JP4801116B2 - Anti eye or treatment - Google Patents

Description

BACKGROUND OF THE INVENTION Coated abrasive products are used to polish a variety of substrates that can include soft and difficult to finish materials such as painted surfaces. When finishing these soft materials, abrasive paper products cannot be carried out to their full potential because of premature eye blockage. Boding is the agglomeration of swarf that clogs the space between the abrasive grains, thereby preventing the workpiece substrate or surface from being able to continue to be effectively polished. Abrasive industry solutions can be applied as a top size coating or incorporated into a top size coat, commonly referred to as a first sizing coating The use of chemical compounds such as metal soaps (ie zinc stearate, calcium stearate). Stearate technology provides adequate aggregate removal and anti-loading properties. However, metal stearates leave low surface energy material residues on the work surface that can potentially cause post-processing problems such as coating defects in downstream painting processes.

  This contamination of the low surface energy material can be detected by measuring the water contact angle on the polished substrate. The general procedure for addressing this item is to clean the polished surface with a cloth clean, preferably to ensure that all contamination has been removed, or finish with a non-stearate product. .

SUMMARY OF THE INVENTION It would be desirable to eliminate the step of cleaning the polished surface that would waste valuable time and money in the painting process. Furthermore, non-stearate products generally do not provide long life.
The present invention includes, as a first form, (a) a base material layer having a first surface, (b) a polishing layer having a plurality of abrasive grains arranged on the first surface of the base material layer, (c) A coated abrasive comprising: an overcoat layer disposed over an abrasive layer; and (d) an inorganic anti-layer or agent layer disposed over the overcoat layer, wherein the inorganic anti-layer or agent The layer comprises a thermoplastic resin or thermosetting resin and an inorganic anti-mark or agent selected from the group consisting of metal silicates and metal sulfates (provided that the inorganic anti-mark or agent layer comprises: Does not contain an organic anti-index or additive selected from the group consisting of metal salts of organic acids, organophosphates, organosilicates, and organic borates, and the inorganic anti-index or additive is Having an average particle size of less than 30 micrometers and a Mohs hardness value of less than 7). Agent on.
In the present invention, as a second embodiment, (a) a step of attaching a plurality of abrasive grains to the first surface of the base material layer, (b) a step of attaching an overcoat layer on the abrasive grains, and (c) An inorganic antiresistant further comprising (i) a thermoplastic resin or a thermosetting resin on the abrasive grains, and (ii) an inorganic anti-marking agent selected from the group consisting of metal silicates and metal sulfates. Eye or agent layer (provided that the inorganic anti-agent layer is an organic anti-layer selected from the group consisting of metal salts of organic acids, organic phosphates, organic silicates, and organic borates) An abrasive material comprising the steps of: depositing an additive-free and inorganic inhibitor or agent having an average particle size of less than 30 micrometers and a Mohs hardness value of less than 7. It relates to a method for forming.

  In one embodiment, the abrasive, such as a coated abrasive or a composite abrasive, is an inorganic material selected from the group consisting of metal silicates, silica, metal carbonates, and metal sulfates. It is top-coated with a layer consisting essentially of an anti-corrosive or agent.

  The layer consists essentially of inorganic coatings or additives, which are typical of conventional types, including metal salts of organic acids, organic phosphates, organic silicates, organic borates, etc. It means that it does not contain any additives having organic components such as anti-eyes, ie additives. However, it does not exclude the presence of a cured binder component that provides an excipient to which the inorganic eye or agent is applied.

  The metal silicate can be selected from the group consisting of magnesium silicate, potassium aluminum silicate, aluminum silicate, and calcium silicate. In one embodiment, the magnesium silicate includes talc, the potassium aluminum silicate includes mica, the aluminum silicate includes clay, and the calcium silicate includes wollastonite. The silica can be selected from the group consisting of fused silica, fumed silica, and precipitated amorphous silica. An example of the metal carbonate is calcium carbonate. Metal sulfates can include hydrated calcium sulfate or anhydrous calcium sulfate.

  The anti-marking or agent can have a Mohs hardness value of less than about 7, preferably less than about 3. The anti-marking agent can have an average particle size of less than about 30 micrometers, preferably in the range between about 1 and about 20 micrometers. This forms sufficiently fine particles that bond with shavings from a polished surface, such as a painted metal surface, to prevent the anti-sticking or agent from clogging the shavings in the surface of the abrasive cloth. Make it possible. That is, the anti-particles, ie, the agent particles, are generated by polishing the coating surface with abrasive cloth to produce abrasive debris, and the anti-particles, ie, agent particles, which bind to these shavings particles and suppress their aggregation are released. It consists of such a particle size.

  In a further embodiment, the anti-eye or agent concentration is concentrated primarily in the over sized layer. For example, the concentration can be at least 10% by volume of the top adhesive layer, preferably at least about 60% by volume.

  The anti-marking agent is preferably dispersed in a binder comprising, for example, a thermoplastic or thermosetting resin. For example, the thermoplastic resin can include latex, and the thermosetting resin can be selected from the group consisting of urea formaldehyde, phenol, epoxy, urethane, and radiation curable resin systems.

  A substrate layer having a first surface, an abrasive layer having a plurality of abrasive particles disposed on the first surface of the substrate layer, and an inorganic anti-layer disposed on the abrasive layer Thus, an abrasive, such as an abrasive cloth or abrasive composite, comprising a layer consisting essentially of the agent is also provided. In one embodiment, the anti- eye or agent is deposited on a cured oversize adhesive layer.

  Abrasive material, such as abrasive cloth or abrasive composite, comprising depositing a plurality of abrasive grains on the first surface of the substrate layer and depositing a layer consisting essentially of a resistance or agent on the abrasive grains. A method for forming is also provided.

  The foregoing and other objects, aspects and advantages of the present invention will become apparent from the following more detailed description of preferred embodiments of the invention. The accompanying drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.

DETAILED DESCRIPTION OF THE INVENTION Abrasive cloth papers are generally abrasive grits adhered to a support substrate that can be used to polish or otherwise abrade the surface of the article to which they are applied. Including products with

  The backing substrate of the abrasive cloth paper may be stiff, but is generally flexible, typically web materials such as paper, cloth, fibrous pads, polymeric films, vulcanized fibers, or combinations of these materials. Including. In some applications, the support substrate initially comprises an aggregate of loose fibers to which abrasive grains are added with or without additional binder material to provide a polishing web with consistent abrasive grains. The loose assembly of fibers and abrasives may be compressed in the absence of any adhesive binder, or otherwise fixed or cured in the presence of binder to form an abrasive cloth. Is possible.

  Abrasive grains generally have the ability to polish articles during processing, typically sand, flint, corundum, metal oxides such as aluminum oxide, aluminum-zirconia, ceramic alumina, diamond, silicon carbide, garnet, rouge, and It can be any material including clocus and the like. Abrasive grains generally have a sharp tip that acts as a polishing means, but the quality and quantity of the sharp tip depends on the utility. The abrasive can be embedded in or mixed with the support substrate, but more generally is adhered to the support substrate by a suitable binder material. Abrasive grains can be applied or blended with a web that takes a specific pattern or form of particles, or can be randomly distributed. In general, careful measurement methods are taken to ensure that the abrasive cloth has fixed particles with an appropriate distribution of granular cutting edges in one or more layers.

  The binder material is generally any convenient material that acts to adhere the abrasive grains to the support substrate and can be resistant to negation of the polishing process. Common binder materials include phenolic resin, glue, varnish, epoxy resin, acrylate, polyfunctional acrylate, urea-formaldehyde resin, trifunctional urethane, polyurethane resin, lacquer, enamel and support substrate Any of a variety of other materials that have the ability to stabilize the abrasive in an adhesive relationship can be mentioned. In general, the binder material is carefully selected to provide the maximum ability of the abrasive cloth to polish the surface of interest. Care is taken in selecting a binder material that is resistant to softening or burning or both due to overheating and that can provide adequate adhesion.

  The abrasive can be sprayed or otherwise coated with a binder material and deposited on or in the supporting substrate, or the supporting substrate can be coated with the binder material, after which the abrasive is applied thereon. It is possible to deposit on. Many alternative forms are known in the prior art and are within the scope of the present invention, such as support substrate, particulate material, binder material, means for placing abrasive grains on the support substrate, and means for adhering abrasive grains. Seen as a variation considered in

  In general, in the production of conventional abrasive cloths, the base (with or without pre-treatment) is provided with a base adhesive layer of binder resin and applied while the abrasive is still sticky. Is applied onto the base adhesive layer and the binder is cured to hold the abrasive in place. Next, an overcoat adhesive layer essentially comprising a binder resin, optionally including fillers and grinding aids, is applied onto the abrasive grains and allowed to cure. The primary function of the overcoat adhesive layer is to hold the abrasives firmly in place, without the product being processed being dragged away from the abrasive cloth structure before their polishing capacity is depleted. It is possible to polish. In some cases, a top adhesive layer is deposited on the overcoat adhesive layer. The function of this layer is to place an additive on the surface of the abrasive cloth that provides special characteristics such as enhanced polishing capability, surface lubricity, antistatic properties or in this case anti-glare properties. The top adhesive layer is generally, but not necessarily required, but does not play any role in securing abrasive grains in place on the abrasive cloth.

  The additive can be applied as a dispersant in the binder (to be cured later) or in a liquid dispersion that is simply dried leaving the additive on the surface. In one embodiment, the binder comprises a thermoplastic or thermosetting resin. For example, the thermoplastic resin can include latex, and the thermosetting resin can be selected from the group consisting of urea formaldehyde, phenol, epoxy, urethane, and radiation curable resin systems. With some additives, adhesion to the surface can be achieved without the need for a dispersion medium.

  According to the present invention, the anti-glazing agent applied on the overcoat adhesive layer can be selected from the group consisting of metal silicates, silica, metal carbonates, and metal sulfates. The metal silicate can be selected from the group consisting of magnesium silicate, potassium aluminum silicate, aluminum silicate, and calcium silicate. In one embodiment, the magnesium silicate includes talc, the potassium aluminum silicate includes mica, the aluminum silicate includes clay, and the calcium silicate includes wollastonite. The silica can be selected from the group consisting of fused silica, fumed silica, and precipitated amorphous silica. An example of the metal carbonate is calcium carbonate. Metal sulfates can include hydrated calcium sulfate or anhydrous calcium sulfate.

  In accordance with the present invention, the inorganic anti-bonding agent, in the course of use, releases fine particles covering the fine shaving particles produced by the polishing process, thereby forming agglomerates and polishing cloth. It appears to prevent the formation of troublesome larger particles (known as “eyes”) that are trapped on the paper surface and reduce its effectiveness. Thus, the abrasive cloth eyes are reduced without causing the problems associated with the use of conventional stearate resistance or layers. With these additives, a fine film of low energy material is applied onto the polished surface, which makes subsequent surface painting or glazing extremely difficult unless the film is removed.

  The anti-eyes or agents of the present invention are, in one embodiment, relatively soft, for example having a Mohs hardness value of less than about 7, preferably less than about 3. In one embodiment, since the finer particle size material appears to function better as an anti-mark or agent, the anti-mark or agent is an average of less than about 30 micrometers, preferably between about 1 and about 20 micrometers. It has a particle size.

  It is believed that one mechanism for providing non-eyes or properties is to prevent swarf particles from adhering to each other with anti-eyes or agents, thereby reducing the eyes. While this technique produces fine dust while sanding, the shavings, without inorganic anti-wetting agents, prevent effective polishing, reduce the life of the abrasive cloth, and become clogged between abrasive grains. Tend to form balls or large pieces. There is a difference in the appearance of shavings resulting from sanding with stearylated and non-stearated products.

  In accordance with the present invention, the concentration of anti-bonding agent on the polishing surface of the top adhesive layer is about 10% by volume, preferably greater than about 60%. This ensures that the anti-eyes, i.e. the agent, are present sufficiently to be effective in producing fine dust that prevents the shavings from agglomerating.

  The anti-glazing agent can be used with other abrasives such as abrasive composites (nonwoven fabrics).

Example 1: Hydrated magnesium silicate (talc) at various median particle sizes
In the following examples and subsequent examples, standard conventional abrasive cloth is used. The substrate material is A-heavy paper, and the base adhesive layer and the overcoat adhesive layer contain a urea-formaldehyde binder. In each case, the abrasive is P320 aluminum oxide. A top adhesive layer containing a resistance, that is, an additive is applied to the basic abrasive cloth. In one case, no additive was added for comparative purposes. In the second case, a top adhesive layer containing zinc stearate was applied, and in the three other cases, the applied film was hydrated magnesium silicate (talc) with different particle sizes. The additive was added as a dispersion in latex and water.

  Next, abrasive cloth paper was used to polish the acrylic panel using a double-action paper sanding machine for 6-minute contact at intervals of 2 minutes. Polishing was performed with a 12.7 cm (5-inch) disk having a 4.5 kg (10-lb) load. The amount of cut after a total polishing time of 12 minutes was recorded and the polishing performance was measured as a percentage of the control cut. The average surface roughness value, Ra (arithmetic average value) was also measured. The results are recorded in Table 1 below, which shows that talc is as effective as conventional zinc stearate.

Vertal 1500, Supreme HT, and Arctic Mist are talcs commercially available from Luzenac America, Inc.

Example 2: Hydrated magnesium silicate (talc) with various abrasive grain sizes, Supreme HT
The table below shows the polishing performance of Supreme HT talc without the resistance or resistance to aluminum oxide abrasive cloths in zinc stearate and abrasive grains P80, P180, and P320 (Tables 2, 3, and 4 respectively). This will be explained in comparison with the control. The results show that those incorporating the anti-eyes or agents of the present invention have a higher cutting rate than the basic control, especially in finer abrasive grains.

Example 3: Amorphous silica, calcium silicate (wollastonite), aluminum silicate (clay), and potassium aluminum silicate (mica)
Standard P320 abrasive grain A-weight paper aluminum oxide Conventional abrasive cloth paper is used. This basic abrasive cloth has a top adhesive layer containing an anti-glazing or additive of either amorphous silica, calcium silicate (wollastonite), aluminum silicate (clay) or potassium aluminum silicate (mica). Apply. The polishing results set forth in Table 5 below show that the anti-eyes or agents incorporating the present invention had a higher cutting rate relative to the basic control.

MN-23 is an amorphous silica commercially available from Eagle Pitcher.
Wollastonite 325 is calcium silicate commercially available from NYCO Minerals, Inc.
Optiwhite is a clay commercially available from Burgess Pigment Company.
Burgess 17 is a clay commercially available from Burgess Pigment.
Mica 325 is a mica commercially available from Oglebay Norton Specialty Minerals.

Example 4: Calcium sulfate (anhydrous and hydrated)
Standard P320 abrasive grain A-weight paper aluminum oxide Conventional abrasive cloth paper is used. A top adhesive layer containing calcium sulfate (anhydrous or hydrated) resistance or additive is applied to the basic abrasive cloth. The polishing results set forth in Table 6 below show that the anti-eyes or agents incorporating the present invention had a higher cutting rate relative to the basic control.

SNOW WHITE is an anhydrous calcium sulfate commercially available from United States Gypsum Company.
TERRA ALBA is a hydrated calcium sulfate commercially available from United States Gypsum.

Example 5: Water contact angle of abrasive coated panel after sanding and polishing The primer panel was polished with P320 abrasive polishing cloth paper having a top adhesive layer as described in Examples 1-4. The same sanding procedure was used for each abrasive cloth. Next, a drop of water was dropped on each newly polished panel and on the unpolished panel, and the contact angle (θ) was recorded as described in the figure. The contact angle is the angle between the liquid surface and the solid planar surface at the contact line. A higher contact angle indicates less wetting. The results are shown in Table 7, which clearly shows that the panel polished with abrasive cloth according to the present invention is essentially the same or lower than the panel polished with anti-glare or layerless abrasive cloth It represents having a contact angle. Abrasive cloth paper having a conventional zinc stearate texture or layer clearly deposited a low surface energy residue whose presence is represented by a very high water contact angle. This result indicates that the paint applied to these surfaces does not wet the surface easily, thus leading to surface defects.

The water contact angle on the unpolished panel is 69 degrees.

  While the invention has been shown in detail and described in terms of preferred embodiments thereof, various changes in form and detail may be made therein without departing from the scope of the invention as encompassed by the appended claims. It will be appreciated by those skilled in the art.

Embodiments related to the present invention are listed below.
[Embodiment 1] An abrasive that is top-coated with a layer consisting essentially of an inorganic antibonding agent selected from the group consisting of metal silicate, silica, metal carbonate, and metal sulfate.
[Embodiment 2] The abrasive according to embodiment 1, wherein the metal silicate is selected from the group consisting of magnesium silicate, potassium aluminum silicate, aluminum silicate, and calcium silicate.
[Embodiment 3] The abrasive according to Embodiment 2 in which the magnesium silicate contains talc.
[Embodiment 4] The abrasive according to Embodiment 2, wherein the potassium aluminum silicate contains mica.
[Embodiment 5] The abrasive according to Embodiment 2 in which the aluminum silicate contains clay.
[Embodiment 6] The abrasive according to Embodiment 2, wherein the calcium silicate contains wollastonite.
[Embodiment 7] The abrasive according to embodiment 1, wherein the silica is selected from the group consisting of fused silica, fumed silica, and precipitated amorphous silica.
[Embodiment 8] The abrasive according to Embodiment 1, wherein the metal carbonate contains calcium carbonate.
[Embodiment 9] The abrasive according to Embodiment 1, wherein the metal sulfate contains hydrated calcium sulfate or anhydrous calcium sulfate.
[Embodiment 10] The abrasive of embodiment 1, wherein the anti-glazing agent is a Mohs hardness value less than about 7.
[Embodiment 11] The abrasive of embodiment 1, wherein the anti-glazing agent is an average particle size of less than about 30 micrometers.
[Twelfth Embodiment] The abrasive according to the eleventh embodiment, wherein the anti-glazing agent, that is, the agent has an average particle diameter in the range of 1 to 20 micrometers.
[Thirteenth Embodiment] The abrasive according to the first embodiment, wherein the anti-glazing agent is mainly concentrated in the top adhesive layer.
[Embodiment 14] The abrasive of embodiment 1, wherein the resistance or agent provides at least 10% by volume of the top adhesive layer.
[Embodiment 15] The abrasive of embodiment 14, wherein the anti- eye or agent provides at least 60% by volume of the top adhesive layer.
[Embodiment 16] When the anti-particle, that is, the agent particles, polishes the coated surface using abrasive cloth to produce abrasive debris, the anti-particle, that is, the agent particles that bind to these shaving particles and suppress the aggregation thereof. The abrasive according to embodiment 1, comprising a particle size such that it is released.
[Embodiment 17] The abrasive according to embodiment 1, wherein the abrasive is selected from the group consisting of abrasive cloth and abrasive composites.
[Embodiment 18] The abrasive according to embodiment 1, wherein the anti-glazing agent is dispersed in the binder.
[Embodiment 19] The abrasive according to embodiment 18, wherein the binder comprises a thermoplastic or thermosetting resin.
[Embodiment 20] The abrasive according to embodiment 19, wherein the thermoplastic resin contains latex.
[Embodiment 21] The abrasive according to embodiment 19, wherein the thermosetting resin is selected from the group consisting of urea formaldehyde, phenol, epoxy, urethane, and a radiation curable resin system.
[Embodiment 22] A base material layer having a first surface,
An abrasive comprising a polishing layer having a plurality of abrasive grains disposed on a first surface of a substrate layer, and a layer consisting essentially of an inorganic anti-glare or agent disposed on the polishing layer.
[Embodiment 23] The abrasive of embodiment 22, wherein the anti-glazing agent is selected from the group consisting of metal silicate, silica, metal carbonate, and metal sulfate.
[Embodiment 24] The abrasive according to embodiment 23, wherein the metal silicate is selected from the group consisting of magnesium silicate, potassium aluminum silicate, aluminum silicate, and calcium silicate.
[Embodiment 25] When the anti-particle, that is, the agent particles, polishes the coated surface using abrasive cloth to produce abrasive debris, the anti-particle, that is, the agent particles that bind to these shaving particles and suppress the aggregation thereof. Embodiment 23. The abrasive of embodiment 22 having a particle size such that it is released.
[Embodiment 26] A plurality of abrasive grains are adhered to the first surface of the base material layer, and a layer consisting essentially of an anti-foam or agent on the abrasive grains is deposited, wherein the anti-focal or agent is a metal silicate, A method for forming an abrasive comprising selecting from the group consisting of silica, metal carbonate, and metal sulfate.
Embodiment 27 The method of embodiment 26, wherein the metal silicate is selected from the group consisting of magnesium silicate, potassium aluminum silicate, aluminum silicate, and calcium silicate.
[Embodiment 28] The method of embodiment 27, wherein the magnesium silicate comprises talc.
[Embodiment 29] The method of embodiment 26, further comprising forming an anti-eyes or agent from a material having a Mohs hardness value of less than about 7.
[Embodiment 30] The method of embodiment 26, further comprising the step of forming an anti- eye or agent from a material having an average particle size of less than about 30 micrometers.
[Embodiment 31] The method according to embodiment 26, further comprising the step of forming the abrasive surface of the abrasive so that the anti- eye or agent is primarily thereon.
[Embodiment 32] The method according to embodiment 26, further comprising the step of dispersing an anti-eyes or agent in a binder comprising a thermoplastic or thermosetting resin.

The figure illustrates the contact angle θ given by solids, liquids and gases.

Claims (2)

(A) a base material layer having a first surface;
(B) a polishing layer having a plurality of abrasive grains disposed on the first surface of the substrate layer;
(C) an overcoat layer disposed on the polishing layer;
And (d) a coated abrasive comprising an inorganic anti-glare or agent layer disposed on the overcoat layer,
The inorganic anti-layer or agent layer includes a binder which is a thermoplastic resin or a thermosetting resin , and an inorganic anti-layer or agent selected from the group consisting of metal silicate and metal sulfate (provided that The inorganic layer or agent layer does not include an organic layer or additive selected from the group consisting of metal salts of organic acids, organic phosphates, organic silicates, and organic borates, and The inorganic coating or agent has an average particle size of less than 30 micrometers and a Mohs hardness value of less than 7). Step (a) that form a polishing layer by attaching a plurality of abrasive grains on the first surface of the substrate layer,
(B) attaching an overcoat layer on the polishing layer ;
And (c) an inorganic coating selected from the group consisting of (i) a binder that is a thermoplastic resin or a thermosetting resin , and (ii) a metal silicate and a metal sulfate on the overcoat layer. In other words, an inorganic anti-layer or agent layer containing an agent (provided that the inorganic anti-layer or agent layer is selected from the group consisting of organic acid metal salts, organic phosphates, organic silicates, and organic borates. The selected organic resist or additive is not included, and the inorganic resist or additive has an average particle size of less than 30 micrometers and a Mohs hardness value of less than 7. The method for forming an abrasive | polishing material including the process to make.

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