JP7274499B2 - Abrasive product comprising impregnated woven cloth and abrasive particles - Google Patents

Description

The present application relates to fabrics containing abrasive products.

Abrasive products are widely established and used in a variety of industries such as aerospace, automotive manufacturing, general industry, marine, metalworking, paint preparation, precision grinding and finishing, primary metals, thermal spray, transportation heavy equipment and wood. used in processing.

Abrasive products are usually covered with a polyester, cotton, or aramid backing, a fabric that can be, for example, a rubber, elastomer, thermoplastic, or thermoset material chemically or physically attached to the backing. and an overlying layer of various abrasive compounds and particles. Categories of abrasive products include, but are not limited to: wet/dry belts, files, narrow, portable, superabrasive and micro-finishing, wide and flat finishing belts and materials. Abrasive products may be in the form of pads, discs or belts.

Abrasive products inevitably experience high shear stresses during their use. Shear occurs due to the sticking of the backside of the abrasive product to the moving backing and due to friction between the front side, the abrading side of the abrasive product, and the surface of the application to be abraded. The two forces acting on the back and front sides of the abrasive product are in opposite directions, thus causing shear within the abrasive product. This shear can be unidirectional if the abrasive product is an abrasive belt that runs in a single direction while abrading the application being abraded. Shear may also be bi-directional, however, if the abrasive product is, for example, a pad that moves in two directions, particularly in an approximately circular motion across the application being abraded.

JP 2013-240839 A discloses a polishing cloth comprising a backing material which may be plain, twill or satin weave. The warp yarns are at least partially core-seed fibers. The cloth is used in abrasive belts.

JP 2011-093083 discloses a layered scouring pad comprising a multifilament hard twisted yarn fabric and its substrate having an Asker A hardness of 60. The fabric may be plain weave, twill weave or satin weave, with plain weave being preferred as it provides the strongest bond between the warp and weft threads.

WO 2012/042040 states that in coated abrasives in the form of ``sheets, belts, mop discs, flap discs'', if high performance is required to bind the abrasive, ``mainly phenolic resins are used', otherwise 'urea resins and also animal glues' are used, and for wet grinding 'epoxy, urethane or alkyd resins' are used.

U.S. Patent Application Publication No. 2010/0323574 discloses weft filaments extending to levels N1, N3, N5 and N7; warp fibers A, B and C woven with weft filaments; warp fibers G all having the same second weave pattern and woven with said weft filaments of levels N1, N3, N5 and N7. , H and I; additional weft filaments extending to levels N2, N4 and N6; and warp filaments D, J, E, K, F and L, not woven with any weft filaments. is disclosed. The fabric is for use in manufacturing composite material parts such as stays, rods and landing gear struts.

GB 1390603 discloses an upper and lower weft filament, a reinforcing wire (extending in the warp direction), running parallel to the reinforcing wire and not woven with said upper and lower weft filaments. , yarns extending like warp yarns, binder weft yarns woven with both said upper and lower weft filaments, and warp yarns woven only with said upper weft filaments or only with said lower weft filaments. A fabric is disclosed comprising: It also discloses a conveyor belt, including its fabric, impregnated with an elastomeric material, preferably PVC plastisol.

SUMMARY OF THE INVENTION The present invention seeks to provide improved fabrics for abrasive products and abrasive products containing them.

The present invention
[1]
a) a first layer (A) of first uncrimped weft multifilaments, running necessarily parallel to each other and separated from each other by a distance D;
b) a second layer (B) of second uncrimped weft multifilaments, running essentially parallel to each other and separated from each other by said distance D;
for each first uncrimped weft multifilament there is one corresponding second uncrimped weft multifilament and vice versa, forming a continuous multifilament pair; Each such consecutive multifilament pair can be designated by a unique and ascending integer index N;
c) the following weave patterns c1-c4:
around the first uncrimped weft multifilament of all multifilament pairs with an index N satisfying c1−(N mod 4)=0, such index N being represented by N _A entanglement; the first and second unwound of all multifilament pairs with index N satisfying (N mod 4)=1, such index N being denoted by _NB Threading between crepe weft multifilaments; the second non of all multifilament pairs with index N satisfying (N mod 4)=2, such index N being denoted by _NC entanglement around the crimped weft multifilament; and an index N satisfying (N mod 4)=3, such index N being the first of all multifilament pairs having an index N denoted by _ND threading between the and second uncrimped weft multifilaments;
_{or c2—entanglement around the second uncrimped weft multifilament of all multifilament pairs with said index N A ;} threading between the second uncrimped weft multifilaments; entanglement around the first uncrimped weft multifilaments of all multifilament pairs having said index N _C ; and all having said index N _D threading between the first and second uncrimped weft multifilaments of the multifilament pair of;
or c3-threading between the first and second uncrimped weft multifilaments of all multifilament pairs with said index N _A ; of all multifilament pairs with said index N _B entanglement around the first uncrimped weft multifilament; threading between the first and second uncrimped weft multifilaments of all multifilament pairs with said index N _C ; and said index N _D entanglement around the second uncrimped weft multifilament of every multifilament pair;
or c4-threading between the first and second uncrimped weft multifilaments of all multifilament pairs with said index N _A ; of all multifilament pairs with said index N _B entanglement around the second uncrimped weft multifilament; threading between the first and second uncrimped weft multifilaments of all multifilament pairs having said index N _C ; and said index N _D crimped warp filaments having one of the entanglement around the first uncrimped weft multifilament of all filament pairs having
d) uncrimped warp filaments passing between the first and second uncrimped weft multifilaments of every multifilament pair; and e) optionally the weave patterns c1, c2, c3 defined above. or c4; crimped antistatic warp filaments;
provided that there are crimped warp filaments of all four said defined weave types c1, c2, c3 and c4;
Here, said fabric does not comprise any other crimped warp filaments besides said crimped warp filaments and said optional crimped antistatic warp filaments.
Woven fabrics, including
[2] The fabric of [1] above, wherein each uncrimped warp filament is spaced in the weft direction from the next uncrimped warp filament by an even number of crimped warp filaments, said even number being at least two.
[3] The fabric of [1] or [2] above, wherein each uncrimped warp filament is sandwiched in the weft direction by two immediately adjacent crimped warp filaments.
[4] The crimped warp filaments of weave patterns c1 and c2 defined in [1] are always present in pairs and immediately adjacent to each other in the weft direction, and weave pattern c3 defined in [1]. and c4 crimped warp filaments are always present in pairs and immediately adjacent to each other in the weft direction.
[5] The fabric of one of [1] to [4], wherein the number ratio of said crimped warp filaments c) to non-crimped warp filaments d) is in the range of 4:1 to 12:1. .
[6] The crimped warp filaments c) and the non-crimped warp filaments d) are arranged in a repeating unit in the weft direction, and in the repeating units, the non-crimped warp filaments d) and the weave patterns c1, c2, A fabric according to any one of the above [1] to [5], wherein the c3 and c4 crimped warp filaments are always arranged in the same order in the weft direction.
[7] The fabric of one of [1] to [6] above, comprising said crimped antistatic warp filaments e).
[8] said first uncrimped weft multifilament a), second uncrimped weft multifilament b), crimped warp filaments c), uncrimped warp filaments d) and optionally crimped antistatic A fabric according to one of the above [1] to [7], consisting of warp filaments e).
[9]
i) the fabric of any one of the above [1] to [8] impregnated with an impregnation comprising or consisting of a thermoplastic resin, a thermoplastic elastomer, a thermoset resin, an elastomer or mixtures thereof;
ii) comprising or consisting of the same thermoplastic resin, thermoplastic elastomer, thermoset resin, elastomer or mixtures thereof as in the impregnation of said impregnated fabric immediately adjacent to one side of said impregnated fabric; An abrasive article comprising a first top layer having a first top surface that is free of fabric and iii) a first particulate abrasive embedded in the first top surface of said first top layer.
[10] The abrasive product of [9], which is an endless abrasive belt.
[11]
iv) containing the same thermoplastic resin, thermoplastic elastomer, thermoset, elastomer or mixture thereof as in impregnation (6) of said impregnated fabric immediately adjacent to the other side of said impregnated fabric or and v) a second particulate abrasive embedded in the second top surface of said second top layer; The abrasive product of [9].
[12]
i) the fabric of any one of the above [1] to [8] impregnated with an impregnation comprising or consisting of a thermoplastic resin, thermoplastic elastomer, thermoset resin or elastomer or mixtures thereof;
ii) optionally comprising or consisting of the same thermoplastic resin, thermoplastic elastomer, thermoset resin, elastomer or mixture thereof as in the impregnation of said impregnated fabric immediately adjacent to one side of said impregnated fabric; a first cover layer with no fabric;
iii) a first abrasive embedded in a first top sheet surface adjacent to one side of said impregnated cloth or, if said first cover layer is present, adjacent said first cover layer; An abrasive product comprising a first prefabricated abrasive sheet having a first top sheet surface containing particles.
[13]
iv) optionally comprising or consisting of the same thermoplastic, thermoplastic elastomer, thermoset, elastomer or mixtures thereof as the impregnation of said impregnated fabric immediately adjacent to the other side of said impregnated fabric; a second cover layer, but without fabric;
iv) embedded in said second upper sheet surface adjacent to the other side of said impregnated fabric or, if said second cover layer is present, adjacent said second cover layer; The abrasive product of [12] above, further comprising a second pre-manufactured abrasive sheet having a second upper sheet surface comprising second abrasive particles.
[14] The abrasive product of [12] or [13], which is an abrasive pad or an abrasive disc.
[15] The abrasive product of one of [11] to [14] above, wherein the impregnation comprises or consists of a thermoplastic resin or thermoplastic elastomer, in particular TPU.
I will provide a.

1-3 are schematic representations of embodiments of the fabric of the present invention, i.e., FIG. 1 as cross-section in the warp direction, FIG. 2 as top view, and FIG. containing only one crimped warp filament, either in 20° shear (Fig. 3, top) or in 20° shear (Fig. 3, bottom); 1-3 are schematic representations of embodiments of the fabric of the present invention, i.e., FIG. 1 as cross-section in the warp direction, FIG. 2 as top view, and FIG. containing only one crimped warp filament, either in 20° shear (Fig. 3, top) or in 20° shear (Fig. 3, bottom); 1-3 are schematic representations of embodiments of the fabric of the present invention, i.e., FIG. 1 as cross-section in the warp direction, FIG. 2 as top view, and FIG. containing only one crimped warp filament, either in 20° shear (Fig. 3, top) or in 20° shear (Fig. 3, bottom); FIG. 4 contains a schematic representation of a prior art fabric; Figure 5 contains a schematic representation of the inventive fabric of Figure 1 as a cross-section in the weft direction; 6 and 7 are schematic cross-sectional views of embodiments of an abrasive belt and an abrasive pad or disc, respectively, of the present invention, each comprising the fabric of FIG. 6 and 7 are schematic cross-sectional views of embodiments of an abrasive belt and an abrasive pad or disc, respectively, of the present invention, each comprising the fabric of FIG.

The present invention provides a matrix of thermoplastic, thermoset or elastomeric materials or mixtures thereof that directly permeates the woven and bonded layers of a unidirectionally reinforced, multi-layered woven fabric component. The use of a matrix is provided and the fabric is embedded and entangled in the matrix, providing a fully impregnated physical entanglement of the matrix and fabric. Such entanglement aids in minimizing layer separation, through good abrasion properties, improves the bonding/adhesion properties of the polymer matrix and resistance to product penetration/strike problems, generally improving belt performance and service life. . On the other hand, it offers good integration and dimensional flexibility.

The movement of the abrasive product of the present invention onto the product being abraded can be in either the warp or weft direction of the fabric, or both. In one specific embodiment, the movement may be approximately or exactly circular. The inventive fabrics and the inventive abrasive products containing them exhibit equally good resistance to shear delamination when the shear is in either the warp or weft direction. This is surprising because the fabrics of the present invention differ in both the weave structure and filament density in the warp direction from the weave structure and filament density in the weft direction. Differences in fabric construction, for example, because one of the directions of the fabric (warp or weft direction, typically warp direction) must also meet the requirements of the traction layer in the abrasive belt; No demand is necessary in the other direction (weft or warp direction, typically the weft direction). From the sole point of view of equally good resistance to shear delamination in both the warp and weft directions, fabrics having the same weave structure and filament count in the warp and weft directions may be highly preferred.

Because the fabrics of the present invention provide equally good resistance to shear delamination in either the warp or fill direction, the abrasive product of the present invention for the primary, or sole, direction of abrasive motion. The orientation of the fabric in is not critical. When the abrasive product is, however, an abrasive belt, the warp direction of the fabric is preferably the direction of travel of the belt.

A possible theoretical explanation for the increased resistance to shear delamination in the warp direction of the fabrics of the present invention is provided with reference to FIGS. 1-4. The fabrics of the present invention primarily provide good resistance to shear delamination in the weft direction. This is because the weft filaments are all multifilaments intermeshed with impregnations adhering to them more closely than possibly single filaments. A possible further theoretical explanation for the improved resistance to shear delamination in the weft direction is provided with reference to FIG.

In the fabrics of the present invention, all uncrimped weft filaments are multifilaments (hereinafter referred to as "uncrimped weft multifilaments"). The non-crimped weft multifilament preferably consists of polyester, eg PET. The titer of the uncrimped weft multifilament, especially when made of polyester, eg PET, preferably ranges from 670 to 2100 dtex. Also preferably, the tensile strength of the uncrimped weft multifilament is preferably in the range 15-250 cN/tex, more preferably in the range 30-100 cN/tex and very preferably in the range 60-80 cN/tex. Also preferably, their heat shrinkage (percentage reduction in length under heating at 180° C. for 2 minutes) is 0.5-15%, more preferably 0.5-5% and very It is preferably in the range of 1-2%. Also preferably, the uncrimped weft multifilament may preferably have some or S- or Z-twist, or no twist, and the number of turns per meter is preferably from 0 to 50, more than It preferably ranges from 0-30 and very preferably from 0-10. The uncrimped weft multifilament is optionally stapled by, for example, the known "core-spinning" process (see, for example, US Pat. No. 2,992,150) to further enhance the adhesion to it of the impregnation. It may be spun with fibers such as polyester or natural fibers such as cotton. Preferably, however, said uncrimped weft multifilament is free of such staple fibres. Said impregnation adheres well to such weft multifilaments even in the absence of staple fibers, thanks to the overall fabric of the invention.

The fabric of the present invention comprises first and second uncrimped weft multifilaments of the type described above. For each first uncrimped weft multifilament there is one corresponding second uncrimped weft multifilament and vice versa, forming a continuous multifilament pair. , each of which can be assigned an integer index N. This index N is arbitrary, provided that the integer N increases with the order of successive multifilament pairs in the warp direction. The index N may be in the range N _min to N _max , where N _min is the smallest possible index typically assigned to the first multifilament pair of the fabric example in question; N _max is typically the highest possible index assigned to the last multifilament pair of the fabric example in question. Whether a given index N is assigned to the name N _{A ,} N _B , N _C or N _D depends on the result of the modulo-4 operation done on N, so-called according to 4 as used herein. It is the remainder obtained by "Euclidean integer division" of N.

The crimped warp filaments are all preferably also multifilament, spun yarns or combinations of multifilament yarns and staple fibers spun together by the commonly known "core-spinning" process. Any such crimped warp filaments are preferably free of natural fibres, such as cotton, jute, hemp or cellulosic fibres. The impregnation provides sufficient adhesion of the fabrics of the present invention even without such natural fibers. The crimped warp filaments are preferably made of polyester, eg PET. The titer of the crimped warp filaments is preferably in the range from 550 to 2000 dtex, especially when made of polyester, eg PET. Also preferably, the tensile strength of the crimped warp filaments is preferably in the range 15-250 cN/tex, more preferably in the range 15-40 cN/tex and very preferably in the range 20-30 cN/tex. Also preferably, their thermal shrinkage (percentage reduction in length under heating at 180° C. for 2 minutes) is 0.5 to 15%, more preferably 5 to 15% and very preferably It is in the range of 8-12%. Also preferably, the crimped warp yarns may preferably have an S- or Z-twist, the number of turns per meter being preferably from 0 to 400, more preferably from 250 to 400 and very preferably is in the range of 300-400. Alternatively, their degree of twist may preferably range from 5 to 15%, more preferably from 7 to 13% and very preferably from 9 to 11%.

The crimped warp filaments have one of four different weave types c1-c4. These four weave patterns are as in Table 1 below, using the indices N _A -N _D defined above for the multifilament pair in question:

That is, said weave patterns c1, c4, c2 and c3 are the entanglement around the first uncrimped weft multifilament, the threading between the first and second uncrimped weft multifilaments, the second uncrimped weft multifilament For indices N _A , N _B , N _C and N _D as the entanglement around the weft multifilament and the threading between the first and second uncrimped weft multifilaments proceeds c1-c4-c2-c3: The only difference is that they are sorted circularly.

For the fabric of the invention, the crimped warp filaments of said weave types c1 and c2 always appear in pairs and are immediately adjacent to each other in the weft direction, and that the crimped warp filaments of said weave types c3 and c4 , always appear in pairs and are immediately adjacent to each other in the weft direction.

The fabric of the present invention comprises crimped warp filaments of all the aforementioned weave types c1-c4. Preferably it contains an equal number of crimped warp filaments of each of the four weave types c1, c2, c3 and c4, and more preferably also an equal number within each repeating unit described above.

The non-crimped warp filaments are all preferably multifilaments or a plurality of such multifilaments, eg, 3-8 such multifilaments, which are aligned parallel to each other and immediately adjacent. The non-crimped warp filaments preferably consist of polyester, especially PET, or aramid. The titer of the uncrimped warp filaments (or the sum of the titers of all multifilaments if multiple multifilaments are present) preferably ranges from 500 to 5000 dtex. More preferably, when the uncrimped warp filaments are made of polyester, such as PET, their titer (or the sum of the titers of all of them if multiple multifilaments are present) is in the range of 550 to 2000 dtex. if they are made of aramid their titer (or the sum of the titers of all of them if multiple multifilaments are present) more preferably ranges from 440 to 3500 dtex. Also preferably, the tensile strength of the non-crimped warp filaments (or the total tensile strength of the whole when multiple multifilaments are present) is preferably in the range of 15 to 250 cN/tex, more preferably 30 to 100 cN/tex. and very preferably between 60 and 80 cN/tex. Also preferably, their heat shrinkage (percentage reduction in length under heating at 180°C for 2 minutes) is 0.5-15%, more preferably 0.5-5% and very preferably in the range of 1-2%. Also preferably, the uncrimped warp multifilament may preferably have some S- or Z-twist, or no twist, and the number of turns per meter is preferably from 0 to 400, more preferably is in the range 50-300 and very preferably 70-140.

For the fabric of the present invention, the crimped warp filaments and the non-crimped warp filaments are present in repeating units in the weft direction, the crimped warp filaments having a weave pattern c1, the crimped warp filaments having a weave pattern c2, the weave More preferably, the order in which the crimped warp filaments having the pattern c3, the crimped warp filaments having the weave pattern c4, and the non-crimped warp filaments are arranged in the weft direction is always the same.

Preferably also, each non-crimped warp filament is spaced in the weft direction from the next non-crimped warp filament by an even number of crimped warp filaments, the even number being at least two. More preferably here, any immediately adjacent crimped warp filaments have either the c1/c2 weave type or the c3/c4 weave type described above.

More preferably also each non-crimped warp filament is sandwiched in the weft direction by two immediately adjacent crimped warp filaments. That is, two continuous uncrimped warp filaments are preferably never directly adjacent to each other in the weft direction; between them there is preferably always at least one, preferably two (see above) crimped warp filaments. do.

There are typically 4 to 12 crimped warp filaments per uncrimped warp filament, with a specific ratio of 12:1 being particularly preferred for multiples that are parallel and immediately adjacent to each other. This applies to the above embodiments of the non-crimped warp filaments that are filaments of Another highly preferred embodiment is a 4:1 ratio of crimped warp filaments to non-crimped warp filaments.

In one specific preferred embodiment of the fabric, the ratio of crimped warp filaments to non-crimped warp filaments may be 4:1. When these warp filaments occur in repeating units, the order of the filaments in these repeating units is always the same, an exemplary such order being C(c1)-C(c2)-UC-C (c3)-C(c4) or any cyclic permutation thereof, where C represents crimped warp filaments and UC represents uncrimped warp filaments, and the weave pattern is indicated in brackets.

In another preferred embodiment of the fabric, the ratio of crimped warp filaments to non-crimped warp filaments may be 12:1. The order of the filaments is always the same when the warp filaments occur in a repeating unit in which an exemplary such order is C(c3)-C(c4)-C(c1)-C(c2)-C( c3)-C(c4)-UC-C(c1)-C(c2)-C(c3)-C(c4)-C(c1)-C(c2) or any cyclic permutation thereof, wherein where C and UC are as previously described and the weave pattern is indicated in brackets.

Said uncrimped weft yarns, crimped warp yarns and uncrimped warp multifilaments may all preferably be in the form of bicomponent fibres. A subclass of such composite fibers are those in which a plurality of filaments of a high melting point polymer are combined with a plurality of filaments of a low melting point polymer; It is a thing. Here, "high melting point" and "low melting point" are relative to each other. The purpose of such bicomponent fibers is that they are heated so that only the low melting point material is softened, along with the melting multifilaments, especially at their overcross portions, either during or after weaving. be,. Upon cooling again, the fabric exhibits increased resistance to deformation under shear and thus to shear delamination due to the binding hot melt adhesive in the overcloth portion.

An example of a composite fiber in which multiple filaments of a high melting point polymer are embedded in a low melting point polymer is a so-called "sea-island" filament; are "core-seed" fibers with a core:seed weight ratio of, for example, 50:50 to 80:20; either concentric or eccentric. Preferred are said core-sheath bicomponent fibers, which are of the highly preferred concentric type.

The difference in melting point or melting interval can be controlled, for example, by having the same type but two different molecular weights, or by two chemically different but interchangeable polymers. Examples of polymeric material pairs for high-melting and low-melting polymers are eg high and low molecular weight polyesters, especially PET; polyesters and polyamide-6,6; polyamide-6,6 and copolyesters.

Combining two different types of polymers in one composite multifilament results in self-curling or self-crimping of the composite fiber, which is undesirable for purposes of the present invention. To counteract that, in the cross-section of the bicomponent fibers, they should have at least approximately Cn symmetry (whose axis of rotation runs along the central axis of the bicomponent fiber and n is an integer equal to or greater than 2). Preferably, the two plurality of filaments are uniformly distributed so as to have; or the regions of low melting point polymer are uniformly distributed or arranged. In the highly preferred case of concentric core-seed bicomponent fibers, n can be infinite.

These types of bicomponent fibers, as such, are all conventional and well known in the art.

The fabrics of the present invention may optionally comprise crimped antistatic warp filaments of one of the above defined weave types c1-c4. These antistatic filaments are preferably spun yarns, for example of carbon fibre, or conductive polyester, cotton , nylon or aramid fibers. Such conductive fibers are conventional as such. The tensile strength of the crimped antistatic warp filaments is preferably in the range 15-250 cN/tex, more preferably in the range 15-40 cN/tex and very preferably in the range 20-30 cN/tex. Also preferably, their thermal shrinkage (percentage reduction in length under heating at 180° C. for 2 minutes) is 0.5 to 15%, more preferably 5 to 15% and very preferably It is in the range of 8-12%. Also preferably, the crimped antistatic warp filaments may preferably have an S- or Z-twist and the number of turns per meter preferably ranges from 0 to 400 and more preferably from 100 to 400. is. More preferably, there is exactly one crimped antistatic warp filament separated by every four consecutive uncrimped warp filaments.

In the warp direction, the fabric of the present invention comprises, in addition to crimped warp filaments having one of said weave patterns c1, c2, c3 or c4 and optionally crimped antistatic warp filaments, other types of warp filaments. Contains no crimped filaments. More preferably, the fabric of the present invention comprises, in addition to crimped warp filaments having a weave pattern c1, c2, c3 or c4 and optionally crimped antistatic warp filaments and non-crimped warp filaments, in the warp direction: Does not contain other types of filaments. In the weft direction, the fabric of the invention preferably does not comprise other filaments besides the non-crimped first and second weft filaments. Very preferably, the fabrics of the present invention comprise, in addition to non-crimped first and second weft filaments, non-crimped warp filaments, crimped warp filaments and optionally crimped antistatic warp filaments, other does not contain any filaments.

If the warp filaments occur in repeating units, the order of the filaments in these repeating units being always the same, and crimped antistatic warp filaments are also present, preferably also these crimped antistatic warp yarns Filaments are always included in the same position in the repeating unit. Apart from that, their number and position(s) in the repeating unit are arbitrary. There is preferably one such crimped antistatic warp filament per repeat unit.

The fabric tension of the entire fabric is preferably in the range of 4000-8000 N/50 mm, more preferably 5000-7000 N/50 mm in the warp direction, preferably 6000-9000 N/50 mm, more preferably 6500-8500 N/50 mm in the weft direction. 50 mm range.

The fabrics of the present invention, impregnated with thermoplastic resins, thermoplastic elastomers, elastomers or thermosetting resins, may be precursors to abrasive products of the present invention.

As said impregnation, the thermoplastic resin is preferably a thermoplastic polyolefin (eg polyethylene or polypropylene), a substantially random ethylene/C3-12-α-olefin copolymer (examples of α-olefins are 1-propene, 1 -butene, 1-pentene, 1-hexene and 1-octene), thermoplastic polyamides, ethylene-vinyl acetate copolymers, poly(vinyl acetate) and PVC.

As said impregnation, the thermoplastic elastomer is preferably a block copolymer of a thermoplastic elastomer, such as a styrene block copolymer, especially styrene-butadiene-styrene, styrene-isoprene-styrene, styrene-ethylene/butylene-styrene and styrene-ethylene/propylene. -styrene block copolymers), copolymers of hard blocks of medium density polyethylene and soft blocks of ethylene/α-olefin copolymers, thermoplastic polyurethanes (e.g. copolymers of polyester diols or polyether diols and diisocyanates), polyethers- /ester block amides and thermoplastic elastomer ionomers.

As said impregnation, the thermosetting resin is, for example, a phenol-formaldehyde resin, a thermosetting polyurethane, an epoxy resin, or a polycarboxylic acid, such as a glycol, such as poly(meth)acrylic acid crosslinked with glycerol. good.

The impregnated elastomer is, for example, polyurethane, natural rubber, polyisoprene, polybutadiene, styrene-butadiene rubber (SBR), nitrile-butadiene rubber (NBR), ethylene-propylene-diene rubber (EPDM) or acrylate rubber. good. All these may be crosslinked or vulcanized during or after the impregnation step, preferably simultaneously. The elastomer may have been previously mixed with a thermoplastic resin, as explained above.

Said impregnation preferably consists of a thermoplastic elastomer, more preferably TPU. Suitable TPUs can be obtained by reacting diisocyanates containing hard block segments with soft block segments of polyester diols.

Such impregnated fabrics may be obtained, for example, by the following steps:
a) providing a fabric of the invention;
b) one side of the fabric typically using a suitable solvent such as DMF, acetone, dimethylsulfoxide or a solution thereof in others and a suitable painting method such as air knife , air knife, or kiss-roller or transfer coating to seal with a relatively thin layer of thermoplastic resin or thermoplastic elastomer;
c) optionally under heat or other type of irradiation and/or reduced pressure to evaporate said solvent to provide a thin primer of thermoplastic resin or thermoplastic elastomer on the side of the fabric in question; the paint is still porous and gas permeable;
d) applying to the opposite side of said fabric a relatively thin film coating of a thermoplastic, thermoset or elastomer or mixture thereof as in a base coat, e.g. by calendering or extruding; The fabric is pushed and pushed through until it encounters the primer; the trapped gas escapes through the primer, thereby obtaining an impregnated fabric.

The resulting impregnated fabric will typically have impregnated material on both sides of the fabric of the present invention, with the filament portion of the fabric not exposed to the environment. On one side of the fabric, the fabric will form a continuous layer of geometrically well-defined surface, which will completely embed the fabric. This continuous layer may also preferably comprise a first top layer which consists entirely of impregnated material and is completely free of fabric. This first top layer, when the methods described above are used, is usually applied by calendering or extruding a relatively thick film coating of thermoplastics, thermosets, elastomers or mixtures thereof. on the fabric side. The thickness of this first top layer, if present, is represented by D _i and typically ranges from 100 to 500 micrometers. If present, the first top layer will form said geometrically well-defined surface. The thickness D _i may be determined using ultrasound reflections. That is, a suitable ultrasound probe may be placed on said geometrically well-defined surface. The time difference between the emission of an ultrasonic pulse from the probe onto the belt and the detection of the first ultrasonic echo (reflected from the surface of the implanted fabric) can be measured. If the longitudinal velocity of the sound wave in the thermoplastic or thermoplastic elastomer used is known, D _i can be determined. Regarding the longitudinal velocity of sound waves in thermoplastic resins or thermoplastic elastomers used, see, for example, James E. et al. Mark, "Physical Properties of Polymers Handbook", 2nd Edition, Chapter 60 "Acoustic properties of polymers", Table 60.1 thereof, and references cited therein. Such belt thickness measuring devices and suitable probes are known in practice and commercially available. An example is the 38DL Plus from NDT Instruments, which has a single element modulator as the probe.

Optionally, and as an optional step e) in the process described above, a sheet of the same thermoplastic, thermoset, elastomer or mixture thereof as used in said impregnation is added to the other side of the impregnated fabric. It can be laminated or calendered on the side. In the method described above, this is the side that was originally sealed with a relatively thin layer of thermoplastic, thermoset, elastomer or mixture thereof. This then forms an optional second top layer with a second geometrically well-defined top surface on the other side of the fabric.

Abrasive products of the present invention comprise at least one type of particulate abrasive. Particulate abrasive(s) are conventional as such. Examples of abrasives include, without limitation, alumina (e.g., fused aluminum oxide, including brown aluminum oxide, heat treated aluminum oxide, and white aluminum oxide; ceramic aluminum oxide; corundum; ruby; sapphire; or doped alumina), refractory carbides (e.g. silicon carbide; boron carbide; tungsten carbide; titanium carbide or cementite ( _Fe3C )), refractory nitrides (e.g. boron nitride, titanium nitride, silicon nitride, zirconium nitride; tungsten nitride; vanadium nitride; chromium nitride tantalum nitride or niobium nitride), chroma, alumina zirconia, diamonds, iron oxides, titanium diboride, ceria, garnet (e.g. pyrope; almandite; manganese garnet; glauco (-) garnet and ash) garnet), powdered glass, metal particles and combinations thereof. The abrasive particles are typically 0.01 to 30 micrometers, preferably 0.05 to 10 micrometers, and more preferably 0.1 to 5 micrometers, as obtained by laser diffraction determination of particle size distribution. may have a mass median diameter (MMD) ranging from The abrasive particles may typically have a Mohs hardness of at least about 7, preferably at least 8.

Abrasive products of the present invention may be prepared by providing an impregnated cloth as described above and applying a particulate abrasive material as described above. This may be done in several ways.

In a first preferred embodiment, the abrasive product comprises abrasive particles embedded in the top surface(s) of the top layer(s) itself. The material of the impregnation and therefore of the upper layer(s) is a thermoplastic, a thermoset, an elastomer or a mixture thereof, thus softening or melting on heating. The top surface(s) of the top layer(s) may alternatively be softened by being uniformly heated almost to their (their) melting point, for example by an array of IR lamps. Upon heating, the particulate abrasive is sprayed or dusted onto the softened surface(s), for example, by electrostatic spraying. Alternatively, the abrasive particles may be electrostatically sprayed onto the still cold top surface(s), which is passed through heated calender rolls while simultaneously applying a thermoplastic, thermoset, elastomer or mixture thereof. and embed abrasive particles in the softened surface(s). In either of these two alternatives, after cooling, an abrasive product is obtained having abrasive particles directly embedded in the top surface(s). The total thickness of each abrasive-containing upper layer, D _i ', may also be determined using ultrasonic reflections, as outlined above, for the upper layer still free of abrasive particles. When the abrasive particles are very small relative to the expected thickness of the top continuous top layer containing the abrasive, for example, their mass median diameter (MMD, see above) is between 0.01 and 0.5. In the micrometer range, the time difference between the generation of the ultrasound pulse and the echo reflected from the surface of the embedded fabric can be obtained. D _i ' is substantially the same as D _i described above. If the abrasive particles are large MMDs, the ultrasonic probe will be at the apex of the abrasive particles, but not directly on the outer surface. In this case, the time difference between the first echo reflected from the outer surface and the second echo reflected from the surface of the embedded fabric can be obtained.

When the particulate abrasive is directly embedded in the thermoplastic, thermoset, elastomer or mixtures thereof contained in the upper layer(s) outlined above, under shear stress, the inventive fabrics Optimizing the impregnation for enhanced resistance to delamination. This is because there are no additional layers and thus no other possible delamination concerns during polishing use.

A second preferred method for obtaining the abrasive particles of the present invention is to apply one or two prefabricated sheets containing abrasive particles, as described above, to said impregnation (the same thermoplastic or thermal material as in the impregnation). to one or both sides of the top layer(s) of plastic elastomer (if no top layer(s) are present) or to the surface(s) of the top layer(s) if such top layer(s) are present. That is. By including abrasive particles in the form of pre-manufactured sheets containing them, we take advantage of the variety of sheets available in the market, having experience with each step in manufacturing them with the desired uniformity. can be possible. It can also impart additional mechanical rigidity to the abrasive product which is beneficial in terms of good abrasive action on the substrate being polished.

In this second embodiment, the term "applying a prefabricated sheet containing abrasive particles" firstly refers to heat and pressure, e.g. Impregnated cloth/optional top layer(s) and prefabricated polish, which can act as an adhesive, or in conjunction with further thermoplastic or thermoset resin or elastomeric adhesives or adhesive primers It is understood to mean the bonding of the compounds of the sheet. Second, simply laying the prefabricated abrasive sheet on top of the impregnated cloth/optional top layer(s) compound without effecting any physical or chemical bonding between them; It is understood to mean obtaining an abrasive product of the present invention that can easily replace the pre-manufactured abrasive sheet once worn or torn.

As in the first previously described embodiment, each optional first and second top layer(s) will also have thicknesses D _i1 and D _i2 , respectively, such that each first and the prefabricated sheet containing the second abrasive particles will have thicknesses D _i1 ′ and D _i2 ′, respectively. Each of these thicknesses is also measurable by ultrasound, as described above, but this also applies in particular to the impregnation and optional first and second top layer(s) of the thermoplastic resin or This is because the thermoplastic elastomer usually differs from the matrix material of the pre-manufactured abrasive sheet(s) and additional ultrasonic echoes are obtained at each interface.

The term "prefabricated sheet containing abrasive particles" can mean any planar sheet material, eg, in the form of sheets, ribbons, tapes or discs. These pre-manufactured sheets comprise abrasive particles embedded in a plastic, e.g. typically polyester, support, optionally with the use of an adhesive, or may be of the sandpaper type. . The latter is particularly preferred for said abrasive particles that are not physically or chemically bonded to the compound of the impregnated cloth/optional top layer(s).

When a prefabricated abrasive sheet is bonded to an impregnated fabric/optional top layer(s) compound, the resulting abrasive product's resistance to delamination under shear during use depends on the impregnation. It can be similar to that in the first method outlined above, which directly embeds the abrasive particles.

If the pre-manufactured abrasive sheet is simply applied to the impregnated cloth/optional top layer(s) compound with no physical or chemical bonding, the adhesion between them during use in abrading is Due to the pressure that the abrasive product typically exerts against the surface of the product being abraded, utilizing the static coefficient of friction between the impregnated surface and the bottom side of the prefabricated abrasive sheet. occur. If the bottom side has noticeable surface roughness or surface unevenness, e.g. due to explicit surface probing or embossing, then during use in polishing the uneven bottom surface will eventually become impregnated or top surface. It can begin to conform to the surface of the upper continuous top layer: its use in polishing generates frictional heat, and the impregnation, which is of medium Shore A hardness at room temperature and softens with the application of heat, eventually deforms slightly. It will conform to the uneven bottom surface.

There are many companies on the market that provide abrasive particles and/or pre-manufactured abrasive sheets, for example Minnesota Mining & Manufacturing (USA), D.L. K. Holdings Limited (UK), KGS Diamond International AG (Netherlands, Portugal) and SIA Abrasives (Switzerland).

In any of the foregoing embodiments, the abrasive particles, whether used as such or in the form of pre-manufactured abrasive sheets, may ultimately cover only the outer surface portion of the abrasive product of the present invention. . Sections of the outer surface not covered by abrasive particles or abrasive sheets may constitute recessed channels through which abraded material and/or excess frictional heat may be removed. Furthermore, if only a portion of the outer surface is covered, the pressure exerted on the surface of the product being polished increases by the reciprocal of that portion if the rest of the parameters of the polishing process remain unchanged.

The overall thickness of the abrasive product of the invention, D _tot , typically ranges from 0.5 to 5 mm, preferably from 1 to 3 mm. The thickness D _tot can be measured with conventional measuring equipment, if necessary by applying a weak overpressure of eg 0.2 bar.

Abrasive products of the present invention can have any necessarily sheet-like shape with sufficient surface area, for example, capable of abrading a sufficient portion of the surface of the product being abraded. The abrasive product may be used flat or rolled up into a cylinder. The abrasive product may be manual or powered, for example by a power drill having a circular rubber backing disc on which the abrasive product of the invention is fixed or rests. good too. Preferably, it has the shape of an abrasive belt or of an abrasive disc or pad. In the abrasive belts of the present invention, the abrasive particles are embedded directly in the uppermost surface of the fabric-free top layer, which preferably consists of the same thermoplastic or thermoplastic elastomer as the impregnation in the fabric (see above). Abrasive belts normally operate like normal conveyor belts, ie in an endless configuration using driven and idler pulleys. For the abrasive belt of the present invention, it preferably has an abrasive particle coating only on one side and not on the other side facing said pulley. The abrasive belts of the present invention comprise thermoplastic resins or thermoplastic elastomers and can be any conventional adhesive for conveyor belts while using thermoplastic resins, thermoset resins, elastomers or mixtures thereof as hot melt adhesives. can be made endless by end-joining techniques such as the so-called "finger end" or overlap-joining techniques. The abrasive pad is preferably planar and preferably has a square, rectangular, triangular or arc segment or circle segment shape and preferably also has a rounded tip. The abrasive discs of the present invention preferably have a necessarily or exactly circular shape and are preferably intended for use in circular rubbing motions. In the polishing pads or discs of the present invention, abrasive coatings are applied to one or both sides of the impregnated cloth; preferably they are applied to only one side thereof. The abrasive coating is preferably applied in the form of a prefabricated abrasive sheet either directly to the impregnated cloth or to a non-fabric cover layer of the same material as the impregnation.

Abrasive products of the present invention can have a wide variety of applications, depending on the abrasive material and shape involved. Non-limiting examples include deburring (e.g. inner diameter deburring), blending (e.g. corner blending), buffering, dechroming, cleaning, coating removal, descaling, polishing (e.g. drum polishing; edge polishing; mold sanding; wide belt sanding; portable belt sanding or stroke sanding), edge chamfering, edge sewing, finishing (e.g. contour finishing; fine finishing; flat area finishing; intermediate finishing; stainless steel finishing; straight brush finishing; super finishing; finishing or transmission micro-finishing), gate removal, grinding (e.g. high pressure grinding; light grinding; plate grinding; right angle grinding; sheet grinding; oscillating frame grinding; slab grinding or centerless & cylindrical grinding); Descaling, parting line removal, polishing (eg, plate polishing; internal polishing; sheet or coil polishing), metal preparation prior to painting, radiusing, polishing, particle setting, machining, and the like.

The resistance to delamination of the fabric of the present invention when used in an abrasive product and the abrasive action is in the warp direction of the fabric is illustrated with reference to FIGS. 1-4.

Figures 1 (cross-sectional view) and 2 (top view) illustrate exemplary fabrics of the present invention. The fabric comprises uncrimped warp filaments 1, first and second uncrimped weft multifilaments (shown in cross-section in FIG. It has crimped warp filaments 41-44. For each first uncrimped weft multifilament 301 or 302 or 303 or 304 or 305 or 306 or 307 or 308 one corresponding second uncrimped weft multifilament 309 or 310 or 311 or 312 or 313 or 314 or 315 or 316 and vice versa, continuous multifilament pairs 301/309, 302/310, 303/311, 304/312, 305/313, 306/314, 307/ 315, 308/316 are formed. Each of these consecutive multifilament pairs can be designated by an integer index; for example, according to Table 2 below:

FIG. 3 is a schematic side view of the crimped warp filaments 41 of the fabric of FIG. 1, one without shear and one with 20° shear (bottom of FIG. 3). The crimped warp filaments 41 have a descending filament portion of length V (indicated by numeral 411) and an ascending filament portion of length W (indicated by numeral 412). where W=V in the non-shear state.

If the fabric is shearing, the rising filament portion 412 will be under tension. However, if the uncrimped warp filament 1 and the crimped warp filaments 41-44 are assumed to be at a reasonably high tensile strength, the half pitch L and the length W of the rising filament portion 412 are It can be assumed to be unchanged in shear. When the descending filament portions 411 are under shear, they are under compressive stress and their length V' is graphically shortened under that compressive stress.

式中、Ｗは前記上昇するフィラメント部分４１２の長さであり（非せん断状態とせん断状態とで等しく、さらに、非せん断状態においては、下降するフィラメント部分４１１の長さＶと等しい）、このＷは次のとおり計算することができる：

式中、Ｌは前記ハーフピッチであり、Ｈは対応するペア（例えば、３０８／３１６）に一致する、隣接する非捲縮横糸マルチフィラメントの中心間の垂直方向の距離である；Ｘは非捲縮横糸マルチフィラメント（複数あり）３０１－３１６の直径である；Ｙは捲縮縦糸フィラメント４１の直径である；及びδはせん断角である。 This graphically shortened length V′ of descending filament portion 411 under shear is based on the shear angle, filament diameter and inter-filament distance, and assuming that L and W rest constants are: can be computed exactly under :

where W is the length of the ascending filament portion 412 (equal in unsheared and sheared conditions, and in the unsheared condition is equal to the length V of the descending filament portion 411), and W can be computed as:

where L is the half-pitch, H is the vertical distance between the centers of adjacent uncrimped weft multifilaments that match corresponding pairs (e.g., 308/316); is the diameter of the crimped weft multifilament(s) 301-316; Y is the diameter of the crimped warp filament 41; and δ is the shear angle.

これは、（１）の括弧内の項が常に０より小さく、（１）で計算されるＶ’が常にＷ（＝Ｖ）より小さく、比Ｖ’：Ｖが常に１より小さいことを意味する。 For meaningful shear angles δ, sin(δ) is greater than or equal to zero, and L and H are always greater than zero. Then in (1) always:

This means that the term in brackets in (1) is always less than 0, V' calculated in (1) is always less than W (=V), and the ratio V':V is always less than 1. .

はハーフピッチＬの増加とともに０に近づくようになり、与えられたＨ、Ｘ、Ｙ、及びδで、（１）で計算されるＶ’はＷに近づくようになる。したがって、Ｖ’：Ｖ（＝Ｖ’：Ｗ）の比は、ハーフピッチＬの増加とともに１に近づくようになる。 Given H and δ, the term appearing in (1)

approaches 0 with increasing half-pitch L, and V′ calculated in (1) approaches W given H, X, Y, and δ. Therefore, the ratio of V':V (=V':W) approaches 1 as the half pitch L increases.

In the exemplary embodiment of FIGS. 1-3, where D=15 units, L=30 units, H=15 units, X=4.35, Y=4.35 units and δ=20°, the formula is Using: W=V=32.39 units, V′=26.29 units, and V′:V(=V:W)=0.831. This corresponds to a graphical shortening of the descending filament portion 611 of 16.9% at 20° shear.

The putative actual response of the descending filament portions 411 to such compressive stress is that (for monofilaments) they bulge somewhat outward from their long axis or (for multifilaments) the individual filaments contained therein bulge somewhat. fluffing, or the multifilament becoming somewhat larger. This putative actual response of the descending filament portions 411 to compressive stress is the possible delamination of impregnations adhering to these descending filament portions 411 and thus of such impregnations adhering to the warp filaments 41 . It is believed to be the main reason for delamination. This putative actual response of descending filament portion 411 to compressive stress cannot be fully illustrated in FIG. Instead, FIG. 3 shows a graphical shortening of the descending filament portion 411 from the non-sheared state V to the sheared state V'. The more pronounced the graphically shortening V' of descending filament portion 411 is, the more pronounced the actual response of descending filament portion 411 to compressive stress is to be expected.

In the fabrics of the present invention, simply alternating the first and second uncrimped weft multifilaments, as shown in FIG. 4, never passing between any uncrimped weft multifilaments 301-316; 301-308 and 309-316, respectively, the half-pitch L for the alternately entwined, crimped warp filaments 5, if used, can be equal to D, thus 30 instead of just 15. Under shear, if the length W of the rising filament portion 52 is assumed to be constant, and all other parameters are assumed to be the same for FIGS. 1-3, then at a shear angle of 20°, For the descending filament portion 51 of such alternating crimped warp filaments 5, using equations (1) and (2) above: W = V = 19.35 units, V' = 12.42 units and V': V(=V':W)=0.642 can be obtained. This corresponds to a graphical shortening of these descending filament portions 51 of 35.8% at 20° shear. This is much greater than the 16.9% observed for the crimped warp filaments 41 of the inventive fabric of FIG. It indicates a more pronounced actual reaction of the descending filament portions 51 and thus a greater tendency of impregnation to adhere to the descending filament portions 51 of such filaments to delaminate under shear.

式中、Ｈ、Ｌ及びδは、前記定義したものである。
である。
Ｌ及びＨは常に０より大きいため、及び有意義なせん断角δについて、ｓｉｎ（δ）は０より大きいか又は等しいため、式（３）で計算されるＨ’は、ハーフピッチＬの増加とともに小さくなる。式（３）によるＨ’は、せん断角が０と等しい場合、Ｈと等しく、δが０より大きい場合、Ｈより小さくなる。ハーフピッチＬが大きくなるにつれ、式（３）のＨ’は、せん断角δの増加とともに、より速く０に収束する。 In the fabrics of the present invention, the weave half-pitch L in the warp direction is approximately twice the distance D between the centers of adjacent uncrimped weft filaments. This is because there are always additional filament pairs that cause the crimped warp filaments 41-44 to pass between their first and second uncrimped filaments. A first uncrimped weft multifilament (e.g., 303 or 308 in Figure 3) and a second uncrimped weft multifilament (e.g., 311 or 311 in Figure 3) in any such multifilament pair in fabric shear. 316), the formula for calculating the center-to-center view distance H' is:

wherein H, L and δ are as defined above.
is.
Since L and H are always greater than 0, and since sin(δ) is greater than or equal to 0 for any significant shear angle δ, H′ calculated by equation (3) decreases with increasing half-pitch L. Become. H′ according to equation (3) is equal to H when the shear angle is equal to 0 and less than H when δ is greater than 0. As the half-pitch L increases, H' in equation (3) converges to 0 faster with increasing shear angle δ.

Second, due to the behavior of equation (3), the additional multifilament pair (e.g., 303/311 in FIG. 3) is laterally , begins to compress the descending filament portions 411 so that they partially oppose said outward bulging, enlarging or fuzzing, and thus also adhere to these descending filament portions 411 . It can be expected that the delamination of the impregnation is suppressed.

Third, due to the behavior of equation (3) above, with increasing half-pitch L, because of H' converging to 0 faster, in the inventive fabric of FIGS. becomes more pronounced than in the fabric with crimped warp filaments 5 shown in FIG. For such a simply alternating crimped warp filament, it can be expected that the half-pitch L is only equal to its distance D, not twice the distance D. Thus, the inventive fabric of FIGS. 1-3 does not shear to the same extent as the fabric comprising the warp filaments 5 due to its tendency to be compressed (more pronounced reduction in H') rather than sheared. It is foreseen that it cannot be done. 3. The schematic illustration at the bottom of FIG. 3 shows that the inventive fabric of FIGS. Considering the figure overlap with 1, we would indeed expect it to resist shear up to 20°.

The foregoing considerations have been made specifically with respect to the crimped warp filament 41 appearing in FIGS. can be applied to This is because they all have the same weave pattern as the crimped warp filaments 41 .

Considering all of the above, when impregnated and formed into an abrasive product, the fabric of FIG. , is expected to be less prone to shear delamination.

Essential to this improved resistance to shear delamination under abrasive action in the warp direction of the fabric is that the fabric of the present invention therefore comprises crimped warp filaments 41-44 in the weave type described with respect to FIGS. 1-2. , including the uncrimped warp filaments 1, but as shown in FIG. That is, it does not contain any crimped warp filaments 5 entangled around the filaments.

The improved resistance to delamination of the fabric of the present invention when used in an abrasive product and the abrasive action is in the weft direction of the fabric is illustrated with reference to FIG.

Figure 5 shows four cross-sectional views of the inventive fabric of Figure 1 in the weft direction. The first cross section is through a continuous multifilament pair with uncrimped weft multifilaments 302, 310; a third through a continuous multifilament pair having uncrimped weft multifilaments 304, 312; and a fourth through a uncrimped weft multifilament. Through a continuous multifilament pair having filaments 305,313. In each of the four cross-sections, the dashed box indicates the repeat unit in the weft direction. This repeating unit in all cross-sections also includes one crimped warp filament that passes between the first and second uncrimped weft multifilaments of each successive multifilament pair: the first and third. In the cross-sectional view of FIG. The threading of the crimped warp filaments 42, 43 between the first and second uncrimped weft multifilaments is indicated by vertical lines; When passing between the crimped weft multifilaments forming the ascending filament portion 412 (illustrated in FIG. 3), these are the upper solid line and the lower dashed line; or these crimped warp filaments 42, 43 are When passing between the first and second uncrimped weft multifilaments to form the descending filament portion 411 (described in FIG. 3), these vertical lines are the upper dashed line and the lower solid line. . Both the crimped warp filaments 42, 43 pass between the first/second uncrimped weft multifilaments 302/310, 303/311, 304/312 and 305/313 to the first uncrimped weft Twist around the multifilaments 302-305 and around the second uncrimped weft multifilaments 310-313. Therefore, the crimped warp filaments 42, 43 cannot rotate at all about their central axes and therefore, firstly, in opposite directions, said first uncrimped weft multifilament 302-305 and said It inhibits axial displacement motion of the second uncrimped weft multifilaments 310-313. Such an axial displacement movement is in effect supported by the uncrimped warp filaments 1, and rotation about their central axis causes said first uncrimped weft multifilament 302-305 and said second uncrimped weft multifilament 302-305 in opposite directions. facilitating such axial displacement motion of the uncrimped weft filaments 310-313, perhaps acting as a roller. If the uncrimped weft multifilaments 302-305 and 310-313 are close enough, or upon shearing in the weft direction, the crimped warp filaments 42, 43 are also pulled in opposite directions by friction. suppress their further axial displacement. because they cannot rotate.

Also, as shown in FIG. 5, when the repeating unit still further comprises crimped warp filaments 41, 44, the suppression of axial displacement in opposite directions of the uncrimped weft multifilaments 302-305 and 310-313 is even more become conspicuous. It is for the same reason as explained for the crimped warp filaments 42,43.

In summary, the fabric of Figure 1 is also expected to be shear resistant and thus shear delamination resistant in its weft direction.

The direction of shear varies between the warp direction (resulting in stronger compression of the fabric as described with reference to FIG. 3) and the weft direction (non-crimped weft filaments 302-305 and 310-313 and uncrimped warp filaments Resistance to shear delamination when simultaneously using said stronger compression of the fabric, which causes increased friction between 1 and, as explained with reference to FIG. 5, counteracts shear in the weft direction instead is expected to be particularly pronounced.

The resistance of the abrasive products of the present invention to shear delamination under abrasive action can be readily tested experimentally in a Taber industries. Instead of a standardized Taber polishing wheel, a conventional polishing wheel of the same size but containing as the outer surface to be polished a ribbon of the abrasive product of the present invention to be tested is used. This setup allows the abrasive product of the present invention to be tested for shear in any direction of the weave of the fabric contained therein (warp, weft, or a combination of both). A ribbon need only be cut from the abrasive product of the present invention in a suitable orientation.

FIG. 6 shows a fabric of the invention along its longitudinal direction passing through the uncrimped warp filament 1 and the first and second uncrimped weft multifilaments, 301-308 and 309-316, respectively. 1 is a schematic cross-sectional view of an abrasive belt of the present invention, including The longitudinal (warp) direction of the fabric is also considered the direction of travel of the abrasive belt. The first and second uncrimped weft multifilaments 301-308 and 309-316, each made of polyester and having a thickness of 0.25-0.45 mm in the described embodiment. The non-crimped warp filaments 1 are typically multifilaments made of polyester or, more preferably, made of aramid. The crimped warp filaments 41-44 are typically multifilaments made of polyester and have a titer of 550-2000 dtex in the illustrated embodiment. There are typically 4 or 12 crimped warp filaments 41-44 per uncrimped warp filament. The abrasive belt consists of impregnation 6, typically of TPU, e.g. Lubrizol's Estane® TPU type, impregnation 6, and impregnation material identical to impregnation 6, completely free of fabric, a top continuous It has an upper layer 7 with a The boundary between the top continuous top layer 7 and the impregnated fabric is indicated by a dashed line. A top continuous top layer 7 has a top surface 8 with abrasive particles 9 directly embedded therein. The top continuous top layer, after embedding the abrasive particles, has the ultrasonically measurable thickness D _i ' as outlined above. Embedding the abrasive particles 9 directly into the upper surface 8 of the top layer 7 helps reduce the overall thickness D _tot of the belt and provides support in terms of bendability across the pulley. This abrasive belt of the invention typically has an overall thickness D _tot in the range 1-3 mm, visible by the measuring instrument.

FIG. 7 is a view of the uncrimped warp filament 1 and the first and second uncrimped weft multifilaments, 301-308 and 309-316, respectively, along their longitudinal direction. 1 is a schematic cross-sectional view of a polishing pad or disc of the present invention, including a fabric; FIG. It comprises the fabric of the invention, the impregnation 6 and, on one side of the impregnation fabric, a first cover layer 71 of thickness D _i1 consisting of the same impregnation material as the impregnation 6 but completely without fabric. In the embodiment shown, there is a second cover layer 72 of thickness D _i2 also made of the same material as the impregnation 6 but completely free of fabric. This polishing pad or belt is in the form of a first prefabricated sheet 101 having a thickness D _i1 ′ and comprising these first abrasive particles 91 embedded in its first top sheet surface 111, It contains first abrasive particles 91 . It may be, for example, a type 262L polishing tape, or a type S so-called "micro-finishing film", both manufactured by Minnesota Mining & Manufacturing. This first prefabricated sheet 101 is laminated to the first top layer 71 under heat and pressure, optionally in combination with a compatible hot melt adhesive (not shown). A second pre-manufactured sheet 102, identical or different from the first pre-manufactured sheet 101, of thickness D _i2 ′, having abrasive particles 92 (abrasive A second prefabricated sheet 102 , which further comprises particles 91 , which may be the same as or different from particles 91 , is laminated to the second top layer 72 . This second prefabricated abrasive-containing layer is optional.

Claims (15)

i) A woven fabric impregnated with an impregnation (6) comprising or consisting of a thermoplastic resin, a thermoplastic elastomer, a thermoset resin, an elastomer or a mixture thereof; said fabric comprising:
a) a first layer (A) of first uncrimped weft multifilaments (301-308) running essentially parallel to each other and separated from each other by a distance D;
b) a second layer (B) of second uncrimped weft multifilaments (309-316) running essentially parallel to each other and separated from each other by said distance D;
wherein for each of said first uncrimped weft multifilaments (301-308) there is one corresponding second uncrimped weft multifilament (309-316) and vice versa. Yes, forming continuous multifilament pairs (301/309, 302/310, 303/311, 304/312, 305/313, 306/314, 307/315, 308/316), each Such continuous multifilament pairs can be designated by a unique and ascending integer index N;
c) the following weave patterns c1-c4:
The first of all multifilament pairs (302/310, 306/314) with an index N that satisfies c1−(N mod 4)=0, and such index N is represented by N _A. Entanglement around 1 uncrimped weft multifilament (302, 306); all multifilaments with index N satisfying (N mod 4)=1, such index N being denoted _NB threading between the first (303, 307) and second (311, 315) uncrimped weft multifilaments of the filament pair (303/311, 307/315); satisfying (N mod 4)=2 The second _uncrimped weft multifilament (312, 316) entanglements around; and index N satisfying (N mod 4)=3, such index N being represented by _ND , all multifilament pairs (301/309, 305/313 ) between the first (301, 305) and second (309, 313) uncrimped weft multifilaments;
or c2--entanglement around the second uncrimped weft multifilament (310, _{314) of all multifilament pairs with said index N A ;} all multifilament pairs (303 / threading between the first (303, 307) and second (311, 315) non-crimped weft multifilaments of 311, 307 (315); all multifilament _pairs ( 304/312, 308/316) entanglement around the first uncrimped weft multifilament (304, 308); and all multifilament _pairs (301/309, 305/313 ) between the first and second uncrimped weft multifilaments;
or c3—the first (302, 306) and second (310, 314) uncrimped weft multifilaments of all multifilament pairs (302/310, 306/314) with said index _NA entanglement around the first uncrimped weft multifilament (303, 307) of all multifilament pairs (303/311, 307/315) with said index N _B ; said index N _C threading between first (304, 308) and second (312, 316) uncrimped weft multifilaments (304/312, 308/316) of all multifilament pairs; and said index entanglement around the second uncrimped weft multifilament (309, 313) of all multifilament pairs (301/309, 305/313) with _ND ;
or c4—the first (302, 306) and second (310, 314) uncrimped weft multifilaments of all multifilament pairs (302/310, 306/314) with said index _NA entanglement around the second uncrimped weft multifilament (311, 315) of all multifilament pairs (303/311, 307/315) with said index N _B ; said index N _C threading between first (304, 308) and second (312, 316) uncrimped weft multifilaments of all multifilament pairs (304/312, 308/316); and said index entanglement around the first uncrimped weft multifilament (301, 305) of all multifilament pairs (301/309, 305/313) having _ND filaments (41-44);
d) the first (301-308) of all multifilament pairs (301/309, 302/310, 303/311, 304/312, 305/313, 306/314, 307/315, 308/316) ) and a second (309-316) uncrimped warp filament (1) passing between the uncrimped weft multifilaments; and e) one of the weave types c1, c2, c3 or c4 defined above crimped antistatic warp filaments having;
However, for all four said defined weave types c1, c2, c3 and c4 there are crimped warp filaments (41-44);
wherein the fabric does not contain any crimped warp filaments other than the crimped warp filaments (41-44) and the crimped antistatic warp filaments,
each uncrimped warp filament (1) is separated in the weft direction from the next uncrimped warp filament (1) by an even number of crimped warp filaments (41-44), said even number being at least two; and (N mod 4) represents the remainder obtained by the Euclidean integer division of N by 4;
fabrics, including
as well as:
iia) a fabric comprising or consisting of the same thermoplastic, thermoplastic elastomer, thermoset, elastomer or mixtures thereof as in impregnation (6) immediately adjacent to one side of said impregnated fabric and iiia) first particulates embedded in the first top surface (8) of said first top layer (7). shaped abrasive (9);
or iib) immediately adjacent to one side of said impregnated fabric, comprising or consisting of the same thermoplastic resin, thermoplastic elastomer, thermoset resin, elastomer or mixtures thereof as in impregnation (6) a fabricless first cover layer (71); and
iiib) a matrix material, a first top sheet surface (111) adjacent to said first cover layer (71) and first abrasive particles embedded in said first top sheet surface (111) ( 91), wherein said matrix material is different from impregnation (6);
or
iic) adjacent to one side of said impregnated fabric, a matrix material, a first top sheet surface (111) and first abrasive particles (91) embedded in said first top sheet surface (111); a first prefabricated abrasive sheet (101), wherein said matrix material is different from the impregnation (6);
Abrasive products, including any of The fabric comprises a first uncrimped weft multifilament a) (301-308), a second uncrimped weft multifilament b) (309-316), crimped warp filaments c) (41-44), 2. The abrasive product of claim 1, comprising uncrimped warp filaments d)(1) and crimped antistatic warp filaments e). i) A woven fabric impregnated with an impregnation (6) comprising or consisting of a thermoplastic resin, a thermoplastic elastomer, a thermoset resin, an elastomer or a mixture thereof; said fabric comprising:
a) a first layer (A) of first uncrimped weft multifilaments (301-308) running essentially parallel to each other and separated from each other by a distance D;
b) a second layer (B) of second uncrimped weft multifilaments (309-316) running essentially parallel to each other and separated from each other by said distance D;
wherein for each of said first uncrimped weft multifilaments (301-308) there is one corresponding second uncrimped weft multifilament (309-316) and vice versa. Yes, forming continuous multifilament pairs (301/309, 302/310, 303/311, 304/312, 305/313, 306/314, 307/315, 308/316), each Such continuous multifilament pairs can be designated by a unique and ascending integer index N;
c) the following weave patterns c1-c4:
An index N that satisfies c1−(N mod 4)=0, such an index N being N _A. (N mod 4)= An index N that satisfies 1, such index N being N _B. between the first (303, 307) and second (311, 315) uncrimped weft multifilaments of all multifilament pairs (303/311, 307/315) with index N represented by index N satisfying (N mod 4)=2, such index N being N _C. entanglement around the second uncrimped weft multifilament (312, 316) of all multifilament pairs (304/312, 308/316) with index N represented by; and (N mod 4) = 3, such index N being N _D. between the first (301, 305) and second (309, 313) uncrimped weft multifilaments of all multifilament pairs (301/309, 305/313) with index N represented by through;
or
c2—the index N _A. said index N _B. the threading between the first (303, 307) and second (311, 315) uncrimped weft multifilaments of all multifilament pairs (303/311, 307 (315); said index N _C. and said index N _D. threading between the first and second uncrimped weft multifilaments of all multifilament pairs (301/309, 305/313) having
or
c3—the index N _A. said index N _B. said index N _C. threading between first (304, 308) and second (312, 316) uncrimped weft multifilaments (304/312, 308/316) of all multifilament pairs; and said index N. _D. entanglement around the second uncrimped weft multifilament (309, 313) of all multifilament pairs (301/309, 305/313) having
or
c4—the index N _A. said index N _B. said index N _C. threading between first (304, 308) and second (312, 316) uncrimped weft multifilaments of all multifilament pairs (304/312, 308/316); and said index N. _D. entanglement around the first uncrimped weft multifilament (301, 305) of all multifilament pairs (301/309, 305/313) having
crimped warp filaments (41-44) having one of; and
d) the first (301-308) of all multifilament pairs (301/309, 302/310, 303/311, 304/312, 305/313, 306/314, 307/315, 308/316) ) and a second (309-316) uncrimped warp filament (1) passing between the uncrimped weft multifilament;
However, for all four said defined weave types c1, c2, c3 and c4 there are crimped warp filaments (41-44);
wherein the fabric does not contain any crimped warp filaments other than the crimped warp filaments (41-44),
each uncrimped warp filament (1) is separated in the weft direction from the next uncrimped warp filament (1) by an even number of crimped warp filaments (41-44), said even number being at least two; as well as
(N mod 4) represents the remainder obtained from Euclidean integer division of N by 4;
fabrics, including
as well as:
iia) a fabric comprising or consisting of the same thermoplastic, thermoplastic elastomer, thermoset, elastomer or mixtures thereof as in impregnation (6) immediately adjacent to one side of said impregnated fabric a first top layer (7) having a first top surface (8) free of
iiia) a first particulate abrasive (9) embedded in a first top surface (8) of said first top layer (7);
or
iib) a fabric comprising or consisting of the same thermoplastic, thermoplastic elastomer, thermoset, elastomer or mixtures thereof as in impregnation (6) immediately adjacent to one side of said impregnated fabric a first cover layer (71) free of; and
iiib) a matrix material, a first top sheet surface (111) adjacent to said first cover layer (71) and first abrasive particles embedded in said first top sheet surface (111) ( 91), wherein said matrix material is different from impregnation (6);
or
iic) adjacent to one side of said impregnated fabric, a matrix material, a first top sheet surface (111) and first abrasive particles (91) embedded in said first top sheet surface (111); a first prefabricated abrasive sheet (101), wherein said matrix material is different from the impregnation (6);
Abrasive products, including any of The fabric comprises a first uncrimped weft multifilament a) (301-308), a second uncrimped weft multifilament b) (309-316), crimped warp filaments c) (41-44) and 4. The abrasive product of claim 3, comprising uncrimped warp filaments d)(1) . An abrasive product according to one of the preceding claims, wherein each non-crimped warp filament (1) is sandwiched in the weft direction by two immediately adjacent crimped warp filaments (42, 43 ). The weave defined in claim 1 wherein the crimped warp filaments of weave types c1 (41) and c2 (42) defined in claim 1 are always present in pairs and immediately adjacent to each other in the weft direction. Abrasive product according to one of the preceding claims, wherein the crimped warp filaments of types c3 (43) and c4 ( 44 ) are always present in pairs and immediately adjacent to each other in the weft direction. The number ratio of crimped warp filaments c) (41-44) to non-crimped warp filaments d) (1) is in the range from 4:1 to 12 :1. abrasive products. The crimped warp filaments c) (41, 42, 43, 44) and the non-crimped warp filaments d) ( 1 ) are arranged in a repeating unit in the weft direction, and in the repeating unit, the non-crimped warp filaments d) Claim wherein the order in which the crimped warp filaments of (1) and said weave patterns c1 (41), c2 (42), c3 (43) and c4 (44) are arranged transversely is always the same. 8. Abrasive product according to any one of items 1-7 . An abrasive product according to one of claims 1 to 8 , comprising iia) and iiia) as defined in claims 1 or 3 . 10. The abrasive product of claim 9 , which is an endless abrasive belt and wherein the warp direction of the fabric is in the direction of belt travel. iv) immediately adjacent to the other side of said impregnated fabric, but consisting of the same thermoplastic resin, thermoplastic elastomer, thermoset, elastomer or mixture thereof as in impregnation (6) of said impregnated fabric a second top layer having a second top surface that is free of fabric; and v) a second particulate abrasive embedded in the second top surface of the second top layer.
10. The abrasive product of claim 9 , further comprising: Abrasive product according to one of claims 1 to 11 , comprising iib) and iiib) as defined in claims 1 or 3 . iv) immediately adjacent to the other side of said impregnated fabric, comprising or consisting of the same thermoplastic resin, thermoplastic elastomer, thermoset resin, elastomer or mixtures thereof as in said impregnation (6); a second cover layer (72) without fabric;
v) a matrix material, a second top sheet surface (112) adjacent to said second cover layer (72) and second abrasive particles embedded in said second top sheet surface (112); 92), wherein said matrix material is different from said impregnation (6);
13. The abrasive product of claim 12 , further comprising: 4. The abrasive product of claims 1-2 or 1-3 , which is an abrasive pad or abrasive disc. Abrasive product according to one of the preceding claims, wherein the impregnation (6) is a thermoplastic resin or a thermoplastic elastomer.

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