JP2005230929A - Nonwoven fabric abrasive and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a nonwoven fabric abrasive having a long service life. <P>SOLUTION: This nonwoven fabric abrasive has a nonwoven fabric formed of fiber arranged at random, an adhesive bonded to the fiber surface of the nonwoven fabric, and abrasive grains bonded to the nonwoven fabric with the adhesive. The adhesive contains binder resin and a needle-like filler. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to nonwoven fabric abrasives, and more particularly to nonwoven fabric abrasives for polishing materials such as metals, plastics, and wood.

  Nonwoven fabric abrasive comprising a substrate such as a nonwoven fabric, an adhesive provided on the surface of the substrate, and abrasive grains at least partially embedded in the adhesive and provided on the surface of the substrate Is widely known to those skilled in the art. Various efforts have been made to extend the service life of such nonwoven fabric abrasives.

  For example, Patent Document 1 describes a nonwoven fabric abrasive in which core-shell type rubber particles are contained in an adhesive. In this case, the adhesive is modified using core-shell type rubber particles. That is, by improving the elastic modulus of the adhesive, the impact applied to the abrasive grains during polishing is reduced, and the abrasive grains are prevented from falling off. As a result, the service life of the nonwoven fabric abrasive is extended.

On the other hand, in a specific technical field, a hard filler such as an inorganic substance is used to modify the adhesive properties. That is, the hardness of the adhesive is increased by mixing the binder resin and the hard filler to constitute the adhesive. However, with respect to the nonwoven fabric abrasive, there is no clear knowledge about the relationship between the properties of the adhesive and the service life of the product, and no attempt has been made to include a hard filler in the adhesive of the nonwoven fabric abrasive.
Japanese Patent Laid-Open No. 11-207848

  The present invention solves the above-mentioned conventional problems, and an object of the present invention is to provide a nonwoven fabric abrasive having a long service life.

The present invention relates to a non-woven fabric abrasive comprising: a non-woven fabric composed of randomly arranged fibers; an adhesive bonded to the surface of the non-woven fabric fibers; and abrasive grains bonded to the non-woven fabric by the adhesive. In
The adhesive provides a nonwoven fabric abrasive comprising a binder resin and a needle-like filler, whereby the above object is achieved.

  The service life of non-woven abrasives has been significantly extended.

  The nonwoven fabric used in the present invention is a bulky sheet material composed of randomly arranged fibers. The nonwoven fabric may be any material that is well known to those skilled in the art as a base material for nonwoven fabric abrasives. Representative non-woven fabrics are described, for example, in JP-B-3-55270, column 10, line 10 to column 11, line 25.

  Preferred nonwovens are polyamides (eg nylon 6 and nylon 6,6 composed of polycaprolactam and polyhexamethyladipamide), polyolefins (eg polypropylene and polyethylene), polyesters (eg polyethylene terephthalate), and polycarbonates. It is comprised from such a thermoplastic organic fiber. Nonwoven fabrics composed of nylon and polyester fibers are generally used. The thickness of the fiber is generally about 19 to 250 μm in diameter. Moreover, generally the thickness of a nonwoven fabric is about 2-50 mm.

  An adhesive refers to a material that bonds a nonwoven fabric and abrasive grains. The adhesive may be any material that has sufficient strength to maintain the bond between the nonwoven and the abrasive during the polishing operation. Generally, an adhesive contains a binder resin and an additive as components. The binder resin refers to an organic resin that functions to join substances in order to change from a liquid that can be applied to a rigid solid. The adhesive precursor refers to an adhesive in which the binder resin is in a liquid state.

  As the binder resin, for example, phenol resin, urea-formaldehyde resin, shellac, epoxy resin, isocyanurate, polyurethane, animal skin and the like can be used.

  A preferred binder resin for use in the nonwoven fabric abrasive of the present invention is a relatively rigid organic resin. For example, after curing, a tensile strength of 3000 psi or more, preferably 3000-11000 psi, elongation 180% or more, preferably 180-800%; Shore D hardness 40 or more, preferably 40-80; and 100% modulus 1 MPa or more, A resin showing 10 to 50 MPa is preferable.

  If the tensile strength of the binder resin is less than 3000 psi, the strength and rigidity of the adhesive after curing are too small to be suitable for a nonwoven fabric abrasive. If the elongation is less than 180%, the flexibility of the adhesive after curing is too small to be suitable for a nonwoven fabric abrasive. If the Shore D hardness is less than 40, the abrasive grains easily fall off from the abrasive during polishing. When the 100% modulus is less than 1 MPa, the strength and rigidity of the adhesive after curing is small and not suitable for an abrasive.

  Specific examples of such resins include polyurethane resins. For example, see Japanese Patent Publication No. 61-37064, column 10, lines 4 to 32. Examples of commercially available products include adiprene L type resins (for example, L-42, L-83, L-100, L-167, L-200, L-213, L, manufactured by Uniroyal Chemical). -300, L-315, etc.), Adekabon titer type resin manufactured by Asahi Denka Co., Ltd. (for example, HUX-232, HUX-240, HUX-260, HUX-320, HUX-350, HUX-380, HUX-381, HUX-380A, HUX-386, HUX-401, HUX-670, HUX-290H, HUX-290N, HUX-394, HUX-680 and the like.

  For the preparation of such a polyurethane resin, generally, a polyol component and a curing agent component for curing the polyol component are used. Examples of the curing agent include isocyanates such as 4,4′-methylenedis-2-chloroaniline (MOCA), those whose ends are blocked with ketoxime, and phenols whose ends are treated with 4,4′-methylenebisaniline. Specific p, p′-methylenedianiline, melamine type resin (for example, “Melan 5100” manufactured by Hitachi Chemical Co., Ltd.) and the like can be mentioned. A polyurethane resin in which the content of the curing agent is 3 to 10% by weight as the NCO amount or the melamine amount is preferable.

  The adhesive precursor may be water-based. An aqueous adhesive precursor refers to an adhesive precursor mainly containing water as a solvent. In general, a water-based adhesive precursor is in a form in which a binder resin is uniformly dispersed in water, and is called an emulsion or a dispersion. Resins that can be uniformly dispersed in water are referred to herein as water-dispersible resins.

  The uncured binder resin needs to be water-dispersible and is preferably thermosetting. This is because it becomes easy to form a nonwoven fabric abrasive by molding. The binder resin preferably exhibits a curing temperature of 100 to 300 ° C, particularly 100 to 200 ° C. When the curing temperature of the binder resin is less than 100 ° C., the curing is insufficient and the abrasive grains are likely to fall off, resulting in a low grinding ratio. On the other hand, when the curing temperature of the binder resin exceeds 300 ° C., the binder resin is decomposed and the abrasive grains are likely to fall off, resulting in a low grinding ratio.

  Moreover, it is preferable that uncured binder resin does not show adhesiveness even if it touches in room temperature environment. This is because it becomes easy to handle the polishing intermediate material which is obtained by applying the adhesive precursor to the nonwoven fabric and drying it.

  A preferred binder resin is a thermosetting resin containing a terminal isocyanate polymer having an anionic group, a thermosetting acrylic polymer having a hydroxyl group, and a melamine-based crosslinking agent and exhibiting water dispersibility. By combining an isocyanate polymer that is a soft segment and an acrylic polymer that is a hard segment, the characteristics of the binder resin can be optimally adjusted in order to adhere abrasive grains to the nonwoven fabric.

  As a result, the water-based adhesive precursor used in the present invention has the strength to hold the abrasive grains to the same level or higher than the solvent-based adhesive precursor, and prevents the abrasive grains from falling off the nonwoven fabric. The nonwoven fabric can be imparted with an appropriate spontaneous action so that polishing on the polished surface becomes possible.

  The terminal isocyanate polymer having an anionic group, the thermosetting acrylic polymer having a hydroxyl group, and the melamine-based crosslinking agent may be blended in the form of an emulsion or an aqueous dispersion, respectively.

  The terminal isocyanate polymer having an anionic group is a terminal isocyanate polymer having an anionic group in the molecule alone or a mixture thereof with a terminal isocyanate polymer having no anionic group in the molecule, preferably a resin component (anionic group in the molecule). The total amount of the terminal isocyanate polymer having an anion group and the terminal isocyanate polymer having no anion group in the molecule) If the resin has 0.001-0.5 equivalent of an anion group per 100 grams, the water dispersibility of the resin is good. It is preferable because an aqueous dispersion can be obtained without using an emulsifier or a dispersant. Examples of the anionic group include a carboxyl group, a sulfone group, and a combination thereof, and a carboxyl group is preferable.

  The terminal isocyanate polymer having an anionic group in the molecule can be obtained by a conventionally known method. For example, when introduction of a carboxyl group is taken as an example, 2,2-dimethylolpropionic acid, 2,2-dimethylolbutyric acid, A polyether polyol and / or polyester polyol having a carboxyl group-containing diol unit such as 2,2-dimethylolvaleric acid can be obtained by reacting with a polyisocyanate as a polyol component.

  The polyol component of the polyether polyol and / or polyester polyol used in the terminal isocyanate polymer having an anionic group in the molecule and the terminal isocyanate polymer having no anionic group in the molecule is preferably one having an average molecular weight of 500 to 4000, The polyisocyanate component is not particularly limited, and examples thereof include aliphatic polyisocyanates such as tetramethylene diisocyanate, hexamethylene diisocyanate, and lysine diisocyanate, 1,4-cyclohexylene diisocyanate, isophorone diisocyanate, and 4,4′-dicyclohexyl diisocyanate. And aromatic polyisocyanates such as alicyclic polyisocyanate, tolylene diisocyanate, 4,4′-diphenylmethane diisocyanate, etc. , Among them aliphatic or alicyclic polyisocyanate is preferred.

  The terminal isocyanate polymer may be a terminal isocyanate polymer chain-extended with dialkylamine, dialkyl hydrazide or the like, and can be arbitrarily selected depending on the use within a range in which water dispersion is possible. An aqueous dispersion of a terminal isocyanate polymer having an anionic group in the molecule is commercially available, and examples thereof include the “bon titer” type manufactured by Asahi Denka Co., Ltd. and the like.

  The thermosetting acrylic polymer having a hydroxyl group is preferably an acrylic polymer emulsion uniformly dispersed in water. This acrylic polymer has a hydroxyl value of 40-100. When the hydroxyl value is less than 40, there are few reaction points, the reaction becomes insufficient, and the object of the present invention cannot be achieved. On the other hand, when the hydroxyl value exceeds 100, the water resistance of the adhesive after curing is lowered. The acrylic polymer has an acid value of 1-30. If the acid value is less than 1, a stable emulsion is difficult to obtain, and if it exceeds 30, the hydrophilicity of the polymer becomes high, so that the emulsion has a high viscosity and the water resistance of the adhesive is lowered. Furthermore, this acrylic polymer has a glass transition point of −40 to 10 ° C. When the glass transition point is lower than −40 ° C., there are difficulties in the physical strength and durability of the adhesive. When it is higher than 10 ° C., the hardness of the adhesive increases and the flexibility at low temperatures decreases. .

The acrylic polymer emulsion is produced from the following unsaturated monomers.
1. Examples of hydroxyl group-containing acrylic monomers include 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2-hydroxypropyl acrylate, lactone-modified 2-hydroxyethyl acrylate, and lactone-modified 2-hydroxyethyl methacrylate. Hydroxyl group-containing ethylenically unsaturated monomer.
2. As alkyl esters of acrylic acid or methacrylic acid, methyl acrylate, ethyl acrylate, propyl acrylate, isopropyl acrylate, butyl acrylate, hexyl acrylate, octyl acrylate, lauryl acrylate, cyclohexyl acrylate, methyl methacrylate, Ethyl methacrylate, propyl methacrylate, isopropyl methacrylate, butyl methacrylate, hexyl methacrylate, octyl methacrylate, lauryl methacrylate and the like.
3. Examples of the α, β-ethylenically unsaturated carboxylic acid include acrylic acid, methacrylic acid, crotonic acid, itaconic acid, maleic acid, maleic anhydride, and fumaric acid.
4). Examples of vinyl aromatic compounds include styrene, α-methyl styrene, vinyl toluene, p-chlorostyrene, vinyl pyridine, and the like.
5). Other vinyl compounds include ethylene glycol diacrylate, ethylene glycol dimethacrylate, triethylene glycol diacrylate, tetraethylene glycol dimethacrylate, 1,6-hexanediol diacrylate, divinylbenzene, trimethylolpropane triacrylate, and the like.

  These unsaturated monomers include a hydroxyl group-containing acrylic monomer and an α, β-ethylenically unsaturated carboxylic acid monomer as essential components, and if necessary, alkyl esters of acrylic acid or methacrylic acid, and other vinyl compounds. In combination, the type and blending ratio can be appropriately selected and used according to the desired physical properties of the resin.

  Further, as a chain transfer agent for molecular weight adjustment, methyl mercaptan, ethyl mercaptan, isopropyl mercaptan, butyl mercaptan, pentyl mercaptan, hexyl mercaptan, octyl mercaptan, decyl mercaptan, undecyl mercaptan, dodecyl mercaptan, t-dodecyl mercaptan, etc. are used. It is preferable.

  The copolymer contained in the acrylic polymer emulsion of the present invention can be produced according to a known method, for example, using a solution polymerization method, an emulsion polymerization method, or a suspension polymerization method, but is preferably carried out according to emulsion polymerization. . In general, the monomer is present in the presence of a dispersion stabilizer such as a surfactant, and in the presence of a polymerization initiator, for example, a radical initiator for radical polymerization such as ammonium persulfate, preferably 60 to 95 ° C. The reaction is preferably performed for 4 to 8 hours at the reaction temperature, three-dimensionally cross-linked, and neutralized with an amine to obtain the desired acrylic polymer emulsion. The particle diameter of the fine particles in the resulting acrylic polymer emulsion is 50 to 200 nm.

  Such microemulsions are commercially available, and examples thereof include “Hitaroid” type manufactured by Hitachi Chemical Co., Ltd., product number AE8200, and the like.

  The melamine crosslinking agent may be a known melamine crosslinking agent as a crosslinking agent for synthetic resins. These can be dispersed in water with or without using an emulsifier or dispersant as required. Although it does not specifically limit as a melamine type crosslinking agent, For example, "Melan 5100" by the above-mentioned Hitachi Chemical Co., Ltd. is mentioned.

  The blending ratio of these adhesive precursor components is generally 100 parts by weight of a terminal isocyanate polymer having an anionic group, 1 to 600 parts by weight of a thermosetting acrylic polymer having a hydroxyl group, and 0.01 to 100 of a melamine crosslinking agent. Parts by weight. If the amount of the thermosetting acrylic polymer having a hydroxyl group is less than 1 part by weight, the flexibility of the cured adhesive becomes too large due to the characteristics of the terminal isocyanate polymer having an anionic group, which is not suitable for a nonwoven fabric abrasive, 600 If it exceeds the parts by weight, the flexibility of the adhesive after curing becomes too small and it is not suitable for a nonwoven fabric abrasive. If the amount of the melamine-based cross-linking agent is less than 0.01 parts by weight, the softness of the adhesive after curing becomes too large to be suitable for a nonwoven fabric abrasive, and if it exceeds 100 parts by weight, the flexibility of the adhesive after curing will be It becomes too small to be suitable for non-woven fabric abrasives. When processing into a brush-like abrasive, a tackifier such as a terpene resin can be further added to increase the interlayer strength of the brush and improve the durability of the brush. The fine particles of the acrylic polymer emulsion having a particle diameter of 0.01 to 200 nm can be used.

  The adhesive of the present invention contains an acicular filler in order to reinforce the adhesive. The needle shape means an elongated shape. The acicular filler has a length in a direction parallel to the central axis and a diameter in a direction perpendicular to the central axis. In this specification, the ratio of the length of the needle-shaped filler to the diameter is referred to as an aspect ratio.

  The acicular filler generally has a diameter of 0.05 to 10 μm and an aspect ratio of 10 to 1000. Preferably, the diameter of the acicular filler is 0.2 to 5 μm, more preferably 50 to 150 μm. The length of the acicular filler is, for example, 1 to 50 μm, preferably 10 to 30 μm.

  When the diameter of the needle-like filler is less than 0.05 μm, the significance of inclusion in the adhesive is poor. When the aspect ratio of the acicular filler is less than 10, the shape cannot be said to be acicular, and when mixed with the binder resin, the viscosity of the resulting adhesive precursor becomes too high. When the aspect ratio exceeds 1000, the filler is cut when mixed with the binder resin, and the filler is not uniform.

  The material of the acicular filler is not particularly limited as long as it is a hard material as compared with the binder resin. For example, the needle filler is a fiber made of alumina, alumina-silica, silicon nitride, silicon carbide, carbon, glass, boron or the like; or alumina, silicon nitride, silicon carbide, alumina-boron oxide, graphite, diamond, potassium titanate Any whisker made of boron carbide or the like may be used.

  The acicular filler is contained in the adhesive precursor at a ratio of 20 wt% or less, preferably 3 to 10 wt% in the adhesive. When the content of the acicular filler exceeds 20% by weight, the above function as an adhesive is lowered.

  The abrasive grains used in the present invention are those usually used in the art. Typically, the average diameter may be 4 to 2000 μm, preferably 20 to 1000 μm, and the Mohs hardness is 4 to 10 Mohs, preferably 6 to 9 Mohs. Specifically, particles made of permis, topaz, garnet, alumina, corundum, silicon carbide, zirconia, diamond, and the like can be used. These particles may be mixed in different sizes or may be mixed in different materials.

  The nonwoven fabric abrasive of the present invention can be produced according to methods known to those skilled in the art. For example, first, an acicular filler is added to a liquid binder resin and dispersed sufficiently uniformly to prepare an adhesive precursor. The liquid binder resin may be a solution or an aqueous dispersion. An adhesive precursor is applied to the surface of the nonwoven fiber. Abrasive grains are dispersed and adhered onto the applied adhesive precursor. Then, the organic solvent and water are evaporated from the adhesive precursor and dried. When a thermosetting resin is used as the binder resin, the adhesive precursor is cured by heating for a certain time. Generally, the adhesive precursor is cured by maintaining at 100 to 300 ° C. for 10 to 30 minutes.

  Abrasive grains may be added in advance when preparing the adhesive precursor, and the adhesive precursor and the abrasive grains may be simultaneously applied to the nonwoven fabric. The drying of the adhesive precursor and the curing of the thermosetting resin may be performed in the same heating process, or may be performed in separate heating processes. Even when the drying of the adhesive precursor and the curing of the thermosetting resin are performed in separate heating processes, the thermosetting resin may be partially cured in the drying process.

  As described above, the nonwoven fabric used as the base material is a bulky fiber material and is highly elastic, so that it can be easily deformed and restored. Therefore, a laminated body in which a plurality of non-woven fabrics are stacked is highly deformable and can be molded relatively freely by applying pressure. In a preferred embodiment of the present invention, a three-dimensional nonwoven fabric abrasive is produced utilizing the easy formability of the nonwoven fabric. A typical example of a three-dimensional nonwoven fabric abrasive is a cylindrical polishing brush having a center hole. FIG. 1 is a perspective view showing a typical configuration form of a cylindrical polishing brush having a central hole. (A) is a laminate format, (b) is a flap format, and (c) is a spiral format.

  FIG. 2 is a schematic view showing a process for producing a polishing intermediate used for producing a three-dimensional nonwoven fabric abrasive. First, the nonwoven fabric 10 is sent out from the nonwoven fabric roll 100. Next, the nonwoven fabric 10 is impregnated with a mixture of an adhesive precursor and abrasive grains. The impregnated nonwoven fabric is heated to fix the thermosetting resin and abrasive grains on the surface of the nonwoven fabric fibers. From there, the adhesive precursor is spray applied.

  Next, the organic solvent and water are evaporated from the adhesive precursor in a drying furnace and dried. Drying is performed at a temperature and a time at which the adhesive precursor is non-tacky at room temperature but the thermosetting resin is not completely cured. If the adhesive precursor is still sticky at room temperature after the drying process, it will be difficult to handle and process the resulting abrasive intermediate, and if the thermosetting resin is completely cured after the drying process, This is because it becomes difficult to form the material thereafter. In a preferred embodiment, the drying step is performed at 100 to 120 ° C. for 1 to 10 minutes. After the drying step, the obtained polishing intermediate 20 is not sticky and can be handled. Therefore, it can be rolled up and stored as a roll 200.

  FIG. 3 is a schematic diagram showing a process of manufacturing a three-dimensional nonwoven fabric abrasive using an abrasive intermediate material. First, the polishing intermediate material 20 is sent out from the roll 200 of the polishing intermediate material. Then, the intermediate member 25 is obtained by punching the polishing intermediate member 20 into an appropriate shape. A plurality of intermediate members 25 are stacked using the jigs 6, 7 and 8, and compressed to increase the density. Then, the adhesive precursor is completely cured by heating while being compressed, and the shape is fixed. In a preferred embodiment, the heat curing step is performed at 100 to 200 ° C. for 10 to 60 minutes. Thereby, a cylindrical polishing brush having a central hole is obtained (see FIG. 1A).

  The following examples further illustrate the present invention in detail but are not to be construed to limit the scope thereof. In the examples, “parts” are based on weight unless otherwise specified.

  “Tismo D” manufactured by Otsuka Chemical Co., Ltd. was prepared as an acicular filler. This acicular filler consists of potassium titanate fibers. The properties are a diameter of 0.3 to 0.6 μm, a length of 10 to 20 μm, a specific gravity of 3.3 to 3.4, a melting point of 1300 to 1350 ° C., a Mohs hardness of 4, and a tensile strength of 7 GPa.

  As binder resin, urethane resin emulsion “Bontiter HUX-260” manufactured by Asahi Denka Co., Ltd., 0.1 part of acrylic polymer emulsion “Hitaroid AE8200” manufactured by Hitachi Chemical Co., Ltd., and melamine resin “Melan 5100” manufactured by Hitachi Chemical Co., Ltd. A resin solution prepared from 24.9 parts was prepared. The properties (after curing) of this urethane resin are tensile strength 6600 psi, elongation 340%, Shore D hardness 70, and 100% modulus 18 MPa.

  The above-mentioned acicular filler was added to the urethane resin in such an amount that the content of the acicular filler was 5% in the binder resin solid content and kneaded to obtain an adhesive precursor.

This adhesive precursor was applied to both sides of a circular nonwoven fabric having a basis weight of 150 g / m ² , a thickness of 10 mm, and a diameter of 10 cm made of 15 denier nylon 6,6, using a spray method. The dry coating amount of the adhesive precursor was 380 g / m ² .

  On this make coat layer, 800 parts of silicon carbide (Minnesota Mining and Manufacturing Co., Ltd. abrasive grains) with particle size (ANSI) # 60 was uniformly dispersed and adhered using a scatter method. The material was then placed in an oven and heated at 110 ° C. for 10 minutes to dry the adhesive precursor. In this way, a polishing intermediate material sheet having no tackiness and capable of being handled was obtained.

  This abrasive intermediate sheet was punched out to prepare two abrasive intermediate discs having a diameter of 10 cm. And these grinding | polishing intermediate material discs were piled up, it was set as the laminated body, and it compressed until it became thickness 10mm. The compressed laminate was placed in an oven and heated at 150 ° C. for 30 minutes to completely cure the adhesive precursor.

The resulting nonwoven fabric abrasive is a polishing wheel having a diameter of 10 cm and a thickness of 10 mm. Using this nonwoven fabric abrasive, the polishing piece was polished. An acrylic plate having a diameter of 10 mm was used as the polishing piece. The polishing conditions were a load of 2268 g / cm ² , a polishing rate of 200 rpm, and a polishing time of 25 minutes.

  Before and after polishing, measure the change in weight (g) of the nonwoven fabric abrasive and the change in weight (g) of the abrasive piece, and calculate the grinding ratio (change in the weight of the abrasive piece / change in the weight of the nonwoven fabric abrasive) did. The results are shown in Table 1.

  A resin liquid prepared from 100 parts of adiprene BL type urethane resin “BL-16” manufactured by Uniroyal Chemical Co., Ltd. and 12.4 parts of amine “MDA-2200” manufactured by Mitsui Takeda Chemical Co., Ltd. was prepared as a binder resin. The properties of this urethane resin (after curing) are tensile strength 5400 psi, elongation 455%, Shore D hardness 48, and 100% modulus 11.4 MPa.

  A resin liquid was prepared in the same manner as in Example 1 except that the above resin was used, and a nonwoven fabric abrasive was prepared and tested. The results are shown in Table 1.

  As binder resins, urethane resin emulsion “Bontiter HUX980” manufactured by Asahi Denka Co., Ltd., 0.1 part acrylic polymer emulsion “Hitaroid AE8200” manufactured by Hitachi Chemical Co., Ltd., and melamine resin “Melan 5100” 24.9 manufactured by Hitachi Chemical Co., Ltd. are used. A resin solution prepared from the part was prepared. The properties (after curing) of this urethane resin are tensile strength 7500 psi, elongation 850%, Shore D hardness 40, and 100% modulus 2 MPa.

  A nonwoven fabric abrasive was prepared and tested in the same manner as in Example 1 except that the urethane resin was used. The results are shown in Table 1.

Comparative Example 1

  A nonwoven fabric abrasive was prepared and tested in the same manner as in Example 1 except that no acicular filler was used. The results are shown in Table 1.

Comparative Example 2

  A nonwoven fabric abrasive was prepared and tested in the same manner as in Example 2 except that no acicular filler was used. The results are shown in Table 1.

Comparative Example 3

  A nonwoven fabric abrasive was prepared and tested in the same manner as in Example 3 except that no acicular filler was used. The results are shown in Table 1.

  The change in the weight of the nonwoven fabric abrasive indicates the amount of abrasive grains dropped from the nonwoven fabric abrasive by polishing. The nonwoven fabric abrasive material of the present invention containing an acicular filler in the adhesive has a small amount of degranulation and good polishing performance lasts for a long time.

  Such an improvement in characteristics has been confirmed not only in the above-mentioned laminate type polishing disc but also in a polishing brush such as a spiral type and a flap type.

It is a perspective view which shows the typical structure type of the cylindrical polishing brush which has a center hole. It is the schematic diagram which showed the process of manufacturing the grinding | polishing intermediate material used for manufacturing a three-dimensional nonwoven fabric abrasive material. It is the schematic diagram which showed the process of manufacturing a three-dimensional nonwoven fabric abrasive material using an abrasive intermediate material.

Explanation of symbols

10 ... Nonwoven fabric,
100 ... non-woven roll,
20: Polishing intermediate material,
200 ... roll of polishing intermediate material,
25 ... Intermediate member,
6, 7, 8 ... Jig.

Claims (4)

A non-woven fabric abrasive comprising: a non-woven fabric composed of randomly arranged fibers; an adhesive bonded to the surface of the non-woven fabric fibers; and abrasive grains bonded to the non-woven fabric by the adhesive;
A nonwoven fabric abrasive in which the adhesive contains a binder resin and an acicular filler.   The nonwoven fabric abrasive according to claim 1, wherein the acicular filler has a diameter of 0.05 to 10 μm and an aspect ratio of 10 to 1000.   The nonwoven fabric abrasive | polishing material of Claim 1 in which the said acicular filler contains in the quantity of 20 weight% or less in an adhesive agent. Applying a thermosetting adhesive precursor and abrasive grains containing a binder resin and a needle-like filler to the surface of a non-woven fiber composed of randomly arranged fibers;
Drying the adhesive precursor to obtain a non-tacky abrasive intermediate;
Molding the abrasive intermediate; and heating the molded abrasive intermediate to cure the adhesive precursor;
The manufacturing method of the nonwoven fabric abrasive | polishing material containing this.

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