A thin-film diamond-coated abrasive belt and its manufacturing method

Abstract

This invention provides a thin-film diamond abrasive-coated grinding belt and its manufacturing method. The method involves gravity-coating the abrasive and employing a three-layer adhesive system consisting of a pre-coating layer, a base coat, and a top coat. Specifically, a suitable abrasive box structure is selected, and a screen is added. Diamond abrasive is evenly distributed through a drop box onto a substrate coated with adhesive and moving at a specific angle and speed. A top coat is then applied. This method can meet the production requirements of small-particle diamond abrasive belts. The prepared grinding belt has an outward-pointing abrasive tip with good sharpness, providing high grinding efficiency.

Description

Technical Field

[0001] This invention relates to abrasive materials, specifically to a thin-film diamond-coated abrasive belt and its manufacturing method. Background Technology

[0002] Diamond abrasive belts are made by coating diamond abrasive grains onto a high-strength polyester film. The directional arrangement of the abrasive grains gives the product a sharp cutting force and features fast and efficient grinding. At the same time, the high-strength polyester film has good bending resistance and is suitable for a variety of application environments.

[0003] Diamond abrasive belts are suitable for grinding and polishing hard and brittle materials such as tungsten carbide coatings, stone, glass, ceramics, monocrystalline silicon, polycrystalline silicon, synthetic materials, cemented carbide, and aluminum alloys. With technological advancements, the market demands increasingly higher precision in grinding and polishing superhard materials, leading to a growing need for diamond abrasive belts with a fineness of 60μm or more.

[0004] Current diamond abrasive belts are made by coating a thin-film substrate with a mixture of diamond micropowder, adhesives, and additives. Because the adhesive covers the diamond, a "sharpening" phenomenon occurs during use, meaning the abrasive material only becomes exposed after a period of use, resulting in low grinding efficiency. Simultaneously, the thin-film substrate has low surface energy and is not easily wetted, leading to poor adhesion between the coating and the substrate. This causes the abrasive and adhesive to easily detach during grinding, resulting in a short belt lifespan and poor polishing performance.

[0005] Grinding belts prepared by sand-planting have higher grinding efficiency and are more durable than those prepared by coating. Sand-planting processes are divided into two types: gravity sand-planting and electrostatic sand-planting.

[0006] In existing technologies, an electrostatic sand-coating method is used to coat diamond abrasive particles onto a high-strength polyester film. The directional arrangement of the abrasive particles gives the product a sharp cutting force. For example, CN109866115A discloses a method for manufacturing diamond abrasive material, including the following steps: (1) surface treatment of diamond to obtain treated diamond; (2) coating a base layer on the surface of a substrate; (3) coating the diamond from step (1) onto the surface of the base layer from step (2) using an electrostatic sand-coating method, and then curing it to obtain the diamond abrasive material; in step (1), the diamond is coated with an inorganic adhesive or a metal adhesive. By pre-treating the diamond through a surface-coating resin process, the resulting diamond powder can be effectively agitated in an electrostatic field, making the subsequent electrostatic sand-coating process easier and allowing for better adhesion to the adhesive, resulting in a better grinding effect for the abrasive material.

[0007] In the diamond crystal structure, each carbon atom is sp...3 The hybrid orbitals form covalent bonds with the other three carbon atoms, forming a tetrahedral structure. Since the structure consists of nonpolar covalent bonds, it cannot be polarized. Therefore, the electrostatic sand-planting method is not ideal for production in practice.

[0008] Current diamond grinding belts are made by mixing diamond abrasive with adhesives and additives to form a slurry, which is then coated onto a thin film. This method results in grinding belts with a large amount of adhesive covering the diamond surface, severely impacting the diamond's grinding force and leading to low grinding power and poor grinding efficiency. Conventional gravity-feeding processes are insufficient for producing diamond grinding belts with a median particle size of 60μm or smaller. Conventional gravity-feeding processes are often used with coarse-grained abrasive and are only suitable for products with a particle size of 60μm or smaller. For finer powders (60μm or smaller), uneven abrasive distribution occurs, making it difficult to guarantee product performance. The resulting products often suffer from poor powder dispersion, low adhesion, low grinding force, short lifespan, and poor grinding effect. Summary of the Invention

[0009] The present invention aims to solve at least one of the problems of the prior art.

[0010] This invention provides a thin-film diamond-coated abrasive grinding belt, which offers better grinding effect, longer service life, and significantly improves the durability of the product.

[0011] A thin-film diamond-coated abrasive belt includes: a thin-film substrate, and a pre-coating layer, a base layer, an abrasive layer, and a top layer sequentially attached to the thin-film substrate; the abrasive layer is uniformly attached to the base layer.

[0012] According to an embodiment of the present invention, the abrasive tip portion of the abrasive layer exposes the adhesive layer.

[0013] This invention employs a three-layer adhesive, namely a pre-coating layer, a base layer, and a top layer. The three layers tightly surround the abrasive, thereby further strengthening the bond strength between the abrasive and the substrate, ensuring that the abrasive can withstand the pressure and impact of grinding forces during the grinding process without easily falling off.

[0014] According to embodiments of the present invention, the film substrate is PET (polyethylene terephthalate) film, PBT (polybutylene terephthalate), PVC (polyvinyl chloride) film, PA (nylon) film, and TPU (thermoplastic polyurethane elastomer) film, etc.

[0015] According to embodiments of the present invention, the thickness of the thin film substrate is 25μm-200μm, optionally 50μm-150μm, specifically, for example, 25μm, 50μm, 75μm, 125μm, 150μm and 200μm. According to embodiments of the present invention, the pre-coating layer is a pre-coated adhesive.

[0016] According to embodiments of the present invention, the pre-coating layer comprises an adhesive, a filler, a coupling agent, a curing agent, and a diluent. Optionally, the mass ratio of the adhesive, filler, coupling agent, curing agent, and diluent is 100:(10-18):(1-3):(12-16):(10-20); Optionally, the adhesive comprises a hydroxyl polyurethane resin and a hydroxyl acrylic resin with a molecular weight of 5000-20000, with a mass ratio of (50-70):(50-30); Optionally, the filler is 800-2000 mesh light calcium carbonate; Optionally, the coupling agent is one or more of A1160 (γ-ureapropyltriethoxysilane) and KBE-9007 (3-isocyanate-propyltriethoxysilane coupling agent); Optionally, the curing agent is an isocyanate curing agent; Optionally, the diluent is one or more of toluene, butanone, and ethyl acetate.

[0017] According to an embodiment of the present invention, the pre-coating layer is composed of or made of the adhesive, filler, coupling agent, curing agent and diluent in the above proportions.

[0018] According to an embodiment of the present invention, the thickness of the pre-coating layer is 5-15 μm, for example 10 μm.

[0019] Thin film substrates (such as PET film) have high surface crystallinity and low surface tension, making them difficult to swell and diffuse due to intermolecular forces after coating, resulting in poor adhesion and easy peeling of the prepared abrasive coating. The saturated polyester resin and acrylic resin used in the pre-coating adhesive of this invention have similar molecular structures to PET film, enabling excellent wetting of the PET film. Simultaneously, the coupling agent added chemically bonds the PET film to the pre-coating adhesive, thus ensuring good adhesion between the pre-coating adhesive and the PET film. Studies have found that using this pre-coating adhesive improves the adhesion of the abrasive coating to the PET film substrate, significantly extending the service life of the abrasive belt.

[0020] According to embodiments of the present invention, the base layer is composed of an adhesive, a filler, a leveling agent, a curing agent, and a diluent. Optionally, the mass ratio of the adhesive, filler, leveling agent, curing agent, and diluent is 100:(10-15):(0.5-2):(15-30):(10-50); Optionally, the adhesive is composed of a hydroxyl-saturated polyester resin with a molecular weight of 8000-20000 and a bisphenol A type epoxy resin with an epoxy equivalent of 170-3000, with a mass ratio of (65-80):(20-35); Optionally, the filler is 800-2000 mesh light calcium carbonate; Optionally, the leveling agent is BYK-333 (polyether-modified polydimethylsiloxane) from BYK Chemicals; Optionally, the curing agent is an isocyanate curing agent; Optionally, the diluent is one or more of toluene, methyl ethyl ketone, and ethyl acetate.

[0021] According to an embodiment of the present invention, the base layer is composed of or made of the adhesive, filler, leveling agent, curing agent and diluent in the above proportions.

[0022] According to an embodiment of the present invention, the thickness of the base adhesive layer is 3-20 μm.

[0023] According to an embodiment of the present invention, the viscosity of the base adhesive layer is 300-1000 CPS, for example 300 CPS, 400 CPS, 450 CPS, 500 CPS, 550 CPS, 600 CPS, 650 CPS, 700 CPS, or 1000 CPS.

[0024] Studies have found that using this base adhesive can ensure excellent adhesion to the pre-coating layer, preventing the abrasive from easily falling off during grinding. At the same time, the base adhesive has suitable hardness while ensuring adhesion, ensuring the abrasive is held in place during grinding, resulting in high grinding force.

[0025] According to an embodiment of the present invention, the abrasive in the abrasive layer is one or more of single-crystal diamond, polycrystalline diamond, and polycrystalline diamond-like material; optionally, the median particle size of the abrasive is 9-60 μm.

[0026] According to an embodiment of the present invention, the abrasive tips in the abrasive layer face outwards.

[0027] According to an embodiment of the present invention, the abrasive layer is prepared by gravity sand planting, which exposes the abrasive portion of the coating layer, with the tip facing outwards, resulting in good sharpness and high grinding efficiency.

[0028] According to an embodiment of the present invention, the adhesive layer is a composite adhesive.

[0029] According to embodiments of the present invention, the adhesive layer comprises an adhesive, copper powder, a surface antistatic agent, a toughening agent, a diluent, and a curing accelerator. Optionally, the mass ratio of the adhesive, copper powder, surface antistatic agent, toughening agent, diluent, and curing accelerator is 100:(8-15):(0.5-3):(5-10):(10-50):(0.5-5). Optionally, the adhesive of the adhesive layer is phenolic resin and epoxy resin, with a mass ratio of (40-80):(20-60). Optionally, the particle size of the copper powder is 8-10 μm. Optionally, the surface antistatic agent is a nonionic and polymeric permanent surface antistatic agent; preferably, the surface antistatic agent brand is Basionics LQ01. Optionally, the toughening agent is polybutadiene nano-rubber particles with a core-shell structure; preferably, it is one or more of Kanekachi MX154 core-shell butadiene rubber toughening agent and Dow F100 toughening agent. Optionally, the diluent is one or more of toluene, cyclohexanone, and methyl ethyl ketone. Optionally, the phenolic resin is a solvent-based methyl phenolic resin, and the epoxy resin is one or more of bisphenol A epoxy resin, bisphenol F epoxy resin, and phenolic epoxy resin; preferably, the epoxy resin corresponding to the grade (Ministry of Chemical Industry grade) is one or more of E-51, E-03, E-06, F-51, and F-44. Optionally, the curing accelerator is triphenylphosphine and its derivatives, imidazoles and their derivatives; preferably, the curing accelerator is one or more of triphenylphosphine, 2-methylimidazole, and 2-phenylimidazole.

[0030] According to an embodiment of the present invention, the adhesive layer is composed of or made of the adhesive, copper powder, antistatic agent, toughening agent, diluent and curing accelerator in the above proportions.

[0031] Studies have found that the grinding belt coating prepared using this composite adhesive exhibits high heat resistance, high toughness, good chip removal performance, and long product life. This composite adhesive uses phenolic and epoxy resins as the main adhesive components. The phenolic resin, formed by the condensation reaction of phenols and aldehydes, has high cross-linking density, good heat resistance, and high hardness, ensuring grinding force even at high grinding temperatures. The epoxy resin molecules possess active functional groups such as epoxy groups and polar hydroxyl groups, resulting in high adhesive strength. The epoxy groups in the epoxy resin react with the phenolic hydroxyl groups in the phenolic resin to form a strong and tough cross-linked structure, thereby enhancing the adhesive layer's performance. A core-shell toughening agent is selected, containing a large number of 100nm rubber particles. These particles have good elasticity and are distributed in a micro-uniform island structure within the coating, significantly improving the coating's crack resistance. While increasing the coating's toughness, it does not reduce its heat resistance.

[0032] The study found that the copper powder added to the adhesive layer improved the thermal conductivity of the grinding belt coating. The excellent thermal conductivity prevented the coating from peeling off due to excessive temperature during the grinding process, thus improving its service life.

[0033] Studies have found that the antistatic agent and copper powder added to the modified adhesive have a synergistic effect, which effectively improves the antistatic effect of the coating. The grinding belt prepared using this adhesive is more easily carried away by the grinding fluid and is less likely to be adsorbed on the surface of the grinding coating, thereby improving the service life of the grinding belt.

[0034] The grinding belt prepared by the composite coating of the present invention has good heat resistance, good surface thermal conductivity, easy grinding discharge, high grinding force, long service life and not easy to fall off.

[0035] Compared with coated products, the gravity-planting sand product of this invention uses three layers of adhesive, namely a pre-coating layer, a base layer, and a top layer, to strengthen the adhesive layer's fixing effect on the abrasive. The adhesive layer's holding force on the abrasive has a significant advantage over the single-layer adhesive of coated products.

[0036] The grinding belt prepared by this invention features a diamond abrasive with an exposed adhesive layer, excellent sharpness, and a pre-coating layer that bridges the adhesive, abrasive, and thin film substrate, resulting in superior grinding performance, long service life, and high strength. This invention employs gravity-fed abrasive application, allowing the abrasive tip to expose the adhesive layer, resulting in excellent sharpness and high grinding efficiency.

[0037] The thin-film diamond-coated abrasive belt provided by this invention employs a three-layer adhesive: a pre-coating layer, a base layer, and a top layer. These three layers tightly surround the abrasive, further strengthening the bond between the abrasive and the substrate. This ensures the abrasive can withstand the pressure and impact of grinding forces during the grinding process without easily detaching. Therefore, this type of belt offers superior grinding performance, a longer service life, and significantly improved product durability. It reduces the need for frequent belt replacements, increases production efficiency, and lowers production costs for users.

[0038] The present invention also provides a method for manufacturing the above-mentioned thin-film-coated diamond-coated abrasive belt, which can avoid defects such as abrasive shedding, adhesive shedding, and low grinding force during the use of the abrasive belt, thereby improving the grinding performance, adhesion, grinding effect and service life of the abrasive belt.

[0039] A method for manufacturing a thin-film diamond-coated abrasive belt includes:

[0040] 1) Provide a corona-treated thin film substrate, and roll-coat a pre-coating layer on the thin film substrate;

[0041] 2) Roll-coating an adhesive layer onto the thin film substrate;

[0042] 3) An abrasive layer is formed by attaching the abrasive to the base adhesive layer using a gravity-based sand-planting method;

[0043] 4) Roller-coating the abrasive layer onto the abrasive layer.

[0044] In the above manufacturing method,

[0045] Step 1) The method for corona treatment of the thin film substrate in the following embodiments is as follows: the discharge voltage for corona treatment is 5000-15000V / m 2 The voltage frequency of the corona treatment is 15kHz-25kHz.

[0046] Step 1) After applying the pre-coating by roller, dry for 5-60 minutes at a temperature of 60-120℃.

[0047] Step 2) After roller coating the base coat, dry for 5-60 minutes at a temperature of 60-120℃.

[0048] Step 3) is achieved through gravity-feeding, where the abrasive is evenly distributed onto a substrate coated with adhesive via a drop box, and then a layer of adhesive is applied. This method produces grinding belts with the abrasive tip facing outwards; they have good sharpness, no "sharpening" phenomenon, and provide high grinding efficiency.

[0049] Step 3) Control the thickness of the base adhesive layer to be 3-20μm, the viscosity to be 300-1000CPS; the distance between the sand drop box and the substrate (i.e., the sand drop height) to be 10-45cm, the angle between the sand drop direction and the substrate running direction to be 50-80 degrees, and the substrate running speed to be 5-10m / min.

[0050] Optionally, in step 3) the gravity sand planting process, the screen mesh size is 40-200 mesh and the vibration frequency is 30-80Hz.

[0051] Research has found that by controlling these conditions, it is possible to ensure that the abrasive tip points outward and that the abrasive is applied evenly.

[0052] Step 3) After sanding, dry for 5-60 minutes at a temperature of 60-120℃.

[0053] In this article, the term "substrate" refers to a thin film substrate (e.g., PET film).

[0054] Step 3) Gravity sand planting is performed using a vibrating sand box for gravity sand planting as described below.

[0055] Step 4) After roller coating the adhesive layer, dry for 5-60 minutes at a temperature of 60-120℃.

[0056] Optionally, the above method also includes step 5), which involves placing the product in a curing oven at 60-100°C for 24-72 hours to cure it.

[0057] The present invention also includes a thin-film diamond-coated abrasive belt prepared by the above method.

[0058] The grinding belt prepared by the method of the present invention has excellent grinding performance, long service life and high strength.

[0059] The manufacturing method of the thin-film diamond gravity-loaded abrasive grinding belt provided by this invention solves the problems of poor dispersion of small-particle micro-powder and weak adhesion of micro-powder to the thin-film substrate in gravity-loaded abrasive manufacturing, as well as the defects of low grinding force and poor lifespan in the grinding belt. This grinding belt has a good lifespan and excellent grinding effect. Attached Figure Description

[0060] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0061] Figure 1 This is a schematic diagram of the cross-section of the thin-film diamond gravity abrasive belt according to an embodiment of the present invention; wherein, 1 is the thin-film substrate, 2 is the pre-coating layer, 3 is the base layer, 4 is the top layer, and 5 is the abrasive layer.

[0062] Figure 2 This is a schematic diagram of the existing roller-type sand box structure; where 1 is the sand box, 2 is the heating jacket, 3 is the sand drop roller, and 4 is the sand cutter.

[0063] Figure 3 This is a schematic diagram of the vibrating sand box structure according to an embodiment of the present invention; wherein, 1 is the sand box lifter, 2 is the upper sand cutter, 3 is the lower sand cutter, 4 is the high-frequency vibrator, 5 is the connecting block, 6 is the controller, and 7 is the screen.

[0064] Figure 4 This is a schematic diagram of the grinding belt manufacturing system and gravity sand planting according to an embodiment of the present invention; wherein, 1 is the sand box lifter, 2 is the upper sanding blade, 3 is the lower sanding blade, 4 is the high-frequency vibrator, 5 is the connecting block, 6 is the controller, 7 is the screen, 8 is the substrate, α is the sand planting angle, and v is the substrate running speed. Detailed Implementation

[0065] The following examples are for illustrative purposes only and are not intended to limit the scope of the invention. Where specific techniques or conditions are not specified in the examples, they should be performed according to the techniques or conditions described in the literature in this field, or according to the product instructions. Reagents or instruments whose manufacturers are not specified are all conventional products that can be purchased from legitimate channels.

[0066] The following embodiment describes a method for corona treatment of PET film: the discharge voltage is 10000V / m. 2 The voltage frequency of the corona treatment is 20 kHz.

[0067] like Figure 1 As shown, this embodiment provides a thin-film diamond-coated abrasive belt, comprising: a thin-film substrate 1, and a pre-coating layer 2, a base layer 3, an abrasive layer 5, and a top layer 4 sequentially attached to the thin-film substrate; the abrasive layer 5 is uniformly attached to the base layer 3. In some embodiments, the top layer 4 protrudes from the abrasive tip portion of the abrasive layer 5.

[0068] Gravity sand planting and sand planting process

[0069] The sand box used in conventional gravity sand planting methods, such as Figure 2 As shown, the abrasive is dispersed once in the abrasive box and falls freely from a certain height. Due to gravity, it inserts into the adhesive layer, forming a sand layer (abrasive layer). For abrasives with large particle size, the abrasive is easy to disperse and has a large gravity, which can form a relatively uniform coating. However, for abrasives with small particle size, the abrasive is not easy to disperse and other methods are needed to increase the uniformity of abrasive dispersion.

[0070] 1) The function of the sandbox

[0071] Conventional gravity sand planting uses, for example Figure 2 The roller-type abrasive discharge device shown includes an abrasive box 1 and a heating jacket 2. The abrasive is evenly dispersed by the gap between the abrasive blade 4 and the abrasive discharge roller 3. The structure is reliable for coarse-grained micro powders. However, for micro powders with a fine particle size of 60μm or less, due to their large specific surface area, strong adhesion between micro powder particles, and strong hygroscopicity, they often exist in the form of particle clusters. Therefore, they are easy to adhere to the abrasive discharge roller, resulting in uneven abrasive dispersion, which cannot meet production requirements.

[0072] like Figure 3 As shown, an embodiment of the present invention provides a vibrating sand box for gravity sand planting, comprising: a sand box lifter 1; an upper sand cutter 2; a lower sand cutter 3; a controller 6 for controlling the sand drop gap between the upper sand cutter 2 and the lower sand cutter 3; a high-frequency vibrator 4 connected to the lower sand cutter 3; a connecting block 5 connected to the high-frequency vibrator 4; and a screen 7 connected to the high-frequency vibrator 4.

[0073] The controller 6 controls the sand drop gap through the linear structure formed by the upper sand cutter 2 and the lower sand cutter 3. The lower sand cutter 3 is connected to the high-frequency vibrator 4. The sand is first dispersed by the vibration and then falls through the gap between the two sand cutters. A screen 7 connected to the high-frequency vibrator 4 is also installed below the lower sand cutter 3. This allows the sand to be further dispersed by the vibrating screen 7 during its fall, ensuring uniform sand drop. Different screen mesh sizes and vibration frequencies can be selected for different particle sizes, thus meeting the production requirements of sand down to P2000.

[0074] Optionally, the mesh size of the sieve is 40-200 mesh.

[0075] In the manufacturing method of the thin-film diamond-coated abrasive belt of the present invention, gravity abrasive is applied using a vibrating sand box as described above. A pre-coating layer is applied to the surface of the thin-film substrate, followed by a base coat. The abrasive is then adhered to the base coat using gravity abrasive application, and finally, a top coat is applied and cured to obtain the product. The diamond abrasive protrudes from the adhesive layer, exhibiting good sharpness. The pre-coating layer, in a bridging manner, firmly bonds the adhesive, abrasive, and thin-film substrate together, thereby improving the grinding effect and service life of the abrasive belt and preventing defects such as abrasive or adhesive detachment during use.

[0076] like Figure 4 As shown, the present invention also provides a thin-film diamond-coated abrasive grinding belt manufacturing system, including a vibrating sand box for gravity abrasive planting (see above for details). Figure 3 ).

[0077] Optionally, the thin-film diamond-coated abrasive belt manufacturing system further includes a conveying device for conveying the substrate 8.

[0078] Optionally, the thin-film diamond-coated abrasive belt manufacturing system further includes a roller coating device for roller coating a pre-coating layer, a base coat, and a top coat.

[0079] Optionally, the thin-film diamond-coated abrasive belt manufacturing system further includes a curing oven for heating and curing the thin-film diamond-coated abrasive belt.

[0080] Optionally, in the thin-film-based diamond sand-planting grinding belt manufacturing system, the distance between the gravity sand-planting vibrating sand box in the vibrating sand box and the belt base in the conveying device is 10-45cm.

[0081] Optionally, the angle between the sand falling direction and the substrate running direction of the thin-film diamond sand-coated abrasive belt manufacturing system is 50-80 degrees; optionally, the substrate running speed is 5-10m / min.

[0082] 2) The impact of sand-planting process on the quality of grinding belts

[0083] Gravity-based abrasive implantation relies solely on the gravity of the abrasive to embed micro-powder into the base layer. Generally, increasing the drop height allows the abrasive to penetrate the base layer with greater impact force, resulting in better bonding between the abrasive and the base layer. However, for fine-grained micro-powder, due to its small weight, air resistance has a significant impact. Simply increasing the drop height causes the micro-powder to float in the air, leading to uneven distribution of the abrasive on the base layer.

[0084] Gravity-based sand planting cannot guarantee that all abrasive particles will be inserted vertically into the adhesive layer. Some abrasive particles will be in a collapsed state. If the base adhesive is too thin, most of the abrasive particles will be exposed through the adhesive layer, increasing the cutting force of the grinding belt. The adhesive layer will not hold the abrasive particles well enough, reducing the service life of the grinding belt. If the base adhesive is too thick, most of the abrasive particles will be buried in the adhesive layer, reducing the cutting efficiency of the prepared grinding belt.

[0085] Furthermore, if the abrasive drop direction is perpendicular to the substrate, after the abrasive penetrates the adhesive layer at one end, it will tilt in the opposite direction of the substrate's movement due to inertia, thus reducing the sharpness of the grinding belt. Therefore, the abrasive drop direction needs to maintain a certain angle with the substrate's movement direction, and the substrate needs to maintain a certain speed to neutralize the negative impact of abrasive inertia, ensuring that the abrasive tip remains pointing outward and guaranteeing the sharpness of the grinding belt. The abrasive drop angle α and the substrate's running speed v are discussed in [the relevant section]. Figure 4 .

[0086] This invention utilizes a gravity-feeding method, employing a vibrating sand box for gravity-feeding. Diamond abrasive is evenly distributed through a screen onto a substrate coated with adhesive and moving at a specific angle and speed, followed by a final coating of adhesive. This method enables the production of small-particle diamond grinding belts. The resulting grinding belts have outward-pointing abrasive tips with high sharpness, providing high grinding efficiency.

[0087] Because PET film substrate is a non-polar material with poor wettability, and the film-based abrasive belt only has a thin layer of adhesive, the bonding force is weak, easily leading to abrasive detachment. This invention introduces a three-layer adhesive: a pre-coating layer, a base coat, and a top coat, to strengthen the adhesive layer's holding power over the abrasive (see...). Figure 1 The pre-coating layer acts as a bridge between the film substrate and the primer layer, providing excellent adhesion to both the film substrate and the primer. The primer helps to fix the abrasive. The top coat enhances the holding force of the abrasive belt on the diamond abrasive, making it less likely to fall off during grinding under stress.

[0088] The following embodiments may employ, for example Figure 4 The thin-film diamond-coated abrasive belt manufacturing system shown manufactures thin-film diamond-coated abrasive belts.

[0089] Example 1

[0090] 1. The substrate layer of the abrasive belt provided in this embodiment is a corona-treated PET film; the median particle size of the diamond powder used is 40 μm;

[0091] The pre-coating is mainly composed of the following components in parts by weight: 60 kg of Evonik's L912 resin (saturated polyester resin with a molecular weight of 15,000); 40 kg of KEDING Materials' MR1777 (hydroxyl acrylic resin); 15 kg of 2000-mesh light calcium carbonate; 2 kg of A-1160 coupling agent; 15 kg of L75 (isocyanate curing agent); 10 kg of toluene; and 5 kg of methyl ethyl ketone.

[0092] The base coat is mainly composed of the following components in parts by weight: 70 kg of L912 resin, 30 kg of Dow DER676E (bisphenol A epoxy resin with an epoxy equivalent of 1600-1950), 12 kg of 1200 mesh calcium carbonate, 1 kg of BYK333 leveling agent, 10 kg of methyl ethyl ketone (MEK), 10 kg of ethyl acetate, and 20 kg of L75 curing agent.

[0093] The adhesive layer is mainly composed of the following components in parts by weight: PR56146 (Sumitomo Chemical solvent-based methyl phenolic resin) 60kg, F51 epoxy resin 40kg, copper powder 12kg; Basionics LQ01 antistatic agent 1kg, MX154 toughening agent 8kg, methyl ethyl ketone 15kg, cyclohexanone 15kg, and triphenylphosphine curing accelerator 3kg.

[0094] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0095] (1) After mixing all the raw materials for the preparation of the pre-coating evenly, the pre-coating is coated onto the surface of the corona-treated PET film by roller. The thickness of the pre-coating is 10 μm. Then, it is dried at 80°C for 20 min to obtain a composite layer material with a pre-coating and a substrate layer.

[0096] (2) After all the raw materials for preparing the base coat are mixed evenly, the viscosity of the base coat is adjusted to 700 cps, and it is coated onto the surface of the pre-coated layer by a roller, with a base coat thickness of 12 μm; then the abrasive is attached to the mixed raw materials for preparing the base coat by gravity sand planting. The gravity sand planting process is as follows: the frequency of the vibrating screen is 50 Hz, the mesh size of the screen is 80#, the sand drop height is 20 cm, the sand planting angle is 70°, and the base speed is 8 m / min. Then it is dried at 80℃ for 30 min.

[0097] (3) After all the raw materials for the preparation of the coating layer are mixed evenly, they are coated onto the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 48 h to obtain the grinding belt.

[0098] Example 2

[0099] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0100] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0101] (1) The pre-coating manufacturing method in this embodiment is the same as that in embodiment 1.

[0102] (2) After all the raw materials for preparing the primer layer are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The primer thickness, primer viscosity, vibration frequency, sand-planting angle, sand-dropping height, and substrate-carrying speed used in this embodiment are the same as in Example 1. A 60-mesh sieve is used. Then, it is dried at 80°C for 30 minutes.

[0103] (3) After all the raw materials for the preparation of the coating layer are mixed evenly, they are coated onto the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 48 h to obtain the grinding belt.

[0104] Example 3

[0105] The raw materials and proportions used in this embodiment, such as the thin film substrate, micro powder, pre-coated adhesive, primer, and top coat, are the same as those in Example 1.

[0106] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0107] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0108] (2) After all the raw materials for preparing the primer layer are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The primer thickness, primer viscosity, vibration frequency, sand-planting angle, sand-dropping height, and substrate-carrying speed used in this embodiment are the same as in Example 1. A 200-mesh sieve is used. Then, it is dried at 60°C for 60 minutes.

[0109] (4) After mixing all the raw materials for the preparation of the coating layer evenly, the coating is applied to the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 48 h to obtain the grinding belt.

[0110] Example 4

[0111] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0112] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0113] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0114] (2) After all the raw materials for preparing the primer layer are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The primer thickness, primer viscosity, vibration frequency, sand-planting angle, sieve mesh number, and substrate speed used in this embodiment are the same as in Example 1. The sand drop height used is 10 cm. Then, it is dried at 60°C for 60 min.

[0115] (4) After mixing all the raw materials for the preparation of the coating layer evenly, the coating is applied to the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 72 h to obtain the grinding belt.

[0116] Example 5

[0117] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0118] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0119] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0120] (2) After all the raw materials for preparing the primer layer are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The primer thickness, primer viscosity, vibration frequency, sand-planting angle, sieve mesh number, and substrate speed used in this embodiment are the same as in Example 1. The sand drop height used is 45cm. Then, it is dried at 60℃ for 60min.

[0121] (4) After mixing all the raw materials for the preparation of the coating layer evenly, the coating is applied to the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 72 h to obtain the grinding belt.

[0122] Example 6

[0123] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0124] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0125] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0126] (2) After all the raw materials for preparing the primer layer are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The primer viscosity, drop height, vibration frequency, sand placement angle, sieve mesh number, and substrate speed used in this embodiment are the same as in Example 1. The primer thickness is 3 μm. Then, it is dried at 60°C for 60 min.

[0127] (4) After mixing all the raw materials for the preparation of the coating layer evenly, the coating is applied to the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 72 h to obtain the grinding belt.

[0128] Example 7

[0129] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0130] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0131] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0132] (2) After all the raw materials for preparing the primer layer are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The primer viscosity, drop height, vibration frequency, sand placement angle, sieve mesh count, and substrate speed used in this embodiment are the same as in Example 1. The primer thickness is 20 μm. Then, it is dried at 60°C for 60 min.

[0133] (4) After mixing all the raw materials for the preparation of the coating layer evenly, the coating is applied to the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 72 h to obtain the grinding belt.

[0134] Example 8

[0135] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0136] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0137] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0138] (3) After all the raw materials for preparing the primer layer are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The primer thickness, primer viscosity, sieve mesh number, sand drop height, sand planting angle, and substrate speed used in this embodiment are the same as in Example 1. The vibration frequency used is 80Hz. Then, it is dried at 80℃ for 30min.

[0139] (4) After mixing all the raw materials for the preparation of the coating layer evenly, the coating is applied to the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 48 h to obtain the grinding belt.

[0140] Example 9

[0141] The raw materials used in this embodiment, such as the thin film substrate, micro powder, pre-coated adhesive, primer, and coating adhesive, are the same as those in Example 1.

[0142] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0143] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0144] (3) After all the raw materials for preparing the primer layer are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The primer thickness, primer viscosity, sieve mesh number, sand drop height, sand planting angle, and substrate speed used in this embodiment are the same as in Example 1. The vibration frequency used is 30Hz. Then, it is dried at 80℃ for 30min.

[0145] (4) After mixing all the raw materials for the preparation of the coating layer evenly, the coating is applied to the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 48 h to obtain the grinding belt.

[0146] Example 10

[0147] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0148] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0149] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0150] (3) After all the raw materials for preparing the base coat are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The substrate speed, sieve mesh size, drop height, base coat thickness, base coat viscosity, and vibration frequency used in this embodiment are the same as in Example 1. The drop angle used is 50°. Then, it is dried at 80°C for 30 minutes.

[0151] (4) After mixing all the raw materials for the preparation of the coating layer evenly, the coating is applied to the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 48 h to obtain the grinding belt.

[0152] Example 11

[0153] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0154] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0155] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0156] (3) After all the raw materials for preparing the base coat are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The substrate speed, sieve mesh size, drop height, base coat viscosity, base coat thickness, and vibration frequency used in this embodiment are the same as in Example 1. The drop angle used is 80°. Then, it is dried at 80°C for 30 minutes.

[0157] (4) After mixing all the raw materials for the preparation of the coating layer evenly, the coating is applied to the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 48 h to obtain the grinding belt.

[0158] Example 12

[0159] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0160] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0161] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0162] (2) After all the raw materials for preparing the base coat are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The base coat thickness, viscosity, vibration frequency, sand-planting angle, sieve mesh count, and sand drop height used in this embodiment are the same as in Example 1. The belt speed used is 5 m / min. Then, it is dried at 60°C for 60 min.

[0163] (4) After mixing all the raw materials for the preparation of the coating layer evenly, the coating is applied to the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 72 h to obtain the grinding belt.

[0164] Example 13

[0165] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0166] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0167] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0168] (2) After all the raw materials for preparing the base coat are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The base coat thickness, viscosity, vibration frequency, sand-planting angle, sieve mesh count, and sand drop height used in this embodiment are the same as in Example 1. The belt speed used is 10 m / min. Then, it is dried at 60°C for 60 min.

[0169] (4) After mixing all the raw materials for the preparation of the coating layer evenly, the coating is applied to the surface of the micro powder by roller, then dried at 100°C for 40 min, and then placed in a curing oven at 100°C for 72 h to obtain the grinding belt.

[0170] Example 14

[0171] The raw materials and proportions of the film substrate, pre-coated adhesive, primer, and top-coating used in this embodiment are the same as those in Example 1.

[0172] The parameters in the manufacturing method of the grinding belt provided in this embodiment are the same as those in Embodiment 1.

[0173] The median particle size of the diamond powder used in this embodiment is 9 μm.

[0174] Example 15

[0175] The raw materials and proportions of the film substrate, pre-coated adhesive, primer, and top-coating used in this embodiment are the same as those in Example 1.

[0176] The parameters in the manufacturing method of the grinding belt provided in this embodiment are the same as those in Embodiment 1.

[0177] The median particle size of the diamond powder used in this embodiment is 60 μm.

[0178] Example 16

[0179] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0180] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0181] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0182] (2) After all the raw materials for preparing the primer layer are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The primer thickness, belt speed, vibration frequency, sand-planting angle, sieve mesh count, and sand drop height used in this embodiment are the same as in Example 1. The viscosity of the primer used is 300 cps. Then, it is dried at 60°C for 60 min.

[0183] (4) The preparation method of the adhesive layer in this embodiment is the same as that in Example 1.

[0184] Example 17

[0185] The raw materials and proportions of the thin film substrate, micro powder, pre-coated adhesive, primer and coating adhesive used in this embodiment are the same as those in Example 1.

[0186] The method for manufacturing the grinding belt provided in this embodiment includes the following steps:

[0187] (1) The pre-coated adhesive manufacturing method in this embodiment is the same as that in embodiment 1.

[0188] (2) After all the raw materials for preparing the primer layer are mixed evenly, they are coated onto the surface of the pre-coated layer using a roller. The primer thickness, belt speed, vibration frequency, sand-planting angle, sieve mesh number, and sand drop height used in this embodiment are the same as in Example 1. The viscosity of the primer used is 1000 cps. Then, it is dried at 60°C for 60 min.

[0189] (4) The preparation method of the adhesive layer in this embodiment is the same as that in Example 1.

[0190] Example 18

[0191] The raw materials and proportions of the thin film substrate, micro powder, and pre-coated adhesive used in this embodiment are the same as those in Example 1.

[0192] In this embodiment, the base layer is mainly composed of the following components in parts by weight: 80 kg of L912 resin, 20 kg of Dow DER676E epoxy resin, 10 kg of 800 mesh calcium carbonate, 0.5 kg of BYK333, 10 kg of methyl ethyl ketone (MEK), and 10 kg of L75 curing agent.

[0193] The adhesive layer is mainly composed of the following components in parts by weight: 80 kg of PR56146 phenolic resin; 20 kg of F51 epoxy resin; 8 kg of copper powder; 0.5 kg of Basionics LQ 01 antistatic agent; 5 kg of MX154 toughening agent; 10 kg of methyl ethyl ketone; and 0.5 kg of triphenylphosphine.

[0194] The method for preparing the abrasive belt in this embodiment is the same as in Embodiment 1.

[0195] Example 19

[0196] The raw materials and proportions of the thin film substrate, micro powder, and pre-coated adhesive used in this embodiment are the same as those in Example 1.

[0197] In this embodiment, the base layer is mainly composed of the following components in parts by weight: 65 kg of L912 resin, 35 kg of Dow DER676E epoxy resin, 15 kg of 1200 mesh calcium carbonate, 2 kg of BYK333 leveling agent, 50 kg of methyl ethyl ketone (MEK), and 30 kg of L75 curing agent.

[0198] The adhesive layer is mainly composed of the following components in parts by weight: 40 kg of PR56146 phenolic resin; 60 kg of F51 epoxy resin; 15 kg of copper powder; 3 kg of Basionics LQ01 antistatic agent; 10 kg of MX154 toughening agent; 50 kg of methyl ethyl ketone; and 5 kg of triphenylphosphine.

[0199] The method for preparing the abrasive belt in this embodiment is the same as in Embodiment 1.

[0200] Comparative Example 1

[0201] The diamond abrasive belt prepared by the conventional three-roll coating method uses the same diamond powder as in Example 1.

[0202] Comparative Example 2

[0203] The raw materials used in this comparative example, including the film substrate, micro powder, pre-coated adhesive, primer, and coating adhesive, are the same as those in Example 1. The drying temperature, curing temperature, drying time, and curing time in each step of this comparative example are also the same as those in Example 1. The sieve used in the sand-planting process of this comparative example is 30 mesh, the sand drop height is 7 cm, the primer thickness is 2 μm, the vibration frequency is 20 Hz, the sand-planting angle is 40°, the substrate speed is 3 m / min, and the primer viscosity is 700 cps.

[0204] Comparative Example 3

[0205] The raw materials used in this comparative example, including the film substrate, micro powder, pre-coated adhesive, primer, and coating adhesive, are the same as those in Example 1. The drying temperature, curing temperature, drying time, and curing time in each step of this comparative example are the same as those in Example 1. The sieve used in the sand-planting process of this comparative example is 250 mesh, the sand drop height is 50 cm, the primer thickness is 50 μm, the vibration frequency is 90 Hz, the sand-planting angle is 85°, the substrate speed is 15 m / min, and the primer viscosity is 700 cps.

[0206] Comparative Example 4

[0207] The raw materials used in this comparative example, such as film substrate, micro powder, pre-coated adhesive, primer, and coating adhesive, are the same as those in Example 1. The drying temperature, curing temperature, drying time, and curing time in each step of this comparative example are the same as those in Example 1. The sieve mesh number, sand drop height, primer thickness, vibration frequency, sand planting angle, and substrate speed used in the sand planting process of this comparative example are the same as those in Example 1. The primer viscosity is 100 cps.

[0208] Comparative Example 5

[0209] The raw materials used in this comparative example, such as the thin film substrate, micro powder, pre-coated adhesive, and re-coating adhesive, are the same as those in Example 1.

[0210] The base coat in this embodiment is mainly prepared by the following components in parts by weight: 50 kg of L912 resin, 50 kg of DER676E epoxy resin, 18 kg of 1200 mesh calcium carbonate, 2.5 kg of BYK333 leveling agent, 45 kg of methyl ethyl ketone, 10 kg of ethyl acetate, and 35 kg of L75 curing agent.

[0211] The method for preparing the grinding belt in this embodiment is the same as in Embodiment 1.

[0212] Comparative Example 6

[0213] The raw materials used in this comparative example, such as the thin film substrate, micro powder, pre-coated adhesive, and primer, are the same as those in Example 1.

[0214] In this embodiment, the adhesive layer is mainly composed of the following components in parts by weight: 60 kg of PR56146 phenolic resin, 40 kg of F51 epoxy resin, 8 kg of MX154 toughening agent, 15 kg of methyl ethyl ketone, 15 kg of cyclohexanone, and 0.5 kg of triphenylphosphine.

[0215] The method for preparing the grinding belt in this embodiment is the same as in Embodiment 1.

[0216] Comparative Example 7

[0217] The raw materials used in this comparative example, such as the thin film substrate, micro powder, pre-coated adhesive, and primer, are the same as those in Example 1.

[0218] The adhesive layer in this embodiment is mainly composed of the following components in parts by weight: 60 kg of PR56146 phenolic resin, 40 kg of F51 epoxy resin, 5 kg of copper powder, 1 kg of Basionics LQ01 antistatic agent, 8 kg of MX154 toughening agent, 15 kg of methyl ethyl ketone, 15 kg of cyclohexanone, and 0.5 kg of triphenylphosphine.

[0219] The method for preparing the grinding belt in this embodiment is the same as in Embodiment 1.

[0220] Comparative Example 8

[0221] The raw materials used in this comparative example, such as the thin film substrate, micro powder, pre-coated adhesive, and primer, are the same as those in Example 1.

[0222] The adhesive layer in this embodiment is mainly composed of the following components in parts by weight: 60 kg of PR56146 phenolic resin, 40 kg of F51 epoxy resin, 12 kg of copper powder, 1 kg of Basionics LQ01 antistatic agent, 2 kg of MX154 toughening agent, 15 kg of methyl ethyl ketone, 15 kg of cyclohexanone, and 0.5 kg of triphenylphosphine.

[0223] The method for preparing the grinding belt in this embodiment is the same as in Embodiment 1.

[0224] Experimental Example 1

[0225] (1) Adhesion test method:

[0226] The abrasive belts prepared in Examples 1-19 and Comparative Examples 1-8 are cut into... The circular grinding disc was used in a polishing machine manufactured by Shenzhen Rongbang, and a grinding experiment was conducted under the conditions shown in the following steps:

[0227] ① Attach the cut circular abrasive disc containing abrasive to the abrasive block using double-sided tape to ensure a smooth contact surface.

[0228] ② Place the smooth stainless steel plate on the grinding machine to ensure that the stainless steel plate surface is of uniform height.

[0229] ③ Place the grinding block on the grinder and evenly drip a small amount of deionized water onto the grinding surface.

[0230] ④ Set the pressure to 500g, the rotation speed to 180rpm, and the grinding time to 1min. Press the switch to start grinding.

[0231] ⑤ When the time is up, remove the metal grinding block, clean it with deionized water, and observe the surface of the grinding disc for any damage. If there is damage, stop the test; otherwise, repeat steps ③-⑤ until damage appears on the surface of the grinding disc. The product lifespan is compared with the time it takes for the grinding disc to become damaged. The test results are shown in Table 1.

[0232] (2) Cutting force testing method:

[0233] The abrasive belts prepared in Examples 1-15 and Comparative Examples 1-3 are cut into... The circular grinding disc was used in a polishing machine manufactured by Shenzhen Rongbang, and a grinding experiment was conducted under the conditions shown in the following steps:

[0234] ① Attach the cut circular abrasive disc containing abrasive material to the rubber pad of the grinder using double-sided tape, with the abrasive side facing upwards. ② Take the ceramic rod used for the test, weigh it using a balance, and record its mass as m1.

[0235] ③ Fix the ceramic rod on the fixture that comes with the grinding machine, ensuring that the ceramic rod protrudes a certain height below the fixture.

[0236] ④ Place the ceramic rod, which is fixed with a clamp, on the grinding machine, ensuring that the exposed part of the ceramic rod is in contact with the grinding surface of the grinding disc, and evenly drip a small amount of deionized water onto the grinding surface.

[0237] ⑤ Set the pressure to 500g, the rotation speed to 180rpm, and the grinding time to 16min. Press the switch to start grinding.

[0238] ⑥ When the time is up, remove the ceramic rod, clean it with deionized water, dry it with a hair dryer, and measure the mass of the ceramic rod, recording it as m2. Use the amount of m1-m2 to evaluate the grinding effect of the abrasive belt. The test results are shown in Table 1.

[0239] Table 1 Grinding Experiment Results

[0240]

[0241]

[0242] Experimental Example 2

[0243] The adhesive used in Example 1 and the adhesive used in Comparative Example 1 were used to prepare adhesive blocks. The heat resistance properties were tested according to the GB / T 1633B50 method. The test results are shown in Table 2.

[0244] Table 2. Vicat Heat Resistance Temperature Test Results

[0245] Composite Glue Formulation Vicat heat resistance temperature / °C Example 1 80 Comparative Example 1 220

[0246] (3) Under the above experimental conditions, evaluate the performance of the comparative examples and comparative embodiments, and write about the technical problem to be solved and the beneficial effects. If necessary, specify the evaluation methods or means.

[0247] A comparison of the grinding experiment results of Comparative Example 1 and the various embodiments shows that the diamond abrasive belt prepared by gravity-loaded abrasive has better performance because the multi-layered adhesive firmly holds the diamond abrasive to the substrate, preventing it from easily falling off during grinding. This allows the prepared abrasive belt to withstand longer grinding times with fewer breakages. In contrast, the abrasive in the abrasive belt prepared in the embodiments protrudes from the adhesive layer surface, resulting in a significantly higher grinding depth than that of Comparative Example 1.

[0248] Comparing the data from Example 1 and Comparative Example 2, it can be seen that Comparative Example 2 has a lower drop height, a thinner base coat, and the abrasive cannot firmly penetrate the base coat. This results in a shorter grinding time and more breakage points. Furthermore, the angle during abrasive application is too small, the substrate speed is slow, the micro-powder density increases, and the abrasive tumbles, causing most of the tip to protrude from the base coat, resulting in lower grinding force.

[0249] By comparing Example 1 and Comparative Example 3, it can be seen that the drop height of the sand in Comparative Example 3 is too high, the thickness of the base adhesive is too thick, and too much sand is embedded in the adhesive layer. Although the wear resistance of the grinding belt is increased, the grinding force is lower and it has no use value.

[0250] By comparing Example 1 and Comparative Example 4, it can be seen that the abrasive belt prepared with a base adhesive has low grinding force due to its low viscosity. This is because the viscosity of the base adhesive used in Example 4 is too low. In order to adjust it to the required viscosity, a solvent is added to the prepared base adhesive during production. This results in a thicker wet film of the base adhesive during coating and abrasive application compared to Example 1, and also higher fluidity. Consequently, more abrasive is covered by the adhesive layer, reducing the grinding force.

[0251] Comparing Example 1 and Comparative Example 5, it can be seen that the epoxy resin ratio in Comparative Example 5 is too high, the primer layer is too brittle, resulting in reduced coating adhesion.

[0252] By comparing Example 1 and Comparative Example 6, it can be seen that under the same conditions, the grinding belt coating prepared by the adhesive layer has poor thermal conductivity, poor chip removal ability, and low grinding force because no copper powder and antistatic agent are added. However, it has little effect on adhesion.

[0253] By comparing Example 1 and Comparative Example 7, it can be seen that under the same conditions, due to the insufficient amount of copper powder added to the adhesive layer, no thermal conductive path was formed in the coating; at the same time, the small amount of copper powder did not form an antistatic synergistic effect with the antistatic agent, and the prepared grinding belt showed little impact on adhesion and low grinding force.

[0254] By comparing Example 1 and Comparative Example 8, it can be seen that under the same conditions, due to the small amount of toughening agent added to the adhesive layer, the adhesive layer is brittle and the coating is prone to large-area peeling during the grinding process. The adhesion and grinding force are not as good as those in Example 1.

[0255] As shown in Table 2, the Vicat heat resistance temperature test results indicate that the composite adhesive used in this grinding belt has higher heat resistance, which can meet most oil-cooled and dry grinding application scenarios.

[0256] Although the present invention has been described in detail above with general descriptions and specific embodiments, modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, all such modifications or improvements made without departing from the spirit of the present invention are within the scope of protection claimed by the present invention.

Claims

1. A thin-film diamond-coated abrasive belt, characterized in that, include: A thin film substrate, and a pre-coating layer, a primer layer, an abrasive layer, and a top adhesive layer sequentially attached to the thin film substrate; The abrasive layer is uniformly adhered to the base adhesive layer; the abrasive tip portion of the abrasive layer protrudes from the top adhesive layer; The adhesive layer comprises an adhesive, copper powder, antistatic agent, toughening agent, diluent, and curing accelerator; the mass ratio of the adhesive, copper powder, antistatic agent, toughening agent, diluent, and curing accelerator is 100:(8-15):(0.5-3):(5-10):(10-50):(0.5-5).

2. The thin-film diamond-coated abrasive belt according to claim 1, characterized in that, The pre-coating layer comprises an adhesive, filler, coupling agent, curing agent, and diluent; the mass ratio of the adhesive, filler, coupling agent, curing agent, and diluent is 100:(10-18):(1-3):(12-16):(10-20); and / or, The base layer is composed of adhesive, filler, leveling agent, curing agent and diluent; the mass ratio of the adhesive, filler, leveling agent, curing agent and diluent is 100: (10-15): (0.5-2): (15-30): (10-50).

3. The thin-film diamond-coated abrasive belt according to claim 1 or 2, characterized in that, The thickness of the pre-coating is 5-15 μm; and / or, The thickness of the base adhesive layer is 3-20 μm; and / or, The viscosity of the base adhesive layer is 300-1000 CPS.

4. The thin-film diamond-coated abrasive belt according to claim 1 or 2, characterized in that, The abrasive in the abrasive layer is one or more of single-crystal diamond, polycrystalline diamond, and polycrystalline-like diamond; and / or, The median particle size of the abrasive is 9-60 μm; and / or, The abrasive tips in the abrasive layer point outwards.

5. The thin-film diamond-coated abrasive belt according to claim 3, characterized in that, The abrasive in the abrasive layer is one or more of single-crystal diamond, polycrystalline diamond, and polycrystalline-like diamond; and / or, The median particle size of the abrasive is 9-60 μm; and / or, The abrasive tips in the abrasive layer point outwards.

6. The method for manufacturing the thin-film diamond-coated abrasive belt according to any one of claims 1-5, characterized in that, include: 1) Provide a corona-treated thin film substrate, and roll-coat a pre-coating layer on the thin film substrate; 2) Roll-coating an adhesive layer onto the film substrate; 3) An abrasive layer is formed by attaching the abrasive to the base layer using a gravity-feeding method; 4) Roller-coating the abrasive layer onto the abrasive layer.

7. The method for manufacturing the thin-film diamond-coated abrasive belt according to claim 6, characterized in that, In step 2), the thickness of the base coat is controlled to be 3-20 μm, and the viscosity to be 300-1000 CPS; and / or, In step 3), the distance between the sand drop box and the substrate is controlled to be 10-45cm, the angle between the sand drop direction and the substrate running direction is 50-80 degrees, and the substrate running speed is 5-10m / min.

8. The method for manufacturing the thin-film diamond-coated abrasive belt according to claim 6 or 7, characterized in that, In step 3), the gravity sand planting method uses a screen mesh of 40-200 mesh and a vibration frequency of 30-80Hz.

9. A thin-film diamond-coated abrasive belt, characterized in that, It is prepared by the method described in any one of claims 6-8.

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