JPS59118374A - Abrasive material and manufacture thereof - Google Patents

Abstract

PURPOSE:To manufacture easily the grinding material of good quality, which has high elasticity and cushioning property, by a method wherein the gaps of entangled fibers are filled with resin expandable bodies uniformly. CONSTITUTION:Natural or chemical fiber webs 2 are laminated on an open-cell foamed body sheet layer 3 and the fibers of the webs 2 are buried perfectly substantially into the foamed body sheet 3 by punching by a needle punch machine 5 under the condition of punching depth of more than 10mm. and punching number of more than 50P/cm<2> in order to form an integral base material 8 in which the fibers are entangled and complicated mutually in the foamed construction 7. Subsequently, a synthetic resin binder 23, such as phenol, epoxy, urethane or the like, containing abrasive grains 22 is impregnated into the base material 8 in an impregnating bath 9 or is sprayed thereon while the base materials 8 are rolled into a roll or punched and laminated into a predetermined from when the binder 23 is wet still to obtain the abrasive material 19 having high elasticity and cushioning property by drying and heat-treating after compressing them to a desired density.

Description

[Detailed Description of the Invention] The purpose of the invention is to obtain an abrasive material for mirror finishing that has sufficient elasticity and air permeability, and has fibers uniformly mixed inside a foam having open cells. The present invention relates to an abrasive material in which cell structures of a foam are entangled and interlocked with each other and fixed with a binder containing abrasive grains, and a method for producing the same.

BACKGROUND OF THE INVENTION Conventionally, as a field of abrasive cloth paper, nonwoven abrasive materials with characteristics of bulk and porous structure have been used in the form of rolls, sheets, wheels, etc. for various abrasive and grinding purposes.

By the way, among such non-woven abrasive materials, wheel or roll type abrasive materials obtained by impregnating a bulky web of polyamide, polyester, etc. with a thermosetting resin binder mixed with abrasive grains and molding the resultant material into a spiral or laminated form are as follows: Compression molded by heating and curing thermosetting resin, it is very hard and similar to a grindstone, and is suitable for grinding purposes, but is not suitable for mirror finishing because it does not have cushioning properties, and it is not suitable for giving elasticity.
If a resin binder with low hardness is used, the heat resistance will also decrease proportionally, and the resin binder will fuse to the surface to be ground during grinding, making it unusable.

Furthermore, in order to improve the above-mentioned drawbacks, a bulky nonwoven fabric is impregnated with a synthetic resin liquid containing abrasive grains and then foamed, or a foamable resin liquid is sprayed to form a predetermined spiral shape or a laminate, and then compressed. Nonwoven abrasives that are molded and foamed during a heating process are also found. However, when foaming is done by uniform chemical foaming, the pot life of the mixture is very short, and the nonwoven fabric has many voids, so it is difficult to control the bubbles to a uniform size, resulting in poor production stability and quality. There are many problems with the manufacturing process, such as stability and foam uniformity, and manufacturing must be carried out under strict process control. Furthermore, the obtained product also has various drawbacks, such as difficulty in uniformly foaming between layers, and large variations in grinding performance.

The present invention has been made as a result of intensive studies to improve the above-mentioned drawbacks.
It has been found that it is difficult to stabilize the nonwoven abrasive manufacturing process and the foaming inside the nonwoven fabric due to the above reasons. The reinforcing fiber web is layered and needle-punched to completely incorporate the fibers into the foam structure of the foam sheet with open cells, forming an integrated base material that is intertwined and intertwined with each other. Provided is an abrasive material for mirror finishing with excellent elasticity, air permeability, and heat dissipation properties, which has a skeleton of an open-cell foam sheet uniformly impregnated with a synthetic resin binder and molded into a predetermined shape, and a method for producing the same. It is something to do.

That is, the present invention uses a foam sheet having open cells, such as phenol, urethane, urea, PVC, PE1PVA1 rubber, or guiscose, which has been uniformly foamed in advance, and the surface thereof is coated with palm fiber, coconut fiber, bi-nap fiber, etc. natural fibers,
or polyamide, polyester, aromatic polyamide, polyvinylidene chloride, polypropylene, water-absorbing acrylic,
Random or cross webs formed from chemical fibers such as glass fibers, rock fibers, metal fibers, etc. are laminated and needle punched to uniformly insert and mix the fibers of the web inside the foam, The web fibers are intertwined with each other in the cellular structure of the foam sheet, forming a complex integrated product, in other words, an integrated base material in which the foam is uniformly mixed between the fiber gaps of the nonwoven fabric.

The conditions for the above needle punching process are preferably a driving depth of iom or more and 16 m or less; if it is less than 1018, the fibers of the web will not protrude to the opposite side of the foam sheet and delamination will occur; on the other hand, if it exceeds 16 cores, the foam will If the body is severely damaged, the elasticity will be significantly reduced and the advantage of having fibers mixed inside the foam will be lost.

The number of strokes is 50 p/cJ, preferably 80 to 200 p4
is good. If it is less than 50 p/+c+A, it will be difficult to integrate the nonwoven fabric layer and the foam sheet, and if it exceeds 500 p/+c+A, the foam will be seriously damaged.

- Also, a resin binder and a resin binder to fix the above-mentioned integrated base material and attach abrasive grains such as alundum, carponidum, gilt bronze sand, fused alumina, metal powder, etc., and phenol, epoxy, urethane, etc. Synthetic resin adhesive liquid is used.

Further, the thickness of the open-cell foam sheet layer of urethane, phenol, urea, PvCl rubber, etc. used in the present invention varies depending on the thickness and weight of the natural or chemical fibers of the laminated fiber web. That is, when the fiber diameter is 10 to 20 deniers, the weight is 50 to 150! Iβ is suitable, and the thickness of the foam sheet layer at this time is preferably about 5 words. It is preferable that the thickness of the continuous foam sheet layer increases as the fiber diameter increases or as the weight increases. This is because as the fiber diameter increases, the gaps between each fiber become larger. Ideally, about 60 to 60% of the space in the fiber layer should be occupied by the open-cell foam sheet. If the occupancy rate of this open-cell foam sheet layer is less than 60%, elasticity cannot be imparted, and if it is more than 60%, the synthetic resin binder solution containing abrasive grains may be used on the original fabric during dipping in the post-treatment process. There is a problem in the working process that it is difficult to apply the adhesive uniformly in the thickness direction, and the problem is that the polishing and grinding force is significantly reduced because the open-cell foam layer does not contribute to the polishing action. It is preferable that the foaming ratio of the open-cell foam sheet is large, so that the fibers constituting the laminated fiber web can easily enter the open-cell foam during the needle punching process, making it easier to obtain an integrated base material. However, if the expansion ratio is too large, the elasticity will decrease, so the expansion ratio is preferably 2 to 10 times, and ideally around 5 times.

Next, the diameter of synthetic fibers such as nylon, polyester, etc. of the natural or chemical fibers constituting the web is divided into f groups depending on the grinding performance. In other words, in the field of fine finishing and sharp finishing with abrasive grains, it is 10 to 15 deniers, and the larger the abrasive grains, the greater the grinding force, and it can be used in the fields of intermediate grinding 81j to heavy grinding, and the fibers used accordingly. The diameter is also 20.30.60
It is Sokugo who makes the so-called sword mouth with 1200 denier.

The fibrous web and open-cell foam formed as described above are intertwined and integrated, and then a synthetic resin binder solution containing abrasive grains is applied by impregnation or spraying, and while it is in a wet state, it is rolled and tightened. An abrasive material suitable for a mirror finish with excellent elasticity, air permeability, and cushioning properties is obtained by dry heating through a molding process such as lamination and pressure.

Next, one embodiment of the invention will be described in detail based on the drawings.

Example 1 A 6,6 nylon fiber 15 denier, cut length 51 M, weight 1001 μ2, formed by a Land Utility machine 1, was dispensed downward onto a urethane open-cell foam sheet 3 with a thickness of 5 dens. The web 1111 is laminated on an endless conveyor 4, transferred to a needle punching machine 5, and subjected to needle punching with a needle depth of 14 and a number of strokes of 200 D/cA.
As shown in the figure, the web-constituting fibers 6 are almost completely embedded in the open-cell foam sheet 3 with some fluff remaining on the surface, and the fibers 6 are intertwined and intertwined with each other within the foam structure 7 to form an integrated base material 8.
form.

Next, it is introduced into an immersion tank 9 filled with a resin binder liquid containing abrasive grains of the following composition.

(Urethane prepolymer with resin binder 100 parts Alumina (Su400) 200 parts MIBK
130 parts pigment
Small amount of abrasive grain sedimentation prevention agent 5 parts lubricant 1 part solid content concentration
70% The amount of the above resin binder attached to the base material in a dipping bath is 3.
After squeezing it with a mangle 10 so that it becomes 00 to 650%, the excess solvent is passed through a dryer 11 to evaporate, and then, while it is still in a wet state, it is rolled up with a winding roll 12 and a core made of 7 enol with an inner diameter of 5 foil. 13 in a spiral shape while applying tension, and tighten it so that the rough outer diameter is 550 m and the density is 0.6 y/cyA.

Next, the release paper 14 which had been rolled upward and 01f'l was wound around the spiral roll, the rough outer diameter was fixed at 3508, and it was left in a dry heat treatment furnace at a temperature of 100°C and a dew point of 80''G for 72 hours. The heat treatment is completed by post-curing at room temperature for 5 hours.The resulting spiral roll is cut into 50mm slices with an outer diameter of 305M and a density of 0.4 y/crA.
A spiral abrasive material 15 shown in FIG. 3 was formed.

Example 2 A web of 6,6 nylon fibers of 30 denier, a cut length of 68 mm, and a weight of 200 liters, formed by a Landau Nitzber machine, was spun downward onto a urethane open-cell foam sheet with a thickness of 7JIIIZ. Laminated with a needle punch machine, needle punch depth 16 m, number of punches 200 p/
Needle punching is performed only from the web side under cJ punching conditions to form an integrated base material.

Next, the integrated base material was immersed in the same resin binder liquid in the same manner as in Example 1, and the amount of solid content attached was 200 g/- to 250 g/-!
After squeezing it with a mangle so that it becomes //-, it is passed through a dryer to evaporate the excess solvent, and the wet integrated base sheet is sequentially cut into 1 m width pieces. The cut piece 16 was prepared with a press plate 17 to a thickness of 10mm, fixed at the four corners with bolts 18, and then subjected to a dry heat treatment at a temperature of 100°C and a dew point of 80'' for 72 hours, and then post-cured for 5 hours at room temperature to increase the thickness. Sa1
Qm, density 0.4 y/cy1. Front and rear laminated abrasive material 1
I got a 9.

The abrasive materials 15 and 19 thus obtained are embedded in a urethane open-cell foam 20, as shown in the partially enlarged plan view of FIG. 4, and the mixed fibers 21 are entangled with each other. In other words, the packing has a resin binder 23 containing abrasive grains 22 attached to the intertwined portions, in other words, urethane open-cell foam is mixed in the interlaced fiber gaps.

The above-mentioned uninvented abrasive is widely used for general finishing purposes such as cleaning, polishing, deburring, etc. It can be used in the field of 2-inch finishing, but since it involves foam, the conditions for use are at a wheel circumferential speed of 300 to 900.
m/min 1 Suitable for decorative finishing under low pressure and use in the final finishing field, Western tableware, spoons, forks, stainless steel products such as watch cases and bands, satin finishing of plastics, hair hair of aluminum. A beautiful mirror finish with fine surface roughness can be obtained for single-line finishing.

Next, in order to compare the present invention and the conventional product, a performance comparison test was conducted under the following test conditions.

test conditions Circumferential speed 300m/m, Processing pressure 1. Q 117cm Grinding time 10 minutes Steel plate to be ground The results obtained are shown in the table below.

As described above, the present invention can easily produce an abrasive material with excellent elasticity and cushioning properties, in which resin foam is evenly filled in the interlaced fiber gaps, that is, the foam is formed in a uniform size in the fiber gaps. It becomes possible to obtain stable quality.

In addition, the open-cell foam and fibers are intertwined together to form a complex abrasive layer, which has good air permeability and excellent dissipation of grinding heat, and has excellent elasticity and cushioning properties, so it can be used even on uneven surfaces. It has various effects such as being able to achieve a mirror finish with even finer surface roughness in the fields of cosmetic finishing and final finishing.

[Brief explanation of drawings]

FIG. 1 is a schematic manufacturing process diagram of one embodiment of the present invention, M2
The figure is a side view showing a state in which the fiber web and the open-cell foam are entangled and intertwined, FIG. 3 is a front view showing an example of the abrasive material of the present invention, and FIG. 4 is a partially enlarged plan view of the same. be. 1... Land roll unit machine 2... Web 6... Open cell foam sheet 4... Endless conveyor 5... Needle punch machine 6... Web constituent fibers 7... Inside foam structure 8. ...Integrated base material 9...Immersion tank 10...Wringing roll 11...Dryer 12...Winding roll 16...Phenol core 14...Release paper 15...Spiral shape Abrasive material 16...Cut pieces 17...Press plate 18...Bolts 19...Laminated abrasive material 20...Open cell foam 21...Fibers 22...Abrasive grains 23...・Resin binder patent applicant Hiroshi Kanai, agent Shimei Hayashi

Claims (1)

[Claims] (1) A natural or chemical fiber web laminated on an open-cell foam sheet layer is subjected to a twenty-one dollar punching process so that the fiber web is almost completely embedded within the foam sheet. The fibers are intertwined and intertwined within the foam structure to form an integrated base material, and the integrated base material is fixed together with a synthetic resin binder liquid such as phenol or epoxy urethane containing abrasive grains. An abrasive material that was created in '09. (2) The abrasive material according to claim 1, wherein the open-cell foam sheet is polyurethane, phenol, urea, PVCSPE1PVA, im, or goucose. (6) A random web or cross web formed by using a web forming machine such as a land univer or a card machine using natural or chemical fibers or mixed fibers is laminated on the open cell foam sheet layer. 1. On the above-mentioned web side, the web fibers are almost completely embedded in the above-mentioned photofoam sheet by performing a 21-degree drilling training under the conditions of a driving depth of 1 oin or more and a driving number of 50 p/cfi or more, and then foaming. After forming an integrated base material in which the fibers are intertwined and intertwined with each other within the structure, a synthetic resin binder such as phenol, epoxy, or urethane containing abrasive grains is applied by impregnation or spraying to form the above-mentioned bond. While the agent is in a wet state, it is rolled into a spiral shape or punched and laminated into a predetermined shape, compressed to the desired density, and then dried.
A method for manufacturing an abrasive that is characterized by heat treatment.