CN1060712C - 涂敷的磨料底材、涂敷磨料制品及其制作方法 - Google Patents
涂敷的磨料底材、涂敷磨料制品及其制作方法 Download PDFInfo
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- CN1060712C CN1060712C CN92113726A CN92113726A CN1060712C CN 1060712 C CN1060712 C CN 1060712C CN 92113726 A CN92113726 A CN 92113726A CN 92113726 A CN92113726 A CN 92113726A CN 1060712 C CN1060712 C CN 1060712C
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Abstract
本发明提供涂敷磨料底材，它包含60%-99%(重量)韧性、耐热的热塑性粘合材料和分布于所述的热塑性粘合材料整体中的1%至40%(重量)的长细比至少为100∶1的纤维质增强物料，两者一起构成硬化组合物。本发明还提供了包含上述底材、涂于底材的工作表面上的第一粘结层、嵌入第一粘结层中的磨料和涂于磨料和第一粘结层上的第二粘结层的涂敷磨料制品及其制作方法。本发明的涂敷磨料制品在较严峻的研磨工况下不会出现底材变形或损坏。
Description
本发明涉及涂敷的磨料制品。更具体地说，本发明涉及其基底材料中含有热塑性树脂和纤维增强物质的涂敷磨料制品。
涂敷磨料制品一般包含用一层或多层粘合剂粘着在底材上的磨料(通常磨料为颗粒形式)。这类制品一般采取片状、圆盘、带、条等形式。
许多磨料制品以圆盘形式用于研磨装置中。典型的这类磨料砂磨或研磨装置包括：用橡胶或塑料之类的弹性材料或增强材料做成的垫板或支承板；磨料圆盘(通常是靠摩擦力装到垫板上)；以及把磨料圆盘和垫板装配在一起的转轴和盖帽，装配时将盖帽拧入轴上的螺纹，从而加压力于圆盘，使圆盘挤压在垫板上。使用时上述示例装置的轴转动起来，磨料涂敷的圆盘表面以较大的力量顶压在工件上。因此圆盘受到很重的应力。对于其它形状(如带状)的磨料制品情况亦是如此。
涂敷磨料制品中常用的底材是用纸、聚合物、布、非织物、硬化纸板，或这些材料的结合所制成的。这些材料中有不少不适合于某些应用，因为它们的强度、挠性或耐冲击性不够高，有些这类材的老化过快而不能采用。在有些场合下，该材料对用作冷却剂和切削液的液体很敏感。因之在某些应用中会出现过早的失效或性能很差。
涂敷磨料底材常用的一种材料是硬化纸板。硬化纸板底材一般耐热而且有较高强度，当涂敷磨料用于涉及高发热和高压的严峻条件的研磨操作中时，这两条是很有利的特性。例如，硬化纸板用于诸如熔焊研磨，外形打磨及边缘打磨等研磨操作中。其中涂敷磨料会接触到140℃以上的温度。但是硬化纸板底材比较贵，容易吸湿，因而对湿度较敏感。
在极端的湿度条件(即很高和很低的湿度条件)下，硬化纸板会由于吸水或失水而分别受到膨胀或收缩的影响。其结果是用硬化纸板做成的研磨制品会趋于卷成杯状，这就导致涂敷的磨料圆盘发生凹形或凸形卷曲。一旦发生这种杯卷或卷曲，受其影响的涂敷磨料圆盘就不会平整地贴合在垫板或支承板上。这就使涂敷磨料圆盘基本上不能工作。
本发明中的涂敷磨料制品可用于较严峻的研磨工况而不会出现明显的底材变形或损坏。这里的“严峻的研磨工况”一词是指研磨过程中摩擦界面处的温度至少为200℃左右(一般至少为300℃左右)，摩擦界面处的压力至少为7kg／cm2左右(一般至少为13.4kg／cm2左右)。被研磨表面在摩擦界面处的温度与压力是指底材上磨料颗粒与工件之间的接触位置处涂敷磨料制品所经受的瞬时或局部值，不带有喷水之类的外部冷却源。虽然在研磨过程中瞬时的或局部的温度可能高于200℃，甚至往往高于300℃，但是由于散热作用，底材上一般所受到的是低于这些值的总体温度或平衡温度。当然，如果需要的话这类制品也可以用于不那么条件苛刻的研磨操作中。
本发明的涂敷磨料底材包括热塑性粘合剂物质(宜为韧性耐热的热塑性粘合材料)；以及有效数量的纤维质增强物料。所述的纤维质增强物料宜分布在整个热塑性粘合材料中。该纤维质增强物料一般由纤维构成，即长阔比至少为100∶1左右的细线状物料。粘合剂与纤维质增强物料一起形成在使用中基本上不变形或裂解的硬化组合物。这种“韧性耐热”的热塑性粘合材料应使硬化组合物具有所要求的特性，使之在各种磨损(即研磨)条件下基本上不变形或裂解。更理想的是，纤维质增强物料与韧性耐热的热塑性粘合材料的硬化组合物在以上定义的严峻研磨工况下基本上不会变形或裂解。
所述的底材宜包含约60％至99％的热塑性粘合材料(以底材重量为基准)，其熔点宜为至少约200℃；同时包含有效数量的纤维质增强物料。所述的硬化组合物宜含有足够数量的热塑性粘合材料以使本发明的底材所具有的孔隙体积小于约0．10％。热塑性材料可选自以下一组物质：聚碳酸酯、聚醚亚胺、聚酯、聚砜、聚苯乙烯、丙烯腈-丁二烯-苯乙烯嵌段共聚物、缩醛聚合物、聚酰胺，以及它们的结合形式。最适用的热塑性粘合材料为聚酰胺材料。纤维质增强物料宜为单股纤维或纤维多股线的形式，如玻璃纤维。纤维质增强物料的熔点宜比热塑性粘合材料的熔点高出至少25℃左右。
本发明的涂敷磨料底材宜包含1％至30％的增韧性剂(以底材总重量为基准)。该增韧性剂宜为橡胶增韧剂或增塑剂。增韧性剂更适宜于选自以下一组物质：甲苯磺酰胺衍生物、苯乙烯-丁二烯共聚物、聚醚骨架聚酰胺、橡胶-聚酰胺接枝共聚物、苯乙烯-(亚乙基亚丁基)-苯乙烯三嵌段共聚物，以及它们的混合物。在这些增韧剂中，橡胶-聚酰胺共聚物和苯乙烯-(亚乙基亚丁基)-苯乙烯三嵌段共聚物更为适用，尤以橡胶-聚酰胺共聚物最佳。
构成涂敷磨料底材的硬化的粘合剂／纤维组合物宜为挠性，在环境条件下的弯曲模量为至少约17，500kg／cm2，更好的是在约17，500至141，000kg／cm2之间，测定方法按ASTM D790号测试方法所概述的步骤进行。这里的“环境条件”一词及其变化形式是指室温(即15至30℃，一般为20至25℃左右)和30％至50％的相对湿度(一般为35％至45％左右的相对湿度)。构成涂敷磨料底材的硬化的粘合剂／纤维组合物还宜具有至少约为17．9kg／cm(宽)的拉伸强度(约150℃下，试样厚度为0．75至1．0mm左右)。
本发明的磨料制品包括带有一个工作表面的底材，亦即其前表面或顶面，在该表面上涂以第一层粘合剂，或称结构涂层。在第一粘合层中嵌入磨料，最好是磨料颗粒，其平均颗粒大小宜为至少约0．1μm，至少约100μm更好；通常再将第二粘合层，或称施胶涂层涂在涂覆磨料及第一粘合层上。第一和第二粘合层均宜包含碳酸钙作填料的可熔酚醛树脂。
需要时本发明的涂敷磨料制品可用注模法制作。这种方法包括有一个步骤热塑性粘合材料、纤维质增强物料以及可选用的增韧剂结合在一起。该方法宜包括将韧性耐热热塑性粘合材料、纤维质增强物料(纤维质增强物料分布在整个粘合剂中，最好是基本上均匀地分布在整个粘合剂中)，以及供选用的增韧剂结合在一起以形成软性的可模制的混合物。该方法还包括用上述软性的可模制混合物做成有一定形状的物件；冷却该成型的物件以形成由韧性耐热的热塑性粘合材料及遍布其中的纤维质增强物料构成的硬化底材。这种硬化底材可用作涂敷磨料制品，它在使用中基本上不会变形或裂解(最好是在被磨表面摩擦界面处温度至少为约200℃，被磨表面摩擦界面处压力至少为约7kg／cm2的条件下)。该方法还进一步包括以下步骤：将一层粘结剂涂到硬化底材上；将一层磨料涂到已敷有一层粘结剂的硬化底材上。
将韧性耐热热塑性粘合材料(宜为聚酰胺)以及纤维质增强物料(宜为玻璃纤维)结合起来这一步比较有利而适宜的方式是：用热塑性粘合材料与纤维质增强物料的软性可模制混合物造粒。该方法亦可有利而适宜地包括以下步骤：在形成成型物件这一步之前往热塑性粘合材料和纤维质增强物料中添加增韧剂。
图1为根据本发明所述的涂敷磨料制品的前视图。图1为草图性质的，用来反映本发明所述的结构。
图2为根据本发明所述的余敷磨料制品的侧向局部剖面放大，按图1中2-2线剖视。
图3为涂敷磨料制品的后视图，显示模制在底材上的肋条。
图4为根据本发明所述的涂敷磨料制品的第二种实施方案(圆盘形状，带有一个连接装配系统)的侧向局部剖面放大，所取位置大致相似于图2，但加进了所述的连接装配系统。
图5为本文描述的角铁试验中用的工件的透视图。
图6为根据本发明所述的圆盘形涂敷磨料制品的另一种实施方案的侧向局部剖面放大，所取位置大致相似于图2，但伸展为圆盘的整个直径并略为偏离中心，这样就不显出中心孔(相当于图1中的部位6)。
图7为根据本发明所述的圆盘形涂敷磨料制品的又一种实施方案的侧向局部剖面放大，所取位置大致相似于图2，但伸展为圆盘的整个直径并略为偏离中心，这样就不显出中心孔(相当于图1中的部位6)。
图1中所示为圆形盘的前视图，它包含有图2的结构。圆盘1表示出本发明所述的涂敷磨料圆盘的工作表面2。这里的工作表面2亦称作前表面或顶面，一般代表了用于研磨工件的表面。图中示出两大部位4和6。部位4包括圆盘」底材的工作表面2上所粘着的，磨料颗粒8形式的磨料。部位6是圆盘的中心孔，用于装配到研磨没备的转轴上去。
一般说来圆盘直径尺寸范围为约6至60cm。圆盘直径为约11至30cm较好，约17至23cm更好。最常用的圆盘的尺寸范围为约17至23cm直径。圆盘上一般有中心孔，亦即图1中的部位6，其直径通常为约2至3cm。
参看图2，本发明所述的涂敷磨料制品10一般包括底材11和第一粘结层12，第一粘结层常称作结构涂层，涂在底材11的工作表面13上。第一粘结层12的目的是将磨料(如许多磨料颗粒14)固着在底材11的工作表面13上。
参看图2，常称作施胶涂层的第二粘结层15则涂覆在磨料颗粒14及第一粘结层12上面。施胶涂层的目的是使磨料颗粒14牢固地固着。常称作超级施胶涂层的第三粘结层16可以涂覆在第二粘结层15上面。第三粘结层16是选用性的，一般用于涂覆极硬表面研磨用的磨料，例如用于研磨不锈钢或奇特金属的工件。
底材11的厚度一般小于约1．5mm以达到最佳的挠性和节省材料。对于最佳挠性而言，底材11的厚度宜在约0．5至1．2mm之间。底材11的厚度在约0．7至1．0mm之间更好。
参看图2，底材11的结构中包含热塑性粘合材料17和纤维质增强物料18。纤维质增强物料可以是单根纤维或多股线形式，或者是纤维簇或织物形式。无论纤维质增强物料18是单根纤维或簇丛形式，纤维质增强物料18宜在底材主体里遍布于热塑性粘合材料17之中。这种分布宜在底材11主体内基本上均匀遍及更好。也就是说，纤维质增强物料不仅加在底材主体的表面上或者底材各层中。而是使纤维质增强物料基本上完全介入底材的内部结构并遍及分布。当然，纤维簇或织物结构要具有足够的尺寸以遍布于底材粘合剂中。
底材上可以有一系列的肋条，即交替的厚薄部分，这种肋条模制在底材上，当需要用于某些应用时可提供进一步的好处。模制肋条可用于设计所需的刚性度或“使用中的感觉”(用有限元素分析法)，用于改善冷却，改善结构完整性，以及当肋条与垫板咬合时增加力矩传递。这些肋条可是直线或曲线形、径向、同心圆、任意图形，或它们的结合形式。
图3中示出圆盘31的后视图。圆盘31表示出带有模制在底材上的一系列径向肋条33的涂敷磨料圆盘。此图代表圆盘31的背面32，这是与图1所示的表面相对的圆盘表面。也就是说，背面32是一般不带有磨料的表面。因此涂覆有磨料的底材表面一般是平的，亦即没有隆起部或肋条。虽然这一特定实施方案中所示的肋条33仅部分伸向中心孔36，留下一个没有模制肋条的部位35，但若需要的话，肋条33可以沿整个背面伸展到中心孔36处。
模制肋条可以与圆盘半径成任何角度。也就是说，肋条可与半径(即从圆盘中心至外缘的线段)处于某个角度关系，也即在0°至90°范围内。肋条亦可安排成与半径成可变角度的型式以使空气流通最大。
此外，底材上可直接模制连接装配系统以便把涂敷磨料固着到工具和／或工具连接段上去。参看图4，涂覆磨料40带有底材41和连装系统42。连装系统42和底材41是一元化整体，亦即是同一连续(模制)的结构。一般情况下若连装系统是模制的连装系统，亦即模制在底材上，则底材的直径要小于约12cm，小于约8cm较好。另外，连装系统亦宜由热塑性粘合材料与有效数量的遍布于热塑性粘合材料内的纤维质增强物料的硬化组合物所构成。这种整体化的连装系统比较有利。这至少是因为能将底材容易而牢靠地装入轮轴的中央。也就是说；如果底材为圆盘形状，连装系统可位于圆盘的几何中心位置处从而可以容易地轮轴上对中。
参看图6中所示的另一种涂敷磨料制品设计方案60，圆盘形的底材61具有升高的边缘部位62，在升高的边缘部位62中，底材61在圆盘外缘部位63处的厚度比圆盘中心部位65处的厚度大。升高的边缘部位62一般宜使基材厚度增加约2×10-2至3×10-2cm(相对于中心部位65的厚度而言)。通常宜使升高的边缘部位62为底材61上唯一的涂覆有磨料66和粘结层67，68及69的部位。
较好的是让本发明所述的圆盘也可具有中间凹下的部位(如从图6中所见)，图中圆盘的底材61模压成带凹陷中心部位65的形状。
本发明的底材带有使刚性度增加的加大厚度的边缘是适宜而有利的。如图6所示，这样做可以得到边缘升高的制品，而磨料则涂覆在边缘上。另外如图7中的圆盘70所示，圆盘70的外缘部位73处，底材71带有增厚的模压边缘部位72。边缘部位72与圆盘70的总表面积相比只代表很小的表面积，这一边缘部位背朝圆盘70的磨料表面75(即与工件接触的表面)向外突出。边缘部位72呈环状，位于底材71的外缘区73 ，圆环部位的厚度比底材中心部位71的厚度大，这一边缘部位72提供了较大的刚性度，使圆盘发生翘曲之前能耐受较高的应力。与图6所示的实施方案不同，图7所示实施方案中磨料76及粘结层77，78和79都是涂覆在带升高边缘部位72的表面的背面上。
本发明中较好的底材还呈现足够的抗弯曲韧性以耐受严峻的研磨工况。“足够的抗弯曲韧性”是指底材有足够刚度以承受严峻的研磨工况，但又不是很脆而在底材中形成裂纹，这种裂纹会降低底材的结构完整性。这一点可以通过对底材或涂敷磨料制品进行角铁试验加以证实，该试验在实施例部分中介绍。
简单地说，角铁试验包括以下步骤：制作涂敷磨料制品；弯曲该涂敷磨料制品(如圆盘)使粘结层碎裂而形成小块的互不相关的磨料区；将磨料涂敷的圆盘在45％的相对湿度下存放于湿度室中3天；将此涂敷磨料圆盘装到直径比圆盘小的硬质酚醛垫板上，使涂敷磨料圆盘外缘的7至8cm左右宽度未受到垫板的支承；将涂敷磨料圆盘／垫板固定到能以4，500rpm的速度旋转的风动研磨机上，空气压力为2．3kg／cm2；使涂敷磨料圆盘／垫板保持40°角，将其以2至6kg(2至3kg较好)的恒定负荷压入到140°角的楔形或V形工件的“V”形槽中；使涂覆磨料圆盘／垫板在约15秒内沿一个方向扫过约0．75m的工件长度，使涂敷磨料圆盘／垫板在约15秒内沿相反方向再扫过约0．75m的工件长度。样品圆盘连续扫经工件10至15min或者到涂覆磨料底材“失效”为止(看这两项中哪一项以较短时间先达到)。
角铁试验中所说的“失效”是由底材的裂解，即失去结构完整性来确定的，这可以来自撕裂，折断，或断裂。裂解也可以用被试验的涂覆磨料制品的底材上边缘裂缝的发展来衡量。在角铁试验中，若涂覆磨料制品底材上在2min的试验期内出现长度超过约0．6cm的表面裂缝或者丧失了结构完整性，则认为该底材不可用，亦即不具有足够的抗弯曲韧性以耐受前面定义的严峻的研磨工况。如果涂敷磨料制品能研磨至少2min左右而不出现这种裂纹或者不丧失结构完整性，则认为它通过了角铁试验，亦即具有可接受的抗弯曲韧性质量。
图5示例说明角铁试验用的工件。该试验用的工件50包括两片(51和52)1018号低碳钢(长0．77m，厚2．54cm)，两片碳钢在界面53处焊在一起形成V型，使两片1018号低碳钢(51和52)之间的夹角54约为140°。
如果未采用耐垫粘结层(即结构涂层和施胶涂层)，如果未使用研磨1018号钢的有效的磨料颗粒，或者如果未使用合适粒度的磨料颗粒，则涂层结构就不能通过角铁试验。这种失效不能归因于底材；而应归因于不合适的结构涂层或施胶涂层，不适用的磨粒颗粒，或者不适当的磨料颗粒粒度。失效也可能是由于结构涂层或施胶涂层的固化不良，或者试验前的挠曲处理不恰当不充分。涂敷磨料制品的挠曲处理一般是在控制的加工条件下进行的。例如让制品通过加载辊子之间。则粘结层均匀而定向地开裂，亦即碎成小块的互不相连的磨料，而底材上则不出现裂缝。这一处理一般都能改善涂敷磨料制品的挠性。
本发明所述底材的较好的韧性也可以通过测定涂敷磨料底材的抗冲击强度来验证。抗冲击强度可按ASTM D256或D3029测试方法中所述的试验步骤进行测定。这些方法均涉及测定使指定尺寸的标准试验样品破裂所需的作用力。对于环境条件下的厚度为0．89mm的样品，本发明的底材宜具有至少约为0．4J的抗冲击强度，亦即加德纳冲击值。对于环境条件下的厚度为0．89mm的样品，本发明的底材具有至少约0．9J的加德纳冲击值较好，最好是至少约1．6J。
本发明的较好的底材亦具有所需的拉伸强度。拉伸强度衡量物质在不断裂的情况下所能耐受的最大纵向应力。拉伸强度表示对转动失效和“断裂”的耐受能力，而转动失效和“断裂”是由于涂敷磨料制品在操作中可能会接触到工件上的不均匀处，这些部位会生很高的阻力而造成的。测试步骤在实施例部分描述。合乎需要的拉伸强度的定义如下：150℃左右的温度下，样品厚度约为0．75至1，0mm时，1cm宽度至少为17．9kg／cm左右。
本发明的较好的底材还具有恰当的保持形状不变的性能，对湿度和温度之类的环境条件相当不敏感。这一点的含义是：本发明的较好的涂敷磨料底材在很宽的环境条件范围内均具有以上列举的性质。底材宜在约10℃至30℃的温度范围和约30％至50％相对湿度(RH)的湿度范围内具有上述性质。底材在更宽的温度范围(即从0℃以下至100℃以上)和更宽的湿度值范围(从10％RH以下至90％RH以上)内具有上述性质则更好。
本发明的涂敷磨料制品中所用的较好的底材一般是这样选择的：即底材与粘结层相容性好，粘结良好(尤其是与结构涂层之间)。粘结良好程度用磨料剥落量来确定。在研磨行业中“剥落”一词用于表示磨料从底材上以不希望的过早的方式脱落，一般是以磨料颗粒形式脱落。本发明的较好底材在边缘剥落试验(在实施例部分中详细描述)条件下，从涂覆有24号级磨料颗粒(美国国家标准所B74．18-1984号标准)的7inch直径圆盘上剥落下来的磨料量不超过约6g。虽然底材的选用很重要，但剥落量往往在更大程度上取决于粘结剂的选择以及底材与粘结剂的相容性。
本发明的涂敷磨料制品包含一种底材，这种底材含有热塑性粘合材料以及有效数量的纤维质增强物料。“有效数量”的纤维质增强物料是指底材中所含纤维质增强物料的量足以如上面讨论的使耐热性、韧性、挠性、刚性、形状保持性、粘结性等至少有所改善。
底材中热塑性粘合材料的数量宜在约60％至99％的范围内，在约65％至95％范围内更好，最好是在约70％至85％范围内(均以底材重量为基准)。典型的较好底材中的其余部分主要是纤维质增强物料，也许还有很少量的遍布在硬化的底材组合物中的孔隙。虽然在粘合剂组成中还可以添加别的组分，但本发明的涂敷磨料底材主要含有热塑性粘合材料和有效数量的纤维质增强物料。
本发明的涂敷磨料制品的底材中适用的粘合剂为热塑性物质。热塑性粘合材料是指这样一类聚合材料(宜为有机聚合材料)，它在接触高温时变软熔化，而在冷却到室温时一般又回复到它的原来状况，即其原始物理状态。在制造过程中，加热这种热塑性粘合材料超过其软化温度，最好超过其熔化温度以使其流动，并将涂敷磨料底材做成所需的形状。底材成形后，使热塑性粘合剂冷却固化。这样可使热塑性粘合材料被模制成各种形状和大小。
适用于制备本发明所述制品中的底材的热塑性物质的例子有：聚碳酸酯、聚醚亚胺、聚酯、聚砜、聚苯乙烯、丙烯腈-丁二烯-苯乙烯嵌段共聚物、缩醛聚合物、聚酰胺，或它们的结合。在这张单子中以聚酰胺(如各种尼龙)和聚酯较好。聚酰胺材料是最适用的热塑性粘合材料，这至少是由于它们固有的韧性和耐热性，它们一般不必涂底料就能与较适用的粘结剂树脂很好地粘着，而且较为便宜。
可用作本发明所述制品中的底材的市售尼龙树脂的例子有：孟山都公司的产品“Vydync”(密苏里州，圣路易斯)；杜邦公司的产品“Zylel”和“Minlon”(特拉华州，威尔明顿)；Huls America公司的产品“Trogamid T”(新泽西州，匹斯卡塔威)；联合化学公司的产品“Capron”(新泽西州，莫里斯顿)；Mobay，公司的产品“Nydur”(宾夕法尼亚州，匹兹堡)；和巴斯夫公司的产品“Utramid”(新泽西州，帕西派尼)。虽然也可以用填充有矿物质的热塑性物质(如填充矿物质的尼龙6树脂“Minlon”)，但其中矿物质并非是这里所定义的“纤维”或“纤维质物料”；矿物质是颗粒的形式，它所具有的长阔比一般低于100∶1。
除了热塑性粘合材料之外，本发明的底材中还包含有效数量的纤维质增强物料。这里所说的“有效数量”的纤维质增强物料是指其数量足以使硬化底材的物理特性(即耐热性、韧性、挠性、刚性、形状保持性能、粘着性等)至少有所改善，但又不是过多的纤维质增强物料以致造成较多数量的孔隙或者对底材的结构完整性产生不利影响。
底材中纤维质增强物料的数量(均以底材重量为基准)宜在约1％至40％范围内，在约5％至35％范围内较好，在约15％至30％范围内最好。
纤维质增强物料可以是单股纤维或纤维多股线形式，或者是纤维簇或织物形式。从有利于制作来说，增强物料宜为单纤维或纤维多股线形式。纤维一般定义为长细比至少约为100∶1的细线状物体。纤维的长细比就是纤维的较长尺寸与较短尺寸之比。纤维簇或织物可以是编织的或非织基体形式。非织簇垫是任意分布的纤维所构成的基体，是用机械手段，热处理或化学方法将纤维粘着或缠结在一起而制成的。
本发明应用中适用的增强纤维的例子包括金属纤维或非金属纤维。非金属纤维包括玻璃纤维、碳纤维、矿物质纤维、耐热有机材料所构成的合成纤维或天然纤维，或者陶瓷材料所制成的纤维。本发明应用中较适宜的纤维包含非金属纤维，更为适宜的纤维有耐热有机纤维、玻璃纤维，或陶瓷纤维。
“耐热”有机纤维的含义是：在本发明的涂敷磨料底材制造与使用条件下，适用的有机纤维一定不能熔化，否则就会解体。适用的天然有机纤维的例子有羊毛、丝、棉，或纤维素。适用的合成有机纤维的例子有聚乙烯醇纤维、聚酯纤维、人造丝纤维、聚酰胺纤维、丙烯酸纤维、芳香聚酰胺纤维，或酚醛胺纤维。较适合于本发明应用的有机纤维为芳香聚酰纤维。这种纤维可从杜邦公司(特拉华州，威尔明顿)购得，其商品名为“Kevlar”和“Nomex”。
一般来说，任何陶瓷纤维均可用于本发明的应用中。适用于本发明的陶瓷纤维的一个例子是可从3M公司(明尼苏达州，圣保尔)以商品购得的“Nextel”。
本发明应用中最适宜的增强纤维为玻璃纤维，这至少是由于玻璃纤维能使涂敷磨料制品具有所需要的特性而且比较便宜。此外，现在已经有适用的界面粘结剂可以增强玻璃纤维与热塑性材料的粘着性。玻璃纤维一般是用一个字母等级来加以分类。例如E玻璃(代表电气)和S玻璃(代表强度)。字母代码也表示直径范围，例如尺码“D”代表直径约为6μm的细丝，尺码“G”代表直径约为10μm的细丝。玻璃纤维中适用的等级包括细丝尺码标号为D至U的E玻璃和S玻璃。较好的玻璃纤维级号有细丝尺码号为“G”的E玻璃和细丝尺码号为“G”的S玻璃。有商品销售的玻璃纤维可从下列公司购得：佛罗里达州奥尔兹玛市的专业玻璃公司；俄亥俄州托雷多市欧文斯-柯宁纤维玻璃公司；和密苏里州罗拉市的Mo-Sci公司。
如果使用玻璃纤维，则玻玻璃维宜与一种界面粘结剂(即偶合剂，例如硅烷偶合剂)配合使用以改善其与热塑性材料的粘着性。硅烷偶合剂的例子有“Z-6020”和“Z-6040”，它们可从密歇根州密德兰市的道-康宁公司购得。
采用长度短到只有100μm的纤维材料或者单根连续纤维长度达到所需值的纤维材料都能得到一定好处。纤维长度宜为约0.5mm至约50mm范围，从约1mm至约25mm更好，最好是从约1．5mm至约10mm。较好的纤维的增强纤维旦数(即细度)范围为约1至约5000旦，一般在约1至约1000旦之间。纤维旦数在约5至约300之间更好，最好是在约5至约200之间。众所周知，所用增强纤维的特定类型对旦数有很大影响。
较好的增韧剂(即橡胶增韧剂和增塑剂)的例子有：甲苯磺酰胺衍生物(如N-丁基和N-乙基对甲苯磺酰胺的混合物，可以商品名“Kcljenllex8”从伊利诺依州芝加哥的AKZO化学公司购得)；苯乙烯-丁二烯共聚物；聚醚骨架聚酰胺(可以商品名“Pebax”从新泽西州格兰罗克市的Atochem公司购得)；橡胶-聚酰胺共聚物(可以商品名“Zylll FN”从特拉华州威尔明顿的杜邦公司购得)；官能化苯乙烯-(亚乙基亚丁基)-苯乙烯三嵌段共聚物(可以商品名“Kra-ton FG1901”从德克萨斯州休斯敦的壳牌化学公司购得)；以及这些物料的混和物。在这一组物质中，橡胶-聚酰胺共聚物和苯乙烯-(亚乙基亚丁基)-苯乙烯三嵌段共聚物更为适用，这至少是由于它们能使本发明的底材及其制造方法具有不少有利的特性。最适用的是橡胶-聚酰胺共聚物，这至少是由于它们能使本发明所述的底材具有有利的抗冲击和研磨特性。
如果底材用注模法制作，则一般以增韧剂颗粒与其它组分的干混合物形式加入增韧剂。过程中通常包括在转鼓中使增韧剂颗粒与含纤维的热塑性材料颗粒混和。更适用的方法包括以下步骤：在一台适用的挤出机中使热塑性材料、增强纤维和增韧剂结合在一起，将此混和物造粒，然后将这些制得的颗粒送入注模机中。可以买到增韧剂与热塑性材料的商品组合物，例如以商品名“Ultramid”从巴斯夫公司(新泽西州帕西派尼市)购买。具体地讲，“Ultramid B3ZG6”可用于本发明中，它是含增韧剂和玻璃纤维的一种尼龙树脂。
除了上述物料之外，本发明中的底材可根据所要求的最终性能而包含有效数量的其它物料或组分。例如，底材中可包含定形剂，亦即熔点高于前面热塑性粘合材料描述中提到的数值的热塑性聚合物。适用的定形剂包括(但不限于)聚苯硫、聚酰亚胺和芳族聚酰胺。较适用的定形剂的例子是聚亚苯基氧化物尼龙混合物，它可以商品名“Noryl GTX910”从马萨诸塞州匹兹菲尔德的通用电气公司购得。但若涂敷磨料结构中所用的是酚醛基的结构涂层和施胶涂层，则聚亚苯基氧化物尼龙混合物不适用，因为酚醛树脂粘结层与尼龙之间的相互作用不均匀，导致抵销定形效果。这种不均匀相互作用是由于难以得到聚亚苯基氧化物与尼龙的均匀混合物。
本发明某些应用中的底材还可以加入其它这类物料，其中包括无机或有机填料。无机填料亦称为矿物填料。填料一般定义为是一种颗粒状物料，其粒度通常小于约100μm，小于约50μm较好。本发明应用中适用填料的例子有炭黑、碳酸钙、二氧化硅、硅酸钙、冰晶石、酚醛填料，或聚乙烯醇填料。如果使用填料，则可推理认为填料充填在增强纤维之间并可防止裂纹在底材中扩散。以底材重量为基准，填料用量一般不高于约20％。宜使用至少为有效数量的填料。这里的“有效数量”一词是指足以用于充填而又不明显降低硬化底材拉伸强度的数量。
本发明某些应用中的底材还可以加入其它有用物料或组分，其中包括(但不限于)颜料、油类、防静电剂、阻燃剂、耐热稳定剂、紫外线稳定剂、内润滑剂、抗氧化剂和加工助剂。这些组分要根据所希望结果的实际需要，一般不要用得过多。
本发明涂敷磨料制品中的粘结层是由树脂状粘结剂形成的。每一层可由同一种或不同的树脂粘结剂形成。可用的树脂粘结剂与底材的热塑性物料相容。树脂粘结剂亦能经受本文中定义的严峻的研磨工况，固化后粘结层不会损坏，也不会过早脱落磨料。
树脂粘结剂宜为热固性树脂层。适用于本发明的可用的热固性树脂粘结剂的例子有(不限于)：酚醛树脂、氨基塑料树脂、聚氨酯树脂、环氧树脂、丙烯酸酯树脂、三聚氰胺-甲醛树脂、丙烯酸异氰尿酸酯树脂、脲甲醛树脂、异氰尿酸酯树脂、丙烯酸聚氨酯树脂、丙烯酸环氧树脂，或它们的混合物。
上述热固性树脂粘结层宜含酚醛树脂、氨基塑料树脂，或它们的结合。所说的酚醛树脂宜为可熔酚醛树脂。有商品出售的酚醛树脂的例子有：德克萨斯州达拉斯的Oxy Chem公司的产品“Varcum”；俄亥俄州哥伦布市Ashland化学公司的产品“Arofene”；康涅狄格州邓布里市联合碳化物公司的产品“Bakelile”。较适用的氨基塑料树脂中每个分子含有至少1．1个侧链α，β-不饱和羰基，它是按美国专利第4，903，440号的披露内容制备的。
第一和第二粘结层(参见图2中的粘结层12和15，亦即结构涂层和施胶涂层)宜含有磨料制品中常用的其它物料。这些物料常称为添加剂，其中包括研磨助剂、偶合剂、润湿剂、染料、颜料、增塑剂、脱模剂，或者它们的结合。一般根据所希望的结果需要多少这种材料就用多少，不宜过多。在第一和第二粘结层中还可以用填料作为添加剂。从经济角度以及有利的效果出发，一般所用的填料数量不超过粘结剂重量的约50％(结构涂层)或者约70％(施胶涂层)。适用的填料例子有二氧化硅细粉之类的硅化合物，例如粒度为4至10mm的粉末状二氧化硅(可从伊利诺依州芝加哥的Akzo美国化学公司购得)，和钙盐，如碳酸钙和硅酸钙(可以商品名“Wollastokup”和“Wollastonite”从纽约州威尔斯波罗市的Nyco公司购得)。
图2中的第三粘结层16(即超施胶涂层)宜含有研磨助剂以增强涂敷磨料的研磨特性。研磨助剂的例子有四氟硼酸钾、冰晶石、铵冰晶石和硫。研磨助剂的用量一般不超过预期的结果所需的量。
粘结层，至少是第一和第二粘结层宜由常用的钙盐充填的树脂(例如可熔酚醛树脂)构成。可熔酚醛树脂较好，这至少是由于其耐热性，对湿分较低的敏感性，较高的硬度以及较低的成本。更适宜的粘结层是在可熔酚醛树脂中含大约45％至55％的碳酸钙或硅酸钙。粘结层最好是包含约50％的碳酸钙填料以及约50％的可熔酚醛树脂、氨基塑料树脂，或两者的组合。这里所说的百分比均以粘结剂重量为基准。
本发明应用中适用的磨料的例子有熔融氧化铝、热处理氧化铝、陶瓷氧化铝、碳化硅、氧化铝-氧化锆、石榴石、金刚石、立方晶形氮化硼，或它们的混合物。“磨料”一词包含磨料颗粒、磨料烧结团块，或多颗粒的磨料颗粒。
较好的磨料是氧化铝基的磨料颗粒。本发明应用中可用的氧化铝颗粒包括熔融氧化铝、热处理氧化铝和陶瓷氧化铝。
本发明较好的应用中，磨料颗粒的平均粒度至少为约0．1μm，至少为约100μm较好。按照美国国家标准所(ANSI)B74．18-1984号标准，粒度约100μm大致相当于120级磨料颗粒的涂敷磨料。磨料可以是定向的或者在涂覆到底材上时是非定向的，这取决于涂敷磨料底材所要求的最终用途。
可以用各种方法制备本发明所述的磨料制品和底材。有利的是在适用的组成(或组分)中有很多是可以通过注模的办法来形成底材的。因此不必过多的实验就很容易达到对制作条件及产品形状的精确控制。本发明底材注模所用的实际条件取决于所用注模机的种类和型号。在实施例部分中将介绍一种注模方法。
本发明涂敷磨料底材的注模还可以有多种替代的以及可以采纳的方法。例如，在注模步骤之前可将纤维质增强物料(如增强纤维)与热塑性物料先混合。为了做到这一点可在加热的挤出机中使纤维与热塑性物料混合，然后挤出造粒。
另外也可以将增强纤维的编织垫，非织垫或缝编垫放在模子中。热塑性物料及任何选用的组分可用模注法充填到簇垫中增强纤维之间的空间中去。在本发明的这一方式中，增强纤维很容易按所要求的方向定向排列。此外，增强纤维也可以是连续的纤维，其长度取决于模子和／或特制成的制品的尺寸及形状。
在某些情况下，模子中可施用常见的脱模剂以利于处理。但若热塑性物料为尼龙，则模子上一般不必涂覆脱模剂。
底材注模后，一般即可用常规方法涂覆结构涂层、磨粒颗粒和施胶涂层。例如把粘结层(即结构涂层和施胶涂层)涂覆到底材上去可以采用辊涂、幕涂、喷涂、刷涂，或者任何其它适宜涂敷流体的方法。这些粘结层可以进行硬化(例如固化)，有许多方法，可以任选一种，不同层可以同时也可以分别硬化。磨料颗粒可以用重力加料沉积，或者是用静电法沉积到涂有粘结剂的底材上，此时使磨料颗粒带电并使底材带有相反的电荷。
构成底材的成分也可以挤出成为薄片状或卷材状，用粘合剂和磨料颗粒均匀涂覆，随后转化成磨料制品，就像通常的磨料制品制作中所做的那样。片材或卷材可用各种办法(如冲剪刀切、喷水切割，或激光切割)切成单个小片或圆盘。这些片材和／或圆盘的形状和大小可以像前面介绍注模时所述的那样。接着可用常规方法(如辊涂粘结剂、静电沉积颗粒)涂覆结构涂层、磨料颗粒和施胶涂层以构成涂敷磨料制品。
另外也可以是让底材保持其薄片或卷材形状，用任何一种常见方法在底材上涂覆结构涂层、磨料颗粒和施胶涂层。然后再冲切出涂敷磨料制品，或者转化其成为最终所需的形状或形式。如果是冲切出涂敷磨料制品，则这些片和／或圆盘的形状及尺寸可以如前面在注模中所述的那样。以下这种情况也属于本发明某些应用的范围之内：用通常的粘接或连接方法将涂敷磨料制品转换为无端头的圈带形式。
另外，同时可挤出两层或多层以形成本发明的底材。例如，将两台常规挤出机连到一个双层膜成型模上就可以形成双层底材，其中的一层使粘合剂与磨料颗粒的粘着性改善，而另一层则比方说可以含有较高数量的填料，这样就可以降低成本而又不牺牲性能。
实施例
通过下列详细的实施例进一步描述本发明。一般资料
沉积在底材上的物料量用每平方米的克数(g／m2)表示，但在引用时这些数量都称作重量；所有比例均基于这些重量值。在所有的实施例中均采用以下缩写记号。N6B尼龙6热塑性树脂，可以商品名“UltramidB3F”从巴斯夫公司购得。MFN6矿物质充填的尼龙6热塑性树脂，可以商品名“Minlon”从杜邦公司购得。PPO66聚(2，6-二甲基-1，4-亚苯基氧化物)／尼龙6，6混合物，可以商品为“Noryl GTX-910”从通用电气公司购得。EFG G级直径，标准E型连续多股玻璃纤维，可从明尼苏达州温诺那市的RTP公司购得，是与尼龙6或尼龙6，6树脂的复合物。在使用“EFG”纤维的所有实施例中，玻璃纤维与尼龙树脂混和在一起，挤出造粒。颗粒长度约为0．32cm。下面实施例中的重量是指玻璃纤维的实际重量和尼龙的实际重量。EFGL G级直径，标准E型连续多股玻璃纤维，可从特拉华州威尔明顿市的帝国化学工业公司购得，是与尼龙6或尼龙6，6的复合物。这些玻璃纤维用熔融尼龙聚合物进行饱和处理，牵拉通过圆形截面的成型模，截断为1．3cm长的颗粒。以下实施例中的重量是指玻璃纤维的实际重量和尼龙的实际重量。SBS苯乙烯-(亚乙基亚丁基)-苯乙烯嵌段共聚物增韧剂，可以商品名“Kraton FG1901”从壳牌化学公司购得。NTS增塑剂，主要是N-丁基和N-乙基(对甲苯磺酰胺)的混合物，可以商品名“Ketjenflex8”从Akzo化学公司购得。RP碱催化可熔酚醛树脂，其中甲醛：苯酚之比在约1．5∶1至约3∶1之间。BAM带有至少1．1个侧链α，β-不饱和羰基的氨基塑料树脂。该树脂的制备方法类似于美国专利第4，903，440号介绍的第2种制备方法所述。该项专利在此列为参引资料。简要地说，该方法包括用37％的甲醛水溶液、丙烯酰胺、91％的仲甲醛和对甲苯磺酸水合物从N-(羟甲基)丙烯酰胺制备N，N′-氧代二亚甲基二丙烯酰胺醚。PH1 2，2-二甲氧基-1，2-二苯基-1-乙酮。CACO粒度为4至20mm的粉末状，未经处理的碳酸钙填料，可从俄亥俄州辛辛那提市的Aluchem公司购得。CMS硅酸钙填料，可以商品名“Wollastokup”从纽约州威尔斯波罗市的Nylo公司购得。CRY白色粉末级冰晶石研磨助剂，可从俄亥俄州克利夫兰市的Kaiser化学公司购得。
底材注模的一般步骤
用注模法制作底材的一般步骤如下。用于底材中的成分先在80℃下干燥4小时。尼龙热塑性树脂为颗粒形式。纤维包含在颗粒中。增韧剂也呈颗粒形式，只有NTS例外，它是在注模之前预先复合到热塑性聚合物中去的。各成分称重后放入一个5加仑容积的桶内。桶中插入浆式混合器，使桶迥转但保持桨式混合器静止不动从而使成分充分混和。然后使所得的混合物落入一台Van Dorn公司制造的300吨注模机的料筒中。该注模机料筒中有三个温度区。第一区的温度约为265℃，第二区的温度约为270℃，第三区的温度约为288℃。注模机料筒喷嘴的温度约为270℃，模子的温度为约93℃。注射时间为约一秒钟。螺杆速度较慢，即低于100转／分(rpm)。注模压力为100kg／cm2。注射速度约为0．025m／s。一次注射的量为约23cm3。组分通过注模而形成圆盘形状，其直径为17．8cm，厚度为0．84mm，中心孔直径为2．2cm。
边缘剥落试验
边缘剥落试验测量工件上4130号低碳钢被切削或打磨下来的数量以及磨料涂敷制品上磨料颗粒损耗的数量。磨料颗粒损耗就相当于“剥落”量，亦即磨料颗粒从底材上过早脱落。每个实施例中的涂敷磨料圆盘(直径17．8cm，中心孔径2．2cm)装到直径为16．5cm，最大厚度为1．5cm的硬质酚醛塑料托盘上。托盘再装到直径为15．2cm的碳钢法兰上。涂敷磨料圆盘以3，550rpm的速度旋转。工件为直径25cm的4130号低碳钢圆盘的外缘(宽1．6mm)，工件方向与垂直于磨料圆盘的位置成18．5°角。工件以2rpm的速度旋转，并以2．1kg的负载使之与涂敷磨料圆盘的磨料表面接触。研磨界面处压力大小约为28kg／cm2范围。试验终点为8分钟。试验终止后对工件称重以确定从工件上切削或打磨下来的金属数量。另外在测试前后也对磨料圆盘进行称重以确定在使用中损耗了多少磨料。理想的涂敷磨料制品的磨料颗粒重量损失低，磨削量则较高。所有重量均以克数给出。
滑动试验Ⅰ
这项试验以及滑动试验Ⅱ和Ⅲ设计用于确定在“最糟糕的情况下的”性能。每项试验的条件逐渐变得更加苛刻。所有三项试验中采用同一种托盘以减少变化因素。每个实施例中的涂敷磨料圆盘(直径为17．8cm，中心孔径2．2cm)装到作托盘(直径16．5cm，最大厚度1．5cm)用的铝板上。然后将磨料涂敷盘装在风动研磨机上以6000rpm的速度旋转。工件为304不锈钢块(宽2．54cm，长17．8cm)。转动的涂敷磨料圆盘保持位置不变，工件则在圆盘下方来回往复运动。研磨界面处的作用力约为6．8kg。研磨连续进行直到涂敷磨料制品失效或研磨时间达到20分钟为止，两者中哪一条时间短就以它为准。制品失去结构完整性就是出现“失效”，亦就是撕裂，折断或断裂。试验中打磨下来的不锈钢的数量也计算出来。
滑动试验Ⅱ
滑动试验Ⅱ的操作步骤与滑动试验I中的相同，只有下列变动。工件为1018号低碳钢块(宽2．54cm，长17．8cm)。研磨界面处的作用力约为9．1kg。
滑动试验Ⅲ滑动试验Ⅲ的操作步骤与滑动试验Ⅱ中的相同，只是工件为304不锈钢块(宽2．54cm、长17．8cm)。这项试验是很苛刻的。这些研磨条件并非典型的工业研磨工况。
拉伸试验
每个实施例中的底材用冲剪或纵向切割的办法做成宽2．54cm，长17．8cm的试验样品。每个试样没有粘结涂层(如结构涂层及施胶涂层)和磨料颗粒。每个试样随后以12．7cm的标距长度装到In-stron试验机上，先以0．51cm／min的速度拉伸至伸长率达到5％，随后以5．1cm／min的速度拉伸以测定拉伸强度，它也就是使试样断裂所需的最大作用力。在室温和150℃的温度下测定拉伸强度。在有些实施例中试样冲剪时是按“机器走向”或底材“横向”进行的。对于注模底材，机器走向的试样在冲剪时是沿着注模过程中组分流动的平行方向进行的，而横向试样在冲剪时则是沿着注模过程中组分流动的垂直方向进行的。在有些实施例中记录的是平均的拉伸强度测定值，也就是机器走向拉伸值与横向拉伸值的平均值。
角铁试验
涂敷磨料圆盘样品(直径17．8cm，厚0．76至0．86mm，中心孔径2．2cm)先进行弯折，也就是使磨料／粘结涂层均匀而定向地开裂，然后摊平放在相对湿度为45％的湿度室中保持3天(除非另有规定说明)。然后将涂敷磨料装到直径10．2cm，最大厚度为1．5cm的硬质酚醛塑料托盘上。这样做的结果是涂敷磨料圆盘的边缘并未受到托盘的支承。随后将每个涂敷磨料圆盘／托盘组件固定在风动研磨机上以4500rpm的速度旋转。研磨机的风压为2．3kg／cm2。该风动研磨机装在辛辛那提Milacron公司T3型工业机器人上，是机器人臂上恒定负载和均衡器的一部分。该恒定负载为约2．3kg／cm2。本项试验用的工件包括两块1018号低碳钢，它们焊接在一起构成一个V形工件，使两块钢板之间约成140°角。每块钢板长0．77m，厚2．54cm。这种工件如图5中所示。涂敷磨料圆盘保持为40°角，用力压入140°角的楔形或V形中并来回扫经工件长度。试样圆盘扫经工件的速率为：涂敷磨料圆盘沿一个方向运动经过0．75m的工件长度用时约为15秒。研磨连续进行直到试验结束为止。试验终点一般为15分钟或者涂敷磨料底材丧失结构完整性(即撕裂、折断、断裂，或出现长度超过0．6cm的边缘开裂)而失效，这两项中哪一项先达到即为终点。一般说来，若涂敷磨料制品的底材在2分钟的试验时间内就出现长度约为0．6cm的边缘开裂或者丧失结构完整性，则该底材是不能采纳的。涂敷磨料制品若能在至少约2分钟研磨中不出现这种开裂或不丧失结构完整性，则此制品“通过”角铁试验，亦即其质量可以接受。实施例1至28和对比例A至C
这一组实施例说明构成本发明底材所用组分的各种比例。对比例A
对比例A用的涂敷磨料为24级的商品名为“Paint Buster”的纤维圆盘，可从明尼苏达州圣保尔市的3M公司购得。对比例B
对比例B用的涂敷磨料为24级的商品名为“GreeCorp”的纤维圆盘，可从明尼苏达州圣保尔市的3M公司购得。对比例C
对比例C用的涂敷磨料用实施例1至16中相同的方法制作，只是其底材为普通的厚度为0．84mm的硬化纸板底材。
实施例1至28
构成本发明底材的各种组分的比例概括于表1中。底材是按前面“底材注模的一般步骤”一节中概述的方式制作的。各圆盘(亦即每个实施例中的圆盘)的配方随后用于涂敷磨料结构中。
表1
实施例1至16
用刷子将结构涂层涂到底材的适当的一侧，重量为434g／m2。结构涂层由48％的RP与52％的CACO所得的含固体84％的混和物构成。在这一组实施例以及所有的实施例中所用的溶剂为90／10比例的水／C2H5C(CH2)2OH。用静电涂覆将24号热处理熔融氧化铝颗粒植入到结构涂层中，重量为1400g／m2。所得材料在88℃下加热预固化90分钟。然后在磨料颗粒上涂以施胶涂层，重量为570g／m2。施胶涂层由48％的RP与52％的CMS所得的含固体78％的混和物构成，所得产物在88℃下加热预固化90分钟，再在120℃下最终加热固化12小时。随后将每个圆盘通过加重量的碳钢和橡胶辊子之间使之弯折，以使磨料／粘结涂层均匀而定向地开裂，试验前在相对湿度为45％的条件下湿润处理3天。每个圆盘均按边缘剥落试验测试。从表2可以看到结果。注意其中的矿物质损耗和钢材磨削量在每个实施例中均为5个左右圆盘的平均值。
实施例17至28
实施例17至28中的涂敷磨料是用分别相应于实施例1至12中的同样方式制备的，只是所用的结构涂层及施胶涂层的组成以及预固化处理不一样。另外，实施例17至28中的涂敷磨料只采用边缘剥落试验进行测试。结构涂层为0．75％PH1，21．6％BAM，26．4％RP和52％CACO的混和物(含固体84％)。结构涂层的预固化是让结构涂层／磨料颗粒在4．6m／min的速率下分三次受紫外光线照射。紫外光源是以118w／cm工作的带聚焦反射器的Fusion“D”灯泡，可从马里兰州洛克维尔市的Fusion系统公司购得。涂覆的底材在灯泡下方约10cm处以大约4．6m／min速率通过。通过次数(本例中为3次)决定于达到足够固化程度的需要，所谓足够固化程度是指即使在适度的变形压力下仍能保持磨料颗粒的取向。试样按上面实施例1至16所述经受最终热固化处理。从表2中可看到打磨结果。
表2边缘剥落试验结果 *在这个实施例中未测定钢材切削量
表2所示结果表明，热塑性底材成功地达到了试验所定的标准，即矿物质损耗不超过6g，钢材磨削量至少为125g。另外，实施例17至28中含BAM的粘结层其性能(按钢材磨削量而定)相当于或优于实施例1至12中含酚醛树脂但不含BAM的粘结层。
实施例1至16中的涂敷磨料圆盘试样还在45％相对湿度下湿润处理3周(而不是表2所列结果用的3天)。然后从湿度室中取出圆盘，放在房间环境条件下1周。这些圆盘按滑动试验Ⅲ和角铁试验进行测试。结果分别列在下面的表3和表4中。滑动试验Ⅲ中未测定磨削量，即从工件上磨削下来的钢材量。在角铁试验中，测试在研磨8分钟之后停止。另外在角铁试验中，只要底材中一出现开裂迹象也就终止测试。在许多例子中这些圆盘其实还可以继续用于打磨。
表3滑动试验Ⅲ
表4角铁试验
表3结果表明，虽然控制例C显示其出现失效前的时间最长，但在此项苛刻的试验中它在打磨4分钟之后就没有任何磨削作用了。而实施例1至16则继续磨削直至失效，大部分都明显超过了4分钟。表4所列结果表明，在此项试验中本发明的磨料制品其性能明显就优于对比例。实施例29与30和对比例D与E
这一组实施例将本发明的底材与普通的涂敷磨料底材进行比较。这些实施例中的涂覆磨料按边缘剥落试验、角铁试验和滑动试验Ⅰ进行测试。测试结果是至少两个圆盘的平均值。测试结果列于表5、6和7中。
实施例29
本实施例中的底材是按“底材注模的一般步骤”制作的。该底材含74．7％N6B，20．0％EFG，3．5％PPO66和1．8％SBS。包含这种底材的涂覆磨料如下制作。底材顶面一侧涂以结构涂层，重量为206g／m2。结构涂层由26．4％RP，21．6％BAM，0．96％PH1，18．2％CMS和33．8％CACO的混和物构成(含固体84％)。接着将50号热处理熔融氧化铝磨料颗粒(可从奥地利特雷巴克市特雷巴克化学公司购得)用静电法植入结构涂层中，重量为618g／m2。涂覆的底材在Fusion“D”紫外线灯泡下方的10cm处通过，灯泡工作功率为118w／cm，通过速度为4．6m／min。通过次数(本例中为3次)取决于达到足够固化程度的需要，所谓足够固化程度提指即使在适度的变形压力下仍能保持磨料颗粒取向不变。样品如实施例1至16所述经受最终热固化处理。然后在磨料颗粒上涂以施胶涂层，重量为380g／m2。该施胶涂层由32％RP，66％CRY和2％氧化铁的混合物构成(含固体78％)，氧化铁用于染色。所得产物在88℃下接受加热预固化90分钟，再在120℃下接受最终热固化处理12小时。随后在测试前对圆盘进行挠曲处理并在45％相对湿度下湿润3天。
实施例30
实施例30中的涂敷磨料制品的制作及测试方式与实施例29中相同，只是涂敷磨料制品在测试前先在一桶室温的水中浸泡24小时，然后在室温下干燥。对比例D
对比例D中的涂敷磨料制品的制作与测试方式与实施例29中相同，只是其底材为普通的0．84mm厚的硬化纸板底材，这种底材可从特拉华州约克林市的NVF公司购得。对比例E
对比例E中的涂敷磨料制品的制作与测试方式与实施例30中的相同，只是采用不同的热塑性底材。该热塑性底材按“底材注模的一般步骤”制作。该底材基本上只包含MFN6。在此底材中没有增强纤维。
表5边缘剥落试验结果
| 实施例 | 矿物质损耗(g) | 钢材磨削量(g) |
| 2930对比例D对比例E | 0．550．940．590．74 | 148136141148 |
表6角铁试验结果 *注意：若出现失效时间超过15分钟则试验停止。在这些例子中涂敷屠料底材
失去结构完整性并非“失效点”。
表7滑动试验I
这些结果表明本发明的磨料制品等价于或超过对比例的性能。对比例E严重失效，圆盘上好几块在角铁试验中同时脱落。虽然对比例E是用充填矿物质的尼龙6制作的，在底材整体中并无纤维质增强物料分布。实施例31至33和对比例F与G
| 实施例 | 总磨削量(g) | 出现失效时间(min) |
| 2930对比例D270对比例E109 | 285175205．25 | 2012 |
这些例子本发明的各个方面与普通底材进行比较。按这些例子制作的涂覆磨料均按边缘剥落试验测试。结果列于表8中。
实施例31
实施例31中的涂敷磨料圆盘是按实施例29中的同样方法制作的，只是所用的是不同的磨料颗粒。这种磨料颗粒为按美国专利第4，744，802和5，011，508号介绍的方法制备的50号陶瓷氧化铝，这两项专利均在此并入本文作为公开内容的一部分。
实施例32
实施例32中的涂敷磨料圆盘是按实施例31中的同样方法制作的，只是圆盘的结构特性不同。该圆盘直径17．8cm，中心孔径2．2cm。该圆盘上有180条肋沿着靠外缘的3．2cm从盘中心向外投射，与半径方向成50°角(见图3)。
实施例33
实施例33中的涂敷磨料圆盘是按实施例32中的同样方法制作的，只是底材的组成不同。该底材含73．5％N6B，20．7％EFG，3．9％NTS和1．9％SBS。对比例F
对比例F中的涂覆磨料为50号“Regal”树脂粘合纤维圆盘，可从明尼苏达州圣保尔市的3M公司购得。对比例G
对比例G中的涂敷磨料圆盘是用实施例31中同样的方法制作的，只是底材为0．84mm厚的硬化纸板底材，它可从特拉华州约克林市的NVF公司购得。
表8边缘剥落试验结果
| 实施例 | 矿物质损耗(g) | 钢材磨削量(g) |
| 313233对比例F对比例G | 1．00．80．80．90．6 | 204221211207221 |
这些结果表明本发明的磨料制品很容易就达到试验标准：即矿物质损耗不超过6g，钢材磨削量至少为125g。实施例34至36和对比例H
这些例子将本发明的各个方面与普通底材进行比较。按这些例子制作的涂敷磨料制品用滑动试验Ⅱ测试。结果列于表9中。
实施例34
实施例34中的底材按“底材注模的一般步骤”制备。底材包含80％N6B，5％EFG，12％PPO66和3％SBS。制作涂敷磨料制品的其余步骤与实施例17至28中所概述的相同。
实施例35
实施例35中的涂敷磨料制品是用实施例34中相同的方法制作的，只是其底材包含74．7％N6B，20％EFG，3．5％PPO66和1．8％SBS。
实施例36
实施例36中的涂敷磨料制品是用实施例34中相同的方法制作的，只是其底材包含54％N6B，31％EFG，12％PPO66和3％SBS。对比例H
对比例H中的涂敷磨料制品包含24号“Three-M-ite”树脂粘合纤维盘，可从明尼苏达州圣保尔市的3M公司购得。
表9滑动试验Ⅱ
| 实施例 | 总磨削量(g) | 出现失效时间(min) |
| 343536对比例H 124 | 1652381834．5(停止磨削) | 3-82020 |
这些结果表明，增强纤维含量对于磨料制品底材达到适宜的性能是很重要的，最好在底材中含约15％至30％的纤维。在实施例34中，底材失效出现时间比其它样品短。底材在工件上翘曲，出现断裂，底材上的小块飞散。据认为这是由于增强玻璃纤维的数量不足以经受本项特殊试验的苛刻条件。这不一定意味着就不能发展一种含1％至5％纤维质增强物料又较长时间经受这项试验的条件的底材。实施例35中的圆盘经受住了整个试验，只是底材稍有变形。在实施例36中，圆盘也经受住了整个试验，但有一些边缘剥落。实施例37至42和对比例I
这一组例子将本发明各种底材结构的拉伸强度值与普通的硬化纸板底材进行比较。试验在室温和150℃下进行。在实施例37至42中，底材均按“底材注模的一般步骤”制作。结果列于表10中。
实施例37
本实施例的底材包含74．7％N6B，20％EFG，3．5％PPO66和1．8％SBS。
实施例38
本实施例的底材包含74．7％N6B，20％EFGL，3．5％PPO66和1．8％SBS。
实施例39
本实施例的底材包含74．7％N6B，10％EFG，10％EFGL，3．5％PPO66和1．8％SBS。
实施例40
本实施例的底材包含80％N6B，5％EFG，12％PPO66和3％SBS。
实施例41
本实施例的底材包含75％N6B，15％PPO66和10％SBS。
实施例42
本实施例的底材包含54％N6B，31％EFG，12％PO66和3％SBS。对比例Ⅰ
本例中的底材为普通的0．84mm厚的硬化纸板，可从特拉华州约克林市NVF公司购得。
表10拉伸强度值
所到结果为至少三个读数的平均值。所有试样显示可接受的拉伸强度。除实施例40以外的所有试样均通过下述标准：150℃下断裂强度至少为2．54cm宽度45．5kg。这些结果还表明，与对比例相比，本发明底材的拉伸强度值随底材取向的变动较小。
实施例43至45
实施例43至45按“底材注模的一般步骤”制备，其组成如下面所述。磨料涂层如实施例1至16中所述涂覆，只是所用的是50号“Cubitron”陶瓷氧化铝颗粒(可从明尼苏达州圣保尔市3M公司购得)。在这些实施例中对滑动试验I作了改动，是用1018号低碳钢作工件，研磨操作20分钟。角铁试验延长到20分钟。这些实施例的试验结果示于表11中。
实施例43
本实施例的底材由100％N6B构成。没有增韧剂或增强纤维。
实施例44
本实施例的底材包含85％N6B和15％EFG。没有用增韧剂。
实施例45
本实施例的底材包含80％N6B和20％EFG。没有用增韧剂。
表11
| 实施例 | 加德纳抗冲击值(0．89mm厚度的焦耳数) | 边缘剥落试验 | 滑动试验(母20分钟内磨削克数) | 角铁试验(出现失效时间) | |||
| 磨削量(g) | 矿物质损耗(g) | ||||||
| 4345 | 9．0+0．41．6 | 209210206 | 1．21．11．0 | 9分钟时失效956797 | 20min20min20min | ||
这些结果表明没有增韧剂也能制备性能改善的较好的底材，但仍宜使用增韧剂为好。这些数据也进一步证明纤维增强物料的下述好处：虽然韧性要比使用增韧剂时低一些，但纤维增强物料可以提供耐热性和耐压性，而这是制作可接受的磨料底材所必需的性能。此外，这些数据还证明了采用最新型磨料颗粒(相对于前面的实施例而言)的底材具有最优良的性能。实施例46和47以及对比例J和K
这一组实施例说明使用橡胶一聚酰胺共聚物增韧剂制作的本发明底材的特性。这些增韧剂可以商品名“Zytel”从杜邦公司购得。在这些实施例中所用的增韧剂为“Zytel”FN树脂，它们是挠性尼龙合金。它们是官能化聚酰胺接枝到官能化丙烯酸橡胶上的接枝共聚物。在实施例46和47中，底材按“底材注模的一般步骤”制作。按实施例43至45中所述将磨料涂层涂到实施例46，47，对比例J和对比例K的样品上。结果列于表12中。
实施例46
本实施例的底材包含71．3％N6B，20％EFG和8．7％“Zytel”FN726增韧剂。
实施例47
本实施例的底材包含71．5％N6B，20％EFG和8．5％“Zytel”FN718增韧剂。对比例J
本例的底材为普通的0．84mm厚的硬化纸板，可从特拉华州约克林市的NVF公司购得。对比例K
本例的底材为50号“Regal”NF硬化纸板盘，可从明尼苏达州圣保尔市的3M公司购得。
表12 *这一样品经过较长期湿润处理。正常情况下这一组成应与对比例K一样失效。
已就本发明的各种具体和较适宜的实施方案和方法作了描述。但是应该理解，还可以作出许多变动和修改而仍属于本发明的主旨与范畴之内。
Claims (11)
1．涂敷磨料底材，其特征在于该底材包含：
(a)韧性、耐热的热塑性粘合材料，以底材重量为基准，所述韧性、耐热的热塑性粘合材料的含量为60％至99％(重量)；和
(b)分布在上述韧性、耐热的热塑性粘合材料整体中的1％至40％(重量)的长细比至少为100∶1的纤维质增强物料，所述纤维质增强物料赋予该底材硬挺性、保持形状不变性和耐热性，其中韧性耐热的热塑性粘合材料与纤维质增强物料一起构成硬化的组合物，它在研磨条件下基本上不会变形或裂解。
2．根据权利要求1所述的涂敷磨料底材，其进一步特征为：
(a)所述韧性、耐热的热塑性粘合材料的熔点至少为200℃；和
(b)所述纤维质增强物料为单纤维形式，其熔点至少比所述韧性、耐热的热塑性粘合材料的熔点高25℃。
3．根据权利要求1所述的涂敷磨料底材，其中进一步包含模注在其上的连装部分。
4．根据权利要求3所述的涂敷磨料底材，其中的底材为圆盘形，所述的连装部分位于圆盘中心。
5．涂敷磨料制品，其特征为包含前述权利要求中任何一项所述的底材，其进一步的特征在于：
(a)在底材的工作表面上涂有第一粘结层；
(b)磨料嵌入第一粘结层中；和
(c)在磨料和第一粘结层上涂以第二粘结层。
6．根据权利要求5所述的涂敷磨料制品，其进一步特征在于所述底材的背面有模制其上的肋条，该肋条以径向方式模制在所述底材的背面上。
7．根据权利要求5所述的涂敷磨料制品，其进一步特征在于所述底材有一个边缘区和中心区；所述边缘区相对于所述中心区而言厚度要增加一些。
8．制作权利要求5、6和7项中任何一项所述的涂敷磨料制品的方法，该方法包括以下步骤：
(a)将韧性、耐热的热塑性粘合材料与1％至40％(重量)的长细比至少为100∶1的纤维质增强物料结合在一起，使纤维质增强物料分布在整个韧性、耐热的热塑性粘合材料中，从而形成软性的可模注混合物；
(b)用上述软性的可模注混合物做成成形的物件；
(c)冷却上述成形物件以形成涂敷磨料制品用的硬化底材；该硬化底材在使用中能耐受工作条件，因而该硬化底材不会明显地变形或裂解；
(d)在硬化底材上涂一层粘结剂；和
(e)在上述涂覆有一层粘结剂的硬化底材上敷一层磨料。
9．根据权利要求8的方法，它进一步包括，在形成成形物件步骤之前向热塑性粘合材料和纤维质增强物料中加入增韧剂。
10．根据权利要求8的方法，其中，在挤出机中将热塑性粘合材料和纤维质增强物料配混在一起，造粒，并且送入注模机中。
11．根据权利要求9的方法，其中，在挤出机中将热塑性粘合材料、纤维质增强物料和增韧剂配混在一起，造粒，并且送入注模机中。
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| US07/811,547 | 1991-12-20 | ||
| US07/811,547 US5316812A (en) | 1991-12-20 | 1991-12-20 | Coated abrasive backing |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3416186A1 (de) * | 1983-05-17 | 1985-01-24 | Hans J. 4400 Münster Fabritius | Schleifscheibe |
| EP0159439A1 (en) * | 1984-03-12 | 1985-10-30 | Philip Mason Grimes | Coated abrasive disc |
| GB2232636A (en) * | 1989-05-24 | 1990-12-19 | Hiram Harry Halliwell | Belt joints |
Non-Patent Citations (1)
| Title |
|---|
| KUNSTSTOFF-HANDBUCH,BANDVI,POLYAMIDE 1966.1.1 CARL HANSER VERLAG MUNCHEN * |
Also Published As
| Publication number | Publication date |
|---|---|
| NO942336L (no) | 1994-06-17 |
| WO1993012912A1 (en) | 1993-07-08 |
| AU2786792A (en) | 1993-07-28 |
| TW252129B (zh) | 1995-07-21 |
| ZA927927B (en) | 1993-04-26 |
| ATE177982T1 (de) | 1999-04-15 |
| MX9206425A (es) | 1993-06-01 |
| CN1073389A (zh) | 1993-06-23 |
| US5316812A (en) | 1994-05-31 |
| US5580634A (en) | 1996-12-03 |
| RU2129065C1 (ru) | 1999-04-20 |
| RU94019995A (ru) | 1997-04-20 |
| EP0617652A1 (en) | 1994-10-05 |
| NO942336D0 (no) | 1994-06-17 |
| DE69228760D1 (de) | 1999-04-29 |
| DE69228760T2 (de) | 1999-08-05 |
| KR100284714B1 (ko) | 2001-03-15 |
| JPH07502215A (ja) | 1995-03-09 |
| US5849646A (en) | 1998-12-15 |
| US5417726A (en) | 1995-05-23 |
| ES2129046T3 (es) | 1999-06-01 |
| JP3630680B2 (ja) | 2005-03-16 |
| CA2126218A1 (en) | 1993-07-08 |
| BR9206937A (pt) | 1995-05-16 |
| EP0617652B1 (en) | 1999-03-24 |
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