JPS6090672A - Nonwoven fabric abrasive made of polyester - Google Patents

Abstract

PURPOSE:To improve impact resilience, abrasion resistance, and adhesive strength by forming an abrasive with a composite polymer consisting of a polyester-series synthetic fiber web, water-repellent polyester resin, and polyurethane resin. CONSTITUTION:A web made of polyester-series synthetic fibers 6 is tentatively fixed with polyester resin 7 to form an unwoven fabric mat. This tentatively fixed mat is used as a substrate, the surface of fibers constituting this substrate is coated with polyurethane resin 8 to form a make-coat layer, which is further coated with thermosetting resin such as phenol containing abrasive grains 3 to form a size coat layer 9, and abrasive grains 3 are stuck on polyurethane resin 8 to form a desired unwoven fabric abrasive made of polyester. In this case, the boundary between polyester resin 7 and polyurethane resin 8 is firmly stuck by urethane bonding, furthermore, polyester-series synthetic fibers 6 and polyester resin are directly stuck to form a firm adhesive section, thus improving the impact resilience, abrasion resistance, and adhesive strength of the abrasive.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention uses a polyester fiber nonwoven fabric, which has the characteristics of polyester synthetic fibers, such as high Young's modulus, hardness, and excellent repellency, as the W-magnetic M1 skeleton of an abrasive material, and coats the fiber skeleton. The present invention relates to the structure of a polyester nonwoven abrasive material that satisfies the function as a reinforcement material by appropriately selecting and using a make coat material and a size coat material.

Conventionally, in nonwoven abrasive materials, polyamide fibers such as nylon 6 and nylon 6.6 fibers have been mainly used as m-fibers for forming webs, and SBR.

Most of them are manufactured by using a thermoplastic resin such as NBR latex, acrylic ester, or vinyl chloride emulsion as a make coat material, and then size-coating a thermosetting resin such as phenol, epoxy, or urethane.

Such polyamide fiber nonwoven abrasive materials have a characteristic that when the make and size coat materials gradually fall off due to the abrasive action, the Young's ridge is small (easily stretches).
Because it is soft and flexible, it tends to lose its elasticity and form, and some products have the disadvantage that they become unusable even if they are not worn out. Furthermore, polyamide fibers are easily degraded (by free phenol), and the current situation is that the degree of deterioration is not sufficient due to variations in the two-nor resin and variations in heat treatment conditions, which adversely affects the ωfM performance.

Additionally, polyamide fibrous webs tend to be thinner and suffer from higher fiber packing densities. This is because the weight ratio of the fibers' tag abrasive grains is limited in terms of polishing performance, and compared to the thickness of polyester fibers, non-woven abrasives made of polyamide fibers have a thickness of about 1%. This is because the abrasive material cannot be obtained and has a high fiber packing density. Therefore, there is a drawback that clogging by the object to be ground occurs quickly. In order to eliminate such shortcomings,
As shown in Fig. 1, polyester fiber 1 is used, and like polyamide fiber, SER, NBR latex, acrylic ester resin emulsion B, etc. are coated with phenol, epoxy, urethane resin, etc., and ωF abrasive grains are applied. A nonwoven abrasive material with a size coat of 4 and a size coat of 3 fixed thereon has also been developed. [7] However, this abrasive material has a weak adhesion strength (adhesive strength) between the polyester fiber 1 and the make coat material 2, and cannot fully demonstrate its function as a make coat material.
1) The volume decreases quickly during use, and although the initial thickness is nearly twice that of polyamide fiber nonwoven abrasives, as it is used, it decreases in volume and becomes thinner, and on top of that, the fibers and make coat material, There is a drawback that the Tizko F material 4 peels off and only the polyester fiber skeleton remains at the end, resulting in a loss of grinding ability. A possible reason for the curling is that synthetic fibers that do not have water absorption properties, such as polyester fibers, have almost no adhesive strength with synthetic resins such as 13BR and MBR, so make coat material 2 and polyester fibers 1
There is a boundary layer 5 which is not in contact with the yuzu abrasive, and therefore, this yuzu abrasive has the disadvantage that it peels off from this boundary layer during use, resulting in faster wear and tear.

Polyamide fibers are synthetic enemy molecules formed by amide bonds -00,NH-, and are acidic molecules.
f+ molecule hexamethylene diamine (Hs+N(O
Hexamethylenediamide (-NH(OHg)6NH-Co) obtained by dehydration condensation with H2)6NHa)
(OHg)400-)p, whereas polyester fiber has terephthalp (HOOC!-Q-OQOH)
Toxf Lenk 5 Equal (HOCHg -0HzO
H) f +1iil Ji combination (-oa/:5-
It has a structural formula of 000-OH2-OH2-0-).

One of the differences between the two is that the water absorption rate is 3-5% for polyamide fiber, while 1 d for polyester resin fiber.
Since polyamide fiber has a polar group NH in its molecules as mentioned above, it has good adhesion to SBR, NER or acrylic ester resin used as a make coat material. Therefore, polyamide fibers are currently being used.

From this point of view, the present invention was developed based on independent studies in order to increase the adhesive strength between polyester synthetic fibers with low water absorption capacity and make coat materials. It was found to be most suitable as a drug. Most of the terminal groups of the above polyester resin are hydroxyl groups (-OH), which are added at random intervals along the main chain of diosulfoM (5O5Na) to make it water dispersible. It has excellent adhesion to mm fibers and can be used as a make coat material. HMD engineering (hexamethylene diine cyanide) -00M-(0H2)6-
The terminal NGO of the polyurethane emulsion whose main component is Noo- and the terminal hydroxyl group (-
on) to form a urethane bond (-NHOO-) to form a three-dimensional crosslinked network. Therefore, as a make coat material, a polyester synthetic fiber and a water-dispersed polyester resin are used as intermediates, and a polyurethane resin is crosslinked together to form a strong film. In other words, the urethane, polyester resin, and polyester synthetic fiber are three-dimensionally cross-linked together, so they have strong adhesion to the polyester synthetic fiber, and because the urethane bond forms a cross-linked network, it has excellent abrasion resistance. A very strong film with excellent rebound properties is formed on the surface of polyester synthetic fibers.

The present invention comprises an abrasive material made of a combination of the above-mentioned polyester synthetic fiber web, a water-dispersible polyester resin, and a polyurethane resin, thereby combining polyamide fibers and SER%N, which are more wear resistant than conventional polyester fiber abrasive base materials.
]3R latex make-coated ω[vi base material also forms an ideal e1 friction material with even better rebound, abrasion resistance, and contact strength.

In addition, the use of polyester synthetic fibers is intended to yield a bulky abrasive material, but it is possible to mix polyester synthetic fibers with a lower melting point into ordinary polyester synthetic fibers with a higher melting point. In the case of the conventional temporary bonding fence by sprinkling a bonding agent, the permeability of the sprayed particles into the inside of the web is insufficient and the bonding is not uniform to the inside, which is a drawback. Although a base material could not be obtained, it became possible to obtain one with any thickness. That is, by mixing about 5 to 40% of low melting point polyester synthetic fibers), after forming the web, heating it at a temperature above the melting point of the low melting point polyester synthetic fibers and below the melting point of the melting point polyester synthetic fibers. This is because it is possible to form a primary temporary fixing non-woven fabric mat.After the secondary temporary fixing layer is applied to this temporary fixing mat by impregnation with polyester and oil, a polyurethane dip make coat is applied to form an abrasive material with a thickness of 60M or more. It became possible.

Next, the configuration of the present invention will be explained in detail with reference to drawing KM.

FIG. 2 shows a cross section of a single fiber of the fiber skeleton constituting the polyester nonwoven fabric abrasive fabric of the present invention, in which 6 is a polyester synthetic fiber, and 7 is a polyester that temporarily binds the polyester synthetic fibers together. 8 is a polyurethane resin used as a make coat layer, and 9 is a size coat layer made of a phenol resin applied to bond the abrasive grains 3 onto the polyurethane resin.

Interface 10 between polyester 7 and polyurethane resin 8
are firmly bonded together by urethane bonding, and there is no boundary layer at the bond between the polyester synthetic fiber 6 and the polyester sacroiliac 7, forming a completely dense layer and forming a strong bond. .

Next, the present invention will be explained in more detail with reference to Examples.

Example 1 A random web having a weight of 350 pld was formed from polyester fibers having a thickness of 30 denier x 38 m using a land univer machine.

Next, a binder liquid having the following composition is sequentially sprayed on both the front and back surfaces of the web, and drying is repeated to obtain a temporarily fixed nonwoven fabric mat in which the fibers are bonded to each other.

Compounding ratio Water-dispersed polyester resin 100 parts Melamine resin 30 parts Catalyst 3 parts M degree 30% The layer with adhesive cloth on both the front and back sides was 100 hours old (solid content), and the polyester resin was completely solidified. thickness 3
A primary temporary fixing nonwoven fabric mat having a weight of 0M and a weight of 5509/rri' was constructed.

Next, this temporarily fixed nonwoven fabric mat was used as a base material and was immersed in a urethane sacroiliac emulsion having the following formulation.

Mixing ratio urethane resin emulsion 100WI melamine toilet fat
30thVS Catalyst 3 parts Water concentration 30% Squeeze the excess liquid with a mangle, adjust the layer M to 250 P/d, and after drying make coat with a polyurethane resin with a mold size of 800 pl, f and thickness of 30%. A second bonded nonwoven mat having layers was formed.

Furthermore, a nonwoven fabric mat with a make coat was immersed in a size coat material solution containing abrasive grains with the following composition, and the mixture ratio was 100 parts phenol and fat, 200 parts abrasive grains, and a small amount of methyl alcohol pigment, with a concentration of 70% Hgy5oy/rr? (solid content), and is subjected to dry heating to fix the abrasive grains on the make coat layer of the secondary adhesive nonwoven fabric mat, and to form a size coat layer coated with phenol resin. . The resulting polyester nonwoven abrasive material weighs 1550
P/ITI' and a thickness of 301 ffl.

Example 2 Mixed fibers of polyester t4ta, 60f kneel 70%, low melting point polyester fiber 15 denier x 51 tone 30% were put into a Landover machine, weight 600y/rr12
, a bulky land web with a thickness of 60 mm is formed. This land web was sandwiched between punch metals whose gauges were adjusted to have a spacing of 50mm on the top and bottom, and then introduced into a dryer maintained at 150°C and heat-treated.
A nonwoven fabric mat whose thickness was controlled to 50 mm was obtained.

Next, the nonwoven fabric mat was dipped in the same polyester resin mixture as in Example 1 and squeezed with a mangle so that the solid content layer was 1801 An'', and the primary temporary fixing nonwoven fabric mat had a weight of 78011/rrl and a thickness of 50 mm. Formed.

Subsequently, it was immersed in a urethane resin compounded solution forming the same make coat layer as in Example 1, and the solid content adhesion amount was 390 f/d.
A make coat layer of urethane resin was formed on the surface of the above-mentioned temporary nonwoven fabric mat by squeezing with a mangle and drying so that the mat was 1170 P/rr? , thickness som
A secondary bonded nonwoven fabric mat of tn was obtained.

Next, the secondary contact layer nonwoven fabric mat was immersed in a resin/abrasive grain mixture having the composition shown in Tl.

Compounding ratio Urethane hatsumode prepolymer 1oo4B Abrasive grains 200 parts Methyl isobutyl ketone pigment A little once 70% Mangle layer kk 1 o o o y/rr? (
The abrasive grains are fixed on the make coat layer of the secondary base mat, and a size coat layer is formed using polyurethane. Weight 2170P7 arms, thickness 5Q ml
A polyester nonwoven abrasive material A was obtained.

The polyester micro woven fabric of the present invention obtained in the above Example 1
As a comparative example with the JF D material, a polyamide fiber web of the same denier and weight as Example 1 was used with Hinipolyester.
Arashi's SDR latex with the same amount of polyurethane resin deposited was deposited, and an abrasive grain-containing Zunor resin was further added as a size coat layer in the same manner as in Example 1 to prepare a polyamide nonwoven fabric @ abrasive material. The thickness of this polyamide non-woven abrasive material is 1511! It was J+.

The polyester non-woven abrasive of the present invention and the conventional polyamide non-woven abrasive of the comparative example were punched into O-wheels with a diameter of 20 cm, and the rotation speed was 5 oor, p, m.

A grinding test was conducted on a vinyl chloride resin plate using cart 10, and the results are shown in FIG. The polyamide nonwoven abrasive material gradually becomes clogged due to the PVC waste being ground, and as time passes, as shown in the figure, the grinding ratio decreases significantly.

In addition, the wheels gradually lost their stiffness and became stiff, until the bales could no longer withstand rotation. On the other hand, the polyester nonwoven fabric DLTL material of the present invention has a coarse mesh, and no decrease in grinding ratio due to clogging is observed. By converting to original debt, rebound elasticity,
Excellent adhesion and gradual reduction in grinding ratio were obtained.

Next, as Comparative Example 2, the same denier as Example 1,
The same S as in Comparative Example 1 using a polyester fiber web of the same weight.
To compare the performance of 4 conventional polyester fiber non-woven abrasive materials A, polyamide non-woven abrasive material B of Comparative Example 1, and polyester non-woven abrasive material 0 of the present invention, which were made in the same way using BR and phenolic resin. The results of measuring the tensile strength, tear strength, and compressive elasticity of each abrasive are shown in Figures 4 and 5.
As shown in the figure.

The above tensile strength was measured under the following test conditions.

Test ridge: Shimaho Autograph test piece 5 cm wide, compression distance 1 Q cm, tensile speed 300 Kawa-1 tear strength was measured by JIS single tank method, and compression recovery rate was measured using test pieces with 20 thicknesses each. It was compressed to 2M, and after being left for 1 hour, the compression was released, and the thickness after 1 minute was measured to calculate the recovery rate.

As shown in Figure 4, the polyester non-woven abrasive material C of the present invention has significantly improved tensile and tear strength compared to the conventional polyester fiber non-woven material A, and is equivalent to or higher than the conventional polyamide non-woven abrasive material B. In addition, as shown in FIG. 5, the compressive elastic recovery rate was extremely superior to that of the nonwoven abrasive materials A-B of Comparative Examples 1 and 2.

The present invention is constructed as described above, and has excellent abrasion resistance and adhesion due to the combination of the excellent elastic properties of polyester fibers, polyester resin, and urethane resin, and urethane bonding. There is little resin shedding of the layer, and the adhesive strength between the polyester fiber and polyester resin is particularly good, so it connects the Nutakagi fiber skeleton of the abrasive base material, has excellent compression recovery rate and rebound resilience, and does not cause clogging. This invention has significant effects such as improved grinding performance, and is ideal as an industrial abrasive for household scrubbing brushes, woodworking, metal J4, etc.

[Brief explanation of the drawing]

Fig. 1 is a cross-sectional view of fibers constituting a conventional polyester fiber non-woven abrasive material, Fig. 2 is a cross-sectional view of fibers constituting a polyester non-woven abrasive material according to an embodiment of the present invention, and Fig. 3 is a cross-sectional view of fibers constituting a polyester non-woven abrasive material according to an embodiment of the present invention. Curve diagram showing the progression of grinding ratio between and comparative example, 4th
The figure is a curve diagram showing the tensile strength and tear strength of the present invention and Comparative Examples 1 and 2, and FIG. 5 is a graph showing the recovery rate. 1... Polyester fiber 2... Make coat resin 3... Abrasive grains 4... Size coat resin 5... Boundary J4 6... Polyester synthetic copper fiber 7... Polyester grape B effect 8...Polyurethane sacrocoat 9...Size coat layer 10...Interface bamboo permit applicant Hiroshi Kanai, agent Kiyoshi Hayashi 1° Akira) 3 4 Portrait of Kaishi 1st grade question (kr)-

Claims (1)

[Claims] 11) A web made of polyester synthetic fibers is temporarily fixed with a polyester resin to form a temporarily fixed nonwoven fabric mat as a base material, the surface of the constituent fibers of the base material is coated with a polyurethane resin to form a make coat layer, and the above-mentioned A size coat layer is formed by coating a make coat layer with a thermosetting resin such as epoxy, thunol, or polyurethane containing abrasive grains such as aluminum oxide or silicon carbide. The polyester nonwoven abrasive material according to claim 1, characterized in that: