CN108914584B - 一种抛光布制造方法 - Google Patents
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Abstract
本发明公开了一种抛光布制造方法，包括以下步骤：将双苯酚、多聚甲醛、有机酸以及甲苯组成混合物，加热并搅拌，此时放热激烈并停止加热；待温度自行上升随后温度开始下降，再重新加热，并保温反应；加水和碳酸氢钠；在压力作用下，蒸馏升温除去水和甲苯；冷却后，加入溶剂溶解合成出的A型酚醛树脂，备用；将尼龙纤维梳理成网得到不织布，用丙烯酸乳液制备的预处理液将不织布进行预固结处理；将制备的A型酚醛树脂、环氧树脂、端氨基聚醚、磨料、消泡剂和水组成上胶处理液，将预固结处理的不织布用上胶处理液处理后，待树脂固化，即得到抛光布。本发明制造的抛光布以抗撕拉强度优良，磨削力增强，耐热性较好，以致磨削的工件无发黑现象。
Description
技术领域
本发明涉及抛光布技术领域，具体来说，涉及一种抛光布制造方法。
背景技术
砂筋轮是一种内含磨料的化学纤维，其结构为尼龙纤维制成的疏松状无纺布，其组织均匀，柔软，富有弹性。无纺布中所有的尼龙纤维在其相互交接处被粘结剂粘在一起，从而形成一个三维结构，磨料在粘结剂作用下，均匀地分布在无纺布中并紧附在纤维上，这种无纺布又称为抛光布，将这种抛光布卷粘成辊状，然后分切成一定宽度的制品，即得到砂筋轮。把砂筋轮装到旋转轴上并压向工件，工作时砂筋轮圆周部分与工件表面的不平度相贴合，利用抛光布来除锈斑，去污物，擦去划痕，并且专业用于不锈钢等材质工件拉纹路、抛光等表面加工。大部分砂筋轮采用以酚醛树脂为主的粘结剂，这种砂筋轮在大多数使用场合中是有效的，但是，若在一定压力下连续使用会产生挠曲，而且热量集积增大，因此在砂筋轮充分发挥作用之前便会发生爆裂，使工件出现发黑，而不能投入大规模工业使用。
发明内容
针对相关技术中的上述技术问题，本发明提出一种抛光布制造方法，能够克服现有技术的上述不足。
为实现上述技术目的，本发明的技术方案是这样实现的：
一种抛光布制造方法，包括以下步骤：
（1）A型酚醛树脂的制备：以重量份计，将1800-2200份双苯酚、100-150份多聚甲醛、50-80份有机酸以及500-800份甲苯组成混合物，加热到60-80℃，并在此过程中搅拌10-30分钟，此时放热激烈并停止加热；15-25分钟后温度自行上升到85-95℃，随后温度开始下降，再重新加热，使温度上升到98-99℃并保温反应4.5-5.5小时；加入700-900份水和100-160份碳酸氢钠，中和未反应的有机酸；在压力作用下，蒸馏温度升到110-130℃，除去水和甲苯；冷却后，加入溶剂溶解合成出的A型酚醛树脂，过滤去除杂质，备用；
（2）将尼龙纤维梳理成网得到不织布；将丙烯酸乳液用水稀释成质量分数为35-45%的水溶液，将900-1000重量份质量分数为35-45%的丙烯酸乳液的水溶液、1-3重量份消泡剂组成预处理液，将不织布浸入所述预处理液中进行预固结处理，使不织布纤维相互粘接，并放入烘箱烘干；
（3）上胶处理：将900-1100重量份步骤（1）中制备的A型酚醛树脂、10-30重量份环氧树脂、20-40重量份端氨基聚醚、950-1050重量份磨料、1-3重量份消泡剂、900-1100重量份水组成上胶处理液，经充分雾化后喷洒到经预固结处理的不织布的一面，上交处理液要渗透到不织布厚度的一半以上，待树脂固化后，将不织布翻过来，将上胶处理液经充分雾化后喷洒到不织布的另一面，烘干使树脂全部固化，即得到抛光布。
优选地，步骤（1）中双苯酚为3.3-乙二烯双苯酚，有机酸为无水乙二酸。
优选地，步骤（1）中压力为5mm汞柱，溶剂为丙酮。
优选地，步骤（3）中上胶处理液的组成为：1000重量份步骤（1）制备的A型酚醛树脂、20重量份环氧树脂、20重量份端氨基聚醚、1000重量份磨料、2重量份消泡剂、1000重量份水。
优选地，步骤（2）中丙烯酸乳液为陶氏公司ST-954牌号；
优选地，步骤（3）中环氧树脂为682牌号，磨料为320目棕刚玉，消泡剂为硅酮。
本发明的有益效果：通过采用丙烯酸乳液对不织布进行预固结处理，并在上交处理液中引入环氧树脂和端氨基聚醚使得抛光布的抗撕拉强度、耐热性提高，吸湿性亦有明显改观，进而解决了砂筋轮在一定压力下连续使用产生挠曲，使工件发黑的问题；本发明制造的抛光布具有较长的使用寿命，而且能使加工工件品质保持一致，可以大规模投入工业使用。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员所获得的所有其他实施例，都属于本发明保护的范围。以下所述实施例仅用于说明本发明，不用于限制本发明，实施例中所使用的各种原料和器械未经特殊说明均可以以商业途径获得。
实施例1
（1）A型酚醛树脂的制备：将2000g3.3-乙二烯双苯酚，130g多聚甲醛，62.7g无水乙二酸以及627g甲苯组成混合物，加热到70℃，并在此过程中搅拌20分钟，此时放热激烈并停止加热；20分钟后温度自行上升到95℃，随后温度开始下降，再重新加热，使温度上升到98-99℃并保温反应5小时；加入800g水和130g碳酸氢钠，中和未反应的无水乙二酸；在5mm汞柱压力作用下，蒸馏温度升到120℃，除去水和甲苯，冷却后，加入溶剂溶解合成出的A型酚醛树脂，过滤去除杂质，备用；
（2）将尼龙纤维梳理成网得到所需的不织布；将丙烯酸乳液用水稀释成质量分数为45%水溶液，将950g质量分数为45%的丙烯酸乳液的水溶液、3g硅酮消泡剂，组成不织布预处理液，将不织布浸入预处理液中进行预粘处理，使不织布纤维相互粘结，并放入烘箱烘干；
（3）上胶处理：将900g步骤（1）中制备的A型酚醛树脂、10g 682环氧树脂、20g端氨基聚醚，950g320目棕刚玉磨料，1g硅酮消泡剂，900g水组成上胶处理液，经充分雾化后喷洒到经预处理的不织布一面，上胶处理液需渗透到不织布厚度的一半以上，待树脂初步固化后，将不织布翻转过来，用所述上胶处理液，用同样的方法喷洒不织布的另一面，烘干，使树脂全部固化，即得到抛光布。
实施例2
（1）A型酚醛树脂的制备：将1800g3.3-乙二烯双苯酚，100g多聚甲醛，50g无水乙二酸以及500g甲苯组成混合物，加热到60℃，并在此过程中搅拌30分钟，此时放热激烈并停止加热；25分钟后温度上升到95℃，随后温度开始下降，再重新加热，使温度上升到98-99℃并保温反应4.5小时；加入700g水和100g碳酸氢钠，中和未反应的无水乙二酸；在5mm汞柱压力作用下，蒸馏温度升到110℃，除去水和甲苯，冷却后，加入溶剂溶解合成出的A型酚醛树脂，过滤去除杂质，备用；
（2）将尼龙纤维梳理成网得到所需的不织布；将丙烯酸乳液用水稀释为35%水溶液，将900g质量分数为35%的丙烯酸乳液的水溶液、1g硅酮消泡剂，组成不织布预处理液，将不织布浸入所述预处理液中进行预粘处理，使不织布纤维相互粘结，并进入烘箱烘干；
（3）上胶处理：将1000g步骤（1）中制备的A型酚醛树脂，20g682环氧树脂，30g端氨基聚醚，1000g320目棕刚玉磨料，2g硅酮消泡剂，1000g水组成上胶处理液，经充分雾化后喷洒到经预处理的不织布一面，上胶处理液徐渗透到不织布厚度一半以上，待树脂初步固化后，将不织布翻转过来，用所述上胶处理液，用同样方法喷洒不织布的另一面，烘干，使树脂全部固化，即得到抛光布。
实施例3
（1）A型酚醛树脂的制备：将2200g3.3-乙二烯双苯酚，150g多聚甲醛，80g无水乙二酸以及800g甲苯组成混合物，加热到80℃，并在此过程中搅拌10分钟，此时放热激烈并停止加热；15分钟后温度上升到85℃，随后温度开始下降，再重新加热，使温度上升到98-99℃并保温反应5.5小时；加入900g水和160g碳酸氢钠，中和未反应的无水乙二酸；在5mm汞柱压力作用下，蒸馏温度升到130℃，除去水和甲苯，冷却后，加入溶剂溶解合成出的A型酚醛树脂，过滤去除杂质，备用；
（2）将尼龙纤维梳理成网得到所需的不织布；将丙烯酸乳液用水稀释为40%水溶液，将900g质量分数为40%的丙烯酸乳液的水溶液、2g硅酮消泡剂，组成不织布预处理液，将不织布浸入所述预处理液中进行预粘处理，使不织布纤维相互粘结，并进入烘箱烘干；
（3）上胶处理：将1100g步骤（1）中制备的A型酚醛树脂，30g682环氧树脂，40g端氨基聚醚，1100g320目棕刚玉磨料，3g硅酮消泡剂，1100g水组成上胶处理液，经充分雾化后喷洒到经预处理的不织布一面，上胶处理液徐渗透到不织布厚度一半以上，待树脂初步固化后，将不织布翻转过来，用所述上胶处理液，用同样方法喷洒不织布的另一面，烘干，使树脂全部固化，即得到抛光布。
实施例4
对实施例1至实施例3制得的抛光布进行性能测试，测试结果如表1所示：
表1 实施例1至实施例3制得的抛光布性能测试结果
综上所述，借助于本发明的上述技术方案，在预固结处理过程中引入丙烯酸乳液，在上胶处理中引入环氧树脂，端氨基聚醚，磨料采用棕刚玉制成的抛光布，在研磨过程中尼龙纤维不断损耗，新的磨层不断地自然形成，使抛光布具有较长的使用寿命的同时，在一定压力转速下，工件无发黑现象，抛光布抗撕拉强度优良，耐热性较好，磨削力较强，吸湿性亦有明显改善，能投入大规模的工业使用。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。
Claims (4)
1.一种抛光布制造方法，其特征在于，包括以下步骤：
（1）A型酚醛树脂的制备：以重量份计，将1800-2200份双苯酚、100-150份多聚甲醛、50-80份有机酸以及500-800份甲苯组成混合物，加热到60-80℃，并在此过程中搅拌10-30分钟，此时放热激烈并停止加热；15-25分钟后温度自行上升到85-95℃，随后温度开始下降，再重新加热，使温度上升到98-99℃并保温反应4.5-5.5小时；加入700-900份水和100-160份碳酸氢钠，中和未反应的有机酸；在压力作用下，蒸馏温度升到110-130℃，除去水和甲苯；冷却后，加入溶剂溶解合成出的A型酚醛树脂，过滤去除杂质，备用，所述压力为5mm汞柱，所述溶剂为丙酮；
（2）将尼龙纤维梳理成网得到不织布；将丙烯酸乳液用水稀释成质量分数为35-45%的水溶液，将900-1000重量份质量分数为35-45%的丙烯酸乳液的水溶液、1-3重量份消泡剂组成预处理液，将不织布浸入所述预处理液中进行预固结处理，使不织布纤维相互粘接，并放入烘箱烘干；
（3）上胶处理：将900-1100重量份步骤（1）中制备的A型酚醛树脂、10-30重量份环氧树脂、20-40重量份端氨基聚醚、950-1050重量份磨料、1-3重量份消泡剂、900-1100重量份水组成上胶处理液，经充分雾化后喷洒到经预固结处理的不织布的一面，上胶处理液要渗透到不织布厚度的一半以上，待树脂固化后，将不织布翻过来，将上胶处理液经充分雾化后喷洒到不织布的另一面，烘干使树脂全部固化，即得到抛光布，所述环氧树脂为682牌号，所述磨料为320目棕刚玉，所述消泡剂为硅酮。
2.根据权利要求1所述的抛光布制造方法，其特征在于，步骤（1）中所述双苯酚为3.3-乙二烯双苯酚，所述有机酸为无水乙二酸。
3.根据权利要求1所述的抛光布制造方法，其特征在于，步骤（3）中所述上胶处理液的组成为：1000重量份步骤（1）制备的A型酚醛树脂、20重量份环氧树脂、20重量份端氨基聚醚、1000重量份磨料、2重量份消泡剂、1000重量份水。
4.根据权利要求1所述的抛光布制造方法，其特征在于，步骤（2）中所述丙烯酸乳液为陶氏公司ST-954牌号。
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