CN1116415A - 磨料制品的制法 - Google Patents
磨料制品的制法 Download PDFInfo
- Publication number
- CN1116415A CN1116415A CN94190949.2A CN94190949A CN1116415A CN 1116415 A CN1116415 A CN 1116415A CN 94190949 A CN94190949 A CN 94190949A CN 1116415 A CN1116415 A CN 1116415A
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- CN
- China
- Prior art keywords
- production mould
- mixture
- backing
- coating machine
- radiation
- Prior art date
- 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.)
- Granted
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Abstract
本发明提供一种制造磨料制品的方法。它包括：a.提供具有前表面的背衬；b.提供具有接触表面的，能透过辐射能的生产模具；c.将含有磨料颗粒和粘合剂前体的混合物施涂于生产模具的接触表面；d.使生产模具接触表面上的混合物与背衬前表面接触，从而使混合物润湿背衬前表面；e.令辐射能通过生产模具，至少部分固化粘合剂，使混合物变为成型的，可操持的结构件；f.将该结构件从生产模具上移去。该结构件可完全固化形成涂覆磨料的制品。
Description
技术领域
本发明涉及一种制造磨料制品的方法，更具体地涉及一种采用辐射使粘合剂前体固化的制法。
背景技术
涂覆磨料制品典型地含有用一种或多种粘合剂粘附于背衬上的许多磨料颗粒。典型的粘合剂包括下列固化树脂：酚醛树脂，氨基塑料树脂，尿烷树脂，环氧树脂，烯不饱和树脂，丙烯酸酯化的异氰脲酸树脂，脲醛树脂，异氰脲酸树脂，丙烯酸酯化的尿烷树脂，丙烯酸酯化的环氧树脂及它们的混合物。其中固化的酚醛树脂是最常用的粘合剂。大多数涂覆磨料制品的制造是用连续方法，先在背衬上涂以粘合剂前体和磨料颗粒。然后，使粘合剂前体固化形成粘合剂。这种固化方法会造成粘合剂前体的聚合和固结。在某些情况下，需要模制出涂覆磨料制品，将某种图案赋于制品表面。模压法能提供含有预先成形的磨料颗粒的可重复生产的涂覆制品。若粘合剂前体是一种热固性树脂，则热固化过程会超过10小时。这样的固化需时太久，因而在许多情况下，对于生产具有预成形磨料颗粒的磨料制品是不切实际的。需要开发一种具有需时较短的方法，以便生产其表面上含有预成形磨料复合物的涂覆磨料制品。
发明的公开
本发明提供一种磨料制品的制法。
本发明方法一般包括以下步骤：
a.提供一种含有磨料颗粒和粘合剂前体的混合物；
b.提供一个具有前表面的背衬；
c.相对于一个具有接触表面的，能透过辐射能的生产模具将背衬定位好，使背衬的前表面朝向生产模具的接触表面，从而在位于生产模具的接触表面和背衬的前表面之间界定出一个混合物接受区域；
d.将步骤(a)的混合物引入混合物接受区域；
e.令辐射能通过生产模具，使得粘合剂前体至少部分地固化，从而获得成形的，可操持的(handleable)结构件；
f.将成形的，可操持的结构件从生产模具上移去。
出于各种原因，其中之一为经济节省，常希望用混合物完全注满混合物接受区域。
本发明的一个实施方案包括以下步骤：
a.提供一个具有前表面的背衬；
b.提供一个具有接触表面的，能透过辐射的生产模具；
c.将含有许多磨料颗粒和一种粘合剂前体的混合物施涂于生产模具的接触表面；
d.使生产模具接触表面上的混合物与背衬的前表面直接接触，从而使混合物润湿背衬的前表面；
e.令辐射能通过生产模具，至少部分地固化粘合剂前体，使混合物变为成形的，可操持的结构；
f.将成形的，可操持的结构件从生产模具上移去。
在本发明方法的第二个实施方案中，混合物是施涂在背衬的前表面上；令能够透过辐射能的生产模具的接触表面与混合物直接接触，使混合物润湿生产模具的接触表面；令辐射能通过生产模具，至少使粘合剂前体部分固化，从而使混合物变为成形的，可操持的结构；最后将成形的，可操持的结构件从生产工具上移去。
混合物中含有许多磨料颗粒和粘合剂前体。粘合剂前体是液态，没有聚合或固化。因为混合物是液态，所以能流动；它能涂于背衬的表面或生产模具的表面。混合物中的粘合剂前体能通过辐射能量的照射得以部分固化。部分固化就导致粘合剂前体的固结，形成粘合剂。当粘合剂部分固化后，所得的硬化混合物被称为成形的，可操持的结构(件)。当成形的，可操持的结构中的粘合剂完全固化时，背衬和成形的，可操持的结构的结合物被称为涂覆磨料制品。
辐射能源的例子包括：电子束，紫外线和可见光。生产模具用基本上不吸收辐射能的材料制成，因为辐射能要透过生产模具进入混合物。可以使用会吸收辐射的材料作为背衬，因为并不需要辐射能量穿透背衬。
生产模具与混合物接触的表面上最好有以某种图案排列的模腔或凹穴。在本发明方法的过程中，混合物会润湿表面并最好填满这些凹穴。因为粘合剂前体至少在生产模具的表面部分固化，所以得到的磨料制品会具有与生产模具图案的反象相对应的形貌图案。
本发明方法可以使用不透过紫外线或可见光的背衬，如背衬非常厚或不透明或既厚又不透明。此外，当磨料复合体为小金字塔形时，可使金字塔的顶点接受更高剂量的辐射，从而使磨料复合物顶尖很硬，而不必使用后固化步骤。
附图的简要说明
图1为根据本发明方法生产磨料制品的一种设备的示意图。
图2是根据本发明方法生产磨料制品的另一种设备的示意图。
图3是本发明方法所用生产模具一段的剖视图。
发明详述
本发明提供一种生产磨料制品的方法，该制品的背衬上面通过粘合剂粘附有许许多多磨料颗粒。
图1显示了用于生产磨料制品的一套设备10。生产模具11为带状、具有两个主表面和两个末端。具有前表面13和背表面14的背衬12，离开开卷滚筒15。与此同时，生产模具11则离开开卷滚筒16。生产模具11的接触表面17在涂覆装置18涂覆上由磨料颗粒和粘合剂前体组成的混合物。在涂覆步骤之前，可以对混合物加热降低其粘度。涂覆装置18可以是任何常规的涂敷装置，如刮刀式涂覆机，落模式涂覆机，帘模式涂覆机，真空模式涂覆机或挤出模式涂覆机。在生产模具11的接触表面17上经混合物涂覆后，令背衬12和生产模具11相接触，使混合物润湿背衬12的前表面13。在图1中，用接触咬送滚筒20使混合物与背衬12接触。该滚筒20还使生产模具/混合物/背衬的结构紧粘着一支撑滚筒22。接着，由辐射能源24发射出足够剂量的辐射能，透过生产模具11的背面25，照射到混合物上，使得粘合剂前体至少部分固化，得到成形的，可操持的结构26。然后使生产模具11与成形的，可操持的结构26分开。生产模具11与成形的，可操持的结构26的分离发生于滚筒27处。刚通过滚筒27后，成形的、可操持的结构26与生产模具11之间的角度α最好要陡些，如大于30°，以使成形的、可操持的结构26能干净利索地与生产模具11分离。生产模具11则被重新卷在卷绕滚筒28上，供再次使用。而生成的涂覆磨料制品则卷在卷绕滚筒30上。如果粘合剂前体没有完全固化，可以通过另一能量源如热能源或另一辐射能量源完全固化，形成涂覆磨料制品。或者，也可以无需使用另一能量源来实现完全固化形成涂覆磨料制品的。在本文所用的“完全固化”之类的词语意思是指粘合剂前体已足够固化，使得得到的产品能发挥磨料制品的功能。
在这一带形磨料制品制成后，可以进行弯曲处理和/或加湿处理，再将它转变成任何所需的形式，如锥、环形带、片、盘等，然后用于研磨。
图2显示了用于制备磨料制品的另一种方法的设备40。在该设备中，混合物是涂覆于背衬上而不是生产模具上。在该设备中，生产模具41是个具有正面和背面的环形带。背衬42具有背面43和前表面44，它离开开卷滚筒45。背衬的前表面44在涂覆装置46处涂上磨料颗粒和粘合剂前体的混合物。用接触咬送滚筒48使混合物紧粘着生产模具41的接触表面47。滚筒48还使生产模具/混合物/背衬的结构紧贴着支撑滚筒50，使得混合物润湿生产模具41的接触表面47。生产模具41用三个旋转滚筒52，54和56驱动。然后辐射能透过生产模具4l的背面57进入混合物，使粘合剂前体至少部分固化。可以用一个辐射能量源58。也可以用第二个辐射能量源60。这些能量源可以是同类型或不同类型的。在粘合剂前体至少部分固化后，得到的成形的，可操持的结构件62便与生产模具41分开，卷在卷绕滚筒64上。在滚筒65处，成形的、可操持的结构62与生产模具41脱离。刚通过滚筒65后，成形的，可操持的结构62与生产模具41之间的角度α最好较陡些，例如大于30°，以使成形的，可操持的结构62能干净利索地与生产模具41分离。如果粘合剂前体没有完全固化，可以通过另一能量源如热能源或另一辐射能量源的照射使其完全固化，形成涂覆磨料制品。或者，也可以无需使用另一能量源来实现完全固化形成涂覆磨料制品。
在这一带形磨料制品制成后，可以进行弯曲处理和/或加湿处理，再将它转化成任何所需的形式，如锥、环形带、片、盘等然后用于研磨。
在这两个实施方案中，常常需要用磨料颗粒和粘合剂前体的混合物完全填满生产模具的接触表面与背衬的前表面之间的空间的。
适用于本发明方法的背衬具有前表面和背面。用于制造背衬的材料的代表性例子有：聚合物薄膜，涂过底料的聚合物薄膜，未上胶的布，预上胶的布，未上胶的纸，预上胶的纸，硫化纤维片材，无纺纤维片材及它们的结合。背衬也可经密封处理或者改变其某些物理性能的处理。这些处理方法是本领域众所周知的。例如，布背衬上可以有浸渍涂层，背面上胶涂层，前面上胶涂层或它们的组合。浸渍涂层是用一种液体物质浸渍背衬并填入背衬的小孔中。涂在背衬背面的背面上胶涂层能在使用中保持其纤维或纱线。位于背衬前表面的前表面上胶涂层起着密封布的孔隙的作用。用于对布进行处理的树脂的例子包括酚醛树脂，乳液，环氧树脂，丙烯酸酯，丙烯酸酯化的环氧树脂，丙烯酸酯化尿烷，聚酯，淀粉及它们的组合。用于布处理的树脂还可含有添加剂如填料、纤维、偶联剂、润湿剂、染料和颜料等。
用于形成磨料复合物的混合物就是将许许多多磨料颗粒分散于粘合剂前体中。本文所用的术语“混合物”是指将许许多多磨料颗粒分散于粘合剂前体中得到的任何的复合物。混合物最好是可流动的。但是，如果混合物不能流动，可以通过其他手段如热或压力或者热与压力两者的结合使混合物与生产模具的接触表面或背衬的前表面接触。这种混合物可以描述为形状适应的(适型的)，即能使其具有与生产模具的接触表面和背衬的前表面反向适应的形状，外观或轮廓。
典型磨料颗粒的大小为约0.1～1500微米，通常为约1～400微米。磨料颗粒的莫氏硬度以大于约8为好，大于9则更佳。但是，颗粒的莫氏硬度也可以低于8。适用于本发明的磨料颗粒例子包括熔融氧化铝、陶瓷氧化铝、热处理氧化铝、白色氧化铝、绿色碳化硅、碳化硅、矾土、氧化锆、金刚石、铈土、立方氮化硼、石榴石和上述磨料颗粒的混合物。术语“磨料颗粒”指单个磨料粒子，也包括多个磨料粒子结合在一起形成的磨料聚集物。磨料聚集物的进一步说明可见专利号为4,311,489、4,652,275和4,799,939的美国专利。
粘合剂前体能通过能量的作用而固化，较佳的是辐射能，更佳的是紫外线，可见光或电子束的辐射能。其他能量包括红外线、热和微波。重要的是这种能量应不致损害本发明方法中所用的生产模具，使得模具能再度使用。粘合剂前体的聚合可以通过自由基机制或阳离子机制。能够因辐射能的照射而聚合的粘合剂前体有丙烯酸酯化的尿烷，丙烯酸酯化的环氧树脂，烯不饱和化合物，具有侧链不饱和羰基的氨基塑料衍生物，具有至少一个侧链丙烯酸酯基团的异氰脲酸酯衍生物，具有至少一个侧链丙烯酸酯基团的异氰酸酯衍生物，乙烯基醚，环氧树脂及它们的混合物。术语“丙烯酸酯”则包括丙烯酸酯和甲基丙烯酸酯。
丙烯酸酯化的尿烷是羟基为未端，NCO扩展的聚酯或聚醚的二丙烯酸酯。市售的丙烯酸酯化的尿烷的例子有UVITHANE 782，(Morton Thiokol化学公司)和CMD6600，CMD8400和CMD8805(Radcure Specialties公司)
丙烯酸酯化的环氧树脂是环氧树脂的二丙烯酸酯，如双酚A环氧树脂的二丙烯酸酯。市售的丙烯酸酯化的环氧树脂的例子有购自Radcure Specialities公司的CMD3500，CMD3600，CMD3700。
烯不饱和化合物包括单体化合物和聚合物，所述单体化合物和聚合物含碳、氢、氧原子，还可含氮、卤原子。一般地，氧原子、氮原子单独地或同时地存在于醚、酯、尿烷、酰胺和尿素基团中。烯不饱和化合物以其分子量小于约4000为宜。优选的烯不饱和化合物为由含脂族一羟基或脂族多羟基的化合物与不饱和羧酸如丙烯酸、异丁烯胶、衣康酸、巴豆酸、异巴豆酸、苹果酸等反应而成的酯。烯不饱和化合物的代表性例子包括异丁烯酸甲酯、异丁烯酸乙酯、苯乙烯、二乙烯基苯、乙烯基甲苯、乙二醇二丙烯酸酯、乙二醇异丁烯酸酯、己二醇二丙烯酸酯、三甘醇二丙烯酸酯、三羟甲基丙烷三丙烯酸酯、甘油三丙烯酸酯、季戊四醇三丙烯酸酯、季戊四醇异丁烯酸酯和季戊四醇四丙烯酸酯。其他烯不饱和化合物包括烯丙酯、聚烯丙酯、聚甲代烯丙酯和羧酸的酰胺，例如，邻苯二甲酸二烯丙酯、己二酸二烯丙酯和N，N-二烯丙基氨基氰。另外一些含氮的烯不饱和化合物包括三(2-丙烯酰氧乙基)异氰脲酸酯、1，3，5-三(2－异丁烯基氧乙基)-striazine、丙烯酰胺、甲基丙烯酰胺、N-甲基丙烯酰胺、N，N-二甲基丙烯酰胺、N-乙烯基吡咯烷酮和N-乙烯基哌啶酮。
适用于本发明的氨基树脂每分子或每低聚体含有至少一个α、β－不饱和羰基侧基。美国专利No.4,903,440和1991年2月24日申请的美国专利申请No.07/659,752对这些物质作了进一步的描述。
关于含有至少一个丙烯酸酯侧基的异氰脲酸酯衍生物和含有至少一种丙烯酸酯侧基的异氰酸酯衍生物的进一步描述可参见美国专利No.4,652,275。优选的异氰脲酸酯为三(羟乙基)异氰脲酸酯的三丙烯酸酯。
环氧树脂含有一个噁丙环，可通过开环进行聚合。适用于本发明的环氧树脂包括单体型环氧树脂和低聚物型环氧树脂。较适用的环氧树脂的代表性例子包括2，2-二[4-(2，3-环氧丙氧基)苯丙烷](双酚的二环氧甘油醚)和Shell化学公司生产的、商品名为“Epon828”、“Epon 1004”和“Epon 1001F”的商品以及Dow化学公司生产的、商品名为“DER-331”、“DER-332”和“DER-334”的商品。适用于本发明的其他环氧树脂包括酚醛清漆的缩水甘油醚(例如，Dow化学公司生产的“DEN-431”和“DEN-428”)。适用于本发明的环氧树脂可在一或多个合适的光引发剂的存在下通过阳离子机制进行聚合。对这些树脂的进一步描述可参见美国专利No.4,318,766。
如果进行紫外线照射或可见光照射，粘合剂中还宜含有光引发剂。产生游离基源的光引发剂的例子包括，但不限于，有机过氧化物、偶氮化合物、醌类、二苯酮、亚硝基化合物、酰基卤、腙、巯基化合物、吡喃鎓化合物、三丙烯酰基咪唑类、双咪唑类、磷杂环戊二烯氧化物、氯烷基三嗪、苯偶烟醚类、苯偶酰缩酮类(benzil ketals)、噻吨酮、乙酰苯衍生物、以及它们的组合。
阳离子光引发剂会产生酸源引发环氧树酯的聚合。阳离子引发剂例如有一种具有鎓阳离子和金属或准金属的含卤素配阴离子的盐。其他阳离子光引发剂还例如有一种具有有机金属配阳离子和金属或准金属的含卤素配阴离子的盐。关于这些化合物的进一步描述可参见美国专利No.4,751,138(第6栏第65行至第9栏第45行)。阳离子光引发剂的另一个例子是一种有机金属盐和一种鎓盐，可参见美国专利No.4,985,340(第4栏第65行至14栏第50行)。以及欧洲专利申请306,161和306,162。另外一些阳离子光引发剂包括有机金属配合物的离子盐，其中，所含金属如欧洲专利申请109,581所述，选自周期表IVB、VB、VIB、VIIB和VIIIB族元素。
除了可辐射固化的树脂，粘合剂前体还可含有可被辐射能以外的能量固化的树脂，如可缩合固化的树脂。这些可缩合固化的树脂的例子包括酚醛树脂、密胺甲醛树脂和尿素甲醛树脂。
粘合剂前体还可含有任意的添加剂，如填充剂(包括研磨助剂)、纤维、润滑剂、湿润剂、表面活性剂、色素、染料、偶合剂、增塑剂和悬浮剂。有助于改善流动性的添加剂的一个例子为DeGussa公司生产的、商品名为“OX-50”的商品。这些物质的数量可进行调节，以产生希望的性能。填充剂的例子包括碳酸钙、硅石、石英、硫酸铝、粘土、白云石、偏硅酸钙以及它们的组合。研磨助剂的例子包括四氟硼酸钾、冰晶石、硫、黄铁矿石、石墨、氯化钠和它们的组合。该混合物可含有高至70％(重量)的填充剂或研磨助剂，通常高至40％(重量)，优选1-10％(重量)，更优选1-5％(重量)。
混合物可通过混合各成分来制备，以使用低速剪切式混合器为宜。也可以使用高速剪切式混合器。通常是将磨料逐渐加入粘合剂前体中。而且，在混合过程中还可抽真空，将混合物中的气泡量减至最小。
在成形的、可操持的结构件的制造过程中，辐射能通过生产模具传递进入混合物，从而至少部分地使粘合剂前体固化。“部分固化”一词表示粘合剂前体聚合至产生的混合物能从生产模具脱卸的程度。一旦从生产模具脱卸后，用任何能量，例如热能或辐射能，即可使粘合剂前体完全固化。也可在成形的、可操持的结构件从生产工具脱卸之前对粘合剂前体进行完全固化。
适用于本发明的辐射能包括电子束、紫外光和可见光。其他辐射能包括红外线和微波。也可采用热能。电子束辐射即人们所称呼的电离辐射，可在约0.1－10兆拉德的剂量范围内使用，以约1～10兆拉德的剂量为宜。紫外线辐射是指波长在约200～400nm区域内的一种非微粒辐射，以用约250～400nm的波长为宜。紫外线辐射的优选剂量为100～300瓦/厘米。可见光辐射是指波长在约400～800nm区域内的一种非微粒辐射，以用约400～550nm的波长为宜。
按照本发明的方法，辐射能量是透过生产模具传递，直接进入混合物的。较理想的情况是，制造生产模具的材料应不吸收多少辐射能或被辐射能降解。例如，如果使用电子束能量，最好不要使用纤维素材料来制造生产模具，因为电子会降解纤维素。如果使用紫外线或可见光，生产模具的材料必须能分别透过足够的紫外线或可见光辐射，以产生希望的固化程度。
生产模具必须以足够的速度运行，避免由辐射源引起对它的降解。对由辐射源引起的降解具有较高抗耐性的生产模具，可以运行得慢些。对由辐射源引起的降解的抗耐性较差的生产模具，则其运行速度应大些。简单地说，生产模具合适的运行速度取决于制造生产模具的材料。
生产模具的形式可以是带式的，例如，环形带，也可以是板、连续板或卷式板(web)、涂覆辊、固定在涂覆辊上的套筒、或模子。生产模具上与混合物接触的那个表面可以是光滑的，也可以有一定形貌或图案。这里，称该表面为“接触表面”。如果生产模具是带、板、卷式板、或套筒，它就有一个接触表面和一个非接触表面。如果生产模具是辊式的，它仅有接触表面。用本发明方法制成的磨料制品的表面形貌必然是生产模具接触表面的形貌之反。生产模具的接触表面的特点一般是它上面有许多凹穴。这些凹穴的开口可以是任何形状的，规则的或不规则的，例如矩形的、半圆形的、圆形的、三角形的、方形的、六角形的、八角形的等等。这些凹穴的壁可以是垂直的或锥形的。许许多多凹穴排成的图案可根据一定的规则排列，也可以是任意的。这些凹穴还可以是互相邻接的。
可用于制造生产模具的热塑性材料，包括聚酯、聚碳酸酯、聚醚砜、聚甲基异丁烯酸酯、聚氨酯、聚氯乙烯、聚烯烃、聚苯乙烯或它们的组合。热塑性材料还可包括一些添加剂，如增塑剂、自由基清除剂或稳定剂、热稳定剂、抗氧化剂和紫外线辐射吸收剂。这些材料对紫外线和可见光基本上是透明的。图3所示为其中的一种生产模具。生产模具70包括两层71和72，层71的表面较平坦光滑，层72的表面上则具有图案。层71的耐热性好，强度大。适合于层71的材料，例如有聚碳酸酯和聚酯。层72的表面能很低。生产模具的接触表面若用这种低表面能的材料就易于使磨料制品从生产模具上脱卸下来。适合于层72的材料的例子包括聚丙烯和聚乙烯。使用某些由热塑性材料制成的生产模具时，设定的生产磨料的操作条件不得产生过多的热量，如热量产生过多，将会使热塑性模具变形或熔化。在有些情况下，紫外线会产生热量。同样值得注意的是，只由单层组成的模具也是可以接受的，在许多情况下，可以选择使用之。
热塑性生产模具可按照下述步骤制造。首先制造出母模具。母模具以用金属(例如镍)制造为宜。母模具可用任何常规的技术如雕刻、切压、滚花、电铸、金刚石车削、激光加工等方法制造。如果希望在生产模具的表面具有图案，母模具应具有与生产模具表面上的图案相反的图案。可用母模具对热塑性材料进行模压以形成该种图形。模压可在热塑性材料处于可流动状态时进行。模压后，将热塑性材料冷却使其固化。
也可用硬化的热固性树脂制造生产模具。可按照下述步骤制造热固性材料的生产模具。先将未硬化的热固性树脂涂覆在上述类型的母模具上。趁未硬化的树脂在母模具的表面时，可加热使该树脂硬化或聚合，从而形成与母模具表面图形相反的形状。然后，从母模具的表面除去硬化的热固性树脂。母模具可用可辐射硬化的树脂如丙烯酸酯化的氨酯低聚物硬化制成。除了用辐射如紫外线照射进行硬化外，制造辐射硬化的生产模具与制造热固性树脂的生产模具是相同的。
用下述方法制造了一种特别有用的生产模具。将具有一个平坦背面和一个其形貌与生产模具所需表面形貌相反的正面的镍制母模具置于水平面上，其正面朝上。在母模具的边缘周围放置一些适当长度的1/4英寸(0.064cm)方形钢料，形成一圈环绕着母模具正面的护堤。用“3M Express”乙烯基聚硅氧烷印模材料(3M公司)的珠粒将护堤与母模具连接。按照厂方建议的方法，将一种合成橡胶材料(“Sylgard#184”，Dow制粒公司)进行了催化，然后，将其足够的量倾倒在母模具的正面上，形成1/16～1/8英寸(0.16～O.32cm)厚的层。在室温下放置该组合件8小时，使气泡散逸，形成凝胶。然后，将该组合件移入炉中，在49℃的温度下保持24小时，以固定所得弹性体的大小。经过在204℃温度下的4小时熟化，弹性体达到了其最大机械强度。冷却后，将该弹性体生产模具与母模具分离，并进行了边缘修齐。这样，就可使用所制成的弹性体生产模具，按照本发明的方法制造磨料制品。
生产模具的接触表面上也可有一层脱模涂层，使磨料从生产模具的脱卸更加容易。这种脱模涂层的例子包括可用硅氧烷类和含氟化合物。
下述一些非限定性的实施例将对本发明作进一步的说明，除非另行指出，所有份数、百分数、比率等都是以重量计算的。
测试法I
将涂覆磨料制品转变成尺寸为7.6厘米×335厘米的环形带，在一恒负载表面磨床上进行试验。将大小为2.5×5×18(厘米)、已预称重的1018低碳钢试验工件置入夹具中。工件应垂直放置，使其2.5×18(厘米)的面与一个表面为锯齿状的橡胶接触轮(肖氏硬度A85；直经约36厘米)接触，该轮子表面有一一相对的齿刃，涂覆磨料制品则夹装在它们的上面。然后，以20转/分的速率令工件垂直地在18厘米的路径上往复移动，同时，当环形磨料带以2050米/分的速率转动时，用弹簧弹顶的柱塞以4.5公斤的力将工件压紧在环形磨料带上。研磨1分钟后，取下加工件，重新秤重，从其原重减去研磨后的重量，算出磨削去的材料量。将新的、已预称重的工件和夹具再放入设备中。在合适的表(即表1和表2)中记录下以分钟表示的试验终点。
测试法II
除了试验终点为5分钟，试验工件为304不锈钢外，测试法II与测试法I基本相同。实施例1
本实施例所用的背衬为J重人造丝背衬。该种背衬在其前表面上经过了用胶乳/酚醛树脂(以固化树脂计算，为85份胶乳/15份酚醛树脂)的上胶处理。然后加热至基本除去挥发性物质并使酚醛树脂凝胶化。
本实施例的磨料制品是用图1所示装置制成。生产模具的材料为聚丙烯，经金刚石车削成的镍制母模具模压而成，该母模具具有由底部互相邻接的许多角锥体组成的图案。角锥体底部宽约350～400微米，角锥体高约350～400微米。该类型的图案如美国专利No.5,152,917所示。
粘合剂前体由三(羟乙基)异氰脲酸酯的三丙烯酸酯(50份)、三羟甲基丙烷三丙烯酸酯(50份)、无定形硅石填充剂(1份，可从De-gussa公司购买，商品名为“OS-50”)、异丁烯酸酯硅烷偶合剂(0.5份)和2，2-二甲氧基-1，2-二苯基-1-乙酮光引发剂(0.5份，可从Ci-ba Geigy公司购买，商品名为“Irgacure 651”)组成。将白色熔融体氧化铝磨料(平均大小为40微米)逐渐加入粘合剂前体中，使所得混合物的组成为2.3份磨料对1份粘合剂前体。所用的辐射能为紫外光，其投射剂量为118瓦/厘米。所用的方法为一以约2.4米/分的速度运行的连续工艺。从装置中取下形成的磨料制品后，将它再于100℃加热8小时，对乳胶/酚醛树脂背衬进行充分的硬化处理。磨料制品不作弯曲处理，迳直进行测试。
比较例A
比较例A的磨料制品为通常的涂层磨料制品。背衬为聚对苯二甲酸乙酯薄膜，磨料颗粒则用40微米的白氧化铝。其表层和底层是用间苯二酚—酚醛树脂。这种磨料制品可从3M公司购买，商品名为“IMPERIAL Microfinishing Film”。
按照测试法I对实施例1和比较例A的磨料制品进行了试验。其结果见表1。
表1
初始磨削量(g) 最终磨削量(g) 总磨削量(g) Ra 时间(分)
比较例A 10.6 5.9 15.8 9 2
实施例1 7.1 4.0 78.2 -- 8
实施例2
除了下述不同外，本实施例的磨料制品按与实施例1相同的方法制成。
光引发剂为2-苄基-2-N，N-二甲氨基-1-(4-吗啉代苯基)-1-丁酮，可从Ciba Geigy公司购买，商品名为“Irgacure 369”。光引发剂的浓度为占粘合剂前体重量的1％。磨料颗粒为P320级热处理过的氧化铝。辐射能采用可见光，其照射剂量为236瓦/厘米。设备的运行速度为约15.2米/分。
比较例B
比较例B的磨料制品为通常的涂覆磨料制品。其背衬与实施例1中的相同，磨料颗粒为P320级热处理氧化铝。其表层用间苯二酚—酚醛树脂，其底层用由65％甲阶酚醛-酚醛树脂和35％冰晶石组成的填充树脂。此磨料制品可从3M公司购买，商品名为P320“Three-M-ite”。
按照测试法I和测试法II对实施例1、2和比较例B的涂覆磨料制品进行了测试。测试法I的结果见表2，测试法II的结果见表3。
表2
初始磨削量(g) 最终磨削量(g) 总磨削量(g) 时间(分)
比较例B 19.7 3.7 71.8 6.5
实施例2 23.7 8.3 144.1 9
表3
初始磨削量(g) 最终磨削量(g) 总磨削量(g)实施例1 9.7 2.0 31.2比较例B 7.8 2.0 23.5
实施例2显示，当使用硬磨料颗粒时，用具有精细结构的磨料制品的磨削性能就显著增加。
对本专业技术人员而言，可在不偏离本发明的范围和实质的情况下，对本发明作各种修改和替换是显而易见的。应该明白，本发明并不受这里所示的解释性实施方式的不恰当限制。
Claims (48)
1.一种制备适用于生产涂覆磨料制品的成形的，可操持的结构件的方法，其特征在于包括：
a.提供一种含有磨料颗粒和粘合剂前体的混合物；
b.提供一个具的前表面的背衬；
c.相对于一个具有接触表面的能透过辐射能的生产模具将背衬定位好，使背衬的前表面朝向生产模具的接触表面，从而在位于生产模具的接触表面和背衬的前表面之间界定出一个混合物接受区域；
d.将步骤(a)的混合物引入混合物接受区域；
e.令辐射能通过生产模具，使得粘合剂前体至少部分地固化从而获得成形的，可操持的结构件；
f.将成形的，可操持的结构件从生产模具上移去。
2.如权利要求1所述的方法，其特征在于生产模具的接触表面上具有一些凹穴。
3.如权利要求2所述的方法，其特征在于所述凹穴以非随机的图案方式排列。
4.如权利要求1所述的方法，其特征在于所述背衬用的是一种选自下述的材料：聚合物膜，涂过底料的聚合物膜，未处理的布，处理过的布，未处理的纸，处理过的纸，硫化纤维片材，无纺纤维片材及它们的结合。
5.如权利要求1所述的方法，其特征在于该磨料颗粒物质是选自下列的材料：熔融氧化铝，陶瓷氧化铝，热处理氧化铝，绿色碳化硅，白色氧化铝，碳化硅，矾土，氧化锆，金刚石，铈土，立方氮化硼，石榴石及其混合物。
6.如权利要求1所述的方法，其特征在于该磨料颗粒的莫氏硬度至少约为8。
7.如权利要求1所述的方法，其特征在于该粘合剂前体能通过辐射的作用固化。
8.如权利要求1所述的方法，其特征在于该粘合剂前体选自：丙烯酸酯化的尿烷、丙烯酸酯化的环氧树脂、烯不饱和化合物、具有侧链不饱和羰基的氨基塑料衍生物、具有至少一个侧链丙烯酸酯基团的异氰脲酸酯衍生物、具有至少一个侧链丙烯酸酯基团的异氰酸酯衍生物、乙烯基醚、环氧树脂及它们的混合物。
9.如权利要求8所述的方法，其特征在于该粘合剂前体还含有光引发剂。
10.如权利要求1所述的方法，其特征在于该混合物用选自下列涂覆机方式进行施涂：刮刀式涂覆机，落模式涂覆机，帘模式涂覆机，真空模式涂覆机和挤出模式涂覆机。
11.如权利要求1所述的方法，其特征在于该生产模具对紫外线辐射或可见光辐射或者同时对紫外线辐射和可见光辐射是可透过的。
12.如权利要求1所述的方法，其特征在于该生产模具的材料是热塑性树脂，热固性树脂或辐射固化的树脂。
13.如权利要求1所述的方法，其特征在于该生产模具是一条环形带。
14.如权利要求1所述的方法，其特征在于该能量源选自：电子束，紫外辐射和可见光。
15.如权利要求1所述的方法，其特征在于该背衬对于该辐射能是不透过的。
16.一种制备涂覆磨料制品的方法，其特征在于，包括使权利要求1所述的成形的，可操持的结构件完全固化的步骤。
17.一种制备适用于生产涂覆磨料制品的成形的，可操持的结构件的方法，其特征在于包括：
a.提供一个具有前表面的背衬；
b.提供一个具有接触表面的能透过辐射能的生产模具；
c.将含有许多磨料颗粒和一种粘合剂前体的混合物施涂于生产模具的接触表面；
d.使生产模具的接触表面上的混合物与背衬的前表面接触，从而使混合物润湿背衬的前表面；
e.令辐射能通过生产模具，至少部分地固化粘合剂，使混合物变为成形的，可操持的结构件；
f.将成形的，可操持的结构件从生产模具上移去。
18.如权利要求17所述的方法，其特征在于生产模具的接触表面上具有一些凹穴。
19.如权利要求18所述的方法，其特征在于所述凹穴以非随机的图案方式排列。
20.如权利要求17所述的方法，其特征在于所述背衬用的是一种选自下述的材料：聚合物膜，涂过底料的聚合物膜，未处理的布，处理过的布，未处理的纸，处理过的纸，硫化纤维片材，无纺纤维片材及它们的结合。
21.如权利要求17所述的方法，其特征在于该磨料颗粒物质是选自下列的材料：熔融氧化铝，陶瓷氧化铝，热处理氧化铝，绿色碳化硅，白色氧化铝，碳化硅，矾土，氧化锆，金刚石，铈土，立方氮化硼，石榴石及其混合物。
22.如权利要求17所述的方法，其特征在于该磨料颗粒的莫氏硬度至少约为8。
23.如权利要求17所述的方法，其特征在于该粘合剂前体能通过辐射的作用固化。
24.如权利要求17所述的方法，其特征在于该粘合剂前体选自：丙烯酸酯化的尿烷、丙烯酸酯化的环氧树脂、烯不饱和化合物、具有侧链不饱和羰基的氨基塑料衍生物、具有至少一个侧链丙烯酸酯基团的异氰脲酸酯衍生物、具有至少一个侧链丙烯酸酯基团的异氰酸酯衍生物、乙烯基醚、环氧树脂及它们的混合物。
25.如权利要求24所述的方法，其特征在于该粘合剂前体还含有光引发剂。
26.如权利要求17所述的方法，其特征在于该混合物用选自下列涂覆机方式进行施涂：刮刀式涂覆机，落模式涂覆机，帘模式涂覆机，真空模式涂覆机和挤出模式涂覆机。
27.如权利要求17所述的方法，其特征在于该生产模具对紫外线辐射或可见光辐射或者同时对紫外线辐射和可见光辐射是可透过的。
28.如权利要求17所述的方法，其特征在于该生产模具的材料是热塑性树脂，热固性树脂或辐射固化的树脂。
29.如权利要求17所述的方法，其特征在于该能量源选自：电子束，紫外辐射和可见光。
30.如权利要求17所述的方法，其特征在于该背衬对于该辐射能是不透过的。
31.如权利要求17所述的方法，其特征在于该生产模具是一条环形带。
32.一种制备涂覆磨料制品的方法，其特征在于，包括使权利要求17所述的成形的，可操持的结构件完全固化的步骤。
33.一种制备适合用于生产涂磨料制品的成形的，可搬运的结构件的方法，其特征在于包括：
a.提供一个具有前表面的背衬；
b.提供一个具有接触表面的能透过辐射能的生产模具；
c.将含有许多磨料颗粒和一种粘合剂前体的混合物施涂于所述背衬的前表面；
d.使背衬前表面上的混合物与生产模具的接触表面直接接触，从而使混合物润湿生产模具的接触表面；
e.令辐射能通过生产模具，至少部分地固化粘合剂，使混合物变为成形的，可操持的结构件；
f.将成形的，可操持的结构件从生产模具上移去。
34.如权利要求33所述的方法，其特征在于生产模具的接触表面上具有一些凹穴。
35.如权利要求34所述的方法，其特征在于所述凹穴以非随机的图案方式排列。
36.如权利要求33所述的方法，其特征在于所述背衬用的是一种选自下述的材料：聚合物膜，涂过底料的聚合物膜，未处理的布，处理过的布，未处理的纸，处理过的纸，硫化纤维片材，无纺纤维片材及它们的结合。
37.如权利要求33所述的方法，其特征在于该磨料颗粒物质是选自下列的材料：熔融氧化铝，陶瓷氧化铝，热处理氧化铝，绿色碳化硅，白色氧化铝，碳化硅，矾土，氧化锆，金刚石，铈土，立方氮化硼，石榴石及其混合物。
38.如权利要求33所述的方法，其特征在于该磨料颗粒的莫氏硬度至少约为8。
39.如权利要求33所述的方法，其特征在于该粘合剂前体能通过辐射的作用固化。
40.如权利要求33所述的方法，其特征在于该粘合剂前体选自：丙烯酸酯化的尿烷、丙烯酸酯化的环氧树脂、烯不饱和化合物、具有侧链不饱和羰基的氨基塑料衍生物、具有至少一个侧链丙烯酸酯基团的异氰脲酸酯衍生物、具有至少一个侧链丙烯酸酯基团的异氰酸酯衍生物、乙烯基醚、环氧树脂及它们的混合物。
41.如权利要求40所述的方法，其特征在于该粘合剂前体还含有光引发剂。
42.如权利要求33所述的方法，其特征在于该混合物用选自下列涂覆机方式进行施涂：刮刀式涂覆机，落模式涂覆机，帘模式涂覆机，真空模式涂覆机和挤出模式涂覆机。
43.如权利要求33所述的方法，其特征在于该生产模具对紫外线辐射或可见光辐射或者同时对紫外线辐射和可见光辐射是可透过的。
44.如权利要求33所述的方法，其特征在于该生产模具的材料是热塑性树脂，热固性树脂或辐射固化的树脂。
45.如权利要求33所述的方法，其特征在于该能量源选自：电子束，紫外辐射和可见光。
46.如权利要求33所述的方法，其特征在于该背衬对于该辐射能是不透过的。
47.如权利要求33所述的方法，其特征在于该生产模具是一条环形带。
48.一种制备涂覆磨料制品的方法，其特征在于，包括使权利要求33所述的成形的，可操持的结构件完全固化的步骤。
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| US4799939A (en) * | 1987-02-26 | 1989-01-24 | Minnesota Mining And Manufacturing Company | Erodable agglomerates and abrasive products containing the same |
| US4950696A (en) * | 1987-08-28 | 1990-08-21 | Minnesota Mining And Manufacturing Company | Energy-induced dual curable compositions |
| US4952612A (en) * | 1987-08-28 | 1990-08-28 | Minnesota Mining And Manufacturing Company | Energy-induced curable compositions |
| US5086086A (en) * | 1987-08-28 | 1992-02-04 | Minnesota Mining And Manufacturing Company | Energy-induced curable compositions |
| JP2707264B2 (ja) * | 1987-12-28 | 1998-01-28 | ハイ・コントロール・リミテッド | 研磨シートおよびその製造方法 |
| US4985340A (en) * | 1988-06-01 | 1991-01-15 | Minnesota Mining And Manufacturing Company | Energy curable compositions: two component curing agents |
| JP2868772B2 (ja) * | 1988-09-20 | 1999-03-10 | 大日本印刷株式会社 | 研磨テープの製造方法 |
| US4903440A (en) * | 1988-11-23 | 1990-02-27 | Minnesota Mining And Manufacturing Company | Abrasive product having binder comprising an aminoplast resin |
| US5055113A (en) * | 1988-11-23 | 1991-10-08 | Minnesota Mining And Manufacturing Company | Abrasive product having binder comprising an aminoplast resin |
| US5175030A (en) * | 1989-02-10 | 1992-12-29 | Minnesota Mining And Manufacturing Company | Microstructure-bearing composite plastic articles and method of making |
| US5014468A (en) * | 1989-05-05 | 1991-05-14 | Norton Company | Patterned coated abrasive for fine surface finishing |
| JP2977884B2 (ja) * | 1990-10-19 | 1999-11-15 | 大日本印刷株式会社 | 研磨テープの製造方法 |
| US5107626A (en) * | 1991-02-06 | 1992-04-28 | Minnesota Mining And Manufacturing Company | Method of providing a patterned surface on a substrate |
| US5152917B1 (en) * | 1991-02-06 | 1998-01-13 | Minnesota Mining & Mfg | Structured abrasive article |
| US5236472A (en) * | 1991-02-22 | 1993-08-17 | Minnesota Mining And Manufacturing Company | Abrasive product having a binder comprising an aminoplast binder |
| US5219462A (en) * | 1992-01-13 | 1993-06-15 | Minnesota Mining And Manufacturing Company | Abrasive article having abrasive composite members positioned in recesses |
| US5178646A (en) * | 1992-01-22 | 1993-01-12 | Minnesota Mining And Manufacturing Company | Coatable thermally curable binder presursor solutions modified with a reactive diluent, abrasive articles incorporating same, and methods of making said abrasive articles |
-
1993
- 1993-12-30 US US08/175,694 patent/US5435816A/en not_active Expired - Lifetime
-
1994
- 1994-01-03 CA CA002153891A patent/CA2153891C/en not_active Expired - Lifetime
- 1994-01-03 CN CN94190949A patent/CN1084242C/zh not_active Expired - Lifetime
- 1994-01-03 AU AU60185/94A patent/AU675828B2/en not_active Ceased
- 1994-01-03 AT AT94906495T patent/ATE197689T1/de active
- 1994-01-03 ES ES94906495T patent/ES2151924T3/es not_active Expired - Lifetime
- 1994-01-03 DE DE69426325T patent/DE69426325T2/de not_active Expired - Lifetime
- 1994-01-03 EP EP94906495A patent/EP0679117B1/en not_active Expired - Lifetime
- 1994-01-03 BR BR9406827A patent/BR9406827A/pt not_active IP Right Cessation
- 1994-01-03 WO PCT/US1994/000032 patent/WO1994015752A1/en active IP Right Grant
-
2003
- 2003-12-03 JP JP2003404522A patent/JP2004148500A/ja active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1315972C (zh) * | 2000-10-16 | 2007-05-16 | 3M创新有限公司 | 制造团聚颗粒的方法 |
| CN103354783A (zh) * | 2011-02-24 | 2013-10-16 | 3M创新有限公司 | 具有泡沫背衬的带涂层磨料制品以及制备方法 |
| CN103354783B (zh) * | 2011-02-24 | 2016-01-20 | 3M创新有限公司 | 具有泡沫背衬的带涂层磨料制品以及制备方法 |
| CN110871410A (zh) * | 2019-11-11 | 2020-03-10 | 淄博理研泰山涂附磨具有限公司 | 一种具有空隙的结构型涂附磨具 |
Also Published As
| Publication number | Publication date |
|---|---|
| ES2151924T3 (es) | 2001-01-16 |
| EP0679117B1 (en) | 2000-11-22 |
| ATE197689T1 (de) | 2000-12-15 |
| US5435816A (en) | 1995-07-25 |
| JP2004148500A (ja) | 2004-05-27 |
| CA2153891A1 (en) | 1994-07-21 |
| EP0679117A1 (en) | 1995-11-02 |
| AU675828B2 (en) | 1997-02-20 |
| AU6018594A (en) | 1994-08-15 |
| CN1084242C (zh) | 2002-05-08 |
| WO1994015752A1 (en) | 1994-07-21 |
| CA2153891C (en) | 1998-12-15 |
| BR9406827A (pt) | 1996-04-02 |
| JPH08505572A (ja) | 1996-06-18 |
| JP3525387B2 (ja) | 2004-05-10 |
| DE69426325D1 (de) | 2000-12-28 |
| DE69426325T2 (de) | 2001-07-05 |
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