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ES2662521T3 - Método para fabricar esquirlas abrasivas, partículas abrasivas conformadas con una abertura o partículas abrasivas en forma de plato - Google Patents

Método para fabricar esquirlas abrasivas, partículas abrasivas conformadas con una abertura o partículas abrasivas en forma de plato Download PDF

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Publication number
ES2662521T3
ES2662521T3 ES09836623.0T ES09836623T ES2662521T3 ES 2662521 T3 ES2662521 T3 ES 2662521T3 ES 09836623 T ES09836623 T ES 09836623T ES 2662521 T3 ES2662521 T3 ES 2662521T3
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Prior art keywords
abrasive particles
sol
gel
cavities
abrasive
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ES09836623.0T
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English (en)
Inventor
Scott R. Culler
Dwight D. Erickson
Negus B. Adefris
John T. Boden
John D. Haas
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3M Innovative Properties Co
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3M Innovative Properties Co
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Classifications

    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
    • B01J2/22—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by pressing in moulds or between rollers
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1409—Abrasive particles per se
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1409—Abrasive particles per se
    • C09K3/1427—Abrasive particles per se obtained by division of a mass agglomerated by melting, at least partially, e.g. with a binder

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

Un método que comprende: proporcionar un molde que tiene una pluralidad de cavidades, comprendiendo la pluralidad de cavidades superficies poliméricas; llenar la pluralidad de cavidades con un sol-gel, comprendiendo el sol-gel partículas que se pueden convertir en alfa-alúmina en un líquido, comprendiendo el líquido un componente volátil; y eliminar al menos una parte del componente volátil del sol-gel mientras que el sol-gel se encuentra en la pluralidad de cavidades y controlar la reología del sol-gel en el molde en función de la tensión de fluencia del sol-gel, la presencia o ausencia de agente de liberación del molde y la velocidad de secado, formando de este modo una pluralidad de partículas abrasivas conformadas precursoras que tienen un tipo seleccionado del grupo que consiste en esquirlas abrasivas, partículas abrasivas conformadas con una abertura, y partículas abrasivas con forma de plato.

Description

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y el ventilador ajustado a 2000 rpm, para soplar aire sobre la superficie del revestimiento, hasta que la temperatura de la superficie del revestimiento alcanzó 21 grados centígrados. Las partículas secas conformadas resultantes uniformemente tenían aberturas centrales 122 en las mismas, como se muestra en la Fig. 8. Estas partículas abrasivas precursoras se pueden calcinar para producir las partículas 120 abrasivas conformadas con una abertura 122.
Partículas abrasivas con forma de plato
En una realización, se fabricó una muestra de sol-gel de bohemita usando la siguiente receta: óxido de aluminio monohidratado en polvo (4824 partes) que tiene la designación comercial “DISPERAL” se dispersó mezclando con alta cizalla una solución que contiene agua (7087 partes) y ácido nítrico acuoso al 70 % (212 partes) durante 13 minutos. El sol-gel resultante se envejeció durante 1 hora antes del revestimiento. El sol-gel se forzó al interior de la herramienta de producción que tiene cavidades del molde de forma triangular de 0,71 mm (28 milipulgadas) de profundidad y 2,8 mm (110 milipulgadas) por cada lado. El ángulo de incidencia α entre la pared lateral y el fondo del molde era de 98 grados. El sol-gel se forzó al interior de las cavidades con una estación de revestimiento provista de matriz ranurada al vacío, de tal forma que todas las aberturas de la herramienta de producción quedaron completamente llenas. Se usó un agente de liberación del molde, aceite de cacahuete al 2 % en agua, sobre la herramienta de producción, para aplicar aproximadamente aproximadamente 1 g/m2 (1 mg/pulg.2). La herramienta de producción revestida con sol-gel se hizo pasar a través de un horno de aire de convección de 8,2 metros (27 pies) a 0,05 metros por segundo (10 pies por minuto) ajustado a 135 grados centígrados con un 60 % de la velocidad del aire en la sección de la zona 1 de 4,11 metros (13,5 pies) y a 121 grados centígrados con un 40 % de la velocidad del aire en la sección de la zona 2 de 4,11 metros (13,5 pies). Las partículas abrasivas precursoras con forma de plato se extrajeron de la herramienta de producción haciéndola pasar por una punta ultrasónica. Las partículas abrasivas precursoras con forma de plato se calcinaron a aproximadamente 650 grados centígrados y a continuación se saturaron con una solución mixta de nitrato con la siguiente concentración (indicada en forma de óxido): 1,8 % de cada uno de MgO, Y2O3, Nd2O3 y La2O3. El exceso de solución de nitrato se eliminó, y las partículas abrasivas precursoras con forma de plato saturadas se dejaron secar, después de lo cual, las partículas se volvieron a calcinar a 650 grados centígrados y se sinterizaron a aproximadamente 1400 grados centígrados, completando de este modo la formación de partículas abrasivas con forma de plato. Tanto la calcinación como la sinterización se llevaron a cabo usando hornos de tubo giratorio.
Opcionalmente, la quinta etapa de proceso implica extraer la pluralidad de partículas abrasivas conformadas precursoras de las cavidades del molde. La pluralidad de partículas abrasivas conformadas precursoras se puede extraer de las cavidades aplicando los siguientes procesos, solos o combinados, sobre el molde: gravedad, vibración, vibración ultrasónica, vacío, o aire comprimido para extraer las partículas del molde. Si se fabrican partículas abrasivas conformadas precursoras fracturadas, las partículas una vez extraídas de las cavidades se pueden volver a montar como piezas de un rompecabezas para que tengan aproximadamente la misma forma de las cavidades del molde donde se han formado.
Las partículas abrasivas conformadas precursoras se pueden secar adicionalmente fuera del molde. Si la dispersión abrasiva se seca hasta el nivel deseado en el molde, esta etapa de secado adicional no es necesaria. Sin embargo, en algunos casos, puede ser rentable emplear esta etapa de secado adicional para minimizar el tiempo durante el que la dispersión abrasiva permanece en el molde. Normalmente, las partículas abrasivas conformadas precursoras estarán secas durante 10 a 480 minutos, o de 120 a 400 minutos, a una temperatura de 50 grados C a 160 grados 25 C, o de 120 grados C a 150 grados C.
Opcionalmente, la sexta etapa de proceso implica calcinar la pluralidad de partículas abrasivas conformadas precursoras. Durante la calcinación se eliminan prácticamente todos los materiales volátiles, y los diferentes componentes que están presentes en la dispersión abrasiva se transforman en óxidos de metal. Las partículas abrasivas conformadas precursoras por lo general se calientan a una temperatura de desde 400 grados C a 800 grados C, y se mantiene en este intervalo de temperatura hasta que el agua libre y más del 90 por ciento en peso de cualquier material volátil se eliminan. En una etapa opcional, se puede desear introducir el aditivo modificante mediante un proceso de impregnación. Se puede introducir una sal soluble en agua mediante impregnación en el interior de los poros de las partículas abrasivas conformadas precursoras calcinadas. Entonces, la pluralidad de partículas abrasivas conformadas precursoras se vuelven a precalcinar. Esta opción se describe detalladamente en la solicitud de patente europea n.°293.163.
Opcionalmente, la séptima etapa de proceso implica la sinterización de la pluralidad de partículas abrasivas conformadas precursoras calcinadas para formar las partículas abrasivas conformadas tales como las esquirlas abrasivas 21, partículas 120 abrasivas conformadas con aberturas 122, o partículas 220 abrasivas con forma de plato. Antes de la sinterización, las partículas abrasivas conformadas precursoras calcinadas no están completamente compactadas y, por tanto, carecen de la dureza deseada para su uso como partículas abrasivas. La sinterización se lleva a cabo mediante el calentamiento de las partículas abrasivas conformadas precursoras calcinadas a una temperatura comprendida de desde 1000 grados C a 1650 grados C, y manteniéndolas en dicho intervalo de temperatura hasta que prácticamente toda la alfa-alúmina monohidratada (o equivalente) se haya convertido en alfa-alúmina y la porosidad se haya reducido a menos del 15 por ciento en volumen. El tiempo durante el cual las partículas abrasivas conformadas precursoras calcinadas deben estar expuestas a la temperatura de sinterización para conseguir este nivel de conversión depende de varios factores, pero normalmente será entre cinco segundos y 48 horas, de forma típica. En otra realización, la duración de la etapa de sinterización está comprendida entre un minuto y 90 minutos. Después de la sinterización, las partículas abrasivas pueden tener una dureza Vickers de 10 GPa, 16 GPa, 18 GPa, 20 GPa, o superior.
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Claims (1)

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ES09836623.0T 2008-12-17 2009-11-24 Método para fabricar esquirlas abrasivas, partículas abrasivas conformadas con una abertura o partículas abrasivas en forma de plato Active ES2662521T3 (es)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US12/337,001 US8123828B2 (en) 2007-12-27 2008-12-17 Method of making abrasive shards, shaped abrasive particles with an opening, or dish-shaped abrasive particles
US337001 2008-12-17
PCT/US2009/065640 WO2010077495A2 (en) 2008-12-17 2009-11-24 Method of making abrasive shards, shaped abrasive particles with an opening, or dish-shaped abrasive particles

Publications (1)

Publication Number Publication Date
ES2662521T3 true ES2662521T3 (es) 2018-04-06

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Country Status (9)

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US (1) US8123828B2 (es)
EP (4) EP3375837B1 (es)
JP (1) JP5690279B2 (es)
KR (1) KR101741850B1 (es)
CN (1) CN102281992B (es)
BR (1) BRPI0922317B1 (es)
ES (1) ES2662521T3 (es)
PL (1) PL2373458T3 (es)
WO (1) WO2010077495A2 (es)

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WO2010077495A2 (en) 2010-07-08
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US8123828B2 (en) 2012-02-28
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US20090165394A1 (en) 2009-07-02
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