JP3628317B2 - Abrasive belt and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an abrasive belt in which a nonwoven fabric is laminated on a base sheet and a method for producing the same.
[0002]
[Prior art]
A polishing belt using a conventional non-woven fabric has a non-woven fabric laminated on and bonded to a base sheet. This abrasive belt is manufactured by the following two methods. The first method is manufactured by the following steps.
(1) Laminate the nonwoven fabric on the base sheet.
(2) Connect the nonwoven fabric to the base sheet with a needle punch.
(3) Abrasive grains are attached to the surface of the nonwoven fabric through a binder.
(4) Curing the binder and bonding the abrasive grains to the fiber surface of the nonwoven fabric.
In the second method, an abrasive belt is produced by the following steps.
(1) Adhere abrasive grains to the nonwoven fabric through a binder.
(2) Laminate the non-woven fabric with abrasive grains on the base sheet and bond.
[0003]
[Problems to be solved by the invention]
The non-woven abrasive belt manufactured by the above method is clogged as compared with the so-called paper abrasive belt produced by attaching abrasive grains directly to the surface of the base sheet, which is an endless belt-like cloth. Has strong features. This is because there is a gap between the fibers. However, the nonwoven fabric polishing belt having this structure has a drawback that it has a lower cutting ability than a paper polishing belt.
[0004]
Furthermore, when the abrasive belt made of non-woven fabric is used by being driven over two rolls, if the workpiece is unevenly distributed on one side of the belt on the surface of the roll and the object to be polished is pressed against the surface of the abrasive belt, it is moved by the roll. There is a drawback that the polishing belt gradually shifts in the lateral direction. This is because the substantial radius on both sides of the roll that drives the polishing belt changes and becomes unbalanced. That is, when the object to be polished is pressed, the nonwoven fabric is elastically deformed so as to be crushed, and the gap between the roll and the polishing belt is narrowed. On the other hand, in the portion where the object to be polished is not pressed, the nonwoven fabric is not crushed, and the distance from the roll is widened. When the distance between the polishing belt driven by the roll and the roll becomes unbalanced at both side portions, the substantial radius at which the roll drives the polishing belt becomes unbalanced. One side of the polishing belt approaching the roll is driven by a thin roll, and the other side of the polishing belt separated from the roll is driven by a thick roll. For this reason, the polishing belt is driven by a taper-shaped roll, which causes a problem of moving in the lateral direction.
[0005]
In addition, the non-woven fabric abrasive belt has a drawback in that it is peeled off at the intermediate layer when it is used for a long time, resulting in a short life. This problem is particularly severe when driven with a thin roll. A polishing belt driven by a thin roll has a longer outer side than an inner side while being curved along the roll. For this reason, every time the polishing belt is bent by the roll, a shift occurs in the longitudinal direction between the inner side and the outer side, and this is repeated to cause a problem of peeling between the inner side and the outer side.
[0006]
The present invention has been developed for the purpose of solving such drawbacks. An important object of the present invention is to provide a non-woven polishing belt having a very high cutting ability and a long life compared to conventional non-woven polishing belts.
Another important object of the present invention is to provide a polishing belt that can reduce lateral displacement even when an object to be polished is pressed against one side while being driven by a roll.
Furthermore, another important object of the present invention is to provide an abrasive belt that can be driven by a thin roll and effectively prevent internal peeling.
[0007]
[Means for Solving the Problems]
The polishing belt of the present invention is a temperature at which thermoplastic fibers 4 having abrasive grains 5 on their surfaces are gathered in a three-dimensional direction and the surfaces of the fibers 4 are thermally deformed with a pressing plate to smooth the surface. And a nonwoven fabric polishing layer 3 pressed in time, and a base material sheet 2 connected to the nonwoven fabric polishing layer 3 in a laminated state. The polishing belt connects the laminated body of the base material sheet 2 and the nonwoven fabric polishing layer 3 in an endless belt shape.
[0008]
The polishing belt of the present invention can be flattened by hot pressing the nonwoven fabric polishing layer 3. Furthermore, the polishing belt of this invention can be 1-10 mm in total thickness including the base material sheet 2, Preferably it can be 2-5 mm.
[0009]
The manufacturing method of the abrasive belt according to claim 5 of the present invention includes an attaching step of attaching abrasive particles 5 with a binder to a nonwoven fabric in which fibers 4 are gathered three-dimensionally without directivity, and a nonwoven fabric to which abrasive particles 5 are attached. Is heated to a temperature at which the fibers 4 are thermally deformed, and is heated to smooth the surface, and a bonding step of bonding the hot-pressed nonwoven fabric to the base sheet 2 is performed.
[0010]
In the attaching process of the abrasive grains 5, the abrasive grains 5 can be adhered to the surface of the fiber 4 by spraying the binder added with the abrasive grains 5 on both surfaces of the nonwoven fabric.
[0011]
Furthermore, the manufacturing method of the abrasive belt according to claim 7 of the present invention includes a laminating step of laminating a nonwoven fabric in which fibers 4 are gathered three-dimensionally without directionality on the base sheet 2, and laminating the base sheet 2. The non-woven fabric is bonded to the non-woven fabric with an adhesion step through a binder, and the non-woven fabric with the abrasive particles 5 is pressed to a temperature at which the fibers 4 are thermally deformed to smooth the surface of the non-woven fabric. A heating press process.
[0012]
In the laminating step, the nonwoven fabric can be laminated and connected to the base material sheet 2 by needle punching.
[0013]
Furthermore, in the method for producing an abrasive belt of the present invention, the abrasive particles 5 can be adhered to the nonwoven fabric by pressing in a heated state to smooth the surface while the binder that adheres the abrasive particles 5 to the nonwoven fabric is uncured. In a state where the binder is cured, the surface can be smoothed by pressing in a heated state.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings. However, the examples shown below exemplify the polishing belt and the manufacturing method thereof for embodying the technical idea of the present invention, and the present invention is based on the following specific examples of the structure and material of the polishing belt. Not specified.
[0015]
Further, in this specification, in order to facilitate understanding of the scope of claims, the numbers corresponding to the members shown in the embodiments are referred to as “claims” and “means for solving the problems”. It is added to the member shown by. However, the members shown in the claims are not limited to the members in the embodiments.
[0016]
The polishing belt 1 shown in FIGS. 1 and 2 has a laminated body in which a nonwoven fabric polishing layer 3 is laminated on a base sheet 2 in the form of an elongated belt, and both ends thereof are connected to form an endless belt. In many cases, the polishing belt 1 is used over two rolls 6 as shown in the figure. However, the polishing belt of the present invention can be used by being attached to one roll. The polishing belt attached to one roll has an inner diameter substantially equal to the outer diameter of the roll so that the roll is not inserted and removed.
[0017]
The polishing belt 1 has a base material sheet 2 laminated on a nonwoven fabric polishing layer 3 and is connected to the base material sheet 2 so as not to come off. The base material sheet 2 shown in FIG. 1 is a net. The net has a feature that the nonwoven fabric polishing layer 3 can be connected so as not to be removed by needle punching. The base material sheet 2 shown in FIG. 2 is paper. The paper base sheet 2 can be connected by bonding the nonwoven fabric polishing layer 3. However, for the polishing belt of the present invention, all sheets having flexibility and sufficient tensile strength, such as woven fabric, can be used. The nonwoven fabric polishing layer 3 is connected to the base sheet 2 by needle punching, or is connected to the base sheet 2 by bonding. Furthermore, the nonwoven fabric polishing layer 3 can be connected to the base sheet 2 by both needle punching and adhesion.
[0018]
The nonwoven fabric polishing layer 3 has thermoplastic fibers 4 such as polyester fibers gathered in a predetermined thickness with no three-dimensional orientation, and abrasive grains 5 are adhered. However, thermoplastic fibers other than polyester fibers can also be used for the fibers 4 of the nonwoven fabric polishing layer 3. The abrasive grains 5 are attached to the surface of the fiber 4 through a binder, or are attached to the surface of the fiber 4 and the voids of the fiber 4. The binder to which the abrasive grains 5 are attached is an adhesive material such as phenol resin, epoxy resin, silicon resin, urethane resin. The kind and application amount of the binder affect the flexibility of the nonwoven fabric polishing layer 3. If a hard binder is used or the amount of binder applied is increased, the nonwoven fabric polishing layer 3 becomes hard. On the other hand, if a flexible binder is used or if the amount of the binder applied is reduced, it becomes flexible and easily deforms. A phenol resin or epoxy resin adhesive can be used as the hard binder, and a silicon resin or urethane resin adhesive can be used as the flexible binder. These binders can also be mixed and used.
[0019]
The nonwoven fabric polishing layer 3 can also bind the contacts of the three-dimensionally aggregated fibers 4 with a binder to which the abrasive grains 5 are attached. However, a dedicated binder may be used for the binder that bonds the contact points of the fibers 4 and the binder that adheres the abrasive grains 5. In this nonwoven fabric polishing layer 3, after the fibers 4 are bonded with a binder, the abrasive grains 5 are adhered with another binder.
[0020]
The abrasive grains 5 are attached to the nonwoven fabric by the following method.
(1) Spray a paste-like binder on the nonwoven fabric. Or after immersing a nonwoven fabric in a paste-form binder, a nonwoven fabric is pinched | interposed with two rolls, an excess binder is squeezed out, and a binder adheres to a nonwoven fabric.
(2) With the binder uncured, the abrasive particles 5 are sprayed and adhered to the nonwoven fabric.
The nonwoven fabric polishing layer 3 to which the abrasive grains 5 are attached by the above method can increase the cutting ability by exposing the abrasive grains 5 to the surface of the binder. However, the abrasive particles 5 can also be adhered by spraying the binder mixed with the abrasive particles 5 onto the nonwoven fabric. This method can easily attach the abrasive grains 5.
[0021]
As shown in FIG. 3, the nonwoven fabric polishing layer 3 to which the abrasive grains 5 are attached is pressed with a pressing plate 7 at a temperature and time for thermally deforming the fibers 4 and smoothing the surface. In this step, the nonwoven fabric polishing layer 3 is pressed while being heated with the pressing plate 7 of a hot press, or the nonwoven fabric polishing layer 3 heated in advance is pressed with the pressing plate 7 which is not heated. In this step, the nonwoven fabric polishing layer 3 is heated to 130 to 150 ° C. and pressed. The pressing time is 15 to 20 minutes, and the pressing pressure is 5 to 7 kg / cm ² . However, the heating temperature of the nonwoven fabric polishing layer 3 may be, for example, 80 to 200 ° C, preferably 100 to 160 ° C. When lowering the heating temperature, the fiber 4 is thermally deformed by lengthening the time for pressing the nonwoven fabric. When the heating temperature of the nonwoven fabric is increased, the pressing time of the nonwoven fabric is shortened. The pressing time can be, for example, 30 seconds to 60 minutes, 1 to 30 minutes, and more preferably 10 to 25 minutes. Since the pressing pressure is set to an optimum value in consideration of the heating temperature, pressing time, application, etc., for example, 0.2 to 15 kg / cm ² , preferably 1 to 10 kg / cm ² , more preferably 3 to 8 kg / Set to the cm ² range.
[0022]
The nonwoven fabric polishing layer 3 can be heated and pressed in a state where it is connected to the base material sheet 2, or can be pressed in a pre-process for bonding to the base material sheet 2. The method of pressing the nonwoven fabric polishing layer 3 in a state where the nonwoven fabric polishing layer 3 is laminated and connected to the base sheet 2 can easily and efficiently manufacture the polishing belt 1. The method of laminating and connecting the pressed nonwoven fabric polishing layer 3 to the base sheet 2 can increase the cutting ability of the nonwoven fabric polishing layer 3. This is because the abrasive grains 5 can adhere to both surfaces of the nonwoven fabric polishing layer 2.
[0023]
【Example】
An abrasive belt is manufactured in the following steps.
[Example 1]
(1) A polyester fiber having a thickness of 44 dtex is laminated on the base material sheet 2 to a thickness of 5 mm without three-dimensional orientation, and a non-woven fabric is laminated on the base material sheet 2.
(2) The binder for binding the fibers 4 is sprayed on the surface of the nonwoven fabric to bond the fibers 4 at the contact points. However, this step can be omitted. This is because the contact points of the fibers 4 can be bonded with a binder to which the abrasive grains 5 are attached. Further, this step can be performed after the following step (3).
(3) The nonwoven fabric is connected to the base sheet 2 by needle punching.
(4) Apply a binder to adhere the abrasive grains 5 to the nonwoven fabric. The binder is sprayed and applied to the nonwoven fabric, or is immersed in the binder and then squeezed with two rolls.
(5) Spray the abrasive grains 5 with the binder uncured. The abrasive grains 5 are attached to the surface of the non-woven fiber 4 with a binder, or are attached to the gap between the fiber surface and the fiber 4.
(6) In a state where the binder is not completely cured, the laminate of the nonwoven fabric polishing layer 3 and the base sheet 2 is pressed by hot pressing as shown in FIG. In the hot press, the pressure of the pressing plate 7 is set to 150 ° C. and pressed for 15 minutes. The press pressure is 7 kg / cm ² .
(7) Then, after the binder is completely cured, both ends are connected and processed into an endless belt shape as shown in FIG.
[0024]
The polishing belt 1 of Example 1 manufactured by the above process has a cutting ability per unit time of about 1 as compared with the polishing belt 1 of the comparative example which is the same process except that the process (6) is omitted. Doubled and lifespan increased 2 to 3 times, and the total amount of cutting until the end of life was drastically improved to about 3 times. However, the grinding amount and life were measured by pressing a stainless steel plate with the same pressure.
[0025]
[Example 2]
(1) A polyester fiber having a thickness of 44 dtex is laminated to a thickness of 2 mm on a conveying sheet without three-dimensional directionality to produce a nonwoven fabric having a predetermined thickness.
(2) The binder for binding the fibers 4 is sprayed on the surface of the nonwoven fabric to bond the fibers 4 at the contact points. However, this step can be omitted. This is because the contact points of the fibers 4 can be bonded with a binder to which the abrasive grains 5 are attached. Further, this step can be performed after the following step (3).
(3) Apply a binder that adheres the abrasive grains 5 to the nonwoven fabric. The binder is sprayed and applied to the nonwoven fabric, or is immersed in the binder and then squeezed with two rolls.
(4) With the binder uncured, the abrasive grains 5 are sprayed on both sides of the nonwoven fabric. The abrasive grains 5 are attached to the surface of the non-woven fiber 4 with a binder, or are attached to the gap between the fiber surface and the fiber 4.
(5) In a state where the binder is not completely cured, the nonwoven fabric is pressed with a hot press as shown in FIG. In the hot press, the pressure of the pressing plate 7 is set to 150 ° C. and pressed for 15 minutes. The press pressure is 5 kg / cm ² .
(6) The nonwoven fabric polishing layer 3 adhered and pressed with the abrasive grains 5 produced in the above process is bonded to the base sheet 2 using an adhesive.
(7) After the adhesive is completely cured, both ends are connected and processed into an endless belt shape as shown in FIG.
[0026]
The polishing belt 1 of Example 2 manufactured by the above process has the cutting ability per unit time changed to the end as compared with the polishing belt 1 of the comparative example which is the same process except that the process (5) is omitted. The total cutting amount until the end of the life was drastically improved to about 5 times. However, the grinding amount and life were measured by pressing the stainless steel plate with the same pressure as in Example 1.
[0027]
【The invention's effect】
The present invention has the advantages that the cutting ability is remarkably improved and the life is extremely long as compared with a conventional non-woven fabric polishing belt. This is because the polishing belt of the present invention smoothes the surface of the nonwoven fabric polishing layer laminated on the base sheet by pressing the fiber so as to thermally deform the fiber in a heated state with a pressing plate. The polishing belt having this structure grinds an object to be polished with a smoothed surface. The smooth surface continuously contacts the object to be polished and cuts efficiently. Conventional nonwoven fabric polishing belts have fibers with irregularities on the surface, and the fibers are likely to get caught on the object to be polished. Therefore, cutting with a smooth cutting surface such as paper could not be performed. In addition, the fibers in the state of being easily caught on the surface were easily cut and worn, and the life was shortened. On the other hand, since the surface of the polishing belt of the present invention is heat-pressed to smooth the surface, there are no fiber irregularities on the surface, and the fibers are firmly bonded with high density. Can be improved dramatically.
[0028]
Further, the polishing belt of the present invention has an advantage that the lateral displacement can be extremely reduced even when the object to be polished is pressed on one side while being driven by a roll. This is because the nonwoven fabric polishing layer is hot-pressed. The hot-pressed nonwoven fabric polishing layer does not deform so as to be crushed even if the object to be polished is pressed against the surface. Therefore, unlike the conventional polishing belt, the substantial radius of the roll does not become unbalanced and does not shift laterally.
[0029]
Further, the polishing belt of the present invention has an advantage that it can effectively prevent internal peeling even when driven by a thin roll. This is because the nonwoven fabric polishing layer is pressed so as to be thin, and the fibers are firmly and integrally bonded. The abrasive belt having this structure has a feature that the inner side and the outer side do not peel even when repeatedly curved with a small radius of curvature, and the life can be remarkably increased even in this use state.
[Brief description of the drawings]
1 is a partially enlarged sectional perspective view of a polishing belt according to Example 1 of the present invention. FIG. 2 is a partially enlarged sectional perspective view of a polishing belt according to Example 2 of the present invention. Schematic showing the process of hot pressing with a pressing plate 【Explanation of symbols】
DESCRIPTION OF SYMBOLS 1 ... Polishing belt 2 ... Base material sheet 3 ... Nonwoven fabric polishing layer 4 ... Fiber 5 ... Abrasive grain 6 ... Roll 7 ... Pressing plate

Claims (10)

Thermoplastic fibers (4) with abrasive grains (5) on the surface are gathered in three dimensions without directionality, and with the pressing plate (7), the fibers (4) are thermally deformed to smooth the surface. A nonwoven fabric polishing layer (3) that is pressed at a temperature and time, and a base material sheet (2) connected in a state of being laminated on the nonwoven fabric polishing layer (3). A polishing belt having a total thickness of 1 to 10 mm including a base sheet (2) , wherein a laminate with a nonwoven fabric polishing layer (3) is connected in an endless belt shape. The polishing belt according to claim 1, wherein the non-woven polishing layer (3) is hot pressed to make the surface flat. Hot press pressing plate (7) With non-woven polishing layer (3) The polishing belt according to claim 2, wherein the belt is heated and pressed. The polishing belt according to claim 1, wherein the total thickness including the base sheet (2) is 2 to 5 mm. An attachment process in which abrasive particles (5) are attached to a nonwoven fabric in which the fibers (4) are gathered in three dimensions without orientation, and the nonwoven fabric to which the abrasive particles (5) are attached is thermally deformed by the fibers (4). comprising a heating press process to smooth the surface and pressed under a condition of heating to the temperature, the heat-pressed nonwoven fabric made of a bonding step of bonding the base sheet (2), a base sheet (2) A method for producing an abrasive belt having an overall thickness of 1-10 mm . The abrasive grains (5) are attached to the surface of the fiber (4) by spraying a binder added with the abrasive grains (5) on both sides of the nonwoven fabric in the attaching step of the abrasive grains (5). A method of manufacturing an abrasive belt. A laminating step of laminating a nonwoven fabric in which the fibers (4) are sterically non-directionally laminated on the base sheet (2), and a non-woven fabric laminated on the base sheet (2), the abrasive particles via a binder (5) adhering step and heating press step of smoothing the surface of the nonwoven fabric by pressing the nonwoven fabric adhering the abrasive grains (5) to a temperature at which the fibers (4) are thermally deformed. The manufacturing method of the abrasive belt which consists of these and makes the whole thickness containing the base material sheet (2) 1-10 mm . The method for producing an abrasive belt according to claim 7, wherein in the laminating step, the nonwoven fabric is needle-punched and laminated and connected to the base sheet (2). The method for producing an abrasive belt according to claim 5 or 7, wherein the surface is smoothed by pressing in a heated state in a state where the binder for adhering the abrasive grains (5) to the nonwoven fabric is uncured. The method for producing an abrasive belt according to claim 5 or 7, wherein the surface is smoothed by pressing in a heated state in a state where the binder for adhering the abrasive grains (5) to the nonwoven fabric is cured.

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