An abrasive tool and a method of making the same

Abstract

The present application belongs to the technical field of abrasive materials, and specifically provides a grinding tool preparation method, comprising the following steps: S1, pretreatment of base cloth and abrasive; S2, adjusting the pH of active filler to 3-4; mixing the abrasive with active filler, adhesive, diluent according to a mass ratio of 100:(20-28):(20-30):(5-10), stirring uniformly to prepare a mortar mixture for standby; S3, uniformly coating the mortar mixture on the surface of the base cloth to obtain the base cloth coated with the mortar mixture; S4, drying and curing the base cloth coated with the mortar mixture to obtain the grinding tool. The grinding tool preparation method provided by the present application is simple to operate and short in time consumption. By controlling the addition amount, type and pH value of the filler, the filler catalyzes the adhesive to have a crosslinking degree of 40%, and the crosslinking degree of 40%, stirring time and speed ensure that the abrasive grain spacing in the mortar mixture is 0.5-1.2 mm, so that the prepared coated grinding tool product has the characteristics of flatness, long polishing life, stable polishing effect, good surface consistency and the like.

Description

Technical Field

[0001] This invention belongs to the field of abrasive materials technology, specifically relating to an abrasive tool and its preparation method. Background Technology

[0002] Abrasives are tools used for cutting, grinding, and polishing. They can have different material phases, including abrasive grains, binders, various fillers, and varying porosities. Besides their widespread use in machinery manufacturing and other metal processing industries, abrasives are also used in food processing, papermaking, and the processing of non-metallic materials such as ceramics, glass, stone, plastics, rubber, and wood.

[0003] Existing resin abrasives, which use resin as a binder to bond abrasive particles together to form a certain strength, require resin and abrasive as their main raw materials, both supplied by resin and abrasive manufacturers. The general manufacturing process is: mixing → molding → curing → post-processing. This process is highly dependent on the quality of the resin and the overall production time is relatively long. Most importantly, in traditional resin abrasives, the abrasive particles are mechanically encapsulated in the resin, resulting in weak resin holding force on the abrasive. This causes the abrasive to break or fall off prematurely before effectively performing its grinding function, leading to a short product lifespan, poor grinding effect, and thus limiting the practicality of the abrasives. Summary of the Invention

[0004] The purpose of this invention is to overcome the problems of short grinding life, unstable grinding effect, and poor surface uniformity in the prior art.

[0005] Therefore, the present invention provides a method for preparing an abrasive, comprising the following steps:

[0006] S1, base fabric, abrasive pretreatment;

[0007] S2. Adjust the pH of the active filler to 3-4; mix the abrasive, active filler, binder and diluent in a mass ratio of 100:(20-28):(20-30):(5-10), stir evenly and prepare a mortar mixture for later use;

[0008] S3. Apply the mortar mixture evenly to the surface of the base fabric to obtain a base fabric coated with the mortar mixture;

[0009] S4. The base fabric coated with the mortar mixture is dried and cured to obtain the abrasive.

[0010] Specifically, in step S2 above, stir at a speed of 50-65 rpm for 10-15 minutes.

[0011] Specifically, the aforementioned active fillers include one or more of cryolite, potassium fluoroborate, potassium fluoroaluminate, zinc chloride, iron sulfide, and potassium sulfate.

[0012] Specifically, the particle size of the aforementioned active filler is <800 mesh.

[0013] Specifically, the adhesives mentioned above include one or more of water-soluble phenolic resins, epoxy resins, and polyurethane resins.

[0014] Specifically, the diluents mentioned above include one or more of water, methanol, ethyl acetate, toluene, and ethylene glycol.

[0015] Specifically, the base fabric mentioned above is polyester fabric.

[0016] Specifically, the basic particle content in the above-mentioned abrasive is over 80%.

[0017] Specifically, in step S3 above, the thickness of the mortar mixture coated on the base fabric surface is 1.5-2 mm.

[0018] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0019] The abrasive preparation method provided by this invention is simple to operate and quick to use. By controlling the amount, type, and pH value of the filler, the filler catalyzes a 40% crosslinking degree of the binder. The combined effect of this 40% crosslinking degree, stirring time, and speed ensures that the abrasive particle spacing in the mortar mixture is between 0.5 and 1.2 mm. This results in coated abrasive products with characteristics such as smoothness and uniformity, long grinding life, stable grinding effect, and good surface consistency. It can be widely used for polishing stone, gemstones, crystal slabs, ceramics, molybdenum vanadium, and stainless steel. It can also be used for polishing hard and brittle materials such as glass, monocrystalline silicon, polycrystalline silicon, target materials, cemented carbide, aluminum alloys, and synthetic materials. It also has excellent polishing effects on tungsten carbide coatings, ceramic coatings, cemented carbide, printing rollers, and papermaking rollers. Detailed Implementation

[0020] The technical solutions of the present invention will be clearly and completely described below with reference to embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Although representative embodiments of the present invention have been described in detail, those skilled in the art will understand that various modifications and changes can be made to the present invention without departing from the scope of the present invention. Therefore, the scope of the present invention should not be limited to the embodiments, but should be defined by the appended claims and their equivalents.

[0021] This invention provides a method for preparing abrasives, comprising the following steps:

[0022] S1, base fabric, abrasive pretreatment;

[0023] Polyester fabric is selected as the base fabric. After the conventional base fabric treatment steps of singeing, washing, impregnation, stretching and drying, sizing, drying and calendering, it is polished for later use.

[0024] The abrasive is shaped and selected to ensure that the content of basic abrasive particles reaches more than 80%, and is properly labeled for future use; the basic particles are the oversize material on the lower inspection sieve specified in GB / T6406-1996;

[0025] S2. Adjust the pH of the active filler to 3-4; mix the abrasive, active filler, binder and diluent in a mass ratio of 100:(20-28):(20-30):(5-10), and stir at 50-65 rpm for 10-15 minutes in a high-speed disperser, such as a double-blade mixing pot, until the mixture is homogeneous and ready for use.

[0026] The active filler includes one or more of cryolite, potassium fluoroborate, potassium fluoroaluminate, zinc chloride, iron sulfide, and potassium sulfate, with a particle size of <800 mesh.

[0027] The adhesive is a synthetic resin adhesive, including one or more of water-soluble phenolic resin, epoxy resin, and polyurethane resin;

[0028] Diluents include one or more of water, methanol, ethyl acetate, toluene, and ethylene glycol;

[0029] S3. On the coated abrasive belt production line, the base fabric is unwound, and the mortar mixture is evenly coated onto the surface of the base fabric using a coating machine with a rubber roller. Then, a scraper is used to smooth the thickness, and the thickness of the mortar mixture is controlled at 1.5-2mm to obtain the base fabric coated with the mortar mixture.

[0030] S4. The base fabric coated with the mortar mixture is sent into a curing oven for hanging and drying. It is dried and cured according to the temperature curve of 80℃, 95℃, 120℃, 120℃, 95℃, and 85℃ to obtain the abrasive.

[0031] The resulting molds can be converted into ring belt products or irregular flocked products of different specifications according to the customer's actual needs.

[0032] The effects of the abrasive preparation method of the present invention will be studied through specific embodiments below.

[0033] Example 1:

[0034] This embodiment provides a grinding tool, which is prepared through the following steps:

[0035] S1, base fabric, abrasive pretreatment;

[0036] Polyester fabric is selected as the base fabric. After the conventional base fabric treatment steps of singeing, washing, impregnation, stretching and drying, sizing, drying and calendering, it is polished for later use.

[0037] The abrasive is shaped and selected to ensure that the basic abrasive particle content reaches more than 80%, and then properly labeled for future use.

[0038] S2. Adjust the pH of the active filler to 3.5; mix the abrasive, active filler, binder and diluent in a mass ratio of 100:25:26:8, stir at 60 rpm for 10 minutes in a double-blade mixing pot, and prepare the mortar mixture for later use.

[0039] The active filler is a mixture of potassium fluoroaluminate and potassium sulfate, with a mass ratio of potassium fluoroaluminate to potassium sulfate of 18:2 and a particle size of <800 mesh; the binder is water-soluble phenolic resin; and the diluent is ethylene glycol.

[0040] The active filler catalyzes the binder with a crosslinking degree of 40%, and the mortar mixture exhibits positional stability. The abrasive particles are regularly distributed in the system with a spacing of 0.5-1.2 mm.

[0041] S3. On the coated abrasive belt production line, the base fabric is unwound, and the mortar mixture is evenly coated onto the surface of the base fabric using a coating machine and a rubber roller. Then, a scraper is used to smooth the thickness of the mortar mixture, which is controlled at 1.5mm, to obtain the base fabric coated with the mortar mixture.

[0042] S4. The base fabric coated with the mortar mixture is sent into a curing oven and suspended for drying and curing to obtain the abrasive.

[0043] The performance of the grinding wheel was tested, and its grinding ratio was 1:15.

[0044] Example 2:

[0045] This embodiment provides a grinding tool, which is prepared through the following steps:

[0046] S1, base fabric, abrasive pretreatment;

[0047] Polyester fabric is selected as the base fabric. After the conventional base fabric treatment steps of singeing, washing, impregnation, stretching and drying, sizing, drying and calendering, it is polished for later use.

[0048] The abrasive is shaped and selected to ensure that the basic abrasive particle content reaches more than 80%, and then properly labeled for future use.

[0049] S2. Adjust the pH of the active filler to 4; mix the abrasive, active filler, binder and diluent in a mass ratio of 100:25:26:8, and stir in a double-blade mixing pot at a speed of 65 rpm for 12 minutes. After stirring evenly, prepare the mortar mixture for later use.

[0050] The active filler is cryolite with a particle size of <800 mesh; the binder is epoxy resin; and the diluent is methanol.

[0051] The active filler catalyzes the binder with a crosslinking degree of 40%, and the mortar mixture exhibits positional stability. The abrasive particles are regularly distributed in the system with a spacing of 0.5-1.2 mm.

[0052] S3. On the coated abrasive belt production line, the base fabric is unwound, and the mortar mixture is evenly coated onto the surface of the base fabric using a coating machine with a rubber roller. Then, a scraper is used to smooth the thickness of the mortar mixture, which is controlled at 2mm, to obtain the base fabric coated with the mortar mixture.

[0053] S4. The base fabric coated with the mortar mixture is sent into a curing oven and suspended for drying and curing to obtain the abrasive.

[0054] The performance of the grinding wheel was tested, and its grinding ratio was 1:12.

[0055] Example 3:

[0056] This embodiment provides a grinding tool, which is prepared through the following steps:

[0057] S1, base fabric, abrasive pretreatment;

[0058] Polyester fabric is selected as the base fabric. After the conventional base fabric treatment steps of singeing, washing, impregnation, stretching and drying, sizing, drying and calendering, it is polished for later use.

[0059] The abrasive is shaped and selected to ensure that the basic abrasive particle content reaches more than 80%, and then properly labeled for future use.

[0060] S2. Adjust the pH of the active filler to 3; mix the abrasive, active filler, binder and diluent in a mass ratio of 100:25:26:8, and stir in a double-blade mixing pot at a speed of 50 rpm for 15 minutes. After stirring evenly, prepare the mortar mixture for later use.

[0061] The active filler is a mixture of zinc chloride and iron sulfide, with a zinc chloride:iron sulfide mass ratio of 18:2 and a particle size of <800 mesh; the binder is epoxy resin; and the diluent is ethyl acetate.

[0062] The active filler catalyzes the binder with a crosslinking degree of 40%, and the mortar mixture exhibits positional stability. The abrasive particles are regularly distributed in the system with a spacing of 0.5-1.2 mm.

[0063] S3. On the coated abrasive belt production line, the base fabric is unwound, and the mortar mixture is evenly coated onto the surface of the base fabric using a coating machine and a rubber roller. Then, a scraper is used to smooth the thickness of the mortar mixture, which is controlled at 1.5mm, to obtain the base fabric coated with the mortar mixture.

[0064] S4. The base fabric coated with the mortar mixture is sent into a curing oven and suspended for drying and curing to obtain the abrasive.

[0065] The performance of the grinding wheel was tested, and its grinding ratio was 1:10.

[0066] Comparative Example 1:

[0067] This comparative example provides an abrasive, which is prepared in the same way as in Example 1, except that the active filler in step S2 is a mixture of calcium carbonate and wollastonite, and the mass ratio of calcium carbonate to wollastonite is 18:2 with a particle size of <800 mesh.

[0068] After stirring in step S2, let it stand for 10 minutes. The abrasive particles in the mixture will show obvious sedimentation.

[0069] The performance of the grinding wheel was tested, and its grinding ratio was 1:2.3.

[0070] Comparative Example 2:

[0071] This comparative example provides a grinding tool prepared in the same way as in Example 1, except that the pH of the active filler is 7 in step S2.

[0072] After stirring in step S2, the viscosity of the mixture system is significantly lower, and the abrasive particles show obvious sedimentation.

[0073] The performance of the grinding wheel was tested, and its grinding ratio was 1:1.5.

[0074] Comparative Example 3:

[0075] This comparative example provides an abrasive, which is prepared using the same method as in Example 1, except that in step S2, the abrasive, active filler, binder, and diluent are mixed in a mass ratio of 100:40:15:5. The active filler is a mixture of potassium fluoroaluminate and potassium sulfate, with a mass ratio of potassium fluoroaluminate to potassium sulfate of 13.5:1.5 and a particle size of <800 mesh.

[0076] After stirring in step S2, the abrasive, adhesive, and filler in the mixture system are clearly separated into layers.

[0077] The performance of the grinding wheel was tested, and its grinding ratio was 1:0.8.

[0078] Comparative Example 4:

[0079] This comparative example provides an abrasive, which is prepared in the same way as in Example 1. The difference is that in step S2, the abrasive, active filler, binder, and diluent are mixed in a mass ratio of 100:10:35:20. The active filler is a mixture of potassium fluoroaluminate and potassium sulfate, with a mass ratio of potassium fluoroaluminate to potassium sulfate of 27:3 and a particle size of <800 mesh.

[0080] After stirring in step S2, the abrasive particles in the mixture showed obvious sedimentation.

[0081] The performance of the grinding wheel was tested, and its grinding ratio was 1:0.2.

[0082] The performance test results of the abrasives in the various embodiments and comparative examples show that the method provided by this invention, by controlling the amount, type, and pH value of the active filler, catalyzes a 40% crosslinking degree of the binder. The combined effect of this 40% crosslinking degree, along with the stirring time and speed, ensures that the abrasive particle spacing in the mortar mixture is between 0.5 and 1.2 mm. This results in coated abrasive products with characteristics such as smoothness and uniformity, long grinding life, stable grinding effect, and good surface consistency.

[0083] The above examples are merely illustrative of the present invention and do not constitute a limitation on the scope of protection of the present invention. All designs that are the same as or similar to the present invention are within the scope of protection of the present invention.

Claims

1. A method for preparing an abrasive, characterized in that, Includes the following steps: S1, base fabric, abrasive pretreatment; S2. Adjust the pH of the active filler to 3-4; mix the abrasive, active filler, binder, and diluent in a mass ratio of 100:(20-28):(20-30):(5-10), stir evenly, and prepare a mortar mixture for later use; the active filler includes one or more of cryolite, potassium fluoroborate, potassium fluoroaluminate, zinc chloride, iron sulfide, and potassium sulfate; the particle size of the active filler is <800 mesh; the binder includes one or more of water-soluble phenolic resin, epoxy resin, and polyurethane resin; the diluent includes one or more of water, methanol, ethyl acetate, toluene, and ethylene glycol; S3. Apply the mortar mixture evenly to the surface of the base fabric to obtain a base fabric coated with the mortar mixture; S4. The base fabric coated with the mortar mixture is dried and cured to obtain the abrasive.

2. The abrasive preparation method according to claim 1, characterized in that: In step S2, stir at a speed of 50-65 rpm for 10-15 minutes.

3. The abrasive preparation method according to claim 1, characterized in that: The base fabric is polyester fabric.

4. The abrasive preparation method according to claim 1, characterized in that: The abrasive contains more than 80% basic particles.

5. The abrasive preparation method according to claim 1, characterized in that: In step S3, the thickness of the mortar mixture coated on the base fabric surface is 1.5-2 mm.

6. The abrasive prepared by the abrasive preparation method according to any one of claims 1-5.