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US 7,168,267 B2Granted
Method of making amorphous materials and ceramics
Assignee3M Innovative Properties Company
InventorsAnatoly Z. Rosenflanz, Ahmet Celikkaya, Thomas J. Anderson
Life of this patent
Estimating the term…
Abstract
Methods of making amorphous material and ceramic materials. Embodiments of the invention can be used to make abrasive particles. The abrasive particles can be incorporated into a variety of abrasive articles, including bonded abrasives, coated abrasives, nonwoven abrasives, and abrasive brushes.
Claims62
A method for making amorphous material comprising at least 35 percent by weight Al2O3, based on the total weight of the amorphous material, the method comprising:
- melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises Al2O3;
- and
- cooling the melt to provide the amorphous material.
7 more elements
A method for making amorphous material comprising at least 35 percent by weight Al2O3, based on the total weight of the amorphous material, the method comprising:
- melting
- (a) particulate, metallic material comprising Al or an alloy thereof;
- and
- (b) at least one of:
- (i) an Al oxide and a source of metal oxide other than the Al oxide;
- or
- (ii) a complex metal oxide comprising Al oxide
- to provide a melt, wherein at least a portion of Al in the melt is oxidized;
- and
- cooling the melt to provide the amorphous material.
7 more elements
A method for making ceramic comprising glass, the glass comprising at least 35 percent by weight Al2O3, based on the weight of the glass, the method comprising:
- melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises Al2O3;
- and
- cooling the melt to provide the ceramic, wherein at least a portion of the melt provides the glass.
7 more elements
A method for making ceramic comprising glass, the glass comprising at least 35 percent by weight Al2O3, based on the total weight of the glass, the method comprising:
- melting
- (a) particulate, metallic material comprising Al or an alloy thereof;
- and
- (b) at least one of:
- (i) an Al oxide and a source of metal oxide other than the Al oxide;
- or
- (ii) a complex metal oxide comprising Al
- to provide a melt, wherein at least a portion of Al in the melt is oxidized;
- and
- cooling the melt to provide the ceramic, wherein at least a portion of the melt provides the glass.
7 more elements
A method for making an article comprising glass comprising Al2O3, the method comprising:
- melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide,
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al2O3;
- cooling the melt to provide glass particles, the glass having a Tg;
- heating the glass particles above the Tg such that the glass particles coalesce to form a shape;
- and
- cooling the shape to provide the article.
9 more elements
A method for making an article comprising glass, the method comprising:
- melting
- (a) particulate, metallic material comprising Al or an alloy thereof;
- and
- (b) at least one of:
- (i) an Al oxide and a source of metal oxide other than the Al oxide;
- or
- (ii) a complex metal oxide comprising Al
- to provide a melt, wherein at least a portion of Al in the melt is oxidized;
- cooling the melt to provide glass particles, the glass having a Tg;
- heating the glass particles above the Tg such that the glass particles coalesce to form a shape;
- and
- cooling the shape to provide the article.
9 more elements
A method for making an article comprising glass comprising Al2O3, the method comprising:
- melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide,
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al2O3;
- cooling the melt to provide glass beads, the glass having a Tg;
- crushing the glass beads to provide glass particles;
- heating the glass particles above the Tg such that the glass particles coalesce to form a shape;
- and
- cooling the shape to provide the article.
10 more elements
A method for making an article comprising glass, the method comprising:
- melting
- (a) particulate, metallic material comprising Al or an alloy thereof;
- and
- (b) at least one of:
- (i) an Al oxide and a source of metal oxide other than the Al oxide;
- or
- (ii) a complex metal oxide comprising Al
- to provide a melt, wherein at least a portion of Al in the melt is oxidized;
- cooling the melt to provide glass beads, the glass having a Tg;
- crushing the glass beads to provide glass particles;
- heating the glass particles above the Tg such that the glass particles coalesce to form a shape;
- and
- cooling the shape to provide the article.
10 more elements
A method for making glass-ceramic comprising at least 35 percent by weight Al2O3, based on the total weight of the glass-ceramic the method comprising:
- melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide,
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al2O3;
- cooling the melt to provide amorphous material;
- and
- heat-treating the amorphous material to convert at least a portion of the amorphous material to the glass-ceramic.
8 more elements
A method for making glass-ceramic comprising at least 35 percent by weight Al2O3, based on the total weight of the glass-ceramic the method comprising:
- melting
- (a) particulate, metallic material comprising Al or an alloy thereof;
- and
- (b) at least one of:
- (i) an Al oxide and a source of metal oxide other than the Al oxide;
- or
- (ii) a complex metal oxide comprising Al oxide
- to provide a melt, wherein at least a portion of Al in the melt is oxidized;
- cooling the melt to provide amorphous material;
- and
- heat-treating the amorphous material to at least a portion of the amorphous material to the glass-ceramic.
8 more elements
A method for making a glass-ceramic article comprising Al2O3, the method comprising:
- melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide,
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al2O3;
- cooling the melt to provide glass;
- crushing glass to provide glass particles, the glass having a Tg;
- heating the glass particles above the Tg such that the glass particles coalesce to form a shape;
- cooling the shape to provide a glass article;
- and
- heat-treating the glass article to provide a glass-ceramic article.
11 more elements
A method for making a glass-ceramic article, the method comprising:
- melting
- (a) particulate, metallic material comprising Al or an alloy thereof;
- and
- (b) at least one of:
- (i) an Al oxide and a source of metal oxide other than the Al oxide;
- or
- (ii) a complex metal oxide comprising Al
- to provide a melt, wherein at least a portion of Al in the melt is oxidized;
- cooling the melt to provide glass;
- crushing glass to provide glass particles, the glass having a Tg;
- heating the glass particles above the Tg such that the glass particles coalesce to form a shape;
- cooling the shape to provide a glass article;
- and
- heat-treating the glass article to provide a glass-ceramic article.
11 more elements
A method for making abrasive particles comprising Al2O3, the method comprising:
- melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide,
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al2O3;
- cooling the melt to provide amorphous material;
- crushing the amorphous material to provide amorphous particles;
- and
- heat-treating the particles such that at least a portion of the amorphous material is converted to glass-ceramic to provide abrasive particles comprising glass-ceramic, the glass-ceramic comprising at least 35 percent by weight Al2O3, based on the total weight of the glass-ceramic.
9 more elements
A method for making abrasive particles, the method comprising:
- melting
- (a) particulate, metallic material comprising Al or an alloy thereof:
- and
- (b) at least one of:
- (i) an Al oxide and a source of metal oxide other than the Al oxide;
- or
- (ii) a complex metal oxide comprising Al oxide
- to provide a melt, wherein at least a portion of Al in the melt is oxidized;
- cooling the melt to provide amorphous material;
- crushing the amorphous material to provide amorphous particles;
- and
- heat-treating the particles such that at least a portion of the amorphous material is converted to glass-ceramic to provide abrasive particles comprising glass-ceramic, the glass ceramic comprising at least 35 percent by weight Al2O3, based on the total weight of the glass-ceramic.
9 more elements
A method for making abrasive particles comprising Al2O3, the method comprising:
- melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide,
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al2O3;
- converting the melt into particles comprising amorphous material, wherein the converting includes cooling the melt to provide the amorphous material;
- and
- heat-treating the amorphous material to convert at least a portion of the amorphous material to glass-ceramic to provide abrasive particles comprising glass-ceramic, the glass-ceramic comprising at least 35 percent by weight Al2O3, based on the total weight of the glass-ceramic.
8 more elements
A method for making abrasive particles comprising Al2O3, the method comprising:
- melting
- (a) particulate, metallic material comprising Al or an alloy thereof;
- and
- (b) at least one of:
- (i) an Al oxide and a source of metal oxide other than the Al oxide;
- or
- (ii) a complex metal oxide comprising Al oxide
- to provide a melt, wherein at least a portion of Al in the melt is oxidized;
- converting the melt into particles comprising amorphous material, wherein the converting includes cooling the melt to provide the amorphous material;
- and
- heat-treating the amorphous material to convert at least a portion of the amorphous material to glass-ceramics and provide abrasive particles comprising glass-ceramic, the glass-ceramic comprising at least 35 percent by weight Al2O3, based on the total weight of the glass-ceramic.
8 more elements
A method of making amorphous material comprising Al2O3, the method comprising:
- flame melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises Al2O3;
- and
- cooling the melt to provide the amorphous material.
7 more elements
A method of making ceramic comprising glass comprising Al2O3, the method comprising:
- flame melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises Al2O3;
- and
- cooling the melt to provide the ceramic, wherein at least a portion of the melt provides the glass.
7 more elements
A method of making glass-ceramic comprising glass comprising Al2O3, the method comprising:
- melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises M oxide comprises Al2O3;
- and
- cooling the melt to provide amorphous material;
- and
- heat-treating the amorphous material to convert at least a portion of the amorphous material to glass-ceramic.
9 more elements
A method for making particles comprising Al2O3,the method comprising:
- flame melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises M oxide comprises Al2O3;
- cooling the melt to provide amorphous material;
- crushing the amorphous material to provide amorphous particles;
- and
- heat-treating the particles such that at a portion of the amorphous material is converted to glass-ceramic to provide abrasive particles comprising glass-ceramic.
9 more elements
A method for making abrasive particles comprising Al2O3, the method comprising:
- flame melting
- (a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof;
- and
- (b) at least one of:
- (i) a M oxide and a source of metal oxide other than the M oxide;
- or
- (ii) a complex metal oxide comprising M oxide
- to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al2O3;
- converting the melt into particles comprising amorphous material, wherein the converting includes cooling the melt to provide the amorphous material;
- and
- heat-treating the amorphous material to convert at least a portion of the amorphous material to glass-ceramic and provide abrasive particles comprising the glass-ceramic.
8 more elements
Dependencies are inferred from the claim text.