JP6865216B2 - エポキシ官能性シランカップリング剤、表面改質された研磨粒子、及び結合研磨物品 - Google Patents
エポキシ官能性シランカップリング剤、表面改質された研磨粒子、及び結合研磨物品 Download PDFInfo
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- JP6865216B2 JP6865216B2 JP2018517588A JP2018517588A JP6865216B2 JP 6865216 B2 JP6865216 B2 JP 6865216B2 JP 2018517588 A JP2018517588 A JP 2018517588A JP 2018517588 A JP2018517588 A JP 2018517588A JP 6865216 B2 JP6865216 B2 JP 6865216B2
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- abrasive particles
- resin
- bonded
- polyepoxide
- alumina
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Description
ポリエポキシドと
式
HNR1R2
[式中、R1は−Z−SiL3を表し、
R2は−Z−SiL3又は1〜4個の炭素原子を有するアルキル基を表し、
各Zは独立して1〜18個の炭素原子を有する二価結合基を表し、
各Lは独立して加水分解性基を表す]
によって表されるアミノシランとの反応生成物を含むエポキシ官能性カップリング剤を用意することと、
エポキシ官能性カップリング剤を基の材表面と接触させることと
を含む方法を提供する。
ポリエポキシドと
式
HNR1R2
[式中、R1は−Z−SiL3を表し、
R2は−Z−SiL3又は1〜4個の炭素原子を有するアルキル基を表し、
各Zは独立して1〜6個の炭素原子を有する二価結合基を表し、
各Lは独立して加水分解性基を表す]
によって表されるアミノシランとの反応生成物を含む、研磨粒子を提供する。
ポリエポキシドと
式
HNR1R2
[式中、R1は−Z−SiL3を表し、
R2は−Z−SiL3又は1〜4個の炭素原子を有するアルキル基を表し、
各Zは独立して1〜18個の炭素原子を有する二価結合基を表し、
各Lは独立して加水分解性基を表す]
によって表されるアミノシランとの反応生成物を含むエポキシ官能性カップリング剤であって、平均すると、ポリエポキシドのエポキシ基のうち半分以下がアミノシランと反応している、エポキシ官能性カップリング剤を提供する。
HNR1R2
[式中、R1は−Z−SiL3を表し、
R2は−Z−SiL3又は1〜4個の炭素原子を有するアルキル(例えば、メチル、エチル、プロピル、又はブチル)基を表す]
によって表される。
実施形態1. 化学結合した表面水酸基を有する基材の表面を処理する方法であって、
ポリエポキシドと
式
HNR1R2
[式中、R1は−Z−SiL3を表し、
R2は−Z−SiL3又は1〜4個の炭素原子を有するアルキル基を表し、
各Zは独立して1〜18個の炭素原子を含む二価結合基を表し、
各Lは独立して加水分解性基を表す]
によって表されるアミノシランとの反応生成物を含むエポキシ官能性カップリング剤を用意することと、
エポキシ官能性カップリング剤を基材表面と接触させることと、
を含む方法。
ポリエポキシドと
式
HNR1R2
[式中、R1は−Z−SiL3を表し、
R2は−Z−SiL3又は1〜4個の炭素原子を有するアルキル基を表し、
各Zは独立して1〜6個の炭素原子を有する二価結合基を表し、
各Lは独立して加水分解性基を表す]
によって表されるアミノシランとの反応生成物を含む、研磨粒子。
式
HNR1R2
[式中、R1は−Z−SiL3を表し、
R2は−Z−SiL3又は1〜4個の炭素原子を有するアルキル基を表し、
各Zは独立して1〜18個の炭素原子を有する二価結合基を表し、
各Lは独立して加水分解性基を表す]
によって表されるアミノシランとの反応生成物を含むエポキシ官能性カップリング剤であって、平均すると、ポリエポキシドのエポキシ基のうち半分以下がアミノシランと反応している、エポキシ官能性カップリング剤。
実施例中の正確に成形されたαアルミナ研磨粒子SAP1〜SAP3は、米国特許第8,142,531号(Adefrisら)実施例1の開示内容にしたがって、正三角形のポリプロピレン金型キャビティでアルミナゾルゲルを成型することによって調製した。SAP2及びSAP3は、93.1重量%のMg(NO2)3、6.43重量%の脱イオン水、及び0.47重量%のCo(NO3)2からなる溶液を含浸させることを除いて同様に作製した。更に、SAP1及びSAP2は、アルミナ微(約0.5マイクロメートル)粒子(HYDRAL COAT 5、Almatis,Pittsburgh,Pennsylvaniaから入手した)のコーティングを有しており、この粒子コーティングは米国特許第5,213,591号(Celikkayaら)の教示にしたがって適用した。
AP1
ESO(20g)を、50mLガラスバイアル中のSCA8.5gへ添加した。不均一な混合物は、激しく撹拌することによって急速に均一な液体になり、結果として色が(淡黄色から淡ピンク色に)変化した。次いで、混合物を、室温で少なくとも24時間連続的に混合した。混合後に得られた溶液は、典型的には淡黄色に戻っていた。
EPB(26g)を、50mLガラスバイアル中のSCA8.51gへ添加した。不均一な混合物は、激しく撹拌することによって均一な液体になった。次いで、混合物を、少なくとも48時間連続的に混合した。得られた生成物は、典型的には無色の液状物であった。
EPR(100g)を、200mLガラスバイアル中のSCA9.90gへ添加した。不均一な混合物は、激しく撹拌することによって均一な液体になった。次いで、混合物を、少なくとも48時間連続的に混合した。得られた生成物は、典型的には無色の液状物であった。
DGO(2.77g)を、100mLガラスバイアル中のSCA4.26g及びTOL28.1gへ添加した。混合物を、少なくとも48時間連続的に混合した。得られた生成物は、典型的には無色の液状物であった。
AP1を、ACEを用いて5%固形物に希釈した。次いで、AP1の100部当たりCAT1の1部を添加した。得られた溶液をよく混合し、スプレーガン(PREVAL SPRAYER、Preval,Coal City,Illinoisから入手した)を使用することによって研磨粒子上に適用した。典型的なコーティングプロセスを、研磨粒子250〜350gを含むガラスビーカー(1L)で行った。スプレープロセス中は、一様なコーティングを促進するために、ガラスビーカーを連続的に振とうした。スプレープロセスが完了したらすぐに、ビーカーを、被覆粒子表面が乾燥してくるまで室温で連続的に撹拌した。次いで、処理された粒状物を、65℃のオーブン中で30分間更に乾燥した。調製された粒状物は、カットオフホイール調製前は、プラスチックバッグ又はガラスジャーで保管した。
100部当たりCAT1 1部をAP1へ添加し、完全に混合した。得られた溶液を、溶媒を添加せずに、純粋な研磨粒子へ適用し、研磨粒子を市販のKitchenAidミキサーで混合した。典型的なコーティングプロセスを、研磨粒子1000〜2000gを含むステンレス鋼ボウルで行った。研磨粒状物を連続的に混合しながら、AP1及びCAT1溶液を、ピペットを用いて研磨粒状物へ添加した。研磨粒状物の混合を、一様なコーティングが達成されるまで継続した。研磨粒子をそのままにし、室温で10分〜1カ月間静置してから使用した。混合後の長期にわたる時間によって、AP1と研磨粒子との縮合反応が可能になった。
AP1を、ACEを用いて5%固形物に希釈した。次いで、AP1の100部当たりCAT2の1部を添加した。得られた溶液をよく混合し、スプレーガン(PREVAL SPRAYER、Preval,Coal City,Illinoisから入手した)を使用することによって研磨粒子上に適用した。典型的なコーティングプロセスを、研磨粒子250〜350gを含むガラスビーカー(1L)で行った。スプレープロセス中は、一様なコーティングを促進するために、ガラスビーカーを連続的に振とうした。スプレープロセスが完了したらすぐに、ビーカーを、被覆粒子表面が乾燥してくるまで室温で連続的に撹拌した。次いで、処理された粒状物を、65℃のオーブン中で30分間更に乾燥した。調製された粒状物は、カットオフホイール調製前は、プラスチックバッグ又はガラスジャーで保管した。
AP1を、ACEを用いて5%固形物に希釈した。得られた溶液をよく混合し、スプレーガン(PREVAL SPRAYER、Preval,Coal City,Illinoisから入手した)を使用することによって研磨粒子上に適用した。典型的なコーティングプロセスを、研磨粒子250〜350gを含むガラスビーカー(1L)で行った。スプレープロセス中は、一様なコーティングを促進するために、ガラスビーカーを連続的に振とうした。スプレープロセスが完了したらすぐに、ビーカーを、被覆粒子表面が乾燥してくるまで室温で連続的に撹拌した。次いで、処理された粒状物を、65℃のオーブン中で30分間更に乾燥した。調製された粒状物は、カットオフホイール調製前は、プラスチックバッグ又はガラスジャーで保管した。
対照材料及び前項で合成された接着促進剤を、TOLで5%固形物に希釈した。次いで、選択された接着促進剤100部当たりCAT1の1部を溶液へ添加し、数分間完全に混合した。調製された接着促進剤を、36番のマイヤーコーティングロッド(RD Specialties,Webster,New York,3.24ミル(0.0823mm)名目上の湿潤厚さ)を用いてソーダ石灰ガラスプレート(2.5インチ×5.0インチ×1/8インチ(6.4cm×12.7cm×0.32cm)(IPAで予め洗浄した))に適用した。適用されたコーティングを、65℃のオーブン中で30分間乾燥し、乾燥したコーティングを観察し、コーティング品質を確認した。観察されたコーティング品質を表2に要約する。
ACEで1:1の重量比に希釈されたPRの薄層を、36番のマイヤーコーティングロッド(RD Specialties)を用い、接着促進剤で被覆されたガラス基材上に作製した。次いで、調製されたフェノール樹脂コーティングを、対流式オーブン中で硬化させた。実験用の温度プロファイル及び時間は、70℃(2時間)、100℃(2時間)、140℃(2時間)、188℃(24時間)、及び40℃(1時間)であった。
次いで、硬化したフェノール樹脂を有する調製されたガラス基材試料を、ダイヤモンドガラスカッターを使用することによって1インチ×2インチ(2.5cm×5.1cm)のサイズに切断した。次いで、切断した試料を、25℃又は100℃の脱イオン水を含むビーカー中に沈めた。浸した試料を、指定の間隔(最初の10分に関しては1分毎に、かつ後の間隔に関しては60分毎に)で水浴から取り出し、フェノール樹脂コーティングを、スポンジパッドがプラスチック棒に取り付けられているスワブで静かに擦った。次いで、擦った試料を、脱イオン水で流しながら静かに洗浄した。接着性を、擦った後に残っているコーティング面積を測定することによって決定した。試験は、各試料に対して3検体で行った。結果を、室温での評価に関しては表3に、100℃での評価に関しては表4に示す。表3及び4において、測定値は3検体の平均を示す。
RP(120g)を、SAP1−3Snの400g及びSAP2−3Snの800gへ添加し、市販のKitchenAidミキサー(5KPM50モデル)にてスピード1で7分間混合した。次いで、この混合物をPPの680gと合わせ、更に7分間混合した。第2の混合ステップの途中で、PO 5mLを混合物へ添加した。
使用した研磨粒状物がSAP1の400g及びSAP2の800gであったことを除いて、実施例5を繰り返した。
使用した研磨粒状物がSAP3−3Snの1200gであったことを除いて、実施例5を繰り返した。
使用した研磨粒状物がSAP3の1200gであったことを除いて、実施例5を繰り返した。
40%の相対湿度及び19℃で14時間劣化(aging:エージング)させた後に、実施例5〜12及び比較例F〜Iの混合物を、1.5mm×1.5mmの開口部を有する振動メッシュを通してそれぞれふるいにかけた。直径125mmの金型キャビティを6個有するMaternini加圧成形機を使用し、ホイールを加圧成形した。全てのホイールに関して、6個のキャビティ全てに対する加圧成形力は、3秒の滞留時間で210bar(21MPa)であった。充填する間の底部プレートの深さは−3.00mmであり、かつ鉱物が反応する間の底部プレートの深さは+0.1mmであった。加圧成形中の室温は18.0〜19.4℃であり、湿度範囲は39〜40%の相対湿度(RH)であった。125mm径ディスクのSCRIM2を、125mm径金型キャビティの底部に置いた。金型は、23mmの内径を有していた。次いで、加圧成形機の自動シャトルボックスによって、充填混合物33.5gをスクリム頂部の各キャビティ中に広げた。次いで、SCRIMを充填混合物の頂部に置き、直径の小さい実験ラベルをスクリムの頂部に置いた。Lumet PPUH in Jaslo,Poland製の28mm×22.45mm×1.2mmの金属フランジを各ラベルの頂部に置いた。金型を閉じ、スクリム−充填物−スクリムのサンドイッチを、210バール(21MPa)の荷重、3秒の滞留時間で加圧成形した。24個のホイールが各ロットから作成され、硬化前のホイール厚さは1.25〜1.30mmであり、硬化前のホイール重量は約33.5±0.5gであった。加圧成形後に、ホイールは、硬化プログラム中に形状を維持するために、アルミニウムプレートとPTFEシートとの間に積層体状に置いた。次いで、カットオフホイール前駆体を金型から取り出し、積層体中で、30時間の硬化サイクルで、詳細には、2時間で75℃に上昇、2時間で90℃に上昇、5時間で110℃に上昇、3時間で135℃に上昇、3時間で188℃に上昇、13時間に亘り188℃に維持、次いで2時間で60℃に冷却、で硬化した。ホイールの最終的な厚さは約0.053インチ(1.35mm)であった。
シート長が40インチ(16cm)、厚さが1/8インチ(3.2mm)のステンレス鋼を、その主表面が水平に対して35度の角度で傾斜した状態で固定した。ガイドレールを、傾斜しているシートの下り傾斜の天面に沿って固定した。DeWalt Model D28114 4.5インチ(11.4cm)/5インチ(12.7cm)のカットオフホイールアングルグラインダーを、工具が重力によって下方に導かれるようにガイドレールに固定した。
使用した研磨粒状物がSAP1−1Snの400g及びSAP2−1Snの800gであったことを除いて、実施例5を繰り返した。
実施例5を繰り返した。
使用した研磨粒状物がSAP1−5Snの400g及びSAP2−5Snの800gであったことを除いて、実施例5を繰り返した。
使用した研磨粒状物がSAP1−5Tiの400g及びSAP2−5Tiの800gであったことを除いて、実施例5を繰り返した。
使用した研磨粒状物がSAP1−5NCの400g及びSAP2−5NCの800gであったことを除いて、実施例5を繰り返した。
使用した研磨粒状物がSAP1−3Sn−SLの400g及びSAP2−3Sn−SLの800gであったことを除いて、実施例5を繰り返した。
実施例Fを繰り返した(使用した研磨粒状物はSAP1の400g及びSAP2の800gであった)。
実施例Fを繰り返した(使用した研磨粒状物はSAP1の400g及びSAP2の800gであった)。
Claims (14)
- 化学結合した表面水酸基を有する研磨粒子を含む基材の表面を処理する方法であって、
ポリエポキシドと
式
HNR1R2
[式中、R1は−Z−SiL3を表し、
R2は−Z−SiL3又は1〜4個の炭素原子を有するアルキル基を表し、
各Zは独立して1〜18個の炭素原子を有する二価結合基を表し、
各Lは独立して加水分解性基を表す]
によって表されるアミノシランとの反応生成物を含むエポキシ官能性カップリング剤を用意することと、
エポキシ官能性カップリング剤を基材の表面と接触させることと、
を含む方法。 - ポリエポキシドの全エポキシ基について平均すると、ポリエポキシドのエポキシ基のうち半分以下がアミノシランと反応している、請求項1に記載の方法。
- ポリエポキシドがエポキシ化大豆油の構成成分を含む、請求項1又は2に記載の方法。
- R2が−Z−SiL3を表す、請求項1〜3のいずれか一項に記載の方法。
- Lが独立してメトキシ、エトキシ、及びアセトキシからなる群から選択される、請求項1〜4のいずれか一項に記載の方法。
- 外面を有するアルミナ研磨粒子であって、外面に共有結合された接着性改質層を有しており、接着性改質層が、エポキシ官能性カップリング剤と研磨粒子の外面に共有結合している水酸基との反応生成物を含み、エポキシ官能性カップリング剤が、
ポリエポキシドと
式
HNR1R2
[式中、R1は−Z−SiL3を表し、
R2は−Z−SiL3又は1〜4個の炭素原子を有するアルキル基を表し、
各Zは独立して1〜6個の炭素原子を有する二価結合基を表し、
各Lは独立して加水分解性基を表す]
によって表されるアミノシランとの反応生成物を含む、アルミナ研磨粒子。 - ポリエポキシドがエポキシ化大豆油の構成成分を含む、請求項6に記載のアルミナ研磨粒子。
- ポリエポキシドの全エポキシ基について平均すると、ポリエポキシドのエポキシ基のうち半分以下がアミノシランと反応している、請求項6又は7に記載のアルミナ研磨粒子。
- R2が−Z−SiL3を表す、請求項6〜8のいずれか一項に記載のアルミナ研磨粒子。
- Lが独立してメトキシ、エトキシ、及びアセトキシからなる群から選択される、請求項6〜9のいずれか一項に記載のアルミナ研磨粒子。
- バインダー材料内に保持された請求項6〜10のいずれか一項に記載の複数のアルミナ研磨粒子を含む、樹脂結合研磨物品。
- バインダー材料がフェノール樹脂を含む、請求項11に記載の樹脂結合研磨物品。
- 樹脂結合研磨ホイールを含む、請求項11又は12に記載の樹脂結合研磨物品。
- 樹脂結合研磨カットオフホイールを含む、請求項11又は12に記載の樹脂結合研磨物品。
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US62/332,958 | 2016-05-06 | ||
PCT/US2016/055538 WO2017062482A1 (en) | 2015-10-07 | 2016-10-05 | Epoxy-functional silane coupling agents, surface-modified abrasive particles, and bonded abrasive articles |
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EP3359588A4 (en) | 2019-09-11 |
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