JPS61279469A - Endurance improved abrasives - Google Patents

Abstract

PURPOSE:To obtain endurance improved new abrasives of extremely excellent abrasive performance by electro-statically transplanting the cut piles of ceramic fiber mingled with cut piles made of specified amount of reinforcing fiber together with transplant binder on base material. CONSTITUTION:The cut piles of ceramic fiber such as silicon cabide fiber, silicon nitriding fiber, molten alumina fiber or the like mingled with reinforcing fiber cut piles of 1 to 50%, or 5 to 20% desirably, in weight are electro-statically transplanted together with transplanted binder on base material. For reinforcing fiber such synthetic fiber as carbon fiber, aramid fiber, polyester fiber, polyamid fiber, and polyolefine fiber, metallic fiber, and glass fiber are recommended. Acrylic resin, polyurethane resin, polyester resin, polyamide resin, epoxy resin, and nylon resin or the compound are suitable for transplant binder, and are to be used depending upon the kinds of cut piles of reinforcing fiber and base material.

Description

[Detailed Description of the Invention] [Industrial Field of Application] The present invention is a new and high-performance abrasive material, which is suitable for use in equipment, parts of electric/electronic/magnetic materials, aircraft, artificial satellites, rockets, etc. Regarding abrasive materials that are ideal for finishing materials and parts that require a high degree of precision, such as vehicles, glass products, and jewelry.

[Prior art]

Conventional finishing abrasive materials for precision instruments include diamond,
Natural abrasives such as garnet and silica sand, fused alumina, zirconium oxide, titanium oxide, zinc oxide, silicon carbide,
Artificial abrasives such as silicon nitride and calcined alumina are common, and grindstones are either cut from natural stones such as sandstone, granite, tuff, or quartz trachyte, or natural or artificial abrasives are used. clay or feldspar.

There are artificial whetstones made by firing a mixture of china clay, sodium silicate, zinc oxide, etc.

Abrasive brushes such as wire brushes and ceramic brushes are mainly used for rough finishing and are rarely used for finishing.Abrasive cloth and abrasive paper are made by applying abrasive particles to cloth or paper with glue or drying oil. is common.

Recently, abrasive cloth and abrasive paper, which are made by kneading ceramic or cermet particles or cut piles into a synthetic resin and coating the surface of a base material such as cloth, nonwoven fabric, or paper, have become popular.

[Problem that the invention seeks to solve]

Among conventional abrasive materials, particles made of diamond, ceramics, and cermet, or cut piles of ceramic fibers, which are popular for finishing polishing of precision instruments, are kneaded into synthetic resin, and this is applied to cloth, nonwoven fabric, paper, etc. In the abrasive cloth and abrasive paper coated on the surface of the human body, the arrangement of the abrasive particles and cut piles mentioned above is random, so only a small portion of the edges that are useful for polishing come out to the surface, making it difficult to polish. Performance is also far from perfect,
It uses extremely expensive materials and only a portion of it has an abrasive effect, making it extremely inefficient.

Also, the method of flocking ceramic fibers to make abrasive cloth has been known for 5 to 6 years and has been studied extensively, but it is difficult to shred ceramic fibers with an accuracy of 0.11 layers or less. Furthermore, since flocked binders are designed primarily for their adhesion to base fibers, they have poor adhesion to ceramics.While adhesives for ceramics have excellent adhesion, they do not have the required characteristics for flocked binders. Even today, there are many problems such as difficulty in coating, poor pile sticking during flocking, and the viscosity of the binder decreases significantly during drying, causing the flocked pile to fall flat. The reality is that it is not.

Furthermore, even if ceramic hair transplantation were completed, 0
．． Ceramic fibers of 5 to 3 d are hard, but have low toughness and are easily broken during polishing work, which is one of the drawbacks that makes it difficult to commercialize ceramic flocking.

[Purpose of the invention]

The present invention is a unique technology discovered through numerous experiments and the development of new technology in order to solve the above-mentioned problems. The purpose of the present invention is to provide a new abrasive material with improved durability.

[Structure of the invention]

That is, the present invention provides durability by electrostatically flocking a pile mixture consisting mainly of cut piles of ceramic fibers and 1 to 50% by weight of cut piles of reinforcing fibers on a base material together with a flocking binder. is an improved abrasive material.

The first feature of the present invention is to use a cut pile mixture consisting mainly of ceramic fiber cut pile as the fibers to be flocked and mixed with 1 to 50% by weight cut pile of reinforcing material fiber.

Ceramic fibers include silicon carbide fibers, silicon nitride fibers, fused alumina #fibers, fused silica alumina fibers, as well as fibers made by melt-spinning silicon carbide, fused alumina, silicon oxide, and zirconium oxide fine powder mixtures.

Specifically, silicon carbide m-fiber "Nicalon" manufactured by 8 Water Carbon Co., Ltd., silica alumina fiber #I "Ibiwool" manufactured by Ibiden, and alumina fiber "Safil (S) manufactured by ICI Ltd. in the UK are used.
AFFIL)", silica-alumina fiber "Carowool" manufactured by Isolite, "NEXTEL", "TYNEX-", a viscous fiber made of silicon carbide and alumina particles manufactured by DuPont
There are commercially available products such as A'' with a single yarn fineness of 05 to 1000 d.

These ceramic fibers are cut into layers of 0.5 to 10.0 m using a zirconium diamond cutter to form cut piles.

Examples of reinforcing fibers for ceramics #a include synthetic fibers such as carbon fibers, aramid fibers, polyester fibers, polyamide fibers, and polyolefin fibers, metal fibers, and glass fibers. Specifically, in addition to the aramid fiber "Kevlar" manufactured by DuPont, the carbon fiber "Traca" manufactured by Toshi, and the polyester resin fiber "Dacron" manufactured by DuPont, various commercially available polyester fibers, polyamide fibers, etc. Single fiber fineness of synthetic fibers, glass fibers such as E-HTS glass and S glass, metal fibers such as steel wire, etc. O05-100
There is a commercially available product of 0 d. These reinforcing fibers are 0.5~
Shred into 10,0×1 pieces to make cut pile.

The cut pile of the ceramic fiber and the cut pile of the reinforcing material fiber are mixed to form a canted pile for flocking.
In this case, the amount of reinforcing fiber cut pile mixed is 1 to 5.
The reinforcing material must be 0% by weight, and more preferably 5 to 20% by weight! If the amount of I-cut pile is less than 1%, the toughness of the ceramic fibers will be extremely low.
The ceramic scar/dopile easily breaks and breaks due to the contact pressure during polishing, and the drawback is that the durability of polishing is poor. On the other hand, if the mixing amount of the reinforcing fiber cut pile exceeds 50% by weight, the proportion of the ceramic cut pile decreases, resulting in lower polishing performance, as well as problems caused by the conductivity of the reinforcing fiber cut pile and poor abrasiveness. Defects such as harm become stronger.

The ceramic fiber cut pile and reinforcing fiber cut pile used in the present invention are separately prepared in a 10 to 20% by weight aqueous solution of a conductive treatment agent such as magnesium sulfate, sodium silicate, calcium sulfate, soda carbonate, sodium chloride, etc. It is preferable to pass through a sieve sorting process after soaking, dehydration, and drying, and add 1 to 50 weight percent, preferably 5 to 20 weight percent, of reinforcing fiber cut pile to the conductive-treated ceramic fiber cut pile, and uniformly add it to the conductive treated ceramic fiber cut pile. Mix and make cut pile for hair transplantation.

The selection of the base material for flocking the cut pile for flocking is determined by the type of material to be polished and its shape, but generally carbon fiber, aramid fiber, glass fiber, asbestos,
Fabrics and non-woven fabrics made of synthetic fibers, fabrics made of steel fibers, metal wire mesh and metal panels, plastic film-sheet panels and foam sheets, ceramic boards and paper can be selected depending on the purpose.

The second feature of the present invention is the selection of the flocked binder.

The flocked binder strongly adheres the base material and the cut pile of ceramic fibers and the car and do pile of reinforcing fibers, and uses hot water or oil to remove frictional heat and powder to be polished during polishing, so the adhesion performance is improved by hot water or oil. The essential conditions are that peeling from the base material and pile removal without deterioration, cracking or cracking of the flocked fabric due to deterioration of the binder, and no swelling or surface change of the binder.

Furthermore, the toughness of the cut pile of the flocked ceramic fibers is low, and although the cut pile of the reinforcing material fibers is protected to some extent, the flocked binder has flexibility and the angle of the pile relative to the base material can be adjusted to a certain degree. Moving cushioning properties are an important element, and the flocked binder must serve to absorb the strong friction and vibrations that act on the ceramic fiber card pile during polishing.In addition, the flocked binder must be suitable for viscosity and pile standing. Needless to say, it is necessary.

As the flocking binder used in the present invention, acrylic resin, polyurethane resin, polyester resin, epoxy resin, and nylon resin alone or in a mixture are suitable, and they can be selectively used depending on the cut pile of the reinforcing fiber and the type of base material.

When flocking a cut pile mainly made of cut pile of ceramic fiber used in the present invention to a base material, the flocking binder is suitable for flocking, has excellent adhesion performance, and has versatility. It is a mixture, and its polymerization method and preparation method will be described below.

Water-soluble acrylic resin has tertiary amine groups, carboxylic acid groups,
Monomer having an unsaturated double bond having a hydroxyl group [A]
, for example dimethylamino methacrylate, diethylamino methacrylate, acrylic acid, methacrylic acid, maleic acid, maleic anhydride, itaconic acid, hydroxyl methacrylate, hydroxylethyl acrylate, hydroxylpropyl acrylate, etc., and unsaturated 2
Hetamine (B) of acrylic ester having a heavy bond,
For example, it can be obtained by polymerization reaction with ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, stearyl methacrylate, lauryl methacrylate, butyl methacrylate, ethyl methacrylate, acrylonitrile, styrene, and the like. In this polymerization reaction, the polymerization solvent has a boiling point of 55 to 100℃ and a flash point of 10 to 50℃.
Using an alcohol or ketone within the range of 0.2 to 1.0 °C based on the resin solid content, adding a radical initiator such as azobisnitrile and heating at 80 to 85 °C for 2 to 8 °C.
A time polymerization reaction is carried out, and the number average molecule i to, ooo~s
o, ooo, conduct a polymerization reaction to obtain a polymer with a glass transition point of 130 to 50°C, preferably 10 to 30°C. Next, add an alkaline component such as triethylamine or an acid component such as acetic acid to this. A neutralized and water-solubilized acrylic resin polymer (P) is produced. This polymer (P
) has a resin acid value of 10 to 90, a resin OH value of 6 to 80, a resin base value of 30 to 90, and a P)I value of 5 to 9.

On the other hand, emulsion-based acrylic resin contains 0.5 to 6 parts by weight of 7-mer (A) having an unsaturated double bond having a tertiary amine group, a carboxylic acid group, and a hydroxyl group, and an acrylic resin having an unsaturated double bond. An emulsifier and water are added to a seven-mer mixture containing acid ester monomer CB) as a main component, stirred at high speed to form an emulsion, a radical initiator is added, and emulsion polymerization is carried out at 70 to 35°C to obtain a glass transition point of -80 to 10. °C, number average molecular weight t
An emulsion-based acrylic resin polymer (Q) is produced which is copolymerized to have a molecular weight of oo, ooo to 1,000,000.

In the water-soluble acrylic resin poly-(P) and acrylic emulsion resin polymer (Q), the solid content ratio is 871 to 3.
/7 to prepare an aqueous mixed polymer (R) having a solid content of 30 to 50% by weight. Add a water-soluble polyglycidyl compound and a water-soluble melamine curing agent to the polymer (R) at a resin solid content ratio of 1,120 to 1/2, respectively, add an antifoaming agent, and then stir well, optionally to adjust the viscosity. A thickener is added to make a flocking binder.

The abrasive material with improved durability according to the present invention can be suitably manufactured by the following steps. First, apply the flocked binder described above on the surface of the base material at a rate of 100 to 500 g/m2.
However, if the surface of the base material is flat, apply it by coating, or if the base material is a molded product, apply it evenly by spraying.6 Next, apply the above ceramic fibers and reinforcing material fibers to the base material coated with the flocked binder. Electrostatically flocked mixed cut pile of
Baking is performed at 70°C for 1 to 6 minutes. In this case, the floating hair is removed and the product is used as is, and the flocked surface is prepared with a diluted product of the mixed polymer (R), a water-soluble polyglycidyl compound, and a water-soluble polyglycidyl compound. A method is to add a melamine curing agent and, in some cases, a capsule foaming agent, and apply it 1 to 5 times with a sponge roller coater, infiltrate the binder between the flocked piles, and dry and bake it again to make the product. be.

The abrasive material in which cut piles of ceramic fibers and reinforcing material fibers are flocked by the method described above has extremely high abrasive efficiency because the cut surface of the ceramic fibers is 10,000 to 10,000 mm straight, all of which destroy the polishing ability. is excellent and.

Since the cut surfaces of the ceramic 2x fibers are evenly arranged in parallel on the same plane, the polishing accuracy is also very good. In addition,
If the flocked pile is made of ceramic fiber alone and a flocked binder with high hardness is used, the ceramic fiber pile will completely break and break if a force of 508/c■2 or less is applied to the flocked surface during polishing, so it cannot be used as an abrasive. The effect of the present invention cannot be exerted because the role of this is lost.

When the above-mentioned flocked binder according to the present invention was used, almost no pile breakage was observed even in flocked piles made of ceramic fibers alone, even when the force acting on the flocked surface during polishing was 100 to 20081 cm2.

Ceramic fiber piles mixed with 5 to 20% reinforcing fibers will hardly break even if a load of 200 to 500 g/cm2 is dropped, and the flocked surface is further coated with binder resin. If the flocked pile is completely fixed, it is possible to completely prevent the ceramic fiber pile from breaking even if a load of 500 g/cm2 or more is applied.

As mentioned above, due to the flexibility of the flocked binder, the addition of reinforcing fiber pile, and the adhesive fixation of the flocked pile,
The drawback of flocked ceramic piles being broken has been improved,
Moreover, it has very excellent performance in that the polishing ability hardly changes. The flocked binder according to the present invention not only has excellent adhesion between the flocked base material and the ceramic pile and its reinforcing pile, but also prevents the pile from coming out and forming contact with the base material when immersed in hot water, oil, or other chemicals. It has excellent properties such as no deterioration in performance such as peeling.

〔Example〕

As a ceramic fiber, silicon carbide m-fiber "Nicalon" manufactured by Romoto Carbon Co., Ltd., 1.5d x 30F, was shredded into 1H lengths using a cutter embedded with diamond and zirconium, and mixed with 5% magnesium sulfate and 15% sodium silicate.
After being soaked in an aqueous solution and subjected to conductive treatment, it is passed through a sieve and sorted after drying.

Aramid fiber “Kevlar 2” made by Toshi as a reinforcing material fiber
8″ 1.5d x 100F or the same company's “Tetron” tow 1.5d
) After being cut into lengths and dyed, the pieces are immersed in an aqueous solution of 5% magnesium sulfate and 15% sodium silicate, and the dried pieces are sieved and sorted.

The method for producing a flocked binder is to mix the cut pile of the above-mentioned "Nicalon" and the reinforcing material mI& in a weight ratio of 8:2 to make a uniform cut pile mixture. , 17 parts of methyl methacrylate, 7 parts of dimethylaminomethacrylate, 2 parts of acrylic acid, ? - A monomer mixed solution of 2 parts of hydroxyethyl methacrylate and 0.4 parts of radical initiator azobisnitrile is added dropwise to carry out a polymerization reaction at 80 to 85°C for 5 hours.
1 part and 7.6 parts of pure water to make an aqueous solution with a resin solid content of 50%. The viscosity of this polymer Z4. MM was added to the polymerization reactor which had been replaced with nitrogen while flowing nitrogen.
Add 17 parts of A, 18 parts of B A, 3 parts of 2-hydroxyethyl methacrylate, 3 parts of ethyl acrylate, 3 parts of sodium dodecylbenzenesulfonate as an emulsifier, 0.2 part of concentrated potassium sulfate as a polymerization initiator, and 55 parts of water. Polymerize at 60-65°C for 4 hours with vigorous stirring until the solid content is 44.
%, number average molecular weight 500.000, glass transition point -28
``A 7-ion type acrylic emulsion resin of C1PH5.5 is obtained.

50 parts of the water-soluble acrylic resin polymerized in this manner, 30 parts by weight of the acrylic emulsion resin, and 0 parts of the antifoaming agent.
．． 2 parts by weight, 6 parts of isopropyl alcohol, 6 parts of pure water
Part by weight, Emacol NSBLA manufactured by Sanyo Shiki Co., Ltd.
K-A 8304 weight 10,000~20,000 C
A flocked binder is prepared by adding Poncoat V manufactured by Dainippon Ink Co., Ltd. and a small amount of ammonia water to adjust the viscosity so that it becomes PS.

The base fabric is 100% polyester taffeta fabric, 100% glass fiber T6 fabric, carbon edge M 100% fabric, or aramid fiber fabric.
g/m” coating and electrostatically flocking the above ceramic 8-rot mixed cut pile. In some cases, the floating stones are removed with compressed air spray and used as a polishing material as a product, and in other cases, the above flocking coating agent is coated with isopropyl alcohol. and water at a ratio of 1:l to dilute to 20% concentration, add Matsumoto Yushi's capsule foaming agent F30, apply it to the flocked surface, and fix the flocked pile with resin through drying and baking processes to make the product. In some cases,

〔Effect of the invention〕

The effects of the ceramic flocked abrasive material obtained by the manufacturing method of the present invention are summarized as follows.

(1) Very good polishing performance and stable quality.

(2) The manufacturing cost is low, and is 1/10 to 1/2 the cost of coatings coated with diamond, zirconium, or ceramic particles.

(3) Because the abrasive cloth and binder are elastic and flexible, and a reinforcing agent is added, there is very little chance of the ceramic breaking or breaking due to impact force or strong friction.

(4) The flocked binder has excellent adhesion performance, so there is no peeling or shedding phenomenon, and water resistance, oil resistance, and chemical resistance are also excellent.

Claims (3)

[Claims] (1) A pile mixture consisting mainly of cut pile of ceramic fibers and 1 to 50% by weight of cut pile of reinforcing material is placed on the base material, and electrostatically flocked together with a flocking binder to improve durability. Improved abrasive material. (2) The reinforcing material fibers are aramid fibers, carbon fibers, polyester fibers, polyamide fibers, polyolefin fibers,
The abrasive material according to claim (1), which is one or more types of fibers selected from the group consisting of metal fibers and glass fibers. (3) The flocking binder is one or two selected from the group consisting of polyurethane resin, polyester resin, polyamide resin, epoxy resin, melamine resin, and acrylic resin.
The polishing material according to claim (1), which is made by blending an epoxy curing agent and a melamine curing agent with at least one resin.