EP3074182A1

EP3074182A1 - Abrasive support, abrasive article comprising the abrasive support, and method for the production thereof

Info

Publication number: EP3074182A1
Application number: EP14815261.4A
Authority: EP
Inventors: Jürgen NIENTIEDT; Christine Doege; Peter Karl
Original assignee: Neenah Gessner GmbH
Current assignee: Neenah Gessner GmbH
Priority date: 2013-11-29
Filing date: 2014-11-28
Publication date: 2016-10-05
Anticipated expiration: 2034-11-28
Also published as: US20170028530A1; WO2015079021A1; US10124467B2; DE102013224549A1; EP3074182B1

Abstract

The invention relates to an abrasive support, to an abrasive article comprising such a support, to the method for producing the same, and to the use of the abrasive article. According to at least one embodiment, the abrasive support comprises an impregnated support material based on synthetic fibers. The impregnated support material has at least on one side having a surface roughness Rz of 100 μm to 500 μm, and having an Rmax of 250 μm to 600 μm. The support has an air permeability of at most 20 l/m2s.

Description

description

Abrasive carrier, abrasive article comprising the

Abrasive carrier and its production process

The invention relates to a support for abrasives, to an abrasive article comprising such a support, as well as to its production method and the use of the abrasive article. In order to meet the versatile technical requirements nowadays, abrasive carriers are required that are tough and strong so as not to break during grinding and to transfer the grinding force to a workpiece well. Furthermore, there is also a high flexibility of the

Abrasive carrier desirable so that it can adapt to the contours of a workpiece without permanently deforming.

For many years fabric carriers have been used to make bow, ribbon and disc shaped abrasive articles, often fabric of natural fibers, for example

Cotton, and synthetic fibers. Although wise

Fabric backing compared to the first widely used in this field abrasive papers a better

Tear strength, dimensional stability, splitting resistance, and

Flexibility on, but is the production of this

Fabric carrier very expensive and therefore often associated with very high production costs. Thus, tissue carriers are made

economic history points disadvantageous. In the application WO 2005/110681 Al, such a fabric carrier is described by way of example.

In the past, attempts have been made to replace the fabric supports with nonwoven fabrics of synthetic fibers and / or glass fibers. In the application DE 10 2010 036554 AI is the

Example described a spunbonded, which is impregnated with a thermosetting resin. In the cured state is However, the abrasive carrier too stiff to serve as a substitute for fabric carrier, for example, for abrasive belts can. Another important point in the manufacture and use of abrasive articles is the liability of the manufacturer

Abrasive on the abrasive carrier. High mechanical and thermal loads during grinding, which are particularly exposed to abrasive belts, can be used to remove the

Guide the abrasive material off the carrier. Particularly sensitive in this respect is the grinding of edges and punctiform elevations on the workpiece.

A way to improve the liability of

Abrasive on a support describes the application WO 97/005990 AI. This is used in the production of a

Abrasive tape improves the adhesion by a "primer", which among other things also a mechanical roughening, for example by grinding, the surface of the support is understood, but the mechanical roughening has the

Disadvantage that the surface of the carrier is opened or

is injured, so that subsequently applied

Binder for the abrasive can penetrate into the carrier. The binder can then lead to embrittlement of the carrier and thus its flexibility negative

influence. In addition, the mechanical roughening represents an additional step.

In the European application EP 0 024 511 AI is the

Improved binder adhesion for the abrasive through two combined effects. Firstly, the addition of suitable chemicals to the coating agent, the surface of the fibers of the

Brushed abrasive carrier. The use of resins that give a rough surface when dried, the contact with the binder of the abrasive is then further improved. The disadvantage of this method is but in that the ones used for fiber roughening

Chemicals, for example, for polyester fibers

Sodium hydroxide solution proposed to chemically degrade many common coating and binder resins. This in turn reduces the durability of the abrasive article. In addition, one is limited to the use of plastics for impregnation, which form a rough surface during drying, which are usually expensive. An object of the present invention is therefore to provide an improved carrier for abrasive, the

especially overcomes the disadvantages of conventional abrasive carriers. Such an abrasive carrier should preferably have high flexibility, tear strength,

Have dimensional stability, gap strength, elasticity, tensile strength and abrasion resistance and be inexpensive to manufacture. Other objects of the invention are to provide an abrasive article comprising such a support for

Abrasive includes specifying a method of manufacturing such an abrasive article carrier and the corresponding abrasive article and use of the abrasive article.

At least one of these objects is solved by the subject-matter of the independent claims. Subclaims indicate advantageous embodiments.

A carrier for abrasives is given. In the context of the application, this can also be referred to as an "abrasive carrier" or even briefly as a "carrier".

In at least one embodiment, an abrasive article carrier comprises an impregnated synthetic fiber-based base material

the impregnated carrier material has at least one side with a surface roughness R _z of 100 pm to 500 m and with an R _max of 250 μm to 600 m, and the carrier has an air permeability of at most 20 l / m ² s.

The carrier has advantageously at the same time a high

Flexibility and elasticity, high strength

(Tear strength, dimensional stability, splitting resistance and

Tensile strength) and also allows a good adhesion of binders or abrasives, so that the carrier can be used for the production of a long-lasting, durable and very easy to handle abrasive article.

In particular, the high flexibility and strength of the carrier can be attributed in the estimation of the inventors to the fact that the carrier comprises a carrier material based on synthetic fibers and is very dense. A measure of the tightness, as stated above, the air permeability, according to DIN EN ISO 9237: 1995, as in

Test methods described, is determined. The carrier has a low air permeability of at most 20 l / m ² s, in particular at most 10 l / m ² s and preferably at most 5 l / m ² s on. This high density of the carrier can be obtained by the fact that the carrier material has been compacted. The carrier according to the invention thus preferably comprises a compacted carrier material.

Another advantage of the high density, which manifests itself in a low air permeability, is that the

impregnated carrier material has little or no pores into which a binder for fixing abrasives, for example a base coat, can penetrate. These binders are often hard and brittle and can lead to embrittlement in conventional carriers. This can be largely avoided in the carrier according to the invention, so that it has a high durability and high flexibility. The carrier allows a good adhesion of binders, for example a base coat, as described in more detail below, and accordingly of abrasives. The

Inventors surprisingly found that a good adhesion is made possible in particular by the particular surface roughness of the impregnated carrier material R _z of 100 μτη to 500 μττι and with R _max of 250 μτη to 600 pm. The

Surface roughness is determined according to DIN EN ISO 4288: 1997, as described in detail below for the test methods. R ₂ is the arithmetic mean of the

Individual brooding depths of all 5 individual measuring sections; _Rmax refers to the largest of the five individual weeds. R _z may preferably be greater than 150 μτη and R _max from 250 μιη to 450 μιη. at

lower surface roughness, the above-mentioned adhesion is worse than in the carrier according to the invention. Is the

Surface roughness of the impregnated carrier material on the abrasive carrying side too large, so is a

Obtained abrasive article with too uneven abrasive surface. This can lead to an uneven sanding pattern.

The surface roughness can be obtained by at least one side of the impregnated carrier material, in contrast to numerous conventional carrier materials, specifically provided with it, for example by means of structuring. It should be noted that the carrier and thus also the impregnated carrier material or only the carrier material preferably flat - plan or curved - is formed. The carrier, the impregnated carrier material or the carrier material thus have two sides. These correspond to the largest pair of opposing ones

Pages. They can also be considered "main pages." It should also be noted that the above

Surface roughness refers to the impregnated carrier material. Optional layers arranged thereon, for example a barrier bar, can reduce the roughness of the

Change carrier surface again. In the impregnated support material, at least one side has a surface roughness R _z of 100 μτη to 500 μτη with an Rmax of 250 μττι to 600 μτη. Both sides may also have such a surface roughness. However, the other side can also be smooth. It may also have lower or higher surface roughness.

The impregnated carrier material of the carrier according to the invention is based on synthetic fibers. So it includes one

Support material based on synthetic fibers which has been impregnated with at least one impregnating agent. "Based on synthetic fibers" should mean that the carrier material to at least 80 wt., In particular

at least 90% by weight, and preferably at least 95% by weight, comprising or consisting entirely of synthetic fibers. It comprises in particular less than 10% by weight and preferably no natural fibers at all. The synthetic fibers are preferably organic polymers which are easier and cheaper to process than inorganic polymers, for example glass fibers, and result in a more flexible carrier.

According to a further embodiment, the

Synthetic fibers synthetic endless fibers or they consist of it. The term "continuous fiber" is known per se to a person skilled in the art, and they generally have a length of at least 50 mm, in particular at least 80 mm, The fiber diameter is preferably 0.5 μm to 60 μm Depending on the application, thinner fibers may be used a diameter of 0.5 m to 10 μτη, in particular 0.5 μτη to 3 , or thicker fibers with a diameter of 10 μτη to 60 μτη,

in particular 10 μπι to 25 μτη, are used.

According to a further embodiment, the carrier material is at least 95 wt.%, In particular at least 99 wt.%, Or completely non-woven. The carrier material is preferably not woven, ie "unwoven" and thus differs from a fabric carrier Support material are preferably laid so that it corresponds to a fiber fabric, for example a nonwoven fabric. The carrier according to the invention is preferably not a tissue carrier. According to a development of this embodiment, the carrier material is a nonwoven. It can in particular a

compacted nonwoven comprising or consisting of above

be described continuous fibers. These are easier and less expensive to produce than fabric carrier. Such a nonwoven fabric can be, for example, by a meltblown or a

Spunbonding be available.

According to a further embodiment, the carrier material is uniformly impregnated by an impregnating agent. This can be done for example by a dip impregnation.

According to a further embodiment, the carrier material is on at least one side with an impregnating agent

impregnated. It may be impregnated, for example, by one or both sides. If it is impregnated on both sides, the carrier material can be soaked uniformly by the impregnating agent.

The impregnated carrier material can on one or both sides, optionally independently of each other, a

Surface roughness R _z of 100 μτια to 500 μπι have a R _max of 250 μτια to 600 μτη. This may have been created by structuring, so that the corresponding page

is structured. According to another embodiment, the

Surface roughness R _z of 100 μπι to 500 μπι and with a R _max of 250 μιη to 600 μτη the at least one side of

impregnated carrier material by calendering,

in particular thermal calendering, produced with at least one structured roller. As a structured roller, for example, a stamping and / or gravure roller can be used. The inventors found out that through treatment By means of calendering, it is possible for the carrier material to be used to enable several advantageous properties in one working step, which makes the production of the carrier very economical. Indicates one side of the impregnated

Support material, the surface roughness R _z from 100 pm to 500 μτη and with a R _max of 250 μτη to 600 μπι, and the other side has a surface roughness outside this range, the latter may also have been produced in the same calendering step.

Compared to the use of exclusively smooth calender rolls, the surface roughness described above can be achieved by the at least one structured roll

impregnated carrier material can be produced. This remains even after impregnation and leads to a better adhesion of a base coat or a

Abrasive. Unlike traditional ones

Structuring methods which involve mechanical roughening, for example sanding, of a carrier do not "injure" the surface or fibers of the carrier material according to this embodiment, thereby improving the durability of the carrier and substantially preventing the penetration of binders into the carrier material , which leads to the advantages described above, as well as with advantage on the use of chemicals for

Fiber roughening be dispensed with.

Furthermore, the calendering also takes place

Compaction of the carrier material. The desired

Density can be controlled by pressure and temperature as described below during calendering. Preferably, the proportion of the solidification surface in the carrier material is 5% to 35%, in particular 10% to 30%. It can be 15% to 28%, especially 20% to 27%.

According to a further embodiment, the

synthetic fibers or continuous fibers, a polymer material, selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, polyamide, polyphenylene sulfide,

Polyolefin, polycarbonate and combinations thereof. The fibers may also consist of the polymer material. The synthetic (continuous) fibers, for example meltblown as well as spunbonded fibers, can consist of only one polymer, so-called monocomponent fibers, and / or of several

Polymers, so-called multi-component fibers exist. The polymers of the multicomponent fibers correspond to one of the above-mentioned combinations. Combinations can also be obtained by different monocomponent fibers.

In multicomponent fibers can be different

Arrangements of the polymers in the individual fibers, such as a "side-by-side" arrangement (the

Fiber cross section reminiscent of one in the middle

sliced pie with each half made of a different polymer), a "segmental array" (the

Fiber cross-section is reminiscent of a cake that has been divided into several pieces, the cake pieces in particular consist alternately of the different polymers), a so-called "Iceland-in-the-sea" arrangement (the

Fiber cross-section is reminiscent of multiple islands of a polymer surrounded by a sea of another polymer) and / or a "core-shell" arrangement (the core consists of a fiber of a first polymer encased by a cladding of a second polymer) In the case of nonwovens, if they comprise or consist of multicomponent fibers, they are subjected to a high-pressure water jet treatment after the web formation, in which the individual fiber components are separated into a plurality of thin individual fibers.

Depending on requirements, the surface of meltblown or the spunbonded nonwoven can be treated by surface treatment methods, such as For example, corona treatment or plasma treatment, in their properties, such as wettability to water or reduced electrostatic charge can be changed. According to a further embodiment, the

Impregnating a resin with a weight-average

Molecular weight of at least 50,000 g / mol, in particular at least 100,000 g / mol and preferably at least 250,000 g / mol. The weight-average molecular weight of the resin may be more preferably at least 500,000 g / mol, and more preferably at least 1,000,000 g / mol. It may also consist of one or more such resins. The inventors have surprisingly found that the resins used as impregnating agent with such a weight-average

Molecular weight of the pores of the carrier material or the

Close fleece particularly well and thus contribute to the tightness of the impregnated substrate. Impregnating agent consisting of a resin with a weight-average

Although molecular weight below 50000 g / mol, while enveloping fibers and these combine with each other, but are not able to bridge gaps between the fibers sufficiently good and close, so that binders can penetrate, which is undesirable. The amount of impregnating agent may be between 5% by weight and 70% by weight, preferably between 15% by weight and 60% by weight, of the dry

Impregnating agent based on the weight of not

impregnated carrier material. According to another embodiment, the impregnating agent is selected from the group consisting of acrylic esters,

Polyvinyl acetate, acrylonitrile-butadiene rubber,

Acrylic ester-styrene copolymers, ethylene-vinyl acetate copolymers, styrene-butadiene rubber, phenolic resins,

Epoxy resins, natural rubber, polyvinyl alcohol, starch,

Melamine-formaldehyde resin, urea-formaldehyde resins, and combinations thereof. Preferably, these have top called weight average molecular weight and are present at appropriate levels in the impregnated carrier material.

According to a further embodiment, a barrier layer is produced, in particular directly, on at least one side of the impregnated carrier material. This

Barline may partially or completely cover the page. The barrier bar or barrier layer seals the

Abrasive carrier additionally from and prevents so that a later used for the preparation of an abrasive article basecoat can penetrate into the impregnated carrier material and can lead to embrittlement of the carrier. The

Air permeability of a carrier with a barrier layer may be at most 10 l / m ² s, in particular at most 5 l / m ² s. In addition, the barrier line act as a bonding agent between the impregnated substrate and a basecoat.

The barrier bar may comprise or consist of a material selected from a group comprising

Acrylic acid esters, polyvinyl acetate, acrylonitrile-butadiene rubber, acrylic acid ester-styrene copolymers, ethylene-vinyl acetate copolymers, styrene-butadiene rubber,

Phenol resin, epoxy resin, natural rubber, and combinations thereof. The dry barrier coating may be produced in an amount of 5 to 40 g / m ² , preferably 5 to 30 g / m ² .

According to another embodiment, the

Barrier layer on one side of the impregnated

Support material with surface roughness R _z of 100 to 500 μιη and arranged with a R _max of 250 μτη to 600 microns. As described above, in the context of the application, a blocking line is not counted to the impregnated carrier material. The

Surface roughness of the carrier on the side facing away from the impregnated carrier material side of the barrier layer layer may differ from that of the impregnated carrier material.

According to a further embodiment, the carrier on the from the impregnated carrier material side facing the barrier layer, a surface roughness R _z of 20 to 300 μαι and with a R _max of 50 m to 400 μτη on. R _z is preferably 20 m to 250 μm and _Raax of 50 μm to 300 μm. Even with this surface roughness and due to the adhesion-promoting properties of the barrier line is a good

Adhesion of a base coat or an abrasive

allows. Furthermore, the impregnating agent and / or the

Clock still various additives and / or fillers have been added. Examples of such additives are paints, crosslinkers, water repellents,

Oleophobic, hydrophilicizing or

Combinations thereof. As fillers, for example

Kaolin, titanium dioxide, talc, calcium carbonate, silica, bentonites or combinations thereof.

A preferred carrier may have a basis weight of more than 105 g / m ² , in particular in the range of 110 to 1870 g / m ² and preferably from 115 to 1760 g / m ² . It may, for example, have a thickness of 0.100 to 2.500 mm, in particular 0.110 to 2.400 mm. The elastic modulus in the longitudinal and transverse directions of the carrier may be from 100 to 10000 MPa. The carrier may have a tensile stiffness index in

Longitudinal direction of 0.3 to 10 MNm / kg and in the transverse direction of 0.2 to 10 MNm / kg.

A preferred carrier, for example, a through

Thermal calendering compressed synthetic fleece

Endless fibers that with one of the above

Impregnating agent in an amount between 5 wt.% And 70

% By weight, preferably between 15% by weight and 60% by weight, based on the weight of the non-impregnated nonwoven fabric, is impregnated. When calendering can also at least one side of the

impregnated nonwoven fabric have been structured. Then, a barrier layer of the above materials may be produced. Such a carrier without barrier coating has, for example, a basis weight of 105 to 1870 g / m ² , preferably from 115 to 1760 g / m ² ; a thickness of 0.100 to 2.500 mm, preferably of 0.110 to 2.400 mm; a

Air permeability of at most 20 l / m ² s, preferably of at most 10 l / m ² s, - a dry tensile strength in the longitudinal direction of 10 to 1500 N / I5mm, preferably from 15 to 1300 N / I5mm; a breaking force dry in the transverse direction of 5 to 1300

N / 15mm, preferably from 10 to 1200 N / 15mm; an elongation at break dry in the longitudinal direction of 10% to 60%, preferably from 12% to 55%; dry elongation at break in the transverse direction of 15% to 65%, preferably from 18 to 60%; a flexural rigidity in the longitudinal direction of 0.2 to 15.0 Nmm, preferably 0.3 to 14.5 Nmm; a bending stiffness in the transverse direction of 0.1 to 14.0 Nmm, preferably 0.2 to 13.5 Nmm; one

Tensile stiffness index in the longitudinal direction of 0.3 to 10.0

MNm / kg, preferably from 0.4 to 9.5 MNm / kg; one

Tensile stiffness index in the transverse direction of 0.2 to 10.0 MNm / kg, preferably from 0.3 to 9.5 MNm / kg; a modulus of elasticity in the longitudinal direction of 100 to 10,000 MPa, preferably 150 to 9500 MPa; a modulus of elasticity in the transverse direction of 100 to 10,000 MPa, preferably 150 to 9500 MPa; on at least one side a surface roughness _z of 100 to 500 .mu.m and with a _max of 250 to 600 .mu.m, preferably R _z of 150 to 500 μιη and R _max of 250 to 450 μπι.

Such a carrier without a barrier coating can

in particular, a basis weight of 115 to 1760 g / m ² , a thickness of 0.110 to 2.400 mm, an air permeability of at most 10 l / m ² s, a breaking force dry in the longitudinal direction of 15 to 1300 N / 15mm, a breaking force dry in the transverse direction of 10 to 1200 N / 15mm, a dry elongation at break of 12% to 55%, an elongation at break dry in the transverse direction of 18 to 60%, a flexural rigidity in

Longitudinal direction from 0.3 to 14.5 Nmm, bending stiffness from 0.2 to 13.5 Nmm, a tensile stiffness index in the longitudinal direction from 0.4 to 9.5 MNm / kg, one

Tension stiffness index in the transverse direction of 0.3 to 9.5 MNm / kg, a modulus of elasticity in the longitudinal direction of 150 to 9500 MPa, a modulus of elasticity in the transverse direction of 150 to 9500 MPa, on at least one side, a surface roughness R _z of 150 to 500 μιη and with have a R _max of 250 to 450 μτη.

Such a carrier with barrier coating has

for example, a basis weight of 110 to 1900 g / m ² , preferably from 155 to 1570 g / m ² ; a thickness of 0.100 to 2.500 mm, preferably from 0.110 to 2.500 mm; a

Air permeability of at most 10 1 / m ² , preferably of at most 5 l / m ² ; a breaking force dry in the longitudinal direction of 10 to 1600 N / 15mm, preferably 15 to 1500 N / 15mm; a breaking force dry in the transverse direction of 5 to 1400

N / 15mm, preferably from 10 to 1500 N / 15mm; an elongation at break dry in the longitudinal direction of 10% to 70%, preferably from 12% to 60%; a dry ultimate elongation in the transverse direction of 10% to 75%, preferably 15% to 70%; a bending stiffness in the longitudinal direction of 0.2 to 15.0 Nmm, preferably from 0.3 to

14.5 Nmm; a bending stiffness in the transverse direction of 0.1 to 14.0 Nmm, preferably 0.2 to 13.5 Nmm; a tensile stiffness index in the longitudinal direction of 0.3 to 10.0 MNm / kg,

preferably from 0.4 to 9.5 MNm / kg; a transverse tensile stiffness index of 0.2 to 10.0 MNm / kg, preferably 0.3 to 9.5 MNm / kg; a modulus of elasticity in the longitudinal direction of 100 to 10,000 MPa, preferably 150 to 9500 MPa; one

Modulus of elasticity in the transverse direction of 100 to 10000 MPa, preferably from 150 to 10000 MPa; on the barrier coated side a surface roughness R _z of 20 to 300 μτη and with a R _max of 50 to 400 μιη, preferably R _z of 20 to 250 μπι and R _max of 50 to 300 μπι.

Such a carrier with barrier coating can

in particular a basis weight of 155 to 1570 g / m ² , a thickness of 0.110 to 2.500 mm, an air permeability of preferably at most 5 l / m ² , a breaking force dry in Longitudinal direction from 15 to 1500 N / 15mm, a transverse dry tensile strength of 10 to 1500 N / 15mm, an elongation at break dry in the longitudinal direction of 12% to 60%, an elongation at break dry in the transverse direction of 15% to 70%, one

Longitudinal flexural stiffness 0.3 to 14.5 niar, transverse flexural strength 0.2 to 13.5 Nmm, longitudinal tensile stiffness index 0.4 to 9.5 MNm / kg, transverse tensile stiffness index of 0, 3 to 9.5 MNm / kg, a modulus of elasticity in the longitudinal direction of 150 to 9500 MPa, a modulus of elasticity in the transverse direction of 150 to 10000 MPa, on the barrier coated side one

Surface roughness R _z of 20 to 250 μπι and having an R _max of 50 to 300 to have. As a further aspect of the invention, an abrasive article is provided. The abrasive article comprises a carrier according to at least one embodiment of the invention.

In accordance with at least one embodiment of the abrasive article, the backing is coated on one side of the impregnated support material having a surface roughness R _z of 100 μm to 500 μm and an R _max of 250 μm to 600 μm

Sanded abrasive. The term "besandet" is the

A person skilled in the art, he means that on the impregnated substrate abrasives are arranged and fixed.

The abrasive is not limited according to the invention. In principle, all materials can be used, which can be applied to the carrier and the

Sanding a material removal from a workpiece

cause. For example, the abrasive may be selected from a group including sand, diamond, corundum

(Alumina), silicon carbide, boron nitride, and combinations thereof. The abrasive is preferably as

Particles, grains, splinters or the like.

For Besanden the carrier is usually with a base coat Mistake. Then the abrasive material is applied and subsequently a topcoat is produced. The Schlei article can thus arranged on the support a base coat, abrasive, as described above, and include a topcoat. A

Barrier layer, if provided, is usually arranged between impregnated carrier material and the basecoat.

The base coat may be selected, for example, from epoxy resin, phenolic resin, alkyd resin, urea resin, or combinations thereof. As a topcoat is usually a hard,

thermosetting resin, which is the abrasive

additionally anchored, used. The topcoat can for

Example of epoxy resin, phenolic resin, alkyd resin, urea resin or combinations thereof.

According to a further embodiment of the abrasive article, a barrier coating layer is produced on the impregnated carrier material and the carrier is, in particular directly, on the side facing away from the impregnated carrier material

Barrier layer sanded. As mentioned above, the barrier coat layer seals the backing to a base coat and improves its adhesion or adhesion

Abrasive. The abrasive article of the invention is suitable for both wet and dry grinding. He can as

For example, as a grinding belt, grinding wheel or

Abrasive sheet be designed. As a further aspect of the invention, therefore, the use of an abrasive article is specified. An abrasive article according to at least one embodiment of the invention can be used as a sanding belt, grinding wheel or abrasive sheet or for their production. According to the application, grinding wheels include flap discs.

As a further aspect of the invention is a method specified. By the method, a carrier for abrasive according to at least one inventive

Embodiment are manufactured. In at least one embodiment, the method includes the steps

(A) producing a carrier material based on synthetic fibers;

(B) calendering the support material with at least one structured roller, so that the support material on

at least one page is structured;

(C) impregnating the support material with a

Impregnating agent;

so that a carrier comprising an impregnated support material based on synthetic fibers, μτη at least one side with a surface roughness R _z of 100 to to 500, and having an R _max of 250 to 600 m, and an air permeability of at most 20 l / m ² s is obtained.

The method is preferred in this order of

Steps (A) to (C) performed.

The carrier material corresponds to a carrier material according to at least one of the embodiments described above. So it can, for example, a nonwoven made of synthetic

Be continuous fibers. The fleece can be, for example, a so-called meltblown web or a spunbonded web. According to a further embodiment, the support material is produced in step (A) by a meltblown process or by a spunbonding process.

To produce a nonwoven fabric for a carrier according to the invention, a so-called meltblown process can be used. Such is, for example, in the publication of A. van due, "Superfine Themoplastic Fibers", Industrial Engineering Chemistry, Vol. 48, pp. 1342-1346, the disclosure content of which is hereby incorporated by reference. Suitable polymers are selected, for example, from a group comprising polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, polyamide, polyphenylene sulfide, polyolefin, polycarbonate, and combinations thereof. It can typically fiber diameter between 0.5 and 10 μττι, preferably between 0.5 and 3 μπι obtained. Depending on the requirements, the polymers can also contain additives, such as

Hydrophilizing agent, hydrophobizing agent,

Crystallization accelerators, colors and combinations thereof are mixed.

For producing a nonwoven fabric for a carrier according to the invention, a so-called spunbonding process can be used. Such is described, for example, in applications US 4,340,563 A, US 3,802,817 A, US 3,855,046 A and US 3,692,618 A, the disclosure contents of which are hereby incorporated by reference.

Polymers suitable for a spunbonding process are

for example, selected from a group that

Polyethylene terephthalate, polybutylene terephthalate,

Polyethylene naphthalate, polybutylene naphthalate, polyamide, polyphenylene sulfide, polyolefin, polycarbonate and

Combinations thereof. Fiber diameters between 6 and 60 μm, preferably between 10 and 25 μm, can typically be obtained. Depending on the requirements, the polymers may contain additives, such as

Hydrophilizing agents, water repellents,

Crystallization accelerators, colors or combinations thereof, are mixed.

Both after the meltblown and after the Spunbonded (endless) fibers can consist of only one polymer (monocomponent fibers) or of several polymers (multicomponent fibers), as already described above.

Nonwoven webs of multicomponent fibers can preferably be fed after web formation to a high-pressure water jet treatment in which the individual fiber components are separated into a plurality of thin individual fibers.

Depending on the requirements, the surface of the support material or the nonwoven fabric may be changed by a surface treatment method, such as corona treatment or plasma treatment, in their properties, such as wettability by water or reduced electrostatic charge.

As already mentioned above, it is the flexibility and strength of the abrasive carrier according to the invention

advantageous that the carrier material or the fleece is as dense. For this, this can be condensed, what

in particular by calendering in step {B). According to another embodiment, calendering in step (B) is designed as a thermal calendering. Thermal calenders required for this purpose are known per se to the person skilled in the art.

The properties of the support material can be adjusted in step (B), for example via the line pressure (nip pressure) and the roller temperature. This can be so

be compressed that a predetermined, described above, advantageously low air permeability is achieved. It may, for example, with a nip pressure of 30 to 300 N / mm, preferably from 50 to 300 N / mm, and a temperature between 80 ° C and 280 ° C, preferably between 100 ° C and 260 ° C, im

Calendered step (B). The inventors found that the use of exclusively smooth calender rolls adversely affects the carrier. In addition to one

desirable compression, smooth calender rolls also produce a smooth, in particular unstructured,

Surface of the substrate, then on the

Binder resin, a base coat, for the abrasive

badly liable.

As described above, the inventors surprisingly found that the use of structured rolls, for example embossing or gravure rolls, the adhesion of a

Binder resin is significantly improved on the support according to the invention. It come here to textured rollers

Insert designed to produce structures on at least one side of the substrate, for example, a continuous synthetic fiber nonwoven web. The

Support material is then in particular with a

Surface roughness R _z of 100 to 500 μτη and generated with an R _max of 300 to 800 μτη on at least one side.

The structured rollers used in step (B) can be used for all common patterns, in particular embossing or engraving patterns, such as, for example, lines, ovals, rhombuses (diamonds),

Have truncated cones and / or ellipses. Appropriate

Patterns are then generated in the substrate.

As mentioned above, the carrier material

preferably compressed in step (B). The share of

Solidification surface may be 5% to 35%, preferably 10% to 30%, more preferably 15% to 28% and particularly preferably 20% to 27%. In step (B), the support material for the

abrasive carrier according to the invention are structured either on one side or on both sides. For example, the calendered backing material produced and calendered after steps (A) and (B), preferably a nonwoven web of synthetic (continuous) fibers, has a basis weight of from 100 to 1100 g / m ² ; a thickness of 0.100 mm to 2.500 mm; an air permeability of at most 500 l / m ² s, preferably at most 200 l / m ² s, and particularly preferably at most 100 l / ms; a modulus of elasticity in the longitudinal direction of 150 to 13000 Pa and in the transverse direction of 100 to 11000 MPa; a tensile stiffness index along 0.4 to 16.0 MNm / kg; a Zugsteifigkeitsindex transverse from 0.2 to 16 MNm / kg and a surface roughness R R ₂ from 100 to 500 μιη and with a R _max of 300 to 800 microns. These parameters, in particular the

Air permeability, can change if that

Carrier material in step (C) is impregnated.

Subsequent to step (B), the carrier material is impregnated in step (C). As a result, the impregnated carrier material of the carrier according to the invention is obtained. For impregnation in step (C) are, for example, size press,

Dip impregnation, foam impregnation, roller impregnation or spraying, in particular dip impregnation, suitable impregnation methods. The carrier material, in particular a nonwoven made of continuous fibers, can, for example, by

Dipping impregnation should be completely impregnated with the impregnating agent. This is in particular a

achieved uniform distribution of the impregnating agent. An impregnating agent can be applied to one or both sides, for example by means of roller, spray or foam application. Here are the same or different

Impregnating agent can be used.

By impregnation, the porosity of the

Abrasive carrier according to the invention so far reduced that later applied coatings can not or only very slightly penetrate into the impregnated carrier material. In addition, by selecting a suitable impregnation the Tear strength, flexibility and nip strength are modified and adjusted.

According to another embodiment, the

Impregnating agent in step (C) in the form of a

Polymer dispersion, a polymer solution or mixtures thereof introduced or applied. Suitable polymer dispersions are, for example, aqueous dispersions of polymers selected from the group consisting of acrylic acid esters, polyvinyl acetate, acrylonitrile-butadiene rubber,

Acrylic ester-styrene copolymers, ethylene-vinyl acetate copolymers, styrene-butadiene rubber, phenolic resin,

Epoxy resin, natural rubber and combinations thereof. Suitable polymer solutions may for example consist of a

Group selected, the polyvinyl alcohol in water,

Starch in water, melamine-formaldehyde resin in water,

Urea-formaldehyde resin, phenolic resins in methanol,

Epoxy resins in methanol and combinations thereof. Preferably, those used as impregnating agents

Resins have a weight-average molecular weight of at least 50,000 g / mol, in particular at least 100,000 g / mol, preferably at least 250,000 g / mol, more preferably at least 500,000 g / mol and more preferably at least 100,000 g / mol. This enables the pores of the support material to be closed efficiently, so that the above-described advantageous air permeability and surface roughness of the impregnated support material are obtained. According to another embodiment, in a further step (D) a barrier layer layer, in particular

directly produced on the impregnated carrier material. Preferably, the barrier bar is on the side of

impregnated support material with a surface roughness R _z of 100 to 500 μπι and applied with a R _max of 250 μιη to 600 μπι. Suitable methods for applying the

Barrier lines are, for example, roller blades, knife knives, Application by means of air brush or roller application.

The barrier coating may be prepared, for example, by applying an aqueous dispersion based on a material selected from a group consisting of acrylic esters,

Polyvinyl acetate, acrylonitrile butadiene rubber,

Epoxy resin, natural rubber and combinations thereof. If a dispersion is applied to the barrier coating, it is advisable to dry it, for example by heating in an oven. The amount applied after drying may be 5 to 40 g / m ² , preferably 5 to 30 g / m ² . Both in the introduction of the impregnating agent {see step (C)) and in the optional creation of a barrier coat (see step (D)) can still various additives

and / or fillers are added. Examples of additives are paints, crosslinkers, water repellents,

Oleophobic, hydrophilicizing or

Combinations thereof. As fillers, for example, kaolin, titanium dioxide, talc, calcium carbonate, silica, bentonites or a combination thereof can be used. According to a further embodiment, in a further step (E) the carrier is calendered. Accordingly, two or more calendering shreds may be provided in the method.

The step (E) can be carried out both with carriers with and without carriers barrier layer. The inventors found out that by the step (E), the surface smoothness, this refers to possible roughening, such as scratches, but not or only insignificantly on the desired, calendered structures, and the

Flexibility of the carrier is increased. During the calendering in step (E), the abrasive carrier is preferably passed through the nip of a pair of rolls consisting of a steel and a steel roll a rubber roller, with a nip pressure of 30 to 300 N / mm, preferably 50 to 300 N / mm. The abrasive carrier is preferably supplied to the calender used so that the side, which is to be sanded later with an abrasive, comes into contact with the steel roller. The calendering temperature is in particular between 20 ° C and 80 ° C, preferably between 50 ° C and 70 ° C.

Furthermore, as an aspect of the invention, there is provided a method of making an abrasive article. This

In this case, the method comprises the steps according to at least one embodiment of the above-described method for

Preparation of a carrier according to the invention. According to at least one embodiment of the method, the support is in a further step (F) on one side of the impregnated support material having a surface roughness R _z from 100 μιη to 500 μπι and with a R _max of 250 μπι to 600 μιη, with a Sanded abrasive. As a result, the Schleifartxkel invention is obtained. The

Abrasive may, but does not have to be directly generated on the impregnated substrate. If one

Barrier exists, the Besanden is done with the

Abrasive usually, especially directly, on the barrier line. The step (F) is suitably carried out after the steps {A} to (C) and the optional steps (D) and / or (E).

According to another embodiment, the step (F) comprises applying a base coat on the side of the

impregnated support material with the surface roughness R ₂ of 100 μπι to 500 μπι and with a R _max of 250 μπι to 600 μτη applying the abrasive on the basecoat and the production of a topcoat. Step (F), so that

"Sanding" with an abrasive may include applying a base coat to the abrasive backing of the invention, then sprinkling the abrasive, drying the basecoat, applying a topcoat to the abrasive, and drying the topcoat or consisting thereof. The base coat may be selected, for example, from epoxy resin, phenolic resin, alkyd resin, urea resin, or combinations thereof. The resins are preferably in a suitable

Solvent dispersed or dissolved and applied to the carrier. The abrasive is then sprinkled onto the still wet base coat, with the individual particles or

Granules, for example, by electrostatic devices on the abrasive carrier according to the invention optimally

can be aligned. Subsequently, the coated with the wet base coat and the abrasive adhering thereon abrasive carrier is dried, for example in a drying oven. After drying, the

Coating the abrasive or the carrier with a topcoat. As a topcoat is usually a hard, thermosetting resin, which anchors the abrasive additionally used. The topcoat can for

Example of epoxy resin, phenolic resin, alkyd resin, urea resin or combinations thereof. This exemplary sanding is completed by the hardening of the

Topcoats.

According to a further embodiment, on one side of the impregnated carrier material with surface roughness R _z of 100 μτη to 500 μπι and with an R _max of 250 pm to 600 pm in step {D) first creates a barrier layer and then in step (F) with the Sanded abrasive. This is advisable because the barrier line largely prevents the penetration of a base coat into the carrier.

With the method according to the invention, an advantageous carrier and thus also an advantageous abrasive article can be produced. It is therefore also a carrier specified according to at least one embodiment of the inventive method can be produced. Furthermore, an abrasive article is disclosed which comprises such a carrier. The abrasive article can be produced by a process for the production of abrasive articles according to at least one embodiment of the invention.

The support may thus be preparable by a process comprising the above-described steps (A), (B) and (C) and optionally (D) and / or {E) according to the respective embodiments.

Preferably, the calendering in step (B) is configured here as a thermal calendering. For example, it may have a nip pressure of from 30 to 300 N / mm, preferably from 50 to 300 N / mm, and a temperature between 80 ° C and 280 ° C _/ preferably between 100 ° C and 260 ° C in step (B).

calendered. The ones used in step (B)

textured rolls can handle all common patterns,

in particular embossing or engraving patterns, such as

Dashes, ovals, rhombuses (diamonds), truncated cones and / or

Have ellipses. The proportion of Ver estigungsfläche here 5% to 35%, preferably 10% to 30%, more preferably 15% to 28% and particularly preferably 20% to 27%, amount. Exemplary embodiment:

The carrier material used was a spunbonded nonwoven made of polyester fibers (continuous fibers) with an average fiber diameter of 18 μm. The diameter was determined by scanning microscopy. The support material had a basis weight of 235 g / m ² , a thickness of 0.550 μιη, an air permeability of 230 l / ms and a surface roughness R _z of 178 μτη at a smoother side and 369 μπι in the

opposite side on. The surface roughness was determined by thermally calendering the substrate with a

Line engraving roller scored. Such a carrier material can be obtained, for example, under the name T 478/235 from Johns Manville, Bobingen (production number 7536). This spunbonded fabric was impregnated with a styrene-butadiene dispersion by dip impregnation and dried. The proportion of the dried impregnating agent was 49% based on the non-impregnated nonwoven. The weight average

The molecular weight of the impregnating resin was> 1000000 g / mol. On the smoother side of the impregnated nonwoven was then a barrier coating by means of

Applied air brush order. The coating consisted of a mixture of styrene-butadiene dispersion and

Acrylic acid ester-styrene copolymer and was 18 g / m ² after drying. Finally, the impregnated and

coated spunbonded between a steel roll and a rubber roll calendered at 50 ° C and 200 N / mm line pressure, wherein the coated with the barrier line side to the

Steel roller showed.

The abrasive carrier of the invention thus prepared had a basis weight of 363 g / m ² , a thickness of 0.526 mm, an air permeability of 0 l / m ² s, a dry ultimate tensile strength of 301 N / 15 mm, a dry ultimate tensile strength of 238 N / 15mm, a breaking elongation dry in the longitudinal direction of 37,0%, a breaking elongation dry in

Transverse direction of 43.7%, a bending stiffness in the longitudinal direction of 7.95 Nmm, a bending stiffness of 5.1 Nmm in the transverse direction, a tensile stiffness index in the longitudinal direction of 1.45 MNm / kg, a tensile stiffness index in the transverse direction of 1.03 MNm / kg, modulus of elasticity in the longitudinal direction of 983 MPa, a modulus of elasticity in the transverse direction of 697 MPa and on the barrier-coated side a surface roughness R _z of 84.1 μηα and with R _max of 97.2 μπι on.

Test methods: The basis weight is determined according to DIN EN ISO 536.

The air permeability is in accordance with DIN EN ISO 9237: 1995

200 Pa pressure difference determined.

The thickness of a carrier or the carrier material is after

DIN EN ISO 534 with 20 N contact pressure and a measuring surface of

200 mm ² determined. The breaking force dry longitudinal and transverse becomes according to DIN EN ISO 1924-2 with a strip width of 15 mm, one

Clamping length of 100 mm and a withdrawal speed of 150 mm / min determined. The elongation at break dry longitudinally and transversely to DIN EN ISO 1924-2 with a strip width of 15 mm, one

Clamping length of 100 mm and a withdrawal speed of 150 mm / min determined. The surface roughness is determined according to DIN EN ISO 4288: 1997. Was measured with a Perthometer the company Mahr, Göttingen, with the following settings:

Scanning distance Lt = 56 mm

Cutoff Lc = 8 mm

Number of individual measurements (individual measuring sections) N = 5

Feed rate of the probe: 0.5 mm / s

Profile filter Ls = 25 μπι

Vertical measuring range 250 pm

Used probe: MFW - 25 with 5 μτη tip radius.

The determined at a measurement R _z - ert is the

Arithmetic mean of the single orders of all 5

Single measuring sections, whereby a single line depth again according to DIN EN ISO 4287 {DIN EN ISO 4287: 1998 + AC: 2008 +

AI: 2009) from all measured values of a single measuring section. The R _max value is a single value and refers to the largest of the five single-order depths. The bending stiffness was determined according to DIN 53123 Part 1.

The tensile stiffness was determined according to DIN ISO 1924-3 with 150 mm / min strain rate.

The modulus of elasticity was determined in accordance with DIN ISO 1924-3 at a rate of elongation of 150 mm / min.

The above standards are used in the German version, the disclosure levels of which are hereby incorporated by reference.

Claims

claims

An abrasive article carrier comprising an impregnated synthetic fiber-based base material

characterized in that

the impregnated carrier material has at least one side with a surface roughness R _z of 100 μτπ to 500 μττι and with an R _max of 250 μπι to 600 μιη and

the carrier has an air permeability of at most 20 l / m ² s.

2. A carrier according to claim 1, wherein the synthetic fibers comprise or consist of synthetic endless fibers.

3. A carrier according to claim 1 or 2, wherein the carrier material is a nonwoven.

4. A carrier according to any one of claims 1 to 3, wherein the carrier material is uniformly impregnated with an impregnating agent.

5. Carrier according to one of claims 1 to 4, wherein the carrier material on at least one side with a

Impregnating agent is impregnated.

6. Carrier according to one of claims 1 to 5, wherein the surface roughness R _z of 100 μτη to 500 μιη and with a R _ma of 250 μτη to 600 μτη the at least one side of

impregnated carrier material by calendering with

at least one structured roller has been produced.

A carrier according to any one of claims 1 to 6, wherein the synthetic fibers comprise a polymeric material selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate,

Polybutylene naphthalate, polyamide, polyphenylene sulfide,

Polyolefin, polycarbonate and combinations thereof.

8. Carrier according to one of claims 1 to 7, wherein the

Impregnating a resin with a weight-average

Molecular weight of at least 50,000 g / mol.

9. A carrier according to any one of claims 1 to 8, wherein on at least one side of the impregnated carrier material, a barrier layer layer is produced.

10. A carrier according to claim 9, wherein the barrier coating layer on one side of the impregnated carrier material

Surface roughness R _z of 100 to 500 μτη and with a R _max of 250 μτ to 600 μιη is arranged.

11. A carrier according to claim 9 or 10, wherein the carrier on the side facing away from the impregnated carrier material side of

Barrier layer has a surface roughness R _z of 20 μπι to 300 μτη and with a R _max of 50 μπι to 400 μΐΏ.

12. A carrier according to any one of claims 1 to 11, wherein the carrier has a modulus of elasticity in the longitudinal and transverse directions of 100 to 10,000 MPa.

13. A carrier according to any one of claims 1 to 12, wherein the carrier has a tensile stiffness index in the longitudinal direction of 0.3 to 10 MNm / kg and in the transverse direction from 0.2 to 10 MNm / kg.

14. An abrasive article comprising a carrier according to any one of claims 1 to 13, wherein the carrier on one side of the impregnated carrier material having a surface roughness R _z of 100 μπι to 500 μτη and having an R _max of 250 μτ ^η to 600 μπ, with an abrasive is sanded.

15. The abrasive article of claim 14, wherein on the

impregnated carrier material, a barrier layer layer is produced and the carrier is sanded on the side facing away from the impregnated carrier material of the barrier layer layer.

16. A process for the preparation of an abrasive carrier comprising the steps of:

(A) producing a carrier material based on synthetic fibers;

at least one page is structured;

(C) impregnating the support material with a

impregnation;

so that a carrier comprising an impregnated carrier material based on synthetic fibers, which has at least one side with a surface roughness R _z of 100 μπι to 500 μιη and with a R _max of 250 μιτι to 600 μπι comprises, and an air permeability of at most 20 l / m ² s is obtained.

17. The method according to claim 16, wherein in a further step (D) at least one barrier layer is produced on the impregnated carrier material.

18. The method according to any one of claims 16 or 17, wherein in a further step (Ξ) the carrier is calendered.

19. A method for producing an abrasive article according to any one of claims 16 to 18, wherein in another

Step (F) of the carrier on one side of the impregnated carrier material having a surface roughness R _z of 100 pm to 500 μπι and having a R _max of 250 μιτη to 600 um, is sanded with an abrasive.

20. Use of an abrasive article according to claim 14 or 15 as a grinding belt, grinding wheel or abrasive sheet

or for their production.