CN1269277A - 有序结构砂带制品 - Google Patents

有序结构砂带制品 Download PDF

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CN1269277A
CN1269277A CN00100992A CN00100992A CN1269277A CN 1269277 A CN1269277 A CN 1269277A CN 00100992 A CN00100992 A CN 00100992A CN 00100992 A CN00100992 A CN 00100992A CN 1269277 A CN1269277 A CN 1269277A
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abrasive
abrasive band
band product
mixture
backing
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J·R·皮泼
M·V·姆茨
R·V·海逖
R·M·奥尔松
G·L·豪尔米斯
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3M Co
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Minnesota Mining and Manufacturing Co
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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
    • 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
    • B24D3/001—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 supporting member
    • B24D3/002—Flexible supporting members, e.g. paper, woven, plastic materials
    • 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

Abstract

涉及一种砂带制品,包括具有排列成规则图案的磨料混合物,该混合物粘结在砂带背衬的至少一个主面上,其中形成每一个所述规则图案的磨料混合物具有一个高峰和一个低峰,当用轮廓仪的测头测量并用表面数据分析仪分析时,所述混合物的高峰的高度值的差异在10%范围内,所述混合物的低峰的高度值差异在10%范围内。该产品具有很好的一致性。

Description

有序结构砂带制品
本申请是申请号为92100694.2，申请日为1992年2月2日，发明名称为“有序结构砂带制品及其制造方法”的发明专利申请的分案申请。
本发明涉及砂带制品，它包括背衬及粘结在背衬上面的磨料混合物。
对于砂带制品，特别是细颗粒的制品，两个主要问题：堵塞和产品的一致性。堵塞是由磨屑(也就是从工件上被磨削下来的物料)填入磨粒之间的间隙，以及以后这些磨削下来的物料积聚而造成的问题。例如，在打磨木头时，由于木屑堵塞在磨料之间，因此使磨粒的磨制能力降低，还可能使木质工件的表面发生燃烧。
美国专利US 2,252,683(Albertson)公开了一种砂带，包括背衬和用树脂粘结剂粘结到背衬上面的磨粒。在制造时，在树脂粘结剂固化前，把砂带放入一个加热的带有图案的模具中。反面图案就转到了背衬上。
美国专利US 2,292,261(Albertson)公开了一种砂带，包括纤维质的背衬和在其上面的磨料面层。磨料面层包含埋在粘结剂中的磨粒。在粘结剂还未固化时，使磨料面层在一个带有多个脊状凸起的压模中经受处理。这就使得磨料面层被模压成沿垂直及水平方向的矩形槽。
美国专利US 3,246,430(Hurst)公开了一种带有被热塑性粘结剂浸透了的纤维质背衬的砂带制品。在把背衬预成形成一个连续的脊状图案后，再加上粘结剂和磨粒。这样就得到有高低的磨料脊状凸起的砂带。
美国专利US 4,773,920(Chasman等)公开了一种砂带磨削制品，具有遍布在自由基可固化粘结剂中的磨粒形成的磨料混合物。该专利也公开了可通过轮转凹版印刷辊把磨料混合物成形为一种图案。
虽然上述专利制出的一些砂带制品能抗堵塞并且制造成本不高，但是它们缺乏高度的一致性。如果用普通方法来制造砂带制品，粘结剂体系在固化前和固化中会流动，因此对产品的一致性有不利的影响。
本发明的目的是解决现有技术中的上述问题，提供一种既能抗堵塞并且又有高度一致性的价廉砂带制品。
为了实现本发明的上述目的，本发明提供了一种有序结构砂带制品和制备这种砂带制品的方法。
按照本发明的一个方面，本发明提供了一种砂带制品，包括一背衬，在其至少一个主面上带有磨料混合物，该混合物包括在粘结剂中分散着的许多磨粒。所述粘结剂是分散磨料的介质，也能把磨料混合物粘到背衬上。磨料混合物有预定的形状，例如角锥形。在使用前，最好单颗磨粒不超出该预定形状的界面范围。所给定的形状的尺寸基本上是一致的。另外，混合物是以预定的排列放置。这种预定的排列显示了某种程度的重复性。预定的排列的重复图案可以是直线形的或者成矩阵形。
按照本发明的另一方面，本发明提供了一种砂带制品，包括一背衬，在其至少一个主面上带有磨料混合物，该混合物包括在可辐射固化的粘结剂中分散着的许多磨粒。所述的磨料混合物具有放置在预定排列中的预定的形状。
磨料混合物的这种精确的特征使砂带制品有高度的一致性。这种一致性又使砂带的性能良好。
按照本发明的另一方面，本发明提供了一种制造砂带制品的方法，包括以下步骤：
(1)把含有粘结剂和磨粒的混合物的浆料引入到一生产工具上；
(2)把背衬引入生产工具的外表面，使浆料湿润所述的背衬的一面形成一中间制品；
(3)粘结剂至少部分固化或胶凝后，中间制品脱离生产工具的外表面形成砂带制品；
(4)从生产工具上取下砂带制品。
上述四个步骤最好连续进行以提供制造砂带制品的有效方法。在各程序实施例中，在把浆料引入生产工具上后，浆料在固化或胶凝前不显示出明显的流动。
按照本发明的又一方面，本发明提供制造砂带制品的方法包括以下步骤：
(1)把含有粘结剂和磨粒的混合物的浆料引入背衬，使浆料湿润所述背衬的正面而形成一中间制品；
(2)把所述的中间制品引入具有外表面的生产工具上，生产工具的外表面有一专门的图案。
(3)至少部分粘结剂固化或胶凝后，中间制品脱离生产工具的外表面形成砂带制品；
(4)把制成的砂带制品从生产工具上取下来。
这四个步骤最好是连续进行以提供制造砂带制品的有效的方法。在各程序实施例中，在把浆料引入生产工具后，浆料在固化或胶凝前不显示出明显的流动。
图1是本发明的砂带制品横截面的侧视图；
图2是制造本发明的砂带制品的装置的示意图；
图3是本发明的砂带制品的透视图；
图4是有直线槽排列的砂带制品的顶视图的放大30倍的扫描电镜显微照片；
图5是有直线槽排列的砂带制品的侧视图的放大100倍的扫描电镜显微照片；
图6是有角锥形排列的砂带制品的顶视图的放大20倍的扫描电镜显微照片；
图7是有角锥形排列的砂带制品的侧视图的放大100倍的扫描电镜显微照片；
图8是有锔齿形排列的砂带制品的放大30倍的扫描电镜显微照片(顶视图)；
图9是有锔齿形排列的砂带制品的放大30倍的扫描电镜显微照片(侧视图)；
图10是本发明的砂带制品的表面轮廓试验测得的曲线；
图11是现有技术制的砂带制品的表面轮廓试验测得的曲线；
图12是直线槽排列的示意的前视图；
图13是直线槽排列的示意的前视图；
图14是直线槽排列的示意的前视图；
图15是现有技术的砂带制品放大20倍的扫描电镜显微照片(顶视图)；
图16是现有技术的砂带制品放大100倍的扫描电镜显微照片(顶视图)；
图17是一种特定图案的排列的示意的前视图；
图18是另一种特定图案的排列的示意的视图；
图19是另一种特定图案的排列的示意的顶视图；
本发明提供了一种有序结构砂带制品和制造这种砂带制品的方法。这里所用的术语“有序结构砂带制品”的意思是指一种砂带制品，其中的混合物是包括在粘结剂中分布的磨粒，它们具有预定的形状并按预定的排列布置。
在图1中，砂带制品10包括一背衬12，在其一个主面上带有磨料混合物14。磨料混合物包括分散在粘结剂18中的许多磨粒16。在该具体实施例中，粘结剂把磨料混合物14粘结到背衬12上。磨料混合物具有看得见的规则形状。砂带制品使用前，磨粒最好不伸出到该形状各面之外，当用砂带制品来研磨物件表面时，混合物破裂，暴露出未使用的磨粒。
适宜用作本发明的背衬的材料包括聚合物的薄膜、纸、布、金属薄膜、硬化纸板，无纺衬底、上述物品的组合和上述物品经处理的改型。最好，背衬是如聚脂薄膜之类的聚合物薄膜。在某些情况下，要求背衬能透过紫外线辐射。另外最好薄膜是涂上如聚乙烯丙烯酸之类的材料的有助于把磨料混合物粘结到背衬上。
在形成砂带制品后，可把背衬层压到另一衬底上。例如，背衬可层压到如金属板之类强度及刚性更好的衬底上，来制出支撑在刚性衬底上的有精确的磨料混合物形状的砂带制品。
背衬上不带磨料混合物的这一面也可带有压敏粘结剂或者钩子和环形固定系统使砂带能固定到支撑垫上。适合于上述目的的压敏粘结剂包括橡胶基粘结剂、丙烯酸基粘结剂和硅酮基粘结剂。
磨料混合物由包括在未固化或未胶凝的粘结剂中分散的磨粒的浆料形成。在固化或胶凝后，磨料混合物固化或固定成预定的形状和预定的排列。
磨粒的尺寸分布在约0.5到约1000微米之间，最好在约1到约100微米之间。如果磨粒尺寸分布范围窄，则由其制成的砂带制品可以使被磨削的工件有更好的表面光洁度。适合于本发明的磨粒的例子包括熔融氧化铝、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、立方氮化硼和它们的混合物。
粘结剂必须是可以提供让磨粒分散在其中的介质。粘结剂最好可以比较快地固化，以加快砂带的制造。一些粘结剂胶凝比较快，但是完全固化则需要一段较长的时间。胶凝能保持磨粒混合物的形状直到固化开始。快速固化或快速胶凝的粘结剂可以使得砂带的磨料混合物有高的一致性。本发明的适合的粘结剂之例包括酚醛树脂、氨基塑料树脂、聚氨酯树脂、环氧树脂、丙烯酸树脂、丙烯酸异氰脲酸酯树脂、尿素-甲醛树脂、异氰脲酸酯树脂、丙烯酸化聚氨酯树脂、丙烯酸化环氧树脂、动物胶和它们的混合物。
根据所用的粘结剂，可用例如热能、红外辐射、电子束、紫外辐射或可见光辐射等能源来进行固化或胶凝。
如前所述，粘结剂可以是用辐射固化的。用辐射固化的粘结剂可以是用辐射能量至少部分固化或至少部分聚合的任何粘结剂。这些粘结剂一般是通过自由基机理来聚合的。它们最好选自：丙烯酸化聚氨酯、丙烯酸化环氧树脂、具有α，β-不饱和羰基的氨基塑料衍生物、烯类不饱和化合物、具有至少一个丙烯酸侧基的异氰脲酸酯衍生物、烯属不饱和化合物、至少一个丙烯酸侧基的异氰酸酯以及和它们的混合物。
丙烯酸聚氨酯是羟基封端的异氰酸酯(NCO)的二丙烯酸酯扩展的聚酯或聚醚。作为商品供应的丙烯酸聚氨酯的例子包括UVITHANE 782(Morton Thiokol公司产品)和CMD 6600，CMD 8400，CMD 8805(Radcure Specialties产品)。丙烯酸环氧是二丙烯酸酯如双酚A的二丙烯酸酯环氧树脂。作为商品供应的丙烯酸环氧的例子包括CMD 3500，CMD 3600，CMD 3700(Radcure Sp哏哞唛ecialties产品)。氨基塑料衍生物具有至少1的α，β-不饱和的羰基侧基，这些衍生物在本发明的参考文件US 4,903,440中有进一步的说明。烯属不饱和化合物包括含碳、氢和氧原子的单体或聚合的化合物，也可含氮和卤素。氧和氮原子通常作为醚、酯、氨基甲酸酯、酰胺、脲基存在。这类物质的例子在本发明的参考文件US 4,903,440中有进一步的说明。至少有一个丙烯酸侧基的异氰酸衍生物和至少有一个丙烯酸侧基的异氰尿酸衍生物。在本发明的参考文件US 4,652,274有说明。上述粘结剂通过自由基聚合机理而固化。
本发明砂带制品的其它合适的粘合剂包括在本发明参考文件US 4,318,766中所说的辐射固化的环氧树脂。这类树脂最好用紫外辐射固化。这类环氧树脂通过碘鎓光引发剂引发的阳离子聚合作用而固化。
环氧树脂和丙烯酸酯树脂混合物也是可以使用的。这类树脂混合物在本发明的参考文件US 4,751,138中有说明。
如果粘合剂通过紫外辐射固化，则需要一种光引发剂引发自由基聚合反应。对这一目的合适的光引发剂的例子包括有机过氧化物，偶氮化物、醌类、二苯甲酮、亚硝基类化合物、丙烯基卤化物、腙类、氢硫基类化合物、吡喃  类化合物、三丙烯基咪唑类化合物、二咪唑类化合物、氯烷基三嗪、苯偶姻醚、联苯酰缩酮、噻吨酮类和苯乙酮衍生物。较好的光引发剂是2，2-二甲氧基-1，2-二苯基-1-乙酮。
如果粘合剂通过可见光辐射固化，要用光引发剂来引发自由基聚合。对这一目的合适的光引发剂的例子在作为本发明的参考文件的US 4,735,632中有说明(见该说明书第3栏，25行到第4栏，10行，第5栏，1-7行，第6栏，1-35行)。
磨粉与粘合剂的重量比为4-1份磨粒对1份粘结剂，最好为约3-2份磨粒对1份粘结剂。该重量比取决于磨粒尺寸及所用粘合剂的类型。
砂带制品可具有在背衬及磨料混合物之间设置的任意的涂料。该涂料用来把磨料混合物粘结到背衬上。该层涂料可用可适合于用来制备磨料混合物本身的粘结剂材料组中的材料制备。
除了磨粒和粘结剂外，磨料混合物还可以含有其它的材料。这些材料系指添加剂，包括偶联剂，湿润剂，染料，颜料和它们的混合物。最好，在磨料混合料中包含偶联剂。加入偶联剂可明显地降低用来形成磨料混合物的浆料的涂覆粘度。适合于用作本发明的偶联剂的例子包括有机硅烷，铝酸锆和钛酸盐。偶联剂的重量一般小于5％，最好是小于1％(以粘结剂重量为基础计算)。
磨料混合物具有至少一种预定的形状，并以预定的排列放置。一般，该预定的形状以一定的周期性重复。这种重复的形状可以沿一个方向重复，最好沿两个方向重复。表面轮廓试验是对这种重复形状的重复性及一致性的测定。表面轮廓可用下面试验来测定。
    表面轮廓测定
被测试的砂带放在一平面上，从轮廓仪(SURFCOM表面轮廓仪，日本的东京西门子公司产品)伸出一测头(半径5微米)横向移动越过砂带。该测头以与磨料混合物形状的排列相垂直而与背衬平面相平行的角度横向移动。当然，该测头与磨料混合物的形状相接触。测头的横向移动速度为0.3毫米/秒。数据分析器是日本东京西门子公司产的SURFLYZER表面织构分析系统。当测头接触砂带制品上的磨料混合物并作横向移动时，数据分析仪绘出磨料混合物的形状的轮廓曲线。在本发明的情况下，曲线将显示出重复形状的一定的周期性特点。当制品的一个区域的曲线与另一个区域的曲线相比较时，输出的振辐和频率基本上是相同的，这就意味着没有不规则的图案，也即显示出很清楚的确定的重复图案。
磨料混合物的形状以一定的周期重复。磨料混合物通常有一高峰(或高区)和一低峰(或低区)。数据分析仪输出的高峰值彼此最多相差10％，而输出的低峰值彼此也最好相差10％。
图3示出这种有序结构的一个实例。规则图案的周期标为距离“a”。高峰值标为距离“b”，而低峰值标为距离“c”。
下面的步骤可作为表面轮廓测定的另一个可用的方案。例如图1所示，截取砂带制品的横截面试样。然后把试样镶嵌在一个夹具中。使得试样可以在显微镜下进行观察。扫描电镜和光学显微镜都可用来观察试样。接着用任何普通的方法把嵌在夹具中的试样抛光，使得在显微镜下观察时，试样的表面非常清晰。在显微镜下观察该试样，并拍下试样的显微照片。随后把试样的显微照片进行数字化处理。在这一步骤中，标上X及Y座标对磨料混合物的预定形状和预先的排列进行测绘。
用制备第一个试样同样的方法制备出砂带制品的第二个试样。第二个试样应该沿着取第一试样同样的平面截取，以使第二试样的形状和排列与第一试样属同一类型的。当第二试样进行数字化处理时，如果两个试样的X、Y坐标的差异不超过10％，那么可认为所测定的形状和排列就是预定的。如果两样品的X和Y坐标的差异超过15％，则可认为所测定的形状和排列是不规则的，并且不是预定的形状和排列。
对于具有如图1、6、7和18的不同的峰或形状的特点的模料混合物，在整个排列中，数字化的轮廓会有变化。也就是说，在外观上，峰与谷有区别。因此，在制备第二个试样时，必须很小心，以使得第二个试样的横截面准确对应于第一个试样的横截面，也就是峰与峰相对应，而谷与谷相对应。每个峰区或形状区与另一个峰区或形状区的几何形状基本上相同。因此，在一个峰区或形状区中给定的数字化轮廓，在另一个峰区或形状区中可发现与其基本上相同的另一个数字化轮廓。
本发明的砂带制品的一致性愈好，那么该砂带制品赋予工件的光洁度的一致性也愈好。有序轮廓的砂带制品具有高水平的一致性，因为磨料混合物的峰高变化一般不超过10％。
本发明的砂带制品有一些优点优于现有技术的砂带制品。在一些情况下，这种砂带制品比磨料混合物不按预定的排列放置的砂带制品有更长的寿命。混合物之间的孔隙能使磨屑从砂带制品上排出，因此，使用中减少了堵塞和热量的聚集。另外，本发明的砂带制品磨损均匀，并且在其表面上的研磨力也很均匀。在使用砂带制品时，一些磨粒脱落，新的磨粒暴露，使得砂带制品具有高的寿命、高的持续的磨削速率，和在制品的整个寿命中都有一致的表面光洁度。
以预定的排列放置的磨料混合物的形状和周期可以在较宽的范围变化。图4和图5示出了直线排列的曲槽。图6和图7示出了角钦形。图8和9示出了直线排列的槽。图1示出了有同样尺寸和形状的凸块14，并示出了由三角棱体构成的规则结构表面。而图3示出了一系列的间隔31和平台32。
每个单元磨料混合物有一边界，其由一个或多个表面所限定。例如，图1中界面以数15表示；图3中，界面以数33表示。磨粒最好不超出该界面。相信这种结构使得砂带制品被磨屑堵塞的量可以减少。通过控制界面磨料混合物可以比较一致地复制出来。
磨料混合物的最佳形状取决于具体的磨削应用。当混合物的面积密度(也就是单位面积中混合物的数目)变化时，便会产生不同的性能。例如，高的面积密度倾向于在磨削中使每个单元混合物产生低的单位压力，因此得到更细的表面光洁度。可以设置连续峰的排列以便得到有柔性的产品。对于中等的单位压力言，例如，对于自动磨削，磨料混合物的高宽比最好约为0.3到1。本发明的优点在于在邻近的规则形状的相应点之间的最大距离可小于1毫米，甚至小于0.5毫米。
本发明的砂带制品可按下面的步骤制备。首先把含有磨粒和粘结剂的浆料加入生产工具；第二步把有正反面的背衬引入生产工具的外表面，浆料使背衬的正面湿润而形成一中间制品；第三步是在粘结剂至少部分固化或胶凝后将中间制品与生产工具的外表面分离；第四步是从生产工具上移下砂带制品。这四个步骤最好是连续进行。
图2是本发明方法的示意图，在压力或重力作用下，从供料槽102中流出的浆料100流到生产工具104上，充满在该工具104中的凹坑(未示出)。如果浆料100没有全部充满这些凹坑，那么在砂带制品的磨料混合物的表面和或内部会产生空洞或者小缺陷。把浆料引入生产工具上的其它方法包括模压涂覆和真空模压涂覆。
最好在进入生产工具104前把浆料100加热，通常加热到40°-90℃的范围内，浆料100加热后，更容易流入生产工具104的凹坑中，因此可以减少缺陷。由于某些原因，最好严格控制磨料浆料的粘度。例如，如果粘度太高，则难以把磨料浆料加到生产工具上。
生产工具104可以是带状、板状、涂料辊、安装在涂料辊上的衬套或者压模。生产工具104最好是一个涂料辊。通常，涂料辊直径为25到45厘米，由金属之类的刚性材料制造。生产工具104安装在涂复机上时，就可由一动力驱动的马达来驱动。
生产工具104的表面上有至少一个特定形状的预定排列，它与是本发明的砂带制品的磨料混合物的特定形状和预定排列是相反的。用作本方法的生产工具可以由金属来制造，例如镍，虽然也可以使用塑料。金属制品生产工具可以用雕刻、滚铣，由加工成要求形状的许多金属零件装配成一整体制成，或者用其它机加工方法制造，也可以用电成形方法制造。最好是使用金刚石车削。这些技术的进一步描述请见Encyclopedia of Polymer Science &Technology，Vol.8，John Wiley & Sons Inc(1968)，p651-665和美国专利US 3,689,346说明书第7栏、30-55行。这些资料作为本说明书的参考文献。
有一些例子是从原型工具复制出塑料生产工具的。与金属工具相比，塑料生产工具的优点是成本低。热塑性树脂(如聚丙烯)可以在其熔点模压在金属工具上然后迅速冷却以得到金属工具的热塑性塑料的复制品。该塑料复制品也可用作生产工具。
对于辐射固化的粘结剂，最好是将生产工具加热，一般加热到30°到140℃，以提供容易的加工及砂带制品脱模。
从退绕站108绕下的背衬106通过一导辊110和一压紧辊112而得到适合的张紧力。压紧辊112也迫使背衬106对着浆料100，以使浆料湿润背衬106而形成一种间制品。
中间制品离开生产工具104之前，粘结剂被固化或胶凝。这里用的“固化”意是指聚合成固态；胶凝意指变得十分粘稠，几乎成为固态。在固化或胶凝后，当砂带制品离开生产工具后，磨料混合物的特定形状不会改变。在某些情况下，粘结剂可以先胶凝，随后中间制品脱离生产工具104。然后再使粘结剂固化。由于尺寸特征不会改变，因此最后制出的砂带制品具有很精确的图案。因此，砂带制品是与生产工具104相对应的复制品。
粘结剂可以用能源114进行固化或胶凝，能源提供如热、红外辐射、或其它辐射能(如电子束辐射、紫外辐射、或可见光辐射)。所用的能源取决于具体用的粘结剂和背衬。缩聚固化树脂可用热、高频、微波或红外辐射来固化或胶凝。
可加聚的树脂可以用热、红外辐射，或者最好用电子束辐射、紫外辐射、或可见光辐射来固化。电子束辐射剂量最好为0.1到10毫拉德(Mrad)，更加可取的是1到6毫拉德。紫外辐射是波长为200到700毫微米(最好为250到400毫微米)的非粒子辐射。可见光辐射是波长为400至800毫微米(最好为400至550毫微米)的非粒子辐射。最好是使用紫外辐射。在一定水平的辐射下，粘结剂的固化速率根据粘结剂的厚度以及磨料混合物的密度、温度和混合物的性质而有变化。
砂带制品116离开生产工具104，越过导辊118至卷绕站120。磨料混合物必须很好地粘在背衬上，否则它会保留生产工具104上。生产工具104上最好含有或涂以离模剂(如硅酮)，提高砂带制品116的离模性。
在一些例子中，在使用砂带制品前，最好将其弯曲，这取决于所采用的具体图案和砂带制品所设计的磨削应用。
砂带制品也可按照下面的方法制造。首先把含有粘结剂和磨粒的混合物的浆料引入有正、反面的背衬上。浆料湿润背衬的正面形成一种中间制品；第二步，把所述的中间制品引入到生产工具上；第三步是在粘结剂至少部分固化或胶凝后，使中间制品离开生产工具的外表面以形成砂带制品；第四步是砂带制品从生产工具上移下来。这四步最好连续进行，因而提供了制备砂带制品的有效的方法。
除了在第二个方法中，磨料浆料在开始时是引入背衬上而不是引入生产工具上外，第二个方法基本上与第一个方法相同。例如，在退绕站108和导辊110之间把浆料引入背衬上。而第二方法的其余的步骤和条件与第一方法是相同的。根据生产工具表面的具体结构，可以优先使用第二种方法而不使用第一种方法。
在第二种方法中，可以用如模压涂覆，滚轧涂覆或真空模压涂覆等方法把浆料引到背衬的正面。浆料重量可以由背衬的张力，压紧压力和浆料的流动速率来控制。
下面的非限制性实例将进一步对本发明进行说明。在这些实例中所用的重量均以克/米计。下面实例中的比例是基于重量比。在这些实例中用的熔融氧化铝是一种白色熔融氧化铝。
在下面实例中使用下列缩写：
TMDIMA2：2，2，4-三甲基六甲撑二异氰酸二甲基丙烯酰氧酯；
IBA：异冰片基丙烯酸酯；
BAM：用类似于US 4,903,440的制备方法2制备的具有丙烯酸侧基的氨基塑性树脂；
TATHEIC：三(羟基乙基)异氰脲酯的三丙烯酸酯；
AMP：用类似于US 4,903,440的制备方法4制备的具有丙烯酸侧基的氨基塑性树脂；
PHI：Ciba Geigy公司商标为IRGACURE651的2，2-二甲氧基-1，2-二苯基-1-乙酮；
LP1：示于图12中的曲线形的排列；
LP2：示于图14中的曲线形的排列；
LP3：示于图13中的以特定角度的直线形状的排列；
LP4：示于图19中的形状的排列；
LP5：示于图17中的线形的排列；
LP6：每厘米40行的直线槽排列；
CC：示于图18中的角锥形的排列。
     干推拉试验
把砂带制品转变成一个直径为2.54厘米的盘。双面胶带层压在背衬的反面上。然后将一块直径为2.5 厘米的牌号为FINESSE-IT的垫板(G可从美国的密尼苏达州圣保尔市的密尼苏达采矿和制造公司购到)压砂带制品上。工件是带有聚氨酯底溱的尺寸为45厘米×77厘米的金属板。这种类型的底漆常用于汽车喷漆工业中。用手把砂带制品在板上打磨2.54厘米×22厘米的面积共30处。操作者的手一次来回运动构成一个行程。在100个行程后测定磨削量，也就是除去的底漆的毫米数。底漆厚度用ELCOMETER测量工具(从英国曼彻斯特的Elcometer仪器公司购得)测量。在10次到100次行程后测定光洁度，也就是涂漆的金属板的表面光洁度。光洁度(Ra)用SURTRONIC3轮廓测定仪(从英国Leicester的RaukTaylor Hobson公司购得)测定。Ra是磨痕尺寸的算术平均值(微英寸)。
     湿推拉试验
除了涂底漆的金属板的表面被水淹没外，湿推拉试验与干推拉试验相同。
     实例1-5
实例1-5的砂带制品说明了本发明砂带制品的各种形状和排列。这些制品用间歇方法制出。实例1说明LP1排列；实例2说明LP2排列；实例3说明LP3排列；实例4说明LP4排列；实例5说明CC排列。
生产工具是16厘米×16厘米的方镍板，其上的排列是反的。生产工具由普通的电成形方法制造。背衬是聚酯薄膜(厚0.5毫米)，是用CF4电晕放电处理过的薄膜。粘结剂由90％TMDIMA2/10％IBA/10％PH1的胶粘磷槌伞·磨粒是熔融氧化铝(平均尺寸为40微米)。浆料中磨粒与粘结剂的重量比为1∶1。浆料加到生产工具上。再把聚酯薄膜放到浆料上，在薄膜上用橡胶辊使浆料湿润薄膜表面。随后将有浆料和背衬的生产工具暴露在紫外光下以使胶粘剂固化。每个试样的制品以40英尺/分的速度三次在400瓦/英寸的AETEK紫外灯下通过。然后从生产工具上移下每个试样制品。将实例1-5的砂带制品分别进行干推拉试验和湿推拉试验。干推拉试验结果列于表1。湿推拉试验结果列于表2。图10示出实例1的砂带制品的表面轮廓测试结果。
            表1实例号    磨削量(μm)    表面光洁度(Ra)
                   10次行程  100次行程1            5.6         16.6      11.32            3.1         13.5      14.53            7.6         13.7      10.04            3.4         15.0      9.0
                 表2
实例号    磨削量(μm)    表面光洁度(Ra)
                        10次行程    100次行程
  1            18.5       17.5        12.0
  2            11.7       20.0        8.0
  3            39.9       15.0        12.0
  4            30.0       17.5        9.5
  5            53.3       24.0        18.5
    实施例6
除了以LP5方式排列外，以制备实例1-5的砂带制品同样的方法制备砂带制品。其湿推拉试验结果见表3。
                 表3
    实例号    磨削量(um)
      3         12.7
      5         18.0
     6                18.0
    对比实例A         7.7
    对比实例B         30.9
对比实例A是600号WETORDRY TRI-M-ITE砂纸(美国密尼苏达州圣保尔市的密尼苏达采矿和制造公司产品)。
对比实例B是300号WETORDRY TRI-M-ITE砂纸(同上)。
从上面的数据可以看出：那些具有尖锐特点的形状，即有棱有角的形状，对于除去底漆最有效，而具有平坦特点的形状则效果较差。另外，LP3排列显示出有限的柔韧性，而CC排列是十分柔韧的。
实例6的制品(LP5排列)的图案有方向性。实例6的制品进行的是改变的干推拉试验，其中一次行程是一个方向的一次运动(向后或向前)。结果示于表4。
      表4
   方向    磨削量(微米)
   向后      2.54
   向前      7.62
    实例7-11
实例7-11的砂带制品，除了用平均颗粒尺寸为12微米的熔融氧化铝外，其制造都与实例1-5的砂带制品的制造相同。实例7说明LP2的排列；实例8说明LP1排列；实例9说明CC排列；实例10说明LP5排列；实例11说明LP3排列。这些实例的砂带制品的湿推拉试验结果见表5。
对比实例A是600号WETORDRY TRI-M-ITE A加载砂纸(美国明尼苏达州圣保尔市的明尼苏达采矿和制造公司产品)。
               表5
实例号    磨削量(μm)    表面光洁度(Ra)
                       10次行期  100次行期
  7          23.0         11         5
  8          30.5         12         5
  9          30.5         12         5
  10         30.5         13         6
  11         38.1         8          6
对比实例A    23.0     11      5
    实例12-14
除了用平均颗粒尺寸为90微米的熔融氧化铝外，实例12-14的砂带制品的制造都与实例1-5的砂带制品的制造相同。实例12说明LP3排列；实例13说明LP5排列，实例14说明CC排列。这些实例的砂带制品的干推拉试验结果示于表6。
对比实例B是320号WETORDRY TRI-M-ITE A加载砂纸(美国明尼苏达州圣保尔市的明尼苏达采矿和制造公司产品)。
             表6
实例号    磨削量(μm)    表面光洁度(Ra)
                       10次行程  100次行程
  12         36.3         40        34
  13         48.3         60        45
  14         50.8         55        49
  对比实例B  30.5         62        33
表7比较了具有平均颗粒尺寸为40微米的磨粒的砂带制品(实例3)和具有平均颗粒尺寸为12微米的磨粒的砂带制品进行干推拉试验的结果。
             表7
实例号    磨削量(μm)    表面光洁度(Ra)
                       10次行程   90次行程
  3          40.6        16.5       11.0
  11         38.1        8.5        4.8
对于LP3排列而言，磨削量受磨料混合物的排列和形状的影响比受磨粒的具体尺寸的影响更大。而一般概念认为所用磨粒尺寸对磨削量有大的影响。这一现象是出乎意料的，并且与本专业的一般概念相反。
    实例15-16和对比实例C和D
这些实例比较了现有技术的砂带制品和本发明的砂带制品的性能。这些实例的砂带制品用连续方法制造，并进行干推拉试验，但是磨削量是磨掉的底漆重量(克)。另外，表面光洁度在每次试验结束时测定，测量Ra与RTM两者，以微英寸表示。其中RTM是最深的刮痕的加权平均值的测量。试验结果示于表8。
这些实例的砂带制品用如图2所示的同样的装置制备。含有磨粒的浆料100从供料槽102供到生产工具104上。随后把背衬引到生产工具104上，因此浆料100湿润背衬的表面形成了一种中间制品。背衬被压辊112压入浆料100中。在浆料100中的粘结剂固化形成砂带制品。随后从生产工具把砂带制品移下来。浆料及背衬用实例1中同样的材料制造。粘结剂的温度为30℃，生产工具的温度为70℃。
    实例15-16
在实例15和16中，安置有紫外灯来使生产工具上的浆料固化。在实例15中，生产工具是有LP6排列的照相凹版辊。而在实例16中，制造工具是有CC排列的照相凹版辊。
    对比实例C和D
在对比实例C和D中，安置有紫外灯，在中间制品移开生产工具后对浆料进行固化。因此，中间制品离开生产工具的时间和胶粘剂固化或胶凝时间之间有一段时间间隔。这段时间的延滞使粘结剂流动，并改变磨料混合物的形状和排列。在对比实例C中，生产工具有CC排列，而在对比实例D中，生产工具有LP6排列。
与现有技术的砂带制品比较，本发明的砂带制品的改进是由于在生产工具上进行固化或胶凝。在图6，7，15和16的显微照片中很容易看出改进。图15和16涉及对比实例C，图6和7涉及实例16。图11说明对比实例D的砂带制品的表面轮廓试验的结果。
        表8
实例号       磨削量(g)    表面光洁度
                        Ra          RTM
  15           0.190    25          135
  16           0.240    25          125
  1            0.200    15          55
对比实例C      0.375    30          175
对比实例D      0.090    20          110
最佳的砂带产品是具有高磨削量和低的的表面光洁度的，本发明的砂带制品满足这些要求。
    实例17-20
这些实例的砂带制品说明各种胶粘剂的效果。除了采用不同的胶粘剂外，这些砂带制品用实例1的同样方法制造和进行试验。浆料中的材料重量比与实例1中一样。实例17的胶粘剂是TMDIMA2，实例18的胶粘剂是BAM，实例19的胶粘剂是AMP，实例20的胶粘剂是TATHEIC。试验结果示于表9。对比实例A是600号WETORDRY TRI-M-ITEA加载砂纸(美国明尼苏达州明尼苏达采矿及制造公司产品)。
         表9
实例号    磨削量(μm)    初始表面光洁度(Ra)
                             10次行程
  17         9.14            12
  18         2.54            10
  19         7.61            8
  20         16.00           5
  对比实例A  1.52            10
    实例21-24
除了使用不同的浆料外，实例21-24的砂带制品用实例16的同样方法制造。在实例21中，磨料浆料平均颗粒尺寸为40微米的熔融氧化铝颗粒(100份)/TMDIMA2(90份)IBA(10份)/PH1(2份)组成；在实例22中，磨料浆料由平均颗粒尺寸为40微米的熔融氧化铝颗粒(200份)/TMDIMA2(90份)/IBA(10份)/PH1(2份)组成；在实例23，磨料浆料由平均颗粒尺寸为40微米的熔融氧化铝颗粒(200份)/AMP(90份)/IBA(10份)/PH1(2份)组成；在实例24中，磨料浆料由平均颗粒尺寸为40微米的熔融氧化铝颗粒(200份)/TATHEIC(90份)/IBA(10份)/PH1(2份)组成。对比实例E是400号WETORDRY TRI-M-ITE A加载砂纸(美国明尼苏达州明尼苏达采矿和制造公司产品)。
    抛光试验
将砂带制品制成35.6厘米直径的圆盘，在RHSTRASBAUGH 6AX型抛光机上进行试验。工件是三根1.2厘米直径的1018钢棒，做成直径为7.5厘米的圆圈，并固定在夹具上。执光不加水进行，加在工件上的正(垂直)负荷是1公斤。工件驱动轴偏离抛光盘中心7.6厘米并且工件驱动轴的转速为63.5转/分。抛光盘的转速为65转/分。砂带制品用双面胶带固定到抛光夹具上。试验每隔5、15、30和60分钟的间隔停下来测定累积的磨削量。试验结果列于表10。
              表10
            磨削量(g)实例号    5分     15分    30分    60分21        15.4    50.6    107.0   193.922        32.9    69.4    159.6   225.723        126.5   292.9   425.7   553.824      117.0    279.8    444.7    634.5对比    141.9    237.7    293.8    335.5实例E
通过适当选择磨料混合物的合适的形状和排列，可以得到最高的磨削速度，最小的磨痕深度和最均匀的磨痕图案。
本发明的砂带制品的加载量比对比实例E的砂带制品小。本发明的砂带制品的磨料混合物的均匀形状和排列使它具有改进的性能。
为了在制造本发明中制备砂带的生产工具领域给以指导，对于图1214及图17-19提供了砂带制品的推荐尺寸。在表11中列出了这些尺寸，以英寸或弧度表示。
        表11
图号    符号    尺寸值
12       a      12°
         b      0.0020英寸
         c      0.0200英寸
         d      0.0055英寸
13       e      90°
         f      0.0140英寸
         g      0.0070英寸
14       h      16°
         j      0.0035英寸
         k      0.0120英寸
         l      0.0040英寸
17       m      0.052英寸
         n      0.014英寸
18       o      0.018英寸
         p      0.018英寸
         r      0.023英寸
         s      0.017英寸
19       t      0.004英寸
         v      0.009英寸
         w      53°
很明显，本专业的技术人员可以在本发明范围和精神内作出许多本发明的变型及改型，另外也应知道，本发明不限于在此列举的解释性具体实例。

Claims (2)

1.一种砂带制品，包括具有排列成规则图案的磨料混合物，该混合物粘结在砂带背衬的至少一个主面上，其中形成每一个所述规则图案的磨料混合物具有一个高峰和一个低峰，当用轮廓仪的测头测量并用表面数据分析仪分析时，所述混合物的高峰的高度值差异在10％范围内，所述混合物的低峰的高度值差异在10％范围内。
2.一种砂带制品，包括具有排列成规则图案的磨料混合物，该混合物粘结在砂带背衬的至少一个主面上，所述制品第一个区域的数字化处理的显微照片的X、Y坐标与所述制品第二个区域的数字化处理的显微照片的X、Y坐标的差异不超过10％，所述第二个区域的截面与所述第一个区域的截面在所述第一个区域和第二个区域的高峰及低峰排列上是完全对应的。
CN00100992A 1991-02-06 2000-01-17 有序结构砂带制品 Granted CN1269277A (zh)

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