CN1229376A - Abrasive article and its method of making - Google Patents

Abrasive article and its method of making Download PDF

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Publication number
CN1229376A
CN1229376A CN 96180431 CN96180431A CN1229376A CN 1229376 A CN1229376 A CN 1229376A CN 96180431 CN96180431 CN 96180431 CN 96180431 A CN96180431 A CN 96180431A CN 1229376 A CN1229376 A CN 1229376A
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China
Prior art keywords
abrasive
particle
shape
adhesive
resin
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Granted
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CN 96180431
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CN1085575C (en
Inventor
S·R·卡勒
J·J·加利亚尔迪
T·W·拉基
E·G·拉森
L·L·马丁
J·W·纳尔森
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3M Co
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Minnesota Mining and Manufacturing Co
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Priority to CN98104583A priority Critical patent/CN1085575C/en
Publication of CN1229376A publication Critical patent/CN1229376A/en
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Publication of CN1085575C publication Critical patent/CN1085575C/en
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Abstract

This invention pertains to an abrasive article comprising precisely shaped particles. The abrasive article may be a coated abrasive article, a bonded abrasive or a nonwoven abrasive article. The precisely shaped particles may further comprise abrasive grits, fillers, grinding aids and lubricants. The precisely shaped particles can be made according to the following method: (a) providing a production tool having a three-dimensional body which has at least one continuous surface, said surface containing at least one opening formed in said continuous surface, said at least one opening providing access to a cavity in said three-dimensional body; (b) providing a dispensing means capable of introducing a binder precursor comprising a thermosetting resin into said at least one cavity through said at least one opeing; (c) providing a means, within a curing zone, for at least partially curing said binder precursor; (d) introducing said binder precursor into at least a portion of said at least one cavity; (e) continuously moving said at least one cavity through said curing zone to at least partially cure said binder precursor to provide a solidified, handleable binder having a shape corresponding to that portion of the cavity into which the binder precursor has been introduced; (f) removing said binder from said at least one cavity; and (g) converting said binder to form a precisely shaped particle. Steps (f) and (g) may be conducted simultaneously. The particles can be bonded together to form a shaped mass, e. g., a wheel; alternatively, the particles can be bonded to a backing to form a coated abrasive article; or the particles can be bonded into a fibrous, nonwoven substrate to form a non-woven abrasive article.

Description

Abrasive product and manufacture method thereof
Background of the present invention
1. the field of the invention
The present invention relates to comprise the granular materials and the manufacture method thereof of adhesive.When this granular materials further comprised abrasive particle, it can use in bonded abrasive, coated abrasives and non-woven abrasive.
2. the description of prior art
Conventional coated abrasives generally is that one deck abrasive particle is bonded on the backing.In the operating period of coated abrasives, in fact only utilized a fraction of abrasive particle in the abrasive grain layer usually.Most abrasive particle is to have slatterned in the abrasive grain layer.And backing is a component more expensive in the coated abrasives, and it is not just damaged as yet and must dispose.
Done multiple trial already, the distribution of abrasive particle on backing make sure and in fact can be utilized more abrasive particle, thereby prolongs the service life of coated abrasives.Owing to prolonged service life of coated abrasives, as the grinding belt of coated abrasives or mill need change with regard to much less, thereby saved the time and reduced the expense of changing operation.Depending merely on backing the abrasive particle of deposition one thick-layer can not deal with problems, and reason is that those abrasive particles that are positioned at below the abrasive particle of top layer are on impossible utilizing.
Known have severally abrasive particle can be distributed in the method that increases the service life on the coated abrasives.A kind of such method is included in and adds the particle that agglomeration of abrasive particles becomes in the coated abrasives.The particle that agglomeration of abrasive particles becomes is the wisp that some abrasive particles is bonded together and forms with adhesive.If the particle that the agglomeration of abrasive particles of using becomes is that shape and size are irregular, then be difficult to control in advance amount with the contacted abrasive particle of surface of the work.For this reason, the method that needs a kind of expense that can make the particle of the definite agglomeration of abrasive particles one-tenth of shape to save.
General introduction of the present invention
The invention provides shape particle of determining and the method for making these particles.Comprise adhesive in the particle.At one preferably in the embodiment, be that many abrasive particles are dispersed in the adhesive.
Method of the present invention comprises the steps:
(a) provide a kind of fabrication tool of said three-dimensional body, it has at least one continuous surface, is formed with a perforate on this continuous surface at least, and at least one perforate is that a cavity that enters in the said three-dimensional body provides access;
(b) provide adhesive precursor that a kind of energy will comprise thermosetting resin to introduce distributor in described at least one cavity by described at least one perforate;
(c) in curing area, provide one to make the partly solidified at least device of described adhesive precursor;
(d) described adhesive precursor is introduced at least a portion space of described at least one cavity;
(e) make described at least one cavity move continuously, make described adhesive precursor partly solidified at least, obtain the cure adhesive that shape is corresponding with the void space of introducing adhesive precursor, can dispose by described curing area;
(f) from described at least one cavity, remove described adhesive;
(g) described adhesive is changed the particle that the formation shape is determined.
Step (f) and (g) can carry out simultaneously.
At one preferably in the embodiment, add many abrasive particles when in step (d), introducing adhesive precursor, thereby formation contains the adhesive of abrasive particle in step (e).The adhesive that comprises abrasive particle in step (f) is removed from least one cavity of fabrication tool.Material beyond the abrasive particle also can add in company with adhesive precursor.
A heat energy or radiation energy or the two can be installed in curing area.Suitable radiation energy comprises employing electron beam, visible light and ultraviolet light.As a kind of alternative of conventional method, can adopt heat energy or radiant energy to combine and be cured with heat energy.
General and preferably in the embodiment, should be with step (d), (e) with (f) with continuous order or carry out in a continuous manner.For these embodiments, fabrication tool is preferably endless belt shape or cylinder shape, is preferably a kind of rotatingcylindrical drum that pivots.Perhaps, also can use belt with two ends.It is this that the belt at two ends is arranged is to separate winding apparatus from one to be transported to a rewind.Be preferably and contain many cavitys in the fabrication tool.
In the step (e) of method, adhesive precursor is transformed into the adhesive that can dispose through overcuring.
Can adopt several method that adhesive is transformed into particle.In one approach, after adhesive is removed, promptly become particle one by one from the cavity one by one of fabrication tool.These particles can comprise additional material or not contain additional material.The typical material that can be included in these particles is an abrasive particle.The gained coating of particles is that the shape with the fabrication tool cavity is identical basically preferably.Like this, the shape that particle had is by the shape decision of the cavity of fabrication tool.In this first method, step (f) and (g) finish simultaneously, this is because after the shaping particle breaks away from from the cavity of fabrication tool, promptly has the character shape of cavity.
In the second approach, the adhesive of removing from the first type surface of fabrication tool is a sheet, size and the substantially the same many shaped portions of shape that size and shape and the cavity of fabrication tool are arranged on this sheet, but these parts are by linking together than the adhesive articulamentum that approaches.In this second method, this sheet breaks or cracked along the thin articulamentum of adhesive subsequently, forms granular material of the present invention.Can screen the particle of making or classification, remove the particle that need not use.If the adhesive articulamentum is broken or very careful when cracked, then the shape with the fabrication tool cavity is identical basically for the gained coating of particles.
Use the carrier band with adhesive precursor be applied on the fabrication tool method also within the scope of the invention.A first type surface that adhesive precursor can be coated to the carrier band is on the front surface, and the carrier band through applying with gained contacts with the continuous surface of the fabrication tool that comprises cavity then.After adhesive precursor in fabrication tool is partly solidified at least, remove from fabrication tool earlier, then remove from the carrier band again with the adhesive in the bonding jail of carrier belt surface.Perhaps, adhesive precursor is coated on the continuous surface of the fabrication tool that contains cavity, these cavitys are full of, the continuous surface of carrier band with the fabrication tool that is filled with adhesive precursor contacted, adhesive precursor contained in the cavity is contacted with the surface of carrier band.After adhesive precursor was partly solidified at least, adhesive just was bonded on the carrier belt surface, is not on fabrication tool.Adhesive can be removed from the carrier band then.Just formed the particle that shape is determined.
The particle that shape is determined can be by using additive used in abrasive application, and its performance is improved, and these additives can use with itself or as the mode of a component of abrasive product.The particle that shape of the present invention is determined can be used to make abrasive product, and each this shaped particles comprises at least one abrasive particle and adhesive, and this adhesive is made from the adhesive precursor that contains thermosetting resin that can solidify through radiant energy or heat energy or this two kinds of energy.These particles can be bonded together and make the object of definite shape, for example emery wheel; Perhaps these particles can be adhered to and make coated abrasives on the backing; Maybe these particles can be adhered on the nonwoven substrates of fiber and make nonwoven abrasive article.
The present invention can be designed to particle be applicable to concrete purposes by changing coating of particles and composition.Method of the present invention provides a kind of easy, fast and the expense method of saving for the abrasive grains of making particle, especially shape and determining.Method of the present invention can be pursued batch identical abrasive grains of manufacturing dimension exactly, thus the more consistent abrasive product of obtained performance.
Another aspect of the present invention relates to a kind of coated abrasives, and it comprises:
(a) has the backing of front and rear surfaces;
(b) the initial engagement coating on the backing front surface (make coat);
(c) be adhered to abrasive material on the backing front surface by the initial engagement coating, this abrasive material comprises:
(1) many abrasive particles;
(2) the definite grinding aid particle of many shapes, it comprises adhesive and the former grain of many grinding aids;
(d) sizing menting property on abrasive material (size coat).
In general, the surf zone of abrasive material should comprise 5-90%, is preferably 10-75%, is preferably the grinding aid particle that the 20-40% shape is determined.
Another aspect of the present invention relates to a kind of bonded abrasive article, and it comprises:
(a) cementing medium;
(b) many abrasive particles;
(c) the definite grinding aid particle of many shapes, it comprises adhesive and the former grain of many grinding aids; Cementing medium is to be used for the grinding aid particle that abrasive particle and shape are determined is bonded together, and becomes the object of definite shape.
Bonded abrasive better is the form of emery wheel, and it comprises cutting emery wheel (cut off wheel).In general, grinding aid particle shared percentage by volume in bonded abrasive that shape is determined is about 5-85%, is preferably 5-75%, and more preferably 5-60% is preferably 10-60%.
Can also comprise abrasive particle in the grinding aid particle that shape is determined.The Mohs' hardness of this abrasive particle is usually approximately greater than 8.Yet, generally be preferably the definite grinding aid particle of shape and form by adhesive and the former grain of grinding aid basically.
Another aspect of the present invention relates to the abrasive grains that a kind of shape is determined, it comprises:
(a) adhesive, this adhesive makes from comprising the resole resin (resole phenolic resin) and the adhesive precursor of radically curable resin;
(b) many abrasive particles that form the definite abrasive grains of shape in the adhesive that are distributed in.
The abrasive grains that this type of shape is determined can be added in the abrasive product or nonwoven abrasive article of coated abrasives, bonding.
Another aspect of the present invention relates to a kind of abrasive product, and it comprises:
(a) cementing medium, wherein cementing medium comprises the filler particles that the shape in many resin binders that are distributed in curing is determined, comprises many filler particles that are distributed in the adhesive in the filler particles that this shape is determined;
(b) many abrasive particles,
Cementing medium plays at least one aspect in following several respects herein:
(1) abrasive particle is bonded on the backing;
(2) abrasive particle is bonded on the nonwoven substrates;
(3) abrasive particle is bonded together, makes the object of definite shape.
Another aspect of the present invention relates to a kind of coated abrasives, and it comprises:
(a) has the backing of front and rear surfaces;
(b) the initial engagement coating on the backing front surface;
(c) be adhered to many abrasive particles on the backing front surface by the initial engagement coating;
(d) sizing menting property on abrasive particle,
The filler particles that has the shape in many resin binders that are distributed in curing to determine at least one coating in initial engagement coating or the sizing menting property, and the filler particles that this shape is determined comprises many filler particles that are distributed in the adhesive.
Brief description of drawings
Fig. 1,2 and 3 is diagrammatic side view that explanation realizes the whole bag of tricks of the present invention.
Figure 4 and 5 are to use the diagrammatic side view of a kind of coated abrasives on the vertical section of particle of the present invention.
Fig. 6 is the perspective view of one section of Fig. 1 fabrication tool.Section shown in this figure is similar with that section of Fig. 1,2 and 3 fabrication tools basically.
Fig. 7 and 8 is diagrammatic side view that explanation realizes other method of the present invention.
Detailed description of the present invention
Term used herein " adhesive precursor " refers to any material, it is (conformable) that can fit or can become and can fit in heating or pressurization or situation about both applying, and can become in radiant energy or heat energy or situation about both applying and do not fit. Term used herein " cure adhesive that can dispose " refers to that polymerization or curing reach basically and no longer flows or at the adhesive precursor that the significant change degree can not occur in shape. Term " cure adhesive that can dispose " does not always refer to the adhesive precursor of fully polymerization or curing, but it is polymerization or curing fully, thereby when fabrication tool continues to move, can remove from fabrication tool, and can not cause the shape of adhesive that obvious change is arranged. With adhesive after fabrication tool is removed, can be exposed under the effect of additional source of energy, adhesive further is cured or polymerization. Term used herein " adhesive " is synonym with term " cure adhesive that can dispose ".
One aspect of the present invention relates to a kind of method of making pellet. Another aspect of the present invention relates to the definite particle of shape that contains the cure adhesive that can dispose. Term " shape is determined " refers to adhesive precursor polymerization or curing in the cavity of fabrication tool. After adhesive precursor solidifies in cavity, the adhesive that gained solidifies is removed from cavity. Remove in some situation of process at this, formed particle, and in its removal process, the edge of particle may break. In addition, when particle was removed from cavity, two, three or more particle can interconnect on total border or otherwise combine. In other cases, removal be the sheet that many particles are linked to be, to further process (such as pulverizing, ball milling etc.) to this and form one by one particle. This process of making individual particle from sheet of particles, the edge of the individual particle of gained may can be combined by round as a ball and/or several i.e. two, three, four or a plurality of particles. Term " shape determine particle " comprises that the particle of edge fracture and edge are by round as a ball particle, also within the scope of the invention. Scope of the present invention comprises that also term " shape determine particle " is to interconnect or otherwise combine two, three, four a plurality of individual particles perhaps in addition.
Another aspect of the present invention relates to abrasive product, and such as bonded abrasive article, coated abrasives and nonwoven abrasive article, they all comprise the granular materials that shape of the present invention is determined.
Fig. 1 illustrates and can realize that the inventive method makes the equipment of particle of the present invention. In equipment 10, adhesive precursor 12 is sent into the endless belt-shaped fabrication tool 16 from hopper 14 under Action of Gravity Field. Transmit at two rollers 18,20 endless belt 16, and at least one roller is power-actuated. Fig. 6 is the perspective view of 16 1 sections of fabrication tools. As can be seen from Figure 6, fabrication tool 16 is the said three-dimensional body with the continuous surface 21 that comprises perforate 22, and these perforates 22 are provided access for the cavity 23 that enters in the said three-dimensional body. At least a portion space of cavity 23 is full of by adhesive precursor 12. Then adhesive precursor 12 is exposed under the effect of the energy 25 as a result adhesive precursor 12 at least part of curing, the cure adhesive that acquisition can be disposed therein by curing area 24. The adhesive particle 26 that shape is determined is removed from fabrication tool 16, is collected in the container 28. External device (ED) 29, for example the generating means of ultrasonic energy can be used for helping adhesive particle 26 to separate from fabrication tool 16. The chip of staying in the fabrication tool can be disposed first, then fresh adhesive precursor is sent in the fabrication tool.
Fig. 2 illustrates the another kind of equipment that can realize the inventive method. The belt carrier 32 that transports from separating winding apparatus 34 is arranged in the equipment 30. The form of separating winding apparatus 34 is rollers. Belt carrier 32 can be made by the form that processed paper for example, cloth, polymer film, supatex fabric, vulcanized paper, their combination and they. For belt carrier 32, material is polymer film preferably, such as polyester film. In Fig. 2,32 pairs of radiation of belt carrier are transparent. Adhesive precursor 36 is transported on the first type surface of belt carrier 32 from hopper 38 under Action of Gravity Field. The first type surface that the above is covered with the belt carrier 32 of adhesive precursor 36 is pressed onto on the surface of fabrication tool 40 by nip rolls 42. With the surface of the contacted fabrication tool 40 of belt carrier be crooked, its surperficial identical with that section of fabrication tool shown in Figure 6 of other side. Nip rolls 42 can also be pressed into adhesive precursor 36 in the cavity of fabrication tool 40. Then, adhesive precursor 36 is exposed under the effect of the energy 44 therein by curing area 43, adhesive precursor 36 at least part of curing this moment, the cure adhesive that acquisition can be disposed. Next, the above has the belt carrier 32 of the cure adhesive that can dispose by another nip rolls 46. Between belt carrier 32 and the cure adhesive that can dispose, sufficient cohesive must be arranged, be convenient to subsequently adhesive be removed from the cavity of fabrication tool 40. Adhesive particle 48 is collected in the container 50 after removing from belt carrier 32. External device (ED) 51, for example the generating means of ultrasonic energy can be used to help particle 48 to separate from belt carrier 32. Then receive belt carrier 32 52 last times at rewind, for reusing. The form of rewind 52 is rollers.
Can adopt another kind of method effectively adhesive particle to be removed from belt carrier. In this method, belt carrier can have a thin water miscible coating at the first type surface of accepting from the adhesive precursor 36 of hopper 38. Water miscible coating will contact with adhesive precursor 36. After adhesive precursor 36 at least part of curing, the above has the belt carrier 32 that can dispose cure adhesive to contact with a water source, and water has just dissolved the water miscible coating on the belt carrier 32 like this, thereby adhesive particle is separated from belt carrier 32. An example that is used for the water miscible coating of this method is water-soluble polymer layer, described polymer such as polyvinyl alcohol, PVP and cellulose derivative.
Fig. 3 illustrates another equipment that can realize the inventive method. In equipment 70, adhesive precursor 72 from hopper 74 blade coatings to fabrication tool 76. Fabrication tool is the form of rotatingcylindrical drum, and it has axle 78. The continuous surface of fabrication tool 76 is crooked, its surperficial identical with that section of fabrication tool shown in Figure 6 of other side. When fabrication tool 76 during around axle 78 rotation, adhesive precursor 72 is exposed under the effect of the energy 80 therein just by curing area 79, adhesive precursor 72 at least part of curing this moment, the cure adhesive that acquisition can be disposed. Next, the particle 82 of the cure adhesive disposed that will obtain from curing schedule is removed from fabrication tool 76, is collected in the hopper 84. Removing the method (such as water spray) that should adopt machinery carries out. Before fresh adhesive precursor added, the chip that should will stay in the fabrication tool 76 was got rid of. The removal of chip can adopt brush, air to spray or any other conventional method. Although in Fig. 3, do not illustrate, can use additional device to help to remove adhesive particle from fabrication tool 76.
Fig. 7 illustrates the another kind of equipment that can realize the inventive method. Have in the equipment 120 from first and separate the belt fabrication tool 122 that winding apparatus 124 conveyings are come. Separating winding apparatus 124 is forms of roller. Fabrication tool 122 preferably transparent by radiation, made by the polymeric material of ultraviolet and/or visible transparent better. For example, this fabrication tool can be made with the polymer that is connected fluorine-containing aliphatic group thereon by containing the polyethylene main chain. This polymer has further description in September 17 nineteen ninety among the disclosed WO 92/15626. Ethene polymers is attached on the polyester. Cavity in the fabrication tool can be the pyramid of a series of square bottom surface, and the position of these pyramids is that dock mutually their bottom surface. In have the surface of the fabrication tool of cavity can be similar with that section of fabrication tool shown in Figure 6. Fabrication tool 122 leaves separates winding apparatus 124, and belt carrier 126 leaves second and separates winding apparatus 128. Belt carrier 126 can be made by the paper that polyvinyl alcohol applies, and its commodity is available from Schoeller Technical Papers, Inc., Pulaski, New York; Article No. is 89-84-4. In the cavity of coating machine 132 with adhesive precursor 130 paint fabrication tools 122. With nip rolls 136 fabrication tool 134 parts that adhesive precursor is housed are contacted with belt carrier 126. Fabrication tool 134 parts and belt carrier 126 that adhesive precursor is housed are pressed onto on the reel 138. Reel 138 is around its axle 140 rotations. Then, the radiation that is arranged in curing area 142 radiation energies 141 is transmitted on the adhesive precursor by fabrication tool 122. Radiation energy can be the middle pressure mercuryvapour uviol lamp with 600 watts/inch (240 watts/centimetre) work. Be subject to the effect that the width of cloth is penetrated, adhesive precursor just is transformed into the cure adhesive that can dispose. By the effect of reel 138, fabrication tool and the belt carrier that can dispose cure adhesive are housed just pass through continuously curing area 142. Near nip rolls 143, belt carrier 126 is separated from the fabrication tool that adhesive is housed. Belt carrier 126 is recoiled at rewind 144. With regard to Fig. 7, use supersonic generator from the belt carrier particle-removing that gets at the back side of belt carrier, this way is also within the scope of the invention. In general, be preferably the back side that supersonic generator is close to belt carrier, make simultaneously belt carrier be in tensioned state. The commodity that example is model " 108 " of supersonic generator commodity are available from Branson.
Fig. 8 illustrates the another kind of equipment that can realize the inventive method. What use in the equipment 160 is endless belt-shaped fabrication tool 162, and it is through a series of rollers 164, and wherein at least one roller is power-actuated. In the cavity of doctor knife coater 168 with adhesive precursor 166 paint fabrication tools 162. Then adhesive precursor 166 will be subject to the effect of radiation energy 172 therein by curing area 170. Radiation energy can be the middle pressure mercuryvapour uviol lamp with 600 watts/inch (240 watts/centimetre) work. This process is continuous, is subject to the effect of the energy 172, and adhesive precursor 166 is transformed into the cure adhesive that can dispose. The particle 178 of adhesive should be bonded on the ganoid reel 174. After leaving curing area 170, with removing device 176 particle 178 is removed from ganoid reel 174 at once, under vacuum action, collected it (not shown).
Fabrication tool is a said three-dimensional body with at least one continuous surface. Have at least one perforate on the continuous surface, be preferably many perforates, these perforates all form at continuous surface. Each perforate provides the entrance that enters the said three-dimensional body cavity. Term used herein " continuous " refers to spatially have the feature of uninterrupted extension; Though perforate and cavity are on continuous surface, they can not be divided into the surface many surfaces that separate. The form of fabrication tool can be fabric, band (such as the endless belt), sheet, applicator roll or be enclosed within sleeve on the applicator roll. Fabrication tool is preferably a kind of instrument that can continued operation, and it for example is endless belt or the cylindrical applicator roll that pivots. In general, cylindrical applicator roll is the form of right circular cylinder, and its diameter is about 25 to 45 centimetres, is made of rigid material. Use has the equipment of two free-ended bands also to be applicable to carry out continuous operation. The used preferably material of fabrication tool is polymer, for example TPO such as polypropylene or metal such as nickel. Fabrication tool also can be made by ceramic material.
The manufacture method of metal worker tool can comprise engraving, lithoprinting, hobbing, etching, annular knurl, with many metal parts that are processed into required form assemble, stamping or other mechanical means, electroforming etc. The better method of making metal worker tool or master tool is the diamond turning method. The another kind of manufacturing master tool and/or metal worker tool preferably technique is to use cutting annular knurl method. This cutting annular knurl method is that further description is arranged among the PCT/US95/13074 at the PCT number of patent application. For example, be that 8 inches, length are that 28 inches cylindrical 1026 mild steel workpiece are electroplated the skim bright nickel at a diameter at first, in order to the adhesiveness of the copper that prevents from corroding and improve and will electroplate afterwards. Then, electroplating 0.050 inch, Knoop hardness at bright nickel is 240 hard copper. One end of this workpiece of electroplating is installed on the chuck, and the other end is supported on the central authorities of the tailstock of the Clausing engine lathe that low-lift pump and aqueous coolant are housed. The outer surface of workpiece scabbled gloss, stay the hard copper of 0.030 inch.
Model is 209 Zeus cutting knurling tool is equipped with high-speed steel (" HSS ") at the top the first knurled wheel. Have the tooth with respect to left-leaning 30 ° of wheel shaft on the first knurled wheel, 30 teeth (" TPI ") are arranged on the per inch, tooth has 90 ° of angles at the back of tooth. This cutter also is equipped with the second knurled wheel of HSS in the bottom. Having on the second knurled wheel with respect to the wheel shaft inclination angle is 0 ° tooth, and 36TPI is 90 ° angle at the back of tooth. Be set to 200mm (7.9 inches) the O.D. position of workpiece by the mounting rod with knurled wheel and regulate the orientation of two knurled wheels. Wheel shaft becomes 30 ° separately approximately with respect to the horizontal central plane of Zeus cutting knurling tool. Then with this Cutting tool installation manner on the cross slide of Clausing lathe. Regulate the height of cutting knurling tool, two rollers can be contacted with workpiece simultaneously. Then first roller at top is removed. Allow coolant flow to the second roller, in order to when chip forms, just they are washed.
1) makes the engagement of the second roller and workpiece. Lathe with the speed of 80rpm on first direction, (move upward with the surface of the second roller engagement) make workpiece rotating, the Tool advance speed parallel with workpiece spindle be 0.010 inch/turn (right-to-left). Regulate the depth of cut of the first roller, in order to produce about 75% of entire depth annular knurl.
2) then the second roller is removed, the first roller is reinstalled in the top. Under condition same as described above, on the record direction, (move downward with the surface of the first roller engagement), lathe makes workpiece rotating, and tool orientation is from right to left, and is parallel with workpiece spindle.
3) the first roller is removed, the second roller is reinstalled in the bottom. This 3rd step repeats first step, and difference is to regulate cutter to reach whole knurl depth.
4) the second roller is removed, the first roller is reinstalled in the top. This 4th step repeats second step, and difference is to regulate cutter to reach whole knurl depth.
5) the first roller is removed, the second roller is reinstalled in the bottom. This five steps repeats the 3rd step, again reaches whole knurl depth.
Have knurled pattern on the surface of the work of gained annular knurl, it is that per inch length has the pyramid of 36.7 square bottom surface on the direction parallel with the pyramid base, and its average height is 0.0099 inch. The top of pyramid is round as a ball, and it is corresponding with the round as a ball shape depression of knurled wheel. With respect to the perpendicular plane of the workpiece longitudinal axis, the summit of pyramid pattern has 11.5 ° helical angle. Apply one deck nickel protection layer at workpiece with the electroless coating method, in order to prevent from corroding and improving the before use stripping performance of polymer.
Above-mentioned annular knurl workpiece can be used for the manufacturing of fabrication tool of the present invention. At first workpiece and a nip rolls are installed in an extruder below. The annular knurl workpiece is remained on 60 ℃ (140 °F), and nip rolls remains on 21 ℃ (70 °F). The Escorene " Polypropylene 3445 " of 214 ℃ (417 °F) is expressed on the annular knurl workpiece, and when workpiece and nip rolls rotation, clamp-ons between workpiece and the nip rolls. Speed with 3.6 m/mins (11.8fpm) is collected the seamless film that obtains 0.022 inch. The uninterrupted pattern that just has pyramid shape depression on the surface of film, these depressions are the anti-phase of depression on the annular knurl workpiece.
Extrusion technique existsPolymer science and technology encyclopedia(Encyclopedia of Polymer Science and Technology), the 8th volume, John Wiley ﹠ Sons, Inc. (1968), there is further description on 651-665 page or leaf and United States Patent (USP) the 3,689,346, the 7th hurdle on 30-55 is capable. Fabrication tool also can have one deck peel ply, in order to more easily adhesive is removed from cavity, and farthest reduces the wearing and tearing of fabrication tool. The example of this peel ply comprises hard layer such as metal carbides, metal nitride, metal boride, diamond or similar adamantine carbon. Also can use the fabrication tool of heating, it better is made of metal, and this situation also within the scope of the invention. The worker prodigiosin of heating makes shaping particles comparatively easy, solidifies quickly, and relatively easily shaped particles is stripped down from instrument. Further data about fabrication tool can be referring to United States Patent (USP) 5,435,816.
In some cases, the polymers manufacturing instrument can copy from original master tool. When fabrication tool was the form of band, this was particularly preferred. The advantage that the polymers manufacturing instrument is better than the metal worker tool is that its price is more honest and cleaner. Another advantage of polymers manufacturing instrument is that it allows radiation arrive the ability of adhesive precursor by fabrication tool from radiation source. The polymers manufacturing instrument can make by the thermoplastic resin of melting such as polypropylene are coated on the master tool. Then make the resin quenching of melting, obtain the thermoplasticity duplicate of master tool. The duplicate of this polymer namely can be used as fabrication tool. In addition, on the surface of fabrication tool one deck peel ply can be arranged, as making peel ply, the fissility that strips down from fabrication tool to improve adhesive with the material of siloxy group or the material of fluorochemical base. Remover is added to make in the polymer of fabrication tool, and this also within the scope of the invention. Typical remover comprises the material of siloxy group and the material of fluorochemical base. Make fabrication tool from the polymer with good stripping performance, this within the scope of the invention. This polymer is described among the disclosed WO 92/15626 on September 17th, 1992. The document has been described a kind of copolymer of fluorochemical grafting, and it comprises a raw polymer (described polymerized unit is derived from the monomer that contains the two keys of terminal olefin) that contains polymerized unit, is grafted with the part of fluorine-containing aliphatic group on this raw polymer. This grafted fluoropolymer aliphatic group generally is derived from the fluorochemical alkene that comprises fluorine-containing aliphatic group and polymerizable double bond.
Generally by a linking group the fluorine-containing aliphatic group in the fluorochemical alkene is connected on the polymerisable pair of key. This fluorochemical alkene can be represented by the formula:
                        (R f) aQ(CR＝CH 2) b
Wherein R represents hydrogen, trifluoromethyl or contains the straight or branched alkyl of 1-4 carbon atom;
A represents the integer of 1-10;
B represents the integer of 1-6;
The Q representative can not disturbed the linking group of radical polymerization (a+b) valency basically;
R fRepresentative comprises the fluorine-containing aliphatic group of the complete fluorinated end that contains at least 7 fluorine atoms.
Can adopt the method identical with making the metal worker tool to make the metal foundation instrument. Other manufacture method of fabrication tool is disclosed in United States Patent (USP) 5,435, in 816.
If fabrication tool is made by thermoplastic, then the condition of method should make the heat that produces in curing area to the unlikely generation harmful effect of fabrication tool.
Have a cavity at least one continuous surface of fabrication tool at least, be preferably many cavitys. The cure adhesive precursor that can dispose will obtain the shape corresponding with cavity shape. Cavity can be any geometry such as pyramid, prism, cylinder, cone or has the thin objects of relative polygon facet. Its geometry can be the shape of cutting a section in the above-mentioned shape. A given fabrication tool can comprise various difform cavitys or various different big or small cavity or both to have both at the same time, and this also within the scope of the invention. In the situation of belt fabrication tool, cavity can have on whole length. Cavity can direct neighbor or the interval land regions is arranged between them. The side that is preferably cavity is slope shape, in order to easily remove adhesive from fabrication tool.
Cavity can have other geometry such as cube, block shape, sphere etc., and this also within the scope of the invention.
All cavitys can be of similar shape, identical size. In this case, the definite particle of all shapes of acquisition all has identical size and shape basically. Perhaps, all cavitys can be of similar shape, but size is different. In this case, determine the problem of the particle size distribution of particle with regard to existing shape. Another situation is, all cavitys can have identical size, but shape is different. In this case, the particle that the gained shape is determined will have identical size, but shape is different. In a further embodiment, cavity can have different shapes and different sizes. In this case, the definite particle of gained shape will have different shapes and size.
Be applicable to adhesive precursor of the present invention and comprise the thermosetting resin that can solidify by radiant energy or heat energy. Adhesive precursor can carry out polymerization through condensation cured mechanism or addition mechanism. Adhesive precursor carries out polymerization through addition mechanism preferably. Adhesive precursor can carry out polymerization through free radical mechanism or cationic mechanism or this two kinds of mechanism. Adhesive precursor can not contain filler, also can contain conventional fillers.
Adhesive precursor should pass through radiant energy or heat energy solidifies. Radiant energy can be electron beam, ultraviolet light, visible light and laser. If use ultraviolet light or visible light, then be preferably and in mixture, comprise light trigger. When being exposed to ultraviolet light or visible light lower time, light trigger can produce radical source or cationic source. Then this radical source or cationic source cause the polymerisation of adhesive precursor. When adopting electron beam, can contain or not contain light trigger in the mixture.
The example of the adhesive precursor that solidifies by radiant energy, comprise polyurethanes, the acroleic acid esterification of acroleic acid esterification epoxies, alefinically unsaturated compounds class, contain the side chain unsaturated carbonyl aminoplast derivative class, contain the acrylate-based isocyanurate derivative class of at least one side chain, contain the acrylate-based isocyanate derivates class of at least one side chain, vinyl ethers, epoxy resin and their mixture. Term " acrylate " comprises esters of acrylic acid and methyl acrylic ester.
The polyurethanes of acroleic acid esterification is the polyesters that increases of hydroxy-end capped isocyanates or the diacrylate class of polyethers. The example of the Acrylated urethanes class that commodity are buied comprises available from " UVITHANE 782 " of Morton Thiokol Chemical with available from " CMD 6600 ", " CMD 8400 " and " CMD 8805 " of Radcure Specialties.
The epoxies of acroleic acid esterification is the diacrylate class of epoxy resin, such as the diacrylate class of bisphenol A epoxide resin. The example of the epoxies of the acroleic acid esterification that commodity are buied comprises " CMD 3500 ", " CMD 3600 " and " CMD 3700 " available from Radcure Specialties.
The alefinically unsaturated compounds class comprises and comprises carbon, hydrogen and oxygen atom, perhaps also can comprise monomer and the polymer compound class of nitrogen and halogen atom. Oxygen or nitrogen-atoms or this two kinds of atoms are present in ether, ester, urethanes, acid amides and the urea groups usually. The molecular weight of alefinically unsaturated compounds class is preferably less than about 4,000, and it preferably will contain the ester that aliphatic monohydroxy or aliphatic polyhydric compound and unsaturated carboxylic acid such as acrylic acid, methacrylic acid, itaconic acid, crotonic acid, iso-crotonic acid, maleic acid etc. react acquisition. The representative example of esters of acrylic acid comprises methyl methacrylate, EMA, ethylene glycol diacrylate, methacrylic acid glycol ester, hexanediol diacrylate, diacrylate triglycol ester, trimethylolpropane triacrylate, three acrylic acid glycerine esters, pentaerythritol triacrylate, methacrylic acid pentaerythritol ester and pentaerythritol tetracrylate. Other alefinically unsaturated compounds class comprises the amide-type of monoene propyl group, polyenoid propyl group and many methacrylic esters and carboxylic acid, such as diallyl phthalate, diallyl adipate and N, and N-diallyl adipamide. Also have other alefinically unsaturated compounds class, comprise styrene, divinylbenzene and vinyltoluene. The alefinically unsaturated compounds class that other is nitrogenous; comprise three (2-acryloyl group-ethyoxyl) isocyanuric acid ester; 1; 3; 5-three (2-methacryloxyethyl)-s-triazine, acrylamide, Methacrylamide, N methacrylamide, N,N-DMAA, NVP and N-vinyl piperidones.
Aminoplast can be monomer and oligomer. Each molecule of amino resin contains at least one side chain α, β-unsaturated carbonyl. These α, beta-unsaturated carbonyl can be acrylate-based, methacrylate based or acrylamido. The example of this resin comprises N-methylol-acrylamide, N, N '-oxo dimethylene diacrylamine, neighbour or to the methylated phenol of acrylamido, the methylated novolaks of acrylamido and their mixture. These materials are in United States Patent (USP) 4,903,440; In 5,055,112 and 5,236,472 further description is arranged.
Contain the acrylate-based isocyanurate derivative class of at least one side chain and contain the acrylate-based isocyanate derivates class of at least one side chain at United States Patent (USP) 4,652, further description is arranged in 274. Isocyurnate material is the triacrylate of three (ethoxy) isocyanuric acid ester preferably.
Be applicable to the example of vinyl ethers of the present invention, comprise the urethane oligomer of vinyl ether functional, its commodity have " VE 4010 ", " VE 4015 ", " VE 2010 ", " VE 2020 " and " VE 4020 ", available from Allied Signal.
Epoxies contains the oxirane ring, carries out polymerization through open loop. Epoxy resin comprises cyclosiloxane monomer epoxy resins and polymer ring epoxy resins. These resins can be very different on its main chain and substituent kind. For example, main chain can be and the common relevant any type of epoxy resin, and the substituting group on it can be at room temperature any group that does not contain active hydrogen atom with the reaction of oxirane ring. Be used for the substituent representative example of epoxy resin, comprise halogen, ester group, ether, sulfonate group, siloxy group, nitro and phosphate-based. The present invention is the example of epoxy resin preferably, comprise 2, [4-(2 for 2-two, the 3-glycidoxy) phenyl] propane (diglycidyl ether of bisphenol-A) and with trade name " Epon 828 ", " Epon 1004 " and " Epon 1001F " available from Shell Chemical Co., with trade name " DER-331 ", " DER-332 " and " DER-334 " material available from Dow Chemical Co.. The epoxy resin that other is suitable comprises the glycidol ethers (for example commodity " DEN-431 " and " DEN-428 ", available from Dow Chemical Co.) of novolaks. Epoxy resin of the present invention can carry out polymerization through the cationic mechanism that adds suitable light trigger (multiple). These resins are at United States Patent (USP) 4,318, further description are arranged in 766 and 4,751,138.
Be exposed to the example that can produce the light trigger of radical source under the ultraviolet light; include but is not limited to be selected from following material; organic peroxide class, azo-compound class, quinones, Benzophenones, nitroso compound class, acyl halide class, hydrozones, sulfhydryl compound class, pyrylium compound class, triacryl imidazoles, diimidazole class, chloro alkyl triazines, benzoin ethers, benzil ketals class, thioxanthene ketone, acetophenone derivs class, and their mixture. Be exposed to visible light and be disclosed in United States Patent (USP) 4,735 according to the lower example that can produce the light trigger of radical source, in 632.
Cation light initiator can produce the polymerisation that acid source causes epoxy resin or polyurethane. Cation light initiator can comprise the salt of cation and metal or metalloid Halogen complex anion. Other cation light initiator comprises the salt that contains organic metal complex cation and metal or metalloid Halogen complex anion. These light triggers have further description at United States Patent (USP) 4,751 in 138 (the 6th hurdles, 65 walk to the 9th hurdle, 45 row). Another example is at United States Patent (USP) 4,985, organic metal salt and salt described in 340 (the 4th hurdles, 65 walk to the 14th hurdle, 50 row) and the european patent application 306,161,306,162. Another cation light initiator comprises the ion salt of organometallic complex, and wherein metal is selected from the element of periodic table IVB, VB, VIB, VIIB and VIIIB family. This light trigger is disclosed in the european patent application 109,581.
Adhesive precursor also can be the adhesive of condensation curable such as phenolic resins, urea formaldehyde resin, melamino-formaldehyde resin etc. Two types phenolic resins is arranged, i.e. fusible phenolic resins and novolaks. The formaldehyde of resole resin and the mol ratio of phenol were generally 1.5: 1.0 to 3.0: 1.0 more than or equal to 1: 1. The formaldehyde of novolac resin and the mol ratio of phenol were less than 1: 1. The example of the phenolic resins that can buy comprises available from the commodity of Occidental Chemicals Corp. " Durez " and " Varcum ", available from the commodity " Resinox " of Monsanto, available from the commodity " Arofene " of Ashland Chemical Co. with available from the commodity " Arotap " of Ashland Chemical Co.. Further details about urea formaldehyde resin can be referring to United States Patent (USP) 5,486,219.
Use comprises the adhesive precursor of condensation curable resin and radically curable resin blend, and this also within the scope of the invention. For example, can with resole resin with acrylate blend be in the same place, make adhesive precursor. A kind of preferably adhesive precursor comprises the isocyanuric acid ester resin of acrylate monomer such as trimethylolpropane triacrylate, acroleic acid esterification such as triacrylate, trimethylolpropane triacrylate or pentaerythritol triacrylate and the resole resin of three (ethoxy) isocyanuric acid ester. In order to help the polymerization of initiating methacrylates base resin, allow adhesive precursor accept the effect of heat and/or radiation. In order to help to cause the polymerization of resole resin, generally allow adhesive precursor accept the effect of heat. For example, adhesive precursor can comprise about 10-90 weight portion phenolic resins, preferably the resin of 20-60 weight portion phenolic resins and about 10-90 weight portion free-radical curable, the preferably resin of 20-60 weight portion free-radical curable.
In a useful especially embodiment, adhesive precursor can contain abrasive particle. The adhesive precursor that solidifies is adhesive, plays a part abrasive particle is bonded together to make shape and determine abrasive grains. The mean particle size of abrasive particle generally is about the 0.1-1500 micron, better is about the 1-1300 micron, better is about the 1-500 micron, preferably is about the 1-150 micron. The Mohs' hardness that is preferably abrasive particle is at least about 8, better is about 9. The example of the material of this abrasive particle comprises fused alumina (fused aluminum oxide), ceramic alumina, white fused aluminum oxide, heat treated aluminium oxide, silica, carborundum, green silicon carbide, alumina zirconia, diamond, ceria, titanium diboride, boron carbide, cubic boron nitride, garnet, kieselguhr and their mixture. Ceramic alumina is preferably by such as United States Patent (USP) 4,314,827; 4,744,802; 4,623,364; 4,770,671; 4,881,951; 5,011,508 and 5,213, the sol-gel process preparation described in 591. Ceramic abrasive grain comprises Alpha-alumina, and maybe can comprise metal oxide modified agent such as magnesia, zirconia, zinc oxide, nickel oxide, hafnium oxide, yittrium oxide, silica, iron oxide, titanium dioxide, lanthana, ceria, neodymia and their mixture. Also can comprise nucleator such as α-aluminium oxide, iron oxide, iron oxide precursor, titanium dioxide, chromium oxide or their mixture in the ceramic alumina. Ceramic alumina also can have such as United States Patent (USP) 5,201, and 916 and 5,090, the shape described in 968. Also can have coating on the surface of ceramic abrasive grain.
Also can have coating on the abrasive particle surface. Face coat can improve the cohesive between the abrasive particle and adhesive in the abrasive grains, and/or can change the nonferromagnetic substance of abrasive particle. This face coat is disclosed in United States Patent (USP) 5,011,508; 1,910,444; 3,041,156; 5,009,675; 4,997,461; In 5,213,591 and 5,042,991. Abrasive particle also can have coupling agent in its surface, such as silane coupling agent.
Can be added with one type abrasive particle, different abrasive particles or the abrasive particle of at least a type and the diluent materials of at least a type of two or more types in the adhesive precursor. Be used as the example of the material of diluent, comprise calcium carbonate, glass vesicle, bead, lime stone (greystone), marble, gypsum, polyvinyl chloride, clay, SiO2、KBF 4、Na 2SiF 6, ice crystal, organic bubble, organic pearl etc.
Can also be added with additive in the used adhesive precursor of the present invention, as filler (comprising grinding aid), fiber, lubricant, wetting agent, surfactant, pigment, dyestuff, coupling agent, plasticizer, antistatic additive and suspending agent.Be applicable to the example of filler of the present invention, comprise wood pulp, vermiculite and their mixture, metal carbonate such as calcium carbonate are (as chalk, calcite, plaster, calcareous tufa, marble and lime stone), miemite, sodium carbonate, magnesium carbonate, silica such as amorphous silicas, quartzy, bead, glass vesicle and glass fibre, silicate such as talcum, clay (montmorillonite), feldspar, mica, calcium silicates, calcium metasilicate, sodium aluminosilicate, sodium metasilicate, metal sulfate such as calcium sulfate, barium sulfate, sodium sulphate, aluminum sodium sulfate, aluminum sulfate, gypsum, vermiculite, wood powder, aluminium hydroxide (aluminum trihydrate), metal oxide such as calcium oxide (lime), aluminium oxide, titanium dioxide and metal sulphite such as calcium sulfite.For example, by weight, the particle that shape is determined can comprise about 20-100 part adhesive, is preferably 40-100 part adhesive and 0-80 part filler, is preferably 0-60 part filler.In another embodiment, by weight, the particle that shape is determined comprises 20-90 part adhesive, is preferably 25-80 part adhesive, more preferably 30-70 part adhesive; 10-80 part abrasive particle is preferably 20-75 part abrasive particle, more preferably 30-70 part abrasive particle; 1-60 part filler is preferably 5-50 part filler, more preferably 10-40 part filler.
Grinding aid is defined as a kind of granular materials, it is added in the abrasive product can produce remarkable influence to the chemistry and the physical process of grinding, thereby improves its performance.Particularly, it is believed that grinding aid meeting (1) reduces abrasive particle and by the friction between the grinding work-piece, (2) prevent that abrasive particle from " block phenomenon " taking place, and promptly prevents the top of metallic particles welding at abrasive particle, (3) interface temperature between reduction abrasive particle and the workpiece, and/or (4) reduce grinding force.Usually, add the service life that grinding aid can improve coated abrasives.Grinding aid comprises the material that many kinds are different, can be inorganic or organic.The example of grinding aid comprises wax, organohalogen compounds, halogen, metal and their alloy.Organohalogen compounds generally can decompose in process of lapping, discharge halogen acids or gaseous halide.This examples of material comprises chlorinated wax such as tetrahedronaphthalene, five chlorinated naphthalenes and polyvinyl chloride.The example of halogen comprises sodium chloride, elpasolite, sodium cryolite, ammonium ice crystal, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluoride, potassium chloride and magnesium chloride.The example of metal comprises tin, lead, bismuth, cobalt, antimony, cadmium, iron and titanium.Other grinding aid comprises sulphur, organosulfur compound, graphite and metal sulfide.Use the mixture of different grinding aids, in some cases, can produce collaborative effect, this also within the scope of the invention.The above-mentioned example of grinding aid is the representative example of grinding aid, and it does not also mean that and comprised all grinding aids.The other example of grinding aid comprises the mixture of sodium metaphosphate, tripotassium phosphate and polyvinyl chloride and potassium tetrafluoroborate.By weight, the grinding aid particle that shape is determined can comprise about 5-95 part adhesive, is preferably 25-70 part adhesive and 5-95 part grinding aid, is preferably 30-75 part grinding aid.
Use chloride acroleic acid esterification adhesive also within the scope of the invention.The example of this adhesive comprises " Ebecryl 436 ", " 584 ", " 585 ", " 586 " and " 588 ", and they all are available from Radcure Specialties, Inc. (Louisville, commodity KY).Although do not wish to stick to certain theoretical explanation, these propylene dichloride acid esters monomers can play adhesive and grinding aid.Under suitable grinding condition, chlorine can discharge in process of lapping.
Be applicable to the example of coupling agent of the present invention, comprise organosilan, zircoaluminate and titanate.Can select suitable coupling agent to be used for abrasive particle and/or filler.Can directly coupling agent be joined in the mixture of adhesive and abrasive particle and/or filler.Perhaps, also can use coupling agent preliminary treatment abrasive particle and/or filler.The example of antistatic additive comprises graphite, carbon black, conducting polymer, wetting agent, vanadium oxide etc.The amount of regulating these materials can obtain required performance.Can also contain water or organic solvent in the adhesive precursor.
Can also contain plasticizer in the particle that shape is determined.The example of plasticizer comprises polyvinyl chloride, dibutyl phthalate, alkyl benzyl phthalic acid ester, polyvinyl acetate, polyvinyl alcohol, cellulose esters, phthalic acid ester, silicone oil, adipate ester and sebacate, many alcohol, many 01 derivatives, tert-butyl-phenyl diphenyl phosphoester, tricresyl phosphate, castor oil, their mixture etc.In the gross weight (not comprising the additive and the abrasive grains that can add) of adhesive, plasticizer dosage is about 0-70%, better is about 0-65%.
The example of lubricant comprises soap, sulfur-based compound, graphite, molybdenum bisuphide, talcum, boron nitride, siloxanes, silicone oil, polyethylene glycol, phosphate, esters of silicon acis, neopentyl polyol esters and polyphenylene oxide, fluorochemical, the mineral oil of wax, metal, their mixture etc.
The consumption of these additives in the particle that shape is determined partly decided on desired properties.The example of additive comprises filler, grinding aid, coupling agent and wetting agent preferably.For example, for diluent particle, the particle that shape is determined can comprise adhesive and filler particles.Again for example, the diluent particle that is used for abrasive product can comprise adhesive and grinding aid.Perhaps, the definite abrasive grains of shape can comprise adhesive, abrasive particle or also comprise filler, grinding aid and coupling agent.
The additive that can also comprise anti-load in the particle that shape is determined." load " this term is to be used for describing material is planted in smear metal (grind get off from workpiece material) therewith to the filling in space between the abrasive particle accumulation.For example, in the process of timber sanding, the smear metal meeting of being made up of wood particle is present in the space between the abrasive particle, thereby has significantly reduced the cutting power of abrasive particle.The example of this anti-support materials comprises the slaine, melocol, wax, mineral oil, crosslinked silane, crosslinked siloxanes, phosphate, fluorochemical and their mixture of aliphatic acid.In one aspect of the invention, in the particle that one or more adding shapes in these anti-support materials can be determined.The particle that these gained shapes can be determined is added in the abrasive product together with the particle of abrasive particle or agglomeration of abrasive particles one-tenth.For example, coated abrasives can have a backing with front and rear surfaces.The initial engagement coating is present on the front surface of backing, and this initial engagement coating is used for abrasive material is bonded to the front surface of backing.Comprise the abrasive particle particle definite in the abrasive material with the shape that contains anti-support materials.On abrasive material is one deck sizing menting property.
Adhesive precursor also can also comprise blowing agent.Blowing agent generally can improve the porosity that shape is determined particle.Blowing agent can be any chemicals or material, and its existence can improve the volume that shape is determined particle.The organic solvent that blowing agent can be steam or particle is expanded.
Adhesive precursor can also comprise surfactant.The example of surfactant comprises the salt of metal alkoxide, fluorochemical, polyalkylene oxide, LCFA etc.That surfactant can be is cationic, anionic or nonionic.The example of surfactant comprises the Chemie available from Byk preferably, Wallingford, the anionic dispersing agents commodity of CT " Disperbyk 111 " and available from ICI Chemicals, Wilmington, the PEO base dispersant commodity " Hypermer KD2 " of DE.
If comprise abrasive particle in the particle, then particle should be able to be broken in process of lapping.The selection of adhesive precursor, abrasive particle and the additive that can add and the crushing performance that consumption all can influence particle.In addition, shape determines that the porosity size of particle also can influence fragmentation and the polishing machine that shape is determined particle.The size of porosity is that degree can be determined by the comprehensive of chemical property, additive (comprising abrasive particle), granulation condition and this Several Factors of adhesive.Like this, concerning shape is determined certain purposes of particle, the size that should determine its porosity according to the required fragmentation of particle or polishing machine.
In order to make the mixture that comprises adhesive precursor and other material (as abrasive particle), can be through each component being mixed such as any routine techniques such as high speed shear mixing, air-flow stirring or lift-over.In the mixed process of mixture, can adopt vacuum, so that carrying secretly of air reduced to minimum.Perhaps, in some cases, in mixed process, air or other gaseous material are entrained in the abrasive material slurry, also suit.This air of carrying secretly can obtain the particle that the bigger shape of porous is determined.
Can adopt the distributor of utilization such as gravity filling, pumping, mouthful pattern coating or vacuum forging die formula coating any routine techniques such as (vacuumdrop die coating), adhesive precursor is added in the cavity of fabrication tool.Also can adhesive precursor be added in the cavity of fabrication tool by the transfer of the first carrier band.The example of carrier band comprises cloth backing (cloth backing of comprise untreated cloth backing, grey cloth backing, handling etc.), nonwoven substrates (comprising paper), polymer film (comprising the film of the film of primary coat, not primary coat, fibrous enhancing film etc.), vulcanized paper and any other suitable substrates type backing.In blend step or promptly, before coating step, adhesive precursor is handled through ultrasonic wave, in order to reduce the viscosity of adhesive precursor.
Although only require a part of space of adhesive precursor cavity filling, the suitable lip-deep cavity of complete filling fabrication tool of adhesive precursor makes the particle of gained contain seldom space or defective.These defectives can make coating of particles depart from the required shape that formalizes really.In addition, when the adhesive material that shape is determined when fabrication tool is removed, its edge may fracture, thereby can produce defective and impair the certainty of shape.Should pay attention to whole process, these defectives of make suring are reduced to minimum.Sometimes, space or defective need, and reason is that they can produce porosity in the particle of gained, thereby makes particle have bigger easy erosion.Should note not making the unlikely plane that exceeds the fabrication tool continuous surface significantly of adhesive precursor equally, and the unlikely perforate that obviously exceeds the fabrication tool cavity.
Have and appropriate to the occasionly before adhesive precursor is added fabrication tool, it is heated, generally be heated to about 40-90 ℃ temperature.After the adhesive precursor heating, its viscosity can descend, and it will flow in the cavity of fabrication tool with comparalive ease as a result.
Be connected on the step that adhesive precursor is added behind the cavity of fabrication tool and comprise, when taking advantage of in the cavity that adhesive precursor is present in fabrication tool, be exposed under radiant energy or the heat energy effect, make it partly solidified at least.Perhaps, when taking advantage of in the cavity that adhesive precursor is present in fabrication tool, make it partly solidified at least, after the cavity of fabrication tool is removed, carry out back curing again at this adhesive.Back curing schedule can omit.The degree of solidifying should be abundant, and the cure adhesive that gained can be disposed can keep its shape when removing from fabrication tool.
The example of the radiation energy that curing area is used comprises electron beam, ultraviolet light, visible light and laser.The energy level of operable electron beam irradiation (being also referred to as ionizing radiation) is about 0.1-20Mrad, is about 1-10Mrad preferably.Ultraviolet radiation is meant that wavelength is about 200-400nm, better is about the non-particle radiation of 250-400nm.The scope of dose of radiation is about 50-1000mJ/cm 2, better be about 100mJ/cm 2To 400mJ/cm 2The lamp of this dosage source that provides is provided, about 100-600 watt/inch for example can be provided, better be about the dosage of 300-600 watt/inch.Visible radiation is meant that wavelength is about 400-800nm, better is about the non-particle radiation of 400-550nm.The abundant required emittance of cure adhesive precursor depends on all multifactor, for example the degree of depth, the chemical species of adhesive precursor and the type (if words of having) of support materials of adhesive precursor in cavity.The condition of heat cure is about 50-200 ℃ concerning temperature, be that a few minutes at zero point were to several thousand minutes to the time.Required actual heat depends on the chemical property of adhesive precursor to a great extent.
After partly solidified at least, the cure adhesive that gained can be disposed should not be bonded on the surface of fabrication tool very securely.In either case, be the adhesive precursor that solidifies will be removed from fabrication tool at this moment.
The cure adhesive that has several replacement methods to can be used for disposing is that adhesive is removed from fabrication tool.A kind of method is that adhesive is directly transferred to gatherer from fabrication tool, in hopper.In this method,, then can adopt the mechanical means of ultrasonic wave, vacuum, air knife or their compound mode or other routine that adhesive is removed from cavity if fabrication tool is made by polymeric material.If fabrication tool is made of metal, then can adopts water spray or air to spray adhesive is removed from cavity.If the cavity that fabrication tool contained runs through fabrication tool fully, for example when fabrication tool is the band that contains fully through the some of them hole, then can adopt ultrasonic wave, mechanical force, water spray, air injection or their compound mode or other mechanical means with binder removal, no matter what the building material of fabrication tool is.
In another approach, adhesive can be transferred to the gatherer from fabrication tool indirectly.In one embodiment, adhesive can be transferred on the smooth roller from fabrication tool.Adhesive to the cohesive of this smooth roller greater than cohesive to fabrication tool.Can adopt then strike off, vacuum, water spray, air are sprayed or other mechanical means are removed from smooth roller and shifted the adhesive of coming.In a specific embodiment scheme, be that adhesive is transferred on the first type surface of the second carrier band from fabrication tool.Adhesive to the cohesive of this carrier band first type surface greater than cohesive to fabrication tool.The example of carrier band comprises cloth backing (cloth backing of comprise untreated cloth backing, grey cloth backing, handling etc.), nonwoven substrates (comprising paper), polymer film (comprising the film of the film of primary coat, not primary coat, fibrous enhancing film etc.), vulcanized paper and any other suitable substrates type backing.The better example of some of carrier band comprises sided corona treatment polyester film of crossing and the cloth base material that contains the polyamide prepolymer sizing menting property.Before transfer of granules that shape is determined is to the carrier band, the carrier band is carried out sided corona treatment, this situation is also within the scope of the invention.In addition, the first and second carrier bands all can be made by identical materials or different materials.
Can be covered with the material of the water-soluble or organic solvent of one deck on the first type surface of the carrier band of using for transfering adhesive.As long as dissolve the material that forms soluble layer, just can easily adhesive be removed from the carrier band.In addition, mechanical means as strike off, vacuum or ultrasonic wave can be used for removing adhesive.Ultrasonic energy can be applied directly on the first type surface of fabric or partially on a side of fabric first type surface.In another embodiment, on the first type surface of carrier band a size coating can be arranged.The example that is applicable to the primer of carrier band comprises ethylene acrylic acid co polymer, polyvinylidene chloride, crosslinked hexanediol diacrylate, aziridine material etc.Adhesive can preferentially be adhered on the carrier band of primer.Adopt then such as strike off, mechanical means vacuum or the ultrasonic wave remove adhesive from the carrier of crossing primer.
With adhesive after fabrication tool is removed, adopt direct or indirect means to be converted into particle.In a kind of mode of transformation, adhesive separates from fabrication tool with the form of particle one by one.Given coating of particles is the shape of the cavity segment space of the partly solidified at least therein fabrication tool of particle basically.An advantage of this mode is that particle has had used suitable rank of use (as being added in the abrasive product) subsequently or suitable particle size distribution.In the conventional method of making abrasive grains, it must also be pulverized, and screens subsequently to obtain suitable particle size distribution.
In second kind of transition regime, adhesive separates from fabrication tool with the form of sheet, and this adhesive sheet is the adhesive material of being determined by the interconnective many shapes of the thin layer of adhesive material.Break or pulverize along the thin position that interconnects then, form particle of the present invention.
Process of the present invention can provide a kind of manufacturing to comprise many economic means that are distributed in the abrasive product of the abrasive particle in the adhesive.An advantage of the inventive method is to obtain the abrasive grains that shape is determined.Yet scope of the present invention also comprises the step that employing is additional, and abrasive grains in irregular shape is pulverized or fragmented into to the abrasive grains that these shapes are determined.
The another kind of form of fabrication tool can be cylinder or the band around a rotation.When fabrication tool pivoted, process can be carried out continuously.Method in prior art, when the fabrication tool transfixion, process is to carry out in mode in batches.Compare with the method that batch mode in the prior art is carried out, continuation method of the present invention is more effective usually, and expense is more saved.
The present invention also provides the abrasive product that comprises the abrasive grains that makes by the inventive method.These abrasive products can be bonded abrasive article, coated abrasives or nonwoven abrasive article.For bonded abrasive article, the object piece that the abrasive grains of shape being determined with cementing medium is bonded together and makes definite shape is as emery wheel, cutting emery wheel.Bonded abrasive article generally makes through molding process.For coated abrasives, the abrasive grains of shape being determined with cementing medium is adhered on the backing.For nonwoven abrasive article, the abrasive grains of shape being determined with cementing medium is adhered on the non woven fibre base material.
Be applicable to that the backing of making coated abrasives comprises the polymer film, cloth, paper, vulcanized paper, foam of polymers, supatex fabric of polymer film, primary coat, form that they were handled and their mixture.The example of polymer film comprises polyester film, polyolefin film (polyethylene and polypropylene screen), PA membrane, polyimide film etc.Another example of backing is as United States Patent (USP) 5,417, the fibre-reinforced thermoplastic described in 726.A kind of common coated abrasives backing is the cloth backing.This cloth is made up of warp-wise (promptly vertical) yarn and broadwise (promptly horizontal) yarn.The cloth backing can be weaves backing, loop bonding backing or wefting insertion backing.The example of weaving structure has on four once through face forges line, florentine drill, a sagging plain weave on the plain weave and two one on the other.In stitch bonded fabrics or wefting insertion backing, warp thread and weft yarn are not interweaved, but they still are orientated by two different directions each other.Warp thread be positioned at weft yarn above, and fix by seam yarn or adhesive and another root warp thread.Yarn on the backing can be natural, synthetic or the both has.The example of natural yarns comprises that cellulose is as cotton, hemp, kapok, flax, sisal, jute, carbon, abaca and their mixture.The example of synthetic yarn comprises polyester yarn, polypropylene yarn, organdy, polyvinyl alcohol yarn, polyimides yarn, aramid yarn, artificial silk, nylon yarn, polyethylene yarn and their mixture.Be used for the present invention preferably yarn be polyester yarn, nylon yarn, polyester and cotton mixture, artificial silk and aramid yarn.The cloth backing can be dyed, extension, destarch or heat stretch are handled.In addition, the yarn in the cloth backing can comprise primer, dyestuff, pigment or wetting agent.Yarn can be twisting or crooked.The backing of coated abrasives can also contain saturator coating, pre-sizing menting property and/or gum knot coating.These coatings have the effect of yarn or fiber in sealing backing and/or the protection backing.Add pre-sizing menting property or gum knot coating, the surface that can also obtain " more smooth " at the front or the back side of backing.Gum knot coating can comprise anti-static material or lubricant material.
Referring to Figure 4 and 5, have in the coated abrasives 100 abrasive grains is adhered to two layers of coatings on the backing.Coating 102 (being commonly referred to the initial engagement coating) is applied on the backing 104, and it is bonded in abrasive grains 106 on the backing 104.Coating 108 (being commonly referred to sizing menting property) is applied on the abrasive grains 106, and it has reinforcement effect to abrasive grains 106.Also can also have the 3rd layer of coating 110, it is commonly referred to sizing menting property, and it is to be applied on the sizing menting property 108.As mentioned above, comprise many abrasive particles 112 and adhesive 114 in the abrasive grains 106.Can be by abrasive grains being applied on the backing such as dripping the routine techniques be coated with (drop coating) or the electrostatic coating.Look the difference of painting method, abrasive grains can be orientated by the rule mode that has shown in Figure 4, or is orientated by random fashion shown in Figure 5.
The abrasive material material is adhered on the base material or, comprises the resin binder and or the spendable additive of curing the abrasive material material used material that is bonded together.Be applicable to the example of resin binder of the present invention, comprise isocyanuric acid ester resin, urea-formaldehyde resins, the isocyanuric acid ester resin of phenolic resins, amino resin, polyurethane resin, epoxy resin, acrylate, acroleic acid esterification, polyurethane resin, vinyl ethers, the epoxy resin of acroleic acid esterification and their mixture of acroleic acid esterification.The additive that can add comprises filler (comprising grinding aid), fiber, lubricant, wetting agent, surfactant, pigment, dyestuff, coupling agent, plasticizer and suspending agent.The example of filler comprises talcum, calcium carbonate, calcium metasilicate, silica and their mixture.To select to obtain required performance the consumption of these materials.
Can be added to coated abrasives, structured abrasive article, the example of filler in nonwoven abrasive article or the bonded abrasive article, comprise wood pulp, vermiculite and their mixture, metal carbonate such as calcium carbonate are (as chalk, calcite, plaster, calcareous tufa, marble and lime stone), miemite, sodium carbonate, magnesium carbonate, silica such as amorphous silicas, quartzy, bead, glass vesicle and glass fibre, silicate such as talcum, clay (montmorillonite), feldspar, mica, calcium silicates, calcium metasilicate, sodium aluminosilicate, sodium metasilicate, metal sulfate such as calcium sulfate, barium sulfate, sodium sulphate, aluminum sodium sulfate, aluminum sulfate, gypsum, vermiculite, wood powder, aluminium hydroxide, metal oxide such as calcium oxide (lime), aluminium oxide, titanium dioxide and metal sulphite such as calcium sulfite.For example, by weight, the cementing medium of abrasive product can comprise about 0-80 part filler, is preferably 0-70 part filler, better is about 10-55 part filler.
The example of the grinding aid in coated abrasives, nonwoven abrasive article or the bonded abrasive article be can be added to, wax, organohalogen compounds, halogen, metal and their alloy comprised.Organohalogen compounds generally can decompose in process of lapping, discharge halogen acids or gaseous halide.This examples of material comprises chlorinated wax such as tetrahedronaphthalene, five chlorinated naphthalenes and polyvinyl chloride.The example of halogen comprises sodium chloride, elpasolite, sodium cryolite, ammonium ice crystal, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluoride, potassium chloride and magnesium chloride.The example of metal comprises tin, lead, bismuth, cobalt, antimony, cadmium, iron and titanium.Other grinding aid comprises sulphur, organosulfur compound, graphite and metal sulfide.The other example of grinding aid comprises the mixture of sodium metaphosphate, tripotassium phosphate and polyvinyl chloride and potassium tetrafluoroborate.Use the mixture of different grinding aids, can produce synergy in some cases, this also within the scope of the invention.For example, by weight, the cementing medium of abrasive product can comprise about 0-80 part grinding aid, is preferably 0-70 part grinding aid, better is about 10-55 part grinding aid.
The example of the cementing medium coupling agent that is used for coated abrasives, non-woven abrasive or bonded abrasive be can be added to, organosilan, zircoaluminate and titanate comprised.Can select suitable coupling agent to be used for abrasive particle and/or filler.Can directly coupling agent be joined in the mixture of cementing medium and abrasive particle and/or filler.Perhaps, also can use coupling agent preliminary treatment abrasive particle and/or filler.
Filler particles and/or the definite grinding aid particle of shape that shape is determined are added in the cementing medium of abrasive product, also within the scope of the invention.Usually, should control the granular size of the definite abrasive grains of definite filler particles of these shapes and/or shape, make and when making abrasive product, can suitably process cementing medium.For example, in coated abrasives or non-woven abrasive, the granular size of the grinding aid particle that filler particles that shape is determined and/or shape are determined should be preferably less than about 50 microns less than about 100 microns, makes the initial engagement coating of gained and/or sizing menting property to apply suitably.
Nonwoven abrasive article has an opening, porous, fibrous nonwoven substrates, and many bonding abrasive grains are thereon arranged on the base material.Such nonwoven abrasive article is disclosed in United States Patent (USP) 2,958, in 593.
The bonded abrasive product generally is with the be bonded together object of the definite shape that forms of cementing medium by many abrasive particles.Cementing medium generally is to solidify or crosslinked organic bond preferably.The shape of object better is the form of emery wheel.Yet, the bonded abrasive that various ways can be arranged is as honing stone, polish stick, saw blade, cutting rod, erection joint, polishing emery wheel, refacer, cup wheel, honing stone, cutting emery wheel, concave bottom emery wheel (depressed center wheels), fin emery wheel etc.The diameter of emery wheel is about 0.1 centimetre to 2 meters, is generally 1 centimetre to 2 meters.The thickness of emery wheel is about 0.001 centimetre to 1 meter, is generally 0.01 centimetre to 0.5 meter.In the useful life period of bonded abrasive article, can repair with the method for any routine.Perhaps, also bonded product can be made and do not need the structure of repairing.
The particle that shape of the present invention is determined can be added in the cutting emery wheel.The diameter of cutting emery wheel is generally 1 centimetre to 500 centimetres, and its thickness is 0.01 centimetre to 1 centimetre.Also can comprise the enhancing fabric in the cutting emery wheel.The example that strengthens base material comprises fabric, net etc.The yarn that strengthens in the base material can be made by synthetic organic fibre such as nylon, polyester, staple fibre, cotton etc.Perhaps, the yarn that strengthens in the base material also can be made by the fiber of inorfil such as glass fibre, aluminium oxide and metal etc.
Bonded abrasive can use organic adhesive medium, vitrifying cementing medium or metal cementing medium.The organic adhesive medium wherein can also add additive as mentioned above.Other organic adhesive medium comprises rubber cement and lac binding agent.In addition, bonded abrasive can comprise the cementing medium of rubber-based.A kind of cementing medium commonly used is with the crosslinked novolaks cementing medium of hexa.The example of the phenolic aldehyde cementing medium that can buy comprises Varcum 8121 (liquid resole resin) and Varcum 7909 (Powdered novolaks), and they are all available from Varcum Chemical Company, Niagara Falls, NY.If bonded abrasive makes through mechanography, then be preferably the mixture that uses Powdered organic adhesive medium and liquid organic adhesive medium.In molding process, at first the particle that liquid organic adhesive medium and abrasive particle and/or shape are determined mixes.Like this, liquid has just wet the surface of the particle that abrasive particle and/or shape determine.Then, drying or pulverous cementing medium are mixed with liquid cementing medium/abrasive particle.In some cases, in cementing medium, should comprise fortifying fibre.Add these fortifying fibres can improve the bonding emery wheel intensity, wearability or hear resistance.The example of this fortifying fibre comprises glass fibre, metallic fiber, organic fiber (as aromatic polyamide fibre, polyolefine fiber, Fypro, polyester fiber etc.), inorfil (as alumina fibre, silicate fiber etc.).
The porosity that generally has certain form in the bonded abrasive article.The size of porosity affects its cracked performance significantly.Usually, many kinds of bonded abrasives are designed to meet required grinding purposes.Bonded abrasive can have the porosity of any size, for example in some cases, by volume, the scope of porosity is about 1%-50%, is generally 1%-40%.There is several method can make bonded abrasive have porosity.A kind of method is to use porous body, diluent or other soft particle.Some examples of porous body comprise the hollow bead of glass, aluminium oxide, metal or polymer.In some cases, add porosity and/or the cracked performance that some fillers can improve bonded abrasive.Another kind method is to add blowing agent in bonded abrasive, and typical blowing agent as mentioned above.Another method is to use some fugitive materials, and it can decompose in the heating process of organic or nature of glass cementing medium, thereby produces hole.These fugitive material application in the vitrifying emery wheel are general more than the application in the resin bonded emery wheel.This fugitive examples of material comprises walnut shell, sugar, two phthalic acid hydrocarbon (diphthalichydrocarbon), thermoplastic granulates etc.
Methods such as bonded abrasive article of the present invention can repressed moulding, injection moulding or transfer formation make.Molded can or colding pressing or the well-known any suitable manner of art technology practician is carried out by hot pressing.After bonded abrasive article is molded and shaped, general polymerization or the curing of adopting the method initiation cementing medium of heating.The manufacturing of bonded abrasive can manage to make abrasive particle of the present invention only to be present in the outside or peripheral of emery wheel.
The concave bottom emery wheel is commonly used to ground flat.There is one this emery wheel is connected to erecting device on the grinding machine in the central authorities of emery wheel.This erecting device can be the centre bore that forms axis hole.In many cases, these concave bottom emery wheels have a flat center or the center of depression.The concave bottom emery wheel can be molded as the shape of tray or saucer, has curved or straight outside open edge.The back side of concave bottom emery wheel (promptly opposite with abrasive coating one side) can comprise and strengthens fabric, strengthens other bracing or strutting arrangement such as metallic plate or plastic plate of paper backings or some.
In use, bonded abrasive can be done or wet state use.In the wet-milling process, bonded abrasive can combine use with water, oil lubricant or water base lubricant.
Abrasive product of the present invention can also comprise conventional abrasive material aggregation particle or single abrasive particle or both and comprise.Conventional abrasive material aggregation particle is in United States Patent (USP) 4,311,489; In 4,652,275 and 4,799,939 further description is arranged.Also can select single abrasive particle, it is easy to use to obtain to have definite shape.The example that uses as single abrasive particle comprises fused alumina, ceramic alumina, heat treated aluminium oxide, carborundum, alumina zirconia, diamond, ceria, cubic boron nitride, garnet and their mixture.At least 10%, be preferably at least 50%, being preferably at least 70% abrasive material should be the abrasive grains that adopts shape of the present invention to determine.In coated abrasives, can adopt single abrasive particle to be used on the definite abrasive grains of shape.Perhaps, also can adopt single abrasive particle be placed on abrasive grains that shape determines below.Also single abrasive particle can be placed between the definite abrasive grains of two-layer shape.
Shape determines that the size of particle should be not more than 2500 microns.Shape determines that the size of particle is preferably the 0.1-1500 micron, and more preferably the 0.1-500 micron is well the 50-500 micron again.As mentioned above, the shape of determining and the surface portion of fabrication tool, for example the cavity shape that forms on the fabrication tool surface is corresponding.Particle of the present invention has definite shape.Why this definite shape forms is because adhesive precursor is partly solidified at least in the cavity of fabrication tool.Yet, when from cavity, removing particle, can make these particles produce some small defectives.If adhesive precursor solidifies insufficiently in cavity, then adhesive precursor will flow, and the gained coating of particles just can not be corresponding with the shape of cavity like this, therefore will make coating of particles uncertain and irregular.This definite shape can be any geometry, as cone, triangular prism body, cylinder, pyramid, spheroid with have by object constant or separated two the relative polygon facets of different distance, i.e. gengon.Pyramid is that its bottom surface has three limits or four edges preferably.Abrasive product can comprise various difform abrasive grains.Fig. 7 has the scanning electron micrograph of the pyramid abrasive grains of triangle bottom surface with about 300 x magnifications.
Former grain of grinding aid and adhesive shared percetage by weight in the grinding aid particle that shape is determined depends on all multifactor, as the size and the distribution of abrasive particle used in the required purposes of abrasive product and the abrasive product.In general, the percetage by weight of the former grain of grinding aid is about 5-95%, and the percetage by weight of adhesive is about 95-5%.Be preferably, by weight, the former grain of grinding aid accounts for 20-75%, and binder constitutes 80-25%.
In another aspect of the present invention, the definite particle of shape does not contain abrasive particle.The particle that these shapes that do not contain abrasive particle are determined can be used as diluent particle in coated abrasives.For example, coated abrasives can comprise backing, on the backing is the particle that abrasive particle and the shape that does not contain abrasive particle are determined and be adhered to.Perhaps, coated abrasives can comprise the definite particle of first coating (initial engagement coating), abrasive particle and shape of the cured resin adhesive on backing, the paint backing front surface, wherein with the initial engagement coating abrasive particle and the definite particle of shape is fixed on the backing.On the stratum granulosum that abrasive particle and shape are determined, be second coating (sizing menting property) of cured resin adhesive again.
The abrasive grains that shape is determined can randomly apply or be placed on the backing.The abrasive grains that shape is determined also can the direction with regulation be orientated on backing.The particle of determining in shape has under the situation of pyramid, cone and prism (as the triangular prism body) shape, as shown in Figure 4, particle is orientated like this, their bottom surface is towards backing, and their summit deviates from backing, or shown in four particles among Fig. 5, particle is orientated like this, backing is pointed on their summit, and their bottom surface deviates from backing.For pyramid and circular cone basis, alleged summit is common summit.
In general, coated abrasives comprises the backing with front and rear surfaces.On the backing front surface is one deck initial engagement coating, and this initial engagement coating is used for abrasive material is adhered to backing.On abrasive material, also maybe one deck sizing menting property can be arranged.Also maybe sizing menting property on one deck can arranged on the sizing menting property.A kind of coating of initial engagement preferably is the crosslinked resole resin that comprises filler particles (as calcium carbonate).A kind of sizing menting property preferably is the crosslinked resole resin that comprises filler particles (as calcium carbonate).Another kind sizing menting property preferably is the crosslinked resole resin that comprises grinding aid particle (as ice crystal, chiolite or tetrafluoro boric acid salt particle).It is a kind of that to go up sizing menting property preferably be cross-linked epoxy resin or also have thermoplastic polymer and grinding aid particle such as ice crystal, chiolite or tetrafluoro boric acid salt particle.Such sizing menting property of going up has further description in european patent application 486,308 and United States Patent (USP) 5,441,549.Maybe can have the last sizing menting property that can prevent its generation " load " phenomenon on the coated abrasives.The various materials of making initial engagement coating, sizing menting property and/or going up sizing menting property depend on that partly demand on the final coated abrasives performance and its grind purposes.
The particle that shape of the present invention is determined also can be added in the abrasive product (lapping coatedabrasive article) of overlap joint coating.The abrasive product that this overlap joint applies comprises backing with front and rear surfaces and the abrasive material that is adhered on the backing front surface.Comprise many shapes that are distributed in the whole initial engagement coating in the abrasive material and determine abrasive grains.
The particle that shape is determined also can be added in the structured abrasive article.Usually, structured abrasive article can comprise the abrasive composites that many shapes that are adhered on the backing are determined.These abrasive composites can comprise the particle that shape is determined, can contain or not contain abrasive particle in these particles.For structured abrasive article, shape determines that the granular size of particle should be preferably less than about 25 microns less than about 50 microns.
Coated abrasives can be transformed into various shape and form such as band, dish, sheet, platform etc.It is seam that a splicing can be arranged on the belt, perhaps can not have seam, as at the band described in the International Application No. WO 93/12911.In addition, can coated abrasives be fixed on the supporting pad with contact adhesive or shackle bindiny mechanism.
Usually, nonwoven abrasive article has nonwoven substrates open, bulk, porous.Nonwoven substrates is made of fiber, and these fibers can be Fypro (for example nylon fiber), polyester fiber, polyolefine fiber, their mixture etc.Fiber in the nonwoven substrates generally is bonded together it with pre-adhesive coatings or pre-bonding cementing medium on the point that is in contact with one another.Abrasive material is to be adhered on this open porous nonwoven substrates.Abrasive material can be made up of the mixture of abrasive particle and initial engagement coating material.This abrasive material is to determine that by applying (for example roller coat or spraying) initial engagement coating precursor and abrasive particle or shape the mixture of abrasive grains makes.Perhaps, nonwoven abrasive article can comprise be present among the nonwoven substrates and on the initial engagement coating, be adhered to abrasive material on the nonwoven substrates by the initial engagement coating.In the structure of this nonwoven abrasive article, the initial engagement coating applies in different steps with abrasive material.In addition, can also on the abrasive material of this nonwoven abrasive article of two types, apply sizing menting property.Nonwoven abrasive article various forms be can be transformed into, sheet, dish, roller, manual pad, endless belt, emery wheel etc. comprised.
Usually, bonded abrasive article is many abrasive particles with the be bonded together object of the definite shape that forms of cementing medium (as the resin binder that solidifies).At least a portion outer surface of bonded abrasive is designed to contact with polished workpiece.This with outer surface that workpiece contacts on comprise cementing medium and abrasive material.This abrasive material comprises the definite particle of shape of the present invention also can comprise other particle.The structure of these different abrasive materials will be described below.
Many different coated abrasives, nonwoven abrasive article, structured abrasive article and bonded abrasive article are arranged, and the particle that they can use shape of the present invention to determine is made.For example, abrasive material can only comprise the abrasive grains that shape is determined, these particles mainly are made up of abrasive particle and adhesive.Perhaps, the definite abrasive grains of shape can comprise abrasive particle, grinding aid, also can also contain other additive and adhesive.
In another example, abrasive material can comprise the mixture that single abrasive particle and shape are determined abrasive grains.The abrasive particle of determining single abrasive particle in the abrasive grains and other usefulness in shape can be identical or different.Single abrasive particle can be in irregular shape or have certain shape such as bar-shaped or triangle.The single abrasive particle of these definite shapes is in United States Patent (USP) 5,009,676; 5,035,723; 5,090,968; 5,103,598; Further describe in 5,201,916 and 5,366,523.Equally, the granular size of the abrasive particle of the single abrasive particle in the abrasive grains determined of shape and other usefulness can be identical or different.Similarly, the granular size of the abrasive grains determined of the granular size of single abrasive particle and shape can be identical or different.
In another example, abrasive material can comprise the mixture of the grinding aid particle that single abrasive particle and shape determine.The grinding aid particle that these shapes are determined mainly is made up of grinding aid and adhesive.Similarly, abrasive material can comprise the mixture of the grinding aid particle that abrasive grains that shape determines and shape determine.Shape determines that the granular size of abrasive grains determines that with shape the granular size of grinding aid particle can be identical or different.Grinding aid particle shared surface area percentage in abrasive material that shape is determined is about 5-90, is preferably 20-40.In addition, the method for making abrasive product can make single abrasive grain layer on the grinding aid stratum granulosum that shape is determined, under and/or between.
The grinding aid particle that shape is determined can produce very big benefit in abrasive product.In some cases, cementing medium may be incompatible with grinding aid.For example, resole resin is as the precursor of cementing medium sometimes, and this resole resin is cured under the alkaline pH condition or is crosslinked.In some cases, acid grinding aid may be to wish usefulness as potassium tetrafluoroborate.In these cases, potassium tetrafluoroborate may disturb the polymerization of some resole resin.The degree of this interference partly depends on the chemical property of concrete used resole resin.The grinding aid particle that shape is determined is that grinding aid wraps in the adhesive basically.Like this, the grinding aid in this particle should be minimum to the curing of cementing medium or the interference effect of polymerization.
Make abrasive product comprise many abrasive particles and the definite grinding aid particle of shape in abrasive material, and comprise grinding aid in cementing medium, this also within the scope of the invention.Grinding aid in the grinding aid particle that grinding aid in the cementing medium and shape are determined can be identical or different.
In another example, the mixture of the definite anti-loaded particle of single abrasive particle and shape can be arranged in the abrasive material.The anti-loaded particle that these shapes are determined comprises anti-support materials and adhesive.Shape determines that the granular size of abrasive grains determines that with shape the granular size of anti-loaded particle can be identical or different.Single abrasive particle and shape determine that the volume ratio of anti-loaded particle is about the single abrasive particle of 0.1-10 part: the anti-loaded particle that 0.1-10 part shape is determined.In addition, the method for making abrasive product can make single abrasive grain layer on the anti-loaded particle layer that shape is determined, under and/or between.
Similarly, can there be shape to determine that abrasive grains and shape determine the mixture of filler particles in the abrasive material.In analogous cases, can there be single abrasive particle and shape to determine the mixture of filler particles in the abrasive material.The filler particles that these shapes are determined comprises filler and adhesive.The volume ratio of the filler particles that abrasive grains that single abrasive particle or shape are determined and shape are determined is about single abrasive particle of 0.1-10 part or the definite abrasive grains of shape: the filler particles that 0.1-10 part shape is determined.In addition, the method for making abrasive product can make single abrasive particle or shape determine the abrasive grains layer determine on the filler particles layer in shape, under and/or between.
In addition, abrasive material can comprise abrasive grains and the diluent particle that shape is determined.These diluent particles can be selected from 1) inorganic particle (being not the inorganic particle of abrasive material), 2) organic granular, 3) comprise the composite thinning agent particle and 4 of the mixture of inorganic particle and adhesive) comprise the composite thinning agent particle of the mixture of organic granular and adhesive.The granular size of these diluent particles is about the 0.01-1500 micron, is generally the 1-1000 micron.The abrasive grains that diluent particle and shape are determined can be identical on granular size and particle size distribution, also can be different.The abrasive grains that shape is determined and the weight ratio of diluent particle, be about the abrasive grains that 1-99 part shape of the present invention is determined: any value between 99-1 part diluent particle, be generally the abrasive grains that 10-90 part shape of the present invention is determined: 90-10 part diluent particle, be preferably the abrasive grains that 25-75 part shape is determined: 75-25 part diluent particle, the abrasive grains determined of 35-65 part shape more preferably: 65-35 part diluent particle is preferably the abrasive grains that 50-50 part shape is determined: 50-50 part diluent particle.
This representative example of the different structure of particle in abrasive material that shape is determined is not limited to this, and it only is particle various different examples that use in abrasive product that shape is determined.
Another aspect of the present invention relates to a kind of coated abrasives and a kind of method of making coated abrasives of novelty.Coated abrasives comprises:
(a) has the backing of front and rear surfaces;
(b) the initial engagement coating on the backing front surface;
(c) be adhered to abrasive material on the backing front surface by the initial engagement coating, wherein this abrasive material comprises many abrasive particles;
(d) sizing menting property on abrasive material, this sizing menting property comprises:
(1) cementing medium of Gu Huaing,
(2) the definite grinding aid particle of many shapes, the grinding aid particle that this shape is determined comprise adhesive and the former grain of many grinding aids.
The method of making coated abrasives comprises the steps:
(a) provide backing with front and rear surfaces;
(b) on the front surface with initial engagement coating precursor paint backing;
(c) many abrasive particles are applied on the initial engagement coating precursor;
(d) backing, initial engagement coating precursor and abrasive particle are under certain condition, make the initial engagement coating precursor partly solidified at least, form the initial engagement coating of solidifying;
(e) with on the sizing menting property precursor paint abrasive particle;
(f) the grinding aid particle that many shapes are determined is applied on the sizing menting property precursor, and the grinding aid particle that shape is determined comprises adhesive and the former grain of many grinding aids;
(g) initial engagement coating, abrasive particle and the sizing menting property precursor of backing, curing are under the certain condition, make the sizing menting property precursor partly solidified at least, make coated abrasives.
Coated abrasives can make by following process.One backing with front and rear surfaces is provided.Be coated on the front surface of backing with the first kind of curable cementing medium that comprises resin binder (being commonly referred to the initial engagement coating); The grinding aid particle that shape is determined or also apply or be applied on first kind of curable cementing medium then together with single abrasive particle.Can drip and be coated with or grinding aid particle that the electrostatic coating shape is determined or comprise abrasive particle.Make first kind of curable cementing medium curing or partly solidified then, form the resin binder that solidifies.Also on the particle that can also second kind of curable cementing medium (being commonly referred to sizing menting property) paint shape that comprises resin binder be determined, make it then to solidify, form the resin binder that solidifies.Can before or after making first kind of curable cementing medium curing, apply second kind of curable cementing medium.
Perhaps, can earlier single abrasive particle be applied or be applied on first kind of cementing medium, then the grinding aid particle coating of again shape being determined in the above.
Determine in Any shape to apply a coating also within the scope of the invention on the outer surface of particle.This coating can be continuous or discrete.Be applicable to the example of the coating of particle, comprise the carbon coating of metal coating, coating of metal oxides, carbide coating, nitride coatings, boride coating, carbon coating, diamond coatings, diamond-like etc.Perhaps, can have organic coating on the surface of particle.Can also comprise filler, coupling agent, antistatic additive, grinding aid etc. in the organic coating.
The required performance that the selection and the consumption of coating depended on particle.For example, adopt some coating can obtain the particle of retroreflectiveness.Perhaps, some coating can be improved the cohesive of particle and other material or base material.
Use the definite rare diffusing abrasive material slurry of preparation of granules of shape also within the scope of the invention.These abrasive material slurry generally comprise the definite particle of shape and the mixture of liquid medium.The particle that shape is determined can further comprise abrasive particle (one or more), grinding aid (one or more), filler (one or more) or lubricant (one or more).The particle that shape is determined can comprise adhesive, abrasive particle and grinding aid or lubricant, and this situation also within the scope of the invention.The details of abrasive particle, grinding aid and filler as mentioned above.The example of lubricant comprises slaine, sulfur-based compound, graphite, molybdenum bisuphide, talcum, boron nitride, siloxanes, silicone oil, polyethylene glycol, phosphate, esters of silicon acis, neopentyl polyol esters and polyphenylene oxide, fluorochemical, the mineral oil of wax, aliphatic acid, their mixture etc.Liquid medium is generally water (comprising deionized water, running water or distilled water), is organic solvent sometimes.Sometimes, liquid is the mixture of water and other additive, and described additive for example is the organic compound, cutting fluid, soap, wax of lubricant, antirust agent, coupling agent, antifoaming agent, antibacterium compound, degreasing compound, oil, grinding aid, emulsification, their mixture etc.
Rare diffusing abrasive material slurry can use in the operation of sandblast type.Perhaps, rare diffusing abrasive material slurry also can combine use with used lapping plate or polishing pad in overlap joint or the polishing operation.Lapping plate can be used plate such as metallic plate, the ceramic wafer etc. of rigid material.Polishing pad can be pad such as foam pad (comprising polyurethane foam pad), polymeric material (as polyamide material, the elastomeric material etc.) pad etc. of flexible material.Polishing pad also can and be adhered to the compound of the polyurethane foamed material on this rigid substrate with the base material (as rigidity plastics or metal) of rigidity relatively.Lapping plate and/or polishing pad have smooth outer surface, but their outer surface also can be veined, top figuratum or discontinuous.
Of the present invention aspect another in, the present invention relates to a kind of method of finishing workpiece outer surface.This method comprises the steps:
(a) abrasive grains that provides many shapes to determine, the abrasive grains that these shapes are determined comprises many abrasive particles that are distributed in the adhesive, and this adhesive is to be made by the adhesive precursor that comprises radically curable resin;
(b) provide at least one workpiece, this workpiece has an outer surface;
(c) provide container, can hold the abrasive grains that at least one described workpiece and described many shapes are determined in the described chamber with a chamber;
(d) make the described relatively many shapes of described workpiece determine the part motion of abrasive grains, make the outer surface of the definite abrasive grains finishing workpiece of shape.
Of the present invention aspect another in, the present invention relates to a kind of method of finishing workpiece outer surface.This method comprises the steps:
(a) provide a kind of fabrication tool of said three-dimensional body, it has at least one continuous surface, and at least one perforate is arranged on the described surface, and described at least one perforate provides the inlet that enters described said three-dimensional body cavity;
(b) provide adhesive precursor that a kind of energy will comprise thermosetting resin to introduce distributor in described at least one cavity by described at least one perforate;
(c) in curing area, provide a kind of partly solidified at least device of described adhesive precursor that makes;
(d) described adhesive precursor is introduced at least a portion space of described at least one cavity;
(e) make described at least one cavity by described curing area continuously, make described adhesive precursor partly solidified at least, obtain the cure adhesive that shape is corresponding with the void space of introducing adhesive precursor, can dispose;
(f) described adhesive is removed from described at least one cavity;
(g) described adhesive is transformed into the particle that many shapes are determined;
(h) particle that provides many described shapes to determine, the particle that these shapes are determined comprises adhesive;
(i) provide at least one workpiece, this workpiece has an outer surface;
(j) provide container, can hold the particle that at least one described workpiece and described many shapes are determined in the described chamber with a chamber;
(k) part of the described workpiece particle definite with respect to described many shapes is moved, make the outer surface of the definite particle finishing workpiece of shape.
The particle that these shapes are determined preferably also comprises at least a following material: abrasive particle, lubricant, filler, grinding aid and their mixture.
Container can be any suitable vessel that has a chamber therein.This chamber is a kind ofly can hold particle that workpiece and many shapes determine or the structure that also has liquid medium.In this chamber, concerning the particle that shape is determined, sufficient space should be arranged, so that the outer surface of finishing workpiece effectively.
No matter be the particle that is added in the abrasive product,, all the particle that shape is determined can be designed to the outer surface part of energy finishing workpiece still as the particle of rare diffusing slurry.Term " fine finishining " is meant that particle has at least a in the following behavior, remove the part (for example grinding) of workpiece outer surface, remove the surface smoothness (promptly reducing scratch depth) (as polishing or polishing) of fragment (comprising undesired material such as dirt, oil, grease etc.) (as cleaning) or raising workpiece from the workpiece outer surface.
The present invention can be used for the surface of many kinds of workpiece of fine finishining.These surface of the works comprise that metal (comprises mild steel, carbon steel, stainless steel, casting pig, titanium, aluminium etc.), metal alloy (copper, brass etc.), particulate metal alloy, pottery, glass, timber (comprises pine tree, Oak Tree, maple, elm, English walnut, hickory, mahogany, cherry tree etc.), timber shape material (comprises flakeboard, clamping plate, glued board etc.), composite, be coated with the surface of lacquer, plastics (thermoplastic that comprises thermoplastic and enhancing), stone material (comprises jewelry, marble, granite and jasper), magnetic medium etc.The other example of glass pieces comprises glass television screen, lens, glass eye surface, window (comprising family expenses window, office's window, automobile window, transom window, train window, bus window etc.), glass display rack, mirror etc.
Workpiece can be flat or can have certain shape or profile.Concrete workpiece also has some examples, comprises metal engine components (comprising camshaft, crank axle, engine main body etc.), hand-operated tools metal forging, fibre optics polishing body, little case, furniture, wooden cabinet, turbine blade, is coated with the automobile component, magnetic medium (comprising hard disk quality processing (rigid disc texturing), floppy disk etc.) of lacquer etc.
Look concrete fine finishining purposes, be about 0.01 kilogram to more than the double centner, be generally 0.1 to 10 kilogram in the power of grinding on the interface.For some purposes, on the interface between abrasive product or rare scattered seed and the workpiece outer surface, can there be liquid equally.This liquid can be water and/or organic solvent.This liquid can also comprise additive such as lubricant, antirust agent, coupling agent, antifoaming agent, antimicrobial compound, degreasing compound, oil, grinding aid, emulsification organic compound, cutting fluid, soap, wax, their mixture etc.Abrasive product can vibrate on polished surface in its use.
Can be by hand or the mode that combines with machinery use abrasive product.For example, abrasive product can be fixed at random rail starts building on tool (random orbital tool) or the throw.In abrasive product and the workpiece outer surface at least one or two are done relative motion mutually.
Can will apply or non-woven abrasive product is transformed into the continuous roller of any form such as sheet, dish, length, band etc.If abrasive product moves with respect to workpiece, then this abrasive product can any required mode move, and this depends in part on concrete fine finishining purposes to a great extent.For example, abrasive product can back-and-forth mode, the mode of rotation mode, circular, fashion, spiral way, oval mode or random motion moves.In addition, abrasive product can also vibrate and/or swing in polishing process.
The workpiece outer surface keeps transfixion in the fine finishining process, perhaps moves with respect to abrasive product, and both of these case all within the scope of the invention.If the workpiece outer surface moves with respect to abrasive product, then this abrasive product can any required mode move, and this depends in part on concrete fine finishining purposes to a great extent.For example, the workpiece outer surface can back-and-forth mode, the mode of rotation mode, circular, fashion, spiral way, oval mode or random motion moves.In addition, the workpiece outer surface can also vibrate and/or swing in the fine finishining process.
The particle that shape is determined can be used as blast media, and this also within the scope of the invention.For this reason, these particles are to spray (with higher speed) to the outer surface of workpiece.The particle that shape is determined can only be made up of adhesive basically.Perhaps, the definite particle of this shape can also comprise abrasive particle, filler, grinding aid, lubricant or their mixture.
In addition, the particle that in control goods traction or anti-skidding, can use shape to determine, this is also within the scope of the invention.For example, the particle that shape is determined can be adhered on the backing, the goods that gained control is drawn are fixed on floor, stair, step, deck, computer mouse pad, aisle, slope, catwalk, the mat etc.Can fix the goods of control traction with contact adhesive, removable adhesive, shackle annex or permanent adhesives.In this case, the goods of this control traction can be regulated the contacted surface of determining with shape of particle significantly, but more are the coefficient of frictions that generally provides bigger, and the result can reduce the possibility of slip.The goods of control traction have the structure similar with coated abrasives basically, and initial engagement coating and sizing menting property are promptly arranged, and this also is good.Perhaps; the particle that shape can be determined be sneaked in the adhesive (better being flowable adhesive), and the composition of this gained is applied to or is coated on floor, stair, step, deck, computer mouse pad, aisle, slope, catwalk, the mat etc.After the composition with this control traction is applied on the surface, adhesive is solidified, become the goods of control traction.The particle that used shape is determined in the goods of control traction can only be made up of adhesive basically.Perhaps, the definite particle of this shape can also comprise abrasive particle, filler, lubricant or their mixture.Comprise shape and determine that the goods of the control traction of particle can use on indoor or outdoor applications.
The particle that uses shape to determine in filament or bristle, this also within the scope of the invention.The diameter of bristle generally is about the 15-2500 micron, is about the 25-2000 micron usually, is preferably the 50-1500 micron.The length-width ratio of bristle is about greater than 1, better is about greater than 5, better is about greater than 10.With many these bristles and lump together, make a brush then.This brush can be flat brush or changes brush.The example of brush construction is in United States Patent (USP) 3,924,286; In 4,627,127 and 5,016,311 further description is arranged.These bristles can comprise the particle that shape is determined, can have or not have abrasive particle in these particles.For bristle, be preferably granular size that used shape determines particle less than about 50 microns, be preferably less than about 25 microns.The manufacturing of bristle can be with extrusion or injection moulding.A kind of structure of good brush especially is to have many single bristles on a pliable and tough substrate.This brush is the thermoplastic through injection moulding.
Do not departing under scope of the present invention and the smart situation of planting, to various improvement of the present invention with to change concerning being skilled in technique of this area all be conspicuous, and what should understand is the present invention to be confined to irrelevantly exemplary embodiment as herein described.
The more following embodiment that does not play restricted effect will further specify the present invention.Except as otherwise noted, all umber, percentage, ratio or the like are all by weight among the embodiment.
In all embodiment, listed abbreviation and the trade name of table 1 below using.
Table 1 material marking
Label Material
TMPTA Trimethylolpropane triacrylate, it with trade name " Sartomer 351 " available from Sartomer, Exton, PA
TATHEIC The triacrylate of three (ethoxy) isocyanuric acid ester, it with trade name " Sartomer 368 " available from Sartomer, Exton, PA
PH1 2-benzyl-2-N, N-dimethylamino-1-(4-morpholino phenyl)-1-butanone, it with trade name " IRGACURE 369 " available from Ciba Geigy Company
KBF 4 Mean particle size is about 10 microns the former grain of potassium tetrafluoroborate grinding aid
CRY Available from the former grain of the sodium aluminum fluoride grinding aid of Washington Mills commodity
CAO1 The ceramic alumina abrasive particle that comprises Alpha-alumina, magnesia and rare-earth oxide modified agent, it with trade name " 321 Cubitron " abrasive particle available from 3M Company, St. Paul, MN
MSCA 3-methacryloxypropyl trimethoxy silane coupling agent, it with trade name " A-174 " available from Union Carbide Corp.
ASF Average surface area is 50m 2The amorphous silicas particle of/g, it with trade name " OX-50 " available from DeGussa Corp. (Richfield Part, NJ)
PVC Polyvinyl chloride, it with trade name " Geon 103EPF-76 " available from Geon Company, Cleveland, Ohio
PETA Pentaerythritol triacrylate, it with trade name " Sartomer 444 " available from Sartomer, Exton, PA
RPR1 Resole resin, it comprises 74% solid in water/cellosolvo, with NaOH catalysis, viscosity is about 2,000 centipoises in the time of 25 ℃
RPR2 Resole resin, it comprises 74% solid in water, with potassium hydroxide catalysed, viscosity is about 2,000 centipoises in the time of 25 ℃
PH2 2,2-dimethoxy-1-2-diphenyl-1-ethyl ketone, it with trade name " Irgacure 651 " available from Ciba Geigy Company
BAO Rank is 180 brown fused alumina abrasive particle, available from Villach, and Austria
GUAM The glycoluril acrylamide resin that contains side chain α, beta-unsaturated carbonyl; By and United States Patent (USP) 5,055, the preparation 5 similar methods in 113 are made this material
DAP The diallyphthalate acyloxy ethyl ester; By and United States Patent (USP) 3,336, similar method is made this material in 418
NPGDA Diacrylic acid pentyl diol ester, it with trade name " Sartomer 247 " available from Sartomer, Exton, PA
Q2 Antifoaming agent, it with trade name " Q2 " available from Dow Corning
CACO 3 Mean particle size is about 15 microns pearl filler
CASIO 3 Mean particle size is 18 microns a calcium silicate filling material
WA Wetting agent, it with trade name " Disperbyk 111 " available from Byk Chemie USA, Wallingford, CT
Made the particle that shape is determined by a kind of program in the following general procedure.The general procedure particle that these shapes are definite that is made as follows coated abrasives is added in the coated abrasives.By a kind of program in the following test program abrasive product is tested.
Make the general procedure I of the definite particle of shape
With similar equipment shown in Figure 8 on make the particle that shape is determined, different is the back side that ultrasonic generator is contained in the carrier band.Load onto the fabrication tool of continuous band forms, wherein contain a series of cavitys with the size of indicating.These cavitys are arranged to predetermined order or arrangement, make that fabrication tool is that shape is determined the anti-phase of particle required form and size basically.Fabrication tool is made by the polypropylene thermoplastic material, it in advance on a master tool by extruded polypropylene material and embossed.A series of cavitys that indicate size and dimension that have are also arranged in the Ni-based plinth instrument.Ni-based plinth instrument makes with cutting annular knurl method.The cavity that certain arrangement is arranged in the fabrication tool, these cavitys are the pyramid shape with square bottom surface, and dock mutually the bottom surface of these cavitys.The height of pyramid is about 560 microns, and the length on each limit, bottom surface is about 1490 microns.This that fragment that comprises the surface of fabrication tool of cavity and fabrication tool shown in Figure 6 is similar.
When leaving under the tension force of fabrication tool at about 30psi when separating winding apparatus, the polyester film carrier band of 51 micron thickness leaves second and separates winding apparatus.This polyester film comprises the ethylene acrylic acid co polymer primer.Adopt the fixed interval (FI) to be about in the cavity of scraper on 51 microns the roll coater with adhesive precursor paint fabrication tool.The employing pressure of nipping is about the nip rolls of 60psi, and the fabrication tool part that adhesive precursor is housed is contacted with the carrier band.Fabrication tool part and carrier band that adhesive precursor is housed are pressed onto on the axle of pivoting.Next, making radiation see through fabrication tool shines in the adhesive precursor.Radiation energy is available from Fusion, four uviol lamps of Inc, and these four lamps use " D " bulb, in 600 watts/inch (240 watts/centimetre) work down.Under the effect of this radiation, adhesive precursor just is transformed into the cure adhesive that can dispose.Be to adopt axle to make fabrication tool and the carrier band that can dispose cure adhesive are housed to pass through curing area continuously.Near nip rolls, the carrier band is stripped down from the fabrication tool that adhesive is housed.Ultrasonic generator (model is 108, and commodity are available from Branson) is placed directly in the back of carrier band.Ultrasonic generator is in high gear work, and it helps from the carrier band particle-removing that gets on.Then, under the tension force of about 100psi, on rewind, recoil the carrier band.This is a continuous process of operating to 180 feet per minute clocks (55 meters/minute) speed at about 130 feet per minute clocks (40 meters/minute).
These particles of removing from the carrier band have two kinds of forms, i.e. Li San particle and sheet of particles (sheet that a plurality of particles are linked to be).These discrete particles comprise that also two or three single particles connect together.Be preferably and discrete particle will be separated.If 25% or particle still less be to remove from the carrier band with the form of sheet of particles, then at first the particle (comprising discrete particle and sheet of particles) of gained is sieved, from sheet of particles, isolate discrete particle.In the cement mixing machine that uses steel or ceramic grinding medium, sheet of particles is carried out ball milling again.The length that mill is situated between is 1 inch (2.54 centimetres), and diameter is 3/4ths inches (1.9 centimetres).In mechanical milling process, note avoiding the discrete particle of wearing into is caused damage.After the ball milling, sieve again.If about 25% or more particles be to remove from the carrier band with the form of sheet of particles, then the particle of gained is carried out ball milling in mode similar to the above.After the ball milling, sieve.
Make the general procedure II of the definite particle of shape
Except following difference, all the other all use the similar degree of general procedure I of the particle definite with making shape to make the particle that shape is determined.Under 50 feet per minute clocks (15 meters/minute) speed, operate, only use a uviol lamp.
Make the general procedure III of the definite particle of shape
Except the size difference of cavity, all the other all use the similar program of general procedure II of the particle definite with making shape to make the particle that shape is determined.The height of pyramid is about 330 microns, and the length on its each limit, bottom surface is about 860 microns.
Make the general procedure IV of the definite particle of shape
Except using two uviol lamps and two lamps all to carry out the work under 600 watts/inch (240 watts/centimetre), all the other all use the similar program of general procedure I of the particle definite with making shape to make the particle that shape is determined.
Make the general procedure V of the definite particle of shape
Except the size difference of cavity, all the other all use the similar program of general procedure IV of the particle definite with making shape to make the particle that shape is determined.The height of pyramid is about 330 microns, and the length on its each limit, bottom surface is about 860 microns.
Make the general procedure VI of the definite particle of shape
Except the size difference of cavity, all the other all use the similar program of general procedure IV of the particle definite with making shape to make the particle that shape is determined.The length on pyramid base is about 1384 microns, and its each side is long all to be about 1295 microns, and the height of pyramid is about 530 microns.Such style is disclosed in United States Patent (USP) 5,152, among Fig. 1 of 917.In addition, be with the diamond turning method but not cutting annular knurl method is made master tool.
Make the general procedure VII of the definite particle of shape
Except following difference, all the other all use the similar program of general procedure I of the particle definite with making shape to make the particle that shape is determined.The size of cavity changes as follows, and the length on pyramid base is about 706 microns, and the height of pyramid is about 240 microns.In addition, only use two uviol lamps and the speed of service to bring up to 250 feet per minute clocks (76 meters/minute).
Make the general procedure I of coated abrasives
The particle that the grinding aid shape is determined is added on the coating mill that its backing made by vulcanized paper.The vulcanized paper dish makes respectively, and its diameter is 17.8 centimetres, and the diameter of centre bore is 2.2 centimetres.The initial engagement coating is conventional calcium carbonate-filled resole resin (48% resin, 52%CaCO 3).At first the grain blobs that shape is determined is coated onto on the initial engagement coating precursor.Then, with rank be 50 CAO1 abrasive particle electrostatic coating to the grinding aid particle, and be about 14 gram/dish electrostatic coatings with weight and enter the initial engagement coating.About 90 minutes of structure object at about 88 ℃ of heating gained makes resole resin partly solidified.Then, sizing menting property is brushed on the definite stratum granulosum of abrasive particle/shape.Sizing menting property also is the resole resin (32% resin, 68% ice crystal) that conventional ice crystal is filled.At about 90 minutes of the structure object of 93 ℃ of heating gained, heating 12 hours in the time of 100 ℃ is then solidified resole resin fully.The weight of wet initial engagement coating is about 4 gram/dishes, and the weight of wet sizing menting property is about 9-10 gram/dish.Before testing, the mill of gained has been carried out bending, and under 45% relative humidity wetting 7 days.
Make the general procedure II of coated abrasives
The particle that the grinding aid shape is determined is added on the coating mill that its backing made by vulcanized paper.The vulcanized paper dish makes respectively, and its diameter is 17.8 centimetres, and the diameter of centre bore is 2.2 centimetres.The initial engagement coating is conventional calcium carbonate-filled resole resin (48% resin, 52%CaCO 3).At first the grain blobs that shape is determined is coated onto on the initial engagement coating precursor.Then, with CAO1 abrasive particle electrostatic coating to the grinding aid particle and enter the initial engagement coating.About 90 minutes of structure object at about 88 ℃ of heating gained makes resole resin partly solidified.Then, sizing menting property is brushed on the definite stratum granulosum of abrasive particle/shape.Sizing menting property also is the resole resin (32% resin, 68% ice crystal) that conventional ice crystal is filled.At about 90 minutes of the structure object of 93 ℃ of heating gained, heating 12 hours in the time of 100 ℃ is then solidified resole resin fully.Sizing menting property is coated on the sizing menting property on the epoxy resin that the potassium tetrafluoroborate of routine is filled subsequently, then solidifies.The coat weight of initial engagement coating, sizing menting property and last sizing menting property all is the used conventional coat weight of this rank CAO1.
Make the general procedure III of coated abrasives
The abrasive grains that shape is determined is added in the coated abrasives.Make the method for coated abrasives and carry out in a continuous manner, gained coated abrasives band is transformed into the annular grinding belt of joint.Backing is the heavy polyester backing of conventional Y with satin weave.This cloth backing is handled with common phenolic resins and phenolic resins/latex-coated fabric facture, to improve the physical property of backing.On the front surface with initial engagement coating precursor paint backing.The initial engagement coating is conventional calcium carbonate-filled resole resin (48% resin, 52%CaCO 3), the coating weight that this initial engagement applies be 290 grams/square metre.The abrasive grains that shape is definite drips and is coated onto in the initial engagement coating precursor.About 60 minutes of structure object at about 96 ℃ of heating gained makes resole resin partly solidified.Then, sizing menting property is coated on the abrasive grains.Sizing menting property also is the resole resin (48% resin, 52% ice crystal) that conventional ice crystal is filled.At about 120 minutes of the structure object of 93 ℃ of heating gained, then, resole resin is solidified fully 107 ℃ of heating 10 hours.The gained coated abrasives has been carried out bending, tested afterwards.
Make the general procedure IV of coated abrasives
The abrasive grains that shape is determined is added in the coated abrasives.Make the method for coated abrasives and carry out in a continuous manner, gained coated abrasives band is transformed into the annular grinding belt of joint.Backing is the heavy polyester backing of conventional Y with satin weave.This cloth backing is handled with common phenolic resins and phenolic resins/latex-coated fabric facture, to improve the physical property of backing.On the front surface with initial engagement coating precursor paint backing.The initial engagement coating is conventional calcium carbonate-filled resole resin (48% resin, 52%CaCO 3), the wet coating weight of this initial engagement coating be about 290 the gram/square metre.Then, be that 36 brown fused alumina is dripped and is coated onto in the initial engagement coating precursor with about 440 gram ranks.Subsequently, with about 450 grams/square metre rank be that 36 CAO1 electrostatic coating is to plumbic ocher.About 90 minutes of structure object at about 88 ℃ of heating gained makes resole resin partly solidified.Then, sizing menting property is coated on the abrasive particle.Sizing menting property also is conventional calcium carbonate-filled resole resin (48% resin, 52% calcium carbonate), its weight in wet base be about 380 grams/square metre.After applying the sizing menting property precursor, the grinding aid grain blobs that shape is determined is coated onto in the wet sizing menting property precursor.At about 120 minutes of the structure object of 93 ℃ of heating gained, then, resole resin is solidified fully 100 ℃ of heating 10 hours.The gained coated abrasives has been carried out bending, tested afterwards.
Method of testing I
At first will apply mill and be installed on the aluminium supporting pad of hypotenuse, be used for grinding the surface of 1018 mild steel workpiece of 18 centimetres of 1.25 cm x then.Under not loading condition, with 5, the speed of 500rpm makes mill rotate, and under about 5.9 kilograms load, the mill part that covers the supporting pad hypotenuse is contacted with workpiece.The coating mill contacts with workpiece with 6 to 7 ° angle.Each mill ground 1 minute a workpiece, another workpiece was ground 1 minute again, so continued, and total milling time is 10 minutes.The amount (being total stock removal) of the metal that the measurement whole test process is removed.Each embodiment tests two coating mills.
Method of testing II
Be contained on the circumference of 36 centimetres of metal wheels applying the grinding belt fragment.Effective grinding area of grinding belt fragment is 109 centimetres of 2.54 cm x.Used grinding is a kind of surface grinding of routine, and workpiece moves back and forth below the contact emery wheel of rotation, the downward feeding that this moment, emery wheel increased progressively between each circulation.Grinding is carried out under the bath condition.The workpiece that grinds with these grinding belt fragments is 1018 steel, and it is centimetre high that it is of a size of 1.27 centimetres wide * 36 centimeter length * 7.6.Be on the surface of 36 centimetres of 1.27 cm x, to grind.The speed of metal wheel is 5830 surface feet/minute (1780 surface rice/minute).The speed of table that workpiece moves back and forth is 20 feet per minute clocks (6 meters/minute).The incremental change of the downward feeding of wheel is that 0.0127 millimeter/workpiece passes through.Lateral feed be 0.45 inch/by (1.14 centimetres/by).
Method of testing III
To on the surface grinder(lathe) machine of constant load, it be tested through the endless belt that the abrasive material that applies is made 335 centimetres of 7.6 cm x.Preweighted 304 stainless steel work-pieces that size are about 18 centimetres of 2.5 cm x, 5 cm x are installed on the bearing support.Workpiece is vertically placed, and the surface that makes 18 centimetres of 2.5 cm x is about the zigzag rubber contact wheel of 36 centimetres 65 Xiao A hardness towards diameter, on one folded one sawtooth platform of this wheel, adorning should annular the coating grinding belt.Speed with 20 cycles per minute makes workpiece up-and-down movement on 18 centimetres length then, and the depression bar that this moment spring is housed is pressed in workpiece on the grinding belt with 11.3 kilograms power, and the grinding belt wheel rotates with about 2050 meters/minute speed simultaneously.After grinding is carried out 1 minute, the workpiece support plane sub-assembly is taken off, weigh once more, calculate the weight that is ground off from the weight that the initial weight of workpiece deducts after the wearing and tearing, more preweighted new workpiece and bearing support are installed on the equipment.The time of test is 40 minutes.
Method of testing IV
Annular is applied grinding belt (335 centimetres of 7.6 cm x) to be contained on the surface grinder(lathe) of constant load.With about 2580 surface rice/minute speed to make band be to rotate on the aluminium contact wheel of 51 centimetres (20 inches) and the free pulley at diameter.Polished workpiece is 304 stainless steel bars, and diameter is 1.9 centimetres, and being about is 30 centimetres.Be pressed on the surface of rod on the abrasive belts 5 seconds when with the speed of 0.18 cel clock being, when applying the grinding belt rust, promptly no longer significantly during grinding work-piece, just reached the terminal point of test.
Method of testing V
Endless belt with abrasive product is made 6.3 centimetres of 203 cm x is contained on the Thompson grinding machine.Effective grinding area of grinding belt is 2.54 centimetres of 203 cm x.Workpiece is 304 stainless steels, and size is that 2.54 centimetres wide * 17.78 centimeter length * 10.2 are centimetre high, it is installed in move back and forth on the platform.On the surface of 17.78 centimetres of 2.54 cm x, grind.Used grinding is conventional surface grinding, and workpiece moves back and forth below the rotation grinding belt, each time of workpiece by between the downward feeding that increases progressively.Grinding condition is: feeding downwards is about 254 microns, and the workbench gait of march is 7.6 meters/minute, and belt speed is about 1710 surperficial meter per second clocks.Between below abrasive belts twice passes through in succession, adopt water spray (containing 1% antirust agent) that workpiece is cooled off.When grinding belt no longer effectively during grinding, be exactly the terminal point of test.
Embodiment 1-6 and comparative example A
This group embodiment relatively contains shape to determine the nonferromagnetic substance of the coated abrasives of grinding aid particle (embodiment 1-6) and do not contain the nonferromagnetic substance that shape is determined the coated abrasives of grinding aid particle (comparative example A).Except following difference, the grinding aid particle that shape is determined is made by the general procedure I that makes the definite particle of shape.For embodiment 1-3, the last polyester film of crossing primer is exposed under the corona source effect with 20% power work, contact with the grinding aid precursor composition then.At first use high shear mixer that consumption (representing with umber) is mixed as following table 2 listed TMPTA, TATHEIC, PH1, MSCA and ASF, be used for preparing the grinding aid slurry.Then, with grinding aid (KBF 4Or CRY) adds this adhesive precursor gradually as the grinding aid slurry.Table 2 is listed the amount (gram/dish) that is added to the grinding aid particle that shape is determined in the coated abrasives equally.
The prescription of the grinding aid slurry of table 2 embodiment 1-6
Material Embodiment 1 Embodiment 2 Embodiment 3 Embodiment 4 Embodiment 5 Embodiment 6
TMPTA ????50 ????50 ????50 ????70 ????70 ????70
TATHEIC ????50 ????50 ????50 ????30 ????30 ????30
PH1 ????1 ????1 ????1 ????1 ????1 ????1
MSCA ????1 ????1 ????1 ????1 ????1 ????1
ASF ????1 ????1 ????1 ????1 ????1 ????1
KBF 4 ????0 ????0 ????0 ????49 ????49 ????49
CRY ????50.6 ????50.6 ????50.6 ????0 ????0 ????0
The amount of grinding aid particle ????2 ????5 ????7 ????2 ????5 ????7
The coated abrasives of embodiment 1-6 is made by the general procedure I that makes coated abrasives.Except goods did not contain the definite grinding aid particle of shape, comparative example A's coated abrasives was made by the general procedure I that makes coated abrasives.
By the coated abrasives of method of testing I test gained, test result is listed in the table 3.
Table 3 method of testing I
Embodiment 1-6 and comparative example A
Embodiment Initial stock removal (gram) Total stock removal (gram)
????1 ????44.6 ????146.9
????2 ????45.1 ????195
????3 ????44.3 ????221
????4 ????44.1 ????136.9
????5 ????50.4 ????197.8
????6 ????48.4 ????208.5
????A ????32.7 ????111.8
From above-mentioned data as can be seen, add the definite particle of shape and improved the nonferromagnetic substance that applies mill.
It should be noted that initial stock removal is the stainless steel amount of removing in first grinding of 60 seconds.These grinding values are the mean value of two coating mills.
Embodiment 7-13 and Comparative Examples B-E
This group embodiment relatively contains shape to determine the nonferromagnetic substance of the coated abrasives of grinding aid particle (embodiment 7-13) and do not contain the nonferromagnetic substance that shape is determined the coated abrasives of grinding aid particle (Comparative Examples B-E).For embodiment 7,8,10,11 and 12, the particle that shape is determined is made by the general procedure II that makes the definite particle of shape.For embodiment 9 and 13, the particle that shape is determined is made by the general procedure III that makes the definite particle of shape.At first use high shear mixer with 1700 gram TMPTA, 30 gram ASF, 60 gram MSCA, 1350 gram KBF 4, 1550 gram PVC and 22.5 gram PH1 mix preparation grinding aid slurry.Embodiment 7-13 coated abrasives is made by the general procedure II that makes coated abrasives.Except goods did not contain the definite grinding aid particle of shape, the coated abrasives of Comparative Examples B-E was made by the general procedure II that makes coated abrasives.Listed rank, the shape of CAO1 for these embodiment and determined the amount (showing) of grinding aid particle and the amount (showing) of CAO1 with gram/dish cart with gram/dish cart.
The amount of the material of table 4 embodiment 7-13 and Comparative Examples B-E
Embodiment The rank of CAO1 Grinding aid particle (gram/dish) CAO1 (gram/dish)
????B ????24 ????0 ????36
????7 ????24 ????5 ????23.5
????8 ????24 ????2.5 ????20.5
????C ????36 ????0 ????20
????9 ????36 ????12 ????4
????D ????50 ????0 ????21
????10 ????50 ????2.5 ????20
????11 ????50 ????5 ????14.2
????12 ????50 ????7.5 ????12.2
????E ????80 ????0 ????19.5
????13 ????80 ????5 ????15
By the coated abrasives of method of testing I test gained, test result is listed in the table 5.
Table 5 method of testing I
Embodiment 7-13 and Comparative Examples B-E
Embodiment Total stock removal (gram)
????B ????264
????7 ????302
????8 ????320
????C ????121
????9 ????333
????D ????157
????10 ????196
????11 ????235
????12 ????255
????E ????115
????13 ????120
From above-mentioned data as can be seen, add the nonferromagnetic substance that the definite particle of shape has improved the coated abrasives dish.
Embodiment 14-28
This group embodiment has compared the nonferromagnetic substance that the shape that contains various adhesive compositions is determined the coated abrasives of abrasive grains (embodiment 14-29).What following table 6 was listed is to be used to make the prescription (consumption is listed with weight portion) that shape is determined the abrasive material slurry of abrasive grains.The abrasive grains that shape is determined is pressed the listed program manufacturing of table 7.The abrasive grains of shape being determined by the general procedure III that makes coated abrasives is added in the coated abrasives.The weight of the abrasive grains that the shape of each embodiment is determined and the weight of sizing menting property are also listed in the table 7.
The abrasive material slurry prescription of table 6 embodiment 14-28
Material Embodiment 14,15,16 Embodiment 17,18 Embodiment 19 Embodiment 20 Embodiment 21
????TATHEIC ????516 ????0 ????0 ????0 ????0
????TMPTA ????1204 ????1720 ????1720 ????0 ????0
????PH2 ????20 ????20 ????20 ????20 ????20
????MSCA ????60 ????60 ????60 ????60 ????60
????ASF ????30 ????60 ????60 ????20 ????20
????CRY ????1200 ????1200 ????0 ????1200 ????0
????BAO ????4000 ????4120 ????4120 ????3800 ????3800
????KBF 4 ????0 ????0 ????1200 ????0 ????0
????GUAM ????0 ????0 ????0 ????860 ????860
????DAP ????0 ????0 ????0 ????516 ????516
????NPGDA ????0 ????0 ????0 ????344 ????344
????Q2 ????0 ????0 ????0 ????1.5 ????1.5
????CACO 3 ????0 ????0 ????0 ????0 ????1200
????CASIO 3 ????0 ????0 ????0 ????0 ????0
The abrasive material slurry prescription (continuing) of table 6 embodiment 14-28
Material Embodiment 22 Embodiment 23 Embodiment 24 Embodiment 25,26 Embodiment 27,28
????TATHEIC ????0 ????0 ????0 ????0 ????0
????TMPTA ????0 ????0 ????0 ????0 ????0
????PH2 ????20 ????26 ????26 ????26 ????26
????MSCA ????60 ????60 ????60 ????60 ????60
????ASF ????20 ????0 ????0 ????0 ????0
????CRY ????0 ????0 ????0 ????0 ????0
????BAO ????3800 ????3600 ????3600 ????3500 ????3600
????WA ????0 ????0 ????0 ????1.5 ????1.5
????GUAM ????860 ????0 ????0 ????0 ????0
????DAP ????516 ????0 ????0 ????0 ????0
????NPGDA ????344 ????0 ????0 ????0 ????0
????PETA ????0 ????860 ????860 ????1190 ????860
????RPR1 ????0 ????0 ????0 ????689 ????1160
????RPR2 ????0 ????1160 ????1160 ????0 ????0
????Q2 ????1.5 ????1.5 ????1.5 ????1.5 ????1.5
????CACO 3 ????0 ????1200 ????0 ????0 ????0
????CASIO 3 ????1200 ????0 ????1200 ????1200 ????1200
Table 7 embodiment 14-28
Embodiment Make the general procedure of abrasive product Abrasive grains weight (gram/square inch) Sizing menting property weight (gram/square inch)
????14 ????IV ????0.53 ????.25
????15 ????IV ????0.53 ????.32
????16 ????IV ????0.53 ????.42
????17 ????V ????0.35 ????.27
????18 ????IV ????0.53 ????.37
????19 ????IV ????0.53 ????.299
????20 ????IV ????0.53 ????.41
????21 ????IV ????0.53 ????.42
????22 ????IV ????0.53 ????.41
????23 ????IV ????0.53 ????.42
????24 ????IV ????0.53 ????.40
????25 ????V ????0.37 ????.27
????26 ????VI ????0.44 ????.30
????27 ????V ????0.37 ????.26
????28 ????VI ????0.43 ????.28
By method of testing II test coated abrasives band, test result is listed in the table 8.Also listed total stock removal that the gram numerical table with the metal removed shows.
Table 8 method of testing II
Embodiment Total stock removal (gram)
????F ????400
????14 ????120
????15 ????142
????16 ????190
????17 ????211
????18 ????180
????19 ????108
????20 ????155
????21 ????135
????22 ????156
????23 ????185
????24 ????310
????25 ????268
????26 ????367
????27 ????265
????28 ????304
Embodiment 29-31 and Comparative Examples F
This group embodiment relatively comprises shape and determines the coated abrasives of particle (embodiment 29-31) and do not contain the coated abrasives that shape is determined particle.The particle that embodiment 29 shapes are determined is made by the general procedure VII that makes the definite particle of shape.Except the cavity size difference, the particle that embodiment 30 shapes are determined is made by the general procedure VII that makes the definite particle of shape.For embodiment 30 and 31, the height of pyramid is about 350 microns, and the length on each limit, bottom surface is about 1020 microns.The particle that comes the shape of processing and implementation example 31 to determine than jogging speed with 150 feet per minute clocks (46 meters/minute).At first use high shear mixer that consumption (representing with umber) is mixed as following table 9 listed TMPTA, TATHEIC, PH1, MSCA and ASF and be used for preparing the grinding aid slurry.Then, grinding aid is added this adhesive precursor gradually as the grinding aid slurry.
The prescription of the grinding aid slurry of table 9 embodiment 29-31
Material Embodiment 29 Embodiment 30 Embodiment 31
????TMPTA ????99.01 ????99.01 ????99.01
????PH1 ????0.99 ????0.99 ????0.99
????MSCA ????1 ????1 ????1
????ASF ????1 ????1 ????1
????KBF 4 ????182 ????182 ????0
????CRY ????0 ????0 ????136
The coated abrasives of embodiment 29 is made by the general procedure IV that makes coated abrasives.For embodiment 29, the weight of grinding aid particle be about 230 the gram/square metre.
Except following difference, the coated abrasives of embodiment 30 is made by the general procedure IV that makes coated abrasives.The grinding aid grain blobs is not coated onto on the sizing menting property precursor.After the sizing menting property precursor cures, will go up on the glued precursor coating paint sizing menting property.Going up glued precursor coating is the phenolic resins that conventional ice crystal is filled.With the grinding aid particle coating to weight be about 180 grams/square metre wet going up on the glued precursor coating.Then, the structure object of heating gained makes resin solidification.
Except following difference, the coated abrasives of embodiment 31 is made by the general procedure IV that makes coated abrasives.The grinding aid grain blobs is not coated onto on the wet sizing menting property.With the grinding aid grain blobs be coated with enter weight be about 110 the gram/square metre the initial engagement coating precursor on, replace brown alumina abrasive grain.In addition, on the last glued precursor coating paint sizing menting property with routine, and the upward glued precursor adhesive that is heating and curing.Going up glued precursor coating is the solvent basic ring epoxy resins that conventional potassium tetrafluoroborate is filled.
Except following difference, the coated abrasives of Comparative Examples F is made by the general procedure IV that makes coated abrasives.The grinding aid grain blobs that shape is determined is not coated onto on the wet sizing menting property precursor.In addition, on the last glued precursor coating paint sizing menting property with routine, and the upward glued precursor adhesive that is heating and curing.Going up glued precursor coating is the solvent basic ring epoxy resins that conventional potassium tetrafluoroborate is filled.
Gained coated abrasives by method of testing IlI, IV and V test implementation example 29-31 and Comparative Examples F.Test result is listed in respectively in the table 10,11 and 12.
Table 10 method of testing III
Embodiment 29-31 and Comparative Examples F
Embodiment Initial stock removal (gram) Final stock removal (gram) Total stock removal (gram)
????F ????113.44 ????8.68 ????1316.44
????29 ????100.44 ????14.16 ????1612.88
????30 ????102.72 ????14.13 ????1595.71
????31 ????121.70 ????17.15 ????1910.44
Table 11 method of testing IV
Embodiment 29,30 and 31 and Comparative Examples F
Embodiment Total stock removal (gram)
????F ????681
????29 ????499
????30 ????555
????31 ????626
Table 12 method of testing V embodiment 29,30 and 31 and Comparative Examples F
Embodiment Total stock removal (gram)
????F ????2664
????29 ????2281
????30 ????2574
????31 ????2672
Above-mentioned grinding data show, can reach the nonferromagnetic substance of varying level under different grinding conditions.
Embodiment 32-40
This group embodiment has shown the situation that adopts the former grain manufacturing of different grinding aids shape to determine the grinding aid particle.Be used for making the definite grinding aid grains of composition prescription of this shape of organizing embodiment and list in table 13.
The prescription of the grinding aid slurry of table 13 embodiment 32-40
Material Embodiment 32 Embodiment 33 Embodiment 34 Embodiment 35 Embodiment 36
????TMPTA ????28 ????31 ????57 ????37 ????37
????PH1 ????0.57 ????0.8 ????0.58 ????0.74 ????0.74
????KBF 4 ????17.9 ????0 ????0 ????31.13 ????0
????CRY ????17.9 ????17.05 ????0 ????0 ????31.13
????FES * ????0 ????17.05 ????0 ????0 ????0
????PVC ????0 ????0 ????42.24 ????31.13 ????31.13
The prescription (continuing) of the grinding aid slurry of table 13 embodiment 32-40
Material Embodiment 37 Embodiment 38 Embodiment 39 Embodiment 40
????TMPTA ????29 ????99.01 ????99.01 ????99.01
????PH1 ????0.28 ????0.99 ????0.99 ????0.99
????KBF 4 ????0 ????182 ????182 ????182
????CRY ????70.72 ????0 ????0 ????0
????FES * ????0 ????0 ????0 ????0
????PVC ????0 ????0 ????0 ????0
*FES is iron sulfide grinding aid (FeS 2)
Except the speed of service was 100 feet per minute clocks (30.5 meters/minute), embodiment 32 and the grinding aid particle that 37 shape is determined were pressed the identical method manufacturing of embodiment 31.
Except the speed of service was 50 feet per minute clocks (16 meters/minute), the grinding aid particle that the shape of embodiment 33 is determined was pressed the identical method manufacturing of embodiment 31.
Except the speed of service was 100 feet per minute clocks (30.5 meters/minute), the grinding aid particle that embodiment 34,35 and 36 shapes are determined was pressed the identical method manufacturing of embodiment 31.In addition, particle is tending towards breaking away from the form of sheet when the carrier band is removed, and is not the form disengaging with discrete particle.These sheets are carried out ball milling, sheet is transformed into discrete particle.
Except the carrier band is that the polyester film of 50 micron thickness and the power condition of corona treatment are 25%, the grinding aid particle that embodiment 38 shapes are determined is pressed the identical method manufacturing of embodiment 29.In addition, the speed of service becomes 150 feet per minute clocks (46 meters/minute).
Except the carrier band is that the polyester film of 50 micron thickness and the power condition of corona treatment are 25%, the grinding aid particle that the shape of embodiment 39 is determined is pressed the identical method manufacturing of embodiment 30.In addition, the speed of service becomes 100 feet per minute clocks (31 meters/minute).
Except the particle size difference, the grinding aid particle that embodiment 40 shapes are determined is pressed the identical method manufacturing of embodiment 39.Particle is the pyramid of square bottom surface, and the height of this pyramid is about 560 microns, and the length on each limit of substrate is about 1490 microns.

Claims (60)

1. coated abrasives, it comprises:
(a) has the backing of front and rear surfaces;
(b) the initial engagement coating on the backing front surface;
(c) be adhered to and be positioned at the abrasive material on the initial engagement coating on the backing, this abrasive material comprises:
(1) many abrasive particles;
(2) the definite grinding aid particle of many shapes, the grinding aid particle that these shapes are determined comprise adhesive and the former grain of many grinding aids, and the grinding aid particle that these shapes are determined occupies the surface area of about 5-90% on the abrasive material;
(d) sizing menting property on abrasive material.
2. coated abrasives as claimed in claim 1, wherein the definite grinding aid particle of shape occupies the surface area of about 20-40% on the abrasive material.
3. coated abrasives as claimed in claim 1, wherein abrasive particle is selected from fused alumina, ceramic alumina, heat treated aluminium oxide, carborundum, alumina zirconia, diamond, ceria, cubic boron nitride, garnet and their mixture.
4. coated abrasives as claimed in claim 1, wherein the size of the grinding aid particle determined of shape is about the 0.1-2500 micron.
5. coated abrasives as claimed in claim 1, wherein the size of the grinding aid particle determined of shape is about the 0.1-500 micron.
6. coated abrasives as claimed in claim 1, wherein the definite grinding aid coating of particles of shape is selected from pyramid, cone, prism, spheroid and ellipsoid.
7. coated abrasives as claimed in claim 1, wherein the definite grinding aid particle of shape is the pyramid of triangle bottom surface.
8. coated abrasives as claimed in claim 1, wherein the definite grinding aid particle of shape is the pyramid of quadrangle bottom surface.
9. coated abrasives as claimed in claim 1, wherein adhesive is made by adhesive precursor, described adhesive precursor be selected from polyurethane resin, the acroleic acid esterification of acroleic acid esterification epoxy resin, olefinic unsaturated-resin, contain the side chain unsaturated carbonyl amino resin, contain the acrylate-based isocyanurate derivative of at least one side chain and contain the acrylate-based isocyanate derivates of at least one side chain.
10. coated abrasives as claimed in claim 9, wherein adhesive precursor also comprises radical initiator.
11. coated abrasives as claimed in claim 1; wherein the definite grinding aid particle of shape also comprises at least a additive that is selected from following substances, filler, fiber, antistatic additive, lubricant, wetting agent, surfactant, pigment, dyestuff, coupling agent, plasticizer and suspending agent.
12. coated abrasives as claimed in claim 1, wherein the definite grinding aid particle of shape comprises the former grain of grinding aid of 5-95 weight % and the adhesive of 95-5 weight %.
13. coated abrasives as claimed in claim 1, wherein the definite grinding aid particle of shape comprises the former grain of grinding aid of 30-75 weight % and the adhesive of 70-25 weight %.
14. coated abrasives as claimed in claim 1, wherein the former grain-by-grain seed selection of grinding aid is from sodium chloride, elpasolite, sodium cryolite, ammonium ice crystal, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluoride, potassium chloride, magnesium chloride and their mixture.
15. coated abrasives as claimed in claim 1, wherein the initial engagement coating be selected from epoxy resin, the acroleic acid esterification of phenolic resins, epoxy resin, urea-formaldehyde resins, acrylate, acroleic acid esterification polyurethane resin, contain side chain α, the amino resin of beta-unsaturated carbonyl, maleimide resin and polyurethane resin.
16. coated abrasives as claimed in claim 1, wherein sizing menting property be selected from epoxy resin, the acroleic acid esterification of phenolic resins, epoxy resin, urea-formaldehyde resins, acrylate, acroleic acid esterification polyurethane resin, contain side chain α, the amino resin of beta-unsaturated carbonyl, maleimide resin and polyurethane resin.
17. coated abrasives as claimed in claim 1, wherein backing is selected from the polymer film, cloth, vulcanized paper, their mixture of paper, nonwoven substrates, polymer film, primary coat and the form that they were handled.
18. the abrasive product of a bonding, it comprises:
(a) cementing medium;
(b) many abrasive particles;
(c) the definite grinding aid particle of many shapes, the grinding aid particle that these shapes are determined comprise adhesive and the former grain of many grinding aids, and the percentage by volume of the grinding aid particle that these shapes are determined is about 5-85%; And cementing medium is used for being determined by abrasive particle and shape the object that forms definite shape of grinding aid particle.
19. the abrasive product of bonding as claimed in claim 18, wherein the percentage by volume of the grinding aid particle determined of shape is about 5-75%.
20. abrasive product as claimed in claim 18, wherein abrasive particle is selected from fused alumina, ceramic alumina, heat treated aluminium oxide, carborundum, alumina zirconia, diamond, ceria, cubic boron nitride, garnet and their mixture.
21. the abrasive product of bonding as claimed in claim 18, wherein the size of the grinding aid particle determined of shape is about the 0.1-2500 micron.
22. the abrasive product of bonding as claimed in claim 18, wherein the size of the grinding aid particle determined of shape is about the 0.1-500 micron.
23. the abrasive product of bonding as claimed in claim 18, wherein the definite grinding aid coating of particles of shape is selected from pyramid, cone, prism, spheroid and ellipsoid.
24. the abrasive product of bonding as claimed in claim 18, wherein the definite grinding aid particle of shape is the pyramid of triangle bottom surface.
25. the abrasive product of bonding as claimed in claim 18, wherein the definite grinding aid particle of shape is the pyramid of quadrangle bottom surface.
26. the abrasive product of bonding as claimed in claim 18, wherein adhesive is made by adhesive precursor, described adhesive precursor be selected from polyurethane resin, the acroleic acid esterification of acroleic acid esterification epoxy resin, olefinic unsaturated-resin, contain the side chain unsaturated carbonyl amino resin, contain the acrylate-based isocyanurate derivative of at least one side chain and contain the acrylate-based isocyanate derivates of at least one side chain.
27. the abrasive product of bonding as claimed in claim 26, wherein adhesive precursor also comprises radical initiator.
28. the abrasive product of bonding as claimed in claim 18; wherein the definite grinding aid particle of shape also comprises at least a additive that is selected from following substances, filler, fiber, antistatic additive, lubricant, wetting agent, surfactant, pigment, dyestuff, coupling agent, plasticizer and suspending agent.
29. the abrasive product of bonding as claimed in claim 18, wherein the definite grinding aid particle of shape comprises the former grain of grinding aid of 5-95 weight % and the adhesive of 95-5 weight %.
30. the abrasive product of bonding as claimed in claim 18, wherein the definite grinding aid particle of shape comprises the former grain of grinding aid of 25-75 weight % and the adhesive of 75-25 weight %.
31. coated abrasives as claimed in claim 1, wherein the former grain-by-grain seed selection of grinding aid is from sodium chloride, elpasolite, sodium cryolite, ammonium ice crystal, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluoride, potassium chloride, magnesium chloride and their mixture.
32. the abrasive product of bonding as claimed in claim 18, wherein cementing medium be selected from epoxy resin, the acroleic acid esterification of phenolic resins, epoxy resin, urea-formaldehyde resins, acrylate, acroleic acid esterification polyurethane resin, contain side chain α, the amino resin of beta-unsaturated carbonyl, maleimide resin and polyurethane resin.
33. a coated abrasives, it comprises:
(a) has the backing of front and rear surfaces;
(b) the initial engagement coating on the backing front surface;
(c) be adhered to the abrasive grains that the many shapes on the backing front surface are determined by described initial engagement coating, the abrasive grains that these shapes are determined comprises many abrasive particles that are distributed in the adhesive, and adhesive makes from the adhesive precursor of the mixture that comprises resole resin and radically curable resin;
(d) sizing menting property on the abrasive grains that shape is determined.
34. coated abrasives as claimed in claim 33, wherein the weight ratio of the resin of resole resin and free-radical curable is about 10-90 weight portion phenolic resins: the resin of 10-90 weight portion free-radical curable.
35. coated abrasives as claimed in claim 33, wherein the weight ratio of the resin of resole resin and free-radical curable is about 20-60 weight portion phenolic resins: the resin of 20-60 weight portion free-radical curable.
36. abrasive product as claimed in claim 33, wherein abrasive particle is selected from fused alumina, ceramic alumina, heat treated aluminium oxide, carborundum, alumina zirconia, diamond, ceria, cubic boron nitride, garnet and their mixture.
37. coated abrasives as claimed in claim 33, wherein the size of the abrasive grains determined of shape is about the 0.1-2500 micron.
38. coated abrasives as claimed in claim 33, wherein the size of the abrasive grains determined of shape is about the 0.1-500 micron.
39. coated abrasives as claimed in claim 33, wherein the shape of the abrasive grains determined of shape is selected from pyramid, cone, prism, spheroid and ellipsoid.
40. coated abrasives as claimed in claim 33, wherein adhesive precursor also comprises radical initiator.
41. coated abrasives as claimed in claim 33; wherein the definite abrasive grains of shape also comprises at least a additive that is selected from following substances, filler, fiber, antistatic additive, lubricant, wetting agent, surfactant, pigment, dyestuff, coupling agent, plasticizer and suspending agent.
42. coated abrasives as claimed in claim 33, wherein the definite abrasive grains of shape comprises the abrasive particle of 5-95 weight % and the adhesive of 95-5 weight %.
43. coated abrasives as claimed in claim 33, wherein the definite abrasive grains of shape comprises the abrasive particle of 25-75 weight % and the adhesive of 75-25 weight %.
44. coated abrasives as claimed in claim 33, wherein the initial engagement coating be selected from epoxy resin, the acroleic acid esterification of phenolic resins, epoxy resin, urea-formaldehyde resins, acrylate, acroleic acid esterification polyurethane resin, contain side chain α, the amino resin of beta-unsaturated carbonyl, maleimide resin and polyurethane resin.
45. coated abrasives as claimed in claim 33, wherein sizing menting property be selected from epoxy resin, the acroleic acid esterification of phenolic resins, epoxy resin, urea-formaldehyde resins, acrylate, acroleic acid esterification polyurethane resin, contain side chain α, the amino resin of beta-unsaturated carbonyl, maleimide resin and polyurethane resin.
46. coated abrasives as claimed in claim 33, wherein backing is selected from the polymer film, cloth, vulcanized paper, their mixture of paper, nonwoven substrates, polymer film, primary coat and the form that they were handled.
47. the abrasive product of a bonding, it comprises:
(a) cementing medium;
(b) abrasive grains determined of many shapes, the abrasive grains that these shapes are determined comprises many abrasive particles that are distributed in the adhesive, and adhesive makes from the adhesive precursor of the mixture that comprises resole resin and radically curable resin;
And the abrasive grains that cementing medium is determined by shape forms the object of definite shape.
48. the abrasive product of bonding as claimed in claim 47, wherein the weight ratio of the resin of resole resin and free-radical curable is about 10-90 weight portion phenolic resins: the resin of 10-90 weight portion free-radical curable.
49. the abrasive product of bonding as claimed in claim 47, wherein the weight ratio of the resin of resole resin and free-radical curable is about 20-60 weight portion phenolic resins: the resin of 20-60 weight portion free-radical curable.
50. abrasive product as claimed in claim 47, wherein abrasive particle is selected from fused alumina, ceramic alumina, heat treated aluminium oxide, carborundum, alumina zirconia, diamond, ceria, cubic boron nitride, garnet and their mixture.
51. the abrasive product of bonding as claimed in claim 47, wherein the size of the abrasive grains determined of shape is about the 0.1-2500 micron.
52. the abrasive product of bonding as claimed in claim 47, wherein the size of the abrasive grains determined of shape is about the 0.1-500 micron.
53. the abrasive product of bonding as claimed in claim 47, wherein the shape of the abrasive grains determined of shape is selected from pyramid, cone, prism, spheroid and ellipsoid.
54. the abrasive product of bonding as claimed in claim 47, wherein adhesive precursor also comprises radical initiator.
55. the abrasive product of bonding as claimed in claim 47; wherein the definite abrasive grains of shape also comprises at least a additive that is selected from following substances, filler, fiber, antistatic additive, lubricant, wetting agent, surfactant, pigment, dyestuff, coupling agent, plasticizer and suspending agent.
56. the abrasive product of bonding as claimed in claim 47, wherein the definite abrasive grains of shape comprises the abrasive particle of 5-95 weight % and the adhesive of 95-5 weight %.
57. the abrasive product of bonding as claimed in claim 47, wherein the definite abrasive grains of shape comprises the abrasive particle of 25-75 weight % and the adhesive of 75-25 weight %.
58. the abrasive product of bonding as claimed in claim 47, wherein the initial engagement coating be selected from epoxy resin, the acroleic acid esterification of phenolic resins, epoxy resin, urea-formaldehyde resins, acrylate, acroleic acid esterification polyurethane resin, contain side chain α, the amino resin of beta-unsaturated carbonyl, maleimide resin and polyurethane resin.
59. a coated abrasives, it comprises:
(a) has the backing of front and rear surfaces;
(b) the initial engagement coating on the backing front surface;
(c) many abrasive particles that are adhered on the initial engagement coating;
(d) be positioned at sizing menting property on the abrasive material, this sizing menting property comprises cementing medium, comprises mass part in this cementing medium and embeds the grinding aid particle that the shape in the cementing medium is determined.
60. a method of making coated abrasives, it comprises the steps:
(a) provide backing with front and rear surfaces;
(b) on the front surface with initial engagement coating precursor paint backing;
(c) many abrasive particles are partially submerged in the initial engagement coating precursor at least;
(d) make the initial engagement coating precursor be transformed into the initial engagement coating;
(e) with on the sizing menting property precursor paint abrasive particle, this sizing menting property precursor comprises cementing medium;
(f) the grinding aid particle that many shapes are determined is partially submerged in the sizing menting property precursor at least;
(g) backing, initial engagement coating, abrasive particle and sizing menting property precursor are under the certain condition, make the sizing menting property precursor be transformed into sizing menting property, thereby make coated abrasives.
CN98104583A 1996-09-11 1996-09-11 Abrasive article and its method of making Expired - Fee Related CN1085575C (en)

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