High-elasticity sand cloth, and preparation method and application thereof

Abstract

The application discloses high-elasticity abrasive cloth and a preparation method and application thereof, and belongs to the technical field of high-elasticity abrasive cloth production. The high-elasticity abrasive cloth comprises a cloth base and glue A, glue B, glue C and glue D which are coated on the cloth base in sequence; the glue A comprises a first phenolic resin and an anionic emulsifier; the glue B comprises a self-crosslinking acrylic acid copolymer emulsion and an anionic water-based acrylic acid emulsion; the glue C comprises a second phenolic resin and heavy calcium; the glue D comprises a second phenolic resin and a low-melting-point additive; the solid content of the first phenolic resin is 48%-52%, and the solid content of the second phenolic resin is 68%-72%. The glue A, the glue B, the glue C and the glue D with specific compositions are coated on the surface of the cloth base in sequence, the problem of insufficient synchronous consumption of the abrasive cloth is solved, and the abrasive cloth can have toughness and good elasticity at the same time.

Description

Technical Field

[0001] This invention relates to the field of high-elasticity abrasive cloth production technology, specifically to a high-elasticity abrasive cloth, its preparation method, and its application. Background Technology

[0002] High-elasticity abrasive cloth, as a type of abrasive tool, is commonly used for grinding and polishing the outer walls of pipes. Most existing high-elasticity abrasive cloths are produced using a blended fabric base, treated with an emulsion. However, this method results in insufficient synchronous consumption of the abrasive cloth; the fabric base is often consumed after the abrasive is used, leading to low utilization. Furthermore, because the emulsion-treated high-elasticity abrasive cloth is too soft, it relies solely on centrifugal force generated by rotation during grinding or polishing, resulting in low grinding efficiency. This significantly limits the application of high-elasticity abrasive cloth in the grinding and polishing of pipe outer walls.

[0003] To address the problems existing in the aforementioned high-elasticity abrasive cloth materials, the current research focus is on developing a high-elasticity abrasive cloth that is consumed simultaneously during use and has excellent elasticity and toughness. Summary of the Invention

[0004] Based on the deficiencies of the existing technology, the purpose of this invention is to provide a high-elasticity abrasive cloth, its preparation method and application, wherein the high-elasticity abrasive cloth has good synchronous consumption during use and has excellent elasticity and toughness.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] A high-elastic abrasive cloth, the high-elastic abrasive cloth comprising an abrasive cloth base and adhesive liquids A, B, C and D sequentially coated on the abrasive cloth base;

[0007] The adhesive A comprises a first phenolic resin and an anionic emulsifier; the adhesive B comprises a self-crosslinking acrylic copolymer emulsion and an anionic aqueous acrylic emulsion; the adhesive C comprises a second phenolic resin and heavy calcium carbonate; the adhesive D comprises a second phenolic resin and a low-melting-point additive.

[0008] The first phenolic resin has a solid content of 48%-52%, and the second phenolic resin has a solid content of 68%-72%.

[0009] As a preferred embodiment of the high-elasticity abrasive cloth of the present invention, the viscosity of the first phenolic resin is 900-1300 cps / 25℃, the pH is 9-10, the free formaldehyde content is 0.10%-0.15%, the free phenol content is 0.3%-0.6%, the water solubility is >20%, and the gel time measured by the hot plate test at 25℃ is 70-85s.

[0010] As a preferred embodiment of the high-elasticity abrasive cloth of the present invention, the viscosity of the second aldehyde resin is 250-500 cps / 25℃, the pH is 8-9, the free formaldehyde content is 0.10%-0.3%, the free phenol content is 6%-10%, the water solubility is >1%, and the gel time measured by the hot plate test at 130℃ is 4-8 min.

[0011] As a preferred embodiment of the high-elasticity abrasive cloth of the present invention, the abrasive cloth base of the high-elasticity abrasive cloth is a pure cotton cloth base. Pure cotton cloth has better moisture absorption and moisture retention than polyurethane cloth base, and has good toughness after absorbing water. At the same time, the carbonization characteristic of pure cotton cloth at high temperature makes the abrasive cloth more synchronously consumable.

[0012] This invention involves sequentially coating the surface of an abrasive cloth base with adhesives A, B, C, and D, each with a specific composition. First, adhesive A is primarily present in the cloth base, aiming to increase its toughness and wear resistance. Adhesive B, with good elasticity, is present on the surface of the cloth base, exhibiting significant deformation and serving to connect the cloth base to adhesive C. Adhesive C possesses excellent bonding strength, used to bond the abrasive. Adhesive D, with good brittleness, covers the surface of the abrasive, aiming to facilitate rapid contact between the abrasive and the workpiece, enabling quick breakage during grinding.

[0013] The proper combination of the above four adhesives solves the problem of insufficient synchronous consumption of abrasive cloth, allowing the abrasive cloth to maintain a certain degree of elasticity while possessing toughness.

[0014] In a preferred embodiment of the high-elastic abrasive cloth of the present invention, the mass ratio of the first phenolic resin to the anionic emulsifier in the adhesive solution A is 1:1-9. The inventors have found through numerous experiments that if there is too much first phenolic resin, the final product will be more brittle and prone to cracking; if there is too little first phenolic resin, the synchronicity of the cloth base will be reduced during the application of the abrasive cloth, resulting in the phenomenon that the abrasive has been completely consumed but the cloth base is still there, causing the subsequent abrasive cloth to slip.

[0015] As a more preferred embodiment of the high-elasticity abrasive cloth of the present invention, the solid content of the anionic emulsifier is 47%-53%; the glass transition temperature is 33-38°C.

[0016] In a preferred embodiment of the high-elasticity abrasive cloth of the present invention, the mass ratio of self-crosslinking acrylic copolymer emulsion to anionic aqueous acrylic emulsion in the adhesive B is 2-3:1-2. Through extensive experiments, the inventors have found that a ratio within the above range ensures good adhesion between the abrasive and the cloth base. Excessive use of self-crosslinking acrylic copolymer emulsion reduces the elasticity of the abrasive cloth, resulting in fragmented abrasive particles falling off during grinding. Excessive use of anionic aqueous acrylic emulsion reduces the adhesion between the abrasive and the cloth base, leading to the abrasive falling off before complete consumption.

[0017] As a more preferred embodiment of the high-elasticity abrasive cloth of the present invention, the self-crosslinking acrylic copolymer emulsion has a solid content ≥45%, a viscosity >2000cps / 25℃, a pH of 7.5-8.5, and a glass transition temperature of 6-8℃.

[0018] As a more preferred embodiment of the high-elasticity abrasive cloth of the present invention, the anionic aqueous acrylic emulsion has a solid content of 49%-51%, a viscosity of 30-190 cps / 25℃, and a pH of 3.5-6.5, and the anionic aqueous acrylic emulsion does not contain alkylphenol polyoxyethylene ether, plasticizer or organic solvent.

[0019] In a preferred embodiment of the high-elastic abrasive cloth of the present invention, the mass ratio of the second phenolic resin to the heavy calcium carbonate in the adhesive solution C is 5:2-4. The inventors have found through a large number of experiments that the mass ratio of the second phenolic resin to the heavy calcium carbonate is related to the particle size of the abrasive. When the particle size of the abrasive is coarser, the amount of heavy calcium carbonate added is greater.

[0020] In a preferred embodiment of the high-elasticity abrasive cloth of the present invention, the mass ratio of the second phenolic resin to the low-melting-point additive in the adhesive solution D is 2-5:1. The inventors have found through a large number of experiments that the mass ratio of the second phenolic resin to the low-melting-point additive is related to the particle size of the abrasive. The coarser the particle size of the abrasive, the more low-melting-point additive is added.

[0021] In a preferred embodiment of the high-elasticity abrasive cloth of the present invention, the low-melting-point additive in the adhesive solution D includes at least one of sodium fluoroborate and potassium fluoroborate.

[0022] In a preferred embodiment of the high-elasticity abrasive cloth of the present invention, the mass ratio of adhesive A, adhesive B, adhesive C, and adhesive D is adhesive A: adhesive B: adhesive C: adhesive D = 180-200: 65-70: 100-50: 170-60.

[0023] In a second aspect, the present invention also provides a method for preparing high-elasticity abrasive cloth as described in the first aspect, the method comprising the following steps:

[0024] S1. Impregnate the pure cotton fabric with adhesive solution A and then dry it.

[0025] S2. After the pure cotton fabric base has been impregnated with adhesive in step S1, adhesive B, adhesive C, and adhesive D are applied sequentially, dried, and cured to obtain the high-elasticity abrasive cloth.

[0026] In a preferred embodiment of the preparation method of the high-elasticity abrasive cloth of the present invention, in step S1, the impregnation specifically involves using two pressure rollers to completely press the adhesive A into the pure cotton fabric base.

[0027] In a preferred embodiment of the preparation method of the high-elasticity abrasive cloth of the present invention, in step S1, the cloth is dried to a moisture content of 1%-3%.

[0028] In a preferred embodiment of the preparation method of the high-elasticity abrasive cloth of the present invention, in step S2, after coating with adhesive B, the cloth is dried to a moisture content of 3%-7%.

[0029] In a preferred embodiment of the preparation method of the high-elasticity abrasive cloth of the present invention, in step S2, after applying adhesive C, the abrasive is bonded, and then adhesive D is applied; the present invention forms an adhesive film on the abrasive with adhesive D and then dries it, the purpose of which is to further consolidate the adhesion of the abrasive and avoid the abrasive cloth from falling off prematurely due to the heat generated by grinding during grinding or polishing.

[0030] In a more preferred embodiment of the preparation method of the high-elasticity abrasive cloth of the present invention, the cloth base is kept under tension during the bonding abrasive process.

[0031] In a preferred embodiment of the preparation method of the high-elasticity abrasive cloth of the present invention, in step S2, after applying adhesive D, the abrasive cloth is wound into a roll with the abrasive surface facing outwards, and then baked until the resin is completely cured to obtain the high-elasticity abrasive cloth.

[0032] The beneficial effects of this invention are as follows:

[0033] This invention provides a high-elastic abrasive cloth, wherein a specific composition of adhesive liquid A, adhesive liquid B, adhesive liquid C and adhesive liquid D are sequentially coated on the surface of the abrasive cloth base, which solves the problem of insufficient simultaneous consumption of abrasive cloth and allows the abrasive cloth to maintain a certain degree of elasticity while having toughness. Detailed Implementation

[0034] To better illustrate the purpose, technical solution, and advantages of this invention, the invention will be further described below with reference to specific embodiments and comparative examples. The purpose of this description is to provide a detailed understanding of the invention, not to limit its scope. All other embodiments obtained by those skilled in the art without inventive effort are within the protection scope of this invention. Unless otherwise specified, the experimental reagents and instruments involved in the implementation of this invention are commonly used reagents and instruments.

[0035] In the components described in each embodiment and comparative example:

[0036] First Phenolic Resin 1: Solid content is 50.43%, viscosity is 1100cps / 25℃, pH is 9.41, free formaldehyde content is 0.12%, free phenol content is 0.5%, water solubility is >20%, and gel time measured by hot plate test at 25℃ is 80s; FR-SZ70.

[0037] First phenolic resin 2: solid content is 70.14%, viscosity is 700cps / 25℃, pH is 9.31, free formaldehyde content is 0.63%, free phenol content is 5.39%, water solubility is >30%, and the gel time measured by hot plate test at 25℃ is 7min24s; FR-SZ77.

[0038] First phenolic resin 3: solid content is 62.1%, viscosity is 298cps / 25℃, pH is 9.4, free formaldehyde content is 0.2%, free phenol content is 0.23%, water solubility is >10%, and gel time measured by hot plate test at 25℃ is 5min21s; FR-SZ55.

[0039] Second phenolic resin 1: solid content is 71.5%, viscosity is 374 mpa.s, pH is 8.7, free formaldehyde content is 0.15%, free phenol content is 7.2%, water solubility is >1%, and gel time measured by hot plate test at 130℃ is 5 min 24 s; FR-SZ50.

[0040] Second phenolic resin 2: solid content is 78.8%, viscosity is 2350 mpa.s, pH is 8.2, free formaldehyde content is 0.41%, free phenol content is 10.8%, water solubility is >3.05, and gel time measured by hot plate test at 130℃ is 9 min 2 s; FR-SZ48.

[0041] Anionic emulsifier 1: Solid content 49%; Glass transition temperature 35℃; FR-RY888.

[0042] Anionic emulsifier 2: Solid content is 68%; glass transition temperature is 9℃; FR-RY07.

[0043] Self-crosslinking acrylic copolymer emulsion: solid content ≥45%, viscosity >2000cps / 25℃, pH 7.5-8.5, glass transition temperature 6-8℃; FR-RY12.

[0044] Anionic aqueous acrylic emulsion: solid content 49%-51%, viscosity 30-190cps / 25℃, pH 3.5-6.5; FR-RY79.

[0045] Heavy calcium carbonate, commercially available.

[0046] Low melting point additive: potassium fluoroborate, commercially available.

[0047] Examples 1-5 and Comparative Examples 1-5

[0048] Examples 1-5 and Comparative Examples 1-5 are high-elastic abrasive cloths of the present invention; the components and proportions of the high-elastic abrasive cloths described in Examples 1-5 and Comparative Examples 1-5 are shown in Table 1-2.

[0049] The preparation methods of the high-elasticity abrasive cloth in Examples 1-5 and Comparative Examples 1-5 include the following steps:

[0050] The preparation method includes the following steps:

[0051] S1. Use adhesive solution A to impregnate the pure cotton fabric base, that is, use two pressure rollers to completely press adhesive solution A into the pure cotton fabric base, and dry it until the moisture content is 1%-3% to obtain a fabric base with a mass of 189g / ㎡.

[0052] S2. After the pure cotton fabric base has been impregnated with resin in step S1, apply adhesive B in sequence, dry it to a moisture content of 3%-7% to obtain a fabric base with a mass of 68g / ㎡, apply adhesive C, use 150# abrasive to bond the abrasive, apply adhesive D, wind the abrasive cloth into a roll with the abrasive side facing outward, and bake it until the resin is completely cured to obtain the high-elastic abrasive cloth.

[0053] Table 1

[0054]

[0055]

[0056] Table 2

[0057]

[0058] Comparative Examples 6-9

[0059] Comparative Examples 6-9 are high-elasticity abrasive cloths of the present invention; the components and proportions of the high-elasticity abrasive cloths described in Comparative Examples 6-9 are shown in Table 3. The preparation method of the high-elasticity abrasive cloths of Comparative Examples 6-9 includes the following steps:

[0060] The preparation method includes the following steps:

[0061] S1. Impregnate the pure cotton fabric with adhesive solution A, that is, press the adhesive solution A completely into the pure cotton fabric with two pressure rollers, and dry it until the moisture content is 1%-3% to obtain a fabric with a mass of 194g / ㎡.

[0062] S2. After the pure cotton fabric base has been impregnated with resin in step S1, apply adhesive B in sequence, dry it to a moisture content of 3%-7% to obtain a fabric base with a mass of 68g / ㎡, apply adhesive C, use 150# abrasive to bond the abrasive, apply adhesive D, wind the abrasive cloth into a roll with the abrasive side facing outward, and bake it until the resin is completely cured to obtain the high-elastic abrasive cloth.

[0063] Table 3

[0064]

[0065] Examples 6-8

[0066] Examples 6-8 are high-elastic abrasive cloths of the present invention; the components and proportions of the high-elastic abrasive cloths in Examples 6-8 are shown in Table 4, and the preparation method of the high-elastic abrasive cloths is the same as that in Example 1.

[0067] Table 4

[0068]

[0069] Comparative Example 10

[0070] The only difference between Comparative Example 10 and Example 1 is that the second phenolic resin 1 is replaced with the second phenolic resin 2, and all other aspects are the same as in Example 1.

[0071] Example 1

[0072] To verify the performance of the product described in this invention, the following performance tests were conducted on the products of each embodiment and comparative example, with the specific steps as follows:

[0073] (1) Fabric strength test: The radial width of the fabric is 50mm. The tensile testing machine is used to test the fabric strength at the time of breakage. The fabric strength is considered to be good if the fabric strength is above 1800MPa.

[0074] (2) Fabric toughness test: Take a fabric with a radial width of 50mm and a length of 220mm. Use a tensile testing machine, set the tensile force to 600N, and the clamp spacing to 150mm. Test the product's elongation length. An elongation of more than 20mm is considered to be good toughness.

[0075] (3) Elasticity test: Take a 10cm (radial length) * 5cm (weft width) cloth base, pour 100℃ water, and test the curvature of the sand cloth towards the cloth base surface. If the curvature of the sand cloth towards the cloth base surface exceeds 270°, and it can maintain its shape and continuous elasticity after bending, it is considered excellent.

[0076] (4) Test for slippage and burnt workpiece during grinding: Collect dust and particles after grinding the product and pickle them. Observe whether there are abrasive particles with a particle size greater than 80% of the abrasive particle size. If they are present, it indicates that the cloth base is consumed before the abrasive or the bonding strength is insufficient, causing the abrasive to fall off. Test the grinding temperature of the surface of the workpiece during the grinding process. If the temperature exceeds 550℃ and the grinding material turns blue or green, it indicates that the workpiece is burned.

[0077] The test results are shown in Table 5.

[0078] Table 5

[0079]

[0080] As can be seen from Table 5, when the technical solution of the present invention is adopted, the obtained high-elastic abrasive cloth has excellent cloth strength and cloth toughness; the cloth strength is greater than 1800MPa and the cloth toughness is greater than 20mm; it can bend to the cloth surface by more than 270° arc, and can maintain its shape and continuous elasticity after bending; at the same time, the abrasive cloth of the present invention can be consumed at the same time as the abrasive particles are consumed, ensuring that the phenomenon of slippage and workpiece burning will not occur during grinding due to the cloth not being consumed during use.

[0081] Comparing Examples 1-5 with Comparative Examples 1-5, it can be seen that the specific selection of the first phenolic resin has a significant impact on the overall performance of the product. The first phenolic resin selected in Examples 1-5 is within the scope of the present invention, and the final product has better fabric strength and toughness, better shaping state and elasticity after bending, and no slippage or burnt workpiece occurs during grinding.

[0082] Comparing Examples 1-5 and Comparative Examples 6-9, it can be seen that the specific combination of the first phenolic resin and the nonionic emulsifier in this invention has a significant impact on the overall performance of the product. Although the mass ratio of the first phenolic resin to the anionic emulsifier in Comparative Examples 6-9 is within the range of this invention, the selection of the two is not within the range of this invention, resulting in poor overall performance of the final product. In particular, in Comparative Example 9, during the preparation of the abrasive cloth, the small droplets of the dispersed phase of the adhesive solution aggregated into large droplets, which eventually caused the oil and water phases to separate into two immiscible phases, making the adhesive solution unusable.

[0083] Comparing Example 1 and Comparative Example 10, it can be seen that the specific selection of the second phenolic resin has a significant impact on the overall performance of the product; the second phenolic resin selected in Example 1 is within the scope of the present invention, and the final product has better fabric strength and toughness, better shaping state and elasticity after bending, and reduces the phenomenon of slippage and burnt workpiece during grinding.

[0084] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. A high-elasticity abrasive cloth, characterized in that, The high-elastic abrasive cloth includes an abrasive cloth base and adhesives A, B, C, and D sequentially coated on the abrasive cloth base; The adhesive A comprises a first phenolic resin and an anionic emulsifier, wherein the mass ratio of the first phenolic resin to the anionic emulsifier is 1:1-9; the adhesive B comprises a self-crosslinking acrylic copolymer emulsion and an anionic aqueous acrylic emulsion, wherein the mass ratio of the self-crosslinking acrylic copolymer emulsion to the anionic aqueous acrylic emulsion is 2-3:1-2; the adhesive C comprises a second phenolic resin and heavy calcium carbonate; the adhesive D comprises a second phenolic resin and a low-melting-point additive. The first phenolic resin has a solid content of 48%-52%, a viscosity of 900-1300 cps / 25℃, a pH of 9-10, a free formaldehyde content of 0.10%-0.15%, a free phenol content of 0.3%-0.6%, a water solubility of >20%, and a gel time of 70-85s measured by the hot plate test at 25℃. The second phenolic resin has a solid content of 68%-72%, a viscosity of 250-500 cps / 25℃, a pH of 8-9, a free formaldehyde content of 0.10%-0.3%, a free phenol content of 6%-10%, a water solubility of >1%, and a gel time of 4-8 min measured by the hot plate test at 130℃.

2. The high-elasticity abrasive cloth as described in claim 1, characterized in that, In the adhesive B, the solid content of the self-crosslinking acrylic copolymer emulsion is ≥45%, and the glass transition temperature is 6-8℃; The solid content of anionic aqueous acrylic emulsions is 49%-51%.

3. The high-elasticity abrasive cloth as described in claim 1, characterized in that, In the adhesive solution C, the mass ratio of the second phenolic resin to the heavy calcium carbonate is 5:2-4.

4. The high-elasticity abrasive cloth as described in claim 1, characterized in that, In the adhesive solution D, the mass ratio of the second phenolic resin to the low-melting-point additive is 2-5:

1.

5. The high-elasticity abrasive cloth as described in claim 1 or 4, characterized in that, In the adhesive solution D, the low-melting-point additives include at least one of sodium fluoroborate and potassium fluoroborate.

6. The high-elasticity abrasive cloth as described in claim 1, characterized in that, The mass ratio of adhesive A, adhesive B, adhesive C, and adhesive D is adhesive A: adhesive B: adhesive C: adhesive D = 180-200: 65-70: 100-50: 170-60.

7. The method for preparing high-elasticity abrasive cloth according to any one of claims 1-6, characterized in that, The preparation method includes the following steps: S1. Impregnate the pure cotton fabric with adhesive solution A and then dry it. S2. After the pure cotton fabric base has been impregnated with adhesive in step S1, adhesive B, adhesive C, and adhesive D are applied sequentially, dried, and cured to obtain the high-elasticity abrasive cloth.

8. The method for preparing high-elasticity abrasive cloth as described in claim 7, characterized in that, In step S2, after applying adhesive C, the abrasive is bonded, and then adhesive D is applied.

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