U.S. patent application number 10/154792 was filed with the patent office on 2002-11-28 for polishing compound for sheet metal coating.
Invention is credited to Akiyama, Motoharu, Hokkirigawa, Kazuo, Yoshimura, Noriyuki.
Application Number | 20020174605 10/154792 |
Document ID | / |
Family ID | 19001370 |
Filed Date | 2002-11-28 |
United States Patent
Application |
20020174605 |
Kind Code |
A1 |
Hokkirigawa, Kazuo ; et
al. |
November 28, 2002 |
POLISHING COMPOUND FOR SHEET METAL COATING
Abstract
There is provided a polishing compound for sheet metal coating
comprising an polishing material and a surfactant in which a RB
ceramics and/or CRB ceramics powder is used at least as a part of
the polishing material, thereby shortening a stain removing process
of a coated surface in reparative sheet metal coating work of cars,
etc. without conducting a washing process thereafter.
Inventors: |
Hokkirigawa, Kazuo;
(Yonezawa-shi, JP) ; Akiyama, Motoharu;
(Nagano-ken, JP) ; Yoshimura, Noriyuki;
(Nagano-ken, JP) |
Correspondence
Address: |
FLYNN, THIEL, BOUTELL & TANIS, P.C.
2026 Rambling Road
Kalamazoo
MI
49008-1699
US
|
Family ID: |
19001370 |
Appl. No.: |
10/154792 |
Filed: |
May 24, 2002 |
Current U.S.
Class: |
51/303 ; 51/307;
51/308; 51/309 |
Current CPC
Class: |
C09K 3/1409 20130101;
C09K 3/1463 20130101 |
Class at
Publication: |
51/303 ; 51/307;
51/308; 51/309 |
International
Class: |
C09K 003/14; C09C
001/68 |
Foreign Application Data
Date |
Code |
Application Number |
May 25, 2001 |
JP |
2001-157523 |
Claims
What is claimed is:
1. A polishing compound for sheet metal coating comprising an
polishing material and a detergent in which a RB ceramics and/or
CRB ceramics powder is used at least as a part of the polishing
material.
2. A polishing compound for sheet metal coating claimed in claim 1
in which an polishing material is one or not less than two kinds of
powders selected from a group consisting of diatomaceous earth,
pumice powder, alumina, silica, calcium oxide, silicon nitride,
silicon carbide, cesium oxide, synthetic or natural diamond, metal
silicide, tungsten oxide, titanium nitride and titanium oxide.
3. A polishing compound for sheet metal coating claimed in claim 2
in which an polishing material comprises a RB ceramics and/or CRB
ceramics powder and one or not less than two kinds of powders
selected from a group consisting of silica, calcium oxide, aluminum
oxide, silicon nitride, silicon carbide, cesium oxide, synthetic or
natural diamond, metal silicide, tungsten oxide, titanium nitride
and titanium oxide, in a weight ratio of 30 to 90:70 to 10,
respectively.
4. A polishing compound for sheet metal coating claimed in any one
of claims 1 to 3 in which an average particle diameter of RB
ceramics and/or CRB ceramics powder is 1 to 1,000 .mu.m.
5. A polishing compound for sheet metal coating claimed in any one
of claims 1 to 4 in which a detergent is one or not less than two
surfactants selected from a group consisting of an anionic-,
amphoteric surfactant, nonionic surfactant and cationic
surfactant.
6. A polishing compound for sheet metal coating claimed in any one
of claims 1 to 5 in which an polishing material and a detergent are
solidified with a binder.
7. A polishing compound for sheet metal coating claimed in claim 6
in which a binder is a water soluble polymer.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a polishing compound for sheet
metal coating and more particularly relates to a polishing compound
for sheet metal coating for removing stains on a coated surface and
simultaneously washing the surface in reparative sheet metal
coating work of cars, etc. and other similar operation.
BACKGROUND OF THE INVENTION
[0002] Conventional reparative sheet metal coating work of cars,
etc. is carried out by removing stains with polishing materials
such as polishing grains, paper, etc. and then washing and
degreasing a coated surface by means of toweling, cotton cloth and
other rags saturated with a degreasing agent, followed by face
coating.
[0003] However, it has been imperfect and taken a long time for
these conventional polishing materials to abrade the surface and
sometimes difficult to wash out wax or oily dirt from hands
completely, although stains of ordinary dirt or dust can be
removed.
[0004] Such wax or oily dirt from hands still sticks on the coated
surface even after a stain removing process with conventional
polishing materials and thus should be washed out additionally.
[0005] Inferiority in adhesion, scaling, peeling, blister and the
like would be resulted in after coating, if the above mentioned
additional wash-out process is neglected. This is the reason why
the conventional stain removing work takes a long time including
the indispensable process to wash out and degrease the coated
surface with a degreasing agent after the polishing process is
finished, which causes a problem of lowering efficiency in the
reparative sheet metal coating work.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is an object of the present invention to
provide a polishing compound for sheet metal coating in reparative
sheet metal coating work of cars, etc., which shortens a stain
removing process of a coated surface without conducting a wash-out
process thereafter.
[0007] The inventors have eagerly investigated and found that the
above mentioned problem can be solved by using RB ceramics and/or
CRB ceramics at least partially as an polishing material for a
polishing compound for sheet metal coating and further formulating
the ceramics in a detergent. The present invention has been
developed on the basis of this fact.
PREFERRED EMBDIMENTS OF THE INVENTION
[0008] RB ceramics used in the present powder detergent is a powder
of RB ceramics or CRB ceramics formed by grinding these ceramics to
particles of 1 to 1000 .mu.m.
[0009] Each material of RB ceramics and CRB ceramics used in the
present invention is prepared by the following manner.
[0010] As is known, Dr. Kazuo Hokkirigawa, the first inventor of
the present invention, proposed an idea to obtain a porous carbon
material by the use of rice bran which is by-produced 0.9 million
ton/year in Japan or 33 million ton/year in the world (see, Kinou
Zairyou, Vol. 17, No. 5, pp. 24 to 28, May 1997).
[0011] The above mentioned literature describes a method for
preparing a carbon material or so-called RB ceramics by mixing and
kneading a defatted product of rice bran and a thermosetting resin,
press-molding the mixture to form a molded material, drying and
then baking the dried material in an atmosphere of inert gas.
[0012] Defatted rice bran used in the present invention is not
limited to a specific species of rice and may either be a product
of Japan or foreign countries.
[0013] A thermosetting resin used herein may also be any resin
which can be thermally set and typically includes phenol-,
diarylphthalate-, unsaturated polyester-, epoxy-, polyimide- and
triazine resins, although a phenol resin is preferably used.
[0014] A thermoplastic resin such as polyamide may also be used
together without departing from a scope of the present
invention.
[0015] A mixing ratio of the defatted rice bran to the
thermosetting resin is in the range of 50 to 90:50 to 10 and
preferably 70 to 80:30 to 20 in by weight.
[0016] According to the above mentioned method, difference in ratio
of shrinkage between the press-molded material and the finally
molded material which is baked in an atmosphere of inert gas
reached almost 25%. Such a difference made it substantially
difficult to form a precisely molded material, but has been finally
improved as a result of development of CRB ceramics.
[0017] CRB ceramics used in the present invention is an improved
material of RB ceramics obtained from defatted rice bran and a
thermosetting resin. The defatted product of rice bran and the
thermosetting resin are mixed and kneaded, primarily baked in an
inert gas at 700 to 1,000.degree. C. and ground to form a
carbonated powder of about 60 mesh or less. The powder is then
mixed and kneaded with the thermosetting resin , press-molded at a
pressure of 20 to 30 Mpa and heat-treated again in an atmosphere of
inert gas at 100 to 1,100.degree. C. to form CRB ceramics as a
black resin or porous product.
[0018] General properties of RB ceramics and CRB ceramics are as in
the following:
[0019] extremely high hardness;
[0020] oil absorptive;
[0021] extremely small heat expansion coefficient;
[0022] porous structure;
[0023] electrical conductivity;
[0024] low specific gravity, light weighted;
[0025] improved abrasion resistance;
[0026] easiness of molding and mold die making;
[0027] capable of being powdered; and
[0028] less negative effect to global environment and more resource
conservation due to rice bran to be used a s a starting
material.
[0029] The most typical distinction of RB ceramics and CRB ceramics
is that a difference in ratio of shrinkage between molded RB
ceramics and a final product thereof is almost 25%, while that of
CRB ceramics is so low as 3% or less, which makes the latter
material much useful. However, such distinction between them is not
important in the present invention, because the final product is
formed not as a molded material but as a powder. So, either of RB
ceramics or CRB ceramics may basically be used in the present
invention.
[0030] Hardness is an important factor of RB ceramics and/or CRB
ceramics used in the present invention, which is influenced by the
primary baking temperature of RB ceramics and both of the primary
baking temperature and the secondary heat-treating temperature of
CRB ceramics.
[0031] In general, the primary baking and the secondary heat
treatment at a temperature of 500 to 1,000.degree. C. yield RB
ceramics or CRB ceramics of high hardness.
[0032] Particle size of a RB ceramics or CRB ceramics powder may
vary depending on the purpose to be used but usually in the range
of 1 to 1,000 .mu.m in average particle diameter, although, in
general, a powder of a larger particle diameter is applied to a
coarse surface and smaller one to a smooth surface.
[0033] Well-known polishing materials which may be used in
combination with RB ceramics and/or CRB ceramics in the present
invention include diatomaceous earth, pumice powder, alumina,
silica, calcium oxide, silicon nitride, silicon carbide, cesium
oxide, synthetic or natural diamond, metal silicide, tungsten
oxide, titanium nitride, titanium oxide and the like.
[0034] It is preferable to use diatomaceous earth and pumice powder
as a natural polishing material; or an alumina polishing material
such brown-, white-, pale red- and crushed type alumina polishing
material, and a silicon carbide grinding material such as black-
and green silicon carbide grinding material as a synthetic one.
These polishing or grinding materials may be used alone or in
combination with two or more of them.
[0035] A combining ratio of these materials may vary depending on
the purpose to be used and, in general, 30 to 90 parts by weight of
a RB ceramics and/or CRB ceramics powder is combined with 70 to 10
parts by weight of one or not less than two kinds of powders
selected from a group consisting of silica, calcium oxide, aluminum
oxide, silicon nitride, silicon carbide, cesium oxide, natural or
synthetic diamond, metal silicide, tungsten oxide, titanium nitride
and titanium oxide.
[0036] A detergent used in the present invention is selected from
annionic surfactant, amphoteric surfactant, nonionic_surfactant
or_cationic surfactant and the like.
[0037] The anionic surfactant includes, for example, a fatty acid
salt such as potassium laurate, potassium myristate and potassium
oleate; an alkyl sulfate such as sodium laurylsulfate, ammonium
laurylsulfate andlauryl sulfate triethanolamine;
alkylbenzene-sulfonate such as sodium dodecylbenzenesulfonate; a
N-acylamino acid salt such as lauroylsarcosine sodium salt and
lauroylsarcosine potassium salt; an alkyl ether carbonate such as
polyoxyethylene dodecyl ether sodium acetate; a N-acyl taurine salt
such as N-lauroyl-methyltaurine sodium salt and
N-cocoylmethyltaurine sodium salt; a N-acylalnine salt such as
lauroylalanine sodium salt; a sulfonate such as sodium
laurylsulfoacetate; polyoxyethylene alkyl ether sulfuric acid ester
salt such as sodium polyoxyethylene lauryl ether sulfate and
poloyoxyethylene lauryl ether sulfuric acid triethanolamine; an
alkanesulfonate such as sodium tetradecanesulfonate and sodium
pentadecanesulfonate; an .alpha.-olefinic sulfonate such as sodium
tetradecenesulfonate; an alkylphosphate such as sodium
laurylphosphate; a polyoxyethylene lauryl ether phosphate such as
sodium polyoxyethylene lauryl ether phosphate and the like.
[0038] The amphoteric surfactant includes, for example, an acetic
acid betain type surfactant such as lauryldimethylaminoacetic acid
betain, lauric acid amide propyl-dimethylaminoacetic acid betain
and coconut oil fatty acid amide propyldimethyl-aminoacetic acid
betain; and an imidazoline type surfactant such as N-coconut oil
fatty acid acyl-N-carboxymethyl-N-hydroxyethylenediamine sodium
salt.
[0039] The nonionic surfactant includes, for example, a
polyoxyethylene alkyl ether such as polyoxyethylene lauryl ether;
and an alkyl alkanolamide.
[0040] The cationic surfactant includes, for example, an
alkylammonium salt such as lauryltrimethylammonium chloride; and an
lauryldimethylamine oxide.
[0041] An amount of the detergent to be added is preferably 1 to 30
parts by weight per 100 parts by weight of the polishing
material.
[0042] An amount thereof less than 1 part by weight results in too
weak detergency to wash out wax and dirt from hands sufficiently,
while the amount of more than 30 parts by weight lowers rinsing
efficiency and is not preferable from an economical viewpoint.
[0043] The detergent may either be used alone or in combination of
two or more.
[0044] The present polishing compound for sheet metal coating may
be compounded by mixing an polishing material and a surfactant in
the following two manners.
[0045] In one type, a polishing material is dispersed in an aqueous
solution of detergent to form a polishing compound for sheet metal
coating of adequate viscosity in a state of paste or liquid
depending on an amount of water to be added to the detergent. When
the liquid or pasty polishing compound for sheet metal coating is
used in practice, the polishing material and the detergent are
thoroughly mixed by shaking a container containing the compound
sufficiently to apply by means of rag or other waste cloth soaked
therewith.
[0046] In the other type, a detergent and a powdery polishing
material are mixed and solidified with a binder. When the thus
formed solid compound is used in practice, the compound is soaked
in a solvent such as water which dissolves the binder, and applied
to a surface to be coated by scoring thereon, thereby the coated
surface being abraded and washed.
[0047] A binder used in the present invention includes
carboxymethyl cellulose (CMC), polyvinyl alcohol (PVA), starch,
alcohol soluble polyamide, etc. In particular, carboxy-methyl
cellulose (CMC), polyvinyl alcohol (PVA) and starch are a water
soluble high polymer and preferably used in the present
invention.
[0048] The present invention will be summarized as in the
following.
[0049] 1. A polishing compound for sheet metal coating comprising a
polishing material and a detergent in which a RB ceramics and/or
CRB ceramics powder is used at least as a part of the polishing
material.
[0050] 2. A polishing compound for sheet metal coating described in
the above item 1 in which an polishing material is one or not less
than two kinds of powders selected from a group consisting of
diatomaceous earth, pumice powder, alumina, silica, calcium oxide,
silicon nitride, silicon carbide, cesium oxide, synthetic or
natural diamond, metal silicide, tungsten oxide, titanium nitride
and titanium oxide.
[0051] 3. A polishing compound for sheet metal coating described in
the above item 2 in which an polishing material comprises a RB
ceramics and/or CRB ceramics powder and one or not less than two
kinds of powders selected from a group consisting of silica,
calcium oxide, aluminum oxide, silicon nitride, silicon carbide,
cesium oxide, synthetic or natural diamond, metal silicide,
tungsten oxide, titanium nitride and titanium oxide, in a weight
ratio of 30 to 90:70 to 10, respectively.
[0052] 4. A polishing compound for sheet metal coating described in
any one of the above items 1 to 3 in which an average particle
diameter of RB ceramics and/or CRB ceramics powder is 1 to 300
.mu.m.
[0053] 5. A polishing compound for sheet metal coating described in
any one of the above items 1 to 4 in which a detergent is one or
not less than two surfactants selected from a group consisting of
an anionic surfactant, amphoteric surfactant, nonionic surfactant
or cationic surfactant.
[0054] 6. A polishing compound for sheet metal coating described in
any one of the above items 1 to 5 in which an polishing material
and a detergent are solidified with a binder.
[0055] 7. A polishing compound for sheet metal coating described in
the above item 6 in which a binder is a water soluble polymer.
[0056] As has been described above, the present invention provides
a polishing compound for sheet metal coating in reparative sheet
metal coating work of cars, which shortens a stain removing process
of a coated surface without conducting a cleaning process
thereafter in reparative sheet metal coating work of cars, etc. by
using an environmentally acceptable material of RB ceramics and/or
CRB ceramics as an polishing material.
[0057] Further, as RB ceramics and/or CRB ceramics is a black
material, its residue on the abraded surface is quite noticeable,
if any, and is useful as an indicator of surface washing with
water.
[0058] The present invention will be further described by the
following examples.
EXAMPLE 1
[0059] Preparation of CRB ceramics
[0060] A defatted product of rice bran in an amount of 75 kg and a
liquid phenol resin (resol) in an amount of 25 kg were mixed and
kneaded by heating at 50 to 60.degree. C. to form a plastic and
homogeneous mixture.
[0061] The mixture was primarily baked by means of a rotary kiln in
a nitrogen atmosphere at 900.degree. C. for 60 minutes. The thus
baked and carbonized material was screened through a 100-mesh
screen to obtain a carbonized powder of 50 to 250 .mu.m in particle
diameter.
[0062] The carbonized powder in an amount of 75 kg and a solid
phenol resin (resol) in an amount of 25 kg were mixed and kneaded
by heating at 100 to 150.degree. C. to form a plastic and
homogeneous mixture.
[0063] Preparation of polishing material
[0064] Then, the plastic mixture was press-molded at a pressure of
20 Mpa to form a spherical body of 3 cm in diameter. The mold die
temperature was 150.degree. C.
[0065] The thus molded body was taken out of the mold die and
subjected to a heat treatment by heating-up to 500.degree. C. in a
nitrogen atmosphere at a heat rising rate of 1.degree. C. per
minute, keeping at 500.degree. C. for 60 minutes and then baking
900.degree. C. for 120 minutes.
[0066] The molded body was then cooled at a cool down rate of 2 to
3.degree. C. per minute down to at 500.degree. C., followed by
natural heat dissipation under 500.degree. C.
[0067] The spherical body of 3 cm in diameter was ground by a
grinder and further pulverized by a ball mill to form CRB ceramics
primary particles of 5 to 10 .mu.m in average particle
diameter.
[0068] Preparation of polishing compound for sheet metal
coating
[0069] Primary fine particles of CRB ceramics having an average
particle diameter of 5 .mu.m in an amount of 2 kg, 2.5 kg of water
and 0.5 kg of potassium laurate were mixed at room temperature and
further treated by means of a roll mill to yield a homogeneously
slurried polishing compound for sheet metal coating.
[0070] Polishing process and coating
[0071] The slurried polishing compound for sheet metal coating was
brought to an polishing and washing site and impregnated into rags
to carefully rub a flawed car surface to be coated. When the flawed
surface was smoothened, the surface was washed with water and
dried. After confirming the absence of oil film on the surface, a
commercially available paint was sprayed thereon several times to
the sheet metal coating. Inferior in adhesion, scaling, peeling,
blister and other defects were not observed after the coating
process.
EXAMPLE 2
[0072] Preparation of CRB ceramics
[0073] A defatted product of rice bran in an amount of 75 kg and a
liquid phenol resin (resol) in an amount of 25 kg were mixed and
kneaded by heating at 50 to 60.degree. C. to form a plastic and
homogeneous mixture.
[0074] The mixture was primarily baked by means of a rotary kiln in
a nitrogen atmosphere at 900.degree. C. for 60 minutes. The thus
baked and carbonized material was screened through a 100-mesh
screen to obtain a carbonized powder of 50 to 250 .mu.m in particle
diameter.
[0075] The carbonized powder in an amount of 75 kg and a solid
phenol resin (resol) in an amount of 25 kg were mixed and kneaded
by heating at 100 to 150.degree. C. to form a plastic and
homogeneous mixture.
[0076] Preparation of polishing material
[0077] Then, the plastic mixture was press-molded at a pressure of
20 Mpa to form a spherical body of 3 cm in diameter. The mold die
temperature was 150.degree. C.
[0078] The thus molded body was taken out of the mold die and
subjected to a heat treatment by heating-up to 500.degree. C. in a
nitrogen atmosphere at a heat rising rate of 1.degree. C. per
minute, keeping at 500.degree. C. for 60 minutes and then baking
850.degree. C. for 120 minutes.
[0079] The molded body was then cooled at a cool down rate of 2 to
3.degree. C. per minute down to at 500.degree. C., followed by
natural heat dissipation under 500.degree. C.
[0080] The spherical body of 3 cm in diameter was ground by a
grinder and then screened through a 300-mesh screen to form CRB
ceramics primary particles of 50 to 80 .mu.m in average particle
diameter.
[0081] Preparation of polishing compound for sheet metal
coating
[0082] Primary fine particles of CRB ceramics having an average
particle diameter of 70 .mu.m in an amount of 2 kg, 0.5 kg of
powdery silica having an average particle diameter of 10 .mu.m, 2.5
kg of water and 0.5 kg of potassium laurate were mixed at room
temperature while further stirring to yield a homogeneously
slurried polishing compound for sheet metal coating.
[0083] Polishing process and coating
[0084] The slurried polishing compound for sheet metal coating was
brought to an polishing and washing site and impregnated into rags
to carefully rub a flawed car surface to be coated. When the flawed
surface was smoothened, the surface was washed with water and
dried. After confirming the absence of oil film on the surface, a
commercially available paint was sprayed thereon several times to
the sheet metal coating. Inferior in adhesion, scaling, peeling,
blister and other defects were not observed after the coating
process.
EXAMPLE 3
[0085] Preparation of RB ceramics
[0086] A defatted product of rice bran in an amount of 75 kg and a
liquid phenol resin (resol) in an amount of 25 kg were mixed and
kneaded by heating at 50 to 60.degree. C. to form a plastic and
homogeneous mixture.
[0087] The mixture was primarily baked by means of a rotary kiln in
a nitrogen atmosphere at 900.degree. C. for 80 minutes. The thus
baked and carbonized material was screened through a 100-mesh
screen to obtain a carbonized powder of 50 to 250 .mu.m in particle
diameter.
[0088] Preparation of polishing material
[0089] The carbonized powder was further pulverized by a ball mill
to form RB ceramics primary fine particles of 30 to 40 .mu.m in
average particle diameter.
[0090] Preparation of polishing compound for sheet metal
coating
[0091] Primary fine particles of RB ceramics having an average
particle diameter of 30 .mu.m in an amount of 2 kg, 1 kg of powdery
alumina having an average particle diameter of 5 .mu.m, 3.0 kg of
water and 0.5 kg of potassium laurate as an anionic surfactant were
mixed at room temperature and further treated by means of a roll
mill to yield a homogeneously slurried polishing compound for sheet
metal coating.
[0092] Polishing process and coating
[0093] The slurried polishing compound for sheet metal coating was
brought to an polishing and washing site and impregnated into rags
to carefully rub a flawed car surface to be coated. When the flawed
surface was smoothened, the surface was washed with water and
dried. After confirming the absence of oil film on the surface, a
commercially available paint was sprayed thereon several times to
the sheet metal coating. Inferior in adhesion, scaling, peeling,
blister and other defects were not observed after the coating
process.
EXAMPLE 4
[0094] Preparation of RB ceramics
[0095] A defatted product of rice bran in an amount of 75 kg and a
liquid phenol resin (resol) in an amount of 25 kg were mixed and
kneaded by heating at 50 to 60.degree. C. to form a plastic and
homogeneous mixture.
[0096] Preparation of polishing material
[0097] The mixture was primarily baked by means of a rotary kiln in
a nitrogen atmosphere at 900.degree. C. for 70 minutes. The thus
baked material was screened through a 60-mesh screen to obtain a
carbonized powder of 200 to 400 .mu.m in particle diameter, which
was further pulverized by means of a ball mill to form primary fine
particles of RB ceramics having an average particle diameter of 100
to 200 .mu.m.
[0098] Preparation of polishing compound for sheet metal
coating
[0099] Primary fine particles of RB ceramics having an average
particle diameter of 150 .mu.m in an amount of 2 kg, 1 kg of
powdery alumina having an average particle diameter of 5 .mu.m, 1.5
kg of water and 0.5 kg of potassium laurate as an anionic
surfactant were mixed at room temperature and further added with
0.5 kg of carboxymethyl cellulose (CMC) to form a plastic
composition. The plastic composition was molded into a cylindrical
body of 3 cm in diameter and 15 cm in height, which was dried to
form a molded polishing compound for sheet metal coating.
[0100] Polishing process and coating
[0101] The molded polishing compound for sheet metal coating was
brought to an polishing and washing site and soaked with water to
directly and carefully rub a rusted and flawed car surface to be
coated. As a result, the rust was completely removed. When the
flawed surface was smoothened, the surface was washed with water
and dried. After confirming the absence of oil film on the surface,
a commercially available paint was sprayed thereon several times to
the sheet metal coating. Inferior in adhesion, scaling, peeling,
blister and other defects were not observed after the coating
process.
* * * * *