EP3368247B1 - Procédé de fabrication de non-tissé abrasif - Google Patents

Procédé de fabrication de non-tissé abrasif Download PDF

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Publication number
EP3368247B1
EP3368247B1 EP16790558.7A EP16790558A EP3368247B1 EP 3368247 B1 EP3368247 B1 EP 3368247B1 EP 16790558 A EP16790558 A EP 16790558A EP 3368247 B1 EP3368247 B1 EP 3368247B1
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EP
European Patent Office
Prior art keywords
unit
abrasive
woven
fleece
yarn
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP16790558.7A
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German (de)
English (en)
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EP3368247A1 (fr
Inventor
Martin Joppich
Achim JÄGER
Jörn-Oliver NOLTE
Markus Flory
Andreas Lange
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Vsm Vereinigte Schmirgel und Maschinen Fabriken Ag
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Vsm Vereinigte Schmirgel und Maschinen Fabriken Ag
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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
    • B24D11/001—Manufacture of flexible abrasive materials
    • B24D11/005—Making abrasive webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • B24D3/20—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially organic
    • B24D3/28—Resins or natural or synthetic macromolecular compounds

Definitions

  • the invention relates to a method for producing abrasive fleece.
  • the usual process steps for the production of an abrasive fleece are described.
  • Materials such as nylon, polyester or mixtures thereof serve as the starting material for such abrasive nonwovens.
  • the starting material is first subjected to fleece formation and then to subsequent fleece consolidation.
  • the web is a pre-bonded web that does not yet include abrasive particles.
  • the mat is then passed through an adhesive coater and then through a particle coater to apply the abrasive particles.
  • a suitable synthetic resin is used as an adhesive, which hardens in a heat stage and then binds the abrasive particles to the base material.
  • the US 5,811,186 A describes a process for making filaments from melt-extruded, melt-bonded thermoplastic fibers. Abrasive particles can then be applied from these filaments.
  • the DE 21 02 786 A describes a method and a device for producing a thread covered with abrasives, in which a thread is covered on its outer surface with an abrasive consisting of individual abrasive grains, the thread having such a low inherent rigidity that it z.
  • the US2014/0259960A1 describes a web in which a binder material can bind the fibers at crossing points. An abrasive product can be formed from this web.
  • US 4,227,350A describes the production of an abrasive fleece, in which a suitable fleece is first formed from threads, which is then provided with abrasive particles and a further coating.
  • the US 3,817,004A describes the production of a wiping mob, in which individual cords or threads are coated, which are then picked up on a holder or a headband in such a way that they hang down to form the wiping mob.
  • the object of the invention is therefore to improve the homogeneity and the reproducibility of the abrasive fleece produced.
  • the method according to the invention is a method for producing abrasive fleece, in which fleece fibers of a specific starting material are subjected to the process steps of fleece formation and subsequent fleece consolidation, the fleece fibers being coated with abrasive grains before the fleece formation process step and/or before the fleece consolidation process step, that the abrasive grains adhere to the base material.
  • An essential finding of the invention is therefore to apply the abrasive grains to the fleece fibers before the formation of the fleece and/or before the final strengthening of the fleece. It has been shown that in this way the abrasive grains can be applied to the fleece fibers much more evenly, since the fleece fibers are still accessible in a separated state.
  • the fleece fibers consist of a polyamide and/or of a polyamide mixture and/or of nylon.
  • the fleece is formed using a carding method and/or using an aerodynamic method.
  • the fleece is consolidated using an entanglement process, for example using water jet entanglement.
  • an entanglement process for example using water jet entanglement.
  • the material fed to the web consolidation is already mixed with abrasive grains, there is a risk that the tools used in the web consolidation will wear out quickly.
  • water jet turbulence has the particular advantage that it is hardly necessary to intervene in the fleece material.
  • the same advantages can also be achieved when bonding the fleece using a thermal method, for example using ultrasonic bonding. Entanglement processes and thermal processes can also be used particularly preferably in combination in the web consolidation.
  • the abrasive grains prefferably be applied directly to the abrasive fibers that have not yet fully hardened.
  • the fleece fibers are coated with a synthetic resin that ensures adhesion between the abrasive grains and fleece fibers.
  • a light-curing synthetic resin is preferably used as the synthetic resin.
  • the fleece fibers are continuously coated.
  • the fleece fibers are coated intermittently.
  • the intermittent coating can be advantageous in particular when the average diameter of the abrasive grains is in the range of the average diameter of the abrasive fibers or is larger than this, so that it is desirable to provide a controlled spacing along the batt fiber between the abrasive grits.
  • the basic structure of the system consists of a mixing unit 101, an extruder 103, a spinneret 105, a bundling unit 107, a coating unit 109 and a fleece bonding unit 115.
  • the mixing unit 101 is connected to the extruder 103 via the connecting flange 102 .
  • In the mixing unit can various granules are mixed and then fed to the extruder 103 in a mixed form.
  • the granules are compacted under high pressure and melted.
  • the melted granulate is then fed to the spinneret 105 via the melt channel 104 .
  • the spinneret 105 is kept at the necessary spinning temperature (in the case of nylon, for example, 290° C.) by a heating unit that is not shown in any more detail.
  • the spinneret 105 has a multiplicity of spinning orifices which, depending on the viscosity of the melt, have a suitable diameter in order to be able to spin continuous filaments. In the case of nylon, for example, the diameter of each spinning orifice is 0.4 mm.
  • the number of spinning orifices can vary widely depending on the required strength and diameter of the abrasive yarn, starting with a single spin orifice up to several 100 spin orifices.
  • the spinning opening itself can also be shaped differently. In addition to a circular opening, a star-shaped opening is also conceivable, for example, in order to improve the surface adhesion of the synthetic resin or binder, for example.
  • the threads 106 spun by the spinneret are then combined at the inlet of the bundling unit 107 and mixed together there to form a cohesive yarn 108 and stretched.
  • a detailed description of the bundling unit 107 follows below with reference to FIG 2 .
  • a first process interface is marked with A below the bundling unit 107 .
  • the first process interface A is intended to indicate that there are various options for further processing the yarn 108 at this point.
  • One possibility is according to 1 the manner shown, ie the direct further processing in the coating unit 109.
  • Another possibility is to wind the yarn 108 onto spools at the first process interface A and to store these spools until further processing.
  • the yarn 108 bundled by the bundling unit 107 is then fed to a coating unit 109, in which the yarn 108 is coated with a resin and coated with abrasive grains.
  • a detailed description of the coating unit 109 follows below with reference to FIG 3 .
  • a second process interface is marked with B below the coating unit 109 .
  • the second process interface B should in turn indicate that there are also various options for further processing the abrasive yarn 112 at this point.
  • One possibility is according to 1 the manner shown, ie the grinding yarn 112 is deposited, for example, on a conveyor belt 110 for direct further processing.
  • the belt speed v and thus also the density of the deposited material 113 can be influenced.
  • the laid material 113 can then be further processed into a grinding fleece, for example, using the known methods of fleece processing.
  • Another possibility for further processing of the abrasive yarn 112 at the second process interface B is that the abrasive yarn 112 is wound up and then further processed into a fabric abrasive using a weaving process.
  • the material 113 deposited on the conveyor belt 110 is then fed to a fleece bonding unit 115 in which the loose fibers are bonded into a coherent abrasive fleece.
  • a detailed description of the web consolidation unit 115 is provided below with reference to FIG 4 .
  • a third process interface is marked with C in front of the web consolidation unit 115 .
  • the third process interface C should in turn indicate that there are also various options for solidifying the deposited material 113 at this point. The most important possibilities are chemical bonding, thermal bonding, hydroentanglement and needling. All options can also be combined by connecting them in series.
  • Foam and liquid applications are used in chemical bonding. A slight pre-consolidation is possible with the water jet technology.
  • the fleece is dewatered by suction of the foam application. This is followed by drying with cylinder and through-flow dryers.
  • the thermal hardening takes place with drum furnaces.
  • the fleece fibers are bonded with hot air.
  • the through-air drying process is based on a combination of screen drum and radial fan. The fan sucks the air out of the screening drum and directs it back to the outside of the drum via heating elements. This creates a suction pull on the drum surface, which holds the fleece on the drum and at the same time flows through it. In this process, several drums can also be connected in series.
  • hydroentanglement In addition to the central bonding unit with several water beams, hydroentanglement also includes downstream spunlace drums and a compacting and dewatering system.
  • Needle machines for web bonding can be designed as single board or double board variants. Both can be used with top-down or bottom-up needling. For some applications, a tandem machine is also conceivable, with one board working from above and one board from below.
  • a fourth process interface is marked with D after the web consolidation unit 115 .
  • the finished abrasive fleece is available for assembly.
  • the ready-made non-woven abrasive can then be dispatched.
  • the main control unit 114 is connected to the components described in the manner shown in order to measure and control the relevant process parameters.
  • the ring opening 201 can be adjusted in the plane perpendicular to the transport direction of the combined threads by a positioning device that is not shown in detail.
  • the suction jet unit 202 consists of a longitudinal guide unit 203, an air injector unit 204 and a compressed air connection 205.
  • the inner diameter of the longitudinal guide unit 203 is somewhat smaller (e.g. 2 mm) than the inner diameter of the air injector unit 204 (e.g. 3 mm).
  • Compressed air with a pressure of 7 kg/cm 2 is connected to the compressed air connection 205 , so that the compressed air follows the path indicated by the arrows 206 . In this way, a high-velocity suction jet is produced in the air injector unit 204 .
  • the flow speed in the middle of the channel can be a few kilometers/minute.
  • a typical flow rate in the center of the channel is, for example, 3000 m/min.
  • the suction jet deters the newly spun filaments 106 and at the same time causes the filaments to curl with one another in an irregular and random manner.
  • the speed of the yarn has a certain slip compared to the flow speed of the air (e.g. 10%)
  • the speed of the yarn is correspondingly smaller (e.g. 2700 m/min) than that of the air flow (e.g. 3000 m/min as mentioned above).
  • the air injector unit 204 Within the air injector unit 204, vortices and turbulence develop around the semi-solid filaments, causing the semi-solid filaments to mix, harden and form a coherent yarn therewith. In addition, the air flow within the air injector unit 204 exerts a suction effect on the yarn, so that the yarn is transported further, tapered and oriented and in this way finally leaves the bundling unit 107 as a coherent yarn 108 .
  • the coating unit 109 basically comprises a pull-off roller unit 301, a dancer roller unit 302, a primer coating nozzle 303, an abrasive coating nozzle 304, a UV irradiation unit 307 and a control-measuring unit 308.
  • the take-off roller unit 301 ensures that the yarn 108 that leaves the bundling unit 107 is transported further.
  • a dancer roller unit 302 is provided in the known manner.
  • the primer coating die 303 contains a primer or adhesive 305 such that an adhesive layer is formed on the yarn 108 as the yarn 108 passes through the primer coating die 303 .
  • the adhesive layer improves the adhesion and the adhesion of the subsequent coating in the abrasive coating die 304.
  • the thickness of the adhesive layer can be adjusted by the feeding speed of the adhesive 305 and optionally also by an adjustable diameter of the primer coating die 303.
  • the yarn 108 with the adhesive layer is then fed through the abrasive coating die 304 which contains a mixture 306 composed of a light-curing resin, abrasive grains and a filling material.
  • the mixture 306 adheres to the adhesive layer so that the desired abrasive layer is formed in the outer diameter.
  • the thickness of the abrasive layer can be adjusted by the feeding speed of the mixture 306 and optionally also by an adjustable diameter of the abrasive coating nozzle 304 .
  • the primer coating nozzle 303 and the abrasive coating nozzle 304 can each have controllable closures that hold back or release the coating material in the desired manner.
  • the abrasive coating nozzle 304 alone or the primer coating nozzle 303 and the abrasive coating nozzle 304 together can be controlled in a uniform cycle or according to a specific cycle pattern in order to apply an intermittent coating to the abrasive yarn in a targeted manner.
  • the yarn 108 enters the UV irradiation unit 307 after the abrasive coating nozzle 304, so that the photo-curing resin is cured and the abrasive grains are held together.
  • the wavelength of the UV light from the UV irradiation unit 307 depends on the respective synthetic resin and can be in the range of 200 nm to 500 nm, for example.
  • the synthetic resins used here are usually cured in a wavelength range of 315 - 380 nm.
  • the abrasive yarn formed in this way passes through the control measuring unit 308, which measures the outer diameter of the abrasive yarn.
  • the coating control unit 309 is connected to the components described in the manner shown in order to measure and control the relevant process parameters. Above all, the outer diameter measured by the control-measuring unit 308 is evaluated, so that the parameters of the primer coating nozzle 303 and the abrasive coating nozzle 306 can be readjusted on the basis of this evaluation.
  • the atmosphere inside the coating unit 109 may be nitrogen or an oxygen-depleted gas in order to achieve stable polymerization of the photocuring resin.
  • the yarn 108 can be produced at very high speeds. In principle, speeds of several 100 meters/minute up to a few kilometers/minute are possible, so that the production speed in the coating unit 109 can be adapted to the speed of the yarn emerging from the bundling unit 107 .
  • a possible composition of mixture 306 is described in more detail below: Any suitable material capable of increasing the mechanical strength or abrasion resistance of the photocurable resin without adversely affecting the curing process can be used as the filler material.
  • the filling material thus exerts a kind of support function on the abrasive grains.
  • abrasive grains with a smaller average diameter than the abrasive grains mentioned above can also be used as filling material.
  • powder consisting of metal oxide, metal carbide or non-metal oxide or carbide or of metals can also be advantageous.
  • Fine abrasive grains for example, which have an average diameter of about 2 ⁇ m to 10 ⁇ m can therefore be used particularly preferably as the filling material.
  • the abrasive grains can be made of aluminum oxide or alumina, silicon carbide, CBN, diamond, zirconium corundum, etc., with the mean diameter of the grains being chosen depending on the grinding application.
  • the abrasive grains can have an average diameter of 20 ⁇ m to 200 ⁇ m, what in the abrasive area would correspond to a grit in the range of about P800 to P80.
  • the abrasive grains are added at about 5% volume of the light-curing resin liquid and can be wetted with a small amount of ethyl alcohol beforehand.
  • the photocurable resin liquid may be, for example, an acrylate prepolymer (an oligomer or a monomer) mixed with 1% by weight of an acetolphenone derivative as a photoinitiator.
  • the photo-curing resin liquid is based on a radical polymerization in which the radical polymerization of the oligomer or monomer is induced by a free radical generated by the photoinitiator irradiated by the ultraviolet light.
  • the oligomer, the monomer and the photoinitiator are not limited to these.
  • an unsaturated polyester can be used as the oligomer and styrene can be used as the monomer.
  • polyester acrylate, polyether acrylate, acrylic oligomer acrylate, epoxy acrylate, polybutadiene acrylate, silicone acrylate or polyurethane acrylate can also be used for the oligomer.
  • the monomer for example, N-vinyl pyrolidone, vinyl acetate, monofunctional acrylate, bifunctional acrylate, or trifunctional acrylate can also be used.
  • the polymerization initiator for example, an acetophenone derivative such as acetophonone or trichloroacetophenone, benzoin ether, benzophenone or xanthone can be used.
  • the photo-curing resin instead of the radical polymerization type, a photo-addition polymerization type, a photo-cationic polymerization type, or an acid-drying type or an acid-hardening type can be used.
  • the non-woven fabric is formed into a non-woven material 113 by depositing the grinding yarn 112 onto the conveyor belt 110 according to FIG 1 .
  • the fleece material 113 formed in this way leaves the conveyor belt 110 horizontally and is fed to the subsequent conveyor belt 401 for fleece consolidation via a further belt and roller system 402 .
  • the kinematics of the vertical needle movement is shown in the in 4 needle machines shown realized by a crank drive 403 consisting of eccentrics and connecting rods and straight guides.
  • the needle bar 404 continuously executes a linear up and down movement with each revolution of the crankshaft, which movement runs approximately sinusoidally over time.
  • These oscillating double-stroke movements take place with a specific stroke frequency and amplitude, with the stroke frequency and amplitude being adjustable via the control unit 114 .
  • Numerous needles are in the so-called needle boards after one Arrangement scheme orthogonal to the board level lined up parallel to each other.
  • the needle board itself is attached to the needle bar 404, which extends across the working width as a rigid support.
  • Parallel perforated plates are arranged horizontally for the passage of the fleece inside the needle machine. If the needles pierce the fleece from above, it supports the lower perforated plate as a so-called needle plate 406 against puncture forces from above.
  • the surfaces of the throat plate and hold-down device are smooth, guide the fleece and create the space for the throughput via their adjustable distance.
  • a pair of take-off rollers 405 frictionally drives the needled fleece via a clamping gap and imprints the take-off speed on it. However, as long as the needles are engaged, the flow of non-woven fabric is stopped in the needle zone.
  • a device not shown in detail which can position the abrasive yarn 112 perpendicularly to the direction of movement v before it is deposited.
  • the abrasive yarn 112 can be guided at the second process interface B, for example, through an eyelet that is moved back and forth along a traverse perpendicular to the direction of movement v.
  • an air flow unit can also be used in order to place the grinding yarn 112 on different positions of the conveyor belt 110 by means of a purposefully varying air flow.
  • figure 5 shows a first variant of the system 1 .
  • the reference symbols in figure 5 correspond to the reference numbers 1 , so for the description of the components refer to the description of 1 can be referred.
  • several spinnerets 105a, 105b, 105c are now provided perpendicular to the direction of movement v, which can be identical or different in design, in such a way that the desired placement of the abrasive yarn 112 is formed over the entire width of the conveyor belt 110.
  • the spinnerets can produce identical or different filament diameters.
  • FIG. 6 shows a second variant of the system 1 with a stretching unit 601, with a finishing unit 602 and with a consolidation unit 605.
  • the process interfaces A, B, C and D basically correspond to the process interfaces A, B, C and D from 1 , however, different variants are conceivable with regard to the stretching unit 601 and the finishing unit 602, which are explained in more detail here.
  • the stretching unit 601 can be designed like the bundling unit 107, as detailed in 2 is shown.
  • the equipment unit 602 can also be designed like the coating unit 109, as detailed in 3 is shown.
  • the synthetic resin and the primer to be dispensed with entirely in the finishing unit 602 and the abrasive grains to be applied directly to the yarn that has not yet fully hardened or to the yarn surface that has been made plastic again.
  • a coating nozzle can again be used for coating, such as that according to the abrasive coating nozzle 304 in 3 was described.
  • a further variant is that the drying or curing of the synthetic resin only takes place after the grinding yarn has been placed on the conveyor belt 603 . Curing can take place by means of UV radiation or also by means of conventional thermal drying or drying in some other way. An example of this situation is given in 6 a thermal drying unit 604 is shown above the conveyor belt 603. The basic idea of this variant is that the state of the not yet fully hardened grinding yarn is used, in order to bring about a certain solidification as soon as it is deposited on the conveyor belt 603.
  • FIG. 7 shows a third variant of the system 1 with a stretching unit 701, with a finishing unit 702 and with a consolidation unit 705.
  • the process interfaces A, C and D basically correspond to the process interfaces A, C and D from 1 , so that the stretching unit 701 can be designed like the bundling unit 107, as detailed in 2 is shown.
  • the variant shown is now already placing the yarn behind the first process interface A on the conveyor belt 703. Once the laid down yarn passes the finishing unit 702, the abrasive grit 706 is sprinkled or sprayed onto the laid down yarn. This is followed by drying or curing with the drying unit 704 and solidification with the solidification unit 705.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Claims (11)

  1. Procédé de fabrication de non-tissé abrasif, dans lequel des fibres non tissées (108) d'un certain matériau de base sont soumises aux étapes de procédé d'une formation de non-tissé et d'un liage de non-tissé subséquent, où les fibres non tissées (108) sont revêtues de grains abrasifs de sorte que ceux-ci adhèrent sur le matériau de base préalablement à l'étape du procédé de formation de non-tissé et/ou préalablement à l'étape du procédé de liage du non-tissé.
  2. Procédé suivant la revendication 1, dans lequel les fibres non tissées (108) sont constituées d'un polyamide ou d'un mélange de polyamide.
  3. Procédé suivant la revendication 1, dans lequel les fibres non tissées (108) sont constituées de nylon.
  4. Procédé suivant une des revendications 1 à 3, dans lequel la formation du non-tissé a lieu au moyen d'un procédé de cardage.
  5. Procédé suivant une des revendications 1 à 4, dans lequel la formation du non-tissé a lieu au moyen d'un procédé aérodynamique.
  6. Procédé suivant une des revendications 1 à 5, dans lequel le liage du non-tissé a lieu au moyen d'un procédé de tourbillonnement, par exemple par hydroliage.
  7. Procédé suivant une des revendications 1 à 6, dans lequel le liage du non-tissé a lieu au moyen d'un procédé thermique, par exemple par ultrason.
  8. Procédé suivant une des revendications 1 à 7, dans lequel les fibres non tissées (108) sont revêtues d'une résine synthétique préalablement avant d'être recouverts de grains abrasifs.
  9. Procédé suivant la revendication 8, dans lequel la résine synthétique utilisée est une résine synthétique photomérisable.
  10. Procédé suivant une des revendications 1 à 9, dans lequel les fibres non tissées (108) sont revêtues en continu.
  11. Procédé suivant une des revendications 1 à 9, dans lequel les fibres non tissées (108) sont revêtues de façon intermittente.
EP16790558.7A 2015-10-28 2016-10-28 Procédé de fabrication de non-tissé abrasif Active EP3368247B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP15191975.0A EP3162502A1 (fr) 2015-10-28 2015-10-28 Non-tisse abrasif et son procede de fabrication
PCT/EP2016/076061 WO2017072293A1 (fr) 2015-10-28 2016-10-28 Non-tissé abrasif et son procédé de fabrication

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EP3368247A1 EP3368247A1 (fr) 2018-09-05
EP3368247B1 true EP3368247B1 (fr) 2023-06-28

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EP16790558.7A Active EP3368247B1 (fr) 2015-10-28 2016-10-28 Procédé de fabrication de non-tissé abrasif

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US (1) US10843309B2 (fr)
EP (2) EP3162502A1 (fr)
KR (1) KR20180075578A (fr)
CN (1) CN108290275A (fr)
BR (1) BR112018008664A2 (fr)
FI (1) FI3368247T3 (fr)
WO (1) WO2017072293A1 (fr)

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DE102019207822A1 (de) 2019-05-28 2020-12-03 Robert Bosch Gmbh Verfahren zur Herstellung eines Schleifartikels sowie Schleifartikel
US20230136260A1 (en) 2020-02-28 2023-05-04 Wendt Poliertechnik Gmbh & Co. Kg Polishing tool
DE202020000786U1 (de) 2020-02-28 2021-05-31 Wendt Poliertechnik Gmbh & Co. Kg Polierwerkzeug
DE102020001283A1 (de) 2020-02-28 2021-09-02 Wendt Poliertechnik Gmbh & Co. Kg Polierwerkzeug

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Publication number Publication date
EP3368247A1 (fr) 2018-09-05
KR20180075578A (ko) 2018-07-04
EP3162502A1 (fr) 2017-05-03
FI3368247T3 (en) 2023-08-08
BR112018008664A2 (pt) 2018-10-30
US10843309B2 (en) 2020-11-24
CN108290275A (zh) 2018-07-17
US20180326556A1 (en) 2018-11-15
WO2017072293A1 (fr) 2017-05-04

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