Coated abrasive materials and method of manufacture

• US 8,118,896 B2
• Filed: 09/21/2005
• Issued: 02/21/2012
• Est. Priority Date: 09/23/2004
• Status: Active Grant

• Current Assignee: Element Six (Holdings) Ltd. (Anglo American PLC)
• Original Assignee: Element Six (Holdings) Ltd. (Anglo American PLC)
• Inventors: Can, Antionette, Mochubele, Anna Emela, Davies, Geoffrey John, Myburgh, Johannes Lodewikus
• Primary Examiner(s): Hailey, Patricia L
• Application Number:
  US11/578,861
• Publication Number:
  US 20080168717A1
• Time in Patent Office: 2,344 Days
• Field of Search: 512/95, 513/07, 513/09, 427/212, 427/213.31, 427/215, 427226-229, 427/331, 977/773
• US Class Current: 51/295
• CPC Class Codes: C01P 2002/72 by d-values or two theta-values, e.g. as X-ray diagram
• CPC Class Codes: C01P 2004/03 obtained by SEM
• CPC Class Codes: C01P 2004/84 one phase coated with the other
• CPC Class Codes: C01P 2006/12 Surface area
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 2235/3225 Yttrium oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3232 Titanium oxides or titanates, e.g. rutile or anatase
• CPC Class Codes: C04B 2235/3244 Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3258 Tungsten oxides, tungstates, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3418 Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
• CPC Class Codes: C04B 2235/386 Boron nitrides
• CPC Class Codes: C04B 2235/427 Diamond
• CPC Class Codes: C04B 2235/441 Alkoxides, e.g. methoxide, tert-butoxide
• CPC Class Codes: C04B 2235/46 Gases other than oxygen used as reactant, e.g. nitrogen used to make a nitride phase
• CPC Class Codes: C04B 2235/465 Ammonia
• CPC Class Codes: C04B 2235/5409 expressed by specific surface values
• CPC Class Codes: C04B 2235/5427 millimeter or submillimeter sized, i.e. larger than 0,1 mm
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/5445 submicron sized, i.e. from 0,1 to 1 micron
• CPC Class Codes: C04B 2235/5472 Bimodal, multi-modal or multi-fraction
• CPC Class Codes: C04B 35/624 : Sol-gel processing
• CPC Class Codes: C04B 35/62635 : Mixing details
• CPC Class Codes: C04B 35/6264 : Mixing media, e.g. organic solvents
• CPC Class Codes: C04B 35/6265 : involving reduction or oxidation
• CPC Class Codes: C04B 35/62655 : Drying, e.g. freeze-drying, spray-drying, microwave or supercritical drying
• CPC Class Codes: C04B 35/62675 : characterised by the treatment temperature
• CPC Class Codes: C04B 35/6268 : characterised by the applied pressure or type of atmosphere, e.g. in vacuum, hydrogen or a specific oxygen pressure
• CPC Class Codes: C04B 35/62807 : Silica or silicates
• CPC Class Codes: C04B 35/62813 : Alumina or aluminates
• CPC Class Codes: C04B 35/62818 : Refractory metal oxides
• CPC Class Codes: C04B 35/62821 : Titanium oxide
• CPC Class Codes: C04B 35/62823 : Zirconium or hafnium oxide
• CPC Class Codes: C04B 35/62831 : Carbides
• CPC Class Codes: C04B 35/62836 : Nitrides
• CPC Class Codes: C04B 35/62886 : by wet chemical techniques
• CPC Class Codes: C04B 35/62892 : with a coating layer consisting of particles
• CPC Class Codes: C04B 35/62897 : Coatings characterised by their thickness
• CPC Class Codes: C09C 3/063 : Coating
• CPC Class Codes: C09K 3/1445 : the coating consisting exclusively of metals
• CPC Class Codes: Y10S 977/773 : Nanoparticle, i.e. structure having three dimensions of 100 nm or less

Abstract

A method of coating ultrahard abrasive particles having vitreophilic surfaces, or treated to render their surfaces vitreophilic, are coated with an oxide precursor material, which is then heat treated to dry and purify the coats. The heat treated, coated ultrahard abrasive particles are further treated to convert the coats to an oxide, nitride, carbide, oxynitride, oxycarbide, or carbonitride thereof, or an elemental form thereof, or a glass.

Claims

1. A method of coating ultrahard abrasive particles, comprising:

providing a plurality of ultrahard abrasive particles selected from the group consisting of diamond, cubic boron nitride, and a combination thereof, wherein the ultrahard abrasive particles have vitreophilic surfaces which form chemical bonds with oxides;

coating the ultrahard abrasive particles with an oxide precursor material selected from the group consisting of an amorphous or nano-crystalline oxide, a hydroxide, and an oxo-hydroxide; and

heat treating the coated ultrahard abrasive particles to dry and purify the coats.

7. The method according to claim 1, wherein the ultrahard abrasive particles are treated in a surface treatment process in order to render the surfaces thereof vitreophilic.

8. The method according to claim 1, wherein the ultrahard abrasive particles are suspended in a liquid medium, and wherein a chemical reagent is introduced to form oxide precursor entities that bond to the surfaces of the respective particles and build up into coats on the particles.

9. The method according to claim 8, wherein the chemical reagent is at least one alkoxide or solution of the alkoxide(s) in an alcohol.

10. The method according to claim 9, wherein the alkoxide is an alkoxide of an element selected from the group consisting of aluminium, titanium, silicon, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, hafnium, and yttrium.

11. The method according to claim 8, wherein the alcohol has the same alkyl group as the alkoxide(s).

12. The method according to claim 8, wherein the liquid medium is an aliquot of water and alcohol.

13. The method according to claim 12, wherein two or more alkoxides are introduced into the liquid medium, wherein the two or more alkoxides are of elements selected from the group consisting of aluminium, titanium, silicon, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, hafnium, and yttrium.

14. The method according to claim 8, wherein the chemical reagent is an aliquot of water and alcohol.

15. The method according to claim 8, wherein the liquid medium is at least one alkoxide or solution of the alkoxide(s) in an alcohol.

16. The method according to claim 15, wherein the liquid medium comprises two or more alkoxides in an alcohol solution, wherein the two or more alkoxides are of elements selected from the group consisting of aluminium, titanium, silicon, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, hafnium, and yttrium.

17. The method according to claim. 15, wherein the alkoxide is an alkoxide of an element selected from the group consisting of aluminum, titanium, silicon, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, hafnium, and yttrium.

18. The method according to claim 8, wherein the chemical reagent or liquid medium is a solution of a mixed alkoxide compound or complex incorporating two or more elements selected from the group consisting of aluminium, titanium, silicon, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, hafnium, and yttrium.

19. The method according to claim 1, wherein the oxide precursor material coats are substantially micro-porous.

20. The method according to claim 9, wherein the coated ultrahard abrasive particles are subjected to temperature controlled heating in air, vacuum, or inert gas to remove volatiles and unwanted chemical species attached to the high surface area of the micro-porous, amorphous coats.

21. The method according to claim 20, wherein the coated ultrahard abrasive particles are subjected to further heat treatment or calcination to crystallize the coats to form fine grained or nano-size grained oxide ceramics.

22. The method according to claim 20, wherein the coated ultrahard abrasive particles are subjected to further heat treatment to vitrify the coats to form glasses.

23. The method according to claim 20, wherein the oxide coats are reduced by hydrogen and are converted into micro or nano-grain sized elements or metals.

24. The method according to claim 19, wherein the coated ultrahard abrasive particles are subjected to temperature controlled reactions in reactive gases to convert the coat materials into non-oxide ceramics or glasses.

25. The method according to claim 24, wherein nitrides are formed by reacting the coats with ammonia gas.

26. The method according to claim 24, wherein carbides are formed by reacting the coats in mixtures of carbonaceous gases and hydrogen.

27. The method according to claim 26, wherein the carbides are formed by reacting the coats in a mixture of methane or ethane and hydrogen.

28. The method according to claim 19, wherein the coated ultrahard abrasive particles are subjected to temperature controlled reactions in reactive gases to convert the coat materials into oxynitride or oxycarbide ceramics or glasses.

2. The method according to claim I, wherein the coated ultrahard abrasive particles are treated to convert the oxide precursor material to an oxide, nitride, carbide, oxynitride, oxycarbide, or carbonitride of the oxide precursor material, or an elemental form of the oxide precursor material, or a combination thereof.

3. The method according to claim 2, wherein the converted oxide precursor material is selected from the group consisting of micron, sub-micron, or nano-grain sized oxides, nitrides, carbides, oxynitrides, oxycarbides or carbonitrides of the oxide precursor materials, elemental precursor materials, and a combination thereof.

4. The method according to claim 2, wherein the converted oxide precursor material is selected from the group consisting of oxides, nitrides, carbides, oxynitrides, oxycarbides and carbonitrides of aluminium, titanium, silicon, vanadium, zirconium, niobium, hafnium, tantalum, chromium, molybdenum, and tungsten, the elemental forms of molybdenum or tungsten, and a combination thereof.

5. The method according to claim 2, wherein the converted oxide precursor material is selected from the group consisting of a nano-grain sized compound of aluminium, titanium, silicon, vanadium, zirconium, niobium, hafnium, tantalum, chromium, molybdenum, or tungsten, and a combination thereof.

6. The method according to claim 2, wherein the converted oxide precursor material is a nano-grain sized elemental form of tungsten, molybdenum, or a combination or alloy thereof.

29. A coated ultrahard abrasive particulate material comprising diamond or cubic boron nitride particles of sub-micron or nano size with coats selected from the group consisting of nitrides of titanium, vanadium, niobium, tantalum, molybdenum, or tungsten, and carbides of vanadium, niobium, tantalum, molybdenum, or tungsten.

30. The coated ultrahard abrasive particulate material according to claim 29, wherein the coat thicknesses are less than 2 microns.

31. A coated ultrahard abrasive particulate material comprising diamond or cubic boron nitride particles of sub-micron or nano size with coats selected from the group consisting of anatase phase titania, rutile phase titania, tetragonal zirconia, monoclinic zirconia, zirconia stabilized with yttria or magnesia, the transient structures and alpha phase of alumina, and the oxides of vanadium, niobium, tantalum, hafnium, molybdenum, and tungsten.

32. The coated ultrahard abrasive particle material according to claim 31, wherein the coat thicknesses are less than 2 microns.

33. A coated ultrahard abrasive particulate material comprising diamond or cubic boron nitride particles of sub-micron or nano size coated with silica glass.

34. The coated ultrahard abrasive particle material according to claim 33, wherein the coat thicknesses are less than 2 microns.

35. A coated ultrahard abrasive particulate material comprising diamond or cubic boron nitride particles of sub-micron or nano size with coats selected from the group consisting of oxides of titanium, vanadium, niobium, tantalum, aluminium, silicon, molybdenum, or tungsten, nitrides or carbides of titanium, vanadium, niobium, tantalum, or molybdenum, and molybdenum or tungsten metal.

36. The coated ultrahard abrasive particle material according to claim 35, wherein the coat thicknesses are less than 2 microns.