EP2551057A1 - Method for producing a coated abrasive, coated abrasive and use of a coated abrasive - Google Patents

Method for producing a coated abrasive, coated abrasive and use of a coated abrasive Download PDF

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Publication number
EP2551057A1
EP2551057A1 EP11175222A EP11175222A EP2551057A1 EP 2551057 A1 EP2551057 A1 EP 2551057A1 EP 11175222 A EP11175222 A EP 11175222A EP 11175222 A EP11175222 A EP 11175222A EP 2551057 A1 EP2551057 A1 EP 2551057A1
Authority
EP
European Patent Office
Prior art keywords
abrasive
additive
particles
abrasive grains
binder
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP11175222A
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German (de)
French (fr)
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EP2551057B1 (en
Inventor
Adrian Schoch
Bruno Oberhänsli
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sia Abrasives Industries AG
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Sia Abrasives Industries AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to EP11175222.6A priority Critical patent/EP2551057B1/en
Application filed by Sia Abrasives Industries AG filed Critical Sia Abrasives Industries AG
Priority to CN201280036977.8A priority patent/CN103702801B/en
Priority to BR112014001627-5A priority patent/BR112014001627B1/en
Priority to KR1020147002018A priority patent/KR101949126B1/en
Priority to US14/234,917 priority patent/US9555520B2/en
Priority to PCT/EP2012/064376 priority patent/WO2013014116A1/en
Publication of EP2551057A1 publication Critical patent/EP2551057A1/en
Application granted granted Critical
Publication of EP2551057B1 publication Critical patent/EP2551057B1/en
Priority to US15/376,820 priority patent/US10562153B2/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/001—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as supporting member
    • B24D3/002—Flexible supporting members, e.g. paper, woven, plastic materials
    • B24D3/004—Flexible supporting members, e.g. paper, woven, plastic materials with special coatings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
    • B24D11/001—Manufacture of flexible abrasive materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
    • B24D11/001—Manufacture of flexible abrasive materials
    • B24D11/005—Making abrasive webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties

Definitions

  • the present invention relates to a process for producing a coated abrasive, a coated abrasive and the use of a coated abrasive.
  • abrasives such as abrasive belts or fiber discs
  • Some surfaces such as stainless steel, require additional coating of the abrasive with so-called "grinding aids".
  • KF 4 potassium tetrafluoroborate
  • the additional coating is applied as a liquid mixture which, in addition to the actual abrasive additive, may also contain a binder, a solvent (such as water) and optionally paints, rheology additives, wetting agents, defoamers or fillers.
  • This liquid mixture is applied to an abrasive precursor comprising a backing, a plurality of abrasive grains, and at least one cured first size coat.
  • the liquid applied additional coating is cured, for example by heating, so that there is a second coat layer.
  • the additive coating may also be applied to an abrasive precursor containing only a backing, a base binder, and abrasive grains, however no cape. The cured additional coating then forms the only covering binder.
  • the abrasive additive is applied in step b) in dry form, in particular scattered.
  • the abrasive precursor may contain one or more layers of a capping agent.
  • the bottom coat binder is usually referred to as “top coat 1" or “size coat” and the top coat binder as “top coat 2" or “supersize coat”.
  • top coat binder it is essential that the top coat binder is uncured, ie the top binder, which forms the outermost layer and faces away from the base of the abrasive precursor.
  • the dry-applied abrasive additive does not penetrate into deeper layers of the capping, but remains in a concentrated amount on its surface.
  • the abrasive additive is distributed relatively parallel to the surface of the abrasive and thus much more homogeneous. It thus accumulates less in the areas between the individual abrasive grains. Consequently, a larger proportion of the applied abrasive additive can come into contact with a surface to be processed, as is the case with the usual liquid application. Therefore, in the dry application of this invention, in most embodiments, less abrasive additive per area is needed than is required to achieve the same total stock removal with a conventional liquid coating.
  • the result is a higher one Intelabtragsmenge.
  • the application amount of the abrasive grains can be reduced compared to conventional abrasives; the resulting reduction in the total amount of material removed can be compensated for by the dry application of the grinding additive according to the invention.
  • the production process according to the invention is therefore significantly more economical. Since only comparatively little abrasive additive is present between the abrasive grains, more chip space remains there, in which abrasion arising during grinding can be absorbed; This also leads to an increase in the service life.
  • a dry applied abrasive additive can be firmly bonded to it solely by curing the cap binder.
  • the abrasive additive is fixed by the still uncured binder, as this can migrate by capillary forces in the dry grinding additive.
  • This type of production also eliminates the need to first prepare a liquid additional coating and then to cure this again by an additional process step.
  • a dry-applied abrasive additive results in much better fixation of the abrasive grains than is the case with wet-applied abrasive additive.
  • the abrasive grains therefore break out less easily when machining a surface. This effect is particularly pronounced at high application rates of the grinding additive.
  • the abrasive additive is relatively homogeneously distributed in a direction perpendicular to the backing so that a relatively high proportion is in the vicinity or even in direct contact with the abrasive grains. The binding force between abrasive grains and cap binder is thereby reduced.
  • dry is understood to mean that the abrasive additive is not applied as a dispersed or suspended constituent of a liquid dispersion or suspension. It is not excluded that the abrasive additive has liquid adhesions on its outer surface, which may be caused, for example, by atmospheric moisture. Overall, however, any liquid content of the material applied in step b) should be less than 5% by weight and preferably less than 1% by weight in the context of the invention. In many embodiments, such a low liquid content allows the grinding additive to flow freely and therefore can be easily applied.
  • a “grinding additive” is understood here and below as meaning a substance which has at least one, preferably more of the following properties: reduction of the temperature occurring during the grinding, in particular due to a lubricating effect; Reducing the temperature by melting and recrystallizing the abrasive additive; Prevention of metal plating (so-called “vitrification”); Preventing the oxidation of the machined surface (oxides are often harder and therefore harder to machine than metal); and / or preventing a transformation of the structure of the abrasive grains, for example from alpha corundum to the more brittle spinel.
  • the abrasive additive can be applied in step b) in the form of a powder, in the form of flakes, in the form of fibers, in the form of agglomerates and / or in the form of capsules, in particular sprinkled.
  • Below an agglomerate is here and below an accumulation of previously loose individual particles to a solidified Composite understood.
  • the solidification can take place, for example, by means of an additional substance and, for example, by pressing, hardening, drying and / or irradiation.
  • the abrasive additive is surrounded by a shell, which may contain, for example, waxes, fats and / or polymer solutions. The preparation of such capsules per se is known to the person skilled in the art.
  • the capsules may also contain liquid ingredients in addition to the abrasive additive. However, if these liquid ingredients are surrounded by the shell and can not escape from this, so these capsules are still considered within the scope of the invention as "dry" and streubar.
  • At least a major part of the particles of the abrasive additive has a size which is in the range from 0.1 ⁇ m to 2 mm, preferably from 0.1 ⁇ m to 0.5 mm, particularly preferably from 0.1 ⁇ m to 0.1 mm.
  • the d s90 value of the particle size distribution of the abrasive additive may range from 1 ⁇ m to 5 ⁇ m; the d.sub.50 value can be in the range of 10 .mu.m and 40 .mu.m ; the d s10 value can be in the range of 20 ⁇ m to 100 ⁇ m.
  • a d s90 value of 3 ⁇ m means that 90% by weight of the particles of the abrasive additive have a size of 3 ⁇ m or more.
  • the average size of the particles of the abrasive additive is less than the mean size of the abrasive grains. This allows the particles of the abrasive additive to evenly cover both the surfaces of the abrasive grains and the spaces therebetween.
  • the abrasive additive is in the form of agglomerates or capsules.
  • the ratio of the average diameter of the agglomerates to the mean diameter of the abrasive grains is preferably less than 5, more preferably less than 3 and even more preferably less than 2.
  • the average diameter of the agglomerates is smaller than the average diameter of the abrasive grains.
  • the size of the agglomerates is smaller than the ds3 value of the abrasive grains.
  • the grinding additive can be applied in an application amount ranging from 10 g / m 2 to 500 g / m 2 , preferably from 20 g / m 2 to 400 g / m 2 , particularly preferably from 25 g / m 2 to 250 g / m 2 lies.
  • application quantities in the range from 30 g / m 2 to 35 g / m 2 have proved particularly favorable at a particle size of # 400, with a particle size of # 36 in the range from 160 g / m 2 to 180 g / m 2 .
  • any substance which has also been used in the previously customary liquid application process can be used as the grinding additive.
  • the abrasive additive may for example contain or consist of a salt, which in particular contains boron and / or fluorine, in particular potassium tetrafluoroborate and / or cryolite.
  • the abrasive additive may also include mica, sand, pigments, fumed silica, carbon, glass, talc, corundum and / or contain or consist of other mineral substances.
  • the pad of the abrasive precursor may be any pad customary in the abrasive industry, particularly a flexible pad such as a textile pad, a paper, a film, vulcanized fiber, or a combination thereof.
  • the invention is also not limited to particular abrasive grains;
  • the abrasive grain may be, for example, corundum (in various variants, in particular white corundum, semi-precious corundum, blue corundum, zirconium corundum, and ceramic corundum and / or brown corundum), silicon carbide, cubic boron nitride, diamond or mixtures thereof.
  • the size of the abrasive grains is not essential to the invention.
  • the abrasive may be in various forms of manufacture, for example as a grinding wheel or abrasive belt.
  • the abrasive grains can be bonded to the substrate by means of a known basic binder.
  • a known basic binder This may be, for example, a synthetic resin known per se.
  • a known per se binder can be used, for example, also made of synthetic resin.
  • the capping agent may also contain other conventional active ingredients and / or fillers.
  • the capping agent may be a phenolic resin, an epoxy, a urea resin, a melamine resin or an unsaturated polyester resin. Particularly preferably, the capping agent is a phenolic resin or an epoxide.
  • the uncured size coat binder to which the abrasive additive is applied in step b) may have a viscosity which is conventional for abrasives without a further supercoat and without abrasive additive. The viscosity adjustment for a capping agent is known to the person skilled in the art.
  • the size coat binder can be applied in an amount ranging from 40 g / m 2 to 700 g / m 2 , preferably from 50 g / m 2 to 600 g / m 2 , particularly preferably from 60 g / m 2 to 500 g / m 2 be applied.
  • the solids content may be about in the range of 40 wt .-% to 95 wt .-%, preferably from 45 wt .-% to 93 wt .-%, particularly preferably from 50 wt .-% to 90 wt .-%.
  • the quantities applied and the solids content may depend on the size of the abrasive grains. For example, with a grain size of P400, an application rate of 67 g / m 2 and a solids content may be suitable, while with a grain size of P24 an application rate of 430 g / m 2 and a solids content of 88% may be more advantageous.
  • Such an abrasive comprises a backing, a plurality of abrasive grains bonded to the backing, a size coat binder which at least partially covers the abrasive grains, and at least one abrasive additive which has been dry applied and bound by the size coat.
  • the abrasive additive is distributed more homogeneously parallel to the surface of the abrasive than in conventional wet application.
  • a large part of the particles of the abrasive additive is in the vicinity of the surface of the top coat.
  • the average application rate of abrasive additive particles above the abrasive grains is less than 60%, preferably less than 50%, most preferably less than 40%, of the average abrasive particle particle size between the abrasive grains.
  • Order volume is understood to mean the mass occupancy per area, which can be expressed in g / m 2 .
  • the particles of the abrasive additive are thus not particularly enriched between the abrasive grains nor above the abrasive grains and thus visibly more homogeneous than distributed with roller application over the entire surface.
  • “Above the abrasive grains” means the particles of the abrasive additive are arranged on the side of the abrasive grains facing away from the backing.
  • the ratio of the layer thickness of the abrasive additive above the abrasive grains to the layer thickness of the abrasive additive between the abrasive grains is preferably at least 30%, preferably at least 50%, particularly preferably at least 70%. Such a ratio means that above the abrasive grains is a larger relative proportion of the abrasive additive than is the case with conventional liquid coated abrasives.
  • the layer thickness of the abrasive additive at the tips of the abrasive grains is very low, so that uncoated grain tips are visible from the eye.
  • the layer thickness can be determined by measuring a photograph of a sectional view of the abrasive. The photo can be taken by a microscope.
  • FIG. 1a schematically illustrated conventional coated abrasive comprises a base 1, abrasive grains 3, which are bonded by means of a base binder 2 to the pad 1, and a cap binder 4, which covers the abrasive grains 3.
  • a liquid additive coating 6 was applied by means of rollers containing a multiplicity of particles 5 of a grinding additive.
  • the particles 5 were substantially enriched between the individual abrasive grains 3. In this way, a large part of the particles 5 when processing a surface does not come into contact with this.
  • FIG. 1b As can be seen, a portion of the abrasive grains 3 has been removed. However, many particles 5 of the abrasive additive have remained unused until then, which is economically very ineffective.
  • FIG. 2a shows an abrasive according to the invention in which the abrasive additive has been applied dry as explained in more detail below.
  • the particles 5 of the abrasive additive are arranged in the vicinity of the outer surface of the cap binder 4. In addition, they are distributed more homogeneously over this surface and not enriched in the areas between the abrasive grains 3. In this way, a larger proportion of the particles 5 of the abrasive additive comes into contact with a surface to be processed and can unfold its desired effect there. This larger share is in the in FIG. 2b shown used state of the abrasive 1 removed.
  • abrasive precursors were first prepared. These contained a pad 1 of vulcanized fiber of thickness 0.8 mm. Abrasive grains 3 of two different corundum variants of sizes # 36 and # 50 were bonded to the base 1 in an amount of 800 g / m 2 (particle size # 36) or 570 g / m 2 (particle size # 50) by means of a base binder 2.
  • the basic binder 2 of phenol resin and chalk was applied in an amount of 178 g / m 2 (particle size # 36) or 175 g / m 2 (particle size # 50).
  • the potassium tetrafluoroborate powder was purchased from Solvay Fluor GmbH, 30173 Hannover, Germany.
  • the size distribution of the particles of the powder is determined by the cumulative distribution in FIG. 3 given.
  • the abrasive additive was applied in the form of a liquid additive coating.
  • This liquid additional coating had the following composition: Phenolic resin 75% 12% by weight KBF 4 50% by weight cryolite 10% by weight water 17% by weight Dye, wetting agent, TiO 2, plasticizer, thickener 11% by weight
  • the potassium tetrafluoroborate particles in each of the examples each had an average size of 25 ⁇ m.
  • Table 1 documents for the abrasives according to Examples 1 to 7 the total abrasion which could be achieved with these abrasives with abrasive grains of grain size # 36.
  • the cured abrasive was punched into 180 mm diameter abrasive wheels.
  • the grinding wheels were mounted on a grinding machine, operated at a cutting speed of 33.6 m / s and pressed with a force of 50 N vertically successively on a plurality of juxtaposed, 4 mm thick plates made of stainless steel (X5CrNi18-10 1.4301).
  • the tangential feed was 1.5 m / min, which was ground with a contact roller.
  • the amount of material removed was determined individually for each plate. The processing was carried out until the removal amount per plate had fallen to approximately 35% of the removal rate of the first plate.
  • Table 1 shows the total stock removal and coating loss achieved, that is, the mass of the original abrasive disc removed from it during processing.
  • Example No. 3 dry application (Example No. 3) is compared to the usual, wet Application (example # 1) only needed about half the abrasive additive to achieve about the same total removal.
  • Table 1 Example no. 1 2 3 4 5 6 7 order type wet (comparative example, averages of 8 samples) dry dry dry dry dry dry Order quantity KBF 4 [g / m 2 ] 172 (contained in 344 g / m 2 wet applied additional coating) 43 87 112 152 178 208 Total removal [g] 159 119 160 180 192 216 220 Covering loss [g] 3.5 2.9 3.0 3.1 3.4 3.4 4.0
  • FIGS. 4 to 7 contain photographs of top views on the coated abrasives 8 to 11 according to Table 2.
  • the FIGS. 4 and 5 So show abrasive with a grain size # 36, where FIG. 4 a grinding wheel according to the invention with dry applied abrasive additive shows and FIG. 5 an abrasive with wet abrasive additive.
  • the FIGS. 6 and 7 show abrasives with grain size # 50.
  • the particles of the abrasive additive according to the inventive, dry application ( FIGS. 4 and 6 ) on the surface of the abrasive and especially also above the individual abrasive grains available.
  • the particles of the abrasive additive are distributed substantially homogeneously over the surface.
  • the particles of the abrasive additive further penetrated between the abrasive grains and therefore practically no longer visible.
  • Table 2 Example no. 8th 9 10 11 Figure no.
  • FIG. 5 is a photograph of a sectional view through a conventional abrasive wherein the abrasive additive 5 is embedded in a liquid applied additive coating 6. As can be clearly seen here, a large part of the abrasive additive is in the areas between the abrasive grains 3, where it can not develop its intended effect, however.
  • FIG. 9 shows a photograph of a sectional view through another abrasive according to the invention.
  • the abrasive grains 3 are bonded by means of a base binder 2 to a substrate 1 of vulcanized fiber of 0.8 mm thickness.
  • Base 1, base binder 2 and abrasive grains 3 are of a layer of cap binder. 4 covered.
  • Above this layer is another layer of dry-applied abrasive additive 5.
  • the layer of abrasive additive 5 has a substantially homogeneous thickness.
  • the abrasive additive 5 has practically not penetrated into the layer of cap binder 4.
  • the particles of the abrasive additive 5 are bound directly by the cap 4. Thus, it requires no further binder, as is required in the conventional, wet application of the additional coating.
  • FIG. 10 Abbott curves of several abrasives are shown, which were determined according to DIN EN ISO 4287.
  • the first curve (1) was measured on a pad to which an abrasive grain mixture of corundum was bonded. This mixture contained P120 semi-precious corundum and # 120 grade ceramic corundum.
  • This pad had a height difference of 436 microns.
  • the height difference is understood here and below to mean the difference between the heights of a surface of the surface farthest from the substrate and a surface closest to the substrate; the height difference is thus equal to the difference of the ordinate values of the Abbott curve at 0% and at 100%.
  • the second curve (2) After application of a cap binder, the second curve (2) with a height difference of 368 ⁇ m resulted.
  • the third curve (3) was determined for an inventive abrasive in which potassium tetrafluoroborate (KBF 4 ) of an average particle size of 25 microns and in an amount of about 64 g / m 2 was applied dry; the height difference here is 386 ⁇ m.
  • the fourth curve (4) shows the result for a conventional abrasive in which the potassium tetrafluoroborate was applied in a dispersion; it resulted in a height difference of 288 microns. The dispersion was applied in an amount of 120 g / m 2 , which resulted in an application rate of 54 g / m 2 of potassium tetrafluoroborate.
  • the third curve (3) of the abrasive according to the invention is at less than about 15% of material levels above the fourth curve (4) of the conventional abrasive, while it is lower at higher material levels. This is due to the fact that with dry application a relatively large number of the particles of the grinding additive are in the region of the highest elevations (ie in the region of a cutting chamber depth of 0 ⁇ m). With wet application according to curve (3) a larger part of the abrasive additive has sunk into the area between abrasive grains, so that here the material content is greater for larger cutting room depths.
  • the height difference of the curve (3) for the inventive abrasive larger than the height difference of the curve (4) to the conventional abrasive. This is also due to the fact that a large proportion of the particles of the abrasive additive is in the region of the highest elevations.

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Abstract

The method involves providing an abrasive-precursor comprising a base (1) and multiple abrasive grits (3) which are bonded to the base. A layer of binder covering (4) partially covers the abrasive grits. The uppermost binder covering is unhardened. An abrasive additive is applied on the uppermost unhardened binder covering. The uppermost binder covering is hardened. The abrasive additive is applied, particularly scattered on the uppermost unhardened binder covering in dry form or powder, particularly in the form of flakes, fibers, agglomerates or capsules. An independent claim is included for a coated abrasive with a certain ration of layer thickness of abrasive additive above the abrasive grits to layer thickness of abrasive additive between the abrasive grits.

Description

Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung eines beschichteten Schleifmittels, ein beschichtetes Schleifmittel und die Verwendung eines beschichteten Schleifmittels.The present invention relates to a process for producing a coated abrasive, a coated abrasive and the use of a coated abrasive.

Mit flexiblen Schleifmitteln wie beispielsweise Schleifbändern oder Fiberscheiben kann eine Vielzahl von Oberflächen bearbeitet werden. Einige Oberflächen, wie beispielsweise solche aus rostfreiem Stahl, erfordern eine Zusatzbeschichtung des Schleifmittels mit so genannten Schleifadditiven ("grinding aids"). Als Schleifadditive kommen üblicherweise Salze zum Einsatz, welche vornehmlich die Elemente Bor und/oder Fluor enthalten. Typische Vertreter sind Kaliumtetrafluoroborat (KBF4) und Kryolith (Na3AlF6 = Aluminiumtrinatriumhexafluorid). Eine derartige Zusatzbeschichtung kann beispielsweise die Lebensdauer eines Schleifmittels und damit auch die Gesamtabtragsmenge um ein Vielfaches verlängern.With flexible abrasives such as abrasive belts or fiber discs, a variety of surfaces can be processed. Some surfaces, such as stainless steel, require additional coating of the abrasive with so-called "grinding aids". As grinding additives usually salts are used, which contain primarily the elements boron and / or fluorine. Typical representatives are potassium tetrafluoroborate (KBF 4 ) and cryolite (Na 3 AlF 6 = aluminum trisodium hexafluoride). Such an additional coating, for example, extend the life of an abrasive and thus the Gesamtabtragsmenge by a multiple.

Bei der Herstellung dieser herkömmlich beschichteten Schleifmittel wird die Zusatzbeschichtung als flüssige Mischung aufgetragen, die neben dem eigentlichen Schleifadditiv noch ein Bindemittel, ein Lösungsmittel (wie beispielsweise Wasser) und gegebenenfalls Farben, Rheologieadditive, Netzmittel, Entschäumer oder Füllstoffe enthalten kann. Diese flüssige Mischung wird auf ein Schleifmittel-Vorprodukt aufgetragen, welches eine Unterlage, eine Vielzahl von Schleifkörnern sowie mindestens einen gehärteten ersten Deckbinder umfasst. Anschliessend wird die flüssig aufgetragene Zusatzbeschichtung gehärtet, beispielsweise durch Erhitzen, so dass sich eine zweite Deckbinderschicht ergibt. Alternativ kann die Zusatzbeschichtung auch auf ein Schleifmittel-Vorprodukt aufgetragen werden, welches nur eine Unterlage, einen Grundbinder und Schleifkörner enthält, jedoch keinen Deckbinder. Die gehärtete Zusatzbeschichtung bildet dann den einzigen Deckbinder.In the production of these conventionally coated abrasives, the additional coating is applied as a liquid mixture which, in addition to the actual abrasive additive, may also contain a binder, a solvent (such as water) and optionally paints, rheology additives, wetting agents, defoamers or fillers. This liquid mixture is applied to an abrasive precursor comprising a backing, a plurality of abrasive grains, and at least one cured first size coat. Subsequently, the liquid applied additional coating is cured, for example by heating, so that there is a second coat layer. Alternatively, the additive coating may also be applied to an abrasive precursor containing only a backing, a base binder, and abrasive grains, however no cape. The cured additional coating then forms the only covering binder.

Dieses Herstellungsverfahren ist jedoch recht aufwändig, da zunächst eine das Schleifadditiv enthaltende Suspension angefertigt und diese nach dem Auftragen wieder gehärtet werden muss. Darüber hinaus wird die flüssige Zusatzbeschichtung üblicherweise mittels eines Walzverfahrens aufgetragen. Nachteilig beim Walzenauftrag ist, dass sich das Schleifadditiv in den Vertiefungen zwischen den einzelnen Schleifkörnern anreichert, wohingegen die Spitzen der Schleifkörner mit nur wenig Schleifadditiv bedeckt werden, was der Standzeit und der Schleifleistung abträglich ist. In der Regel erreicht ein Schleifmittel bereits das Ende seiner Standzeit, wenn die Schleifkörner nur bis auf etwa 40 % der anfänglichen Höhe abgenutzt sind. Partikel des Schleifadditivs, welche sich unterhalb dieses Niveaus befinden, kommen nicht mit der bearbeiteten Oberfläche nicht in Berührung. Dieser Teil des Schleifadditivs kann also seinen Zweck gar nicht erst erfüllen, was äusserst unökonomisch ist.However, this production process is quite complex, since first a slurry containing the abrasive additive prepared and this must be cured again after application. In addition, the liquid additive coating is usually applied by means of a rolling process. A disadvantage of roller application is that the abrasive additive accumulates in the recesses between the individual abrasive grains, whereas the tips of the abrasive grains are covered with only a small amount of abrasive additive, which is detrimental to tool life and grinding performance. Typically, an abrasive will already reach the end of its life if the abrasive grains wear only to about 40% of their initial height. Particles of the abrasive additive which are below this level do not come into contact with the machined surface. This part of the grinding additive can therefore not fulfill its purpose, which is extremely uneconomical.

Es ist daher eine Aufgabe der vorliegenden Erfindung, die Nachteile im Stand der Technik zu überwinden und insbesondere ein Verfahren zur Herstellung eines beschichteten Schleifmittels bereitzustellen, welches ökonomisch und einfach ausführbar ist und welches eine möglichst effektive Verteilung des Schleifadditivs in den Bereichen des Schleifmittels garantiert, die mit der zu bearbeitenden Oberfläche tatsächlich in Kontakt geraten.It is therefore an object of the present invention to overcome the disadvantages of the prior art, and more particularly to provide a process for producing a coated abrasive which is economical and easy to carry out and which guarantees the most effective distribution of the abrasive additive in the regions of the abrasive actually come in contact with the surface to be processed.

Diese Aufgabe wird zum einen gelöst durch ein Verfahren zur Herstellung eines beschichteten Schleifmittels, welches die folgenden Schritte enthält:

  1. a) Herstellung oder Bereitstellung eines Schleifmittel-Vorprodukts, umfassend eine Unterlage, eine Vielzahl von Schleifkörnern, welche an die Unterlage gebunden sind, sowie mindestens eine Schicht eines ungehärteten Deckbinders, welcher die Schleifkörner zumindest teilweise bedeckt, wobei der oberste Deckbinder (4) ungehärtet ist;
  2. b) Aufbringung mindestens eines Schleifadditivs auf den obersten, ungehärteten Deckbinder;
  3. c) Härtung des obersten Deckbinders.
This object is achieved on the one hand by a process for producing a coated abrasive, which comprises the following steps:
  1. a) producing or providing an abrasive precursor comprising a backing, a plurality of abrasive grains bonded to the backing, and at least one layer of uncured cover binder which at least partially covers the abrasive grains, the top coat binder (4) being uncured;
  2. b) applying at least one abrasive additive to the uppermost uncured size coat binder;
  3. c) hardening of the topmost coat binder.

Erfindungsgemäss wird das Schleifadditiv in Schritt b) in trockener Form aufgebracht, insbesondere aufgestreut.According to the invention, the abrasive additive is applied in step b) in dry form, in particular scattered.

Das Schleifmittel-Vorprodukt kann eine oder mehrere Schichten eines Deckbinders enthalten. Im Falle von zwei Deckbinder-Schichten wird üblicherweise der untere Deckbinder als "Deckbinder 1" oder "size coat" und der obere Deckbinder als "Deckbinder 2" oder "supersize coat" bezeichnet. Für die Erfindung ist es wesentlich, dass der oberste Deckbinder ungehärtet ist, also der Deckbinder, der die äusserste Schicht bildet und von der Unterlage des Schleifmittel-Vorprodukts abgewandt ist.The abrasive precursor may contain one or more layers of a capping agent. In the case of two top coat layers, the bottom coat binder is usually referred to as "top coat 1" or "size coat" and the top coat binder as "top coat 2" or "supersize coat". For the invention, it is essential that the top coat binder is uncured, ie the top binder, which forms the outermost layer and faces away from the base of the abrasive precursor.

Das trocken aufgebrachte Schleifadditiv dringt nicht in tiefere Schichten des Deckbinders ein, sondern verbleibt in konzentrierter Menge an dessen Oberfläche. Zudem verteilt sich das Schleifadditiv relativ parallel zur Oberfläche des Schleifmittels und somit deutlich homogener. Es reichert sich also weniger in den Bereichen zwischen den einzelnen Schleifkörnern an. Folglich kann ein grösserer Anteil des aufgetragenen Schleifadditivs in Kontakt mit einer zu bearbeitenden Oberfläche gelangen, als dies beim bisher üblichen flüssigen Auftrag der Fall ist. Daher wird bei dem erfindungsgemässen trockenen Auftrag in den meisten Ausführungsbeispielen weniger Schleifadditiv pro Fläche benötigt, als dies zur Erzielung der gleichen Gesamtabtragsmenge mit einer herkömmlichen flüssigen Beschichtung erforderlich ist. Wird dieselbe Auftragsmenge des Schleifadditivs wie bei einer herkömmlichen flüssigen Beschichtung verwendet, so ergibt sich eine höhere Gesamtabtragsmenge. Umgekehrt kann auch die Auftragsmenge der Schleifkörner im Vergleich zu herkömmlichen Schleifmitteln reduziert werden; die hierdurch entstehende Verringerung der Gesamtabtragsmenge kann durch die erfindungsgemässe, trockene Aufbringung des Schleifadditivs kompensiert werden. Das erfindungsgemässe Herstellungsverfahren ist damit deutlich ökonomischer. Da zwischen den Schleifkörnern nur vergleichsweise wenig Schleifadditiv vorhanden ist, verbleibt dort zudem mehr Spanraum, in den beim Schleifen entstehender Abrieb aufgenommen werden kann; auch dies führt zu einer Erhöhung der Standzeit.The dry-applied abrasive additive does not penetrate into deeper layers of the capping, but remains in a concentrated amount on its surface. In addition, the abrasive additive is distributed relatively parallel to the surface of the abrasive and thus much more homogeneous. It thus accumulates less in the areas between the individual abrasive grains. Consequently, a larger proportion of the applied abrasive additive can come into contact with a surface to be processed, as is the case with the usual liquid application. Therefore, in the dry application of this invention, in most embodiments, less abrasive additive per area is needed than is required to achieve the same total stock removal with a conventional liquid coating. If the same application rate of the abrasive additive is used as in a conventional liquid coating, the result is a higher one Gesamtabtragsmenge. Conversely, the application amount of the abrasive grains can be reduced compared to conventional abrasives; the resulting reduction in the total amount of material removed can be compensated for by the dry application of the grinding additive according to the invention. The production process according to the invention is therefore significantly more economical. Since only comparatively little abrasive additive is present between the abrasive grains, more chip space remains there, in which abrasion arising during grinding can be absorbed; This also leads to an increase in the service life.

Wie ebenfalls festgestellt wurde, kann auch ein trocken aufgetragenes Schleifadditiv allein durch Härtung des Deckbinders fest an diesen gebunden werden. Das Schleifadditiv wird dabei durch den noch ungehärteten Deckbinder fixiert, da dieser durch Kapillarkräfte in das trockene Schleifadditiv migrieren kann. Durch diese Art der Herstellung entfällt ausserdem die Notwendigkeit, zunächst eine flüssige Zusatzbeschichtung herzustellen und diese anschliessend durch einen zusätzlichen Prozessschritt wieder zu härten.As also noted, even a dry applied abrasive additive can be firmly bonded to it solely by curing the cap binder. The abrasive additive is fixed by the still uncured binder, as this can migrate by capillary forces in the dry grinding additive. This type of production also eliminates the need to first prepare a liquid additional coating and then to cure this again by an additional process step.

Des Weiteren wurde erkannt, dass zumindest bei Schleifmitteln mit einer einzigen Deckbinderschicht ein trocken aufgetragenes Schleifadditiv zu einer weitaus besseren Fixierung der Schleifkörner führt, als dies bei nass aufgetragenem Schleifadditiv der Fall ist. Die Schleifkörner brechen also bei der Bearbeitung einer Oberfläche weniger leicht heraus. Dieser Effekt ist bei hohen Auftragsmengen des Schleifadditivs besonders ausgeprägt. Beim herkömmlichen Nassauftrag ist das Schleifadditiv in einer Richtung senkrecht zur Unterlage relativ homogenen verteilt, so dass sich ein vergleichsweise hoher Anteil in der Nähe oder sogar in direktem Kontakt mit den Schleifkörnern befindet. Die Bindungskraft zwischen Schleifkörnern und Deckbinder wird hierdurch herabgesetzt. Im Gegensatz dazu befindet sich in gleicher Menge trocken aufgetragenes Schleifadditiv im Mittel in einem grösseren Abstand von den Schleifkörnern, so dass die Bindung zwischen Schleifkörnern und Deckbinder hierdurch weniger oder gar nicht beeinträchtigt wird.Furthermore, it has been recognized that, at least for abrasives having a single size coat, a dry-applied abrasive additive results in much better fixation of the abrasive grains than is the case with wet-applied abrasive additive. The abrasive grains therefore break out less easily when machining a surface. This effect is particularly pronounced at high application rates of the grinding additive. In conventional wet application, the abrasive additive is relatively homogeneously distributed in a direction perpendicular to the backing so that a relatively high proportion is in the vicinity or even in direct contact with the abrasive grains. The binding force between abrasive grains and cap binder is thereby reduced. In contrast, is in the same Amount of dry abrasive additive on average at a greater distance from the abrasive grains, so that the bond between abrasive grains and cap binder is thereby less affected or not at all.

Unter "trocken" wird im Rahmen der Erfindung verstanden, dass das Schleifadditiv nicht als dispergierter oder suspendierter Bestandteil einer flüssigen Dispersion bzw. Suspension aufgetragen wird. Es ist nicht ausgeschlossen, dass das Schleifadditiv an seiner äusseren Oberfläche flüssige Anhaftungen aufweist, die beispielsweise durch die Luftfeuchtigkeit entstehen können. Insgesamt sollte im Rahmen der Erfindung ein allfälliger Flüssigkeitsanteil des im Schritt b) aufgetragenen Materials aber geringer als 5 Gew.-% und bevorzugt geringer als 1 Gew.-% sein. In vielen Ausführungsbeispielen erlaubt ein derart geringer Flüssigkeitsanteil, dass das Schleifadditiv rieselfähig ist und daher einfach aufgebracht werden kann.In the context of the invention, "dry" is understood to mean that the abrasive additive is not applied as a dispersed or suspended constituent of a liquid dispersion or suspension. It is not excluded that the abrasive additive has liquid adhesions on its outer surface, which may be caused, for example, by atmospheric moisture. Overall, however, any liquid content of the material applied in step b) should be less than 5% by weight and preferably less than 1% by weight in the context of the invention. In many embodiments, such a low liquid content allows the grinding additive to flow freely and therefore can be easily applied.

Unter einem "Schleifadditiv" wird hier und im Folgenden ein Stoff verstanden, der mindestens eine, bevorzugt mehrere der folgenden Eigenschaften besitzt: Reduktion der beim Schleifen auftretenden Temperatur, insbesondere aufgrund einer Schmierwirkung; Reduktion der Temperatur durch Schmelzen und Rekristallisieren des Schleifadditivs; Verhinderung des Platierens mit Metall (so genanntes "Verglasen"); Verhinderung der Oxidation der bearbeiteten Oberfläche (Oxide sind häufig härter und daher schwerer zu zerspanen als Metall); und/oder Verhinderung einer Umwandlung der Struktur der Schleifkörner, beispielsweise von Alphakorund zum spröderen Spinell.A "grinding additive" is understood here and below as meaning a substance which has at least one, preferably more of the following properties: reduction of the temperature occurring during the grinding, in particular due to a lubricating effect; Reducing the temperature by melting and recrystallizing the abrasive additive; Prevention of metal plating (so-called "vitrification"); Preventing the oxidation of the machined surface (oxides are often harder and therefore harder to machine than metal); and / or preventing a transformation of the structure of the abrasive grains, for example from alpha corundum to the more brittle spinel.

Das Schleifadditiv kann in Schritt b) in Form eines Pulvers, in Form von Flocken, in Form von Fasern, in Form von Agglomeraten und/oder in Form von Kapseln aufgebracht, insbesondere aufgestreut werden. Unter einem Agglomerat wird hier und im Folgenden eine Anhäufung von vorher losen Einzelteilchen zu einem verfestigten Verbund verstanden. Die Verfestigung kann beispielsweise mittels einer zusätzlichen Substanz und etwa durch Pressen, Härten, Trocknen und/oder Bestrahlen erfolgen. Bei einer Kapsel ist das Schleifadditiv von einer Hülle umgeben, die beispielsweise Wachse, Fette und/oder Polymerlösungen enthalten oder daraus bestehen kann. Die Herstellung derartiger Kapseln an sich ist dem Fachmann bekannt.The abrasive additive can be applied in step b) in the form of a powder, in the form of flakes, in the form of fibers, in the form of agglomerates and / or in the form of capsules, in particular sprinkled. Below an agglomerate is here and below an accumulation of previously loose individual particles to a solidified Composite understood. The solidification can take place, for example, by means of an additional substance and, for example, by pressing, hardening, drying and / or irradiation. In one capsule, the abrasive additive is surrounded by a shell, which may contain, for example, waxes, fats and / or polymer solutions. The preparation of such capsules per se is known to the person skilled in the art.

Die Kapseln können neben dem Schleifmitteladditiv auch flüssige Bestandteile enthalten. Sofern diese flüssigen Bestandteile jedoch durch die Hülle umgeben sind und aus dieser nicht austreten können, so werden diese Kapseln im Rahmen der Erfindung dennoch als "trocken" und streubar angesehen.The capsules may also contain liquid ingredients in addition to the abrasive additive. However, if these liquid ingredients are surrounded by the shell and can not escape from this, so these capsules are still considered within the scope of the invention as "dry" and streubar.

Vorteilhafterweise hat zumindest ein Grossteil der Partikel des Schleifadditivs eine Grösse, die im Bereich von 0,1 µm bis 2 mm liegt, bevorzugt von 0,1 µm bis 0,5 mm, besonders bevorzugt von 0,1 µm bis 0,1 mm. Bevorzugt sollten mindestens 90 Gew.-%, weiter bevorzugt mindestens 95 Gew.-%, noch weiter bevorzugt mindestens 99 Gew.-% der Partikel und besonders bevorzugt alle Partikel des Schleifadditivs eine Grösse in diesem Bereich haben.Advantageously, at least a major part of the particles of the abrasive additive has a size which is in the range from 0.1 μm to 2 mm, preferably from 0.1 μm to 0.5 mm, particularly preferably from 0.1 μm to 0.1 mm. Preferably, at least 90% by weight, more preferably at least 95% by weight, even more preferably at least 99% by weight of the particles, and most preferably all particles of the abrasive additive should have a size in this range.

Der ds90-Wert der Grössenverteilung der Partikel des Schleifadditivs kann im Bereich von 1 µm bis 5 µm liegen; der ds50-Wert kann im Bereich von 10 µm und 40 µm liegen; der ds10-Wert kann im Bereich von 20 µm bis 100 µm liegen. Dabei bedeutet beispielsweise ein ds90-Wert von 3 µm, dass 90 Gew.-% der Partikel des Schleifadditivs eine Grösse von 3 µm oder mehr haben.The d s90 value of the particle size distribution of the abrasive additive may range from 1 μm to 5 μm; the d.sub.50 value can be in the range of 10 .mu.m and 40 .mu.m ; the d s10 value can be in the range of 20 μm to 100 μm. In this case, for example, a d s90 value of 3 μm means that 90% by weight of the particles of the abrasive additive have a size of 3 μm or more.

Es ist ebenfalls zweckmässig, wenn die mittlere Grösse der Partikel des Schleifadditivs geringer ist als die mittlere Grösse der Schleifkörner. Hierdurch können die Partikel des Schleifadditivs sowohl die Oberflächen der Schleifkörner als auch die Zwischenräume dazwischen gleichmässig überdecken. Falls das Schleifadditiv in Form von Agglomeraten oder Kapseln vorliegt, so ist das Verhältnis aus mittlerem Durchmesser der Agglomerate zum mittleren Durchmesser der Schleifkörner bevorzugt kleiner als 5, weiter bevorzugt kleiner als 3 und noch weiter bevorzugt kleiner als 2. Besonders bevorzugt ist der mittlere Durchmesser der Agglomerate kleiner als der mittlere Durchmesser der Schleifkörner. Ebenfalls bevorzugt ist die Grösse der Agglomerate kleiner als der ds3-Wert der Schleifkörner.It is also expedient if the average size of the particles of the abrasive additive is less than the mean size of the abrasive grains. This allows the particles of the abrasive additive to evenly cover both the surfaces of the abrasive grains and the spaces therebetween. If the abrasive additive is in the form of agglomerates or capsules, Thus, the ratio of the average diameter of the agglomerates to the mean diameter of the abrasive grains is preferably less than 5, more preferably less than 3 and even more preferably less than 2. Particularly preferably, the average diameter of the agglomerates is smaller than the average diameter of the abrasive grains. Also preferably, the size of the agglomerates is smaller than the ds3 value of the abrasive grains.

Das Schleifadditiv kann in einer Auftragsmenge aufgetragen werden, die im Bereich von 10 g/m2 bis 500 g/m2, bevorzugt von 20 g/m2 bis 400 g/m2, besonders bevorzugt von 25 g/m2 bis 250 g/m2 liegt. Bei Verwendung von Kaliumtetrafluoroborat als Schleifmitteladditiv haben sich bei einer Korngrösse von # 400 Auftragsmengen im Bereich von 30 g/m2 bis 35 g/m2 als besonders günstig erwiesen, bei einer Korngrösse von # 36 im Bereich von 160 g/m2 bis 180 g/m2.The grinding additive can be applied in an application amount ranging from 10 g / m 2 to 500 g / m 2 , preferably from 20 g / m 2 to 400 g / m 2 , particularly preferably from 25 g / m 2 to 250 g / m 2 lies. When using potassium tetrafluoroborate as an abrasive additive, application quantities in the range from 30 g / m 2 to 35 g / m 2 have proved particularly favorable at a particle size of # 400, with a particle size of # 36 in the range from 160 g / m 2 to 180 g / m 2 .

Wie oben bereits ausgeführt wurde, genügen derartige, im Vergleich zum Stand der Technik geringe Auftragsmengen, um einen zufrieden stellenden Gesamtabtrag zu erzielen. Insbesondere entsprechen die oben genannten Auftragsmengen für Kaliumtetrafluoroborat in etwa den Auftragsmengen, wie sie bei einer herkömmlichen, flüssigen Beschichtung mit Kaliumtetrafluoroborat Verwendung finden; die Gesamtabtragsmenge ist jedoch deutlich höher als bei der herkömmlichen, flüssigen Beschichtung.As already stated above, such low order quantities compared with the prior art suffice to achieve a satisfactory overall removal. In particular, the above order quantities for potassium tetrafluoroborate correspond approximately to the application rates used in a conventional liquid coating with potassium tetrafluoroborate; However, the total erosion amount is much higher than in the conventional liquid coating.

In dem erfindungsgemässen Verfahren kann jeder Stoff als Schleifadditiv verwendet werden, der auch in den bisher üblichen flüssigen Auftragsverfahren eingesetzt wurde. Das Schleifadditiv kann beispielsweise ein Salz enthalten oder daraus bestehen, welche insbesondere Bor und/oder Fluor enthält, insbesondere Kaliumtetrafluoroborat und/oder Kryolith.In the process according to the invention, any substance which has also been used in the previously customary liquid application process can be used as the grinding additive. The abrasive additive may for example contain or consist of a salt, which in particular contains boron and / or fluorine, in particular potassium tetrafluoroborate and / or cryolite.

Alternativ oder zusätzlich kann das Schleifadditiv auch Glimmer, Sand, Pigmente, pyrogene Kieselsäure, Karbon, Glas, Talkum, Korund und/oder andere mineralische Stoffe enthalten oder daraus bestehen.Alternatively or additionally, the abrasive additive may also include mica, sand, pigments, fumed silica, carbon, glass, talc, corundum and / or contain or consist of other mineral substances.

Insbesondere kann Schleifadditiv mindestens einen oder mehrere der folgenden Stoffe enthalten oder daraus bestehen:

  • Al2O3 (Aluminiumoxid, Korund)
  • Al(OH)3 (Aluminiumhydroxid Hydral 710 / PGA-SD)
  • AlCl3 (Aluminiumchlorid)
  • BN (Bornitrid, hexagonal)
  • BaBr2 (Bariumbromid)
  • CaF2 (Calciumfluorid, Flussspat)
  • CaCl2 (Calciumchlorid)
  • CaBr2 (Calciumbromide)
  • C (Graphit)
  • C10H4Cl4 (Tetrachlornaphthalin)
  • C7H8Br5 (Pentabromtoluen)
  • C9H2Cl6O3 (Chlorendic Anhydride)
  • C12H18Br6 (Hexabromcyclododecan)
  • C12H10OBr10 (Decabromdiphenyloxid (Flammschutzmittel))
  • C18H12Cl12 (Dechloran A (Flammschutzmittel))
  • CaCO3 (Calciumcarbonat)
  • Ca3(PO4)2 (Calciumphosphat)
  • Ca(OH)2 (Calciumhydroxid)
  • (CH2CHCl)n (Polyvinylchlorid, PVC)
  • Cs2SO4 (Cäsiumsulfat)
  • CuSO4 (Kupfersulfat)
  • CoSO4 (Cobaltsulfat)
  • C20H22Cl20 (halogenierte Paraffine Chlorez 700, 760)
  • FeS2 (Eisen-II-disulfid Pyrit)
  • FeSO4 (Eisensulfat)
  • KBF4 (Kaliumfluoroborat)
  • K3AlF6 (Kaliumfluoroaluminat)
  • K2TiF6 (Kaliumfluorotitanat)
  • KCl (Kaliumchlorid)
  • K4P2O7 (Kaliumpyrophosphat)
  • K2SO4 (Kaliumsulfat)
  • KNO2 (Kaliumnitrit)
  • K3PO4 (Kaliumphosphat)
  • K2HPO4 (Kaliumhydrogenphosphat)
  • Li2SO4 . H2O (Lithiumsulfat)
  • MgF (Magnesiumfluorid)
  • MoS2 (Molybdän-IV-sulfid)
  • MoO3 (Molybdän-VI-oxid)
  • MnS (Mangan-II-sulfid)
  • MgO (Magnesiumoxid)
  • Mg(OH)2 (Magnesiumhydroxid)
  • MgCO3 (Magnesiumcarbonat)
  • MgCO3 Mg(OH)2 3 H2O (Nesquehonit)
  • MgO CO2 H2O (Magnesiumcarbonat-Subhydrat)
  • MgSO4 . 7 H2O (Magnesiumsulfat)
  • MnSO4 (Mangansulfat)
  • MgCl2 (Magnesiumchlorid)
  • MgBr2 (Magnesiumbromide)
  • Na3AlF6 (Natriumfluoroaluminat, Kryolith)
  • NaBF4 (Natriumfluoroborat)
  • Na2[B4O5(OH)4] · H2O (Natriumborat, Borax)
  • (NH4)3AlF6 (Ammoniumfluoroaluminat)
  • NaCl (Natriumchlorid)
  • Na4P2O7 10 H2O (Natriumpyrophosphat)
  • Na2SiO3 9 H2O (Natriumsilikat)
  • NH4Cl (Ammoniumchlorid)
  • (NH4)2SO4 (Ammoniumsulfat)
  • (NH4)3PO4 (Ammoniumphosphat)
  • Na2CO3 10 H2O (Natriumcarbonat, Kristallsoda)
  • Na2SO4 10 H2O (Natriumsulfat, Glaubersalz)
  • NaNO2 (Natriumnitrit)
  • Na3PO4 (Natriumphosphat)
  • PbCl2 (Blei-II-chlorid)
  • Pb (Blei)
  • S3Sb2 (Antimon-III-sulfid)
  • Sb2O3 (Antimonoxid)
  • Sn (Zinn)
  • Se.. (Selenide)
  • Te.. (Telluride)
  • ZnS (Zink-II-sulfid)
  • Zn2P2O7 (Zinkpyrophosphat)
  • 2 ZnO 3 B2O3 3.5 H2O (Zinkborat, Firebrake)
  • 4ZnO B203 H2O (Zinkborat, Firebrake 415)
In particular, abrasive additive may contain or consist of at least one or more of the following substances:
  • Al 2 O 3 (alumina, corundum)
  • Al (OH) 3 (aluminum hydroxide Hydral 710 / PGA-SD)
  • AlCl 3 (aluminum chloride)
  • BN (boron nitride, hexagonal)
  • BaBr 2 (barium bromide)
  • CaF 2 (calcium fluoride, fluorspar)
  • CaCl 2 (calcium chloride)
  • CaBr 2 (calcium bromides)
  • C (graphite)
  • C 10 H 4 Cl 4 (tetrachloronaphthalene)
  • C 7 H 8 Br 5 (pentabromo toluene)
  • C 9 H 2 Cl 6 O 3 (chlorendic anhydrides)
  • C 12 H 18 Br 6 (hexabromocyclododecane)
  • C 12 H 10 OBr 10 (decabromodiphenyl oxide (flame retardant))
  • C 18 H 12 Cl 12 (Dechloran A (flame retardant))
  • CaCO 3 (calcium carbonate)
  • Ca 3 (PO 4 ) 2 (calcium phosphate)
  • Ca (OH) 2 (calcium hydroxide)
  • (CH 2 CHCl) n (polyvinyl chloride, PVC)
  • Cs 2 SO 4 (cesium sulphate)
  • CuSO 4 (copper sulphate)
  • CoSO 4 (cobalt sulfate)
  • C 20 H 22 Cl 20 (halogenated paraffins Chlorez 700, 760)
  • FeS 2 (iron II disulfide pyrite)
  • FeSO 4 (iron sulphate)
  • KBF 4 (potassium fluoroborate)
  • K 3 AlF 6 (potassium fluoroaluminate)
  • K 2 TiF 6 (potassium fluorotitanate)
  • KCl (potassium chloride)
  • K 4 P 2 O 7 (potassium pyrophosphate)
  • K 2 SO 4 (potassium sulfate)
  • KNO 2 (potassium nitrite)
  • K 3 PO 4 (potassium phosphate)
  • K 2 HPO 4 (potassium hydrogen phosphate)
  • Li 2 SO 4 . H 2 O (lithium sulfate)
  • MgF (magnesium fluoride)
  • MoS 2 (Molybdenum IV sulfide)
  • MoO 3 (molybdenum VI oxide)
  • MnS (manganese-II-sulphide)
  • MgO (magnesium oxide)
  • Mg (OH) 2 (magnesium hydroxide)
  • MgCO 3 (magnesium carbonate)
  • MgCO 3 Mg (OH) 2 3 H 2 O (nesquehonite)
  • MgO CO 2 H 2 O (magnesium carbonate subhydrate)
  • MgSO 4. 7H 2 O (magnesium sulfate)
  • MnSO 4 (manganese sulfate)
  • MgCl 2 (magnesium chloride)
  • MgBr 2 (magnesium bromide)
  • Na 3 AlF 6 (sodium fluoroaluminate, cryolite)
  • NaBF 4 (sodium fluoroborate)
  • Na 2 [B 4 O 5 (OH) 4 ] .H 2 O (sodium borate, borax)
  • (NH 4 ) 3 AlF 6 (ammonium fluoroaluminate)
  • NaCl (sodium chloride)
  • Na 4 P 2 O 7 10 H 2 O (sodium pyrophosphate)
  • Na 2 SiO 3 9 H 2 O (sodium silicate)
  • NH 4 Cl (ammonium chloride)
  • (NH 4 ) 2 SO 4 (ammonium sulfate)
  • (NH 4 ) 3 PO 4 (ammonium phosphate)
  • Na 2 CO 3 10 H 2 O (sodium carbonate, soda ash)
  • Na 2 SO 4 10 H 2 O (sodium sulfate, Glauber's salt)
  • NaNO 2 (sodium nitrite)
  • Na 3 PO 4 (sodium phosphate)
  • PbCl 2 (lead II chloride)
  • Pb (lead)
  • S 3 Sb 2 (antimony III sulfide)
  • Sb 2 O 3 (antimony oxide)
  • Sn (tin)
  • Se .. (Selenide)
  • Te .. (Telluride)
  • ZnS (zinc II sulfide)
  • Zn 2 P 2 O 7 (zinc pyrophosphate)
  • 2 ZnO 3 B 2 O 3 3.5H 2 O (zinc borate, Firebrake)
  • 4ZnO B203 H2O (zinc borate, Firebrake 415)

Die Unterlage des Schleifmittel-Vorprodukts kann jede in der Schleifmittelindustrie übliche Unterlage sein, insbesondere eine flexible Unterlage, wie beispielsweise eine textile Unterlage, ein Papier, eine Folie, Vulkanfiber oder eine Kombination davon. Die Erfindung ist ebenfalls nicht auf bestimmte Schleifkörner beschränkt; das Schleifkorn kann beispielsweise Korund (in verschiedenen Varianten, insbesondere Weisskorund, Halbedelkorund, Blaukorund, Zirkonkorund keramischer Korund und/oder Braunkorund), Siliziumkarbid, kubisches Bornitrid, Diamant oder Mischungen davon sein. Auch die Grösse der Schleifkörner ist nicht wesentlich für die Erfindung. Das Schleifmittel kann in unterschiedlichen Konfektionsformen vorliegen, beispielsweise als Schleifscheibe oder als Schleifband.The pad of the abrasive precursor may be any pad customary in the abrasive industry, particularly a flexible pad such as a textile pad, a paper, a film, vulcanized fiber, or a combination thereof. The invention is also not limited to particular abrasive grains; The abrasive grain may be, for example, corundum (in various variants, in particular white corundum, semi-precious corundum, blue corundum, zirconium corundum, and ceramic corundum and / or brown corundum), silicon carbide, cubic boron nitride, diamond or mixtures thereof. The size of the abrasive grains is not essential to the invention. The abrasive may be in various forms of manufacture, for example as a grinding wheel or abrasive belt.

Die Schleifkörner können mithilfe eines an sich bekannten Grundbinders an die Unterlage gebunden werden. Dabei kann es sich etwa um ein an sich bekanntes Kunstharz handeln. Auch als Deckbinder kann ein an sich bekanntes Bindemittel verwendet werden, beispielsweise ebenfalls aus Kunstharz. Der Deckbinder kann zudem weitere übliche Wirkstoffe und/oder Füllstoffe enthalten.The abrasive grains can be bonded to the substrate by means of a known basic binder. This may be, for example, a synthetic resin known per se. Also as a cap binder, a known per se binder can be used, for example, also made of synthetic resin. The capping agent may also contain other conventional active ingredients and / or fillers.

Der Deckbinder kann ein Phenolharz, ein Epoxid, ein Harnstoffharz, ein Melaminharz oder ein ungesättigtes Polyesterharz sein. Besonders bevorzugt ist der Deckbinder ein Phenolharz oder ein Epoxid. Der ungehärtete Deckbinder, auf den das Schleifadditiv im Schritt b) aufgebracht wird, kann eine Viskosität aufweisen, wie sie für Schleifmittel ohne weitere Deckbinderschicht (so genannter "super size coat") und ohne Schleifadditiv üblich ist. Die Viskositätseinstellung für einen Deckbinder ist dem Fachmann bekannt.The capping agent may be a phenolic resin, an epoxy, a urea resin, a melamine resin or an unsaturated polyester resin. Particularly preferably, the capping agent is a phenolic resin or an epoxide. The uncured size coat binder to which the abrasive additive is applied in step b) may have a viscosity which is conventional for abrasives without a further supercoat and without abrasive additive. The viscosity adjustment for a capping agent is known to the person skilled in the art.

Ein Teil des Deckbinders dient zur Fixierung des Schleifadditivs. Dies kann dadurch ausgeglichen werden, dass eine grössere Auftragsmenge des Deckbinders als üblich verwendet wird und/oder dass der Deckbinder einen höheren Harzgehalt als üblich aufweist. Beispielsweise kann der Deckbinder in einer Auftragsmenge im Bereich von 40 g/m2 bis 700 g/m2, bevorzugt von 50 g/m2 bis 600 g/m2, besonders bevorzugt von 60 g/m2 bis 500 g/m2 aufgetragen werden. Der Feststoffgehalt kann etwa im Bereich von 40 Gew.-% bis 95 Gew.-%, bevorzugt von 45 Gew.-% bis 93 Gew.-%, besonders bevorzugt von 50 Gew.-% bis 90 Gew.-% liegen. Die Auftragsmengen und der Feststoffgehalt können dabei von der Grösse der Schleifkörner abhängen. Beispielsweise kann bei einer Körnung von P400 eine Auftragsmenge von 67 g/m2 und ein Feststoffanteil geeignet sein, während bei einer Körnung von P24 eine Auftragsmenge von 430 g/m2 und ein Feststoffgehalt von 88 % vorteilhafter sein kann.Part of the cap binder serves to fix the abrasive additive. This can be compensated for by using a larger application amount of the capping agent than usual and / or by having the cap binder having a higher resin content than usual. For example, the size coat binder can be applied in an amount ranging from 40 g / m 2 to 700 g / m 2 , preferably from 50 g / m 2 to 600 g / m 2 , particularly preferably from 60 g / m 2 to 500 g / m 2 be applied. The solids content may be about in the range of 40 wt .-% to 95 wt .-%, preferably from 45 wt .-% to 93 wt .-%, particularly preferably from 50 wt .-% to 90 wt .-%. The quantities applied and the solids content may depend on the size of the abrasive grains. For example, with a grain size of P400, an application rate of 67 g / m 2 and a solids content may be suitable, while with a grain size of P24 an application rate of 430 g / m 2 and a solids content of 88% may be more advantageous.

Ein weiterer Aspekt der Erfindung ist ein beschichtetes Schleifmittel, welches durch ein wie oben beschriebenes Verfahren erhältlich ist. Ein solches Schleifmittel umfasst also eine Unterlage, eine Vielzahl von Schleifkörnern, welche an die Unterlage gebunden sind, einen Deckbinder, welcher die Schleifkörner zumindest teilweise bedeckt, sowie mindestens ein Schleifadditiv, welches trocken aufgetragen wurde und vom Deckbinder gebunden ist.Another aspect of the invention is a coated abrasive obtainable by a process as described above. Thus, such an abrasive comprises a backing, a plurality of abrasive grains bonded to the backing, a size coat binder which at least partially covers the abrasive grains, and at least one abrasive additive which has been dry applied and bound by the size coat.

Wie bereits ausgeführt wurde, ist das Schleifadditiv parallel zur Oberfläche des Schleifmittels homogener verteilt als beim herkömmlichen Nassauftrag.As already stated, the abrasive additive is distributed more homogeneously parallel to the surface of the abrasive than in conventional wet application.

Bevorzugt sind mindestens 60 Gew.-%, bevorzugt mindestens 80 Gew.-%, besonders bevorzugt mindestens 90 Gew.-% der Partikel des Schleifadditivs in einer Aussenschicht des Schleifmittels angeordnet, deren Dicke höchstens 60 %, bevorzugt höchstens 40 %, besonders bevorzugt höchstens 30 % der gesamten Dicke der Schicht aus Deckbinder und Schleifadditiven beträgt. Mit anderen Worten befindet sich also ein grosser Teil der Partikel des Schleifadditivs in der Nähe der Oberfläche der Deckbinderschicht.Preferably, at least 60 wt .-%, preferably at least 80 wt .-%, more preferably at least 90 wt .-% of the particles of the abrasive additive disposed in an outer layer of the abrasive whose thickness is at most 60%, preferably at most 40%, particularly preferably at most 30% of the total thickness of the coat binder and abrasive additive layer. In other words, therefore, a large part of the particles of the abrasive additive is in the vicinity of the surface of the top coat.

Ebenfalls bevorzugt weicht die durchschnittliche Auftragsmenge der Partikel des Schleifadditivs oberhalb der Schleifkörner von der durchschnittlichen Auftragsmenge der Partikel des Schleifadditivs zwischen den Schleifkörnern um weniger als 60 %, bevorzugt um weniger als 50 %, besonders bevorzugt um weniger als 40 % ab. Als Auftragsmenge wird auch hier die Massenbelegung pro Fläche verstanden, die in g/m2 angegeben werden kann. Die Partikel des Schleifadditivs sind also weder zwischen den Schleifkörnern noch oberhalb der Schleifkörner besonders angereichert und somit sichtbar homogener als mit Walzenauftrag über die gesamte Oberfläche verteilt. "Oberhalb der Schleifkörner" bedeutet dabei, dass die Partikel des Schleifadditivs auf der der Unterlage abgewandten Seite der Schleifkörner angeordnet sind.Also preferably, the average application rate of abrasive additive particles above the abrasive grains is less than 60%, preferably less than 50%, most preferably less than 40%, of the average abrasive particle particle size between the abrasive grains. Order volume is understood to mean the mass occupancy per area, which can be expressed in g / m 2 . The particles of the abrasive additive are thus not particularly enriched between the abrasive grains nor above the abrasive grains and thus visibly more homogeneous than distributed with roller application over the entire surface. "Above the abrasive grains" means the particles of the abrasive additive are arranged on the side of the abrasive grains facing away from the backing.

Bevorzugt beträgt das Verhältnis der Schichtdicke des Schleifadditivs oberhalb der Schleifkörner zur Schichtdicke des Schleifadditivs zwischen den Schleifkörnern mindestens 30 %, bevorzugt mindestens 50 %, besonders bevorzugt mindestens 70 %. Ein derartiges Verhältnis bedeutet, dass sich oberhalb der Schleifkörner ein grösserer relativer Anteil des Schleifadditivs befindet, als dies bei herkömmlichen, flüssig beschichteten Schleifmittel der Fall ist. Bei herkömmlicher Auftragsweise ist die Schichtdicke des Schleifadditivs an den Spitzen der Schleifkörner sehr gering, so dass unbeschichtete Kornspitzen vom Auge sichtbar sind. Die Schichtdicke kann durch Ausmessen an einem Foto einer Schnittansicht des Schleifmittels bestimmt werden. Das Foto kann dabei durch ein Mikroskop aufgenommen werden.The ratio of the layer thickness of the abrasive additive above the abrasive grains to the layer thickness of the abrasive additive between the abrasive grains is preferably at least 30%, preferably at least 50%, particularly preferably at least 70%. Such a ratio means that above the abrasive grains is a larger relative proportion of the abrasive additive than is the case with conventional liquid coated abrasives. In conventional application, the layer thickness of the abrasive additive at the tips of the abrasive grains is very low, so that uncoated grain tips are visible from the eye. The layer thickness can be determined by measuring a photograph of a sectional view of the abrasive. The photo can be taken by a microscope.

Schliesslich betrifft die Erfindung auch die Verwendung eines mit dem oben beschriebenen Verfahren hergestellten Schleifmittels zur Bearbeitung einer Oberfläche, insbesondere einer Oberfläche, die mindestens ein Metall enthält oder daraus besteht, insbesondere rostfreien Stahl, Titan und/oder mindestens eine so genannte Superlegierung. Bei den Superlegierungen (englisch: "superalloy") kann es sich z.B. um Nickelbasislegierungen, Kobaltlegierungen, Nickel/Eisenlegierungen oder harte Bronze handeln. Derartige Superlegierungen sind beispielsweise unter den Handelsnamen Inconel, Waspaloy oder Rene bekannt. Im Folgenden wird die Erfindung anhand mehrerer Ausführungsbeispiele und Zeichnungen erläutert. Dabei zeigen:

Figuren 1a und 1b
schematische Schnittansichten eines ersten bekannten Schleifmittels mit nass aufgebrachtem Schleifadditiv vor und nach dem Gebrauch;
Figuren 2a und 2b
schematische Schnittansichten eines ersten erfindungsgemässen Schleifmittels mit trocken aufgebrachtem Schleifadditiv vor und nach dem Gebrauch;
Figur 3
eine Grössenverteilung von Partikeln eines Schleifadditivs;
Figur 4
eine Fotografie einer Draufsicht auf ein zweites erfindungsgemässes Schleifmittel mit Schleifkörnern der Grösse # 36 und KBF4 als Schleifadditiv, welches trocken in einer Auftragsmenge von 178 g/m2 aufgetragen wurde;
Figur 5
eine Fotografie einer Draufsicht auf ein zweites Vergleichsbeispiel eines Schleifmittels mit Schleifkörnern der Grösse # 36 und KBF4 als Schleifadditiv, welches durch Walzenauftrag flüssig aufgetragen wurde;
Figur 6
eine Fotografie einer Draufsicht auf ein drittes erfindungsgemässes Schleifmittel mit Schleifkörnern der Grösse # 50 und Schleifadditiv, welches trocken aufgetragen wurde;
Figur 7
eine Fotografie einer Draufsicht auf ein drittes Vergleichsbeispiel eines Schleifmittels mit Schleifkörnern der Grösse # 50 und Schleifadditiv, welches durch Walzenauftrag flüssig aufgetragen wurde;
Figur 8
eine Fotografie einer Schnittansicht eines vierten Vergleichsbeispiels;
Figur 9
eine Fotografie einer Schnittansicht eines vierten erfindungsgemässen Schleifmittels;
Figur 10
Abbott-Kurven mehrerer Schleifmittel.
Finally, the invention also relates to the use of an abrasive produced by the method described above for processing a surface, in particular a surface containing or consisting of at least one metal, in particular stainless steel, titanium and / or at least one so-called superalloy. The superalloys can be, for example, nickel-base alloys, cobalt alloys, nickel / iron alloys or hard bronze. Such superalloys are known, for example, under the trade names Inconel, Waspaloy or Rene. In the following the invention will be explained with reference to several embodiments and drawings. Showing:
FIGS. 1a and 1b
schematic sectional views of a first known abrasive with wet-applied abrasive additive before and after use;
FIGS. 2a and 2b
schematic sectional views of a first inventive abrasive with dry-applied abrasive additive before and after use;
FIG. 3
a size distribution of particles of a grinding additive;
FIG. 4
a photograph of a top view of a second abrasive according to the invention with abrasive grains size # 36 and KBF 4 as a grinding additive, which was applied dry in an application rate of 178 g / m 2 ;
FIG. 5
a photograph of a top view of a second comparative example of an abrasive with size # 36 abrasive grains and KBF 4 as a grinding additive, which was liquid applied by roller application;
FIG. 6
a photograph of a top view of a third inventive abrasive with size # 50 abrasive grains and abrasive additive, which was applied dry;
FIG. 7
a photograph of a top view of a third comparative example of an abrasive with size # 50 abrasive grains and abrasive additive, which was liquid applied by roller application;
FIG. 8
a photograph of a sectional view of a fourth comparative example;
FIG. 9
a photograph of a sectional view of a fourth inventive abrasive;
FIG. 10
Abbott curves of several abrasives.

Das in Figur 1a schematisch dargestellte herkömmliche beschichtete Schleifmittel enthält eine Unterlage 1, Schleifkörner 3, die mittels eines Grundbinders 2 an die Unterlage 1 gebunden sind, sowie einen Deckbinder 4, der die Schleifkörner 3 bedeckt. Mit Hilfe eines bekannten Walzverfahrens wurde eine flüssige Zusatzbeschichtung 6 mit Hilfe von Walzen aufgetragen, die eine Vielzahl von Partikeln 5 eines Schleifadditivs enthält. Durch das Walzen wurden die Partikel 5 im Wesentlichen zwischen den einzelnen Schleifkörnern 3 angereichert. Auf diese Weise kommt ein Grossteil der Partikel 5 beim Bearbeiten einer Oberfläche gar nicht in Berührung mit dieser. Nach dem Gebrauch des Schleifmittels 1 ist, wie in Figur 1b ersichtlich, ein Teil der Schleifkörner 3 abgetragen worden. Viele Partikel 5 des Schleifadditivs sind bis zu diesem Zeitpunkt jedoch noch unbenutzt geblieben, was wirtschaftlich äusserst uneffektiv ist.This in FIG. 1a schematically illustrated conventional coated abrasive comprises a base 1, abrasive grains 3, which are bonded by means of a base binder 2 to the pad 1, and a cap binder 4, which covers the abrasive grains 3. By means of a known rolling process, a liquid additive coating 6 was applied by means of rollers containing a multiplicity of particles 5 of a grinding additive. By rolling, the particles 5 were substantially enriched between the individual abrasive grains 3. In this way, a large part of the particles 5 when processing a surface does not come into contact with this. After using the abrasive 1, as in FIG. 1b As can be seen, a portion of the abrasive grains 3 has been removed. However, many particles 5 of the abrasive additive have remained unused until then, which is economically very ineffective.

Im Gegensatz dazu zeigt Figur 2a ein erfindungsgemässes Schleifmittel, bei dem das Schleifadditiv wie unten näher erläutert trocken aufgebracht wurde. Hier sind die Partikel 5 des Schleifadditivs in der Nähe der äusseren Oberfläche des Deckbinders 4 angeordnet. Zudem sind sie homogener über diese Oberfläche verteilt und nicht in den Bereichen zwischen den Schleifkörnern 3 angereichert. Auf diese Weise kommt ein grösserer Anteil der Partikel 5 des Schleifadditivs mit einer zu bearbeiteten Oberfläche in Kontakt und kann dort seine gewünschte Wirkung entfalten. Dieser grössere Anteil ist in dem in Figur 2b dargestellten gebrauchten Zustand des Schleifmittels 1 abgetragen.In contrast, shows FIG. 2a an abrasive according to the invention in which the abrasive additive has been applied dry as explained in more detail below. Here, the particles 5 of the abrasive additive are arranged in the vicinity of the outer surface of the cap binder 4. In addition, they are distributed more homogeneously over this surface and not enriched in the areas between the abrasive grains 3. In this way, a larger proportion of the particles 5 of the abrasive additive comes into contact with a surface to be processed and can unfold its desired effect there. This larger share is in the in FIG. 2b shown used state of the abrasive 1 removed.

Zur Herstellung beschichteter Schleifmittel wurde zunächst eine Vielzahl von Schleifmittel-Vorprodukten vorbereitet. Diese enthielten eine Unterlage 1 aus Vulkanfiber der Stärke 0,8 mm. Mittels eines Grundbinders 2 wurden Schleifkörner 3 aus zwei verschiedenen Korundvarianten der Grössen # 36 und # 50 in einer Menge von 800 g/m2 (Korngrösse # 36) bzw. 570 g/m2 (Korngrösse # 50) an die Unterlage 1 gebunden. Der Grundbinder 2 aus Phenolharz und Kreide wurde in einer Menge von 178 g/m2 (Korngrösse # 36) bzw. 175 g/m2 (Korngrösse # 50) aufgetragen. Anschliessend wurde ein ungehärteter und daher noch flüssiger Deckbinder 4 aus Phenolharz/Kreide in einer Nassmenge von 650 g/m2 (Korngrösse # 36) bzw. 450 g/m2 (Korngrösse # 50) aufgetragen.To produce coated abrasives, a variety of abrasive precursors were first prepared. These contained a pad 1 of vulcanized fiber of thickness 0.8 mm. Abrasive grains 3 of two different corundum variants of sizes # 36 and # 50 were bonded to the base 1 in an amount of 800 g / m 2 (particle size # 36) or 570 g / m 2 (particle size # 50) by means of a base binder 2. The basic binder 2 of phenol resin and chalk was applied in an amount of 178 g / m 2 (particle size # 36) or 175 g / m 2 (particle size # 50). Subsequently, an uncured and therefore still liquid cap binder 4 of phenolic resin / chalk in a wet amount of 650 g / m 2 (particle size # 36) or 450 g / m 2 (particle size # 50) was applied.

Auf dieses somit hergestellte Schleifmittel-Vorprodukt wurde in den Beispielen 1 bis 7 gemäss Tabelle 1 und den Beispielen 8 bis 11 gemäss Tabelle 2 Kaliumtetrafluoroborat (KBF4) als Schleifadditiv aufgetragen.On this thus prepared abrasive precursor was in Examples 1 to 7 according to Table 1 and Examples 8 to 11 according to Table 2 potassium tetrafluoroborate (KBF 4 ) applied as a grinding additive.

Das Kaliumtetrafluoroborat-Pulver wurde von der Firma Solvay Fluor GmbH, 30173 Hannover, Deutschland bezogen. Die Grössenverteilung der Partikel des Pulvers ist durch die Summenverteilung in Figur 3 gegeben.The potassium tetrafluoroborate powder was purchased from Solvay Fluor GmbH, 30173 Hannover, Germany. The size distribution of the particles of the powder is determined by the cumulative distribution in FIG. 3 given.

In den Vergleichsbeispielen 1, 9 und 11 wurde das Schleifadditiv in Form einer flüssigen Zusatzbeschichtung aufgebracht. Diese flüssige Zusatzbeschichtung hatte die folgende Zusammensetzung: Phenolharz 75% 12 Gew.-% KBF4 50 Gew.-% Kryolith 10 Gew.-% Wasser 17 Gew.-% Farbstoff, Netzmittel, Ti02, Weichmacher, Verdicker 11 Gew.-% In Comparative Examples 1, 9 and 11, the abrasive additive was applied in the form of a liquid additive coating. This liquid additional coating had the following composition: Phenolic resin 75% 12% by weight KBF 4 50% by weight cryolite 10% by weight water 17% by weight Dye, wetting agent, TiO 2, plasticizer, thickener 11% by weight

Zur Herstellung der erfindungsgemässen Beispiele 2 bis 8 und 10 wurde pulverförmiges Kaliumtetrafluoroborat (KBF4) in trockener Form auf den noch ungehärteten Deckbinder aufgetragen. Das Kaliumtetrafluoroborat wurde mit Hilfe einer an sich bekannten Auftragsstation für pulverförmige Medien gleichmässig auf das Schleifmittel-Vorprodukt aufgebracht. Die Auftragsmengen sind in den Tabellen 1 und 2 wiedergegeben.To prepare Examples 2 to 8 and 10 according to the invention, powdered potassium tetrafluoroborate (KBF 4 ) was applied in dry form to the still unhardened coat binder. The potassium tetrafluoroborate was uniformly applied to the abrasive precursor using a conventional application station for powdered media. The order quantities are shown in Tables 1 and 2.

Die Kaliumtetrafluoroborat-Partikel hatten in allen Beispielen (sowohl als trockenes Pulver in den erfindungsgemässen Beispielen als auch als dispergierte Partikel in den Vergleichsbeispielen) jeweils eine mittlere Grösse von 25 µm.The potassium tetrafluoroborate particles in each of the examples (both as dry powder in the examples according to the invention and as dispersed particles in the comparative examples) each had an average size of 25 μm.

Tabelle 1 dokumentiert für die Schleifmittel gemäss Beispielen 1 bis 7 den Gesamtabtrag, der mit diesen Schleifmitteln mit Schleifkörnern der Korngrösse # 36 erzielt werden konnte. Zur Bestimmung dieses Gesamtabtrags wurde das gehärtete Schleifmittel zu Schleifscheiben mit einem Durchmesser von 180 mm gestanzt. Die Schleifscheiben wurden an einer Schleifmaschine befestigt, mit einer Schnittgeschwindigkeit von 33,6 m/s betrieben und mit einer Kraft von 50 N senkrecht nacheinander auf eine Vielzahl von nebeneinander angeordneten, 4 mm dicken Platten aus rostfreiem Stahl (X5CrNi18-10 1.4301) angedrückt. Der Tangentialvorschub betrug 1,5 m/min, wobei mit einer Kontaktwalze geschliffen wurde. Durch Differenzmessung wurde für jede Platte einzeln die Menge des abgetragenen Materials bestimmt. Die Bearbeitung wurde so lange durchgeführt, bis die Abtragsmenge pro Platte auf ca. 35 % der Abtragsmenge der ersten Platte gefallen war. In Tabelle 1 sind der hiermit erzielte Gesamtabtrag und der Belagsverlust angegeben, also die Masse der ursprünglichen Schleifscheibe, die während der Bearbeitung von dieser abgetragen wurde.Table 1 documents for the abrasives according to Examples 1 to 7 the total abrasion which could be achieved with these abrasives with abrasive grains of grain size # 36. To determine this total erosion, the cured abrasive was punched into 180 mm diameter abrasive wheels. The grinding wheels were mounted on a grinding machine, operated at a cutting speed of 33.6 m / s and pressed with a force of 50 N vertically successively on a plurality of juxtaposed, 4 mm thick plates made of stainless steel (X5CrNi18-10 1.4301). The tangential feed was 1.5 m / min, which was ground with a contact roller. By measuring the difference, the amount of material removed was determined individually for each plate. The processing was carried out until the removal amount per plate had fallen to approximately 35% of the removal rate of the first plate. Table 1 shows the total stock removal and coating loss achieved, that is, the mass of the original abrasive disc removed from it during processing.

Wie aus Tabelle 1 ersichtlich ist, ist bei erfindungsgemässem, trockenem Auftrag (Beispiel Nr. 3) gegenüber dem üblichen, nassen Auftrag (Beispiel Nr. 1) nur in etwa halb soviel Schleifadditiv nötig, um ungefähr den gleichen Gesamtabtrag zu erreichen. Tabelle 1 Beispiel Nr. 1 2 3 4 5 6 7 Auftragsart nass (Vergleichs-beispiel, Mittelwerte aus 8 Proben) trocken trocken trocken trocken trocken trocken Auftragsmenge KBF4 [g/m2] 172 (enthalten in 344 g/m2 nass aufge-tragener Zusatzbeschichtung) 43 87 112 152 178 208 Gesamtabtrag [g] 159 119 160 180 192 216 220 Belagsverlust [g] 3,5 2,9 3,0 3,1 3,4 3,4 4,0 As can be seen from Table 1, according to the invention, dry application (Example No. 3) is compared to the usual, wet Application (example # 1) only needed about half the abrasive additive to achieve about the same total removal. Table 1 Example no. 1 2 3 4 5 6 7 order type wet (comparative example, averages of 8 samples) dry dry dry dry dry dry Order quantity KBF 4 [g / m 2 ] 172 (contained in 344 g / m 2 wet applied additional coating) 43 87 112 152 178 208 Total removal [g] 159 119 160 180 192 216 220 Covering loss [g] 3.5 2.9 3.0 3.1 3.4 3.4 4.0

Die Figuren 4 bis 7 enthalten Fotografien von Draufsichten auf die beschichteten Schleifmittel 8 bis 11 gemäss Tabelle 2. Die Figuren 4 und 5 zeigen also Schleifmittel mit einer Korngrösse # 36, wobei Figur 4 eine Schleifscheibe mit erfindungsgemäss trocken aufgetragenem Schleifadditiv zeigt und Figur 5 ein Schleifmittel mit nass aufgetragenen Schleifadditiv. Die Figuren 6 und 7 zeigen Schleifmittel mit Korngrösse # 50.The FIGS. 4 to 7 contain photographs of top views on the coated abrasives 8 to 11 according to Table 2. The FIGS. 4 and 5 So show abrasive with a grain size # 36, where FIG. 4 a grinding wheel according to the invention with dry applied abrasive additive shows and FIG. 5 an abrasive with wet abrasive additive. The FIGS. 6 and 7 show abrasives with grain size # 50.

Wie aus dem Vergleich der Figuren hervorgeht, sind die Partikel des Schleifadditivs nach dem erfindungsgemässen, trockenen Auftrag (Figuren 4 und 6) an der Oberfläche des Schleifmittels und insbesondere auch oberhalb der einzelnen Schleifkörner vorhanden. Zudem sind die Partikel des Schleifadditivs im Wesentlichen homogen über die Oberfläche verteilt. Bei den Vergleichsbeispielen mit nassem Auftrag (Figuren 5 und 7) hingegen sind die Partikel des Schleifadditivs weiter zwischen die Schleifkörner eingedrungen und daher praktisch nicht mehr sichtbar. Tabelle 2 Beispiel Nr. 8 9 10 11 Figur Nr. 4 5 6 7 Korngrosse # 36 # 36 # 50 # 50 Auftragsart trocken nass (Vergleichsbeispiel) trocken nass (Vergleichsbeispiel) Auftragsmenge KBF4 [g/m2] 178 172 (enthalten in 344 g/m2 nass aufgetragener Zusatz-beschichtung) 136 138 (enthalten in 276 g/m2 nass aufgetragener Zusatz-beschichtung) As can be seen from the comparison of the figures, the particles of the abrasive additive according to the inventive, dry application ( FIGS. 4 and 6 ) on the surface of the abrasive and especially also above the individual abrasive grains available. In addition, the particles of the abrasive additive are distributed substantially homogeneously over the surface. In the case of the comparative examples with wet application ( Figures 5 and 7 ), however, the particles of the abrasive additive further penetrated between the abrasive grains and therefore practically no longer visible. Table 2 Example no. 8th 9 10 11 Figure no. 4 5 6 7 Large grain # 36 # 36 # 50 # 50 order type dry wet (comparative example) dry wet (comparative example) Order quantity KBF 4 [g / m 2 ] 178 172 (contained in 344 g / m 2 wet applied additive coating) 136 138 (contained in 276 g / m 2 wet applied additive coating)

In Figur 8 ist eine Fotografie einer Schnittansicht durch ein herkömmliches Schleifmittel dargestellt, bei dem das Schleifadditiv 5 in einer flüssig aufgebrachten Zusatzbeschichtung 6 eingebettet ist. Wie hier deutlich zu erkennen ist, befindet sich ein grosser Teil des Schleifadditivs in den Bereichen zwischen den Schleifkörnern 3, wo es seine vorgesehene Wirkung jedoch gar nicht entfalten kann.In FIG. 8 FIG. 5 is a photograph of a sectional view through a conventional abrasive wherein the abrasive additive 5 is embedded in a liquid applied additive coating 6. As can be clearly seen here, a large part of the abrasive additive is in the areas between the abrasive grains 3, where it can not develop its intended effect, however.

Figur 9 zeigt eine Fotografie einer Schnittansicht durch ein weiteres erfindungsgemässes Schleifmittel. Die Schleifkörner 3 sind mithilfe eines Grundbinders 2 an einer Unterlage 1 aus Vulkanfiber der Stärke 0,8 mm gebunden. Unterlage 1, Grundbinder 2 und Schleifkörner 3 sind von einer Schicht aus Deckbinder 4 überdeckt. Oberhalb dieser Schicht befindet sich eine weitere Schicht aus trocken aufgetragenem Schleifadditiv 5. Wie auch aus dieser Abbildung hervorgeht, weist die Schicht aus Schleifadditiv 5 eine im Wesentlichen homogene Dicke auf. Zudem ist erkennbar, dass das Schleifadditiv 5 praktisch nicht in die Schicht aus Deckbinder 4 eingedrungen ist. Ausserdem werden die Partikel des Schleifadditivs 5 direkt durch den Deckbinder 4 gebunden. Es bedarf also keines weiteren Bindemittels, wie es beim herkömmlichen, nassen Auftrag der Zusatzbeschichtung erforderlich ist. FIG. 9 shows a photograph of a sectional view through another abrasive according to the invention. The abrasive grains 3 are bonded by means of a base binder 2 to a substrate 1 of vulcanized fiber of 0.8 mm thickness. Base 1, base binder 2 and abrasive grains 3 are of a layer of cap binder. 4 covered. Above this layer is another layer of dry-applied abrasive additive 5. As can be seen from this figure, the layer of abrasive additive 5 has a substantially homogeneous thickness. In addition, it can be seen that the abrasive additive 5 has practically not penetrated into the layer of cap binder 4. In addition, the particles of the abrasive additive 5 are bound directly by the cap 4. Thus, it requires no further binder, as is required in the conventional, wet application of the additional coating.

In Figur 10 sind Abbott-Kurven mehrerer Schleifmittel gezeigt, die gemäss DIN EN ISO 4287 bestimmt wurden. Die erste Kurve (1) wurde an einer Unterlage gemessen, an die eine Schleifkorn-Mischung aus Korund gebunden war. Diese Mischung enthielt Halbedelkorund der Körnung P120 und keramischen Korund der Körnung #120. Diese Unterlage wies eine Höhendifferenz von 436 µm auf. Unter der Höhendifferenz wird hier und im Folgenden die Differenz der Höhen eines von der Unterlage am weitesten entfernten Punktes der Oberfläche und eines der Unterlage am nächsten liegenden Punktes der Oberfläche verstanden; die Höhendifferenz ist also gleich der Differenz der Ordinatenwerte der Abbott-Kurve bei 0 % und bei 100 %.In FIG. 10 Abbott curves of several abrasives are shown, which were determined according to DIN EN ISO 4287. The first curve (1) was measured on a pad to which an abrasive grain mixture of corundum was bonded. This mixture contained P120 semi-precious corundum and # 120 grade ceramic corundum. This pad had a height difference of 436 microns. The height difference is understood here and below to mean the difference between the heights of a surface of the surface farthest from the substrate and a surface closest to the substrate; the height difference is thus equal to the difference of the ordinate values of the Abbott curve at 0% and at 100%.

Nach Auftragen eines Deckbinders ergab sich die zweite Kurve (2) mit einer Höhendifferenz von 368 µm. Die dritte Kurve (3) wurde für ein erfindungsgemässes Schleifmittel bestimmt, bei dem Kaliumtetrafluoroborat (KBF4) einer mittleren Korngrösse von 25 µm und in einer Menge von etwa 64 g/m2 trocken aufgetragen wurde; die Höhendifferenz beträgt hier 386 µm. Im Vergleich dazu zeigt die vierte Kurve (4) das Ergebnis für ein herkömmliches Schleifmittel, bei dem das Kaliumtetrafluoroborat in einer Dispersion aufgetragen wurde; es ergab sich eine Höhendifferenz von 288 µm. Die Dispersion wurde in einer Menge von 120 g/m2 aufgetragen, was eine Auftragsmenge von 54 g/m2 des Kaliumtetrafluoroborats ergab.After application of a cap binder, the second curve (2) with a height difference of 368 μm resulted. The third curve (3) was determined for an inventive abrasive in which potassium tetrafluoroborate (KBF 4 ) of an average particle size of 25 microns and in an amount of about 64 g / m 2 was applied dry; the height difference here is 386 μm. In comparison, the fourth curve (4) shows the result for a conventional abrasive in which the potassium tetrafluoroborate was applied in a dispersion; it resulted in a height difference of 288 microns. The dispersion was applied in an amount of 120 g / m 2 , which resulted in an application rate of 54 g / m 2 of potassium tetrafluoroborate.

Wie an Figur 10 zu erkennen ist, liegt die dritte Kurve (3) des erfindungsgemässen Schleifmittels bei Materialanteilen von weniger als etwa 15 % oberhalb der vierten Kurve (4) des herkömmlichen Schleifmittels, während sie bei höheren Materialanteilen darunter liegt. Dies ist darauf zurückzuführen, dass sich bei trockenem Auftrag relativ viele der Partikel des Schleiadditivs im Bereich der höchsten Erhebungen (also im Bereich einer Schneideraumtiefe von 0 µm) befinden. Bei nassem Auftrag gemäss Kurve (3) ist ein grösserer Teil des Schleifadditivs in den Bereich zwischen Schleifkörnern eingesunken, so dass hier der Materialanteil bei grösseren Schneideraumtiefen grösser ist. Zudem ist die Höhendifferenz der Kurve (3) zum erfindungsgemässen Schleifmittel grösser als die Höhendifferenz der Kurve (4) zum herkömmlichen Schleifmittel. Auch dies ist darauf zurückzuführen, dass sich ein grosser Anteil der Partikel des Schleifadditivs im Bereich der höchsten Erhebungen befindet.How to FIG. 10 it can be seen, the third curve (3) of the abrasive according to the invention is at less than about 15% of material levels above the fourth curve (4) of the conventional abrasive, while it is lower at higher material levels. This is due to the fact that with dry application a relatively large number of the particles of the grinding additive are in the region of the highest elevations (ie in the region of a cutting chamber depth of 0 μm). With wet application according to curve (3) a larger part of the abrasive additive has sunk into the area between abrasive grains, so that here the material content is greater for larger cutting room depths. In addition, the height difference of the curve (3) for the inventive abrasive larger than the height difference of the curve (4) to the conventional abrasive. This is also due to the fact that a large proportion of the particles of the abrasive additive is in the region of the highest elevations.

Claims (10)

Verfahren zur Herstellung eines beschichteten Schleifmittels, enthaltend die folgenden Schritte: a) Herstellung oder Bereitstellung eines Schleifmittel-Vorprodukts, umfassend eine Unterlage (1), eine Vielzahl von Schleifkörnern (3), welche an die Unterlage gebunden sind, sowie mindestens eine Schicht eine Deckbinders (4), welcher die Schleifkörner (3) zumindest teilweise bedeckt, wobei der oberste Deckbinder (4) ungehärtet ist; b) Aufbringung mindestens eines Schleifadditivs auf den obersten, ungehärteten Deckbinder (4); c) Härtung des obersten Deckbinders (4); dadurch gekennzeichnet, dass
das Schleifadditiv in Schritt b) in trockener Form aufgebracht, insbesondere aufgestreut wird. Process for the preparation of a coated abrasive, comprising the following steps: a) producing or providing an abrasive precursor comprising a backing (1), a plurality of abrasive grains (3) bonded to the backing, and at least one layer of a cap binder (4) at least partially covering the abrasive grains (3) covered, wherein the uppermost cover binder (4) is uncured; b) applying at least one abrasive additive to the top, uncured cover binder (4); c) hardening of the topmost cap (4); characterized in that
the abrasive additive in step b) is applied in dry form, in particular scattered. Verfahren gemäss einem der vorangehenden Ansprüche,
dadurch gekennzeichnet, dass
das Schleifadditiv in Schritt b) in Form eines Pulvers, in Form von Flocken, in Form von Fasern, in Form von Agglomeraten und/oder in Form von Kapseln aufgebracht, insbesondere aufgestreut wird.Method according to one of the preceding claims,
characterized in that
the abrasive additive is applied in step b) in the form of a powder, in the form of flakes, in the form of fibers, in the form of agglomerates and / or in the form of capsules, in particular scattered. Verfahren gemäss einem der vorangehenden Ansprüche,
dadurch gekennzeichnet, dass
mindestens 90 Gew.-%, bevorzugt mindestens 95 Gew.-%, weiter bevorzugt mindestens 99 Gew.-% der Partikel (5) des Schleifadditivs, besonders bevorzugt alle Partikel (5) des Schleifadditivs eine Grösse im Bereich von 0,1 µm bis 2 mm, bevorzugt von 0,1 µm bis 0,5 µm, besonders bevorzugt von 0,1 µm bis 0,1 mm haben.Method according to one of the preceding claims,
characterized in that
at least 90% by weight, preferably at least 95% by weight, more preferably at least 99% by weight of the particles (5) of the abrasive additive, particularly preferably all particles (5) of the abrasive additive have a size in the range from 0.1 μm to 2 mm, preferably from 0.1 .mu.m to 0.5 .mu.m, particularly preferably from 0.1 .mu.m to 0.1 mm. Verfahren gemäss einem der vorangehenden Ansprüche,
dadurch gekennzeichnet, dass
die mittlere Grösse der Partikel (5) des Schleifadditivs geringer ist als die mittlere Grösse der Schleifkörner (3).Method according to one of the preceding claims,
characterized in that
the mean particle size (5) of the abrasive additive is less than the average size of the abrasive grains (3). Verfahren gemäss einem der vorangehenden Ansprüche,
dadurch gekennzeichnet, dass
das Schleifadditiv in einer Auftragsmenge aufgetragen wird, die im Bereich von 10 g/m2 bis 500 g/m2, bevorzugt von 20 g/m2 bis 400 g/m2, besonders bevorzugt von 25 g/m2 bis 250 g/m2 liegt.Method according to one of the preceding claims,
characterized in that
the abrasive additive is applied in an application amount ranging from 10 g / m 2 to 500 g / m 2 , preferably from 20 g / m 2 to 400 g / m 2 , particularly preferably from 25 g / m 2 to 250 g / m 2 lies. Beschichtetes Schleifmittel, erhältlich durch ein Verfahren gemäss einem der vorangehenden Ansprüche.Coated abrasive obtainable by a process according to any one of the preceding claims. Schleifmittel gemäss Anspruch 6,
dadurch gekennzeichnet, dass
das Verhältnis der Schichtdicke des Schleifadditivs oberhalb der Schleifkörner (3) zur Schichtdicke des Schleifadditivs zwischen den Schleifkörnern (3) mindestens 30 %, bevorzugt mindestens 50 %, besonders bevorzugt mindestens 70 % beträgt.Abrasive according to claim 6,
characterized in that
the ratio of the layer thickness of the abrasive additive above the abrasive grains (3) to the layer thickness of the abrasive additive between the abrasive grains (3) is at least 30%, preferably at least 50%, particularly preferably at least 70%. Schleifmittel gemäss einem der Ansprüche 6 und 7,
dadurch gekennzeichnet, dass
mindestens 60 Gew.-%, bevorzugt mindestens 80 Gew.-%, besonders bevorzugt mindestens 90 Gew.-% der Partikel (5) des Schleifadditivs in einer Aussenschicht des Schleifmittels angeordnet sind, deren Dicke höchstens 60 %, bevorzugt höchstens 40 %, besonders bevorzugt höchstens 30 % der gesamten Dicke der Schicht aus oberstem Deckbinder (4) und Schleifadditiven beträgt.Abrasive according to one of claims 6 and 7,
characterized in that
at least 60 wt .-%, preferably at least 80 wt .-%, more preferably at least 90 wt .-% of the particles (5) of the abrasive additive are disposed in an outer layer of the abrasive whose thickness is at most 60%, preferably at most 40%, especially preferably at most 30% of the total thickness of the top coat (4) layer and abrasive additives. Schleifmittel gemäss einem der Ansprüche 6 bis 8,
dadurch gekennzeichnet, dass
die durchschnittliche Auftragsmenge der Partikel (5) des Schleifadditivs oberhalb der Schleifkörner (3) von der durchschnittlichen Auftragsmenge der Partikel (5) des Schleifadditivs zwischen den Schleifkörnern (3) um weniger als 60 %, bevorzugt um weniger als 50 %, besonders bevorzugt um weniger als 40 % abweicht.An abrasive according to any one of claims 6 to 8,
characterized in that
the average order of the particles (5) of the Abrasive additive above the abrasive grains (3) deviates from the average application rate of the particles (5) of the abrasive additive between the abrasive grains (3) by less than 60%, preferably by less than 50%, more preferably by less than 40%. Verwendung eines beschichteten Schleifmittels gemäss einem der Ansprüche 6 bis 9 zur Bearbeitung einer Oberfläche, insbesondere einer Oberfläche, die mindestens ein Metall enthält oder daraus besteht, insbesondere rostfreien Stahl, Titan und/oder mindestens eine Superlegierung.Use of a coated abrasive according to any one of claims 6 to 9 for machining a surface, in particular a surface containing or consisting of at least one metal, in particular stainless steel, titanium and / or at least one superalloy.
EP11175222.6A 2011-07-25 2011-07-25 Method for producing a coated abrasive, coated abrasive and use of a coated abrasive Active EP2551057B1 (en)

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EP11175222.6A EP2551057B1 (en) 2011-07-25 2011-07-25 Method for producing a coated abrasive, coated abrasive and use of a coated abrasive
BR112014001627-5A BR112014001627B1 (en) 2011-07-25 2012-07-23 method for producing a coated abrasive product and coated abrasive product
KR1020147002018A KR101949126B1 (en) 2011-07-25 2012-07-23 Method for producing a coated grinding means, coating grinding means, and use of a coated grinding means
US14/234,917 US9555520B2 (en) 2011-07-25 2012-07-23 Method for producing a coated grinding means
CN201280036977.8A CN103702801B (en) 2011-07-25 2012-07-23 Application for the grinding tool of the method for grinding tool for manufacturing coating, the grinding tool of coating and coating
PCT/EP2012/064376 WO2013014116A1 (en) 2011-07-25 2012-07-23 Method for producing a coated grinding means, coating grinding means, and use of a coated grinding means
US15/376,820 US10562153B2 (en) 2011-07-25 2016-12-13 Coated grinding means

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