JPH04336975A - Grinding and polishing brush - Google Patents

Abstract

PURPOSE:To provide a grinding and polishing brush with a good precision of grinding surface, and an excellent mechanical strength and antiabrasive property of itself. CONSTITUTION:This grinding and polishing brush is formed by making uniform long fibers of alumina type fibers with the fiber diameter 5 to 30mum, and combining them with a resin, which consists of a wool material whose sectional area is 0.01mm<2> to 2.5mm<2>.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a brush for polishing and grinding the surfaces of various materials such as resin, rubber, metal, ceramics, glass, stone, wood, and composite materials. In particular, the present invention relates to the brush having a characteristic bristle material.

0002

2. Description of the Related Art It has been proposed to use a monofilament made of synthetic resin containing abrasive grains and having a diameter of about 0.1 to 2.0 mm as the bristle material of an abrasive and grinding brush.

[0003]For example, JP-A-61-176304, JP-A-61-234804, JP-A-61
-252075, etc., the bristles are monofilaments obtained by melt-spinning thermoplastic resin containing abrasive particles, which are further processed in some cases to improve stiffness, uniformity, and abrasive properties as brushes. , products with improved durability, etc. have been proposed.

[0004] Japanese Patent Laid-Open No. 63-21920 proposes a brush that uses, as a bristle material, flat threads formed from a wholly aromatic polyamide layer and a wholly aromatic polyamide layer containing inorganic particles.

[0005] In JP-A-2-232174, inorganic long fibers such as alumina fibers are used, and the fibers contain 50 to 81% by volume.
A polishing rotary tool is disclosed in which the polishing tool is hardened with a thermosetting resin and formed into a cylindrical brush shape that is integrated with a rotating shaft.

[0006]

[Problems to be Solved by the Invention] Monofilaments made of thermoplastic resin containing abrasive particles have a limit in the content of abrasive particles when melt-spun, and furthermore, because they are thermoplastic, resin sag occurs. , the wear of the bristles is large, the polishing efficiency is not very high, and the precision of the surface to be polished is not sufficient.

Furthermore, in the brush-like rotary tool described in JP-A-2-232174, due to its shape, the bristles are only relatively thick, and the cross-sectional shapes of the bristles are not the same. With such bristle materials, it is difficult to polish curved or indented surfaces, and furthermore, the precision of the polished surface is not sufficient.

[0008] Even if the surface of the material to be polished is a curved surface or an indented surface, the present invention has good abrasive grinding accuracy, high abrasive grinding ability, and has excellent mechanical strength and wear resistance. Our purpose is to provide abrasive grinding brushes.

[0009]

[Means for Solving the Problems] The present invention provides fiber diameters of 5 to 5.
30 μm long alumina fibers are aligned and bonded with resin, and the cross-sectional area is 1 x 10-2 mm.
An abrasive grinding brush made of bristle material with a diameter of 2 to 2.5 mm2.

Known alumina fibers can be used as the alumina fibers of the present invention. Among them, Al2O3 is 60% by weight or more,
High-strength, high-hardness alumina fibers containing 30% by weight or less of SiO2, a tensile strength of 100 kg/mm2 or more, and a Mohs hardness of 4 or more are preferred.

[0011] The alumina fibers are in the form of so-called long fibers. The diameter thereof is 5 to 30 μm, preferably 7 to 25 μm.

[0012] When this diameter exceeds 30 μm, the polishing performance is excellent when abrasively grinding, but the unevenness of the polished surface becomes too large, the surface roughness increases, and it is difficult to obtain a highly accurate polished surface. It cannot be expressed.

On the other hand, if the diameter of the alumina fiber is less than 5 μm, the unevenness of the surface to be polished will be reduced, but the polishing performance will be poor and the wear rate of the bristles will be high.

[0014] Note that other fibers can be used in combination with the alumina fibers. For example, ceramic fibers such as silicon carbide fibers, tyranno fibers, silicon nitride fibers, silicon oxynitride fibers; steel fibers, stainless steel fibers,
Metal fibers such as boron fibers, tungsten fibers, brass fibers; carbon fibers, etc., are selected for their hardness, strength, impact resistance,
Two or more types may be combined in order to balance physical properties such as thermal conductivity.

Furthermore, for polishing and grinding brushes, in order to improve the precision of the surface of the material to be polished in proportion to the hardness of the material to be polished, choose one with moderate stiffness of the bristles.
To adjust the stiffness of this hair material, use flexible fibers such as glass fibers; rayon fibers, polyamide fibers, polyester fibers, acrylic fibers, vinylon fibers, polyethylene fibers, polypropylene fibers, vinyl chloride fibers, Teflon fibers, etc. Synthetic fibers; natural fibers such as cotton, linen, wool, silk, kozo, mitsumata, and jute may be used in combination.

In order to combine alumina fibers with other fibers, the alumina fibers can be mixed filament by filament, or if the other fibers are flexible fibers, the alumina fibers can be wrapped around the outer periphery of a bundle of alumina fibers. It is also preferable from the viewpoint of reinforcing the fibers.

[0017] As resins for hardening these fibers, epoxy resins, phenolic resins, unsaturated polyester resins,
Thermosetting resins such as vinyl ester resin, alkyd resin, urea-formalin resin, polyimide resin; polyethylene, polypropylene, polymethyl methacrylate, polystyrene, polyvinyl chloride, ABS resin, AS resin,
Thermoplastic resins such as polyacrylamide, polyacetal, polysulfone, polycarbonate, polyphenylene oxide, polyether sulfone, polyether ketone, polyamideimide, etc., and thermoplastic elastomers such as styrene elastomer, olefin elastomer, polyethylene elastomer, urethane elastomer, etc. be.

Among these, epoxy resin, phenol resin, unsaturated polyester resin, vinyl ester resin,
Polyimide resin etc. are suitable. Furthermore, these resins may be colored by mixing a small amount of various organic or inorganic fillers, or by mixing various pigments, dyes, etc. Furthermore, by foaming these resins to make them porous, the stiffness of the hair material can be adjusted depending on the degree of foaming.

[0019] In order to bond alumina fibers with resin, well-known methods for producing fiber-reinforced composite materials can be applied. That is, first, a so-called prepreg manufacturing method is applied, and a predetermined number of continuous fiber bundles or sheet-like continuous fibers are aligned and impregnated with the above-mentioned hardening resin. If the resin to be hardened is a thermosetting resin, it is in an uncured or semi-cured state as it is, or in a state dissolved in a solvent;
If the resin to be hardened is a thermoplastic resin, it is used in a molten state or dissolved in a solvent.

[0020] The impregnated resin may be cured by a known method depending on the resin to be cured. When the resin to be hardened is a thermosetting resin, if a solvent is used, the solvent is first volatilized and then heated to harden, or if no solvent is used, the resin is heated and hardened as is. If the resin to be hardened is a thermoplastic resin, if a solvent is used, it is sufficient to volatilize the solvent first.
If used in a molten state, it will harden if cooled to room temperature.

The bundle of long fibers is a so-called tow or yarn, and each bundle has approximately 50 to 1,000 fibers, and the number may be determined in advance according to the required cross-sectional area of the hair material.

The sheet-like continuous fibers are so-called prepreg sheets, and the thickness thereof is appropriately selected to suit the required cross-sectional area of the hair material, but is generally about 10 μm to 300 μm.

The proportion of the long fibers in the hair material is 20 to 90% by volume, preferably 40 to 80% by volume. If it is less than 20% by volume, it is not preferable because the polishing ability is low and the surface of the abrasive material to be polished is uneven, resulting in low precision. If it exceeds 90% by volume, there will be many parts of the bundle of long fibers that are not filled with resin, making it difficult to maintain the form of the hair material, and the long fibers will easily break, which is not preferable.

[0024] The cross-sectional area of the hair material made of alumina fibers bonded with resin is 0.01 mm2 to 2.5 mm2. Preferably, it is 0.02 mm2 to 1 mm2. If the cross-sectional area of the bristle material is smaller than 0.01 mm2, it will be difficult to handle the fiber bundle when producing the bristle material, and it will also be easily damaged when producing a brush from the obtained bristle material, which is undesirable. . If the cross-sectional area of the hair material is larger than 2.5 mm2,
Although the polishing performance is high, the depth of the unevenness on the surface of the material to be polished tends to increase, and the width and spacing of the unevenness become uneven, resulting in poor polishing accuracy, which is not preferable.

[0025] The cross-sectional area of the hair material can be adjusted by adjusting the diameter of the long fibers, their number, the ratio to the resin, etc., depending on the purpose of use. In other words, when tow or yarn is used, the cross-sectional area is equivalent to that of a hair material that has been hardened with resin, and can be reduced by tearing or removing a portion. Furthermore, the prepreg sheet can be cut into narrow widths in the same direction as the long fibers, and the cross-sectional area can be adjusted based on the thickness and width.

The shape of the cross section may be appropriately selected depending on the purpose of the brush, such as circular, elliptical, polygonal, star-shaped, or oblate. Furthermore, twisting may be applied. In order to obtain these shapes, the resin to be bonded is deformed into those shapes before it hardens.

[0027] Examples of abrasive brushes using the bristle material of the present invention include roll brushes, flat brushes, channel brushes, cup brushes, wheel brushes, high-density brushes,
It can be applied to various well-known shapes such as bar brushes.

[0028] When making a brush, the length of the bristle material may be selected as appropriate for each brush. Further, as the arrangement of the bristles of the brush, well-known arrangements such as linear, spiral, staggered, radial, etc. can be applied. The members other than the bristle material forming these brushes may be well-known materials. Known manufacturing methods can also be applied to manufacturing the brush. That is, in general,
Collect, arrange, and implant hair materials. In this case, the bristles may remain uncured.

Known techniques can also be applied to polishing and grinding a material to be polished using the brush of the present invention.

[0030]

[Effects of the Invention] The abrasive and grinding brush of the present invention uses uniform bristles, has adjustable stiffness, and has excellent mechanical strength and abrasion resistance. Furthermore, it has excellent corrosion resistance and oxidation resistance, so there is no reaction with the material to be polished, and its high thermal conductivity means that there is little negative effect from frictional heat.
Abrasive grinding can be performed with high efficiency and precision on materials and conditions where conventional abrasive materials cannot be used. The abrasive and grinding brush of the present invention can be used not only to abrasive and grind various materials such as metals such as steel, aluminum, and alloys, but also to abrasive and grind the surfaces of glass, composite materials, resins, ceramics, rubber, etc. Compared to conventional brushes made of synthetic resin containing abrasive grains, fully aromatic polyamide, etc., this brush has less wear and tear on the bristles, and is superior in terms of polishing ability and uniformity of surface roughness accuracy.

Furthermore, when polishing a paint film, for example, when applying multiple layers of paint such as epoxy resin, melamine alkyd resin, polyester resin, or acrylic resin to a steel plate, each painted surface It eliminates height differences, creates a fine surface roughness, increases the anchoring effect, and is effective in preventing paint from peeling off.

Specifically, it is suitable for use in polishing automobile paint lines, polishing various processing rolls, microscratching printed circuit boards, lead frames, etc., polishing heating conveyor nets, polishing and grinding in steel manufacturing processes, and the like.

[0033]

[Examples] The present invention will be further explained below with reference to Examples, but the present invention is not limited thereto. The polishing and grinding brush used the bristle material in each example and was made into a cup-shaped rotating brush with an outer diameter of 120 mm, a width of 35 mm, and a bristle length of 30 mm. The evaluation of polishing and grinding was performed using a rotating brush with a rotation speed of 1000 r. p
．． m, load 0.3 Kg/cm2, 30 minutes, under water flow conditions, steel plate (S45C, Vickers hardness 700, center line average roughness Ra = 0.03 μm, maximum height Rmax = 0.
5 μm) and the surface of the steel plate to a thickness of 50 μm with Shinto paint (
Co., Ltd. acrylic resin paint (Rockwell hardness (ASTM-D785) = M100, Ra = 0.
02 μm and Rmax=0.5 μm) were abrasively ground and evaluated based on their surface roughness and wear rate of the bristles.

The surface roughness of the polished product was determined by scanning perpendicularly to the polishing direction using a stylus type roughness meter (Tokyo Seimitsu Co., Ltd., Surfcom) and measuring the center line average roughness Ra (μm).
and the maximum height Rmax (μm) were measured. The wear rate of the bristle material was calculated from the rate of decrease in the weight of the brush after drying it at 100° C. for 2 hours before and after use.

Example 1 Bisphenol A type epoxy resin (Sumi Epoxy ELA
-134 Sumitomo Chemical Co., Ltd.) 60 parts by weight, cresol novolac type epoxy resin (Sumi Epoxy ESCN)
-220 (manufactured by Sumitomo Chemical Co., Ltd.) 40 parts by weight, 5 parts by weight of dicyandiamide, 3-(3,4 dichlorophenyl)
4 parts by weight of -1,1-dimethylurea was dissolved in trichlorethylene to prepare a solution having a solid content concentration of 30% by weight.

[0036] Alumina fiber Altex (
500 continuous filament tows (manufactured by Sumitomo Chemical Co., Ltd.), 85% by weight of Al2O3, 15% by weight of SiO2, were immersed in the epoxy resin solution, and then heated in a hot air circulation oven for 17 hours.
The epoxy resin was cured by heating at 0°C for 3 minutes and then at 200°C for 3 minutes, and wound onto a drum with a diameter of 30cm, with a fiber volume content (Vf) of 60% and a cross-sectional area of 0.07m.
m2 of hair material was obtained. Using this bristle material, two cup-shaped rotating brushes were manufactured with a volume filling rate of 60%, and a steel plate was polished with one of the cup-shaped rotating brushes. The evaluation results are shown in Table 1.

Example 2 Using the remaining rotating brush produced in Example 1,
A film of acrylic resin paint applied to a steel plate was polished. The evaluation results are shown in Table 1.

Example 3 A bristle material was prepared with a Vf of 40% and a cross-sectional area of 0.1 mm2, and using this bristle material, the volume filling rate of the bristle material was 60%.
Two rotary brushes were produced in the same manner as in Example 1, except that a cup-shaped rotary brush of 10% was used, and a steel plate was polished with one of them. The evaluation results are shown in Table 1.

Example 4 Using the remaining rotating brush produced in Example 3,
A film of acrylic resin paint applied to a steel plate was polished. The evaluation results are shown in Table 1.

Example 5 The same procedure as Example 1 was carried out except that the tow was made of 500 pieces of Altex with a diameter of 20 μm. Vf was 60% and the cross-sectional area was 0.
．． A bristle material of 26 mm2 was obtained. Using this, two cup-shaped rotary brushes with a bristle volume filling rate of 45% were produced, and a steel plate was polished with one of them. The evaluation results are shown in Table 1.

Example 6 Using the remaining rotating brush produced in Example 5,
A film of acrylic resin paint applied to a steel plate was polished. The evaluation results are shown in Table 1.

Example 7 A hair material having a Vf of 60% and a cross-sectional area of 0.13 mm2 was obtained in the same manner as in Example 1, except that a tow consisting of 1000 Altex fibers having a diameter of 10 μm was used. Using this, two cup-shaped rotary brushes with a bristle volume filling rate of 53% were produced, and a steel plate was polished with one of them. The evaluation results are shown in Table 1.

Example 8 Using the remaining rotating brush produced in Example 7,
A film of acrylic resin paint applied to a steel plate was polished. The evaluation results are shown in Table 1.

Example 9 A hair material having a Vf of 60% and a cross-sectional area of 0.52 mm2 was obtained in the same manner as in Example 1, except that a tow consisting of 1000 Altex fibers having a diameter of 20 μm was used. Using this, two cup-shaped rotary brushes with a bristle volume filling rate of 40% were produced, and a steel plate was polished with one of them. The evaluation results are shown in Table 1.

Example 10 Using the remaining rotating brush produced in Example 9,
A film of acrylic resin paint applied to a steel plate was polished. The evaluation results are shown in Table 1.

Example 11 A tow made of 500 pieces of Altex with a diameter of 10μ is used as the core, and the outer periphery is covered with rayon cloth, making 500 reciprocations per 1 m length.
Wound one turn at a time, the volume ratio of Altex and rayon cloth is 1:
It was made into a bundle of 1. This bundle was impregnated with epoxy resin and cured in the same manner as in Example 1, and the total Vf of Altex and rayon cloth was 60% and the cross-sectional area was 0.13 mm2.
The hair material was obtained. Using this, the volume filling rate of hair material is 55%.
Two cup-shaped rotating brushes were made, and a steel plate was polished with one of them. The evaluation results are shown in Table 1.

Example 12 The remaining rotating brush produced in Example 11 was used to polish a coating film of an acrylic resin paint applied to a steel plate. The evaluation results are shown in Table 1.

Example 13 A tow consisting of 500 pieces of Altex with a diameter of 10 μm was used as a core, and the outer circumference was wound with E-glass 200 times back and forth per 1 meter length to form a bundle with a volume ratio of Altex and E-glass of 1:1. did. This bundle was impregnated with epoxy resin and cured in the same manner as in Example 1 to obtain a bristle material having a total Vf of Altex and E-glass of 60% and a cross-sectional area of 0.13 mm2. Using this, two cup-shaped rotary brushes with a bristle volume filling rate of 40% were produced, and a steel plate was polished with one of them. The evaluation results are shown in Table 1.

Example 14 Using the remaining rotating brush produced in Example 13, a coating film of an acrylic resin paint applied to a steel plate was polished. The evaluation results are shown in Table 1.

Comparative Example 1 Commercially available hair material, trade name Tregrit, product number 153-0.5
5W-50C (manufactured by Toray Monofilament Co., Ltd., nylon 6 mixed with 30% by weight of aluminum oxide powder with an average particle size of #500, cross-sectional area 0.24 mm2) was used in a cup-shaped rotation with a volume filling rate of bristle material of 42%. Two brushes were made, and one of them was used to polish the steel plate. Table 1 shows the evaluation results.
Shown below.

Comparative Example 2 Using the remaining rotating brush produced in Comparative Example 1,
A film of acrylic resin paint applied to a steel plate was polished. The evaluation results are shown in Table 1.

Comparative Example 3 A commercially available hair material, trade name: Conex Bristle (manufactured by Teijin Ltd., wholly aromatic polyamide mixed with 10% by volume of aluminum oxide with an average particle size of 10μ, cross-sectional area of 0.1mm2) was used. 2 cup-shaped rotating brushes with a bristle volume filling rate of 53%
A steel plate was polished with one of them. The evaluation results are shown in Table 1.

Comparative Example 4 Using the remaining rotating brush produced in Comparative Example 3,
A film of acrylic resin paint applied to a steel plate was polished. The evaluation results are shown in Table 1.

Comparative Example 5 A hair material having a Vf of 60% and a cross-sectional area of 3.2 mm2 was obtained in the same manner as in Example 1, except that a tow consisting of 2000 Altex fibers having a diameter of 35 μm was used. Using this, two cup-shaped rotary brushes with a bristle volume filling rate of 30% were produced, and a steel plate was polished with one of them. The evaluation results are shown in Table 1.

Comparative Example 6 Using the remaining rotating brush produced in Comparative Example 5,
A film of acrylic resin paint applied to a steel plate was polished. The evaluation results are shown in Table 1.

[0056]

Claims (1)

[Claims] [Claim 1] An abrasive made of a hair material made of long fibers of alumina fibers with a fiber diameter of 5 to 30 μm aligned and bonded with a resin, the cross-sectional area of which is 0.01 mm2 to 2.5 mm2. grinding brush.