WO2012029547A1 - 研磨布およびその製造方法 - Google Patents
研磨布およびその製造方法 Download PDFInfo
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- WO2012029547A1 WO2012029547A1 PCT/JP2011/068645 JP2011068645W WO2012029547A1 WO 2012029547 A1 WO2012029547 A1 WO 2012029547A1 JP 2011068645 W JP2011068645 W JP 2011068645W WO 2012029547 A1 WO2012029547 A1 WO 2012029547A1
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- Prior art keywords
- fiber
- polishing cloth
- fibers
- sea
- ultrafine
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
-
- G—PHYSICS
- G11—INFORMATION STORAGE
- G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
- G11B5/00—Recording by magnetisation or demagnetisation of a record carrier; Reproducing by magnetic means; Record carriers therefor
- G11B5/84—Processes or apparatus specially adapted for manufacturing record carriers
- G11B5/8404—Processes or apparatus specially adapted for manufacturing record carriers manufacturing base layers
Definitions
- the present invention relates to a polishing cloth and a method for manufacturing the same that are suitably used when performing ultra-high-precision polishing and / or cleaning on substrates such as aluminum alloy substrates and glass substrates used for magnetic recording disks and the like. Is.
- Magnetic recording disks are required to be smoothed to the limit of the disk surface with the recent increase in storage density.
- a perpendicular recording medium in which an easy axis of magnetization in a magnetic film is oriented in a perpendicular direction has become the mainstream as a recording method for a magnetic recording disk.
- the disk surface before the formation of the magnetic film is required to have a substrate surface roughness of 0.2 nm or less and to minimize scratches on the substrate surface called scratch defects.
- the requirement for the substrate before forming the magnetic layer is the smoothing to the limit as described above.
- the fibers constituting the nonwoven fabric of the polishing cloth are made extremely fine, and in order to minimize scratches on the surface of the substrate, the nonwoven fabric constituting the polishing cloth is provided with a high cushioning property.
- Proposals have been made to impregnate molecular elastic bodies.
- a polishing cloth has been proposed in which a non-woven fabric composed of ultrafine fibers having a single fiber diameter of 0.05 to 2.0 ⁇ m contains a polymer elastic body mainly composed of polyurethane (see Patent Documents 1 and 2). In this proposal, a surface roughness of about 0.2 nm is achieved.
- an object of the present invention is to provide a high-performance polishing cloth that has fewer scratch defects than a conventional polishing cloth made of ultrafine fibers and enables high-precision polishing. It is in.
- Another object of the present invention is to provide a method for efficiently producing the above polishing cloth.
- the present invention is intended to solve the above-mentioned problems, and the polishing cloth of the present invention has an ultrafine fiber bundle formed by converging ultrafine fibers having an average single fiber diameter of 0.05 to 2.0 ⁇ m. And an average size in the width direction of the ultrafine fiber bundles of the surface fiber raised portions of the non-woven fabric, which is mainly composed of the ultrafine fiber bundles.
- the average size in the width direction of the ultrafine fiber bundle of the surface fiber raised portion is 50 to 120 ⁇ m.
- the surface roughness of the polishing cloth is 5 to 18 ⁇ m.
- the CV value of the ultrafine fiber is 1 to 30%.
- the method for producing an abrasive cloth of the present invention is a method for producing an abrasive cloth comprising a combination of at least the following steps (1) to (5), and is made into ultrafine fibers brought in by a needle punch in the following step (2).
- the number of sea-island type composite fibers that can be made into ultrafine fibers brought in by the needle punch in the step (2) is 3 to 4 bars / 1 barb.
- the present invention it is possible to obtain a polishing cloth that has a smaller size in the width direction of the ultrafine fiber bundle of the surface fiber raised portion made of the ultrafine fiber bundle and has excellent smoothness than the conventional abrasive cloth. Therefore, it is possible to reduce the surface roughness of scratches and objects to be polished in slurry grinding using a tape-like polishing cloth and / or cleaning using a slurry on the substrate surface of the recording disk. A cloth is obtained.
- the polishing cloth of the present invention is preferably used when an aluminum alloy substrate or a glass substrate used for a magnetic disk is polished and / or subjected to a cleaning process with an ultra-high precision finish.
- the above polishing cloth can be produced efficiently.
- FIG. 1 is an enlarged (40 ⁇ ) photograph of a drawing substitute SEM showing an example of the surface of the polishing cloth of the present invention.
- FIG. 2 is a schematic diagram for explaining a method for estimating the number of composite fibers brought in at the time of needle punching with respect to the relationship between the needles and the composite fibers at the time of needle punching.
- the inventors of the present invention have proposed that the structure of the surface fiber raised portion composed of ultrafine fiber bundles on the surface of the polishing cloth is extremely fine.
- the nonwoven fabric constituting the polishing cloth is mainly composed of a nonwoven fabric in which ultrafine fiber bundles formed by converging ultrafine fibers having an average single fiber diameter of 0.05 to 2.0 ⁇ m are entangled, and the surface of the polishing cloth is extremely fine. It has been clarified that the above-mentioned problems can be solved at once by using a nonwoven fabric having a size of 50 to 180 ⁇ m in the width direction formed by the ultrafine fiber bundle of the structure of the surface fiber raised portion composed of the fiber bundle. is there.
- the average single fiber diameter of the ultrafine fibers used in the present invention is important to be 0.05 to 2.0 ⁇ m from the viewpoint of the density of the polishing cloth surface fibers, the fiber strength, and the gripping ability of the abrasive grains.
- the average single fiber diameter is important to be 0.05 to 2.0 ⁇ m from the viewpoint of the density of the polishing cloth surface fibers, the fiber strength, and the gripping ability of the abrasive grains.
- Examples of the polymer forming the ultrafine fiber used in the present invention include polyester, polyamide, polyolefin, polyphenylene sulfide (PPS), and the like. Many polycondensation polymers represented by polyester and polyamide have a high melting point and are excellent in heat resistance against heat generated during polishing, and these are preferably used. Specific examples of the polyester include polyethylene terephthalate, polybutylene terephthalate, and potytrimethylene terephthalate. Specific examples of the polyamide include nylon 6, nylon 66, nylon 12, and the like.
- the polymer constituting the ultrafine fiber may be copolymerized with other copolymerization components, and these polymers may contain additives such as particles, flame retardants and antistatic agents. good.
- additives such as particles, flame retardants and antistatic agents. good.
- other copolymer components include sodium 5-sulfoisophthalate, 3-hydroxybutanoic acid, nylon 6, nylon 66, nylon 12, and the like.
- the particles include titanium oxide.
- the flame retardant include an organic flame retardant and an inorganic flame retardant.
- the antistatic agent include alcohol-based antistatic agents.
- a short fiber nonwoven fabric obtained by forming a laminated fiber web using a card and a cross wrapper and then performing needle punching or water jet punching.
- the long fiber nonwoven fabric obtained from the spunbond method, the melt blow method, etc., the nonwoven fabric obtained by the papermaking method, etc. can be employ
- a short fiber nonwoven fabric and a spunbond nonwoven fabric are preferably used because an aspect of an ultrafine fiber bundle as described later can be obtained by a needle punching process.
- the nonwoven fabric which is the fiber entangled body contains a polymer elastic body.
- a polymer elastic body in the fiber entangled body, it is possible to prevent the ultrafine fibers from falling off from the polishing cloth due to the binder effect of the polymer elastic body, and to form uniform napping at the time of raising.
- cushioning properties can be imparted to the polishing cloth, and scratch defects on the surface of the substrate to be polished by polishing can be reduced.
- polyurethane, polyurea, polyurethane / polyurea elastomer, polyacrylic acid, acrylonitrile / butadiene elastomer, styrene / butadiene elastomer and the like can be used.
- polyurethane elastomers such as polyurethane and polyurethane / polyurea elastomer are preferably used.
- the weight average molecular weight of the polymer diol component of the polyurethane used as the main component of the polymer elastic body is preferably 500 to 5000, more preferably 1000 to 3000.
- the weight average molecular weight is preferably 500 or more, more preferably 1000 or more.
- a weight average molecular weight into 5000 or less, More preferably, 3000 or less, the increase in the viscosity of a polyurethane solution can be suppressed and it can make it easy to impregnate a microfiber layer with polyurethane.
- diol component that is the raw material of the polyurethane
- polyether diol polyester diol
- polycarbonate diol polycarbonate diol
- polylactone diol copolymers thereof are preferably used.
- the diisocyanate component that is a raw material of polyurethane, aromatic diisocyanate, alicyclic isocyanate, aliphatic isocyanate and the like can be used.
- the ratio of the polyether diol component in the polymer diol is 60% by mass or more, More preferably, it is 70 mass% or more.
- the weight average molecular weight of the polyurethane used in the present invention is preferably 100,000 to 300,000, more preferably 150,000 to 250,000.
- the weight average molecular weight of the polyurethane is preferably 100,000 to 300,000, more preferably 150,000 to 250,000.
- the gel point of the polyurethane is preferably in the range of 2.5 to 6.0 ml.
- the gel point is more preferably in the range of 3.0 to 5.0 ml.
- the gelation point of polyurethane refers to a solution in which 100 g of N, N′-dimethylformamide (hereinafter sometimes abbreviated as DMF) having a polyurethane concentration of 1% by mass is added dropwise with distilled water while stirring.
- DMF N, N′-dimethylformamide
- This is the value of the amount of water dripping when the solidification of polyurethane starts and becomes slightly cloudy under a temperature condition of 25 ⁇ 1 ° C. For this reason, it is necessary to use the DMF used for the measurement of the gel point with a water content of 0.03% or less.
- the method for measuring the gel point described above is described on the assumption that the polyurethane DMF solution is transparent. However, when the polyurethane DMF solution is slightly cloudy in advance, coagulation of the polyurethane starts to become cloudy.
- the amount of water dripping when the degree changes can be regarded as the gel point.
- the gel point is less than 2.5 ml
- the coagulation rate is too fast, and foaming of the polyurethane existing in the interior space of the nonwoven fabric may be largely rough.
- the gel point is less than 2.5 ml
- unevenness occurs in the napped length of the ultrafine fibers on the napped surface, In some cases, the distribution of the napped fibers is uneven, and it is impossible to obtain a state in which the abrasive grains are uniformly dispersed on the napped surfaces, so that it is not possible to achieve ultra-high precision finishing.
- polyurethane is preferably used as the main component as the polymer elastic body, but it contains other resins as long as it does not impair the performance and the uniform dispersion state of napped fibers as a binder. Also good.
- other resins include polyester resins, polyamide resins and polyolefin elastomer resins, acrylic resins and ethylene-vinyl acetate resins.
- the polymer elastic body includes various additives such as phosphorus-based, halogen-based, inorganic-based flame retardants, phenol-based, sulfur-based, phosphorus-based antioxidants, benzotriazole-based, benzophenone-based, salicylate.
- UV absorbers such as cyanoacrylates, oxalic acid anilides, light stabilizers such as hindered amines and benzoates, hydrolysis stabilizers such as polycarbodiimides, plasticizers, antistatic agents, surfactants and A small amount of a coagulation adjusting agent or the like may be contained.
- the shape of the polymer elastic body inside the nonwoven fabric is at least part of the single fibers located on the outermost periphery of the fiber bundle made of ultrafine fibers from the viewpoint that the fibers are not dropped off and the directionality of the napped fibers is uniform. It is a preferable aspect that is in a state of being bonded.
- This form can be obtained by the method (B) described later. That is, since the polyvinyl alcohol protects most of the outer periphery of the ultrafine fiber bundle, polyurethane is prevented from entering the inside of the ultrafine fiber bundle, and the outer periphery of the fiber bundle that is not partially protected by polyvinyl alcohol The polyurethane will adhere.
- the degree of freedom of the napped ultrafine fibers on the napped surface can be appropriately controlled by partially adhering and restraining the fibers located on the outermost periphery of the ultrafine fiber bundle with the polymer elastic body.
- the free directionality of the napped fibers after the buffing process is extremely reduced. That is, the napped fibers can be adjusted to be aligned in one direction.
- the napped fibers are uniformly aligned in one direction, and the unevenness of the fine fibers existing on the napped surface is small, and the ultra fine fibers can be uniformly arranged.
- the napped fibers are densely and uniformly distributed in a state aligned in one direction, and the directionality of the fibers is aligned in one direction.
- cushioning and fitting properties are important in terms of polishing accuracy. These cushioning properties and fitting properties can be controlled and adjusted by the ratio of fine fibers and the polymer elastic body and the porosity (which can be seen by the apparent density).
- the ultrafine fibers and the polymer elastic body are preferably 50 to 100% by mass, more preferably 80 to 100% by mass, based on the total mass of the polishing cloth.
- the ultrafine fiber is preferably 40 to 90% by mass, more preferably 50 to 80% by mass, based on the total weight of the polishing cloth.
- the content of the elastic polymer is preferably 10 to 50% by mass, more preferably 10 to 40% by mass, based on the total mass of the polishing pad.
- the surface state, porosity, cushioning property, hardness, strength, and the like of the polishing cloth can be appropriately adjusted depending on the content of the polymer elastic body.
- the polishing cloth of the present invention may contain a reinforcing material such as a woven fabric as a component other than the ultrafine fibers and the polymer elastic body.
- the polishing cloth of the present invention it is important that at least one surface of the polishing cloth is a raised surface made of ultrafine fibers from the viewpoint of the denseness and dispersibility of the ultrafine fibers on the surface of the polishing cloth.
- FIG. 1 is a drawing-substitute SEM enlarged (40 ⁇ ) photograph showing an example of the structure of the surface fiber napped portion formed by the ultrafine fiber bundle on the surface of the polishing cloth of the present invention.
- the napped surface of the polishing cloth is formed with a structure including a surface fiber napped portion composed of a bundle of ultrafine fibers.
- the surface fiber raised portion is shown by a square in FIG.
- the direction of the ultrafine fiber bundle (the width direction of the fiber bundle) is the transverse direction of the structure of the surface fiber napped portion, and the length direction in which the ultrafine fibers of the ultrafine fiber bundle are aligned. Is the length direction of the structure of the surface fiber raised portion.
- the ultrafine fibers may be evenly arranged, the ultrafine fibers may be somewhat separated from each other, may be partially bonded, or are aggregated. May be.
- the bond refers to a chemical reaction or physical fusion
- the aggregation refers to a molecular force such as a hydrogen bond
- the average size in the width direction of the ultrafine fiber bundle having the structure of the surface fiber raised portion is in the range of 50 to 180 ⁇ m, and preferably in the range of 50 to 120 ⁇ m.
- the average size in the width direction of the ultrafine fiber bundle having the structure of the surface fiber raised portion is 180 ⁇ m or less, the ultrafine fiber bundles of the surface fiber raised portion do not overlap each other, and the unevenness on the surface of the polishing cloth is reduced.
- it is difficult to give scratch defects to the object to be polished, and the surface roughness of the object to be polished can be reduced.
- the average size in the width direction of the ultrafine fiber bundle having the structure of the surface fiber raised portion is 50 ⁇ m or more, the amount of ultrafine fibers existing on the surface of the polishing pad is increased, and the surface coverage is increased.
- the average size in the length direction of the ultrafine fiber bundle having the structure of the surface fiber raised portion is preferably 100 ⁇ m to 500 ⁇ m.
- the length direction of the ultrafine fiber bundle is the length direction of the ultrafine fiber, and corresponds to the length direction of the rectangle in FIG.
- the average size in the length direction of the structure of the surface fiber raised portion is 500 ⁇ m or less, the superfine fiber bundles hardly overlap each other, the unevenness on the surface of the polishing cloth is reduced, and when used for polishing, the surface is polished. It is difficult to give scratch defects, and the surface roughness of the cloth to be polished can be reduced.
- the average size of a length direction is 100 micrometers or more, the quantity of the ultrafine fiber which exists on the surface increases, and it is a preferable aspect with high surface coverage.
- the surface roughness of the polishing cloth of the present invention is preferably 5 to 18 ⁇ m.
- the surface roughness is more preferably 5 to 15 ⁇ m, still more preferably 5 to 8 ⁇ m.
- the surface roughness is larger than 5 ⁇ m, it is preferable from the viewpoints of retainability and dispersibility of abrasive grains during slurry grinding.
- the surface roughness is smaller than 18 ⁇ m, it is difficult to give scratch defects to the object to be polished when used for polishing, and the surface roughness of the object to be polished can be reduced.
- the basis weight of the polishing cloth of the present invention is preferably 100 to 400 g / m 2 and more preferably 150 to 300 g / m 2 from the viewpoint of the form stability of the polishing cloth.
- the abrasive cloth of the present invention can be suitably obtained by combining at least the following steps (1) to (5).
- the number of sea-island type composite fibers that can be made into ultrafine fibers brought in by the needle punch in the following step (2) is 3 to 6/1. It is important to use barbs.
- ultrafine fiber generating fibers such as sea-island type composite fibers can be used.
- a fiber entanglement is produced from an ultrafine fiber-generating fiber, and an ultrafine fiber is generated from a sea-island composite fiber in the fiber entanglement.
- a fiber entangled body in which the bundle is entangled can be obtained.
- the composite fibers that can be made into ultrafine fibers are: (a) Two component thermoplastic resins with different solvent solubility are used as sea components and island components, and the sea components are dissolved and removed using a solvent to remove the island components from ultrafine fibers. And (b) a peelable composite fiber in which two-component thermoplastic resins are alternately arranged in a radial or multilayer fashion on the fiber cross section, and each component is separated into ultrafine fibers by separation. Can be adopted.
- sea-island type composite fiber For the sea-island type composite fiber, the sea-island type composite fiber, in which the sea component and the island component are spun together by using the sea-island type composite base, or the sea component and the island component are mixed and spun to mix.
- sea-island type composite fibers are preferably used from the viewpoint that ultrafine fibers having a uniform fineness are obtained, and that a sufficiently long ultrafine fiber is obtained and contributes to the strength of the sheet-like material.
- polyethylene, polypropylene, polystyrene, copolymer polyester obtained by copolymerizing sodium sulfoisophthalic acid, polyethylene glycol, or the like, polylactic acid, or the like can be used.
- the dissolution and removal of the sea component may be performed at any timing and step before the elastic polymer is applied, after the elastic polymer is applied, and after the raising treatment.
- a method for obtaining a fiber entanglement such as a nonwoven fabric a method of entanglement of a fiber web with a needle punch or a water jet punch, a spun bond method, a melt blow method, a paper making method, or the like can be employed.
- a method that undergoes processing such as needle punching or water jet punching is preferably used.
- the number of punches in the needle punching process is preferably 2000 to 8000 / cm 2 , more preferably 3000 to 5000 / cm 2 from the viewpoint of forming a dense raised surface by high entanglement of fibers. If the number of punchings is 2000 / cm 2 or more, the surface fibers are excellent in density and a desired high-precision finish can be obtained. Further, when the number of punching is 8000 / cm 2 or less, the workability is not deteriorated and the fiber is not damaged and the strength is not lowered.
- the fiber density of the nonwoven fabric after needle punching is preferably 0.15 to 0.4 g / cm 3 , more preferably 0.2 to 0.3 g / cm 3 from the viewpoint of densification of the number of surface fibers. is there.
- the average size in the width direction of the structure of the surface fiber raised portion needs to be 50 to 180 ⁇ m, and the average size is preferably 50 to 120 ⁇ m.
- the number of composite fibers such as ultrafine fiber generating fibers brought in by one needle punch is 3 to 6/1 barb, and the number is preferably 3 to 4 / 1 barb.
- the number of composite fibers such as composite fibers that can be made into ultrafine fibers caught on the barb is determined by the shape of the barb and the diameter of the composite fiber.
- the concept of the number of composite fibers that can be made into ultrafine fibers caught on barbs will be described with reference to FIG.
- an isosceles triangle is assumed in which the angle formed at the back of the barb ( ⁇ in FIG. 2) is the apex angle, and the tip of the barb (A in FIG. 2) is one side from the back of the barb (B in FIG. 2). .
- the composite fibers are densely packed and arranged from the back of the isosceles triangle (back of the barb).
- a case where the area occupation ratio of the composite fiber is 50% or more in the isosceles triangle is regarded as a composite fiber that can be brought into ultrafine fibers, The total number of these items is defined as the number of items brought in.
- the needle punching step of step (2) is a step of performing ultrafine processing on the nonwoven fabric of step (5). It is important to be before.
- the needle used in the needle punching process has 1 to 3 barbs, the barb has a kick up of 0 to 50 ⁇ m, an undercut angle of 0 to 40 °, and a throat depth of 40 to 80 ⁇ m. Those having a slow length of 0.5 to 1.0 mm are preferably used.
- the non-woven fabric containing the elastic polymer obtained in this way is preferably compressed by dry heat or wet heat or both to further increase the density from the viewpoint of densification of the number of surface fibers.
- the above-described ultrafine fiber bundle is mainly composed of a nonwoven fabric.
- the non-woven fabric is made mainly of polyurethane before and / or after the ultrafine fiber treatment. It is preferable to give a molecular elastic body.
- a polymer elastic body has roles such as surface unevenness, cushioning for vibration absorption, and fiber shape maintenance. That is, by filling and integrating the polymer elastic body into the interior space of the nonwoven fabric, it is excellent in the fit to the object to be polished and the effect of suppressing scratches on the surface of the object to be polished.
- a method for applying a polymer elastic body such as polyurethane to the nonwoven fabric a method of applying the polymer elastic body to the nonwoven fabric or solidifying it after impregnation can be employed.
- a method of wet coagulation after impregnating the elastic polymer solution into the nonwoven fabric is preferably used.
- polyurethane used as a polymer elastic body is made into a solution with a solvent such as dimethylformamide, and (A) a nonwoven fabric entangled with a composite fiber that can be made into ultrafine fibers is impregnated with the polyurethane solution, and water or an organic solvent aqueous solution
- a method of dissolving and removing the polymer component of the composite fiber that can be made into ultrafine fibers after solidifying in a solvent that does not dissolve polyurethane is exemplified.
- the raising of the surface of the nonwoven fabric thus obtained can be suitably performed by buffing using a sand paper or a roll dancer.
- a sand paper or a roll dancer In particular, by using sand paper, uniform and dense napping can be formed on the surface of the nonwoven fabric.
- the uniformity and density of surface fiber distribution on the surface is improved, and the direction of napped fibers is improved.
- the number of buffing stages is preferably multistage buffing having 3 or more stages, and the sandpaper used in each stage is preferably in the range of No. 150 to No. 600 defined by JIS.
- the polishing cloth is cut into a tape shape having a width of 30 to 50 mm, and slurry grinding and cleaning are performed. It is preferably used as a cleaning tape.
- a method of performing slurry grinding and cleaning of an aluminum alloy magnetic recording disk or a glass magnetic recording disk using such a polishing tape and a slurry containing loose abrasive grains is a preferable method.
- a slurry in which high-hardness abrasive grains such as diamond fine particles are dispersed in an aqueous dispersion medium is preferably used.
- the abrasive grains suitable for the ultrafine fibers constituting the polishing cloth of the present invention are composed of single crystal diamond from the viewpoints of holding of abrasive grains, dispersibility, suppression of scratch defects and reduction of surface roughness.
- the diameter is preferably 1 to 20 nm, and more preferably 1 to 10 nm.
- the polishing cloth of the present invention is suitably used for polishing or cleaning an aluminum alloy substrate or glass substrate used for a magnetic disk with an ultra-high precision finish.
- MFR Polymer melt flow rate 4-5 g of sample pellets are placed in a cylinder of an MFR meter electric furnace, and the amount of resin extruded in 10 minutes using a melt indexer (S101) manufactured by Toyo Seiki Co., Ltd. under a load of 2160 gf and a temperature of 285 ° C. (g ) was measured. The same measurement was repeated 3 times, and the average value was defined as MFR.
- S101 melt indexer manufactured by Toyo Seiki Co., Ltd. under a load of 2160 gf and a temperature of 285 ° C.
- FIG. 2 is a schematic diagram for explaining a method for estimating the number of composite fibers brought in at the time of needle punching, regarding the relationship between needles and composite fibers at the time of needle punching.
- Conjugate fibers arranged out of an isosceles triangle BAD are considered to be composite fibers that can be brought into the isosceles triangle BAD when the area occupancy of the composite fiber is 50% or more, and the total number of them is defined as the number did.
- Average fiber diameter and fiber diameter CV Using a cross-section of the polishing cloth cut in the thickness direction as an observation surface, it was observed with a scanning electron microscope (SEM) at a measurement magnification of 5000 times, and the diameters of 50 single fibers extracted at random were measured. This measurement is performed at three locations, the diameter of a total of 150 single fibers is measured, and an average value and a standard deviation value are calculated using this as a population. The average value was defined as the average fiber diameter, and the value obtained by dividing the standard deviation value by the average value expressed as a percentage (%) was defined as the fiber diameter CV.
- SEM scanning electron microscope
- Structure size measurement of surface fiber napped portion As shown in FIG. 1, it is formed by observing the polishing cloth surface as an observation surface at a magnification of 40 times from SEM and arranging the ultrafine fibers present on the surface in contact with each other.
- the ultrafine fiber bundle formed was defined as the structure of the surface fiber napped portion. 50 structures of the surface fiber raised portions were randomly extracted, and the sizes of the 50 extracted surface fiber raised structures in the width direction and the length direction were measured, and an average value thereof was calculated.
- the abrasive cloth was a 30 mm wide tape.
- a glass substrate made of amorphous glass manufactured by KMG whose surface roughness was controlled to 0.3 nm or less was used.
- a slurry having a concentration of 0.01% of free abrasive grains in which single crystal diamond particles having a primary particle diameter of 5 nm were clustered to an average diameter of 80 nm was dropped at a rate of 50 ml / min.
- the tape running speed was 70 mm / min
- the disk rotation speed was 600 rpm
- the swing was 100 times / min
- the pressing pressure was 1.5 kgf
- polishing was performed for 15 seconds. This was performed on both sides of each disk.
- Substrate Surface Roughness to be Polished Measurement was performed in a tapping mode using “AFM NanoScope” (registered trademark) IIIa manufactured by Veeco.
- the observation area on the substrate was 10 ⁇ m ⁇ 10 ⁇ m, an arbitrary point on the substrate was measured, and the average value of the arbitrary three points was defined as the surface roughness (Ra).
- the substrate surface roughness was 2.0 nm or less, the polishing performance was good.
- Example 1 (raw cotton) (Sea component and island component) Nylon 6 having a melting point of 220 ° C. and MFR of 10.5 is used as an island component, and copolymerized polystyrene (co-PSt) obtained by copolymerizing 22 mol% of 2-ethylhexyl acrylate having a melting point of 53 ° C. and MFR of 12 is Ingredients.
- a laminated fiber web was formed through the card and cross wrapping process using the raw cotton of the above-mentioned sea-island type composite fibers.
- the obtained laminated fiber web was subjected to a needle depth of 8 mm and a number of punches of 3200 using a needle punch machine in which needles having a throat depth of 60 ⁇ m, a kick-up of 0 ⁇ m, an undercut angle of 4 ° and a throat length of 0.9 mm were implanted.
- the nonwoven fabric composed of the sea-island type composite fiber was subjected to hot water shrinkage treatment, then impregnated with a 12% aqueous solution of polyvinyl alcohol and dried. Thereafter, the sea component co-PST was dissolved and removed in trichlorethylene and dried to obtain an ultrafine fiber nonwoven fabric in which ultrafine fiber bundles were entangled.
- a polyurethane (gel point 4.2 ml) in which the polymer diol is composed of 75% by mass of a polyether and 25% by mass of a polyester is added to the nonwoven fabric thus obtained in a solid content of 20% by mass with respect to the mass of the fiber.
- the polyurethane was coagulated with a 30% DMF aqueous solution having a liquid temperature of 35 ° C., and DMF and polyvinyl alcohol were removed with hot water having a temperature of about 85 ° C. Thereafter, the paper was cut in the thickness direction by a half-cutting machine having an endless band knife, and the non-half-cut surface was ground in three stages using a JIS # 240 sandpaper to form napped hairs to produce a polishing cloth.
- the obtained polishing cloth has an average single fiber diameter of ultrafine fibers of 0.72 ⁇ m, a fiber diameter CV value of 7.0%, a thickness of 0.5 mm, and a basis weight of 180 g / m 2 . Yes, the apparent density was 0.36 g / cm 3 .
- the polishing performance was evaluated using the obtained polishing cloth, the substrate surface roughness and the number of scratches were satisfactory, and the surface after polishing was also highly uniform. The results are shown in Table 1.
- Example 2 (raw cotton) (Sea component and island component) The sea component and the island component were the same as those used in Example 1.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers In the same manner as in Example 1, a nonwoven fabric made of sea-island composite fibers having a basis weight of 680 g / m 2 and an apparent density of 0.224 g / cm 3 was produced.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 1.
- the obtained polishing cloth has an average single fiber diameter of ultrafine fibers of 1.53 ⁇ m, a fiber diameter CV value of 5.8%, a thickness of 0.51 mm, and a basis weight of 186 g / m 2 .
- the apparent density was 0.365 g / cm 3 .
- Table 1 The results are shown in Table 1.
- Example 3 (raw cotton) (Sea component and island component) The sea component and the island component were the same as those used in Example 1.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers Except for using a needle with a throat depth of 60 ⁇ m, a kick-up of 10 ⁇ m, an undercut angle of 27 °, and a throat length of 0.8 mm, the basis weight is 800 g / m 2 and the apparent density is 0.00.
- a 190 g / cm 3 ultrafine fiber-generating fiber nonwoven fabric was prepared.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 1.
- the obtained polishing cloth has an average fiber diameter of 0.72 ⁇ m, the CV value of the fiber diameter is 7.0%, the thickness is 0.49 mm, and the basis weight is 175 g / m 2. The density was 0.357 g / cm 3 . The results are shown in Table 1.
- Example 4 (raw cotton) The sea component and the island component were the same as those used in Example 2.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers In the same manner as in Example 3, a nonwoven fabric made of sea-island composite fibers having a basis weight of 680 g / m 2 and an apparent density of 0.224 g / cm 3 was produced.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 1.
- the obtained abrasive cloth has an average fiber diameter of ultrafine fibers of 1.53 ⁇ m, a fiber diameter CV value of 5.8%, a thickness of 0.5 mm, and a basis weight of 180 g / m 2 .
- the apparent density was 0.360 g / cm 3 .
- Table 1 The results are shown in Table 1.
- Example 5 (raw cotton) (Sea component and island component) The sea component and the island component were the same as those used in Example 1.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers In the same manner as in Example 3, a nonwoven fabric made of sea-island composite fibers having a basis weight of 680 g / m 2 and an apparent density of 0.224 g / cm 3 was produced.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 3.
- the obtained polishing cloth has an average fiber diameter of 0.50 ⁇ m of ultrafine fibers, a CV value of the fiber diameter of 7.7%, a thickness of 0.48 mm, and a basis weight of 175 g / m 2 .
- the apparent density was 0.365 g / cm 3 .
- Table 1 The results are shown in Table 1.
- Example 6 (raw cotton) (Sea component and island component) The sea component and the island component were the same as those used in Example 1.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers A nonwoven fabric made of sea-island composite fibers was obtained in the same manner as in Example 1 except that JIS # 320 sandpaper was used.
- the nonwoven fabric made of the sea-island type composite fiber was subjected to hot water shrinkage, and then impregnated with a 12% aqueous solution of polyvinyl alcohol and dried.
- 20% by mass of a solid content with respect to the mass of fiber is added to a polyurethane whose polymer diol is 75% by mass of polyether and 25% by mass of polyester.
- the sea component co-PST was dissolved and removed in trichlorethylene and dried to obtain an ultrafine fiber nonwoven fabric composed of an ultrafine fiber bundle and polyurethane.
- the obtained ultra-fine fiber nonwoven fabric is half-cut in the thickness direction with a half-cutting machine having an endless band knife, and the half-cut surface is ground in three steps using JIS # 320 sandpaper to form napped hairs to produce a polishing cloth. did.
- the obtained polishing cloth has an average fiber diameter of ultrafine fibers of 0.72 ⁇ m, a fiber diameter CV value of 32.3%, a thickness of 0.55 mm, and a basis weight of 180 g / m 2.
- the density was 0.327 g / cm 3 .
- Table 1 The results are shown in Table 1.
- Example 7 (raw cotton) (Sea component and island component) The sea component and the island component were the same as those used in Example 5.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers In the same manner as in Example 3, a nonwoven fabric made of sea-island composite fibers was obtained.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 5.
- the obtained polishing cloth has an average fiber diameter of ultrafine fibers of 0.72 ⁇ m, a fiber diameter CV value of 32.3%, a thickness of 0.5 mm, and a basis weight of 190 g / m 2 .
- the apparent density was 0.380 g / cm 3 .
- Table 1 The results are shown in Table 1.
- Example 8 (raw cotton) (Sea component and island component) The sea component and the island component were the same as those used in Example 1.
- the single fiber fineness is 2.2 dtex and the fiber length is the same as in Example 1 except that a sea island type composite base with 600 islands / hole is used and the discharge rate is 1.0 g / min / hole.
- a 51 mm sea-island composite fiber raw cotton was obtained.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers In the same manner as in Example 6, a nonwoven fabric made of sea-island composite fibers was obtained.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 1.
- the obtained polishing cloth has an average fiber diameter of 0.35 ⁇ m, the CV value of the fiber diameter is 6.2%, the thickness is 0.5 mm, and the basis weight is 177 g / m 2.
- the density was 0.354 g / cm 3 .
- Table 1 The results are shown in Table 1.
- Example 9 (raw cotton) (Sea component and island component) The sea component and the island component were the same as those used in Example 1.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers In the same manner as in Example 1, a nonwoven fabric made of sea-island composite fibers having a basis weight of 680 g / m 2 and an apparent density of 0.224 g / cm 3 was produced. The number of sea-island composite fibers brought in by needle punching was 3/1 barbs.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 1.
- the obtained polishing cloth has an average fiber diameter of ultrafine fibers of 0.52 ⁇ m, a fiber diameter CV value of 5.5%, a thickness of 0.5 mm, and a basis weight of 180 g / m 2 .
- the apparent density was 0.36 g / cm 3 .
- the polishing performance was evaluated using the obtained polishing cloth, the substrate surface roughness and the number of scratches were satisfactory, and the surface after polishing was also highly uniform.
- the results are shown in Table 1.
- Example 10 (raw cotton) (Sea component and island component) Polyethylene terephthalate having a melting point of 260 ° C. and MFR of 46.5 was used as an island component, and polystyrene having a melting point of 85 ° C. and MFR of 117 was used as a sea component.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers In the same manner as in Example 1, a nonwoven fabric made of sea-island composite fibers having a basis weight of 650 g / m 2 and an apparent density of 0.224 g / cm 3 was produced. The number of sea-island type composite fibers brought in by needle punching was 4/1 barb.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 1.
- the obtained polishing cloth has an average fiber diameter of ultrafine fibers of 0.75 ⁇ m, a fiber diameter CV value of 6.8%, a thickness of 0.5 mm, and a basis weight of 190 g / m 2 .
- the apparent density was 0.38 g / cm 3 .
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers In the same manner as in Example 1, a nonwoven fabric made of sea-island composite fibers having a basis weight of 650 g / m 2 and an apparent density of 0.224 g / cm 3 was produced. The number of sea-island composite fibers brought in by needle punching was 3/1 barbs.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 1.
- the obtained abrasive cloth has an average fiber diameter of ultrafine fibers of 0.94 ⁇ m, a fiber diameter CV value of 5.2%, a thickness of 0.5 mm, and a basis weight of 190 g / m 2 .
- the apparent density was 0.38 g / cm 3 .
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers Except for using a needle with a throat depth of 65 ⁇ m, a kick-up of 10 ⁇ m, an undercut angle of 35 °, and a throat length of 0.9 ⁇ m, the basis weight is 870 g / m 2 and the apparent density is 0.220 g / m.
- a non-woven fabric made of cm 3 sea-island type composite fibers was prepared.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 1.
- the obtained polishing cloth has an average fiber diameter of ultrafine fibers of 0.72 ⁇ m, a fiber diameter CV value of 7.0%, a thickness of 0.51 mm, and a basis weight of 180 g / m 2.
- the density was 0.360 g / cm 3 .
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers In the same manner as in Comparative Example 1, a nonwoven fabric made of sea-island composite fibers was obtained.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 1.
- the obtained polishing cloth has an average fiber diameter of ultrafine fibers of 1.53 ⁇ m, a fiber diameter CV value of 5.8%, a thickness of 0.51 mm, and a basis weight of 180 g / m 2 .
- the apparent density was 0.353 g / cm 3 .
- Table 2 The results are shown in Table 2.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers In the same manner as in Comparative Example 1, a nonwoven fabric made of sea-island composite fibers was obtained.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 6.
- the obtained polishing cloth had an average fiber diameter of ultrafine fibers of 3.73 ⁇ m, a fiber diameter CV value of 6.9%, a thickness of 0.53 mm, and a basis weight of 184 g / m 2.
- the density was 0.347 g / cm 3 .
- Table 2 The results are shown in Table 2.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers Except for using a needle with a throat depth of 40 ⁇ m, a kick-up of 0 ⁇ m, an undercut angle of 2 °, and a throat length of 0.8 mm, the basis weight is 660 G / m 2 and the apparent density is 0.188 g / cm 3 .
- a nonwoven fabric made of sea-island type composite fibers was prepared.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 1.
- the obtained polishing cloth has an average fiber diameter of 0.50 ⁇ m of ultrafine fibers, a CV value of the fiber diameter of 7.7%, a thickness of 0.52 mm, and a basis weight of 162 g / m 2 .
- the apparent density was 0.311 g / cm 3 .
- Table 2 The results are shown in Table 2.
- Nonwoven fabric made of composite fibers that can be made into ultrafine fibers In the same manner as in Example 1, a nonwoven fabric made of sea-island type composite fibers having a basis weight of 640 g / m 2 and an apparent density of 0.196 g / cm 3 was produced.
- polishing cloth A polishing cloth was obtained in the same manner as in Example 1.
- the obtained polishing cloth had an average fiber diameter of ultrafine fibers of 3.73 ⁇ m, a fiber diameter CV value of 6.8%, a thickness of 0.51 mm, and a basis weight of 192 g / m 2.
- the density was 0.376 g / cm 3 .
- Table 2 The results are shown in Table 2.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
- Nonwoven Fabrics (AREA)
- Manufacturing Of Magnetic Record Carriers (AREA)
- Treatment Of Fiber Materials (AREA)
- Polishing Bodies And Polishing Tools (AREA)
Abstract
Description
(1)平均単繊維繊度が0.05~2.0μmに極細繊維化可能な海島型複合繊維を作製する工程、
(2)該海島型用複合繊維を用いて、カード、クロスラッパーにより繊維ウェブを形成・積層し、ニードルパンチにより不織布を得る工程、
(3)該不織布に高分子弾性体を、極細化後の極細繊維質量に対し10~200質量%付与する工程、
(4)少なくとも片面にバッフィング処理を施す工程、および
(5)該海島型複合繊維に極細化処理を行う工程。
(1)平均単繊維繊度が0.05~2.0μmに極細繊維化可能な海島型複合繊維を作製する工程、
(2)該海島型用複合繊維を用いて、カード、クロスラッパーによりウェブを積層し、ニードルパンチにより不織布を得る工程、
(3)該不織布に高分子弾性体を極細化後の極細繊維質量に対し10~200質量%付与する工程、
(4)少なくとも片面にバッフィング処理を施す工程、および
(5)該海島型複合繊維に極細化処理を行う工程。
パーキンエルマー社(Perkin Elmaer)製DSC-7を用いて、2nd runで、ポリマーの溶融を示すピークトップ温度をポリマーの融点とした。このときの昇温速度は16℃/分で、サンプル量は10mgとした。
試料ペレット4~5gを、MFR計電気炉のシリンダーに入れ、東洋精機社製メルトインデクサー(S101)を用いて、荷重2160gf、温度285℃の条件で、10分間に押し出される樹脂の量(g)を測定した。同様の測定を3回繰り返し、平均値をMFRとした。
図2は、ニードルパンチ時におけるニードルと複合繊維の関係について、ニードルパンチ時の複合繊維持ち込み本数の推定方法を説明するための模式図である。図2に示すニードルと複合繊維の模式図を用いて、ニードルパンチ時の複合繊維持ち込み本数の推定方法について説明する。まず、図2のBC上にバーブの先端(図2のA)とバーブの奥(図2のB)の長さと同じ長さとなる点Dを求める。次に、図2のバーブの先端AとDを線分で結び、BA=BDとなる二等辺三角形BADを作る。この二等辺三角形内に、複合繊維を細密充填し配列させる。二等辺三角形BADからはみ出して配列された複合繊維については、二等辺三角形BAD内に複合繊維の面積占有率が50%以上となる場合を持ち込める複合繊維とみなし、それらの合計本数を持ち込み本数と定義した。
研磨布を厚み方向にカットした断面を観察面として、走査型電子顕微鏡(SEM)により測定倍率5000倍で観察し、無作為に抽出した50本の単繊維直径を測定した。この測定を3ヶ所で行い、合計150本の単繊維の直径を測定し、これを母集団とした平均値および標準偏差値を算出する。該平均値を平均繊維直径とし、該標準偏差値を該平均値で割った値を百分率(%)で表したものを、繊維直径CVとした。
図1に示されるように、研磨布表面を観察面としてSEMより倍率40倍で観察し、表面に存在する極細繊維同士が接して配列することにより形成される極細繊維束を、表面繊維立毛部分の構造と定義した。この表面繊維立毛部分の構造を無作為に50個抽出し、抽出した50個の表面繊維立毛構造の幅方向および長さ方向のサイズを測定し、それらの平均値を算出した。
研磨布の表面を測定面として、表面粗さ測定器SE-40Cを用い、カットオフ2.5mm、評価長さ12.5mm、評価速度0.5m/sで表面粗さ測定を行った。ナップに対して順目方向に3回測定し、平均値を算出した。
研磨布を、30mm幅のテープとした。研磨対象として、表面粗さが0.3nm以下に制御されたKMG社製のアモルファスガラスからなるガラス基板を用いた。研磨布の表面に、1次粒子径5nm単結晶ダイヤモンド粒子が平均径80nmにクラスター化した遊離砥粒の濃度0.01%のスラリーを、50ml/分で滴下した。また、テープ走行速度70mm/分、ディスク回転数は、600rpm、揺動は100回/分とし、押付圧は1.5kgfとし、15秒間研磨した。これを、各ディスクの両面について実施した。
Veeco社製“AFM NanoScope”(登録商標)IIIaを用い、タッピングモードで測定した。基板上の観察領域は、10μm×10μmとし、基板上の任意の1点を測定し、任意の3点の平均値を表面粗さ(Ra)とした。基板表面粗さが2.0nm以下を、研磨性能良好とした。
研磨加工後の基板5枚の両面、すなわち計10表面の全領域を測定対象として、光学表面分析計(Candela6100)を用いて、深さ2nm以上の溝をスクラッチとしてスクラッチ点数を測定し、10表面の測定値の平均値で評価した。数値が低いほど高性能であることを示す。スクラッチ個数が、20個以下を研磨性能良好とした。
(原綿)
(海成分と島成分)
融点が220℃で、MFRが10.5のナイロン6を島成分とし、融点が53℃で、MFRが12のアクリル酸2‐エチルヘキシルを22mol%共重合した共重合ポリスチレン(co-PSt)を海成分とした。
上記の海成分と島成分を用い、376島/ホールの海島型複合口金を用いて、紡糸温度285℃、島/海質量比率40/60、吐出量1.7g/分・ホール、紡糸速度1200m/分で海島複合繊維を溶融紡糸した。次いで、85℃の温度の紡糸用の油剤液浴中で3.0倍に延伸し、押し込み型捲縮機を用いて捲縮を付与し、カットして、繊度が6.5dtexで、繊維長が51mmの海島型複合繊維の原綿を得た。
上記の海島型複合繊維の原綿を用いて、カードとクロスラッパー工程を経て、積層繊維ウェブを形成した。次いで、得られた積層繊維ウェブを、スロートデプス60μm、キックアップ0μm、アンダーカットアングル4°、スロートレングス0.9mmのニードルを植込んだニードルパンチ機を用いて、針深度8mm、パンチ本数3200本/cm2でニードルパンチし、目付が800g/m2で、見掛け密度が0.190g/cm3の海島型複合繊維からなる不織布を作製した。ニードルパンチによる海島型複合繊維の持ち込み本数は、3本/1バーブであった。
上記の海島型複合繊維からなる不織布を、熱水収縮処理させた後、ポリビニルアルコール12%水溶液に含浸し乾燥した。その後、トリクロロエチレン中で海成分のco-PSTを溶解除去し、乾燥を行って、極細繊維束が絡合してなる極細繊維不織布を得た。
(原綿)
(海成分と島成分)
海成分と島成分は、実施例1で用いたものと同様のものを用いた。
上記の海成分と島成分を用い、200島/ホールの海島型複合口金を用いて、紡糸温度285℃、島/海質量比率40/60、吐出量0.9g/分・ホール、紡糸速度1200m/分の条件で、海島型複合繊維を溶融紡糸した。次いで、85℃の温度で紡糸用の油剤液浴中で3.0倍に延伸し、押し込み型捲縮機を用いて捲縮を付与し、カットして、繊度が5.2dtexで、繊維長が51mmの海島型複合繊維の原綿を得た。
実施例1と同様にして、目付が680g/m2で、見掛け密度が0.224g/cm3の海島型複合繊維からなる不織布を作製した。
実施例1と同様にして研磨布を得た。得られた研磨布は、極細繊維の平均単繊維径が1.53μmであり、繊維直径のCV値は5.8%であり、厚さが0.51mmであり、目付が186g/m2であり、見かけ密度が0.365g/cm3であった。結果を表1に示す。
(原綿)
(海成分と島成分)
海成分と島成分は、実施例1で用いたものと同様のものを用いた。
紡糸と延伸は、実施例1と同様に行った。
スロートデプス60μm、キックアップ10μm、アンダーカットアングル27°、スロートレングス0.8mmのニードルを用いたこと以外は、実施例1と同様にして、目付が800g/m2であり、見掛け密度が0.190g/cm3の極細繊維発生型繊維不織布を作製した。
実施例1と同様にして研磨布を得た。
(原綿)
海成分と島成分は、実施例2と用いたものと同様のものを用いた。
紡糸と延伸は、実施例2と同様に行った。
実施例3と同様にして目付が680g/m2であり、見掛け密度が0.224g/cm3の海島型複合繊維からなる不織布を作製した。
実施例1と同様にして研磨布を得た。
(原綿)
(海成分と島成分)
海成分と島成分は、実施例1で用いたものと同様のものを用いた。
上記の海成分と島成分を用い、800島/ホールの海島型複合口金を用いて、紡糸温度285℃、島/海質量比率30/70、吐出量2.1g/分・ホール、紡糸速度1200m/分の条件で、海島型複合繊維を溶融紡糸した。次いで、85℃の温度の液浴中で3.0倍に延伸し、押し込み型捲縮機を用いて捲縮を付与し、カットして、繊度が12.1dtexで、繊維長が51mmの海島型複合繊維の原綿を得た。
実施例3と同様にして、目付が680g/m2であり、見掛け密度が0.224g/cm3の海島型複合繊維からなる不織布を作製した。
実施例3と同様にして研磨布を得た。
(原綿)
(海成分と島成分)
海成分と島成分は、実施例1で用いたものと同様のものを用いた。
上記の海成分と島成分を50重量%混合して、紡糸温度285℃で海島型複合繊維を溶融紡糸する、いわゆる混合紡糸法により海成分中に島成分が約1000個配置された海島型複合繊維を紡糸速度1200m/分の条件で溶融紡糸した。次いで、85℃の温度の紡糸用の油剤液浴中で3.0倍に延伸し、押し込み型捲縮機を用いて捲縮を付与し、カットして、繊度が11.6dtexで、繊維長が51mmの海島型複合繊維の原綿を得た。
JIS#320番のサンドペーパーを用いたこと以外は、実施例1と同様にして海島型複合繊維からなる不織布を得た。
上記の海島型複合繊維からなる不織布を熱水収縮させた後、ポリビニルアルコール12%水溶液に含浸し乾燥した。この不織布に、ポリマージオールがポリエーテル系75質量%とポリエステル系25質量%とからなるポリウレタンを、繊維質量に対して固形分で20質量%付与し、液温35℃の30%DMF水溶液でポリウレタンを凝固させ、約85℃の温度の熱水でDMFを除去した。その後、トリクロロエチレン中で海成分のco-PSTを溶解除去し、乾燥を行って、極細繊維束とポリウレタンからなる極細繊維不織布を得た。
(原綿)
(海成分と島成分)
海成分と島成分は、実施例5で用いたものと同様のものを用いた。
紡糸と延伸は、実施例5と同様に行った。
実施例3と同様にして、海島型複合繊維からなる不織布を得た。
実施例5と同様にして研磨布を得た。得られた研磨布は極細繊維の平均繊維径が0.72μmであり、繊維直径のCV値は32.3%であり、厚さが0.5mmであり、目付が190g/m2であり、見かけ密度が0.380g/cm3であった。結果を表1に示す。
(原綿)
(海成分と島成分)
海成分と島成分は、実施例1で用いたものと同様のものを用いた。
島本数600島/ホールの海島型複合口金を用いて、吐出量1.0g/分・ホールとしたこと以外は、実施例1と同様にして、単繊維繊度が2.2dtexで、繊維長が51mmの海島型複合繊維の原綿を得た。
実施例6と同様にして、海島型複合繊維からなる不織布を得た。
実施例1と同様にして研磨布を得た。得られた研磨布は、極細繊維の平均繊維径が0.35μmであり、繊維直径のCV値は6.2%、厚さが0.5mmであり、目付は177g/m2であり、見かけ密度が0.354g/cm3であった。結果を表1に示す。
(原綿)
(海成分と島成分)
海成分と島成分は、実施例1で用いたものと同様のものを用いた。
448島/ホールの海島型複合口金を用いて、島/海質量比率50/50、吐出量2.0/分・ホールとしたこと以外は、実施例1と同様にして、繊度が6.8dtexで、繊維長が51mmの海島型複合繊維の原綿を得た。
実施例1と同様にして、目付が680g/m2で、見掛け密度が0.224g/cm3の海島型複合繊維からなる不織布を作製した。ニードルパンチによる海島型複合繊維の持ち込み本数は、3本/1バーブであった。
実施例1と同様にして研磨布を得た。得られた研磨布は、極細繊維の平均繊維径が0.52μmであり、繊維直径のCV値は5.5%であり、厚さは0.5mmであり、目付は180g/m2であり、見かけ密度は0.36g/cm3であった。得られた研磨布を用いて研磨性能評価を実施したところ、基板表面粗さ、スクラッチ個数ともに満足のいくものであり、研磨後の表面も均一性の高いものであった。結果を表1に示す。
[実施例10]
(原綿)
(海成分と島成分)
融点が260℃で、MFRが46.5のポリエチレンテレフタレートを島成分とし、融点が85℃で、MFRが117のポリスチレンを海成分とした。
200島/ホールの海島型複合口金を用いて、島/海質量比率50/50、吐出量1.0/分・ホールとしたこと以外は、実施例1と同様にして、繊度が2.5dtexで、繊維長が51mmの海島型複合繊維の原綿を得た。
実施例1と同様にして、目付が650g/m2で、見掛け密度が0.224g/cm3の海島型複合繊維からなる不織布を作製した。ニードルパンチによる海島型複合繊維の持ち込み本数は、4本/1バーブであった。
実施例1と同様にして研磨布を得た。得られた研磨布は、極細繊維の平均繊維径が0.75μmであり、繊維直径のCV値は6.8%であり、厚さは0.5mmであり、目付は190g/m2であり、見かけ密度は0.38g/cm3であった。得られた研磨布を用いて研磨性能評価を実施したところ、基板表面粗さ、スクラッチ個数ともに満足のいくものであり、研磨後の表面も均一性の高いものであった。結果を表1に示す。
[実施例11]
(原綿)
(海成分と島成分)
海成分と島成分は、実施例11で用いたものと同様のものを用いた。
200島/ホールの海島型複合口金を用いて、島/海質量比率50/50、吐出量1.6/分・ホールとしたこと以外は、実施例1と同様にして、繊度が4.1dtexで、繊維長が51mmの海島型複合繊維の原綿を得た。
実施例1と同様にして、目付が650g/m2で、見掛け密度が0.224g/cm3の海島型複合繊維からなる不織布を作製した。ニードルパンチによる海島型複合繊維の持ち込み本数は、3本/1バーブであった。
実施例1と同様にして研磨布を得た。得られた研磨布は、極細繊維の平均繊維径が0.94μmであり、繊維直径のCV値は5.2%であり、厚さは0.5mmであり、目付は190g/m2であり、見かけ密度は0.38g/cm3であった。得られた研磨布を用いて研磨性能評価を実施したところ、基板表面粗さ、スクラッチ個数ともに満足のいくものであり、研磨後の表面も均一性の高いものであった。結果を表1に示す。
(原綿)
(海成分と島成分)
海成分と島成分は、実施例1で用いたものと同様のものを用いた。
紡糸と延伸は、実施例1と同様に行った。
スロートデプス65μm、キックアップ10μm、アンダーカットアングル35°、スロートレングス0.9μmのニードルを用いたこと以外は、実施例1と同様にして目付が870g/m2で、見掛け密度が0.220g/cm3の海島型複合繊維からなる不織布を作製した。
実施例1と同様にして、研磨布を得た。得られた研磨布は、極細繊維の平均繊維径が0.72μmであり、繊維直径のCV値は7.0%であり、厚さ0.51mmであり、目付180g/m2であり、見かけ密度が0.360g/cm3であった。得られた研磨布を用いて研磨性能評価を実施したところ、基板表面粗さおよびスクラッチ個数ともに満足のいくものではなかった。結果を表2に示す。
(原綿)
(海成分と島成分)
海成分と島成分は、実施例2で用いたものと同様のものを用いた。
紡糸と延伸は、実施例2と同様に行った。
比較例1と同様にして、海島型複合繊維からなる不織布を得た。
実施例1と同様にして研磨布を得た。得られた研磨布は、極細繊維の平均繊維径が1.53μmであり、繊維直径のCV値は5.8%であり、厚さ0.51mmであり、目付180g/m2、であり、見かけ密度0.353g/cm3であった。結果を表2に示す。
(海成分と島成分)
海成分と島成分は、実施例1で用いたものと同様のものを用いた。
上記海成分・島成分を用い、36島/ホールの海島型複合口金を用いて、紡糸温度285℃、島/海質量比率50/50、吐出量1.5g/分・ホール、紡糸速度1000m/分にて溶融紡糸した。次いで、85℃の温度の紡糸用の油剤液浴中で3.0倍に延伸し、押し込み型捲縮機にて捲縮を付与し、カットして、繊度が3.8dtexで、繊維長が51mmの海島型複合繊維の原綿を得た。
比較例1と同様にして、海島型複合繊維からなる不織布を得た。
実施例6と同様にして研磨布を得た。得られた研磨布は、極細繊維の平均繊維径が3.73μm、繊維直径のCV値は6.9%であり、厚さが0.53mmであり、目付が184g/m2であり、見かけ密度が0.347g/cm3であった。結果を表2に示す。
(原綿)
(海成分と島成分)
海成分と島成分は、実施例5で用いたものと同様のものを用いた。
紡糸と延伸は、実施例5と同様に行った。
スロートデプス40μm、キックアップ0μm、アンダーカットアングル2°、スロートレングス0.8mmのニードルを用いたこと以外は、実施例1と同様にして目付660G/m2、見掛け密度0.188g/cm3の海島型複合繊維からなる不織布を作製した。
実施例1と同様にして研磨布を得た。得られた研磨布は、極細繊維の平均繊維径が0.50μmであり、繊維直径のCV値は7.7%であり、厚さが0.52mmであり、目付が162g/m2であり、見かけ密度が0.311g/cm3であった。結果を表2に示す。
(原綿)
(海成分と島成分)
海成分と島成分は、比較例3で用いたものと同様のものを用いた。
紡糸と延伸は、実施例3と同様に行った。
実施例1と同様にして目付640g/m2、見掛け密度0.196g/cm3の海島型複合繊維からなる不織布を作製した。
実施例1と同様にして研磨布を得た。
B:バーブの奥
C:Bから針先端方向の任意の点(但し、BC>BAを満足する点)
D:BC上にありBAと同じ長さになる点
Claims (6)
- 平均単繊維直径が0.05~2.0μmの極細繊維からなる極細繊維束が絡合してなる不織布と高分子弾性体を主体として構成される研磨布であって、前記不織布の前記極細繊維束が構成する表面繊維立毛部分の極細繊維束の幅方向の平均サイズが、50~180μmであることを特徴とする研磨布。
- 表面繊維立毛部分の極細繊維束の幅方向の平均サイズが、50~120μmであることを特徴とする請求項1記載の研磨布。
- 研磨布の表面粗さが5~18μmであることを特徴とする請求項1または2記載の研磨布。
- 極細繊維のCV値が1~30%であることを特徴とする請求項1~3のいずれかに記載の研磨布。
- 少なくとも下記工程(1)~(5)を組み合わせてなる研磨布の製造方法であって、下記工程(2)のニードルパンチで持ち込まれる極細繊維化可能な海島型複合繊維の本数を3~6本/1バーブとすることを特徴とする研磨布の製造方法。
(1)平均単繊維繊度が0.05~2.0μmに極細繊維化可能な海島型複合繊維を作製する工程、
(2)該海島型複合繊維を用いて、カード、クロスラッパーによりウェブを積層し、ニードルパンチにより不織布を得る工程、
(3)該不織布に高分子弾性体を、極細化後の極細繊維質量に対し10~200質量%付与する工程、
(4)少なくとも片面にバッフィング処理を施す工程、および
(5)該海島型複合繊維に極細化処理を行う工程。 - ニードルパンチで持ち込まれる海島型複合繊維の本数が、3~4本/1バーブであることを特徴とする請求項5記載の研磨布の製造方法。
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CN201180040935.7A CN103068523B (zh) | 2010-08-31 | 2011-08-18 | 研磨布及其制造方法 |
KR1020137003510A KR101865430B1 (ko) | 2010-08-31 | 2011-08-18 | 연마포 및 그의 제조 방법 |
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JP6180873B2 (ja) * | 2013-08-30 | 2017-08-16 | 株式会社クラレ | 繊維複合シート、研磨パッド及びその製造方法 |
WO2015098902A1 (ja) * | 2013-12-27 | 2015-07-02 | 東レ株式会社 | トナークリーニング用シートおよびその製造方法 |
JP6398467B2 (ja) * | 2014-08-27 | 2018-10-03 | 東レ株式会社 | シート状物 |
DE102014116354A1 (de) * | 2014-11-10 | 2016-05-12 | J.H. Ziegler Gmbh | Kaschierungstextilverbundmaterial |
DE102014116356A1 (de) * | 2014-11-10 | 2016-05-12 | J.H. Ziegler Gmbh | Kaschierungstextilverbundmaterial |
CN107206570B (zh) * | 2015-01-30 | 2021-04-02 | 应用材料公司 | 多层纳米纤维化学机械抛光垫 |
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JP2019084294A (ja) * | 2017-11-10 | 2019-06-06 | 花王株式会社 | ワイピングシート |
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JP6959280B2 (ja) * | 2019-02-28 | 2021-11-02 | 花王株式会社 | 洗浄用部材及びその製造方法 |
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