JPS609663A - Nonwoven fabric abrasive - Google Patents

Abstract

PURPOSE:To make surface grinding finish for uniform ground depth performable, by making up a nonwoven fabric mat carrying a concavoconvex pattern by means of heat embossing, while having abrasive grains contained in a convex fiber layer alone upon impregnation of a resin binder containing abrasive grains. CONSTITUTION:Utilizing a fusing point differential in a synthetic fiber and an inherent property of tacking thermoplastic synthetic resin, a concave part 1 being resinified as pressed into specified pattern form or random form by a heat emboss roll and an unpressed bulky convex part 2 both are formed whereby such a nonwoven fabric mat 3 carrying concavoconvex patterns over the whole surface is formed up. Next, a resin binder containing abrasive grains 4 or abrasive particles is impregnated, having these abrasive grains 4 contained in a fiber layer of the convex part 2 alone, thus a nonwoven fabric abrasive 5 is made up. In this connection, when it is made to be a spiral molding body, there is formed with an empty space 6 whereby heat radiative properties and cushion effects are secured. Thus, the abrasive grain contained convex part works at an acute angle so that such surface grinding as being uniform in ground depth and waveless is performable and, what is more, the occurrence of loading is reduced.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a nonwoven abrasive product partially containing abrasive grains.

Conventionally, this type of abrasive product has been created by impregnating or spraying a synthetic resin containing abrasive grains on a non-woven mat.This type of low-density abrasive product is suitable for finishing metals, wood, etc. Although it is effective for polishing, it is also suitable for heavy grinding fields,
High speed cutting is not possible. Furthermore, the current situation is that it is not possible to obtain a flat surface with a uniform depth on the ground surface, so its uses are currently limited.

In other words, surfaces finished with low-density abrasive products not only have uneven depth of abrasion, but also have undulations that prevent a glossy finish. Currently, abrasive cloth belts and cloth puff assemblies are used in these fields, but abrasive cloth belts have a high initial grinding force, but the abrasive force rapidly decreases, and they have difficulty adapting to the object to be ground. It has no properties and cannot be used on uneven shapes.

In addition, the cloth puff assembly is made by forming a resin layer containing hard abrasive grains similar to that of a grinding wheel on a flexible base material, so that the entire surface of the wheel does not contain abrasive grains, and if it wears out even in places, the whole wheel will be damaged. It had the disadvantage that it had to be replaced.

The present invention solves the above-mentioned drawbacks by forming a nonwoven fabric mat having an uneven pattern on the entire surface by forming concave portions made of thermoplastic synthetic resin for temporary fixing and bulky convex portions that are not pressed. The present invention provides a nonwoven abrasive material in which only the fiber layer of the convex portions contains abrasive grains by impregnation with a resin binder containing abrasive grains.

Next, the structure of the nonwoven abrasive material of the present invention will be explained with reference to the drawings.

FIG. 1 is a schematic cross-sectional view of the main parts of a nonwoven abrasive material according to one embodiment of the present invention, and synthetic fibers include polyamide, polyester, polypropylene, polyvinylidene chloride, or nylon 66-nylon 6 composite fiber. , polyester composite fibers, polyglopylene-polyethylene composite fibers, polyester-ethylene vinyl acetate composite fibers, etc., each singly or by appropriately mixing these fibers, and then a thermoplastic resin binder is sprayed and adhered to the fiber web in advance. The temporarily fixed synthetic fiber nonwoven fabric is pressed with a heated embossing roll having a certain uneven pattern, and the area of the four parts f1+ that are resinized and fused by pressing is 5 to 20%, as well as the bulky convex parts (2) that are not pressed.
A concavo-convex pattern nonwoven fabric mat (3) having approximately resin-made fused concave portions having an area of 95 to 80 inches is formed.

The above-mentioned non-woven fabric mat contains a resin binder (for example, phenolic resin, By impregnating with epoxy resin, polyurethane resin, NBR, SBR, etc. alone or in an appropriate mixture), drying, and heat treatment, abrasive grains or abrasive particles (long) are uniformly applied only inside the constituent fibers of the bulky convex portion (2). A non-woven abrasive fabric in which abrasive grains or abrasive particle-containing areas exist in the form of regular or irregular dots with only a small amount of abrasive grains adhering to the surface. constitutes material (5).

The area of the recesses formed in the nonwoven fabric mat is 5 to 20.
% is suitable, and if it is less than 5 inches, it is not much different from a non-woven abrasive product impregnated with a normal non-woven mat, and if it is more than 20 inches,
Since there are fewer convex portions containing abrasive grains, which causes the problem of rapid wear, a preferable value is 10 to 15%, since edge grinding can be performed appropriately on the surface to be ground, and resinized concave portions are appropriately present. It has the advantage of being hard to fall off and having little wear and tear.

Alternatively, as shown in Fig. 2, a molded product can be obtained by impregnating a nonwoven fabric mat (3) with an uneven pattern with an abrasive grain-containing resin binder and then rolling it into a spiral shape. When formed into a body, complete voids (6) are formed between the laminated mats, so when formed into a wheel, heat dissipates quickly, the heat load on the wheel is small, clogging is less likely to occur, and the voids are completely sealed. This makes it possible to obtain groundbreaking non-woven abrasive products that have excellent polishing effects.

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

Example 1 A composite fiber 15'deX8B*Ia whose core part is 66 nylon and sheath part is 6 nylon is spun using a jindowe/(- machine to form a web having a weight of 1 oop/m'. Next, the following binder is used. Apply liquid to the front and back sides of the web respectively.
? Spray and dry to obtain a temporarily fixed nonwoven fabric.

Contains scattering binder SBR latex 100 copies Melamine resin 85 parts Catalyst 8.5 parts Next, apply this temporarily fixed nonwoven fabric to an embossing roll.

A pair of heating rolls with silicone rubber bottoms (220°C
) A nonwoven fabric mat having a continuous uneven pattern in which the area of the heat-sealed recesses pressed by the convex portions of the embossing roll was approximately 10 inches was formed.

The thickness of the convex part of the above nonwoven fabric mat is 5 fl, and the thickness of the concave part is 1 m.
I failed. Next, this nonwoven fabric mat was impregnated with the following binder, and the weight of the product was adjusted to 8009N.

Urethane prepolymer with dipping binder 100 parts EK Pigment Low Aluminum oxide 800 g β The nonwoven abrasive obtained by drying and heating weighs 800 parts.
fβ, thickness convex portion 5-1 4 parts 1 mm convex portion constituting fiber layer uniformly contains and adheres abrasive grains to the inside and surface, forming a nonwoven fabric abrasive material with an uneven pattern having locally abrasive grain-containing portions did.

Example 2゜Example 1. A nonwoven fabric mat having an uneven pattern formed in the same manner as above was immersed in an abrasive grain-containing urethane prepolymer, and then rolled into a spiral shape while still wet to a predetermined outer diameter. Temperature: 100°C, dew point: 40°C After being left in a heat treatment chamber for 24 hours, it was finished to the final outer diameter and cut into rings of a predetermined width to form a spiral nonwoven abrasive wheel.

A grinding test was conducted to compare the performance of the spiral nonwoven abrasive wheel obtained in the above example and a conventional spiral abrasive wheel.

Grinding conditions Daughter wheel outer diameter 805-1 width 50 fins, load I
Kg/as, the rotation speed was 8000 rpm, a stainless steel plate was used as the object to be ground, and traverse was performed at 10 m/min.

The grinding time was 10 minutes.

The grinding results are shown in the table below.

As is clear from the table above, the present invention has excellent grinding effects;
Communicating! After 521 hours, the ground surface of the product according to the present invention was flat, whereas the conventional product had undulations. This is presumed to be due to the difference between simple plane polishing and edge polishing using convex portions containing abrasive grains.

Since the present invention is configured as described above, the abrasive grain-containing convex portion acts on the surface of the material to be ground at an acute angle, thereby making it possible to finish the grinding on a flat surface with a uniform grinding depth and no undulations. , when formed into a spiral shape or a laminated product,
Even if the first layer is worn out, the convex portions of the second layer appear, and stable grinding performance can always be exhibited.

Furthermore, when the spiral or laminated product described above is formed into a wheel, complete voids are formed between the layers, so heat dissipation is good, the heat load on the wheel is reduced, and the life of the wheel is extended. Also, clogging is less likely to occur.

It has excellent effects such as excellent cushioning effect.

[Brief explanation of drawings]

FIG. 1 is a schematic sectional view of the main parts showing one embodiment of the present invention, and FIG.
The figure is a front view showing another embodiment. il+...concavity, (2j...convexity, (3)...nonwoven fabric mat, (4)...abrasive grain or abrasive particle, (6)...
...Non-woven abrasive material, (6)...Gap C9

Claims (1)

[Scope of Claims] A synthetic fiber non-woven fabric temporarily fixed with a binder mainly composed of thermoplastic resin is pressed with a heated embossing roll, and the suppressed portions formed are substantially resin-fused concave portions and unpressed convex portions. 1. A nonwoven fabric abrasive material comprising: a nonwoven fabric mat having a concavo-convex pattern consisting of a concave and convex pattern, and abrasive grains or abrasive particles are fixed to the convex portions of the nonwoven fabric mat using a resin binder. 2. The nonwoven abrasive material according to claim 1, characterized in that the abrasive grain-containing convex portions have an area of 5 to 100 g.