WO2020007015A1 - 一种金刚石复合材料及其制备方法和应用 - Google Patents

一种金刚石复合材料及其制备方法和应用 Download PDF

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Publication number
WO2020007015A1
WO2020007015A1 PCT/CN2018/125415 CN2018125415W WO2020007015A1 WO 2020007015 A1 WO2020007015 A1 WO 2020007015A1 CN 2018125415 W CN2018125415 W CN 2018125415W WO 2020007015 A1 WO2020007015 A1 WO 2020007015A1
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water
diamond
composite material
diamond composite
foam
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PCT/CN2018/125415
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English (en)
French (fr)
Inventor
朱联烽
田多胜
邓宏念
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东莞市中微纳米科技有限公司
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Publication of WO2020007015A1 publication Critical patent/WO2020007015A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B37/00—Lapping machines or devices; Accessories
    • B24B37/11—Lapping tools
    • B24B37/12—Lapping plates for working plane surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B37/00—Lapping machines or devices; Accessories
    • B24B37/11—Lapping tools
    • B24B37/12—Lapping plates for working plane surfaces
    • B24B37/14—Lapping plates for working plane surfaces characterised by the composition or properties of the plate materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B24D18/009—Tools not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00241—Physical properties of the materials not provided for elsewhere in C04B2111/00
    • C04B2111/00362—Friction materials, e.g. used as brake linings, anti-skid materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/40—Porous or lightweight materials

Definitions

  • the invention relates to the technical field of fine grinding of hard and brittle materials, in particular to a diamond composite material and a preparation method and application thereof.
  • Zirconia ceramics, artificial sapphire and other super-hard materials have considerable potential for application on smartphones, such as fingerprint identification films, ceramic back covers, lens protection films, etc.
  • the production of hard material products lies in the fine grinding and polishing of the surface of the material, so that it has a bright surface.
  • the hard material surface polishing process needs to undergo three stages of rough grinding, fine grinding and polishing.
  • the fine grinding process uses an abrasive free machining method, that is, a diamond grinding liquid containing a particle diameter of 2 to 4 ⁇ m is added to a rotating On a flat copper plate, the sample is processed by pressing the processed surface on the copper plate. Due to the good ductility of metallic copper, some diamond abrasive particles will be embedded on the surface of the copper disc under the pressure of the sample. These fixed abrasive particles will act on the sample together with the abrasive on the surface of the disc, and the surface of the sample will be gradually polished. bright. Occasionally, large sample particles will fall off during fine grinding.
  • the key solution to the problem of scratches in the fine grinding process is to etch a series of concentric annular shallow grooves with a depth of about 0.5 mm, a width of about 1 mm, and an interval of about 1 mm on the surface of the copper disc. Particles that fall off during processing will roll into these shallow grooves instead of traveling upstream of the disk surface.
  • the shallow groove on the disk surface must not be too deep, otherwise the abrasive liquid cannot climb back to the copper disk surface, and the cutting efficiency will be greatly reduced or even disappeared.
  • an object of the present invention is to provide a diamond composite material, a preparation method and application thereof.
  • the invention solves the problem of frequent slotting and deepening of the copper disc fine grinding, and at the same time does not need to add diamond grinding liquid in this way, reducing the amount of diamond abrasive particles and saving the cost of consumables.
  • the invention provides a diamond composite material, which includes a honeycomb core material and a water-soluble gypsum foam filled in the pores of the honeycomb core material.
  • the water-soluble gypsum foam includes the following weight percentage components: inorganic composite binder 30 ⁇ 80%, diamond abrasive grains 1-30%, talc 10-30%, water-based adhesive 0.5-15%, foam 5-20%, glass fiber 0.2-1%, polycarboxylic acid water reducer 0.3-1 %, Water 8-50%, and the sum of the weight percentages of the components of the water-soluble gypsum foam is 100%.
  • the weight ratio of the honeycomb core material to the water-soluble gypsum foam is 0.2 to 0.05: 1.
  • the diamond abrasive particles have a particle diameter of 0.5 to 5 ⁇ m.
  • the inorganic composite binder includes hemihydrate gypsum and silica fume, and a mass ratio of the hemihydrate gypsum and silica fume is 90 to 97: 1 to 10.
  • the aqueous adhesive is an acrylic emulsion, a polyvinyl alcohol aqueous solution, a polyurethane emulsion, or an ethylene-vinyl acetate emulsion.
  • a honeycomb shape of the honeycomb core material is a hexagon, and a length of a side of a honeycomb hole of the honeycomb core material is 3 to 10 mm.
  • the material of the honeycomb core material is aluminum or copper.
  • the invention also provides a method for preparing the diamond composite material according to the above technical solution, including the following steps:
  • the foamed diamond composite slurry is poured into the holes of the honeycomb core material and baked to obtain a diamond composite material.
  • the baking temperature is 100 to 120 ° C, and the baking time is 3 to 5 hours.
  • the invention also provides the application of the diamond composite material described in the above technical solution or the diamond composite material prepared by the preparation method described in the above technical solution in the field of fine grinding.
  • the invention provides a diamond composite material, which includes a honeycomb core material and a water-soluble gypsum foam filled in the pores of the honeycomb core material.
  • the water-soluble gypsum foam includes the following weight percentage components: inorganic composite binder 30 ⁇ 80%, diamond abrasive grains 1-30%, talc 10-30%, water-based adhesive 0.5-15%, foam 5-20%, glass fiber 0.2-1%, polycarboxylic acid water reducer 0.3-1 %, Water 8-50%, and the sum of the weight percentages of the components of the water-soluble gypsum foam is 100%.
  • an inorganic composite binder bonds diamond abrasives; diamond abrasives are finely ground abrasives; talc is a filler used to disperse diamond abrasives, and the diamond abrasives fall off in a uniform and controllable amount; water-based adhesive After curing the agent, an elastic polymer film will be formed between the inorganic particles, and the inorganic particles will be bonded to play a role of toughening. By adjusting the amount of the water-based adhesive, the peeling rate of the diamond abrasive particles can be adjusted; the glass fibers can form interlaced The network can increase the toughness of the gypsum foam and prevent the gypsum foam from breaking.
  • the foam acts as a foam and forms a porous foamed composite abrasive block.
  • the presence of holes can help the diamond abrasive particles to fall off.
  • the diamond composite material when used for fine grinding, it will slightly dissolve after contacting with pure water. At this time, the diamond abrasive particles will be released and form a grinding liquid with water.
  • the honeycomb core material has a certain mechanical support force. During grinding, the grinding liquid will climb to the top surface of the core material wall to interact with the processed sample. At the same time, the slightly soluble grinding block will generate a slight depression, and the large particles generated by the grinding will roll down into these pits to avoid scratching. sample.
  • the loss of water-soluble gypsum foam is synchronized with the wear rate of the honeycomb core material, which avoids frequent slotting like copper disks, and does not require additional dripping of diamond abrasive liquid, which improves the use of diamond abrasive particles. effectiveness.
  • FIG. 1 is a schematic structural diagram of a finely ground flat plate prepared in Example 1 of the present invention, in which 100-finely ground flat plate; 101- honeycomb core material wall; 200- water-soluble gypsum foam containing diamond abrasive grains;
  • FIG. 2 is a schematic structural diagram of a fine grinding plate prepared by the present invention when used for fine grinding, wherein 200-water-soluble gypsum foam containing diamond abrasive particles; 201-bubbles; 202-gypsum wall containing diamond abrasive particles; 203-diamond Abrasive particles.
  • the invention provides a diamond composite material, which includes a honeycomb core material and a water-soluble gypsum foam filled in the pores of the honeycomb core material.
  • the water-soluble gypsum foam includes the following weight percentage components: inorganic composite binder 30 ⁇ 80%, diamond abrasive grains 1-30%, talc 10-30%, water-based adhesive 0.5-15%, foam 5-20%, glass fiber 0.2-1%, polycarboxylic acid water reducer 0.3-1 %, Water 8-50%, and the sum of the weight percentages of the components of the water-soluble gypsum foam is 100%.
  • the weight ratio of the honeycomb core material to the water-soluble gypsum foam is preferably 0.2 to 0.05: 1, and more preferably 0.1 to 0.15: 1.
  • the diamond composite material provided by the present invention preferably includes 2 to 5% by weight of diamond abrasive particles, and more preferably 3%.
  • the particle diameter of the diamond abrasive particles is preferably 0.5 to 5 ⁇ m, more preferably 1 to 4 ⁇ m, and most preferably 2 to 3 ⁇ m.
  • the diamond abrasive particles are finely ground abrasives.
  • the diamond composite material provided by the present invention preferably includes 39 to 52% by weight of an inorganic composite binder, and more preferably 42 to 47%.
  • the inorganic composite binder preferably includes hemihydrate gypsum and silica fume, and the mass ratio of the hemihydrate gypsum and silica fume is preferably 90 to 97: 1 to 10.
  • an inorganic composite binder bonds the diamond abrasive.
  • the particle diameter of the silica fume is preferably 50 to 200 nm.
  • hemihydrate gypsum will be hydrated and solidify after the action of water.
  • Hemihydrate gypsum is brittle, and the diamond abrasive is easy to fall off under the condition of grinding pressure.
  • the dropped diamond abrasive will participate in the fine grinding process;
  • silicon Ash is a microscopically spherical powder that can be filled into hemihydrate gypsum to increase the compressive strength of the hemihydrate gypsum binder.
  • silica fume has a pozzolanic effect and can also undergo a certain hydration reaction with water; silicon
  • the inorganic composite binder formed by combining ash with hemihydrate gypsum can effectively improve the strength of the binder.
  • the diamond composite material provided by the present invention preferably includes 12 to 25% by weight of talc, and more preferably 15%.
  • talc is a filler used to disperse diamond abrasives, and the diamond abrasives fall off in a uniform and controllable amount.
  • the source of the talc is not particularly limited, and commercially available products that are well known to those skilled in the art may be used.
  • the diamond composite material provided by the present invention preferably includes 2 to 10% by weight of an aqueous adhesive, and more preferably 5%.
  • the aqueous adhesive is preferably an acrylic emulsion, a polyvinyl alcohol aqueous solution, a polyurethane emulsion, or an ethylene-vinyl acetate emulsion.
  • an elastic polymer film is formed between the inorganic particles, and the inorganic particles are bonded to play a role of toughening.
  • the amount of the water-based adhesive the diamond abrasive particles can be adjusted. Peeling rate.
  • the mass fraction of the polyvinyl alcohol aqueous solution is preferably 3 to 5%.
  • the diamond composite material provided by the present invention preferably comprises 0.3 to 1% by weight of a polycarboxylic acid water reducing agent, and more preferably 0.5%.
  • the source of the polycarboxylic acid water reducing agent is not particularly limited, and commercial products well known to those skilled in the art may be used.
  • the diamond composite material provided by the present invention preferably includes 8 to 16% by weight of foam, and more preferably 12 to 14%.
  • the foam plays a foaming role, forming a porous foamed composite abrasive block, and the existence of holes can help the diamond abrasive particles to fall off.
  • the foam is preferably prepared from a foaming agent solution.
  • the foaming agent solution preferably includes a foaming agent, an aqueous adhesive, and water.
  • the mass concentration of the foaming agent in the foaming agent solution is preferably 10 to 30%, and the mass ratio of the aqueous adhesive in the foaming agent solution is 3 to 5%.
  • the foaming agent is preferably an animal and vegetable protein foaming agent; the water-based adhesive is preferably consistent with the above, and will not be repeated here.
  • the density of the foam is preferably 50 to 80 kg / m 3 , and more preferably 60 to 70 kg / m 3 .
  • the diamond composite material provided by the present invention preferably includes 0.3 to 0.5% by weight of glass fibers.
  • the glass fibers can form an interlaced network, increase the toughness of the gypsum foam, and prevent the gypsum foam from breaking in one piece.
  • the source of the glass fiber is not particularly limited, and commercial products well known to those skilled in the art may be used.
  • the honeycomb shape of the honeycomb core material is preferably hexagonal, and the side length of the honeycomb hole of the honeycomb core material is preferably 3 to 10 mm, and more preferably 5 to 6 mm.
  • the material of the honeycomb core material is preferably aluminum or copper.
  • the source of the honeycomb core material is not particularly limited, and commercial products well known to those skilled in the art may be used.
  • the invention also provides a method for preparing the diamond composite material according to the above technical solution, including the following steps:
  • the foamed diamond composite slurry is poured into the holes of the honeycomb core material and baked to obtain a diamond composite material.
  • water and an aqueous adhesive are mixed to obtain an aqueous adhesive solution.
  • an inorganic composite binder, diamond abrasive particles, talc, polycarboxylic acid water reducing agent and glass fiber are mixed to obtain a premix.
  • the present invention does not specifically limit the mixing manner, and a mixing manner well known to those skilled in the art may be adopted, specifically, such as stirring.
  • the present invention mixes the aqueous adhesive solution and the premix to obtain a slurry.
  • the premix is preferably added to the aqueous adhesive solution.
  • the present invention mixes the slurry with foam to obtain a foamed diamond composite slurry.
  • the present invention does not specifically limit the mixing manner, and a mixing manner well known to those skilled in the art may be adopted.
  • the present invention pours the foamed diamond composite slurry into the pores of the honeycomb core material and bakes to obtain a diamond composite material.
  • the baking temperature is preferably 100 to 120 ° C, and the baking time is preferably 3 to 5 hours.
  • the invention also provides the application of the diamond composite material described in the above technical solution or the diamond composite material prepared by the preparation method described in the above technical solution in the field of fine grinding.
  • the diamond composite material is preferably smoothed by a water grinder to obtain a finely ground flat plate, which is used in the field of fine grinding.
  • the present invention does not specifically limit the specific method of leveling the water grinder, and it is only necessary to adopt a method well known to those skilled in the art.
  • the foam is prepared as follows: a foaming agent aqueous solution is prepared, in which the concentration of the animal and plant foaming agent is 10%, and the proportion of the polyvinyl alcohol aqueous solution is 3%; 50kg / m 3 foam;
  • the diameter of the diamond abrasive particles is 0.5 ⁇ m
  • the foam is sent to a stirred tank, and stirred at a slow speed to obtain a foamed diamond composite slurry;
  • the foamed diamond composite slurry is poured into the pores of the honeycomb core material and baked at 100 ° C for 3 hours. After the water evaporates, the diamond composite slurry forms a water-soluble diamond composite foam abrasive block and is fixed on the honeycomb core material. In the hole, a honeycomb core material plate containing a diamond composite foam grinding block was obtained. The front and back sides of the honeycomb core material plate were smoothed with a water grinder to obtain a plate for fine grinding. The structure is shown in FIG. 1. Among them, 100-finished flat plate; 101- honeycomb core material wall; 200- water-soluble gypsum foam containing diamond abrasive particles.
  • Examples 2 to 8 are comparative tests of 7 different formulations. These formulations are listed in Table 1 together with the formulation of Example 1, and were prepared according to the process steps of Example 1.
  • the diamond composite material provided by the present invention can be used for the fine grinding of flat hard and brittle materials.
  • the hard and brittle materials are flatly pressed against a diamond flat plate and ground with water.
  • 200- water-soluble gypsum foam containing diamond abrasive particles 201- air bubbles; 202- gypsum wall containing diamond abrasive particles; 203- diamond abrasive particles.
  • Diamond composite foam abrasive block is composed of a large number of air bubbles, binder and diamond abrasive particles.
  • the diamond composite foam abrasive block When the diamond composite foam abrasive block is slightly dissolved after contacting with pure water, the diamond abrasive particles will be released and form an abrasive liquid with water.
  • the honeycomb core material has a certain mechanical support force, and the abrasive liquid will climb to the ground during grinding. The top surface of the wall of the core material interacts with the sample being processed.
  • the slightly soluble grinding block will generate slight depressions, and the large particles generated by grinding will fall into these depressions to avoid scratching the sample.
  • the wear of the water-soluble diamond composite foam abrasive block is synchronized with the wear rate of the honeycomb core material, which avoids frequent slotting like a copper disk. There is also no need to add additional diamond polishing liquid, which improves the utilization efficiency of diamond abrasive particles.

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Abstract

一种金刚石复合材料，包括蜂窝芯材和填充于所述蜂窝芯材孔内的水溶性石膏泡沫，所述水溶性石膏泡沫包括以下重量百分比的组分：无机复合粘结剂30～80％、金刚石磨粒1～30％、滑石粉10～30％、水性胶黏剂0.5～15％、泡沫5～20％、玻璃纤维0.2～1％、聚羧酸减水剂0.3～1％、水8～50％，所述水溶性石膏泡沫各组分的重量百分比之和为100％。该金刚石复合材料用于精磨时，在接触到纯净水后会发生微溶，此时金刚石磨粒会被释放出来，与水形成研磨液，蜂窝芯材具有一定的机械支撑力，研磨时研磨液会爬到芯材壁的顶面上与被加工样品进行作用，同时微溶的磨块会产生轻微的凹陷，研磨产生的大颗粒会滚落到这些凹坑中，避免划伤样品。在这种结构中，水溶性石膏泡沫的损耗与蜂窝芯材的磨损速率同步，避免了象铜盘那样经常性开槽，也无需额外滴加金刚石研磨液，提高了金刚石磨粒的利用效率。

Description

一种金刚石复合材料及其制备方法和应用
本申请要求于2018年7月5日提交中国专利局、申请号为CN201810730645.9、发明名称为“一种金刚石复合材料及其制备方法和应用”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本发明涉及硬脆材料精细研磨技术领域，尤其涉及一种金刚石复合材料及其制备方法和应用。
背景技术
氧化锆陶瓷、人造蓝宝石等超硬质材料在智能手机上应用具有相当大的潜力，例如指纹识别片、陶瓷后盖、镜头保护片等。硬质材料产品的生产在于材料表面的精细研磨抛光，使之具有光亮的表面。
硬质材料表面抛光加工需经历粗磨、精磨和抛光三个工段，其中精磨工艺使用的是磨料游离式加工方法，即将含有粒径为2～4μm的金刚石研磨液滴加在一个旋转的平面铜盘上，再将样品被加工表面压在铜盘上进行加工。由于金属铜具有良好的延展性，部分金刚石研磨颗粒在样品的压力作用下会镶嵌在铜盘的表面，这些固定的磨粒会连同盘面上滚动的磨料一起对样品作用，样品的表面逐渐被磨光亮。在精磨时偶尔会产生大的样品颗粒脱落，这些超硬颗粒如果在盘面上游走会划伤整批样品。因此解决精磨加工划伤问题的关键方案是：在铜盘表面刻一系列深度约0.5mm、宽度约1mm、间隔约1mm的同心环形浅槽。加工时脱落的颗粒会滚落到这些浅槽中，而不是在盘面上游走。另外，盘面浅槽不能过深，否则研磨液无法回爬至铜盘面上，切削效率会大打折扣甚至消失。
用铜盘做精磨加工存在的问题是：使用过程中铜盘会损耗，导致槽深减小和盘面平面精度变差，因此需要经常性开槽和修整盘面。同时，这种加工方式涉及使用大量昂贵的金刚石研磨液，很多金刚石并没有充分利用就流走，致使加工成本较高。
发明内容
有鉴于此，本发明的目的在于提供一种金刚石复合材料及其制备方法和应用。本发明解决了铜盘精磨需要经常性开槽加深的问题，同时不需要滴加金刚石研磨液这种方式，减少金刚石磨粒用量，节约耗材成本。
为了实现上述发明目的，本发明提供以下技术方案：
本发明提供了一种金刚石复合材料，包括蜂窝芯材和填充于所述蜂窝芯材孔内的水溶性石膏泡沫，所述水溶性石膏泡沫包括以下重量百分比的组分：无机复合粘结剂30～80％、金刚石磨粒1～30％、滑石粉10～30％、水性胶黏剂0.5～15％、泡沫5～20％、玻璃纤维0.2～1％、聚羧酸减水剂0.3～1％、水8～50％，所述水溶性石膏泡沫各组分的重量百分比之和为100％。
优选地，所述蜂窝芯材与水溶性石膏泡沫的重量比为0.2～0.05：1。
优选地，所述金刚石磨粒的粒径为0.5～5μm。
优选地，所述无机复合粘结剂包括半水石膏和硅灰，所述半水石膏和硅灰的质量比为90～97：1～10。
优选地，所述水性胶黏剂为丙烯酸乳液、聚乙烯醇水溶液、聚氨酯乳液或乙烯-醋酸乙烯酯乳液。
优选地，所述蜂窝芯材的蜂窝形状为六角形，所述蜂窝芯材的蜂窝孔边长为3～10mm。
优选地，所述蜂窝芯材的材质为铝或铜。
本发明还提供了上述技术方案所述的金刚石复合材料的制备方法，包括以下步骤：
将水和水性胶黏剂混合，得到水性胶黏剂溶液；
将无机复合粘结剂、金刚石磨粒、滑石粉、聚羧酸减水剂和玻璃纤维混合，得到预混料；
将水性胶黏剂溶液和预混料混合，得到浆料；
将浆料与泡沫混合，得到泡沫金刚石复合浆料；
将泡沫金刚石复合浆料倒入蜂窝芯材的孔洞中，经烘烤，得到金刚石复合材料。
优选地，所述烘烤的温度为100～120℃，所述烘烤的时间为3～5h。
本发明还提供了上述技术方案所述金刚石复合材料或上述技术方案所述制备方法制得的金刚石复合材料在精磨领域中的应用。
本发明提供了一种金刚石复合材料，包括蜂窝芯材和填充于所述蜂窝芯材孔内的水溶性石膏泡沫，所述水溶性石膏泡沫包括以下重量百分比的组分：无机复合粘结剂30～80％、金刚石磨粒1～30％、滑石粉10～30％、水性胶黏剂0.5～15％、泡沫5～20％、玻璃纤维0.2～1％、聚羧酸减水剂0.3～1％、水8～50％，所述水溶性石膏泡沫各组分的重量百分比之和为100％。本发明中，无机复合粘结剂将金刚石磨料粘接；金刚石磨粒为精细研磨的磨料；滑石粉是一种填料，用于分散金刚石磨料，金刚石磨料以均匀可控地微量脱落；水性胶黏剂固化后会在无机颗粒间形成弹性高分子膜，将无机颗粒粘接起来，起增韧作用，通过调整水性胶黏剂的用量，可以调节金刚石磨粒的剥落速率；玻璃纤维可以形成相互交错的网络，可以增加石膏泡沫的韧性，防止石膏泡沫整块断裂；泡沫起发泡作用，形成多孔发泡复合磨块，孔洞的存在可以有助于金刚石磨粒脱落。本发明中，金刚石复合材料用于精磨时，在接触到纯净水后会发生微溶，此时金刚石磨粒会被释放出来，与水形成研磨液，蜂窝芯材具有一定的机械支撑力，研磨时研磨液会爬到芯材壁的顶面上与被加工样品进行作用，同时微溶的磨块会产生轻微的凹陷，研磨产生的大颗粒会滚落到这些凹坑中，避免划伤样品。在这种结构中，水溶性石膏泡沫的损耗与蜂窝芯材的磨损速率同步，这样就避免了象铜盘那样经常性开槽，也无需额外滴加金刚石研磨液，提高了金刚石磨粒的利用效率。
说明书附图
图1为本发明实施例1制得的精磨平板结构示意图，其中100-精磨平板；101-蜂窝芯材壁；200-含有金刚石磨粒的水溶性石膏泡沫；
图2为本发明制得的精磨平板用于精磨时的结构示意图，其中200-含有金刚石磨粒的水溶性石膏泡沫；201-气泡；202-含有金刚石磨粒的石膏壁；203-金刚石磨粒。
具体实施方式
本发明提供了一种金刚石复合材料，包括蜂窝芯材和填充于所述蜂窝芯材孔内的水溶性石膏泡沫，所述水溶性石膏泡沫包括以下重量百分比的组分：无机复合粘结剂30～80％、金刚石磨粒1～30％、滑石粉10～30％、水性胶黏剂0.5～15％、泡沫5～20％、玻璃纤维0.2～1％、聚羧酸减水剂0.3～1％、水8～50％，所述水溶性石膏泡沫各组分的重量百分比之和为 100％。
在本发明中，所述蜂窝芯材与水溶性石膏泡沫的重量比优选为0.2～0.05：1，更优选为0.1～0.15：1。
本发明提供的金刚石复合材料优选包括2～5％重量百分比的金刚石磨粒，更优选为3％。在本发明中，所述金刚石磨粒的粒径优选为0.5～5μm，更优选为1～4μm，最优选为2～3μm。在本发明中，所述金刚石磨粒为精细研磨的磨料。
本发明提供的金刚石复合材料优选包括39～52％重量百分比的无机复合粘结剂，更优选为42～47％。在本发明中，所述无机复合粘结剂优选包括半水石膏和硅灰，所述半水石膏和硅灰的质量比优选为90～97：1～10。在本发明中，无机复合粘结剂将金刚石磨料粘接。在本发明中，所述硅灰的粒径优选为50～200nm。本发明中，半水石膏和水作用之后会发生水化反应进而固化，半水石膏是脆性的，金刚石磨料容易在磨削压力条件下脱落，脱落的金刚石磨料将参与到精磨过程中；硅灰是一种微观上呈球形的粉体，可以填充到半水石膏中增加半水石膏粘结剂的抗压强度，同时硅灰具有火山灰效应，也可以和水发生一定的水化反应；硅灰与半水石膏结合形成的无机复合粘结剂可以有效提高粘结剂的强度。
本发明提供的金刚石复合材料优选包括12～25％重量百分比的滑石粉，更优选为15％。本发明中，滑石粉是一种填料，用于分散金刚石磨料，金刚石磨料以均匀可控地微量脱落。本发明对所述滑石粉的来源没有特殊的限定，采用本领域技术人员熟知的市售商品即可。
本发明提供的金刚石复合材料优选包括2～10％重量百分比的水性胶黏剂，更优选为5％。在本发明中，所述水性胶黏剂优选为丙烯酸乳液、聚乙烯醇水溶液、聚氨酯乳液或乙烯-醋酸乙烯酯乳液。本发明中，所述水性胶黏剂固化后会在无机颗粒间形成弹性高分子膜，将无机颗粒粘接起来，起增韧作用，通过调整水性胶黏剂的用量，可以调节金刚石磨粒的剥落速率。
在本发明中，所述聚乙烯醇水溶液的质量分数优选为3～5％。
本发明提供的金刚石复合材料优选包括0.3～1％重量百分比的聚羧酸减水剂，更优选为0.5％。本发明对所述聚羧酸减水剂的来源没有特殊的限定，采用本领域技术人员熟知的市售商品即可。
本发明提供的金刚石复合材料优选包括8～16％重量百分比的泡沫，更优选为12～14％。在本发明中，所述泡沫起发泡作用，形成多孔发泡复合磨块，孔洞的存在可以有助于金刚石磨粒脱落。
在本发明中，所述泡沫优选由发泡剂溶液制备得到。在本发明中，所述发泡剂溶液优选包括发泡剂、水性胶黏剂和水。在本发明中，所述发泡剂溶液中发泡剂的质量浓度优选为10～30％，所述水性胶黏剂在发泡剂溶液中的质量比例为3～5％。
在本发明中，所述发泡剂优选为动植物蛋白发泡剂；所述水性胶黏剂优选为与上述一致，在此不再赘述。
在本发明中，所述泡沫的密度优选为50～80kg/m 3，更优选为60～70kg/m 3。
本发明提供的金刚石复合材料优选包括0.3～0.5％重量百分比的玻璃纤维。在本发明中，所述玻璃纤维可以形成相互交错的网络，增加石膏泡沫的韧性，防止石膏泡沫整块断裂。本发明对所述玻璃纤维的来源没有特殊的限定，采用本领域技术人员熟知的市售商品即可。
在本发明中，所述蜂窝芯材的蜂窝形状优选为六角形，所述蜂窝芯材的蜂窝孔边长优选为3～10mm，更优选为5～6mm。
在本发明中，所述蜂窝芯材的材质优选为铝或铜。本发明对所述蜂窝芯材的来源没有特殊的限定，采用本领域技术人员熟知的市售商品即可。
本发明还提供了上述技术方案所述的金刚石复合材料的制备方法，包括以下步骤：
将水和水性胶黏剂混合，得到水性胶黏剂溶液；
将无机复合粘结剂、金刚石磨粒、滑石粉、聚羧酸减水剂和玻璃纤维混合，得到预混料；
将水性胶黏剂溶液和预混料混合，得到浆料；
将浆料与泡沫混合，得到泡沫金刚石复合浆料；
将泡沫金刚石复合浆料倒入蜂窝芯材的孔洞中，经烘烤，得到金刚石复合材料。
本发明将水和水性胶黏剂混合，得到水性胶黏剂溶液。
本发明将无机复合粘结剂、金刚石磨粒、滑石粉、聚羧酸减水剂和玻璃纤维混合，得到预混料。
本发明对所述混合方式没有特殊的限定，采用本领域技术人员熟知的混合方式即可，具体的，如搅拌。
得到水性胶黏剂溶液和预混料后，本发明将水性胶黏剂溶液和预混料混合，得到浆料。在本发明中，优选将所述预混料加入到所述水性胶黏剂溶液中。
得到浆料后，本发明将所述浆料与泡沫混合，得到泡沫金刚石复合浆料。本发明对所述混合方式没有特殊的限定，采用本领域技术人员熟知的混合方式即可。
得到泡沫金刚石复合浆料后，本发明将所述泡沫金刚石复合浆料倒入蜂窝芯材的孔洞中，经烘烤，得到金刚石复合材料。在本发明中，所述烘烤的温度优选为100～120℃，所述烘烤的时间优选为3～5h。
本发明还提供了上述技术方案所述金刚石复合材料或上述技术方案所述制备方法制得的金刚石复合材料在精磨领域中的应用。
在本发明中，所述金刚石复合材料优选经水磨床修平后，得到精磨平板，用于精磨领域。本发明对所述水磨床修平的具体方式没有特殊的限定，采用本领域技术人员熟知的方式即可。
下面结合实施例对本发明提供的金刚石复合材料及其制备方法与应用进行详细的说明，但是不能把它们理解为对本发明保护范围的限定。
实施例1
按重量百分比称取各组分：半水石膏37％、硅灰2％、金刚石磨粒3％，滑石粉15％、聚乙烯醇溶液5％(质量浓度为5％)、泡沫16％、玻璃纤维0.5％、聚羧酸减水剂0.3％，水21.2％；
其中，泡沫按如下方法制备：配制发泡剂水溶液，其中动植物发泡剂浓度为10％，聚乙烯醇水溶液比例为3％，然后将发泡剂溶液送至发泡机，制备出密度为50kg/m 3的泡沫；
上述金刚石磨粒的粒径为0.5μm；
将水、聚乙烯醇溶液加入搅拌釜中；将半水石膏、硅灰、金刚石磨粒，滑石粉、玻璃纤维、聚羧酸减水剂固态组分进行预混，预混完毕后再在搅拌条件下将预混逐步加入搅拌釜中，使固、液组分充分混合，制成浆料；
将泡沫送入搅拌釜，慢速搅拌均匀，制得泡沫金刚石复合浆料；
将泡沫金刚石复合浆料倒入蜂窝芯材的孔洞中，在100℃温度下烘烤3小时，水分蒸发后金刚石复合浆料形成一种水溶性金刚石复合泡沫磨块，并固定在蜂窝芯材的孔洞中，由此获得一种含有金刚石复合泡沫磨块的蜂窝芯材板，将蜂窝芯材板正反面用水磨床修平，获得用于精磨平板，结构如图1所示。其中100-精磨平板；101-蜂窝芯材壁；200-含有金刚石磨粒的水溶性石膏泡沫。
实施例2～8
实施例2～8为7种不同配方的对比试验。这些配方与实施例1的配方一起列于表1中，均按实施例1的工艺步骤制备。
表1.金刚石复合材料重量百分比配方
Figure PCTCN2018125415-appb-000001
本发明提供的金刚石复合材料可用于平面硬脆材料的精磨，对硬脆材料进行平面加工时，将硬脆材料平面压贴在金刚石平板上，加水研磨。如图2所示，其中200-含有金刚石磨粒的水溶性石膏泡沫；201-气泡；202-含有金刚石磨粒的石膏壁；203-金刚石磨粒。金刚石复合泡沫磨块由大量气泡、粘结剂和金刚石磨粒构成。当金刚石复合泡沫磨块在接触到纯净水后会发生微溶，此时金刚石磨粒会被释放出来，与水形成研磨液，蜂窝芯材具有一定的机械支撑力，研磨时研磨液会爬到芯材壁的顶面上与被加工样品进行作用，同时微溶的磨块会产生轻微的凹陷，研磨产生的大颗粒会滚落到这些凹坑中，避免划伤样品。在这种结构中，水溶性金刚石复合泡沫磨块的损耗与蜂窝芯材的磨损速率同步，这样就避免了象铜盘那样经常性开槽。也无需额外滴加金刚石研磨液，提高了金刚石磨粒的利用效率。
以上实施例的说明只是用于帮助理解本发明的方法及其核心思想。应 当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以对本发明进行若干改进和修饰，这些改进和修饰也落入本发明权利要求的保护范围内。对这些实施例的多种修改对本领域的专业技术人员来说是显而易见的，本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下在其它实施例中实现。因此，本发明将不会被限制于本文所示的这些实施例，而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。

Claims (14)

  1. 一种金刚石复合材料，包括蜂窝芯材和填充于所述蜂窝芯材孔内的水溶性石膏泡沫，所述水溶性石膏泡沫包括以下重量百分比的组分：无机复合粘结剂30～80％、金刚石磨粒1～30％、滑石粉10～30％、水性胶黏剂0.5～15％、泡沫5～20％、玻璃纤维0.2～1％、聚羧酸减水剂0.3～1％、水8～50％，所述水溶性石膏泡沫各组分的重量百分比之和为100％。
  2. 根据权利要求1所述的金刚石复合材料，其特征在于，所述蜂窝芯材与水溶性石膏泡沫的重量比为0.2～0.05：1。
  3. 根据权利要求1所述的金刚石复合材料，其特征在于，所述金刚石磨粒的粒径为0.5～5μm。
  4. 根据权利要求1所述的金刚石复合材料，其特征在于，所述无机复合粘结剂包括半水石膏和硅灰，所述半水石膏和硅灰的质量比为90～97：1～10。
  5. 根据权利要求1所述的金刚石复合材料，其特征在于，所述硅灰的粒径为50～200nm。
  6. 根据权利要求1所述的金刚石复合材料，其特征在于，所述水性胶黏剂为丙烯酸乳液、聚乙烯醇水溶液、聚氨酯乳液或乙烯-醋酸乙烯酯乳液。
  7. 根据权利要求1所述的金刚石复合材料，其特征在于，所述蜂窝芯材的蜂窝形状为六角形，所述蜂窝芯材的蜂窝孔边长为3～10mm。
  8. 根据权利要求1或7所述的金刚石复合材料，其特征在于，所述蜂窝芯材的材质为铝或铜。
  9. 根据权利要求1所述的金刚石复合材料，其特征在于，所述泡沫由发泡剂溶液制备得到，所述发泡剂溶液包括发泡剂、水性胶黏剂和水。
  10. 根据权利要求1或9所述的金刚石复合材料，其特征在于，所述泡沫的密度为50～80kg/m 3。
  11. 权利要求1～10任意一项所述的金刚石复合材料的制备方法，包括以下步骤：
    将水和水性胶黏剂混合，得到水性胶黏剂溶液；
    将无机复合粘结剂、金刚石磨粒、滑石粉、聚羧酸减水剂和玻璃纤维 混合，得到预混料；
    将水性胶黏剂溶液和预混料混合，得到浆料；
    将浆料与泡沫混合，得到泡沫金刚石复合浆料；
    将泡沫金刚石复合浆料倒入蜂窝芯材的孔洞中，经烘烤，得到金刚石复合材料。
  12. 根据权利要求11所述的制备方法，其特征在于，所述烘烤的温度为100～120℃，所述烘烤的时间为3～5h。
  13. 权利要求1～10任意一项所述金刚石复合材料或权利要求11～12任意一项所述制备方法制得的金刚石复合材料在精磨领域中的应用。
  14. 根据权利要求13所述的应用，其特征在于，所述金刚石复合材料经水磨床修平后，得到精磨平板，用于精磨领域。
PCT/CN2018/125415 2018-07-05 2018-12-29 一种金刚石复合材料及其制备方法和应用 WO2020007015A1 (zh)

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