EP3368247B1 - Method for manufacturing non-woven abrasive article - Google Patents
Method for manufacturing non-woven abrasive article Download PDFInfo
- Publication number
- EP3368247B1 EP3368247B1 EP16790558.7A EP16790558A EP3368247B1 EP 3368247 B1 EP3368247 B1 EP 3368247B1 EP 16790558 A EP16790558 A EP 16790558A EP 3368247 B1 EP3368247 B1 EP 3368247B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- unit
- abrasive
- woven
- fleece
- yarn
- 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.)
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Links
- 238000000034 method Methods 0.000 title claims description 57
- 238000004519 manufacturing process Methods 0.000 title claims description 11
- 239000006061 abrasive grain Substances 0.000 claims description 26
- 238000007596 consolidation process Methods 0.000 claims description 18
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- 230000015572 biosynthetic process Effects 0.000 claims description 8
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- 238000009960 carding Methods 0.000 claims description 2
- 238000002604 ultrasonography Methods 0.000 claims 1
- 239000011248 coating agent Substances 0.000 description 38
- 238000000576 coating method Methods 0.000 description 38
- 239000000463 material Substances 0.000 description 19
- 239000000835 fiber Substances 0.000 description 17
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 10
- 239000002987 primer (paints) Substances 0.000 description 10
- 229920003002 synthetic resin Polymers 0.000 description 10
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- NAQMVNRVTILPCV-UHFFFAOYSA-N hexane-1,6-diamine Chemical compound NCCCCCCN NAQMVNRVTILPCV-UHFFFAOYSA-N 0.000 description 6
- 239000000853 adhesive Substances 0.000 description 5
- 230000001070 adhesive effect Effects 0.000 description 5
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- 238000009987 spinning Methods 0.000 description 5
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- 229920000572 Nylon 6/12 Polymers 0.000 description 4
- TVIDDXQYHWJXFK-UHFFFAOYSA-N dodecanedioic acid Chemical compound OC(=O)CCCCCCCCCCC(O)=O TVIDDXQYHWJXFK-UHFFFAOYSA-N 0.000 description 4
- JBKVHLHDHHXQEQ-UHFFFAOYSA-N epsilon-caprolactam Chemical compound O=C1CCCCCN1 JBKVHLHDHHXQEQ-UHFFFAOYSA-N 0.000 description 4
- 238000011049 filling Methods 0.000 description 4
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- 239000007788 liquid Substances 0.000 description 4
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- 238000000016 photochemical curing Methods 0.000 description 4
- 239000003082 abrasive agent Substances 0.000 description 3
- 230000001427 coherent effect Effects 0.000 description 3
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- KIDHWZJUCRJVML-UHFFFAOYSA-N putrescine Chemical compound NCCCCN KIDHWZJUCRJVML-UHFFFAOYSA-N 0.000 description 3
- 238000010526 radical polymerization reaction Methods 0.000 description 3
- 238000007142 ring opening reaction Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 238000009281 ultraviolet germicidal irradiation Methods 0.000 description 3
- GUOSQNAUYHMCRU-UHFFFAOYSA-N 11-Aminoundecanoic acid Chemical compound NCCCCCCCCCCC(O)=O GUOSQNAUYHMCRU-UHFFFAOYSA-N 0.000 description 2
- PBLZLIFKVPJDCO-UHFFFAOYSA-N 12-aminododecanoic acid Chemical compound NCCCCCCCCCCCC(O)=O PBLZLIFKVPJDCO-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 241000196324 Embryophyta Species 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
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- 239000002184 metal Substances 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- BDJRBEYXGGNYIS-UHFFFAOYSA-N nonanedioic acid Chemical compound OC(=O)CCCCCCCC(O)=O BDJRBEYXGGNYIS-UHFFFAOYSA-N 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- JNELGWHKGNBSMD-UHFFFAOYSA-N xanthone Chemical compound C1=CC=C2C(=O)C3=CC=CC=C3OC2=C1 JNELGWHKGNBSMD-UHFFFAOYSA-N 0.000 description 2
- OAMHTTBNEJBIKA-UHFFFAOYSA-N 2,2,2-trichloro-1-phenylethanone Chemical compound ClC(Cl)(Cl)C(=O)C1=CC=CC=C1 OAMHTTBNEJBIKA-UHFFFAOYSA-N 0.000 description 1
- NLGDWWCZQDIASO-UHFFFAOYSA-N 2-hydroxy-1-(7-oxabicyclo[4.1.0]hepta-1,3,5-trien-2-yl)-2-phenylethanone Chemical compound OC(C(=O)c1cccc2Oc12)c1ccccc1 NLGDWWCZQDIASO-UHFFFAOYSA-N 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 150000008062 acetophenones Chemical class 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 238000012644 addition polymerization Methods 0.000 description 1
- 235000011037 adipic acid Nutrition 0.000 description 1
- 239000001361 adipic acid Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000007605 air drying Methods 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- RWCCWEUUXYIKHB-UHFFFAOYSA-N benzophenone Chemical compound C=1C=CC=CC=1C(=O)C1=CC=CC=C1 RWCCWEUUXYIKHB-UHFFFAOYSA-N 0.000 description 1
- 239000012965 benzophenone Substances 0.000 description 1
- 230000001588 bifunctional effect Effects 0.000 description 1
- 238000010538 cationic polymerization reaction Methods 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- JMLPVHXESHXUSV-UHFFFAOYSA-N dodecane-1,1-diamine Chemical compound CCCCCCCCCCCC(N)N JMLPVHXESHXUSV-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 235000019441 ethanol Nutrition 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 229910052755 nonmetal Inorganic materials 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 239000003505 polymerization initiator Substances 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000013615 primer Substances 0.000 description 1
- KCTAWXVAICEBSD-UHFFFAOYSA-N prop-2-enoyloxy prop-2-eneperoxoate Chemical compound C=CC(=O)OOOC(=O)C=C KCTAWXVAICEBSD-UHFFFAOYSA-N 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 150000003254 radicals Chemical class 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 229920006305 unsaturated polyester Polymers 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Images
Classifications
-
- 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
- B24D3/02—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 bonding agent
- B24D3/20—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 bonding agent and being essentially organic
- B24D3/28—Resins or natural or synthetic macromolecular compounds
Definitions
- the invention relates to a method for producing abrasive fleece.
- the usual process steps for the production of an abrasive fleece are described.
- Materials such as nylon, polyester or mixtures thereof serve as the starting material for such abrasive nonwovens.
- the starting material is first subjected to fleece formation and then to subsequent fleece consolidation.
- the web is a pre-bonded web that does not yet include abrasive particles.
- the mat is then passed through an adhesive coater and then through a particle coater to apply the abrasive particles.
- a suitable synthetic resin is used as an adhesive, which hardens in a heat stage and then binds the abrasive particles to the base material.
- the US 5,811,186 A describes a process for making filaments from melt-extruded, melt-bonded thermoplastic fibers. Abrasive particles can then be applied from these filaments.
- the DE 21 02 786 A describes a method and a device for producing a thread covered with abrasives, in which a thread is covered on its outer surface with an abrasive consisting of individual abrasive grains, the thread having such a low inherent rigidity that it z.
- the US2014/0259960A1 describes a web in which a binder material can bind the fibers at crossing points. An abrasive product can be formed from this web.
- US 4,227,350A describes the production of an abrasive fleece, in which a suitable fleece is first formed from threads, which is then provided with abrasive particles and a further coating.
- the US 3,817,004A describes the production of a wiping mob, in which individual cords or threads are coated, which are then picked up on a holder or a headband in such a way that they hang down to form the wiping mob.
- the object of the invention is therefore to improve the homogeneity and the reproducibility of the abrasive fleece produced.
- the method according to the invention is a method for producing abrasive fleece, in which fleece fibers of a specific starting material are subjected to the process steps of fleece formation and subsequent fleece consolidation, the fleece fibers being coated with abrasive grains before the fleece formation process step and/or before the fleece consolidation process step, that the abrasive grains adhere to the base material.
- An essential finding of the invention is therefore to apply the abrasive grains to the fleece fibers before the formation of the fleece and/or before the final strengthening of the fleece. It has been shown that in this way the abrasive grains can be applied to the fleece fibers much more evenly, since the fleece fibers are still accessible in a separated state.
- the fleece fibers consist of a polyamide and/or of a polyamide mixture and/or of nylon.
- the fleece is formed using a carding method and/or using an aerodynamic method.
- the fleece is consolidated using an entanglement process, for example using water jet entanglement.
- an entanglement process for example using water jet entanglement.
- the material fed to the web consolidation is already mixed with abrasive grains, there is a risk that the tools used in the web consolidation will wear out quickly.
- water jet turbulence has the particular advantage that it is hardly necessary to intervene in the fleece material.
- the same advantages can also be achieved when bonding the fleece using a thermal method, for example using ultrasonic bonding. Entanglement processes and thermal processes can also be used particularly preferably in combination in the web consolidation.
- the abrasive grains prefferably be applied directly to the abrasive fibers that have not yet fully hardened.
- the fleece fibers are coated with a synthetic resin that ensures adhesion between the abrasive grains and fleece fibers.
- a light-curing synthetic resin is preferably used as the synthetic resin.
- the fleece fibers are continuously coated.
- the fleece fibers are coated intermittently.
- the intermittent coating can be advantageous in particular when the average diameter of the abrasive grains is in the range of the average diameter of the abrasive fibers or is larger than this, so that it is desirable to provide a controlled spacing along the batt fiber between the abrasive grits.
- the basic structure of the system consists of a mixing unit 101, an extruder 103, a spinneret 105, a bundling unit 107, a coating unit 109 and a fleece bonding unit 115.
- the mixing unit 101 is connected to the extruder 103 via the connecting flange 102 .
- In the mixing unit can various granules are mixed and then fed to the extruder 103 in a mixed form.
- the granules are compacted under high pressure and melted.
- the melted granulate is then fed to the spinneret 105 via the melt channel 104 .
- the spinneret 105 is kept at the necessary spinning temperature (in the case of nylon, for example, 290° C.) by a heating unit that is not shown in any more detail.
- the spinneret 105 has a multiplicity of spinning orifices which, depending on the viscosity of the melt, have a suitable diameter in order to be able to spin continuous filaments. In the case of nylon, for example, the diameter of each spinning orifice is 0.4 mm.
- the number of spinning orifices can vary widely depending on the required strength and diameter of the abrasive yarn, starting with a single spin orifice up to several 100 spin orifices.
- the spinning opening itself can also be shaped differently. In addition to a circular opening, a star-shaped opening is also conceivable, for example, in order to improve the surface adhesion of the synthetic resin or binder, for example.
- the threads 106 spun by the spinneret are then combined at the inlet of the bundling unit 107 and mixed together there to form a cohesive yarn 108 and stretched.
- a detailed description of the bundling unit 107 follows below with reference to FIG 2 .
- a first process interface is marked with A below the bundling unit 107 .
- the first process interface A is intended to indicate that there are various options for further processing the yarn 108 at this point.
- One possibility is according to 1 the manner shown, ie the direct further processing in the coating unit 109.
- Another possibility is to wind the yarn 108 onto spools at the first process interface A and to store these spools until further processing.
- the yarn 108 bundled by the bundling unit 107 is then fed to a coating unit 109, in which the yarn 108 is coated with a resin and coated with abrasive grains.
- a detailed description of the coating unit 109 follows below with reference to FIG 3 .
- a second process interface is marked with B below the coating unit 109 .
- the second process interface B should in turn indicate that there are also various options for further processing the abrasive yarn 112 at this point.
- One possibility is according to 1 the manner shown, ie the grinding yarn 112 is deposited, for example, on a conveyor belt 110 for direct further processing.
- the belt speed v and thus also the density of the deposited material 113 can be influenced.
- the laid material 113 can then be further processed into a grinding fleece, for example, using the known methods of fleece processing.
- Another possibility for further processing of the abrasive yarn 112 at the second process interface B is that the abrasive yarn 112 is wound up and then further processed into a fabric abrasive using a weaving process.
- the material 113 deposited on the conveyor belt 110 is then fed to a fleece bonding unit 115 in which the loose fibers are bonded into a coherent abrasive fleece.
- a detailed description of the web consolidation unit 115 is provided below with reference to FIG 4 .
- a third process interface is marked with C in front of the web consolidation unit 115 .
- the third process interface C should in turn indicate that there are also various options for solidifying the deposited material 113 at this point. The most important possibilities are chemical bonding, thermal bonding, hydroentanglement and needling. All options can also be combined by connecting them in series.
- Foam and liquid applications are used in chemical bonding. A slight pre-consolidation is possible with the water jet technology.
- the fleece is dewatered by suction of the foam application. This is followed by drying with cylinder and through-flow dryers.
- the thermal hardening takes place with drum furnaces.
- the fleece fibers are bonded with hot air.
- the through-air drying process is based on a combination of screen drum and radial fan. The fan sucks the air out of the screening drum and directs it back to the outside of the drum via heating elements. This creates a suction pull on the drum surface, which holds the fleece on the drum and at the same time flows through it. In this process, several drums can also be connected in series.
- hydroentanglement In addition to the central bonding unit with several water beams, hydroentanglement also includes downstream spunlace drums and a compacting and dewatering system.
- Needle machines for web bonding can be designed as single board or double board variants. Both can be used with top-down or bottom-up needling. For some applications, a tandem machine is also conceivable, with one board working from above and one board from below.
- a fourth process interface is marked with D after the web consolidation unit 115 .
- the finished abrasive fleece is available for assembly.
- the ready-made non-woven abrasive can then be dispatched.
- the main control unit 114 is connected to the components described in the manner shown in order to measure and control the relevant process parameters.
- the ring opening 201 can be adjusted in the plane perpendicular to the transport direction of the combined threads by a positioning device that is not shown in detail.
- the suction jet unit 202 consists of a longitudinal guide unit 203, an air injector unit 204 and a compressed air connection 205.
- the inner diameter of the longitudinal guide unit 203 is somewhat smaller (e.g. 2 mm) than the inner diameter of the air injector unit 204 (e.g. 3 mm).
- Compressed air with a pressure of 7 kg/cm 2 is connected to the compressed air connection 205 , so that the compressed air follows the path indicated by the arrows 206 . In this way, a high-velocity suction jet is produced in the air injector unit 204 .
- the flow speed in the middle of the channel can be a few kilometers/minute.
- a typical flow rate in the center of the channel is, for example, 3000 m/min.
- the suction jet deters the newly spun filaments 106 and at the same time causes the filaments to curl with one another in an irregular and random manner.
- the speed of the yarn has a certain slip compared to the flow speed of the air (e.g. 10%)
- the speed of the yarn is correspondingly smaller (e.g. 2700 m/min) than that of the air flow (e.g. 3000 m/min as mentioned above).
- the air injector unit 204 Within the air injector unit 204, vortices and turbulence develop around the semi-solid filaments, causing the semi-solid filaments to mix, harden and form a coherent yarn therewith. In addition, the air flow within the air injector unit 204 exerts a suction effect on the yarn, so that the yarn is transported further, tapered and oriented and in this way finally leaves the bundling unit 107 as a coherent yarn 108 .
- the coating unit 109 basically comprises a pull-off roller unit 301, a dancer roller unit 302, a primer coating nozzle 303, an abrasive coating nozzle 304, a UV irradiation unit 307 and a control-measuring unit 308.
- the take-off roller unit 301 ensures that the yarn 108 that leaves the bundling unit 107 is transported further.
- a dancer roller unit 302 is provided in the known manner.
- the primer coating die 303 contains a primer or adhesive 305 such that an adhesive layer is formed on the yarn 108 as the yarn 108 passes through the primer coating die 303 .
- the adhesive layer improves the adhesion and the adhesion of the subsequent coating in the abrasive coating die 304.
- the thickness of the adhesive layer can be adjusted by the feeding speed of the adhesive 305 and optionally also by an adjustable diameter of the primer coating die 303.
- the yarn 108 with the adhesive layer is then fed through the abrasive coating die 304 which contains a mixture 306 composed of a light-curing resin, abrasive grains and a filling material.
- the mixture 306 adheres to the adhesive layer so that the desired abrasive layer is formed in the outer diameter.
- the thickness of the abrasive layer can be adjusted by the feeding speed of the mixture 306 and optionally also by an adjustable diameter of the abrasive coating nozzle 304 .
- the primer coating nozzle 303 and the abrasive coating nozzle 304 can each have controllable closures that hold back or release the coating material in the desired manner.
- the abrasive coating nozzle 304 alone or the primer coating nozzle 303 and the abrasive coating nozzle 304 together can be controlled in a uniform cycle or according to a specific cycle pattern in order to apply an intermittent coating to the abrasive yarn in a targeted manner.
- the yarn 108 enters the UV irradiation unit 307 after the abrasive coating nozzle 304, so that the photo-curing resin is cured and the abrasive grains are held together.
- the wavelength of the UV light from the UV irradiation unit 307 depends on the respective synthetic resin and can be in the range of 200 nm to 500 nm, for example.
- the synthetic resins used here are usually cured in a wavelength range of 315 - 380 nm.
- the abrasive yarn formed in this way passes through the control measuring unit 308, which measures the outer diameter of the abrasive yarn.
- the coating control unit 309 is connected to the components described in the manner shown in order to measure and control the relevant process parameters. Above all, the outer diameter measured by the control-measuring unit 308 is evaluated, so that the parameters of the primer coating nozzle 303 and the abrasive coating nozzle 306 can be readjusted on the basis of this evaluation.
- the atmosphere inside the coating unit 109 may be nitrogen or an oxygen-depleted gas in order to achieve stable polymerization of the photocuring resin.
- the yarn 108 can be produced at very high speeds. In principle, speeds of several 100 meters/minute up to a few kilometers/minute are possible, so that the production speed in the coating unit 109 can be adapted to the speed of the yarn emerging from the bundling unit 107 .
- a possible composition of mixture 306 is described in more detail below: Any suitable material capable of increasing the mechanical strength or abrasion resistance of the photocurable resin without adversely affecting the curing process can be used as the filler material.
- the filling material thus exerts a kind of support function on the abrasive grains.
- abrasive grains with a smaller average diameter than the abrasive grains mentioned above can also be used as filling material.
- powder consisting of metal oxide, metal carbide or non-metal oxide or carbide or of metals can also be advantageous.
- Fine abrasive grains for example, which have an average diameter of about 2 ⁇ m to 10 ⁇ m can therefore be used particularly preferably as the filling material.
- the abrasive grains can be made of aluminum oxide or alumina, silicon carbide, CBN, diamond, zirconium corundum, etc., with the mean diameter of the grains being chosen depending on the grinding application.
- the abrasive grains can have an average diameter of 20 ⁇ m to 200 ⁇ m, what in the abrasive area would correspond to a grit in the range of about P800 to P80.
- the abrasive grains are added at about 5% volume of the light-curing resin liquid and can be wetted with a small amount of ethyl alcohol beforehand.
- the photocurable resin liquid may be, for example, an acrylate prepolymer (an oligomer or a monomer) mixed with 1% by weight of an acetolphenone derivative as a photoinitiator.
- the photo-curing resin liquid is based on a radical polymerization in which the radical polymerization of the oligomer or monomer is induced by a free radical generated by the photoinitiator irradiated by the ultraviolet light.
- the oligomer, the monomer and the photoinitiator are not limited to these.
- an unsaturated polyester can be used as the oligomer and styrene can be used as the monomer.
- polyester acrylate, polyether acrylate, acrylic oligomer acrylate, epoxy acrylate, polybutadiene acrylate, silicone acrylate or polyurethane acrylate can also be used for the oligomer.
- the monomer for example, N-vinyl pyrolidone, vinyl acetate, monofunctional acrylate, bifunctional acrylate, or trifunctional acrylate can also be used.
- the polymerization initiator for example, an acetophenone derivative such as acetophonone or trichloroacetophenone, benzoin ether, benzophenone or xanthone can be used.
- the photo-curing resin instead of the radical polymerization type, a photo-addition polymerization type, a photo-cationic polymerization type, or an acid-drying type or an acid-hardening type can be used.
- the non-woven fabric is formed into a non-woven material 113 by depositing the grinding yarn 112 onto the conveyor belt 110 according to FIG 1 .
- the fleece material 113 formed in this way leaves the conveyor belt 110 horizontally and is fed to the subsequent conveyor belt 401 for fleece consolidation via a further belt and roller system 402 .
- the kinematics of the vertical needle movement is shown in the in 4 needle machines shown realized by a crank drive 403 consisting of eccentrics and connecting rods and straight guides.
- the needle bar 404 continuously executes a linear up and down movement with each revolution of the crankshaft, which movement runs approximately sinusoidally over time.
- These oscillating double-stroke movements take place with a specific stroke frequency and amplitude, with the stroke frequency and amplitude being adjustable via the control unit 114 .
- Numerous needles are in the so-called needle boards after one Arrangement scheme orthogonal to the board level lined up parallel to each other.
- the needle board itself is attached to the needle bar 404, which extends across the working width as a rigid support.
- Parallel perforated plates are arranged horizontally for the passage of the fleece inside the needle machine. If the needles pierce the fleece from above, it supports the lower perforated plate as a so-called needle plate 406 against puncture forces from above.
- the surfaces of the throat plate and hold-down device are smooth, guide the fleece and create the space for the throughput via their adjustable distance.
- a pair of take-off rollers 405 frictionally drives the needled fleece via a clamping gap and imprints the take-off speed on it. However, as long as the needles are engaged, the flow of non-woven fabric is stopped in the needle zone.
- a device not shown in detail which can position the abrasive yarn 112 perpendicularly to the direction of movement v before it is deposited.
- the abrasive yarn 112 can be guided at the second process interface B, for example, through an eyelet that is moved back and forth along a traverse perpendicular to the direction of movement v.
- an air flow unit can also be used in order to place the grinding yarn 112 on different positions of the conveyor belt 110 by means of a purposefully varying air flow.
- figure 5 shows a first variant of the system 1 .
- the reference symbols in figure 5 correspond to the reference numbers 1 , so for the description of the components refer to the description of 1 can be referred.
- several spinnerets 105a, 105b, 105c are now provided perpendicular to the direction of movement v, which can be identical or different in design, in such a way that the desired placement of the abrasive yarn 112 is formed over the entire width of the conveyor belt 110.
- the spinnerets can produce identical or different filament diameters.
- FIG. 6 shows a second variant of the system 1 with a stretching unit 601, with a finishing unit 602 and with a consolidation unit 605.
- the process interfaces A, B, C and D basically correspond to the process interfaces A, B, C and D from 1 , however, different variants are conceivable with regard to the stretching unit 601 and the finishing unit 602, which are explained in more detail here.
- the stretching unit 601 can be designed like the bundling unit 107, as detailed in 2 is shown.
- the equipment unit 602 can also be designed like the coating unit 109, as detailed in 3 is shown.
- the synthetic resin and the primer to be dispensed with entirely in the finishing unit 602 and the abrasive grains to be applied directly to the yarn that has not yet fully hardened or to the yarn surface that has been made plastic again.
- a coating nozzle can again be used for coating, such as that according to the abrasive coating nozzle 304 in 3 was described.
- a further variant is that the drying or curing of the synthetic resin only takes place after the grinding yarn has been placed on the conveyor belt 603 . Curing can take place by means of UV radiation or also by means of conventional thermal drying or drying in some other way. An example of this situation is given in 6 a thermal drying unit 604 is shown above the conveyor belt 603. The basic idea of this variant is that the state of the not yet fully hardened grinding yarn is used, in order to bring about a certain solidification as soon as it is deposited on the conveyor belt 603.
- FIG. 7 shows a third variant of the system 1 with a stretching unit 701, with a finishing unit 702 and with a consolidation unit 705.
- the process interfaces A, C and D basically correspond to the process interfaces A, C and D from 1 , so that the stretching unit 701 can be designed like the bundling unit 107, as detailed in 2 is shown.
- the variant shown is now already placing the yarn behind the first process interface A on the conveyor belt 703. Once the laid down yarn passes the finishing unit 702, the abrasive grit 706 is sprinkled or sprayed onto the laid down yarn. This is followed by drying or curing with the drying unit 704 and solidification with the solidification unit 705.
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Description
Die Erfindung betrifft ein Verfahren zur Herstellung von Schleifvlies.The invention relates to a method for producing abrasive fleece.
In der
Beim Durchgang durch den Klebstoffbeschichter und den Teilchenbeschichter ist es oft schwierig, die Beschichtung stets in der gleich Weise herzustellen. Demnach besteht ein Problem bei dem beschriebenen Herstellungsverfahren darin, das Schleifvlies mit möglichst homogenen und reproduzierbaren Eigenschaften herzustellen.Passing through the adhesive coater and the particle coater, it is often difficult to make the coating the same way every time. Accordingly, there is a problem with the production method described in producing the abrasive fleece with properties that are as homogeneous and reproducible as possible.
Die
Die
Die
Auch die
Die
Aufgabe der Erfindung ist es daher, die Homogenität sowie die Reproduzierbarkeit des hergestellten Schleifvlieses zu verbessern.The object of the invention is therefore to improve the homogeneity and the reproducibility of the abrasive fleece produced.
Diese Aufgabe wird durch die Merkmale des Patentanspruchs 1 gelöst.This object is solved by the features of patent claim 1.
Bevorzugte Ausführungsformen sind durch die Unteransprüche 2 - 11 angegeben.Preferred embodiments are given by the subclaims 2-11.
Das erfindungsgemäße Verfahren ist ein Verfahren zur Herstellung von Schleifvlies, bei dem Vliesfasern eines bestimmten Ausgangsmaterials den Verfahrensschritten einer Vliesbildung und einer nachfolgenden Vliesverfestigung unterworfen werden, wobei die Vliesfasern vor dem Verfahrensschritt der Vliesbildung und/oder vor dem Verfahrensschritt der Vliesverfestigung mit Schleifkörnern derart beschichtet werden, dass die Schleifkörner an dem Ausgangsmaterial haften.The method according to the invention is a method for producing abrasive fleece, in which fleece fibers of a specific starting material are subjected to the process steps of fleece formation and subsequent fleece consolidation, the fleece fibers being coated with abrasive grains before the fleece formation process step and/or before the fleece consolidation process step, that the abrasive grains adhere to the base material.
Eine wesentliche Erkenntnis der Erfindung besteht also darin, die Schleifkörner vor der Vliesbildung und/oder vor der endgültigen Vliesverfestigung auf die Vliesfasern aufzubringen. Es hat sich gezeigt, dass hierdurch das Aufbringen der Schleifkörner auf die Vliesfasern wesentlich gleichmäßiger erfolgen kann, da die Vliesfasern noch in einem separierten Zustand zugänglich sind.An essential finding of the invention is therefore to apply the abrasive grains to the fleece fibers before the formation of the fleece and/or before the final strengthening of the fleece. It has been shown that in this way the abrasive grains can be applied to the fleece fibers much more evenly, since the fleece fibers are still accessible in a separated state.
Gemäß einer bevorzugten Ausführungsform bestehen die Vliesfasern aus einem Polyamid und/oder aus einer Polyamidmischung und/oder aus Nylon.According to a preferred embodiment, the fleece fibers consist of a polyamide and/or of a polyamide mixture and/or of nylon.
Gemäß einer weiteren bevorzugten Ausführungsform erfolgt die Vliesbildung mit einem Kardierverfahren und/oder mit einem aerodynamischen Verfahren.According to a further preferred embodiment, the fleece is formed using a carding method and/or using an aerodynamic method.
Gemäß einer weiteren bevorzugten Ausführungsform erfolgt die Vliesverfestigung mit einem Verwirbelungsverfahren, beispielsweise mit einer Wasserstrahlverwirbelung. Da das der Vliesverfestigung zugeführte Material erfindungsgemäß bereits mit Schleifkörnern versetzt ist, besteht die Gefahr, dass sich die bei der Vliesverfestigung eingesetzten Werkzeuge schnell abnutzen. Die Wasserstrahlverwirbelung hat in diesem Zusammenhang den besonderen Vorteil, dass in das Vliesmaterial kaum noch eingegriffen werden muss. Die gleichen Vorteile können auch bei der Vliesverfestigung mit einem thermischen Verfahren, beispielsweise mit einer Ultraschallverfestigung, erreicht werden. Besonders vorzugsweise können Verwirbelungsverfahren und thermische Verfahren bei der Vliesverfestigung auch kombiniert eingesetzt werden.According to a further preferred embodiment, the fleece is consolidated using an entanglement process, for example using water jet entanglement. Since, according to the invention, the material fed to the web consolidation is already mixed with abrasive grains, there is a risk that the tools used in the web consolidation will wear out quickly. In this context, water jet turbulence has the particular advantage that it is hardly necessary to intervene in the fleece material. The same advantages can also be achieved when bonding the fleece using a thermal method, for example using ultrasonic bonding. Entanglement processes and thermal processes can also be used particularly preferably in combination in the web consolidation.
Grundsätzlich ist es bei dem erfindungsgemäßen Verfahren möglich, dass die Schleifkörner an den noch nicht ganz ausgehärteten Schleiffasern direkt aufgebracht werden. Gemäß einer anderen bevorzugten Ausführungsform werden die Vliesfasern vor der Beschichtung mit den Schleifkörnern mit einem Kunstharz beschichtet, der die Haftung zwischen Schleifkörnern und Vliesfasern sicherstellt. Vorzugsweise wird als Kunstharz ein lichthärtender Kunstharz verwendet.In principle, it is possible with the method according to the invention for the abrasive grains to be applied directly to the abrasive fibers that have not yet fully hardened. According to another preferred embodiment, before being coated with the abrasive grains, the fleece fibers are coated with a synthetic resin that ensures adhesion between the abrasive grains and fleece fibers. A light-curing synthetic resin is preferably used as the synthetic resin.
Gemäß einer weiteren bevorzugten Ausführungsform werden die Vliesfasern kontinuierlich beschichtet. Denkbar ist es aber auch, dass die Vliesfasern intermittierend beschichtet werden. Die intermittierende Beschichtung kann insbesondere dann vorteilhaft sein, wenn der mittlere Durchmesser der Schleifkörner sich im Bereich des mittleren Durchmessers der Schleiffasern bewegt oder größer als dieser ist, sodass es zweckmäßig ist, entlang der Vliesfaser zwischen den Schleifkörnern einen kontrollierten Abstand vorzusehen.According to a further preferred embodiment, the fleece fibers are continuously coated. However, it is also conceivable that the fleece fibers are coated intermittently. The intermittent coating can be advantageous in particular when the average diameter of the abrasive grains is in the range of the average diameter of the abrasive fibers or is larger than this, so that it is desirable to provide a controlled spacing along the batt fiber between the abrasive grits.
Weitere Einzelheiten und Vorteile der Erfindung werden anhand der folgenden Figuren erläutert. Es zeigt
- Fig. 1
- die Gesamtansicht einer Anlage zur Herstellung von Schleifgarn,
- Fig. 2
- eine Detailansicht der
Bündelungseinheit 107 ausFig. 1 , - Fig. 3
- eine Detailansicht der
Beschichtungseinheit 109 ausFig. 1 , - Fig. 4
- eine Detailansicht der
Vliesverfestigungseinheit 115 ausFig. 1 , - Fig. 5
- eine erste Variante der Anlage aus
Fig. 1 , - Fig. 6
- eine zweite Variante der Anlage aus
Fig. 1 , und - Fig. 7
- eine dritte Variante der Anlage aus
Fig. 1 .
- 1
- the overall view of a plant for the production of abrasive yarn,
- 2
- shows a detailed view of the
bundling unit 1071 , - 3
- shows a detailed view of the
coating unit 1091 , - 4
- shows a detailed view of the
web consolidation unit 1151 , - figure 5
- a first variant of the system
1 , - 6
- a second variant of the system
1 , and - Figure 7
- a third variant of the system
1 .
Die Mischeinheit 101 ist über den Verbindungsflansch 102 mit dem Extruder 103 verbunden. In der Mischeinheit können verschiedene Granulate gemischt und in einer gemischten Form dann dem Extruder 103 zugeführt werden.The
Selbstverständlich ist es auch möglich, dass in der Mischeinheit nur eine Komponente bereitbestellt und dem Extruder zugeführt wird. Als Granulate werden können beispielsweise Polyester oder Polyamide verwendet werden, wie etwa Nylon (PA 6.6 mit der chemischen Bezeichnung Polyhexamethylenadipinsäureamid). Beispiele für weitere Polyamide sind:
- PA 69 (Hexamethylendiamin/Azelainsäure)
- PA 612 (Hexamethylendiamin/Dodecandisäure)
- PA 11 (11-Aminoundecansäure)
- PA 12 (Laurinlactam oder ω-Aminododecansäure)
- PA 46 (Tetramethylendiamin/Adipinsäure)
- PA 1212 (Dodecandiamin/Dodecandisäure)
- PA 6/12 (Caprolactam/Laurinlactam)
- PA 69 (hexamethylenediamine/azelaic acid)
- PA 612 (hexamethylenediamine/dodecanedioic acid)
- PA 11 (11-aminoundecanoic acid)
- PA 12 (laurolactam or ω-aminododecanoic acid)
- PA 46 (tetramethylenediamine/adipic acid)
- PA 1212 (dodecanediamine/dodecanedioic acid)
- PA 6/12 (caprolactam/laurolactam)
In dem Extruder 103 wird das Granulat unter hohem Druck verdichtet und zum Schmelzen gebracht. Das aufgeschmolzene Granulat wird dann über den Schmelzkanal 104 der Spinndüse 105 zugeführt.In the
Die Spinndüse 105 wird von einer nicht weiter gezeigten Heizeinheit auf der nötigen Spinntemperatur gehalten (bei Nylon beispielsweise 290°C). Die Spinndüse 105 weist eine Vielzahl von Spinnöffnungen auf, die in Abhängigkeit von der Viskosität der Schmelze einen geeigneten Durchmesser haben, um kontinuierliche Fäden spinnen zu können. Bei Nylon beträgt der Durchmesser je Spinnöffnung beispielsweise 0,4 mm. Die Anzahl der Spinnöffnungen kann in Abhängigkeit von der benötigten Festigkeit und dem benötigten Durchmesser des Schleifgarns stark variieren, beginnend bei einer einzelnen Spinnöffnung bis zu einigen 100 Spinnöffnungen. Auch die Spinnöffnung selber kann unterschiedlich geformt sein. Neben einer kreisrunden Öffnung ist beispielsweise auch eine sternförmige Öffnung denkbar, um auf diese Weise etwa die Oberflächenhaftung des Kunstharzes bzw. Bindemittels zu verbessern.The
Die von der Spinndüse gesponnenen Fäden 106 werden dann am Einlauf der Bündelungseinheit 107 zusammengefasst und dort zu einem zusammenhängenden Garn 108 miteinander vermischt und verstreckt. Eine detaillierte Beschreibung der Bündelungseinheit 107 erfolgt weiter unten anhand von
Unterhalb der Bündelungseinheit 107 ist mit A eine erste Prozess-Schnittstelle markiert. Die erste Prozess-Schnittstelle A soll kennzeichnen, dass es an dieser Stelle verschiedene Möglichkeiten gibt, das Garn 108 weiterzuverarbeiten. Eine Möglichkeit besteht in der gemäß
Das von der Bündelungseinheit 107 gebündelte Garn 108 wird dann einer Beschichtungseinheit 109 zugeführt, in der das Garn 108 mit einem Harz ummantelt und mit Schleifkörnern bestückt wird. Eine detaillierte Beschreibung der Beschichtungseinheit 109 erfolgt weiter unten anhand von
Unterhalb der Beschichtungseinheit 109 ist mit B eine zweite Prozess-Schnittstelle markiert. Die zweite Prozess-Schnittstelle B soll wiederum kennzeichnen, dass es auch an dieser Stelle verschiedene Möglichkeiten gibt, das Schleifgarn 112 weiterzuverarbeiten.A second process interface is marked with B below the
Eine Möglichkeit besteht in der gemäß
Eine andere Möglichkeit der Weiterverarbeitung des Schleifgarns 112 an der zweiten Prozess-Schnittstelle B besteht darin, dass das Schleifgarn 112 aufgewickelt und dann mit einem Webverfahren zu einem Gewebe-Schleifmittel weiterverarbeitet wird.Another possibility for further processing of the
Im Prinzip ist also an der Prozess-Schnittstelle B die Weiterverarbeitung des Schleifgarns zu Schleifmitteln jeglicher Art denkbar.In principle, the further processing of the abrasive yarn into abrasives of any kind is conceivable at the process interface B.
Das auf dem Förderband 110 abgelegte Material 113 wird dann einer Vliesverfestigungseinheit 115 zugeführt, in der die losen Fasern zu einem zusammenhängenden Schleifvlies verfestigt werden. Eine detaillierte Beschreibung der Vliesverfestigungseinheit 115 erfolgt weiter unten anhand von
Vor der Vliesverfestigungseinheit 115 ist mit C eine dritte Prozess-Schnittstelle markiert. Die dritte Prozess-Schnittstelle C soll wiederum kennzeichnen, dass es auch an dieser Stelle verschiedene Möglichkeiten gibt, das abgelegte Material 113 zu verfestigen. Die wichtigsten Möglichkeiten sind die chemische Verfestigung, die thermische Verfestigung, die Wasserstrahlverfestigung und die Vernadelung. Alle Möglichkeiten lassen sich durch eine Hintereinanderschaltung auch kombinieren.A third process interface is marked with C in front of the
Bei der chemischen Verfestigung werden Schaum- und Flüssigkeitsapplikation eingesetzt. Eine leichte Vorverfestigung ist mit der Wasserstrahl- Technologie möglich. Die Entwässerung des Vlieses erfolgt durch Absaugung der Schaumapplikation. Danach erfolgt die Trocknung mit Zylinder- und Durchströmtrockner.Foam and liquid applications are used in chemical bonding. A slight pre-consolidation is possible with the water jet technology. The fleece is dewatered by suction of the foam application. This is followed by drying with cylinder and through-flow dryers.
Die thermische Verfestigung erfolgt mit Trommelöfen. Dabei werden die Vliesfasern mit mittels Heißluft verfestigt. Das Durchströmtrocknungsverfahren basiert auf einer Kombination aus Siebtrommel und Radialventilator. Der Ventilator saugt die Luft aus der Siebtrommel und führt sie über Heizelemente wieder zur Außenseite der Trommel. Dadurch entsteht auf der Trommeloberfläche ein Sogzug, der das Vlies auf der Trommel hält und gleichzeitig durchströmt. Bei diesem Prozess können auch mehrere Trommeln in Reihe geschaltet werden.The thermal hardening takes place with drum furnaces. The fleece fibers are bonded with hot air. The through-air drying process is based on a combination of screen drum and radial fan. The fan sucks the air out of the screening drum and directs it back to the outside of the drum via heating elements. This creates a suction pull on the drum surface, which holds the fleece on the drum and at the same time flows through it. In this process, several drums can also be connected in series.
Die Wasserstrahlverfestigung umfasst neben der zentralen Verfestigungseinheit mit mehreren Wasserbalken desweiteren nachgeschaltete Spunlace-Trommeln sowie ein Kompaktier- und Entwässerungssystem.In addition to the central bonding unit with several water beams, hydroentanglement also includes downstream spunlace drums and a compacting and dewatering system.
Nadelmaschinen zur Vliesverfestigung können als Einbrett- oder Doppelbrettvarianten ausgeführt sein. Beide können mit Vernadelung von oben nach unten oder von unten nach oben eingesetzt werden. Für einige Anwendungsfälle ist auch eine Tandemmaschine denkbar, bei der ein Brett von oben und ein Brett von unten arbeitet.Needle machines for web bonding can be designed as single board or double board variants. Both can be used with top-down or bottom-up needling. For some applications, a tandem machine is also conceivable, with one board working from above and one board from below.
Nach der Vliesverfestigungseinheit 115 ist mit D eine vierte Prozess-Schnittstelle markiert. An der vierten Prozess-Schnittstelle D ist das fertiggestellte Schleifvlies zur Konfektionierung verfügbar. Die konfektionierte Schleifvliesware kann abschließend dann dem Versand zugeführt werden.A fourth process interface is marked with D after the
Die Haupt-Steuereinheit 114 ist in der gezeigten Weise mit den beschriebenen Komponenten verbunden, um die relevanten Prozessparameter zu messen und zu steuern.The
Die Saugstrahleinheit 202 besteht aus einer Längsführungseinheit 203, aus einer Luftinjektoreinheit 204 sowie aus einem Pressluftanschluss 205. Der Innendurchmesser der Längsführungseinheit 203 ist etwas kleiner (beispielsweise 2 mm) als der Innendurchmesser der Luftinjektoreinheit 204 (beispielsweise 3 mm). An dem Pressluftanschluss 205 wird Pressluft mit einem Druck von beispielsweise 7 kg/cm2 angeschlossen, so dass die Pressluft dem angedeuteten Weg gemäß den Pfeilen 206 folgt. Auf diese Weise entsteht in der Luftinjektoreinheit 204 ein Saugstrahl hoher Geschwindigkeit. Die Strömungsgeschwindigkeit in der Mitte des Kanals kann einige Kilometer / Minute betragen. Eine typische Strömungsgeschwindigkeit in der Mitte des Kanals beträgt beispielsweise 3000 m/min.The
Der Saugstrahl schreckt die frisch gesponnenen Fäden 106 ab und bewirkt gleichzeitig eine Kräuselung der Fäden untereinander in unregelmäßiger und willkürlicher Weise.The suction jet deters the newly spun
Da die Geschwindigkeit des Garns gegenüber der Strömungsgeschwindigkeit der Luft einen gewissen Schlupf aufweist (beispielsweise 10%), ist die Geschwindigkeit des Garns entsprechend kleiner (beispielsweise 2700 m/min) als die der Luftströmung (wie oben genannt beispielsweise 3000 m/min).Since the speed of the yarn has a certain slip compared to the flow speed of the air (e.g. 10%), the speed of the yarn is correspondingly smaller (e.g. 2700 m/min) than that of the air flow (e.g. 3000 m/min as mentioned above).
Innerhalb der Luftinjektoreinheit 204 bilden sich rund um die halbfesten Fäden Strömungswirbel und Turbulenzen, die bewirken, dass die halbfesten Fäden sich mischen, aushärten und damit ein zusammenhängendes Garn bilden. Außerdem übt die Luftströmung innerhalb der Luftinjektoreinheit 204 eine Saugwirkung auf das Garn aus, sodass das Garn weitertransportiert, verjüngt und orientiert wird und auf diese Weise schließlich als zusammenhängendes Garn 108 die Bündelungseinheit 107 verlässt.Within the
Für den Weitertransport des Garns 108, das die Bündelungseinheit 107 verlässt, sorgt die Abzugswalzeneinheit 301. Die Abzugswalzen 301 werden in ihrer Geschwindigkeit derart geregelt, dass sich innerhalb des Garns 108 am Eingang der Beschichtungseinheit 109 eine lose Garnspannung in Transportrichtung einstellt. Um Schwankungen der Transportgeschwindigkeit auszugleichen, ist in der bekannten Weise eine Tänzerwalzeneinheit 302 vorgesehen.The take-off
Die Primer-Beschichtungsdüse 303 enthält einen Primer bzw. ein Haftmittel 305, sodass eine Haftmittelschicht an dem Garn 108 gebildet wird, während das Garn 108 die Primer-Beschichtungsdüse 303 durchläuft. Die Haftmittelschicht verbessert die Adhäsion und das Haftvermögen der nachfolgenden Beschichtung in der Schleifmittel-Beschichtungsdüse 304. Die Stärke der Haftmittelschicht kann durch die Zuführgeschwindigkeit des Haftmittels 305 und gegebenenfalls auch durch einen verstellbaren Durchmesser der Primer-Beschichtungsdüse 303 eingestellt werden.The primer coating die 303 contains a primer or adhesive 305 such that an adhesive layer is formed on the
Das Garn 108 mit der Haftmittelschicht wird dann durch die Schleifmittel-Beschichtungsdüse 304 geführt, die eine Mischung 306 enthält, die aus einem lichthärtenden Harz, abrasiven Körnern und einem Füllmaterial besteht. Die Mischung 306 bleibt an der Haftmittelschicht haften, sodass im Außendurchmesser die gewünschte abrasive Schicht entsteht. Die Stärke der abrasiven Schicht kann durch die Zuführgeschwindigkeit der Mischung 306 und gegebenenfalls auch durch einen verstellbaren Durchmesser der Schleifmittel-Beschichtungsdüse 304 eingestellt werden.The
An dieser Stelle wird eine weitere Variante zu der oben beschriebenen Beschichtung des Garns beschrieben: Neben einer kontinuierlichen Beschichtung mit dem Primer, dem Kunstharz und den abrasiven Körnern ist es auch möglich, die Beschichtung intermittierend, d.h. also mit bestimmten Unterbrechungen durchzuführen. Ein Grund hierfür kann beispielsweise darin bestehen, dass eine kontinuierliche Beschichtung dem Garn eine zu hohe Biegesteifigkeit verschafft. Demgegenüber könnte also mit einer intermittierenden Beschichtung die gewünschte Flexibilität und Elastizität des Schleifgarns sehr genau und reproduzierbar eingestellt werden.At this point, another variant of the yarn coating described above is described: In addition to continuous coating with the primer, the synthetic resin and the abrasive grains, it is also possible to carry out the coating intermittently, i.e. with certain interruptions. One reason for this can be, for example, that a continuous coating gives the yarn too much flexural rigidity. In contrast, the desired flexibility and elasticity of the grinding yarn could be set very precisely and reproducibly with an intermittent coating.
Zur Realisierung der intermittierenden Beschichtung ist es denkbar, die Primer-Beschichtungsdüse 303 und die Schleifmittel-Beschichtungsdüse 304 jeweils ansteuerbare Verschlüsse aufweisen, die das Beschichtungsmaterial in der gewünschten Weise zurückhalten oder freigeben. Auf Weise können die Schleifmittel-Beschichtungsdüse 304 alleine oder auch die Primer-Beschichtungsdüse 303 und die Schleifmittel-Beschichtungsdüse 304 zusammen in einem gleichmäßigen Takt oder auch nach einem bestimmten Taktmuster angesteuert werden, um gezielt eine intermittierende Beschichtung auf das Schleifgarn aufzubringen.In order to implement the intermittent coating, it is conceivable for the
Das Garn 108 tritt hinter der Schleifmittel-Beschichtungsdüse 304 in die UV-Bestrahlungseinheit 307 ein, sodass das lichthärtende Harz aushärtet und die abrasiven Körner zusammenhält. Die Wellenlänge des UV-Lichts der UV-Bestrahlungseinheit 307 hängt von dem jeweiligen Kunstharz ab und kann beispielsweise im Bereich von 200 nm bis 500 nm liegen. Üblicherweise erfolgt die Aushärtung der hier verwendeten Kunstharze in einem Wellenbereich von 315 - 380 nm.The
Das auf diese Weise gebildete Schleifgarn passiert schließlich noch die Kontroll-Messeinheit 308, die den Außendurchmesser des Schleifgarns misst.Finally, the abrasive yarn formed in this way passes through the
Die Beschichtungs-Steuereinheit 309 ist in der gezeigten Weise mit den beschriebenen Komponenten verbunden, um die relevanten Prozessparameter zu messen und zu steuern. Vor allem wird der von der Kontroll-Messeinheit 308 gemessene Außendurchmesser ausgewertet, sodass aufgrund dieser Auswertung die Parameter der Primer-Beschichtungsdüse 303 und der Schleifmittel-Beschichtungsdüse 306 nachjustiert werden können.The
Die Atmosphäre innerhalb der Beschichtungseinheit 109 kann zusätzlich aus Stickstoff oder einem sauerstoffverringerten Gas bestehen, um eine stabile Polymerisation des lichthärtenden Harzes zu erreichen.In addition, the atmosphere inside the
Durch die Verwendung des lichthärtenden Harzes kann das Garn 108 mit sehr hohen Geschwindigkeiten produziert werden. Grundsätzlich sind Geschwindigkeiten von mehreren 100 Metern/Minute bis zu einigen Kilometern/Minute möglich, sodass die Produktionsgeschwindigkeit in der Beschichtungseinheit 109 an die Geschwindigkeit des aus der Bündelungseinheit 107 austretenden Garns angepasst werden kann.Through the use of the light-curing resin, the
Im Folgenden wird eine mögliche Zusammensetzung der Mischung 306 noch näher beschrieben:
Als Füllmaterial kann jedes geeignete Material verwendet werden, das dazu geeignet ist, die mechanische Festigkeit oder die Abriebbeständigkeit des lichthärtenden Kunstharzes zu erhöhen, ohne dabei den Prozess der Aushärtung nachteilig zu beeinflussen. Das Füllmaterial übt also eine Art Stützfunktion auf die abrasiven Körner auf.A possible composition of
Any suitable material capable of increasing the mechanical strength or abrasion resistance of the photocurable resin without adversely affecting the curing process can be used as the filler material. The filling material thus exerts a kind of support function on the abrasive grains.
Insbesondere können als Füllmaterial damit auch weitere abrasive Körner mit einem kleineren mittleren Durchmesser als die zuvor erwähnten abrasiven Körner verwendet werden. Aber auch Pulver bestehend aus Metalloxid, Metallkarbid oder Nichtmetalloxid oder Karbid oder aus Metallen kann je nach Anwendung von Vorteil sein.In particular, other abrasive grains with a smaller average diameter than the abrasive grains mentioned above can also be used as filling material. However, depending on the application, powder consisting of metal oxide, metal carbide or non-metal oxide or carbide or of metals can also be advantageous.
Besonders vorzugsweise können als Füllmaterial also beispielsweise feine abrasive Körner verwendet werden, die einen durchschnittlichen Durchmesser von etwa 2 µm bis 10 µm haben.Fine abrasive grains, for example, which have an average diameter of about 2 μm to 10 μm can therefore be used particularly preferably as the filling material.
Die abrasiven Körner können aus Aluminiumoxid bzw. Tonerde, Siliziumkarbid, CBN, Diamant, Zirkonkorund, etc. hergestellt werden, wobei der mittlere Durchmesser der Körner in Abhängigkeit von der Schleifanwendung gewählt werden kann. Beispielsweise können die abrasiven Körner einen mittleren Durchmesser von 20 µm bis 200 µm haben, was im Schleifmittelbereich einer Körnung im Bereich von etwa P800 bis P80 entsprechen würde.The abrasive grains can be made of aluminum oxide or alumina, silicon carbide, CBN, diamond, zirconium corundum, etc., with the mean diameter of the grains being chosen depending on the grinding application. For example, the abrasive grains can have an average diameter of 20 μm to 200 μm, what in the abrasive area would correspond to a grit in the range of about P800 to P80.
Die abrasiven Körner werden mit etwa 5 Volumenprozent der lichthärtenden Kunstharzflüssigkeit zugesetzt und können vorher noch mit einer kleinen Menge Ethylalkohol benetzt werden.The abrasive grains are added at about 5% volume of the light-curing resin liquid and can be wetted with a small amount of ethyl alcohol beforehand.
Die lichthärtende Kunstharzflüssigkeit kann beispielsweise ein Acrylat-Vorpolymer sein (ein Oligomer oder ein Monomer), dem 1 Gewichts-% eines Azetolphenon-Derivats als Fotoinitiator beigemischt ist.The photocurable resin liquid may be, for example, an acrylate prepolymer (an oligomer or a monomer) mixed with 1% by weight of an acetolphenone derivative as a photoinitiator.
Wie oben bereits erwähnt, basiert die lichthärtende Kunstharzflüssigkeit auf einer radikalen Polymerisation, wobei die radikale Polymerisation des Oligomers oder Monomers durch ein freies Radikal induziert wird, das durch den Fotoinitiator erzeugt wird, der durch das ultraviolette Licht bestrahlt wird. Jedoch sind das Oligomer, das Monomer und der Fotoinitiator nicht auf diese beschränkt. Ebenso kann ein ungesättigtes Polyester als das Oligomer und Styren kann als das Monomer verwendet werden.As mentioned above, the photo-curing resin liquid is based on a radical polymerization in which the radical polymerization of the oligomer or monomer is induced by a free radical generated by the photoinitiator irradiated by the ultraviolet light. However, the oligomer, the monomer and the photoinitiator are not limited to these. Also, an unsaturated polyester can be used as the oligomer and styrene can be used as the monomer.
Für das Oligomer können beispielsweise auch Polyesteracrylat, Polyetheracrylat, Acryloligomeracrylat, Epoxidacrylat, Polybutadienacrylat, Siliconacrylat oder Polyurethanacrylate verwendet werden. Für das Monomer können beispielsweise auch N-Vinylpyrolidon, Vinylacetat, monofunktionales Acrylat, bifunktionales Acrylat oder trifunktionales Acrylat verwendet werden. Für den Polymerisationsinitiator können beispielsweise ein Acetophenon-Derivat, derart wie Acetophonon oder Trichloracetophenon, Benzoinether, Benzophenon oder Xanthon verwendet werden.For example, polyester acrylate, polyether acrylate, acrylic oligomer acrylate, epoxy acrylate, polybutadiene acrylate, silicone acrylate or polyurethane acrylate can also be used for the oligomer. For the monomer, for example, N-vinyl pyrolidone, vinyl acetate, monofunctional acrylate, bifunctional acrylate, or trifunctional acrylate can also be used. For the polymerization initiator, for example, an acetophenone derivative such as acetophonone or trichloroacetophenone, benzoin ether, benzophenone or xanthone can be used.
Außerdem können für das lichthärtende Kunstharz statt der radikalen Polymerisationsausführung eine Lichtadditionspolymerisationsausführung, eine lichtcationische Polymerisations-Ausführung oder eine säuretrocknende bzw. säurehärtende Ausführung verwendet werden.Also, for the photo-curing resin, instead of the radical polymerization type, a photo-addition polymerization type, a photo-cationic polymerization type, or an acid-drying type or an acid-hardening type can be used.
Im Folgenden wird die Vliesverfestigung anhand der Vernadelungstechnologie näher beschrieben. Die Kinematik der vertikalen Nadelbewegung wird in der in
Für die Passage des Vlieses innerhalb der Nadelmaschine sind parallele Lochplatten horizontal angeordnet. Durchstechen die Nadeln das Vlies von oben, stützt es die untere Lochplatte als sogenannte Stichplatte 406 gegen Einstichkräfte von oben. Die parallel darüber angeordnete Lochplatte, der sogenannte Niederhalter 407, streift es gegen die Rückzugskräfte der Nadeln ab. Die Oberflächen von Stichplatte und Niederhalter sind glatt, führen das Vlies und bilden über ihren einstellbaren Abstand den Raum für den Durchlauf. Ein Abzugswalzenpaar 405 treibt das genadelte Vlies über einen Klemmspalt reibschlüssig an und prägt ihm die Abzugsgeschwindigkeit ein. Solange jedoch die Nadeln im Eingriff sind, wird der Vliesdurchlauf in der Nadelzone gestoppt.Parallel perforated plates are arranged horizontally for the passage of the fleece inside the needle machine. If the needles pierce the fleece from above, it supports the lower perforated plate as a so-called
Mit Bezug auf die zweite Prozess-Schnittstelle B gemäß
Alternativ zu der Bildung eines einzelnen Schleifgarns 112 ist es weiterhin auch möglich, senkrecht zur Bewegungsrichtung mehrere Spindüsen 105 bzw. einen Spinbalken mit mehreren Spindüsen vorzusehen.
Zunächst einmal kann die Verstreckungseinheit 601 wie die Bündelungseinheit 107 ausgeführt sein, wie diese im Detail in
Als Variante zu der Beschichtungseinheit 109 ist es aber beispielsweise denkbar, dass in der Ausrüstungseinheit 602 auf den Kunstharz und den Primer gänzlich verzichtet wird und die Schleifkörner direkt auf das noch nicht vollständig ausgehärtete Garn oder die wieder plastisch gemachte Garnoberfläche aufgebracht werden. Zum Beschichten kann wiederum eine Beschichtungsdüse eingesetzt werden, wie diese gemäß der Schleifmittel-Beschichtungsdüse 304 in
Eine weitere Variante besteht darin, dass die Trocknung bzw. Aushärtung des Kunstharzes erst erfolgt, nachdem das Schleifgarn auf das Förderband 603 abgelegt wurde. Die Aushärtung kann mittels UV-Strahlung oder aber auch mittels konventioneller thermischer Trocknung oder anderweitiger Trocknung erfolgten. Zur Andeutung dieser Situation ist als Beispiel in
Gemäß der in
Claims (11)
- Method for manufacturing a non-woven abrasive article,wherein non-woven fibres (108) made of a certain starting material are subjected to the method steps of forming a non-woven web then consolidating said non-woven web,whereby, prior to said method step of forming a non-woven web and/or prior to said method step of consolidating said non-woven web, said non-woven fibres (108) are coated with abrasive grains in such a way that said abrasive grains adhere to said starting material.
- Method according to claim 1, whereby said non-woven fibres (108) are made of a polyamide or a polyamide mixture.
- Method according to claim 1, whereby said non-woven fibres (108) are made of nylon.
- Method according to one of the claims 1 through 3, whereby said formation of a non-woven web is carried out using a carding process.
- Method according to one of the claims 1 through 4, whereby said formation of a non-woven web is carried out using an aerodynamic process.
- Method according to one of the claims 1 through 5, whereby said consolidation of said non-woven web is carried out using a turbulence process, for example, a water jet turbulence.
- Method according to one of the claims 1 through 6, whereby said consolidation of said non-woven web is carried out using a thermal process, for example, an ultra-sound solidification.
- Method according to one of the claims 1 through 7, whereby said non-woven fibres (108), prior to being coated with said abrasive grains, are being coated with an artificial resin.
- Method according to claim 8, whereby a light curing resin is used as artificial resin.
- Method according to one of the claims 1 through 9, whereby said non-woven fibres (108) are coated continuously.
- Method according to one of the claims 1 through 9, whereby said non-woven fibres (108) are coated intermittently.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP15191975.0A EP3162502A1 (en) | 2015-10-28 | 2015-10-28 | Non-woven abrasive and method for its manufacture |
PCT/EP2016/076061 WO2017072293A1 (en) | 2015-10-28 | 2016-10-28 | Non-woven abrasive article, and method for manufacturing same |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3368247A1 EP3368247A1 (en) | 2018-09-05 |
EP3368247B1 true EP3368247B1 (en) | 2023-06-28 |
Family
ID=54476708
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
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EP15191975.0A Withdrawn EP3162502A1 (en) | 2015-10-28 | 2015-10-28 | Non-woven abrasive and method for its manufacture |
EP16790558.7A Active EP3368247B1 (en) | 2015-10-28 | 2016-10-28 | Method for manufacturing non-woven abrasive article |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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EP15191975.0A Withdrawn EP3162502A1 (en) | 2015-10-28 | 2015-10-28 | Non-woven abrasive and method for its manufacture |
Country Status (7)
Country | Link |
---|---|
US (1) | US10843309B2 (en) |
EP (2) | EP3162502A1 (en) |
KR (1) | KR20180075578A (en) |
CN (1) | CN108290275A (en) |
BR (1) | BR112018008664A2 (en) |
FI (1) | FI3368247T3 (en) |
WO (1) | WO2017072293A1 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102019207822A1 (en) * | 2019-05-28 | 2020-12-03 | Robert Bosch Gmbh | Process for making an abrasive article and abrasive articles |
WO2021170298A1 (en) | 2020-02-28 | 2021-09-02 | Wendt Poliertechnik Gmbh & Co. Kg | Polishing tool |
DE202020000786U1 (en) | 2020-02-28 | 2021-05-31 | Wendt Poliertechnik Gmbh & Co. Kg | Polishing tool |
DE102020001283A1 (en) | 2020-02-28 | 2021-09-02 | Wendt Poliertechnik Gmbh & Co. Kg | Polishing tool |
Family Cites Families (18)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2375585A (en) * | 1943-05-14 | 1945-05-08 | James H Rhodes & Company | Plastic abrasive pad |
DE1694594C3 (en) * | 1960-01-11 | 1975-05-28 | Minnesota Mining And Manufacturing Co., Saint Paul, Minn. (V.St.A.) | Cleaning and polishing media |
US3016294A (en) * | 1959-04-21 | 1962-01-09 | Norton Co | Abrasive product |
US3020139A (en) * | 1960-04-18 | 1962-02-06 | Norton Co | Abrasive product |
US3324609A (en) * | 1964-08-11 | 1967-06-13 | Norton Co | Non-woven webs |
US3401491A (en) * | 1965-03-25 | 1968-09-17 | Armour & Co | Binder of an epoxy resin, polyamide resin and polyester for fibrous abrasive articles |
DE2102786A1 (en) * | 1971-01-21 | 1972-08-03 | Hermann Behr & Sohn, 7121 Großingersheim | Abrasive coated nylon brush bristles - for finishing car bodies |
US3817004A (en) * | 1972-05-01 | 1974-06-18 | T Moss | Scrubbing or buffing device impregnated with abrasive and method of making same |
US4227350A (en) * | 1977-11-02 | 1980-10-14 | Minnesota Mining And Manufacturing Company | Low-density abrasive product and method of making the same |
US5549962A (en) * | 1993-06-30 | 1996-08-27 | Minnesota Mining And Manufacturing Company | Precisely shaped particles and method of making the same |
JP3911546B2 (en) * | 1995-05-25 | 2007-05-09 | スリーエム カンパニー | Non-stretched, tough, durable, melt-bondable macrodenier thermoplastic multicomponent filament |
DE19522763A1 (en) * | 1995-06-27 | 1997-01-02 | Fleissner Maschf Gmbh Co | Method and device for consolidating a nonwoven fabric |
DE69627538T2 (en) | 1996-05-03 | 2004-04-08 | Minnesota Mining And Manufacturing Company, St. Paul | NON-WOVEN ABRASIVES |
CN1085575C (en) * | 1996-09-11 | 2002-05-29 | 美国3M公司 | Abrasive article and its method of making |
US7985269B2 (en) * | 2006-12-04 | 2011-07-26 | 3M Innovative Properties Company | Nonwoven abrasive articles and methods of making the same |
DE102007008889A1 (en) * | 2007-02-21 | 2008-08-28 | Tesa Ag | Process for producing nano- and / or microstructured surfaces in an adhesive, in particular self-adhesive layer |
US20140259960A1 (en) * | 2013-03-15 | 2014-09-18 | Martin J. Rotter | Nonwoven pads |
TR201808824T4 (en) * | 2015-02-27 | 2018-07-23 | 3M Innovative Properties Co | Multi-purpose consumer scrubbing cloths and application methods. |
-
2015
- 2015-10-28 EP EP15191975.0A patent/EP3162502A1/en not_active Withdrawn
-
2016
- 2016-10-28 CN CN201680069501.2A patent/CN108290275A/en active Pending
- 2016-10-28 KR KR1020187014558A patent/KR20180075578A/en unknown
- 2016-10-28 EP EP16790558.7A patent/EP3368247B1/en active Active
- 2016-10-28 BR BR112018008664A patent/BR112018008664A2/en not_active Application Discontinuation
- 2016-10-28 US US15/771,359 patent/US10843309B2/en active Active
- 2016-10-28 FI FIEP16790558.7T patent/FI3368247T3/en active
- 2016-10-28 WO PCT/EP2016/076061 patent/WO2017072293A1/en active Application Filing
Also Published As
Publication number | Publication date |
---|---|
WO2017072293A1 (en) | 2017-05-04 |
FI3368247T3 (en) | 2023-08-08 |
US20180326556A1 (en) | 2018-11-15 |
US10843309B2 (en) | 2020-11-24 |
BR112018008664A2 (en) | 2018-10-30 |
EP3368247A1 (en) | 2018-09-05 |
CN108290275A (en) | 2018-07-17 |
KR20180075578A (en) | 2018-07-04 |
EP3162502A1 (en) | 2017-05-03 |
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