相关的磁场自发地自身对准,一些磁场平行或在相同的方向上(如在铁氧体磁性中),并且其他磁场通常反平行或在相反方向上成对远离(如在反铁磁性中)。铁磁材料单晶的磁性行为可归因于平行对准;那些原子在反平行排列中的稀释效应保持这些材料的磁强度通常小于纯铁磁固体诸如金属铁的磁强度。铁氧体磁性主要发生在被称为铁氧体的磁性氧化物中。产生铁氧体磁性的自发对准在每种铁磁材料特有的被称为居里点的温度之上被完全破坏。当材料的温度降至居里点以下时,铁氧体磁性恢复。
术语“铁磁体”是指表现出铁氧体磁性的材料。铁氧体磁性是一种某些不带电材料强烈吸引其他材料的物理现象。与其他物质对比之下,铁磁材料容易被磁化,并且在强磁场中,磁化接近被称为饱和度的明确极限。当施加场然后将其撤去时,磁化不会恢复到其初始值。此现象被称为磁滞。当受热至被称为居里点的某一温度(对于每种物质来讲其通常是不同的)时,铁磁材料丧失其固有特性并且不再具有磁性;然而,它们在冷却时再次变成铁磁体。
除非另外指明,否则术语“磁性”和“磁化”意指在20℃下具有铁磁性或亚铁磁性,或能够使之呈现铁磁性或亚铁磁性。优选地,根据本公开的可磁化层或者具有,或者可通过暴露于所施加的磁场而具有至少0.001个电磁单元(emu),更优选地至少0.005个emu,更优选地0.01个emu,至多包括0.1个emu的磁矩,但这不是必需的。
术语“磁场”是指不是由任何一个天文或多个天体(例如,地球或太阳)产生的磁场。一般来讲,在实践本公开的过程中使用的磁场在可磁化磨料颗粒的区域中具有至少约10高斯(1mT),优选地至少约100高斯(10mT),并且更优选地至少约1000高斯(0.1T)的场强。
术语“可磁化”意指能够被磁化或已经处于磁化状态。
术语“湿润”意指轻微润湿;潮湿。
术语“成形磨料颗粒”是指在其制备过程中的某一时刻有意成形(例如挤出、模切、模制、丝网印刷)的陶瓷磨料颗粒,使得所得陶瓷体为有规成形的。如本文所用的术语“成形磨料颗粒”排除通过机械粉碎或研磨操作获得的陶瓷体。
术语“板状粉碎磨料颗粒”是指类似于片状和/或薄片的粉碎磨料颗粒,其特征在于厚度小于宽度和长度。例如,厚度可以小于长度和/或宽度的1/2、1/3、1/4、1/5、1/6、1/7、1/8、1/9,或甚至小于1/10。同样地,宽度可以小于长度的1/2、1/3、1/4、1/5、1/6、1/7、1/8、1/9,或甚至小于1/10。
术语“基本上不含”意指基于所涉及的物体的总重量计含有少于5重量%(例如,小于4重量%、3重量%、2重量%、1重量%、0.1重量%、或甚至小于0.01重量%,或甚至完全不含)。
术语“精确成形磨料颗粒”是指这样的磨料颗粒,其中磨料颗粒的至少一部分具有从用于形成前体精确成形磨料颗粒的模具腔复制的预定形状,该前体精确成形磨料颗粒被烧结以形成精确成形磨料颗粒。精确成形磨料颗粒通常具有基本上复制了用于形成磨料颗粒的模具腔的预定几何形状。
术语“长度”是指物体的最长尺寸。
术语“宽度”是指垂直于其长度的物体的最长尺寸。
术语“厚度”是指垂直于其长度和宽度两者的物体的最长尺寸。
术语“纵横比”是指物体的长度/厚度的比率。
术语“基本上”意指在被提及属性的35百分比内(优选地在30百分比内,更优选地在25百分比内,更优选地在20百分比内,更优选地在10百分比内,并且更优选地在5百分比内)。
复数后缀指示被修饰的词可以是单数或复数。
在考虑具体实施方式以及所附权利要求书时,将进一步理解本公开的特征和优点。
附图说明
图1是根据本公开的一个实施方案的示例性可磁化磨料颗粒100的示意性透视图。
图1A是可磁化磨料颗粒100的示意性侧视图。
图2是根据本公开的一个实施方案的示例性可磁化磨料颗粒200的示意性透视图。
图2A是可磁化磨料颗粒200的示意性侧视图。
图3是示出在实施例1中制备的可磁化磨料颗粒的开口面的数字照片。
图4是示出在实施例1中制备的可磁化磨料颗粒的模具面的数字照片。
图5是示出在实施例1中制备的可磁化磨料颗粒的侧视图的数字照片。
图6是在实施例2中制备的可磁化磨料制品的数字照片。
在说明书和附图中重复使用的参考符号旨在表示本公开的相同或类似的特征结构或元件。应当理解,本领域的技术人员可以设计出许多落入本公开原理的范围内及符合本公开原理的实质的其它修改形式和实施方案。附图可不按比例绘制。
具体实施方式
根据本公开的方法包括一系列顺序步骤,这些步骤可以是连续的或不连续的。
在第一步骤中,提供陶瓷颗粒,陶瓷颗粒具有相应的外表面。陶瓷颗粒可以是任何磨料材料的颗粒。可以使用的可用的陶瓷材料包括例如熔融氧化铝、热处理氧化铝、白色熔融氧化铝、陶瓷氧化铝材料(诸如可从明尼苏达州圣保罗的3M公司(3M Company,St.Paul,Minnesota)以3M CERAMIC ABRASIVE GRAIN商购获得的那些)、黑色碳化硅、绿色碳化硅、二硼化钛、碳化硼、碳化钨、碳化钛、立方氮化硼、石榴石、熔融氧化铝氧化锆、溶胶凝胶衍生陶瓷(例如掺杂氧化铬、二氧化铈、氧化锆、二氧化钛、二氧化硅和/或氧化锡的氧化铝陶瓷)、二氧化硅(例如,石英、玻璃珠、玻璃泡和玻璃纤维)、长石或燧石。溶胶-凝胶衍生的粉碎的陶瓷颗粒的示例可见于美国专利4,314,827(Leitheiser等人)、4,623,364(Cottringer等人)、4,744,802(Schwabel)、4,770,671(Monroe等人)和4,881,951(Monroe等人)中。关于制备溶胶凝胶衍生的磨粒的方法的进一步细节可见于例如美国专利4,314,827(Leitheiser)、5,152,917(Pieper等人),5,213,591(Celikkaya等人),5,435,816(Spurgeon等人),5,672,097(Hoopman等人),5,946,991(Hoopman等人),5,975,987(Hoopman)等人,和6,129,540(Hoopman等人)和见于美国公布专利申请2009/0165394 A1(Culler等人)和2009/0169816 A1(Erickson等人)中。
陶瓷颗粒可以是成形的(例如,精确成形的)或无规的(例如,粉碎的和/或片状的)。使用如例如美国专利5,201,916(Berg)、5,366,523(Rowenhorst(Re 35,570))、5,984,988(Berg)、8,142,531(Adefris等人)和美国专利申请公布2010/0146867(Boden等人)中所述的溶胶凝胶技术,成形陶瓷颗粒和精确成形陶瓷颗粒可通过模制工艺制备。
美国专利8,034,137(Erickson等人)描述了已成形为特定形状,然后将其粉碎以形成碎片的陶瓷氧化铝颗粒,该碎片保持其初始形状特征结构的一部分。在一些实施方案中,陶瓷颗粒为精确成形的(即,陶瓷颗粒具有的形状至少部分地由用于制备它们的生产工具中的腔的形状决定)。
陶瓷颗粒的示例性形状包括粉碎的棱锥(例如,3-、4-、5-或6-面棱锥)、截棱锥(例如,3-、4-、5-或6-面截棱锥)、锥体、截头锥体、杆(例如,圆柱形、蠕虫状)和棱镜(例如,3-、4-、5-或6-面棱镜)。在一些实施方案(例如截棱锥和棱镜)中,陶瓷颗粒分别包括具有通过多个小侧面彼此连接的两个相对的小主面的片状物。
在一些实施方案中,陶瓷颗粒包括纵横比为至少2、至少3、至少5或甚至至少10的粉碎磨料颗粒,但这不是必需的。
优选地,在实践本公开的过程中使用的陶瓷颗粒的莫氏硬度为至少6、至少7或至少8,但也可使用其他硬度。
有关适用作磨料颗粒的陶瓷颗粒以及它们的制备方法的更多细节可见于例如美国专利8,142,531(Adefris等人)、8,142,891(Culler等人)和8,142,532(Erickson等人)中,并且可见于美国专利申请公布2012/0227333(Adefris等人)、2013/0040537(Schwabel等人)和2013/0125477(Adefris)中。
在后续步骤中,用水玻璃润湿陶瓷颗粒的外表面以提供润湿的陶瓷颗粒。该步骤可通过任何合适的方法来实现,诸如例如,将干燥的陶瓷颗粒与足以润湿陶瓷颗粒的少量水玻璃混合,或将陶瓷颗粒浸没在水玻璃中并除去过量的水玻璃以提供润湿的陶瓷颗粒。通常,在该步骤中润湿每个陶瓷颗粒的整个外表面;然而,这不是必需的。混合可通过例如机械方法(例如,搅拌器)来实现。除去过量的水玻璃可通过例如抽吸、蒸发或其他合适的方法来实现。也可使用其他方法。
如本文所用,术语“水玻璃”是指碱金属硅酸盐(例如,硅酸锂、硅酸钠和/或硅酸钾)的水溶液以及它们的组合。碱金属硅酸盐为具有式(SiO2)n(M2O)的化合物及其水合物的通用名,其中n为正整数并且M为碱金属(例如,钠或钾)。该系列的熟知成员为偏硅酸钠Na2SiO3(即n=1,M=Na),其可以无水形式和水合形式(例如,Na2SiO3·5H2O)商购获得。虽然水通常应当为主要液体组分,但也可存在有机共溶剂(例如甲醇、乙醇、异丙醇、甘醇二甲醚、二甘醇二甲醚、丙二醇和/或丙酮)。如果需要,水玻璃中可包含其他组分诸如例如表面活性剂、增稠剂、触变胶和着色剂。
水玻璃中的碱金属硅酸盐的浓度并不重要(只要它溶解并且水玻璃为液体),但优选为25重量%至70重量%,更优选为30重量%至55重量%。在该上下文中,重量百分比是基于存在于水玻璃中的无水形式的碱金属硅酸盐计算的。
磁性颗粒包含可磁化材料诸如例如:铁;钴;镍;作为Permalloy销售的各种等级的镍和铁的各种合金;作为Fernico、Kovar、FerNiCo I或FerNiCo II销售的铁、镍和钴的各种合金;作为Alnico销售的铁、铝、镍、钴,有时还有铜和/或钛的各种等级的各种合金;作为Sendust合金销售的铁、硅和铝(通常按重量为约85:9:6)的合金;Heusler合金(例如,Cu2MnSn);铋化锰(也称为华斯曼诺尔);稀土可磁化材料,诸如钆,镝,钬,氧化铕,钕、铁和硼的合金(例如,Nd2Fe14B),以及钐和钴的合金(例如,SmCo5);MnSb;MnOFe2O3;Y3Fe5O12;CrO2;MnAs;铁氧体,诸如铁素体、磁铁矿;铁酸锌;铁酸镍;铁酸钴、铁酸镁、铁酸钡和铁酸锶;钇铁石榴石;以及前述的组合,但不限于这些。在一些优选的实施方案中,可磁化材料包含选自铁、镍和钴的至少一种金属,两种或更多种此类金属的合金,或至少一种此类金属与至少一种选自磷和锰的元素的合金。在一些优选的实施方案中,可磁化材料为包含8重量百分比(重量%)至12重量%铝、15重量%至26重量%镍、5重量%至24重量%钴、至多6重量%铜、至多1重量%钛的合金,其中总计达100重量%的材料的剩余部分为铁。
可磁化颗粒可具有任何尺寸,但如通过平均粒径判断,优选地比陶瓷颗粒小得多,优选地小4至2000倍,更优选地小100至2000倍,并且甚至更优选地小500至2000倍,但也可使用其他尺寸。在该实施方案中,可磁化颗粒可具有小于6(例如,小于5或小于4)的莫氏硬度,但这不是必需的。
在用水玻璃润湿陶瓷颗粒之后,使可磁化颗粒与润湿的陶瓷颗粒接触,以提供涂有粉末的陶瓷颗粒。这可采用任何合适的方法进行,这些方法包括例如粉末涂覆、机械混合或流化床涂覆。优选地,使用过量的可磁化颗粒以利于最大程度涂覆润湿的陶瓷颗粒。结合到陶瓷芯的可磁化颗粒可与其直接接触,或者它们可通过它们所结合的居间可磁化颗粒间接接触。在一些优选的实施方案中,可磁化颗粒与陶瓷颗粒直接接触。沉积的可磁化颗粒形成优选地为陶瓷颗粒厚度的1/10至1/4的可磁化层(连续的或不连续的),但这不是必需的。
例如,可在此时或加热后除去过量的可磁化颗粒,如下文所述。
将涂有粉末的陶瓷颗粒加热到至少足以使涂有粉末的陶瓷颗粒的可磁化颗粒粘结至其涂覆的相应陶瓷颗粒的温度,从而提供可磁化的磨料颗粒。每个可磁化磨料颗粒在各自的基础上包括可磁化颗粒粘结至其上的陶瓷颗粒。合适的加热温度通常根据陶瓷颗粒和可磁化颗粒的组成而变化。对于硅酸钠水玻璃和氧化铝陶瓷颗粒,至少300℉(149℃)的加热温度持续至少30分钟的时间通常是足够的,但也可使用更高和更低的温度和/或更长和更短的时间。
可根据磨料行业公认的特定标称等级独立地设定根据本公开的用于其制造中的可磁化磨料颗粒和/或陶瓷颗粒的尺寸。示例性磨料行业公认的分级标准包括由ANSI(美国国家标准学会)、FEPA(欧洲磨料制造者联盟)和JIS(日本工业标准)颁布的那些标准。ANSI等级标号(即规定的标称等级)包括例如:ANSI 4、ANSI 6、ANSI 8、ANSI 16、ANSI 24、ANSI36、ANSI 46、ANSI 54、ANSI 60、ANSI 70、ANSI 80、ANSI 90、ANSI 100、ANSI 120、ANSI150、ANSI 180、ANSI 220、ANSI 240、ANSI 280、ANSI 320、ANSI 360、ANSI 400、和ANSI600。FEPA等级标号包括F4、F5、F6、F7、F8、F10、F12、F14、F16、F16、F20、F22、F24、F30、F36、F40、F46、F54、F60、F70、F80、F90、F100、F120、F150、F180、F220、F230、F240、F280、F320、F360、F400、F500、F600、F800、F1000、F1200、F1500和F2000。JIS等级标号包括:JIS8、JIS12、JIS16、JIS24、JIS36、JIS46、JIS54、JIS60、JIS80、JIS100、JIS150、JIS180、JIS220、JIS240、JIS280、JIS320、JIS360、JIS400、JIS600、JIS800、JIS1000、JIS1500、JIS2500、JIS4000、JIS6000、JIS8000和JIS10,000。
另选地,根据本公开的用于其制造中的可磁化磨料颗粒和/或陶瓷颗粒可利用符合ASTM E-11“用于测试目的的筛布和筛的标准规格(Standard Specification for WireCloth and Sieves for Testing Purposes)的美国标准测试筛分级成标称筛分等级。ASTME-11规定了测试筛的设计和构造需求,该测试筛使用安装在框架中的织造筛布的介质根据指定的粒度对材料进行分类。典型名称可以表示为-18+20,其意指陶瓷颗粒可通过符合18目筛的ASTM E-11规范的测试筛,并且保留在符合20目筛的ASTM E-11规范的测试筛上。在一个实施方案中,陶瓷颗粒具有这样的颗粒尺寸:使得大多数颗粒通过18目测试筛并且可保留在20目、25目、30目、35目、40目、45目或50目测试筛上。在多种实施方案中,陶瓷颗粒的标称筛分等级可为:-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或-500+635。另选地,可使用诸如-90+100的定制目尺寸。
本发明人意外地发现,某些陶瓷颗粒可用可磁化颗粒优先涂覆在其外表面的特定部分上。例如,相比于模具表面(即,接触模具腔壁的表面),通过模制工艺(在该工艺中陶瓷颗粒前体(例如,氧化铝前体)当在开面模具中时被干燥并除去以形成成形颗粒前体)形成的氧化铝成形磨料颗粒对于将可磁化颗粒粘结至成形陶瓷颗粒前体的开口(即暴露)面同时仍在模具腔中来讲可具有更高的亲和力。
例如,现在参见图1,可磁化磨料颗粒100具有成形为截头三角形棱锥的陶瓷颗粒105,其中相对的主表面110和120通过侧壁130a、130b、130c连接。主表面120对应于陶瓷颗粒制造期间的开放表面,而其余表面全部对应于模具表面。可磁化颗粒140形成层150并结合到主表面120。
在某些实施方案中,可磁化颗粒也可结合到侧壁的相邻部分。现在参见图2,该图示出可磁化磨料颗粒200,其具有成形为截头三角形棱锥的陶瓷颗粒205,其中相对的主表面210和220通过侧壁230a、230b、230c连接。主表面220对应于陶瓷颗粒制造期间的开放表面,而其余表面全部对应于模具表面。可磁化颗粒240形成层250并结合到主表面220和侧壁230a、230b、230c的相邻部分。
不受理论的束缚,本发明人认为在陶瓷颗粒制造中干燥步骤期间同时仍在模具中的表面形态的差异导致可磁化颗粒优先沉积。具体地讲,据信在干燥期间暴露于空气的表面变得有利于随后与可磁化颗粒粘结。在其中可磁化颗粒优先沉积在开口表面和邻近其发生的侧壁部分上的那些情况下,据信在干燥期间收缩远离模具腔壁导致空中接口和与在干燥期间暴露的开口表面类似的表面特性。
根据本公开制备的可磁化磨料颗粒可以松散的形式使用(例如,自由流动或在浆液中)或者它们可掺入到各种磨料制品(例如,带涂层磨料制品、粘结磨料制品、非织造磨料制品和/或磨料刷)中。由于它们的磁特性,可使用磁场来取向和操纵可磁化磨料颗粒以提供具有受控磨料颗粒取向和位置的上述各种磨料制品。
本公开的选择实施方案
在第一实施方案中,本公开提供了一种制备可磁化磨料颗粒的方法,该方法包括以下步骤:
a)提供陶瓷颗粒,每个陶瓷颗粒具有相应的外表面;
b)用水玻璃润湿陶瓷颗粒的外表面以提供润湿的陶瓷颗粒;以及
c)使可磁化颗粒与润湿的陶瓷颗粒接触,以提供涂有粉末的陶瓷颗粒;以及
d)将涂有粉末的陶瓷颗粒加热到至少足以使涂有粉末的陶瓷颗粒的可磁化颗粒粘结至相应的陶瓷颗粒的温度,从而提供可磁化磨料颗粒,其中每个可磁化磨料颗粒在各自的基础上包括相应陶瓷颗粒,所述相应陶瓷颗粒具有粘结至其上的至少一些可磁化颗粒。
在第二实施方案中,本公开提供了根据第一实施方案所述的方法,其中每个陶瓷颗粒在各自的基础上包括接收表面和至少一个其他表面,其中可磁化颗粒中的一些优先地粘结至包括接收表面的陶瓷颗粒外表面的邻接区域,并且其中所述至少一个其他表面的大部分区域不含粘结至陶瓷颗粒的可磁化颗粒。
在第三实施方案中,本公开提供了根据第一实施方案或第二实施方案所述的方法,其中陶瓷颗粒包含氧化铝。
在第四实施方案中,本公开提供了根据第一实施方案至第三实施方案中任一项所述的方法,其中可磁化颗粒包含铁或镍中的至少一者。
在第五实施方案中,本公开提供了根据第一实施方案至第四实施方案中任一项所述的方法,其中可磁化颗粒包含合金,该合金包含铁、硅和铝。
在第六实施方案中,本公开提供了根据第一实施方案至第五实施方案中任一项所述的方法,其中水玻璃基本上由溶解在水中的硅酸钠组成。
在第七实施方案中,本公开提供了根据第一实施方案至第六实施方案中任一项所述的方法,其中陶瓷颗粒通过模制工艺形成,其中每个接收表面在各自的基础上对应于具有内表面的模具腔的开口,并且其中所述至少一个其他表面中的每一个表面对应于模具腔的内表面。
在第八实施方案中,本公开提供了根据第一实施方案至第七实施方案中任一项所述的方法,其中陶瓷颗粒包括陶瓷片状物,每个陶瓷片状物分别具有通过多个侧壁而彼此连接的相对的第一主表面和第二主表面,并且其中第一主表面为接收表面。
在第九实施方案中,本公开提供了根据第八实施方案所述的方法,其中陶瓷片状物为三角形。
在第十实施方案中,本公开提供了根据第八实施方案或第九实施方案所述的方法,其中第二主表面基本上不含粘结的可磁化颗粒。
在第十一实施方案中,本公开提供了根据第八实施方案至第十实施方案中任一项所述的方法,其中多个侧壁中的每一个侧壁基本上不含粘结的可磁化颗粒。
在第十二实施方案中,本公开提供了根据第八实施方案至第十一实施方案中任一项所述的方法,其中陶瓷片状物被成形为截头三棱锥。
在第十三实施方案中,本公开提供了根据第一实施方案至第十二实施方案中任一项制备的可磁化磨料颗粒。
在第十四实施方案中,本公开提供了根据第十三实施方案所述的可磁化磨料颗粒,其中可磁化磨料颗粒符合磨料行业指定的标称等级。
通过以下非限制性实施例,进一步示出了本公开的目的和优点,但在这些实施例中引用的具体材料及其量以及其它条件和细节不应视为对本公开的不当限制。
实施例
除非另有说明,否则实施例及本说明书的其余部分中的所有份数、百分比、比等均以重量计。除非另外说明,否则所有其它试剂均得自或购自精细化学品供应商诸如密苏里州圣路易斯的西格玛奥德里奇公司(Sigma-Aldrich Company,St.Louis,Missouri),或者可通过已知的方法合成。
实施例中使用的材料缩写列于下表1中。
表1
SAP1的制备
通常根据美国专利公布2015/0267097(Rosenflanz等人)的公开内容来制备SAP1。使用以下方案制备浆液混合物:通过高剪切混合将以RG 4000从荷兰鹿特丹港市的Almatis公司(Almatis,Rotterdam,Netherlands)购得的氧化铝粉末(70.73份)、以DISPERAL从德克萨斯州休斯顿的萨索尔北美公司(Sasol North America,Houston,Texas)购得的氧化铝一水合物粉末(7.07份)分散在包含水(21.57份)和70%硝酸水溶液(0.63份)的溶液中。将该混合物以120转/分钟的速度研磨24小时。研磨后,除去研磨介质并通过将浆液置于干燥器广口瓶中并使用机械泵施加真空(在真空下保持约10分钟)使浆液脱气。将所得浆液倒在具有三角形模具腔的聚乙烯模具上,其中在模具的侧壁和底部之间的拔模角为98度。该模具具有通过干燥5重量%乙醇溶液而沉积的矿物油的局部涂层。使用橡胶滚轴将浆液涂抹到腔体中,使得生产工具的开口被完全填充。然后在热风枪下将盛有陶瓷浆液的模具干燥。干燥后,剧烈摇动片材以分离所得成形磨料前体颗粒。通过将成形磨料前体颗粒置于氧化铝坩埚中并在空气中加热到700℃(加热速率为10℃/分钟)来煅烧成形磨料前体颗粒。未施加等温保持。将约300克煅烧成形磨料前体颗粒置于氧化铝坩埚中,并且使用25℃/分钟的加热速率在购自加利福尼亚州皮科里韦拉的Keith熔炉公司(Keith Furnaces of PicoRivera,California)的KKSK-666-3100型号电加热炉中烧结且在大约1500-1550℃的最终温度下保持45分钟的时间。所得成形磨料颗粒为约2.5mm(边长)×0.50mm(厚度)。
表面粗糙度测量
在SAP1和SAP2的开口面(成形颗粒前体的暴露面,同时在模制工艺期间仍在模具中)和模具面(接触模具腔底壁的主表面,同时在溶胶凝胶模制工艺期间仍在模具中)上均进行表面粗糙度测量。根据制造商的说明,使用购自加利福尼亚州圣何塞的泽塔仪器公司(Zeta Instruments,San Jose,California)的Zeta Instruments Zeta-300光学轮廓仪,将该测试测量为平均表面粗糙度(Ra),以微米为单位。Ra的测试结果在下表2中示出。
表2
实施例1
通过将20克SIL、10克水和0.06克SUR混合并搅拌大约1分钟来制备水玻璃混合物。将125克SAP1和1.5克水玻璃混合物置于容器中。在将封盖施加到容器之后,用手剧烈摇动混合物1分钟。然后将2.56克MAG添加到容器中混合物的顶部。再次用手摇动容器约1分钟。然后将容器中的混合物倾倒在铝盘上。将该混合物尽可能地铺开以防止矿物质结合在一起。将盘置于处于以下循环的溶剂额定的间歇式炉中:在200℉(93.3℃)下15分钟,250℉(121.1℃)下30分钟,在300℉(148.9℃)下30分钟以及在350℉(176.7℃)下30分钟。
拍摄代表性所得可磁化磨料颗粒的数字照片以示出开口面(参见图3)、模具面(参见图4)和侧视图(参见图5)。涂覆在可磁化磨料颗粒的开口面上的MAG的量比涂覆在可磁化磨料颗粒的模具面上的MAG的量多得多。
实施例2
重复实施例1中大体描述的过程,不同的是使用SAP2而不使用SAP1。图6中示出了代表性的所得可磁化磨料颗粒。
以上获得专利证书的申请中所有引用的参考文献、专利和专利申请以一致的方式全文以引用方式并入本文中。在并入的参考文献部分与本申请之间存在不一致或矛盾的情况下,应以前述说明中的信息为准。为了使本领域的普通技术人员能够实践受权利要求书保护的本公开而给出的前述说明不应理解为是对本公开范围的限制,本公开的范围由权利要求书及其所有等同形式限定。
Claims (14)
1.一种制备可磁化磨料颗粒的方法,所述方法包括以下步骤:
a)提供陶瓷颗粒,每个陶瓷颗粒具有相应的外表面;
b)用水玻璃润湿所述陶瓷颗粒的所述外表面以提供润湿的陶瓷颗粒;以及
c)使可磁化颗粒与所述润湿的陶瓷颗粒接触,以提供涂有可磁化颗粒的陶瓷颗粒;以及
d)将所述涂有可磁化颗粒的陶瓷颗粒加热到至少足以使所述涂有可磁化颗粒的陶瓷颗粒的所述可磁化颗粒粘结至相应的所述陶瓷颗粒的温度,从而提供所述可磁化磨料颗粒,其中每个可磁化磨料颗粒在各自的基础上包括单一一个相应陶瓷颗粒,所述单一一个相应陶瓷颗粒具有粘结至其上的至少一些所述可磁化颗粒。
2.根据权利要求1所述的方法,其中每个陶瓷颗粒在各自的基础上包括接收表面和至少一个其他表面,其中所述可磁化颗粒中的一些优先地粘结至包括所述接收表面的所述陶瓷颗粒的所述外表面的邻接区域,并且其中所述至少一个其他表面的大部分区域不含粘结至所述陶瓷颗粒的可磁化颗粒。
3.根据权利要求1所述的方法,其中所述陶瓷颗粒包含氧化铝。
4.根据权利要求1所述的方法,其中所述可磁化颗粒包含铁或镍中的至少一者。
5.根据权利要求1所述的方法,其中所述可磁化颗粒包含合金,所述合金包含铁、硅和铝。
6.根据权利要求1所述的方法,其中所述水玻璃基本上由溶解在水中的硅酸钠组成。
7.根据权利要求2所述的方法,其中所述陶瓷颗粒通过模制工艺形成,其中每个接收表面在各自的基础上对应于具有内表面的模具腔的开口,并且其中所述至少一个其他表面中的每一个表面对应于所述模具腔的所述内表面。
8.根据权利要求2所述的方法,其中所述陶瓷颗粒包括陶瓷片状物,每个所述陶瓷片状物分别具有通过多个侧壁而彼此连接的相对的第一主表面和第二主表面,并且其中所述第一主表面为所述接收表面。
9.根据权利要求8所述的方法,其中所述陶瓷片状物是三角形的。
10.根据权利要求8所述的方法,其中所述第二主表面基本上不含粘结的可磁化颗粒。
11.根据权利要求8所述的方法,其中所述多个侧壁中的每一个侧壁基本上不含粘结的可磁化颗粒。
12.根据权利要求8所述的方法,其中所述陶瓷片状物被成形为截头三棱锥。
13.根据权利要求1至12中任一项制备的可磁化磨料颗粒。
14.根据权利要求13所述的可磁化磨料颗粒,其中所述可磁化磨料颗粒符合磨料行业规定的标称等级。
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EP3532562A1 (en) | 2019-09-04 |
US10947432B2 (en) | 2021-03-16 |
PL3532562T3 (pl) | 2021-10-04 |
WO2018080799A1 (en) | 2018-05-03 |
US20190264081A1 (en) | 2019-08-29 |
EP3532562A4 (en) | 2020-07-01 |
CN109890930A (zh) | 2019-06-14 |
EP3532562B1 (en) | 2021-05-19 |
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