A density-adjustable sand-coating process for coated abrasives
By adding auxiliary fillers to the abrasive and controlling their morphological changes during subsequent processing, the problem of uneven abrasive grain density was solved, achieving uniform distribution and precise control of the abrasive on the substrate, thus improving production efficiency and product quality.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- JIANGSU FENGMANG COMPOUND MATERIAL SCI&TECH GRP CO LTD
- Filing Date
- 2021-12-31
- Publication Date
- 2026-05-26
AI Technical Summary
In existing technologies, the abrasive density distribution on the substrate is uneven, resulting in large fluctuations in product performance and high difficulty in controlling the precision of the equipment, especially in achieving precise adjustment of the abrasive density in different application fields.
After the auxiliary filler is uniformly mixed with the target abrasive, it is distributed on the substrate by electrostatic or gravity sand planting. The auxiliary filler changes its shape during subsequent processing to control the sand planting density. After the shape change, the height of the auxiliary filler is less than the average height of the target abrasive relative to the substrate.
It achieves uniform distribution of abrasive on the substrate, improves production efficiency and product quality, solves the problem of uneven distribution of abrasive density, and achieves precise control.
Smart Images
Figure CN116372826B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of coated abrasives technology, and more particularly to a density-adjustable sand-coating process for coated abrasives. Background Technology
[0002] Currently, the amount of abrasive grains or the density distribution of abrasive grains are described by "the weight of abrasive grains per unit area or the proportion of abrasive grains covering a unit area". According to the different amounts or density distributions of abrasive grains, abrasive grains are usually divided into densely planted abrasive grains and sparsely planted abrasive grains, but there is no clear boundary.
[0003] The magnitude of the above parameters generally affects the grinding performance and application areas of the product. For example, when using the percentage of abrasive coverage per unit area as a measure, under heavy-duty grinding conditions in metals, a relatively high abrasive density is required, commonly known as dense abrasive, tentatively set at 80-100%. In woodworking grinding, a lower abrasive density is often required, commonly known as sparse abrasive or open abrasive, tentatively set at 50-80%. In some paint surface applications, because the material being ground is relatively soft or has a certain degree of adhesion, the grinding debris can easily clog the surface of the grinding wheel, leading to grinding failure or a significant reduction in grinding effect. For such applications, an even lower abrasive density is required, commonly known as ultra-sparse abrasive, tentatively set at 20-50%.
[0004] The distribution of abrasive on the substrate is often achieved using gravity-based and electrostatic abrasive application methods. The abrasive density is controlled by adjusting the parameters of the abrasive application equipment and the abrasive drop density. Abrasive density is a crucial indicator in the production of coated abrasives and a major factor contributing to product performance fluctuations. However, currently, uneven abrasive density distribution is common during the abrasive application process. While the average abrasive amount may meet the standard, significant local deviations in density can lead to substantial performance fluctuations. Furthermore, lower abrasive densities place higher demands on equipment precision control, making it more challenging. Therefore, achieving uniform abrasive application at a specific density on the substrate has become a key research focus for those skilled in the art. Summary of the Invention
[0005] This invention provides a density-adjustable sand-coating process for coated abrasives, which can effectively solve the problems in the background art.
[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:
[0007] A density-adjustable abrasive coating process for coated abrasives includes the following steps:
[0008] Abrasive premixing involves uniformly mixing the target abrasive for coating the abrasive wheel and the auxiliary filler for adjusting the density of the target abrasive in a set ratio to obtain a mixture.
[0009] Sand planting is completed by evenly distributing the mixture on a substrate coated with a binder.
[0010] The auxiliary filler undergoes a morphological change during subsequent processing of the coated abrasive, and its average height relative to the substrate after the change is less than the average height of the target abrasive relative to the substrate.
[0011] Furthermore, the morphological changes of the auxiliary filler during subsequent processing are caused by partial melting.
[0012] Furthermore, the morphological changes of the auxiliary filler during subsequent processing are caused by complete melting.
[0013] Furthermore, the auxiliary filler is composed of at least one fine-particle abrasive and a thermally fusible material.
[0014] Furthermore, after the morphology of the thermally melted material changes, it obtains a solidified state.
[0015] Furthermore, both the fine-particle abrasive and the target abrasive exhibit electrostatic jumping properties.
[0016] Furthermore, the mixture is distributed on the substrate coated with a binder using an electrostatic sand-planting method.
[0017] Furthermore, the mixture is distributed on the substrate coated with binder by gravity sand application.
[0018] Furthermore, only the target abrasive possesses electrostatic jumping properties.
[0019] Furthermore, the melting temperature of the auxiliary filler is less than or equal to 120°C.
[0020] Furthermore, the melting temperature of the auxiliary filler is less than or equal to 100°C.
[0021] Furthermore, it also includes covering the auxiliary filler with a coating adhesive.
[0022] Furthermore, the unmelted portion of the auxiliary filler is completely covered by the melted portion and the adhesive.
[0023] Furthermore, the unmelted portion of the auxiliary filler is covered by the melted portion and the adhesive portion.
[0024] Furthermore, the average height of the unmelted portion of the auxiliary filler relative to the exposed portion of the adhesive is less than or equal to 2 / 3 of the height of the target abrasive.
[0025] Furthermore, the average height of the unmelted portion of the auxiliary filler relative to the exposed portion of the adhesive is less than or equal to 1 / 2 of the height of the target abrasive.
[0026] Furthermore, the average height of the unmelted portion of the auxiliary filler relative to the exposed portion of the adhesive is less than or equal to 1 / 4 of the height of the target abrasive.
[0027] The technical solution of this invention can achieve the following technical effects:
[0028] In this invention, by uniformly mixing the auxiliary filler with the target abrasive, the target abrasive is distributed to cover the substrate surface according to a set ratio with the auxiliary filler before sand planting. After sand planting, both the target abrasive and the auxiliary filler are uniformly distributed relative to the substrate, completely covering the substrate surface and being fixed by the binder. Through this method, the previously difficult-to-control sand planting density adjustment is transformed into an easily controllable material mixing ratio adjustment, thereby solving the dual problems of uneven sand planting density distribution and difficulty in controlling the sand planting process, significantly improving production efficiency and product quality.
[0029] In this invention, the original volume of the auxiliary filler can be larger or smaller than the volume of the target abrasive, both of which are within the protection scope of this invention. However, in this invention, it is necessary to ensure that when the auxiliary filler undergoes a change in morphology, it satisfies the purpose of reducing the average height relative to the substrate, and the reduced height must be smaller than the average height of the target abrasive relative to the substrate. Attached Figure Description
[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0031] Figure 1 A schematic diagram of the process for a density-adjustable sand-coating process for coated abrasives;
[0032] Figure 2 A flowchart for a density-adjustable sand-coating process for coated abrasives;
[0033] Figure 3 This is a schematic diagram of sand planting using auxiliary fillers containing fine-grained abrasive particles and hot-melt materials;
[0034] Figure 4 for Figure 3 A magnified view of a section at point C;
[0035] Figure 5 A schematic diagram illustrating the spread of a blend formed by fine abrasive particles and molten materials;
[0036] Figure 6 This is a method of applying adhesive after the mixture is evenly distributed on a substrate coated with a binder;
[0037] Figure 7 for Figure 6 A magnified view of a section at point A in the middle;
[0038] Figure 8 Another way to apply adhesive after the mixture is evenly distributed on the substrate coated with binder;
[0039] Figure 9 for Figure 8 A magnified view of a section at point B in the middle;
[0040] In the attached diagram, 1 represents the substrate; 2 represents the primer; 3 represents the target abrasive; 4 represents the auxiliary filler; 41 represents the fine abrasive particles; 42 represents the thermoplastic material; and 5 represents the topcoat. Detailed Implementation
[0041] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.
[0042] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.
[0043] like Figure 1 As shown, in this invention, by uniformly mixing the auxiliary filler 4 with the target abrasive 3, the target abrasive 3 is distributed to cover the surface of the substrate 1 according to a set ratio with the auxiliary filler 4 before sand planting. After sand planting, both the target abrasive 3 and the auxiliary filler 4 are uniformly distributed relative to the substrate 1, completely covering the surface of the substrate 1 and fixed by the adhesive. During implementation, as... Figure 2 As shown, the density-adjustable abrasive coating process for coated abrasives includes the following steps:
[0044] S1. Abrasive premixing: The target abrasive 3, which is used to coat the abrasive tool, and the auxiliary filler 4, which is used to adjust the density of the target abrasive 3, are mixed evenly in a set ratio to obtain a mixture.
[0045] S2. Sand Planting: The mixture is evenly distributed on the substrate 1 coated with binder to complete the sand planting.
[0046] By using the above methods, the previously difficult-to-control sand density adjustment is transformed into the easily and precisely controlled material mixing ratio adjustment. This solves the dual problems of uneven sand density distribution and difficulty in controlling the sand planting process, thereby significantly improving production efficiency and product quality.
[0047] In this embodiment, the auxiliary filler 4 undergoes a morphological change during the subsequent processing of the coated abrasive, and its average height relative to the substrate 1 after the change is less than the average height of the target abrasive 3 relative to the substrate 1. After the binder is coated on the substrate 1, a primer 2 is formed. The uniform distribution of the mixture on the primer 2 ensures that the target abrasive 3 performs the functions required by the coated abrasive product during subsequent use, while the auxiliary filler 4 does not perform the grinding function on the object to be ground.
[0048] In this embodiment, the original volume of the auxiliary filler 4 can be larger than the volume of the target abrasive or smaller than the volume of the target abrasive 3, both of which are within the protection scope of the present invention. In the invention, it is necessary to ensure that when the auxiliary filler 4 undergoes a change in shape, it needs to meet the purpose of reducing the average height relative to the substrate 1, and the reduced height needs to be smaller than the average height of the target abrasive 3 relative to the substrate 1.
[0049] In this embodiment, the target abrasive 3 can be selected from a variety of materials such as brown fused alumina, calcined alumina, semi-brittle alumina, white fused alumina, black fused alumina, zirconium fused alumina, black silicon carbide, green silicon carbide, garnet, quartz sand, glass sand, diamond, cubic boron nitride, and metal particles.
[0050] To obtain a complete product, several steps are required before and after the sand-planting process in this embodiment. The complete product manufacturing process can be achieved by referring to the following steps:
[0051] Substrate 1 Preparation—Impregnation—Drying—Edge Trimming—Applying Primer 2—Sand Planting—Drying—Applying Top Adhesive 5—Drying—Rolling Up—Curing—Crimping—Applying Coating—Drying—Curing.
[0052] In summary, considering the complete production steps described above, in this embodiment, the factors that can affect the morphology of auxiliary filler 4 are the temperature changes during the curing step, or the independent heating process.
[0053] As a preferred embodiment, the morphological change of the auxiliary filler 4 during subsequent processing is caused by partial melting. Regarding this partial melting, the present invention protects the following two methods:
[0054] The first type: the auxiliary filler 4 can be completely melted by heating, but only part of it is melted by controlling the temperature. For example, the auxiliary filler 4 is a thermally molten material particle.
[0055] The second type: The auxiliary filler 4 is composed of two or more materials, some of which are fusible while others are not. In this case, such as... Figure 3 and 4 As shown, the preferred auxiliary filler 4 is composed of at least one fine abrasive particle 41 and a thermoplastic material 42. Specifically, a certain number and size of fine abrasive particles 41 are adhered around the thermoplastic material 42 to form an agglomerated abrasive, which is solid within a set temperature range, preferably ≤60°C; however, at higher temperatures, the thermoplastic material deforms, the agglomerated abrasive collapses, and its height decreases significantly. In this case, such as Figure 5 As shown, the fine abrasive particles 41 and the thermally molten material 42 form a blend and spread out.
[0056] Alternatively, as another implementation, the change in morphology of the auxiliary filler 4 during subsequent processing is due to complete melting. In this preferred embodiment, the auxiliary filler 4 can also be in the form of thermally melted material particles.
[0057] In terms of material selection, the hot-melt material 42 can be wax, hot-melt adhesive, thermoplastic material, etc.; the fine abrasive 41 can be one or a mixture of various conventional known abrasives, such as alumina, silicon carbide, quartz, zirconium corundum, garnet, etc.
[0058] In this process, the morphology of the hot-melted material changes, resulting in a solidified state, which serves to bond the fine abrasive particles 41. In this embodiment, it is necessary to ensure that the average height of the auxiliary filler 4 relative to the substrate 1 after re-curing is less than the average height of the target abrasive 3 relative to the substrate 1, thereby guaranteeing the grinding performance of the target abrasive 3.
[0059] As a preferred embodiment, both the fine abrasive particles 41 and the target abrasive 3 exhibit electrostatic jumping properties. In this case, the ratio between the fine abrasive particles 41 and the molten material 42 in the auxiliary filler 4 needs to be considered. When the proportion of the molten portion is low, it may jump along with the inmeltable material under electrostatic action. In this case, electrostatic sand-planting can be used to distribute the mixture on the substrate 1 coated with the binder. In other cases, the mixture needs to be distributed on the substrate 1 coated with the binder using gravity sand-planting. Of course, even without electrostatic sand-planting, the target abrasive 3 can still exhibit electrostatic jumping properties.
[0060] As a preferred embodiment, when the auxiliary filler 4 includes a fusible portion, the agglomerated abrasive melts and spreads under heating conditions, and the melting temperature of the auxiliary filler 4 is less than or equal to 120°C. However, to avoid affecting other steps, a melting temperature of less than or equal to 100°C is more preferable.
[0061] The present invention also includes the following optimization method, further comprising covering the auxiliary filler 4 with a coating adhesive 5. This includes ensuring that the unmelted portion of the auxiliary filler 4 is completely covered by the melted portion and the coating adhesive 5, such as... Figure 6 and 7 As shown; or, the unmelted portion of auxiliary filler 4 is covered by the melted portion and the adhesive 5, as shown. Figure 8 and 9 As shown in the figure above. In the second case, the average height of the unmelted portion of the auxiliary filler 4 relative to the exposed portion of the adhesive 5 is less than or equal to 2 / 3 of the height of the target abrasive 3. Through this proportional relationship, as shown in the figure above, it can be ensured that the final grinding performance is achieved by the target abrasive 3 with a set density distribution. The lower-height auxiliary filler 4 will not come into contact with or interact with the workpiece to be ground during the grinding process of the target abrasive 3. Within the above range, it is better if the average height of the unmelted portion of the auxiliary filler 4 relative to the exposed portion of the adhesive 5 is less than or equal to 1 / 2 of the height of the target abrasive 3. Of course, when the requirements are more stringent, the average height of the unmelted portion of the auxiliary filler 4 relative to the exposed portion of the adhesive 5 can be set to be less than or equal to 1 / 4 of the height of the target abrasive 3.
[0062] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.
Claims
1. A density-adjustable sanding process for coated abrasive tools, characterized in that Includes the following steps: Abrasive premixing involves uniformly mixing the target abrasive for coating the abrasive tool and the auxiliary filler for adjusting the density of the target abrasive in a set ratio to obtain a mixture. Sand planting is completed by uniformly distributing the mixture on a substrate coated with a binder. The auxiliary filler undergoes a morphological change during subsequent processing of the coated abrasive, and its average height relative to the substrate after the change is smaller than the average height of the target abrasive relative to the substrate. The morphological changes of the auxiliary filler during subsequent processing are caused by partial melting; the auxiliary filler is composed of at least one fine abrasive particles and a thermoplastic material to form an agglomerated abrasive, the thermoplastic material deforms, the agglomerated abrasive collapses, and the fine abrasive particles and the thermoplastic material form a blend and spread.
2. The density-adjustable sanding process for coated abrasive according to claim 1, wherein After the morphology of the thermally melted material changes, it obtains a solidified state.
3. The density-adjustable sanding process for coated abrasive according to claim 1, wherein The melting temperature of the auxiliary filler is less than or equal to 120°C.
4. The density-adjustable sanding process for coated abrasive according to claim 1, wherein It also includes covering the auxiliary filler with a coating adhesive.
5. The density-adjustable sanding process for coated abrasive according to claim 4, wherein The unmelted portion of the auxiliary filler is completely covered by the melted portion and the adhesive.
6. The density-adjustable sanding process for coated abrasive according to claim 4, wherein The unmelted portion of the auxiliary filler is covered by the melted portion and the adhesive portion.
7. The density-adjustable sand-coating process for coated abrasives according to claim 6, characterized in that, The average height of the unmelted portion of the auxiliary filler relative to the exposed portion of the adhesive is less than or equal to 2 / 3 of the height of the target abrasive.