JP7105743B2 - Abrasive body manufacturing method - Google Patents

Description

The present invention relates to a method for manufacturing an abrasive body.

Patent Document 1 discloses a conventional method for manufacturing a polishing sheet as a polishing body. In this manufacturing method, first, a flexible sheet and a paste are prepared in the first step. The paste contains abrasive grains and a binder. The binder specifically contains a binder resin and a solvent. In the second step, the paste is regularly supplied onto the sheet by printing means such as screen printing to form a large number of uncured projections. At this time, as disclosed in Patent Document 2, it is conceivable to regularly supply the paste onto the sheet by a droplet jet printer. Then, in the third step, each uncured projection is cured to form a large number of polishing projections formed on the sheet.

The polishing sheet thus obtained comprises a sheet and a large number of polishing projections, and is used for polishing flat panel displays and the like.

JP 2006-136973 A JP 2017-205869 A

However, with the above-described conventional manufacturing method, each polishing protrusion cannot be formed with a high aspect ratio. Therefore, there has been a demand for a polishing body having higher durability and polishing ability.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a polishing body having excellent durability and polishing performance.

The method for producing a polishing body of the present invention comprises a first step of preparing a base material and a paste containing abrasive grains, a binder, and a viscosity modifier ;
a second step of regularly supplying the paste onto the substrate by a dispenser to form a large number of uncured projections;
a third step of curing each of the uncured protrusions to form a plurality of polishing protrusions formed on the base material ;
The binder comprises a binder resin,
The viscosity modifier is silica fine particles having an average particle size of 0.1 μm,
the paste has a viscosity of 80,000 to 500,000 cps;
The polishing convex portion has a truncated cone shape with a circular or polygonal top surface,
The aspect ratio of the height of the convex polishing portion from the base material/the width of the top surface of the convex polishing portion is set to 0.22 to 2.00 .

In the production method of the present invention , a paste in which the binder contains a binder resin, the viscosity modifier is silica fine particles having an average particle diameter of 0.1 μm, and the viscosity is 80,000 to 500,000 cps is adopted . In , since a dispenser is employed, an uncured convex portion with a high aspect ratio can be formed. For this reason, by curing the uncured protrusions in the third step, a truncated cone shape with a circular or polygonal top surface is formed, and the height from the substrate / the width of the top surface of the polishing protrusions High aspect ratio polishing protrusions having an aspect ratio of 0.22 to 2.00 can be formed.

Therefore, the production method of the present invention can produce a polishing body that can exhibit superior durability and polishing performance. In addition, in this manufacturing method, by changing the shape of the supply port of the dispenser, the shape of each polishing projection can be easily changed, and it is possible to easily manufacture a polishing body suitable for the purpose of use.

As the base material, it is possible to employ a rigid substrate in addition to a flexible sheet, film, or the like. As the sheet, a woven fabric or non-woven fabric made of fibers such as natural fibers, synthetic fibers, and carbon fibers can be used. The film may be a single layer or multiple layers made of synthetic resins such as polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), polyimide (PI), polyethylene naphthalate (PEN), aramid, etc., and metals such as aluminum and copper. Layers can be employed. A glass substrate, a ceramic substrate, a metal substrate, or the like can be used as the substrate.

Abrasive grains are alumina (Al ₂ O ₃ ), silica (SiO ₂ ), iron oxide (Fe ₂ O ₃ ), diamond, cerium oxide (CeO ₂ ), silicon carbide (SiC), boron carbide (B ₄ C). , titania ( _TiO2 ), barium carbonate ₍ BaCO3), chromium oxide ( _Cr2O3 ), zirconia ₍ ZrO2), _cubic boron nitride (cBN), silicon nitride _{( Si3N4} ), manganese oxide (Mn ₂ O ₃ ), barium sulfate (BaSO ₄ ), etc. can be employed. The grain size of the abrasive grains is appropriately selected according to the purpose of use of the abrasive body.

Binder resins such as polyester, polyvinyl chloride, polyvinyl acetate, polyacryl, polyvinyl alcohol, polyethylene, polyvinyl acetal, rubber, polyamide, phenolic resin, and vinyl chloride-vinyl acetate copolymer should be used as the binder. can be done. The binder resin can be a thermosetting resin or a photocurable resin. If a binder resin is employed as the binder, the paste may contain a solvent. As the solvent, toluene, xylene, methyl ethyl ketone, methyl isobutyl ketone, ethyl acetate, butyl acetate, ethanol, isopropyl alcohol, anone, Solvesso, etc. can be used depending on the type of binder resin. Pastes may also include viscosity modifiers, curing initiators, surfactants, dyes, pigments, plasticizers, wetting agents, and the like.

The paste contains a viscosity modifier that imparts suitable thixotropic properties to the uncured protrusions . Silica fine particles are used as the viscosity modifier .

According to the inventors' test results, the paste has a viscosity of 80,000 to 500,000 cps when the binder contains a binder resin and a solvent . If the viscosity of the paste is less than 80,000 cps, it is difficult for the aspect ratio of the polishing protrusions to be higher than that of the polishing protrusions obtained by printing. Further, when the viscosity of the paste is less than 80,000 cps, the angle α formed by the top surface and the side surface of the polishing protrusions is less likely to be larger than the angle α of the polishing protrusions obtained by printing. On the other hand, if the viscosity of the paste exceeds 500,000 cps, it is difficult to supply the paste with a dispenser, and the adhesion between the substrate and the polishing protrusions tends to be insufficient. More preferably, the paste has a viscosity of 150,000-200,000 cps. If the viscosity of the paste is within this range, the aspect ratio and angle α of the polishing projections are high, the adhesion between the polishing projections and the substrate is excellent, the polishing performance is high, and high durability and polishing performance are exhibited. It is possible.

The polishing body obtained by the present invention can achieve a high aspect ratio of each polishing protrusion, and therefore can exhibit excellent durability and polishing ability. In addition, since each uncured convex portion is formed by a dispenser, this polishing body can be manufactured appropriately according to the purpose of use.

The substrate is preferably made of a flexible sheet that can be impregnated with a binder resin. In this case, the sheet is impregnated with the paste of each uncured convex portion, and each polishing convex portion is formed in a state of being bitten into the sheet, so that the substrate and the polishing convex portion exhibit high adhesion.

An adhesion layer may be formed between the base material and each polishing convex part to adhere the base material and each polishing convex part. This adhesion layer is preferably made of a binder resin that constitutes a paste. In this case, since the binder resin of the paste of each uncured convex portion and the binder resin of the adhesive layer are likely to be strongly bonded to each other, each polishing convex portion is strongly bonded to the adhesive layer, and the substrate and the polishing convex portion are easily bonded. exhibits high adhesion.

According to the method for manufacturing a polishing body of the present invention, it is possible to manufacture a polishing body having excellent durability and polishing ability. In addition, since the polishing body obtained by the present invention can achieve a high aspect ratio of each polishing protrusion, it can exhibit excellent durability and polishing ability.

FIG. 1 is a partial plan view of the abrasive sheet of Example 1. FIG. 2 is an enlarged cross-sectional view of the main part of the polishing sheet of Example 1. FIG. 3 is a partially enlarged plan view of the polishing sheet of Example 2. FIG. 4 is a partially enlarged plan view of the polishing sheet of Example 3. FIG. 5 is a partially enlarged plan view of the polishing sheet of Example 4. FIG. FIG. 6 is an enlarged cross-sectional view of the main part of the polishing sheet of Example 5. FIG.

Hereinafter, the present invention will be embodied in a polishing sheet as a polishing body, and will be explained through tests. First, as a first step, a flexible sheet 1 was prepared as a base material. The sheet 1 is a woven fabric (thickness: 0.2 mm) of polyester fiber and cotton.

Also, pastes 1 to 11 whose compositions are shown in Table 1 were prepared. Pastes 1 to 4 are prepared for screen printing as a paste supply means, and pastes 5 to 11 are prepared for a dispenser as a paste supply means.

Here, phenol resin was adopted as the binder resin. Propanol was used as an organic solvent . The abrasive grains are alumina powder with D ₅₀ =5 μm. In addition, in order to impart thixotropic properties suitable for uncured convex portions to pastes 1 to 11, silica fine particles (average particle size 0.1 μm) as a viscosity modifier and an amide wax composition (manufactured by Kusumoto Kasei Co., Ltd.) ET7020) were prepared. These were blended in parts by weight shown in Table 1 and then thoroughly mixed to form pastes 1-11. The viscosities of pastes 1 to 11 are shown in Table 2.

A second step was then performed using pastes 1-11. At this time, as shown in Table 2, in Tests 1 to 4, the sheet 1 was placed horizontally, and each paste was regularly supplied onto the sheet 1 by screen printing to form a large number of uncured projections.

In Tests 5 to 11, the sheet 1 was placed horizontally, and each paste was regularly discharged onto the sheet 1 by a dispenser to form a large number of uncured projections. Each uncured protrusion in Tests 1-11 has a frusto-conical shape. The nozzle diameter and discharge pressure of the dispenser were changed according to the viscosity.

Then, as the third step, in Tests 1 to 11, each uncured convex portion was left at 80 ° C together with the sheet 1 to volatilize the solvent from each uncured convex portion, and the sheet 1 and each uncured convex portion were dried. did. Thereafter, the sheet 1 and each uncured projection were heated at 120 to 150° C. to thermally cure the phenolic resin, thereby curing each uncured projection. Thus, as shown in FIG. 1, a polishing sheet having a large number of polishing protrusions 3 formed on the sheet 1 was manufactured.

(Evaluation 1)
For the polishing sheets of Tests 1 to 11, as shown in FIG. asked. Also, the angle α (°) formed between the top surface 3a and the side surface 3b of the polishing convex portion 3 was obtained.

Furthermore, as the adhesion between the sheet 1 and the polishing projections 3, the force (N) when the polishing projections 3 are peeled off from the sheet 1 is measured by pressing 0.1 mm below the top surface 3a of the polishing projections 3 with a jig. A die shear test (Dage Japan) for measurement was performed. If the polishing projections 3 were peeled off from the sheet 1 at less than 20 N, the polishing projections 3 were peeled off from the sheet 1; When it was not peeled off, it was evaluated with ⊚.

Also, in order to evaluate the polishing ability of the polishing sheet, an oil film was formed on the glass substrate with an oil-based ink, and the oil film was removed with the polishing sheet. If the area removal rate of the oil film was 60% or less, it was evaluated by x;

Furthermore, the polishing ability after grinding the thickness of the polishing protrusions 3 in the polishing sheet to 90% or less was defined as the polishing ability after durability, and the initial polishing ability and the polishing ability after durability were obtained in the same manner as described above. If the initial area removal rate/area removal rate after durability is more than 0.8, the durability is low, and if the initial area removal rate/area removal rate after durability is less than 0.8, the durability is high. evaluated. These are also shown in Table 2.

As can be seen from Table 2, in the manufacturing methods of Tests 1 to 4, screen printing was adopted in the second step, so the aspect ratio of the polished protrusions was not so high. In addition, in the manufacturing methods of Tests 1 to 4, the angle α of the polishing convex portion is 50 to 65°. When polishing protrusions with aspect ratios of 0.20 and 0.22 are formed as in the manufacturing methods of Tests 1 and 4, adhesion is inferior and durability is also inferior.

On the other hand, in the manufacturing methods of Tests 5 to 11, since the dispenser is used in the second step, the polishing projections 3 having an aspect ratio of 0.22 or more can be formed. In addition, in the manufacturing methods of Tests 5 to 11, the angle α of the polished protrusions 3 is also 65° or more. This is because in the manufacturing methods of Tests 5 to 11, high-viscosity paste can be ejected to form uncured projections with a high aspect ratio.

However, as can be seen from Test 5, when the viscosity of the paste is 80,000 cps, the aspect ratio of the polishing projections 3 is equivalent to that of the polishing projections obtained by screen printing. Also, when the viscosity of the paste is 80,000 cps, the angle α of the polishing projections 3 is equivalent to the angle α of the polishing projections obtained by screen printing. On the other hand, as can be seen from Tests 10 and 11, when the viscosity of the paste exceeds 500,000 cps, the adhesion between the sheet 1 and the polishing projections 3 is insufficient. This is because it is difficult to supply the paste with a dispenser, so that the uncured protrusions are difficult to adhere to the sheet 1 .

As can be seen from Tests 7 and 8, when the viscosity of the paste is 150,000 to 200,000 cps, the aspect ratio and angle α of the polishing protrusions 3 are high, and the adhesion between the polishing protrusions 3 and the sheet 1 is high. It is excellent and can exhibit high durability and polishing ability.

Therefore, it can be seen that the polishing sheet manufacturing methods of Tests 5 to 11, particularly Tests 5 to 10, and more particularly Tests 7 and 8 can produce polishing sheets with superior durability and polishing ability. In addition, the polishing sheet obtained by these can realize a high aspect ratio of each polishing protrusion 3, and thus can exhibit excellent durability and polishing ability.

In the polishing sheets obtained in Tests 7 and 8, the sheet 1 was flexible and could be impregnated with the binder resin. Each polishing projection 3 is formed in a state of being bitten into the sheet 1. - 特許庁Therefore, these polishing sheets exhibit high adhesion between the sheet 1 and the polishing projections 3 .

(Evaluation 2)
As shown in Table 3, paste 7 was used to form polishing projections of various shapes by tests 7 and 12-14. In Test 7, as shown in FIG. 3, a square-pyramidal truncated polishing projection 5 was formed (Example 2). In Test 12, as shown in FIG. 1, a truncated conical polishing protrusion 3 was formed (Example 1). In Test 13, as shown in FIG. 4, a truncated triangular pyramid-shaped polishing convex portion 7 was formed (Example 3). In Test 14, as shown in FIG. 5, hexagonal frustum-shaped polishing projections 9 were formed (Example 4). The paste feeding means, the aspect ratios and the angles α of the respective polishing projections 3, 5, 7 and 9 in Tests 7 and 12-14 are the same.

Adhesion, polishing ability and durability were evaluated for each polishing sheet. In Test 7 and Tests 12 to 14, the manufacturing method and evaluation method were the same as above except that the shapes of the polishing projections were different. The results are also shown in Table 3.

As shown in Table 3, there is no significant difference in the properties of the polishing sheets due to the difference in the shape of the polishing projections.

(Evaluation 3)
As shown in Table 4, Paste 8 was used to perform Tests 8 and 15-19. In these cases, the aspect ratio was changed by increasing the discharge amount in the height direction of the uncured protrusions from the dispenser. The paste supply means for Test 8 and Tests 15-19 were the same, and the angle α of each polishing projection was 80°.

Each polishing sheet was evaluated for aspect ratio, adhesion, polishing ability and durability. In Test 8 and Tests 15-19, the manufacturing method and evaluation method were the same as above, except that the aspect ratios were different. The results are also shown in Table 4.

As shown in Table 4, it can be seen that even with pastes having the same viscosity, the aspect ratio can be controlled by adjusting the application conditions using the dispenser. Therefore, in the manufacturing method of the present invention, by changing the supply opening of the dispenser, it is possible to easily change the shape of each polishing projection and easily manufacture a polishing body suitable for the purpose of use. is.

(Example 5)
First, the sheet 1 was coated with the same phenolic resin as the binder resin of the pastes 1-11. After that, the second step and the third step were performed in the same manner as in Tests 7 and 8, and a polishing sheet of Example 5 was obtained. The phenolic resin on the sheet 1 serves as an adhesion layer 11 .

In this polishing sheet, the binder resin of the paste of each uncured convex portion and the binder resin of the adhesion layer 11 are firmly bonded to each other as the same resin. Each polishing projection 3 is strongly bonded to the adhesion layer 11 . Therefore, the sheet 1 and each polishing projection 3 exhibit high adhesion.

In the above, the present invention has been described in accordance with Tests 5 to 19 and Examples 1 to 5, but the present invention is not limited to the above Tests 5 to 19 and Examples 1 to 5, and deviates from the gist thereof. Needless to say, it can be appropriately changed and applied to the extent that it does not occur.

For example, in Tests 5 to 19 and Examples 1 to 4, the sheet 1 of the flexible blended woven fabric was used as the base material, but other woven fabrics and non-woven fabrics can be used as the base material. It is also possible to embody the invention in an abrasive disc with a rigid substrate of material.

Further, although the abrasive grains in Tests 5 to 19 and Examples 1 to 4 are alumina powder, it is also possible to adopt powders of silica, iron oxide, diamond, cerium oxide, and the like.

Also, various binder resins, solvents, and the like can be used.

INDUSTRIAL APPLICABILITY The present invention can be used for abrasive sheets, abrasive discs, and the like for cleaning flat panel displays and the like.

1... Base material (sheet)
3, 5, 7, 9... Polishing convex part 11... Adhesion layer

Claims (7)

A first step of preparing a base material and a paste containing abrasive grains, a binder, and a viscosity modifier ;
a second step of regularly supplying the paste onto the substrate by a dispenser to form a large number of uncured projections;
a third step of curing each of the uncured protrusions to form a plurality of polishing protrusions formed on the base material ;
The binder comprises a binder resin,
The viscosity modifier is silica fine particles having an average particle size of 0.1 μm,
the paste has a viscosity of 80,000 to 500,000 cps;
The polishing convex portion has a truncated cone shape with a circular or polygonal top surface,
A method for producing a polishing body, wherein an aspect ratio of the height of the convex polishing portion from the base material/the width of the top surface of the convex polishing portion is set to 0.22 to 2.00 . 2. The method for producing a polishing body according to claim 1, wherein said paste has a viscosity of 150,000 to 200,000 cps. 3. The method of manufacturing a polishing body according to claim 1, wherein the angle formed by the top surface and the side surface of the polishing protrusion is 65 to 85 degrees. 1. The paste comprises 100 parts by mass of the phenolic resin as the binder resin, 3 to 10 parts by mass of propanol, 175 parts by mass of the abrasive grains, and 13 to 15 parts by mass of the silica fine particles. 4. A method for producing a polishing body according to any one of items 1 to 3. 5. The method for producing a polishing body according to claim 4, wherein said propanol is 5 to 6 parts by mass. 6. The method of manufacturing a polishing body according to claim 1, wherein the base material is a flexible sheet that can be impregnated with the binder resin. 7. The method of manufacturing a polishing body according to claim 6, wherein the binder resin is applied to the substrate between the first step and the second step.

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