JP2021504169A - Coated polishing disc and its manufacturing method and usage method - Google Patents

Abstract

The coated polishing disc includes a disc backing and a polishing layer placed on the disc backing. The polishing layer comprises a polishing element secured to the main surface of the disc backing by at least one binder material. Polishing elements are located at the point of contact of the horizontal and vertical lines of the rectangular grid pattern. At least 70 percent of the intersections have one of the polishing elements located. Each of the polishing elements has two triangular polishing plates. Each of the triangular polished plates has its own top and bottom surfaces connected to each other and separated by three side walls. One side wall, each of which is at least 90 percent of the triangular polished plates, faces the disc backing and is located close to the disc backing. The polishing elements are arranged so that the triangular polishing plates in the adjacent polishing elements are orthogonal to each other and have a Z-axis rotation arrangement direction within 10 degrees from the orthogonal to each other. Also disclosed are methods of manufacturing and using coated polished discs.

Description

The present disclosure relates, in a broad sense, to coated abrasive discs, their manufacturing methods and their use.

Coated polishing discs made from triangular polishing strips are useful for polishing, finishing or grinding a wide variety of materials and surfaces in the manufacture of commodities. In particular, finishing of weld beads (eg, mild steel welds in particular), flash, gate, and riser-off casting by off-hand polishing using a handheld right angle grinding machine are important applications for coated polishing discs. In view of the above, there continues to be a need to improve the cost, performance and / or life of coated polished discs.

A coated polished article having a rotatably aligned triangular polishing strip is disclosed in US Pat. No. 9,776,302 (Keipert). The coated polished article has a plurality of triangular polished strips having individual surface features. The plurality of triangular polishing strips are attached to the flexible backing by a make coat containing a resinous adhesive that forms a polishing layer. The surface feature has a defined z-direction rotational arrangement direction, which occurs more frequently in the polishing layer than would be caused by the random z-direction rotational arrangement direction of the surface feature. ..

In one aspect, the present disclosure
With disc backing
A polishing layer placed on top of the disc backing, comprising a polishing element secured to the main surface of the disc backing by at least one binder material, where the polishing element is the intersection of the horizontal and vertical lines of a rectangular lattice pattern. With a polishing layer, where one of the polishing elements is located, at least 70% of the intersections.
Each of the polishing elements has two triangular polishing plates, each of which has a top surface and a bottom surface that are connected to each other and separated by three side walls, respectively. At least 90 percent of the plaque has one side wall facing the disc backing and placed in close proximity to the disc backing.
The polishing elements are arranged so that the triangular polishing plates in the adjacent polishing elements are orthogonal to each other and have a Z-axis rotation arrangement direction within 10 degrees from the orthogonal to each other.
A coated polishing disc is provided.

Advantageously, the coated polishing discs according to the present disclosure are useful for off-hand polishing of mild steel (eg, mild steel welded finish), and they exhibit superior performance compared to similar conventional discs.

Thus, in a second aspect, the present disclosure provides a method of polishing a workpiece, the method of frictionally contacting a portion of the polishing layer of a coated polishing disc according to the present disclosure with the workpiece and polishing the workpiece. This involves moving at least one of the workpiece and the abrasive disc to the other.

In a third aspect, the present disclosure provides a method of making a coated abrasive disc, the method of which is:
Placing the curable make-up layer precursor on the main surface of the disc backing,
Adhering the polishing element to the curable make-up layer precursor,
Abrasive elements are located at the intersections of the horizontal and vertical lines of the rectangular grid pattern, with at least 70 percent of the intersections having one of the abrasive elements.
Each of the polishing elements has two triangular polishing plates, each of which has a top surface and a bottom surface that are connected to each other and separated by three side walls, respectively. At least 90 percent of the plaque has one side wall facing the disc backing and placed in close proximity to the disc backing.
The polishing elements are arranged so that the triangular polishing plates in the adjacent polishing elements are orthogonal to each other and have a Z-axis rotation arrangement direction within 10 degrees from the orthogonal to each other.
Adhering the polishing element to the curable make-up layer precursor and
Placing the curable size layer precursor on at least a partially cured make-up layer precursor and a triangular polishing plate.
To provide a size layer, the curable size layer precursor is at least partially cured.

As used herein,
The term "mild steel" means a carbon-based steel alloy containing less than about 0.25 weight percent carbon.
The term "off-hand polishing" means polishing where the operator manually urges the disc / wheel against the workpiece and vice versa.
The term "proximity" means very close or adjacent (eg, in contact with or embedded in the binder layer).
The term "workpiece" means an object to be polished.

As used herein, the term "triangular abrasive plate" refers to at least a portion of abrasive particles having a predetermined shape that are replicated from the mold cavity used to form the shaped precursor abrasive particles. It means ceramic abrasive particles having. The triangular-polished plate will generally have a predetermined geometry that substantially duplicates the mold cavity used to form the triangular-polished plate. The triangular polishing strips used herein exclude randomly sized abrasive particles obtained by mechanical crushing operations.

As used herein, the "Z-axis rotational arrangement direction" is the longitudinal dimension of the side wall of the triangular polished disc that faces the disc backing most around the Z axis perpendicular to the main surface of the disc backing. It means the angular rotation of.

The features and advantages of the present disclosure will be further understood by considering the detailed description and the appended claims.

It is a schematic top view of the exemplary coated polishing disc 100. It is an enlarged view of the area 1A of FIG. It is a schematic side view of the exemplary coated polishing disc 100 taken along line 1B-1B of FIG. 1A. It is a schematic top view of the exemplary triangular polishing small plate 130a. It is a schematic perspective view of the exemplary triangular polishing small plate 130a. It is a schematic top view of the exemplary triangular polishing small plate 330. It is a schematic cross-sectional side view of the exemplary triangular polishing small plate 330. It is a top view of the exemplary production tool 400 useful for manufacturing the coated polishing disc 100. It is an enlarged view of the area 4A of FIG. It is a schematic sectional view of the production tool 400 taken along the line 4B-4B of FIG. 4A. It is a schematic sectional view of the production tool 400 taken along the line 4C-4C of FIG. 4A.

Repeated use of reference characters herein and in the drawings is intended to represent the same or similar features or elements of the present disclosure. Those skilled in the art can devise many other modifications and embodiments, and it should be understood that they fall within the scope and intent of the principles of the present disclosure. The figure may not be drawn to scale.

FIG. 1 shows an exemplary coated polishing disc 100 according to the present disclosure, in which the polishing element 160 is fixed in an accurate position with respect to the disc backing 110 and in the Z-axis rotational arrangement direction.

Here, referring to FIG. 1A, each polishing element 160 has two triangular polishing plates 130. The polishing element 160 is arranged at the intersection 190 with the horizontal line 192 and the vertical line 194 of the rectangular grid pattern 196. At least 70 percent of the intersections 190 have one of the polishing elements 160 located.

The polishing element 160 is arranged so that the triangular polishing plates 130 in the adjacent polishing elements 160 are orthogonal to each other and have a Z-axis rotation arrangement direction within 10 degrees from the orthogonal to each other.

Next, referring to FIG. 1B, the coated polishing disc 100 includes a polishing layer 120 arranged on the main surface 115 of the disc backing 110. The polishing layer 120 comprises a polishing element 160 individually having two triangular polishing plates 130 secured to the main surface 115 by at least one binder material 140 (shown as make layer 142 and size layer 144). ing. An optional super size layer 146 is arranged on top of the size layer 144.

Next, referring to FIGS. 2A and 2B, the individual triangular-polished plates 130a are connected to each other and separated by three side walls (136a, 136b, 136c), respectively, at the top and bottom surfaces (132, 134). )have.

3A and 3B show another embodiment of the useful triangular abrasive plate 330, which are connected to each other and separated by three inclined side walls (336), respectively. It has a top surface and a bottom surface (332, 334).

The disc backing can include, for example, any known coating polishing backing. In some embodiments, the disc backing comprises a continuous, uninterrupted disc, while in other embodiments, the disc backing can have a central arbor hole for mounting. Similarly, the disc backing may be flat or may have a pressed central hub, eg, a depressed central disc of Type 27. The disc backing may be rigid, semi-rigid, or flexible. In some embodiments, the backing has a mechanical fastener, or an adhesive fastener that is firmly attached to the main surface opposite the polishing layer. Suitable materials for substrates include polymerized films, metal foils, woven fabrics, knitted fabrics, paper, vulcanized fibers, non-woven fabrics, foams, screens, laminates, combinations thereof, and treated versions thereof. .. Vulcanized fiber backing is usually preferred for off-hand grinding applications where rigidity and cost are a concern. In applications where the backing rigidity is desired, flexible backing can also be used by attaching to a rigid backup pad attached to the grinding tool.

The disc backing is generally circular, preferably rotationally symmetric around its center. The disc backing preferably has a circular perimeter, but may have additional features along the perimeter, for example in the case of a scalloped perimeter.

The polishing layer can include a single binder layer with abrasive particles retained therein, and more typically can have a multi-layer structure with a make-up layer and a size layer. The coated polishing disc according to the present disclosure can include an additional layer such as an optional super-sized layer superimposed on the polishing layer, or can optionally include a backing antistatic treatment layer. .. Suitable exemplary binders can be prepared from thermosetting resins, radiation curable resins and combinations thereof.

The make layer can be formed by coating the main surface of the backing with a curable make layer precursor. The make layer precursor is, for example, an adhesive, a phenol resin, an aminoplast resin, a urea-formaldehyde resin, a melamine-formaldehyde resin, a urethane resin, a free group polymerizable polyfunctional (meth) acrylate (for example, pendant α, β-unsaturated). It can contain groups, acrylated urethanes, acrylated epoxies, aminoplast resins with acrylated isocyanurates), epoxy resins (including bis-maleimide and fluorene modified epoxy resins), isocyanurate resins and mixtures thereof. Of these, phenolic resins are preferred, especially when used in combination with vulcanized fiber backing.

Phenol resins are generally formed by condensation of phenol and formaldehyde and are usually classified as resole resins or novolac phenol resins. Novolac phenol resin is acid catalyzed and has a molar ratio of formaldehyde to phenol less than 1: 1. The resol-phenol resin can be catalyzed by an alkaline catalyst and has a formaldehyde to phenol molar ratio of 1 or greater, typically 1.0 to 3.0, providing a pendant methylol group. To do. Suitable alkaline catalysts for catalyzing the reaction between the aldehyde and the phenolic component of the resol-phenolic resin include sodium hydroxide, barium hydroxide, potassium hydroxide, calcium hydroxide, organic amines and sodium carbonate. All of these are as a solution of the catalyst dissolved in water.

The resole-phenolic resin is typically coated as a solution with water and / or an organic solvent (eg, alcohol). Typically, the solution comprises from about 70 weight percent to about 85 weight percent solid, but other concentrations may be used. If the solid content is very low, more energy is needed to remove the water and / or solvent. If the solid content is extremely high, the resulting phenolic resin will become too viscous, typically leading to processing problems.

Phenol forms are well known and are readily available from commercial sources. Examples of commercially available resole-phenol resins useful in the practice of the present disclosure are resole-phenol resins sold by Durez Corporation under the trade names VARCUM (eg 29217, 29306, 29318, 29338, 29353). , Under the trade name AEROFENE (eg, AEROFENE 295), Ashland Chemical Co., Ltd., located in Bartow, Florida. Resol phenol resin sold by PHENOLITE (eg, PHENOLITE TD-2207), Gangnam Chemical Company Ltd., located in Seoul, South Korea. Examples include resole-phenolic resins sold by.

Make layer precursors are added by any known coating method for adding make layers to backing, such as roll coatings, extruded die coatings, curtain coatings, knife coatings, gravure coatings and spray coatings. be able to.

The weight of the make-up layer utilized may depend, for example, on the intended use, the type of abrasive particles, and the nature of the coated abrasive disc being prepared, but is typically 1, 2, 5, 10, or 15. It ranges from grams / square meter (gsm) to 20, 25, 100, 200, 300, 400 and even 600 gsm. The make-up layer is any known for adding a make-up layer (eg, make-up coat) to the backing, including, for example, roll coating, extruded die coating, curtain coating, knife coating, gravure coating and spray coating. It can be added by the coating method.

When the make-up layer precursor is coated on the backing, a triangular polishing plate is added to and adhered to (eg, embedded in) the make-up layer precursor. Triangular polishing strips are nominally added onto the make-up layer precursor according to a predetermined pattern and Z-axis rotational arrangement direction.

In some preferred embodiments, the horizontal and / or vertical spacing between the polishing elements is 1-3 times, more preferably, the average length of the side walls of the triangular polishing plate facing the fiber disc backing. It is 1.2 to 2 times, but other intervals can be used.

One side wall of at least 90 percent (eg, at least 95 percent, at least 99 percent, and even 100 percent) of each of the triangular polished plates is placed facing the disc backing (preferably in close proximity to the disc backing). .. Further, the side walls arranged facing the disc backing have a Z-axis rotation arrangement direction within 10 degrees (preferably within 5 degrees, more preferably within 2 degrees) from the vertical or horizontal line depending on their position. (That is, it has a vertical Z-axis rotation arrangement direction). In this regard, the Z-axis rotation direction of the side wall facing the backing is such that its Z-axis projection onto a rectangular grid pattern (planar) intersects at least one of the vertical lines at an angle of 10 degrees or less. If (including collinear), it is considered to be within 10 degrees of the vertical line. Similarly, the Z-axis rotation direction of the side wall facing the backing is when its Z-axis projection onto a rectangular grid pattern (planar) intersects at least one of the horizontal lines at an angle of 10 degrees or less ( (Including collinear), considered to be within 10 degrees of the horizon.

The triangular polishing strip has sufficient hardness to function as polishing particles in the polishing process. The triangular polished plate preferably has a Mohs hardness of at least 4, at least 5, at least 6, at least 7, and even at least 8. They preferably contain alpha alumina.

In some embodiments, the triangular-polished plate is shaped as a thin triangular prism, while in other embodiments, the triangular-polished plate is as a truncated triangular pyramid (preferably having a taper angle of about 8 degrees). It is shaped. Triangular polished plates can have different side lengths, but are preferably equilateral on their maximum plane.

The crushed or non-abrasive particles, in addition to the abrasive element and / or the abrasive plate, are substantially the largest of the nominally defined grade abrasive particles that can be retained in the abrasive layer, preferably a closed coat (ie, in the abrasive layer). It can be included in an amount sufficient to form a possible number).

Examples of suitable abrasive particles are molten aluminum oxide, heat treated aluminum oxide, white molten aluminum oxide, trade name 3M CERAMIC ABRASIVE GRAIN, St. Minnesota. Ceramic aluminum oxide materials such as ceramic aluminum oxide materials commercially available from Paul's 3M Company, brown aluminum oxide, blue aluminum oxide, silicon carbide (including green silicon carbide), titanium diboride, carbonized Boron, Tungsten Carbide, Garnet, Titanium Carbide, Diamond, Cubic Borone Nitride, Garnet, Fused Alumina Zirconia, Iron Oxide, Chromia, Zirconia, Titania, Tin Oxide, Quartz, Changstone, Pine Stone, Kongo Sand, Sol-Gel Induced Polish Examples include particles and combinations thereof. Of these, molded sol-gel-derived alpha-alumina triangular polished strips are preferred in many embodiments. Abrasives that cannot be treated by the sol-gel pathway can be molded using a temporary or permanent binder, which forms shaped precursor particles and then is sintered. Thus, for example, the triangular abrasive strips described in US Patent Application Publication No. 2016/0068729 (A1) (Erickson et al.) Are formed.

Examples of sol-gel-induced abrasive particles and methods for preparing them are U.S. Pat. Nos. 4,314,827 (Leetheiser et al.), 4,623,364 (Cottringer et al.), 4,744. , 802 (Schwabel), 4,770,671 (Monroe et al.) And 4,881,951 (Monroe et al.). Further, the polishing particles may include, for example, polishing agglomerates such as the polishing agglomerates described in US Pat. No. 4,652,275 (Bloecher et al.) Or No. 4,799,939 (Bloecher et al.). Is also planned. In some embodiments, the triangular abrasive plate is a coupling agent (eg, an organosilane coupling agent) or the like to enhance the adhesion of the abrasive particles to the binder (eg, make-up layer and / or size layer). The surface can be treated with the physical treatment of (for example, iron oxide or titanium oxide). The abrasive particles can be treated prior to binding them to the corresponding binder precursor, or the abrasive particles can be surface treated in situ by including a coupling agent in the binder.

The triangular polishing strip preferably contains ceramic polishing particles such as sol-gel-derived polycrystalline alpha-alumina particles. Triangular polished small plates composed of alpha alumina, magnesium alumina spinel and rare earth hexagonal aluminate crystals are described, for example, in US Pat. No. 5,213,591 (Celikkaya et al.) And US Patent Application Publication No. 2009 / It can be prepared using sol-gel precursor alpha-alumina particles by the methods described in 0165394 (A1) (Culler et al.) And 2009/0169816 (A1) (Erickson et al.).

Alpha-alumina-based triangular polished strips can be manufactured according to the well-known multi-step process. Briefly, the method comprises the steps of producing either seeded or non-seeded sol-gel alpha-alumina precursor dispersion that can be converted to alpha-alumina and the desired external shape. A step of filling one or more mold cavities with a triangular polishing platen with sol-gel, a step of drying the sol-gel to form a precursor triangular polishing plateau, and a mold cavity of the precursor triangular polishing plateau. Steps to remove from, and steps to calcinate the precursor triangle-polished plaque to form a calcinated precursor triangle-polished plaque, and then to calcinate the calcinated precursor triangle-polished plaque. Including the step of forming a triangular polishing plate. The process will be described in more detail below.

Further details regarding the method for producing sol-gel-induced abrasive particles are described, for example, in US Pat. Nos. 4,314,827 (Leitheaser), 5,152,917 (Pieper et al.), 5,435,816. (Spurgeon et al.), No. 5,672,097 (Hoopman et al.), No. 5,946,991 (Hoopman et al.), No. 5,975,987 (Hoopman et al.), And No. 6,129. , 540 (Hoopman et al.), And US Patent Application No. 2009/0165394 (A1) (Culler et al.).

The triangular polishing plate can include a single type of triangular polishing plate or a blend of two or more sizes and / or compositions of the triangular polishing plate. In some preferred embodiments, the triangular-polished plate is essentially a molding tool or means of production in which the individual triangular-polished plates are dried prior to the optional baking and sintering. It will have a shape that is the shape of the hollow portion.

The triangular-polished flakes used in the present disclosure are typically tools cut using precision machining that provide higher feature demarcation than other manufacturing alternatives, such as punching or punching. Manufactured using a mold). Typically, the cavity on the tool surface has a matching flat surface along the sharp edges, forming the sides and apex of the truncated pyramid. The resulting triangular-polished plate has a nominal average shape, which corresponds to the shape of the cavity on the tool surface (eg, truncated pyramid), but changes from the nominal average shape (eg, random changes). ) May occur during production, and triangular-polished plates exhibiting such changes are included within the definition of triangular-polished plates used herein.

In some embodiments, the base and top of the triangular-polished plate are substantially parallel, resulting in a prismatic or truncated pyramidal shape, but this is not a requirement. In some embodiments, the sides of the truncated triangular prism have equal dimensions and form a dihedral angle of approximately 82 degrees with the base. However, it will be recognized that other dihedral angles (including 90 degrees) can be used as well. For example, the dihedral angle between each of the base and the sides may independently range from 45 to 90 degrees, typically 70 to 90 degrees, and more typically 75 to 85 degrees.

As used herein in reference to a triangular-polished plate, the term "length" means the maximum dimension of a triangular-polished plate. "Width" means the maximum dimension of a triangular polished plate that is perpendicular to its length. The term "thickness" or "height" means the dimensions of a triangular-polished plate that is perpendicular to length and width.

Examples of sol-gel-induced triangular alpha-alumina (ie ceramic) abrasive particles are US Pat. Nos. 5,201,916 (Berg), 5,366,523 (Lowenhorst (Re 35,570)), and It can be found in No. 5,984,988 (Berg). Details regarding such abrasive particles and methods for preparing them are described, for example, in US Pat. Nos. 8,142,531 (Adefris et al.), 8,142,891 (Culler et al.) And 8,142. , 532 (Erickson et al.), And US Patent Application Publication Nos. 2012/0227333 (Adefris et al.), 2013/0040537 (Schwabel et al.) And 2013/0125477 (Adefris).

Triangular polished plates are typically selected to have lengths in the range of 1 micron to 15000 microns, more typically 10 microns to about 10000 microns, and even more typically 150 to 2600 microns. However, other lengths can be used as well.

Triangular polished strips are typically selected to have a width in the range of 0.1 micron to 3500 microns, more typically 100 to 3000 microns, and more typically 100 to 2600 microns. However, other lengths can be used as well.

Triangular ground plates are typically selected to have a thickness in the range of 0.1 micron to 1600 microns, more typically 1 micron to 1200 microns, but using other thicknesses. May be good.

In some embodiments, the triangular-polished plate can have an aspect ratio (length vs. thickness) of at least 2, 3, 4, 5, 6 or higher.

The surface coating on the triangular polishing sheet can be used to improve the adhesion between the triangular polishing sheet and the binder in the polished article, or to promote electrostatic deposition of the triangular polishing sheet. .. In one embodiment, the surface coating described in US Pat. No. 5,352,254 (Celikkaya) is used in an amount of surface coating of 0.1 to 2 percent based on the weight of the triangular polished plate. Can be done. Such surface coatings are described in US Pat. Nos. 5,213,591 (Celikkaya et al.), 5,011,508 (Wald et al.), 1,910,444 (Nicholson), No. 3, 041,156 (Rouse et al.), 5,09,675 (Kunz et al.), 5,085,671 (Martin et al.), 4,997,461 (Markoff-Matheny et al.) And It is described in the same No. 5,042,991 (Kunz et al.). In addition, the surface coating can prevent capping of the triangular polished strips. Capping is a term that describes the phenomenon in which metal particles from a workpiece being polished become welded to the top of a triangular abrasive plate. Surface coatings that perform the above functions are known to those skilled in the art.

Abrasive particles can be independently sized according to the specified nominal grades recognized in the polishing industry. Examples of grading standards recognized in the polishing industry include ANSI (American National Standards Institute, American National Standards Institute), FEPA (Federation of European Products of Abrasives, European Federation of Abrasive Producers, Japanese Industrial Standards Institute) and JIS (American National Standards Institute) and JIS (American National Standards Institute). Those promulgated by the Japanese Industrial Standards) can be mentioned. ANSI grade designations (ie defined nominal grades) include, for example, ANSI4, ANSI6, ANSI8, ANSI16, ANSI24, ANSI36, ANSI46, ANSI54, ANSI60, ANSI70, ANSI80, ANSI90, ANSI100, ANSI120, ANSI150, ANSI180, ANSI220, ANSI240, ANSI280. , ANSI320, ANSI360, ANSI400 and ANSI600. FEPA grade designations include F4, F5, F6, F7, F8, F10, F12, F14, F16, F16, F20, F22, F24, F30, F36, F40, F46, F54, F60, F70, F80, F90, Examples thereof include F100, F120, F150, F180, F220, F230, F240, F280, F320, F360, F400, F500, F600, F800, F1000, F1200, F1500 and F2000. As JIS grade designation, JIS8, JIS12, JIS16, JIS24, JIS36, JIS46, JIS54, JIS60, JIS80, JIS100, JIS150, JIS180, JIS220, JIS240, JIS280, JIS320, JIS360, JIS400, JIS600, JIS800, JIS1000, JIS1 Examples thereof include JIS2500, JIS4000, JIS6000, JIS8000 and JIS10000. According to one embodiment of the present disclosure, the average diameter of the abrasive particles may be in the range of 260 to 1400 microns according to FEPA grades F60 to F24.

Alternatively, U.S.A., which complies with ASTM E-11 "Standard Specialization for Wire Cross and Specifications for Testing Purposes". S. A. Abrasive particles can be rated to a nominally reviewed grade using the Standard Test Sieves. ASTM E-11 defines the requirements for the design and construction of test sieves using a woven wire mesh medium mounted in a frame to classify materials according to a specified particle size. A typical designation can be expressed as -18 + 20, which means that the abrasive particles pass a test sieve that meets the ASTM E-11 specifications for sieve # 18 and the ASTM E-11 specifications for sieve # 20. Means that it is held on a test sieve that meets the requirements. In one embodiment, the abrasive particles have a particle size such that most of the particles pass through an 18 mesh test sieve and can be retained on a 20, 25, 30, 35, 40, 45 or 50 mesh test sieve. doing. In various embodiments, the abrasive particles are -18 + 20, -20 / + 25, -25 + 30, -30 + 35, -35 + 40, 5-40 + 45, -45 + 50, -50 + 60, -60 + 70, -70 / + 80, -80 + 100, -100 + 120. , -120 + 140, -140 + 170, -170 + 200, -200 + 230, -230 + 270, -270 + 325, -325 + 400, -400 + 450, -450 + 500 or -500 + 635 can have a nominally examined grade. Alternatively, a custom mesh size such as -90 + 100 can be used.

Referring again to FIG. 1A, the rectangular grid pattern 196 is formed by vertical lines 194 (developed vertically) and horizontal lines 192 (expanded horizontally), with the horizontal lines relative to the vertical lines. It is defined at a right angle. The spacing between vertical and / or horizontal lines may be regular or irregular. The spacing is preferably regular in both the vertical and horizontal directions. It is preferable that the vertical spacing and the horizontal spacing are exactly the same. For example, in some preferred embodiments, the regular vertical spacing (ie, vertical pitch) between the triangular polished slabs can be 1.2 to 2 times the slab length, and the triangle. The regular horizontal spacing (ie, horizontal pitch) between the polishing plates can be 1.2 to 2 times the plate length. Of course, these spacings can vary depending on the size and thickness of the triangular polished strips.

In some preferred embodiments, the vertical and horizontal pitches are 1 to 6 times, more preferably 2 to 5 times, even more preferably 3 to 5 times the thickness of the triangular abrasive particles.

The coated polishing disc according to the present disclosure can be manufactured by a method in which a triangular polishing plate is accurately placed and the placement direction is determined. The method usually involves filling the cavities in the means with one or more triangular polishing plates (typically one or two), respectively, and making the filled production tools and triangular polishing plates. Includes a step of aligning the make-up layer precursor coating backing for transfer to the layer precursor, a step of transferring the abrasive particles from the cavity onto the make-up layer precursor coating backing, and a step of removing the means from the aligned position. .. The make-up layer precursor is then at least partially cured (typically to the extent that the triangular-polished sheet metal is firmly adhered to the backing), and then the size layer precursor is the make-up layer precursor and It is added on top of the abrasive particles and at least partially cured, thereby providing a coated abrasive disc. The process, which may be batch or continuous, can be practiced by hand or automated using, for example, a robotic device. It is not necessary to perform all the steps, or they need to be performed sequentially, but these steps can be performed in the order listed, or additional steps can be performed between them. You may.

Triangular abrasive plates are initially formed by placing them in a properly shaped cavity of the distribution surface of the means of production arranged to have a complementary rectangular grid pattern in the desired Z-axis rotational arrangement. Can be placed in the direction.

An exemplary production tool 400 for manufacturing the coated polishing disc 100 formed by casting a thermoplastic sheet, shown in FIGS. 1 and 1A to 1C, is shown in FIGS. 4 and 4A to 4C. It is shown. Next, referring to FIGS. 4 and 4A-4C, the means of production 400 comprises a rectangular array 430 of paired cavities 420 sized and shaped to receive triangular abrasive strips. It has a distribution surface 410. The cavities 420 have a Z-axis rotational orientation, so that when the triangular-polished plates are filled, they are obtained as a result as they are subsequently transferred, the coating shown in FIG. The desired corresponding rectangular array pattern and Z-axis rotational arrangement direction are formed in the polishing disc.

When almost or all cavities are filled with the desired number of triangular-polished plates, the distribution surface is very close to or in contact with the make-up layer precursor layer on the disc backing, thereby making it nominally horizontal. Triangular polishing strips are embedded and transferred from the means of production into the make-up layer precursor while maintaining the orientation of the orientation. Of course, some unintended placement loss can occur, but in general, placement loss should be manageable within a tolerance of ± 10 degrees or less.

In some embodiments, the depth of the cavity in the means of production is selected so that the triangular abrasive platelets fit perfectly into the cavity. In some preferred embodiments, the triangular-polished plate extends slightly beyond the opening of the cavity. According to this method, they can be transferred to the make-up layer precursor by direct contact, and the chances of the resin being transferred to the production tool are reduced. In some preferred embodiments, when the triangular polishing plate is completely inserted into the cavity, the center of mass of the individual triangular polishing plate is present within each cavity of the means of production tool. If the depth of the cavity becomes too shallow, the center of mass of the triangular polishing plate is located outside the cavity, the triangular polishing plate is not easily held in the cavity, and when the means of production is used in the equipment, Triangular polishing plaques can jump off.

It is preferable that an excess of triangular polishing plates is added to the distribution surface of the production tool so that more triangular polishing plates are provided to fill the cavities in the production tool. Excessive triangular polishing plates, which means that the number of triangular polishing plates present per unit length of the means of production is greater than the number of cavities present, causes the triangular polishing plates to accumulate on the distribution surface. And, as they move around by either gravity or other mechanically applied force, thereby moving in parallel into the cavity, most of the cavity in the means of production is finally filled with triangular-polished plates. Promote assurance that it will be done. Bearing areas and spacing of abrasive particles are often designed for a particular grinding application in the means of production, so it is usually desirable not to have excessive variability in the number of unfilled cavities.

Most of the cavities in the distribution surface are preferably filled with triangular-polished slabs arranged in the individual cavities so that the cavities and the sides of the slabs are at least approximately parallel. This can be achieved by shaping cavities that are slightly larger than the triangular ground plate (or more). To facilitate filling and release, the cavity may have side walls that incline inward as the depth increases, and / or it may be desirable to have a vacuum opening at the bottom of the cavity. Connect to a vacuum source. Triangular polishing plates should be transferred onto the make-up layer precursor coating backing so that they are added upright or upright. Therefore, the shape of the cavity is designed to hold the triangular polished strip in an upright position.

In various embodiments, at least 60, 70, 80, 90 or 95 percent of the distribution surface cavities include a triangular polished plate. In some embodiments, gravity can be used to fill the cavity. In another embodiment, the means of production can be turned upside down and a vacuum can be applied to hold the triangular polishing plate in the cavity. Triangular polishing strips can be added, for example, by spraying, fluidized bed (air or vibration) or electrostatic coating. Excess triangular polishing strips will be removed by gravity because all unretained abrasive particles will fall. The vacuum can then be removed to transfer the triangular polished strips to make layer precursor coated disc backing.

As mentioned above, after the desired number of cavities have been filled, it is possible to add more triangular-polished plates than the number of cavities so that some of the triangular-polished plates will remain on the distribution surface. it can. These excess triangular-polished plates can often be blown off, wiped off, or otherwise removed from the distribution surface. For example, a vacuum or other force can be applied to hold the triangular-polished plate in the cavity and upside down the distribution surface to remove excess portion of the triangular-polished plate from the distribution surface.

After substantially all the cavities of the distribution surface of the production tool are filled with triangular abrasive strips, the distribution surface of the production tool is brought closer to the make-up layer precursor.

In a preferred embodiment, the production tool is formed from a thermoplastic polymer such as polyethylene, polypropylene, polyester or polycarbonate from, for example, a metal master tool. The means of production of the means of production and the master touring used in their manufacture are, for example, US Pat. Nos. 5,152,917 (Pieper et al.), 5,435,816 (Spurgeon et al.), 5, 672,097 (Hoopman et al.), 5,946,991 (Hoopman et al.), 5,975,987 (Hoopman et al.) And 6,129,540 (Hoopman et al.), And the United States. It can be found in Patent Application Publication Nos. 2013/03444786 (A1) (Keipert) and 2016/0311084 (A1) (Culler et al.).

In some preferred embodiments, the means of production are manufactured using additive manufacturing or "3D printing" techniques.

When the triangular-polished plate is embedded in the make-up layer precursor, the make-up layer precursor is at least partially cured to maintain the orientation of the minerals while adding the size layer precursor. Typically, this involves B-stepping the make-up layer precursor, but it is also possible to use a higher degree of curing if desired. B-stepping can be achieved using heat and / or light, and / or using a curing agent, for example, depending on the nature of the selected make-up layer precursor.

The size layer precursor is then added onto the make-up layer precursor and the triangular-polished plate, which are at least partially cured. The sizing layer can be formed by coating the main surface of the backing with a curable sizing layer precursor. Size layer precursors include, for example, adhesives, phenolic resins, aminoplast resins, urea-formaldehyde resins, melamine-formaldehyde resins, urethane resins, free group polymerizable polyfunctional (meth) acrylates (eg pendants α, β-unsaturated). It can contain groups, acrylated urethanes, acrylated epoxies, aminoplast resins with acrylated isocyanurates), epoxy resins (including bis-maleimide and fluorene modified epoxy resins), isocyanurate resins and mixtures thereof. When the make-up layer is formed by using the phenol resin, it is preferable that the size layer is formed by using the phenol resin as well. The size layer precursor is any known coating method for adding a size layer to the backing, including roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, spray coating, etc. Can be added by. If desired, the presized layer precursor or make layer precursor according to the present disclosure can also be used as the size layer precursor.

Also, depending on the intended use, the type of abrasive particles, and the nature of the coated abrasive disc being prepared, the weight of the size layer will necessarily vary, but is usually 1 or 5 gsm to 300, 400, and more. Is in the range of 500 gsm or more. The size layer precursor is any known coating method for applying the size layer precursor (eg size coat) to the backing, including, for example, roll coating, extrusion die coating, curtain coating and spray coating. Can be added by.

In addition, the size layer precursor, and typically the partially cured make-up layer precursor, is sufficiently cured to provide a usable coated abrasive disc. Normally, this curing step requires thermal energy, but other forms of energy, such as radiation curing, can also be used. Useful forms of thermal energy include, for example, heat and infrared radiation. Illustrative sources of thermal energy include ovens (eg, festoon ovens), heating rolls, hot air blowers, infrared lamps and combinations thereof.

In addition to the other components, the binder precursors in the make-up and / or pre-size layer precursors of the coated polished discs according to the present disclosure, if present, are optionally catalysts (eg, thermal activation). It can contain a catalyst or photocatalyst), a free radical initiator (eg, a thermal initiator or photoinitiator), and a curing agent to facilitate curing. Such catalysts (eg, thermal activation catalysts or photocatalysts), free radical initiators (eg, thermal initiators or photoinitiators) and / or curing agents include, for example, those described herein. It may be of any type known for use in.

In addition to other components, make-up layer precursors and size layer precursors can further include, for example, optional additives to modify performance and / or appearance. Illustrative additives include grinded additives, fillers, plasticizers, wetting agents, surfactants, pigments, coupling agents, fibers, lubricants, thixotrope materials, antistatic agents, suspending agents and / or dyes. Can be mentioned.

Exemplary milling additives, which may be organic or inorganic, include halogenated organic compounds such as waxes, tetrachloronaphthalene, pentachloronaphthalene and chlorinated waxes such as polyvinyl chloride, sodium chloride, potassium glacial stones, etc. Halide salts such as sodium glacial stone, ammonia glacial stone, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluoride, potassium chloride, magnesium chloride, as well as tin, lead, bismuth, cobalt, antimony, Examples include metals such as chloride, iron, and titanium and their alloys. Examples of other milling additives include sulfur, organic sulfur compounds, graphite and metal sulfides. A combination of different milling additives can be used.

Exemplary antistatic agents include conductive materials such as vanadium pentoxide (dispersed in sulfonated polyester, for example), wetting agents, carbon black and / or graphite in the binder.

Examples of useful fillers for the present disclosure include silica such as quartz, glass beads, glass bubbles and glass fibers, talc, clay, (montmorillonite) feldspar, mica, calcium silicate, calcium metasilicate, aluminokei. Silicates such as sodium silicate and sodium silicate, calcium sulfate, barium sulfate, sodium sulfate, aluminum / sodium sulfate, metal sulfates such as aluminum sulfate, gypsum, vermiculite, wood flour, aluminum trihydrate, carbon black , Aluminum oxide, titanium dioxide, feldspar, feldspar, and metal sulfates such as calcium sulfate.

Optionally, the supersize layer can be added to at least a portion of the size layer. If present, supersizes usually include milling additives and / or antiloading materials. The optional super-sized layer can serve to prevent or reduce the accumulation of chips (material polished from the workpiece) between the abrasive particles, and this accumulation of chips is the ability to cut the coated abrasive disc. Can be dramatically reduced. Useful supersize layers are typically ground additives (eg potassium tetrafluoroborate), metal salts of fatty acids (eg zinc stearate or calcium stearate), salts of phosphate esters (eg potassium behenyl phosphate). , Phosphates, urea-formaldehyde resins, mineral oils, crosslinked silanes, crosslinked silicones and / or fluorochemicals. Useful super-sized materials are further described, for example, in US Pat. No. 5,556,437 (Lee et al.). Generally, the amount of milling additive incorporated into the coated abrasive product is from about 50 to about 400 gsm, more typically from about 80 to about 300 gsm. The supersize can contain a binder, such as a binder used to prepare a size layer or make-up layer, but it is not necessary to have any binder.

Further details regarding a coated polishing disc comprising a polishing layer fixed to the backing, wherein the polishing layer comprises polishing particles and a make-up layer, a size layer and an optional super-sized layer, are well known. For example, U.S. Pat. Nos. 4,734,104 (Broverg), 4,737,163 (Larkey), 5,203,884 (Buchanan et al.), 5,152,917 (Pieper). Et al.), No. 5,378,251 (Culler et al.), No. 5,417,726 (Stout et al.), No. 5,436,063 (Follett et al.), No. 5,469,386. (Brover et al.), No. 5,609,706 (Bendict et al.), No. 5,520,711 (Helmin), No. 5,954,844 (Law et al.), No. 5,961,674 No. (Gagliardi et al.), No. 4,751,138 (Banger et al.), No. 5,766,277 (DeVoe et al.), No. 6,077,601 (DeVoe et al.), No. 6,228 , 133 (Turber et al.) And 5,975,988 (Christianson).

The coated polishing discs according to the present disclosure are useful for polishing workpieces, for example, by off-hand polishing using a handheld right angle grinding machine. Preferred workpieces include weld beads (eg, mild steel welds in particular), flushes, gates and riser-off castings.

In the first aspect of the selected embodiment of the present disclosure, the present disclosure
With disc backing
A polishing layer placed on top of the disc backing, comprising a polishing element secured to the main surface of the disc backing by at least one binder material, where the polishing element is the intersection of the horizontal and vertical lines of a rectangular lattice pattern. One of the polishing elements is located at least 70% of the intersections (preferably at least 75%, more preferably at least 80%, more preferably at least 85%, even more preferably at least 90%). There is a polishing layer and
With
Each of the polishing elements has two triangular polishing plates, each of which has a top surface and a bottom surface that are connected to each other and separated by three side walls, respectively. At least 90 percent of the plaque has one side wall facing the disc backing and placed in close proximity to the disc backing.
The polishing elements are arranged so that the triangular polishing plates in the adjacent polishing elements are orthogonal to each other and have a Z-axis rotation arrangement direction within 10 degrees from the orthogonal to each other.
A coated polishing disc is provided.

In a second embodiment, the present disclosure provides a coated polishing disc according to the first embodiment, in which one of the polishing elements is located at least 80 percent of the intersections.

In a third embodiment, the present disclosure provides coated polished discs according to the first or second embodiment, each having at least 90% of one side wall of a triangular polished plate surface facing the disc backing. Triangular polishing strips placed in close proximity to the disc backing and adjacent to alternating intersections along the individual horizon have Z-axis rotational placement directions within 5 degrees of the horizon and are individual. Triangular polished strips arranged adjacent to alternating intersections along the vertical line have a Z-axis rotational arrangement direction within 5 degrees of the vertical line.

In a fourth embodiment, the present disclosure provides a coated polishing disc according to any one of the first to third embodiments, each having one side wall of at least 90% of the triangular polishing plates. Triangular polished strips, which face the disc backing and are placed close to the disc backing and adjacent to the alternating intersections along the individual horizon, rotate in the Z-axis within 2 degrees of the horizon. Triangular polishing strips having and arranged adjacent to alternating intersections along the individual vertical lines have a Z-axis rotational arrangement direction within 2 degrees of the vertical line.

In a fifth embodiment, the present disclosure provides a coated polishing disc according to any one of the first to fourth embodiments, wherein the polishing layer further comprises crushed polished particles or non-polished particles. To do.

In a sixth embodiment, the present disclosure provides a coated polished disc with disc backing according to any one of the first to fifth embodiments, including vulcanized fibers.

In a seventh embodiment, the present disclosure comprises one of the first to sixth embodiments, wherein the polishing layer comprises a make-up layer and a size layer arranged on the make-up layer and the polishing element. A coated polishing disc made of any one of the above is provided.

In an eighth embodiment, the present disclosure provides a coated polishing disc according to any one of the first to seventh embodiments, wherein the triangular polishing strip contains alpha alumina.

In a ninth embodiment, the present disclosure provides a method of polishing a workpiece, the method of which is a polishing layer of a coated polishing disc according to any one of the first to eighth embodiments. This includes frictionally contacting a portion with the workpiece and moving at least one of the workpiece and the coated abrasive disc against the other to polish the workpiece.

In a tenth embodiment, the present disclosure provides a method of polishing a workpiece according to a ninth embodiment, wherein the workpiece includes a mild steel weld and the polishing layer contacts the mild steel weld.

In the eleventh embodiment, the present disclosure provides a method of manufacturing a coated polished disc, wherein the method is:
Placing the curable make-up layer precursor on the main surface of the disc backing,
Adhering (eg, contacting and / or embedding) the polishing element to the curable make-up layer precursor.
The polishing elements are placed at the intersections of the horizontal and vertical lines of the rectangular grid pattern, with at least 70 percent (preferably at least 75 percent, more preferably at least 80 percent, more preferably at least 85 percent, even more preferably at least) of the intersections. 90%), one of the polishing elements is placed,
Each of the polishing elements has two triangular polishing plates, each of which has a top surface and a bottom surface that are connected to each other and separated by three side walls, respectively. At least 90 percent of the plaque has one side wall facing the disc backing and placed in close proximity to the disc backing.
The polishing elements are arranged so that the triangular polishing plates in the adjacent polishing elements are orthogonal to each other and have a Z-axis rotation arrangement direction within 10 degrees from the orthogonal to each other.
Adhering (eg, contacting and / or embedding) the abrasive element to the curable make-up layer precursor and
Placing the curable size layer precursor on at least a partially cured make-up layer precursor and a triangular polishing plate.
To provide a size layer, the curable size layer precursor is at least partially cured.

In a twelfth embodiment, the present disclosure provides a method according to an eleventh embodiment in which one of the polishing elements is located at at least 80 percent of the intersections.

In a thirteenth embodiment, the present disclosure provides the method according to the eleventh or twelfth embodiment, each in which at least 90% of one side wall of the triangular polished plate faces the disc backing. Triangular polished strips placed close to the disc backing and adjacent to alternating intersections along the individual horizon have a Z-axis rotation placement direction within 5 degrees of the horizon and are individual vertical lines. Triangular polishing strips arranged adjacent to alternating intersections along the vertical line have a Z-axis rotational arrangement direction within 5 degrees of the vertical line.

In a fourteenth embodiment, the present disclosure provides a method according to an eleventh or twelfth embodiment, each in which at least 90% of one side wall of a triangular polished plate faces a disc backing. Triangular polished strips placed close to the disc backing and adjacent to alternating intersections along the individual horizon have Z-axis rotation placement directions within 2 degrees of the horizon and are individual vertical lines. Triangular polishing strips arranged adjacent to alternating intersections along the vertical line have a Z-axis rotational arrangement direction within 2 degrees of the vertical line.

In a fifteenth embodiment, the present disclosure provides a method according to any one of the eleventh to fourteenth embodiments, wherein the polishing layer further comprises crushed polished particles or non-polished particles.

In a sixteenth embodiment, the present disclosure provides a method according to any one of the eleventh to fifteenth embodiments, wherein the disc backing comprises a vulcanized fiber.

In a seventeenth embodiment, the present disclosure provides a method according to any one of the eleventh to sixteenth embodiments, wherein the triangular polishing strip comprises alpha alumina.

The purposes and advantages of this disclosure are further illustrated by the following non-limiting examples, but the specific materials and amounts thereof, as well as other conditions and details described in these examples, are described in this disclosure. It should not be construed as an unreasonable restriction.

Unless otherwise stated, all parts, percentages, ratios, etc. in the Examples are by weight.

Unless otherwise stated, all other reagents can be obtained, available, or synthesized by known methods from fine chemical vendors such as Sigma-Aldrich Company (St. Louis, Missouri). ..

Example 1
A 7 inch (178 mm) circular plastic transfer tool with triangular cavities as shown in FIGS. 4 and 4A-4C was prepared by 3D printing. The individual repeating units of the tool consisted of a pair of cavities oriented parallel to their major axes, forming a square unit cell with a side dimension of 0.08 inches (2.03 mm). The cavities in adjacent unit cells were rotated 90 degrees in all directions of the four arrays. This pattern was repeated over the entire surface of the tool for a density of 312 cavities per square inch (48.4 cavities per cm2). The transfer tool was treated with a molybdenum sulfide spray lubricant (obtained under the trade name MOLYCOAT from the Dow Corning Corporation in Midland, Michigan) to facilitate the release of abrasive particles.

Excess abrasive particles AP1 were added to the surface of the transfer tool with the cavity opening and the tooling was shaken from side to side by hand. The transfer tool cavity was immediately held upside down and filled with AP1 particles aligned along the long axis of the cavity. The process was repeated until additional AP1 was added and more than 95 percent of the transfer tool cavities were filled with AP1 particles. Excess particles were removed from the surface of the transfer tool, leaving only the particles contained within the cavity.

The make-up resin is 49-part resol-phenolic resin (formaldehyde: phenol, a base-catalyzed condensate with a molar ratio of 1.5: 1 to 2.1: 1) and 41-part calcium carbonate (HUBERCARB, Quincy, Illinois). Huber Engineered Materials) and 10 parts of water were prepared by mixing. 2.8 grams of make-up resin brushed with a vulcanized fiber web (DYNOS VULCANIZED FIBER, 7 inches (17.8 cm) x 0.83 mm thick" with a central hole of 0.875 inches (2.22 cm). It was added to DYNOS GmbH) located in Troisdorf, Germany.

The transfer tool filled with AP1 was placed on a 7 inch (18 cm) x 7 inch (18 cm) square wooden plate with the cavity side up. The make-resin-coated surface of the vulcanized fiber disc was brought into contact with the filled transfer tool and another 7 "x 7" (18 cm x 18 cm) square wooden board was placed on it. The resulting assembly was inverted while maintaining rigid contact so that it fell from the bottom to the surface of the make-up resin first, and then tapped gently to transfer AP1 particles from the transfer tool. The vulcanized fiber disc backing was then dropped from a transfer tool that was no longer substantially particle free, thereby resulting in an AP1-coated vulcanized fiber disc that replicated the transfer tooling pattern.

Drop coat filler particles consisting of AP5 were added in excess to the wet make-up resin and stirred until the entire exposed make-up resin surface was filled with AP5 to volume. The disc was flipped to remove excess AP5. The amount of AP5 added was 10.4 +/- 0.1 g. The make-up resin was partially cured in the oven by heating at 70 ° C. for 45 minutes, then at 90 ° C. for 45 minutes, and then at 105 ° C. for 3 hours.

Example 2
Example 2 was prepared by the method of Example 1 except that AP2 particles were used instead of AP1 particles.

Example 3
Example 3 was prepared by the method of Example 1 except that AP3 particles were used instead of AP1 particles, the make-up resin weight was 3.2 +/- 0.2 grams, and AP4 instead of AP5. Was used and the size resin weight was 12.2 +/- 0.1 grams.

Comparative Example A
Comparative Example A is a commercially available, electrically coated additive manufactured using AP2 abrasive particles (obtained from 3M Company in Saint Paul, Minnesota under the trade name 982C Grade 36+). It was a vulcanized fiber disk.

Comparative Example B
Comparative Example B was generally prepared as described in Example 1. The transfer tool cavities are arranged in a square grid pattern, with the radial placement directions of the particles alternating at 90 degrees in both grid directions. There are 17 cavity arrays per inch (6.7 per cm) in both directions, ie 289 per square inch (44.8 per square cm), or about 10950 for the entire tool. It was hollow. This pattern has already been described as Example 4 in US Pat. No. 9,776,302 (Keipert). The transfer tool was filled with AP3 particles. The amount of make resin was 3.5 grams. The drop-coated secondary particles were 9.4 grams of AP4. Cryolite-sized resin levels were 12.1 grams.

Comparative Example C
Comparative Example C was prepared as described in Example 1. The transfer tool pattern was a center-to-edge spiral pattern in which all cavity openings were oriented substantially along the edge with respect to the grinding direction of the rotary polishing disc. The cavity spacing along the length of the spiral was about 9 per inch (3.5 per cm) and the spiral pitch was about 30 rows per inch (11.8 rows per cm). In Example 1 and Comparative Example B, the total cavity density and the number of cavities per disk were comparable to the transfer tool. The abrasive particles used were AP2. The amount of AP5 drop-coated secondary particles was 11 +/- 0.1 grams and the amount of cryolite-sized resin was 13.7 +/- 0.1 grams.

Grinding test method By grinding 1018 mild carbon steel using the following procedure, the grinding performance of various discs was evaluated. A 7 inch (17.8 cm) diameter polishing disc for evaluation is attached to an automatic servomotor rotary grinding machine set to operate at a constant rotational speed of 5000 rpm and is 7 inches (17.8 cm). ) Ribbed disc pad face plate (051144 EXTRA HARD RED RIBBED, obtained from 3M Company). During the test, the torque applied to the grinding machine was measured. The grinding machine was activated and pressed against the end face of a 1 x 1 inch (2.54 x 2.54 cm) pre-weighed 1018 steel bar under a starting load of 6 pounds (2.7 kg). Under these conditions, the workpiece was ground with a grinding interval of 10 seconds. After each grinding interval, the load was adjusted to maintain a constant torque measurement. Following individual 10 second intervals, the workpiece was cooled to room temperature and weighed to determine the amount of grinding for the polishing operation. The test results were reported as the incremental grinding amount per interval and the total grinding amount removed. The end point of the test was determined when the amount of grinding was less than 25% of the value of the initial amount of grinding or when the load reached 18 pounds (8.2 kg). The total grinding amount was reported and the data peaked at the grinding interval grinding amount of less than 15 grams. Test results were reported as incremental grinding amount (g / cycle) per interval and total stock removed (g). The test results are reported in Table 2 below.

All references, patent documents or patent applications cited in the above patent applications are incorporated herein by reference in their entirety in a consistent manner. In the event of any conflict or denial between a portion of the incorporated references and a portion of the present application, the information in the above description shall prevail. The above description given to enable the practice of a patented disclosure by a person skilled in the art should not be construed as limiting the scope of the present disclosure, and the scope of the present disclosure is the scope of the claims. And all its equivalents.

Claims (15)

It ’s a polishing disc,
With disc backing
A polishing layer placed on top of the disc backing, comprising a polishing element secured to the main surface of the disc backing by at least one binder material, the polishing element having horizontal and vertical lines of a rectangular lattice pattern. A polishing layer, which is arranged at an intersection with, and at least 70% of the intersection, where one of the polishing elements is arranged.
With
Each of the polishing elements has two triangular polishing plates, each of which has a top surface and a bottom surface that are connected to each other and separated by three side walls, respectively. One side wall of at least 90% of the triangular polished plate is placed facing the disc backing and in close proximity to the disc backing.
The polishing elements are arranged so that the triangular polishing plates in the adjacent polishing elements are orthogonal to each other and have a Z-axis rotation arrangement direction within 10 degrees from the orthogonal to each other.
Abrasive disc. The coated polishing disc according to claim 1, wherein one of the polishing elements is arranged at at least 90% of the intersections. Each side wall of at least 90% of the triangular polished plaques was placed facing the disc backing and in close proximity to the disc backing, adjacent to alternating intersections along the individual horizon. The triangular polishing plate has a Z-axis rotation arrangement direction within 5 degrees from the horizontal line, and the triangular polishing plate arranged adjacent to an alternating intersection along each vertical line is the vertical line. The coated polishing disk according to claim 1, which has a Z-axis rotation arrangement direction within 5 degrees from. The coated polishing disc according to claim 1, wherein the polishing layer further contains crushed polishing particles or non-polishing particles. The coated polishing disc according to claim 1, wherein the disc backing includes a vulcanized fiber. The coated polishing disc according to claim 1, wherein the polishing layer includes a make-up layer and a size layer arranged on the make-up layer and the polishing element. The coated polishing disc according to claim 1, wherein the triangular polishing small plate contains alpha alumina. A method of polishing a work piece, wherein a part of the polishing layer of the coated polishing disc according to claim 1 is brought into frictional contact with the work piece, and the work piece and the work piece are polished. A method comprising moving at least one of the polished articles relative to the other. The method according to claim 8, wherein the workpiece includes a mild steel weld and the polishing layer contacts the mild steel weld. It is a method of manufacturing a coated polishing disc.
Placing the curable make-up layer precursor on the main surface of the disc backing,
Adhering the polishing element to the curable make-up layer precursor,
The polishing element is arranged at the intersection of the horizontal and vertical lines of the rectangular lattice pattern, and at least 70% of the intersection is arranged with one of the polishing elements.
Each of the polishing elements has two triangular polishing plates, each of which has a top surface and a bottom surface that are connected to each other and separated by three side walls, respectively. One side wall of at least 90% of the triangular polished plate is placed facing the disc backing and in close proximity to the disc backing.
The polishing elements are arranged so that the triangular polishing plates in the adjacent polishing elements are orthogonal to each other and have a Z-axis rotation arrangement direction within 10 degrees from the orthogonal to each other.
Adhering the polishing element to the curable make-up layer precursor and
Placing the curable size layer precursor on at least a partially cured make-up layer precursor and a triangular polishing plate.
To provide a size layer, the curable size layer precursor is at least partially cured,
Including methods. The method of claim 10, wherein one of the polishing elements is located at least 90 percent of the intersections. Each side wall of at least 90% of the triangular polished plaques was placed facing the disc backing and in close proximity to the disc backing, adjacent to alternating intersections along the individual horizon. The triangular polishing plate has a Z-axis rotation arrangement direction within 5 degrees from the horizontal line, and the triangular polishing plate arranged adjacent to an alternating intersection along each vertical line is the vertical line. The method according to claim 10, which has a Z-axis rotation arrangement direction within 5 degrees from. The method of claim 10, wherein the abrasive layer further comprises crushed abrasive particles or non-abrasive particles. 10. The method of claim 10, wherein the disc backing comprises a vulcanized fiber. 10. The method of claim 10, wherein the triangular polishing strip comprises alpha alumina.