Ultra-wide wear-resistant abrasive belt and preparation method thereof

Abstract

The invention provides an ultra-wide wear-resistant abrasive belt and a preparation method thereof, and relates to the technical field of abrasive tool manufacturing. The ultra-wide wear-resistant abrasive belt is sequentially provided with a protective layer, a composite adhesive layer, an abrasive material layer, a buffer layer, a bottom adhesive layer, a front scraping layer, a cloth base layer and a back scraping layer from top to bottom. Through the specific multi-layer structural design, the overall performance of the ultra-wide wear-resistant abrasive belt is improved. And different coating processes are adopted for different structural layers, so that complete functions of the layers are ensured, and the combination effect is good. The ultra-wide wear-resistant abrasive belt is high in wear resistance, long in service life, low in unit grinding cost, remarkable in comprehensive benefit and particularly suitable for the application scene of grinding of ultra-wide boards, especially density boards and other boards, the raw materials and the preparation process are environmentally friendly, and the ultra-wide wear-resistant abrasive belt has good application prospects.

Description

Technical Field

[0001] The present invention relates to the technical field of abrasive tool manufacturing, and in particular to an ultra-wide wear-resistant abrasive belt and a preparation method thereof. Background Art

[0002] Medium Density Fiberboard (MDF), also known as density fiberboard, is made from wood or other plant fibers. This material is processed through fiber preparation, applied with synthetic resin, and pressed under heat and pressure. Based on density, it can be categorized as high-density fiberboard, medium-density fiberboard, and low-density fiberboard. Due to its uniform structure, fine material, stable performance, impact resistance, and ease of processing, MDF is widely used in domestic furniture, decoration, musical instruments, and packaging.

[0003] The following problems are prone to occur during the production process of density boards: the surface of the density boards may become rough or uneven due to the characteristics of the material during production; the pressing process may form scratches or dents on the surface of the density boards, affecting the aesthetics and functionality, and the pressing process may also cause the thickness of the density boards to exceed the standard, requiring sanding to meet the thickness requirements; the finished density boards are prone to glue residue or other processing residues, which need to be removed by sanding to ensure a clean surface; density boards usually require further processing before use, such as surface treatment, engraving, cutting and trimming, which adds additional processing costs and time. To solve the above problems, existing density board manufacturers usually use sandpaper to sand the density boards to improve the surface flatness and smoothness of the density boards, thereby improving the aesthetics and quality of the density boards.

[0004] With increasingly fierce competition, MDF processing equipment, previously specialized in small-format processing, is shifting toward larger and ultra-larger formats. The existing 1350-1450 mm wide abrasive belts on the market are failing to improve production efficiency, reduce production costs, or reduce unit power and energy consumption. Consequently, higher requirements are being placed on abrasive belt widths and lengths, typically exceeding 2600 mm and 3000-3400 mm. Existing 1400 mm wide abrasive rolls (with a weft elongation greater than 3 at 600 N) are insufficient for producing ultra-wide abrasive belts. This is primarily due to insufficient weft strength and a weft elongation greater than 3 at 600 N. Furthermore, these narrow abrasive rolls fail to meet the required warp and weft strength and weft elongation requirements. For example, belts produced from ultra-wide abrasive rolls produced by Willibang Wood Industry often break and buckle, primarily due to insufficient weft strength and a weft elongation greater than 3 at 600 N. However, existing ultra-wide abrasive roll manufacturing processes cannot achieve both high mechanical strength and low elongation. Furthermore, the surface roughness of treated MDF boards is generally increased, requiring the use of fine abrasives to improve surface quality, resulting in low processing efficiency. Particularly in high-temperature operating environments, the bond between existing abrasive roll layers is not strong enough and easily softens, causing a sharp decline in grinding performance and a significantly shortened service life, increasing replacement frequency and production costs. Furthermore, some binders and additives may release harmful substances during use, leaving room for improvement in environmental performance. Summary of the Invention

[0005] In light of this, the present invention provides an ultra-wide wear-resistant abrasive belt and a method for preparing the same. By adjusting the functional layers of the wear-resistant abrasive belt and combining it with a specific preparation process, the present invention achieves significant improvements in performance, lifespan, cost, and applicability. Furthermore, the raw materials and preparation process are environmentally friendly, and the belt has promising application prospects.

[0006] The first aspect of the present invention is to provide an ultra-wide wear-resistant sanding belt, which is provided with: a protective layer, a rubber layer, an abrasive layer, a buffer layer, a base layer, a front scraping layer, a cloth base layer, and a back scraping layer in sequence from top to bottom.

[0007] Furthermore, the protective layer includes the following raw materials in parts by mass: 40-55 parts of high-temperature resistant phenolic resin, 20-30 parts of mica powder, 5-10 parts of nano-alumina, 3-6 parts of a cross-linking agent, and 1-3 parts of a thermal stabilizer; the cross-linking agent is at least one of hexamethoxymethyl melamine resin (HMMM), hexamethyloxymethyl melamine (HMOM), benzoyl peroxide (BPO), an isocyanate cross-linking agent, and an epoxy cross-linking agent; the thermal stabilizer is antioxidant 1010 and / or antioxidant 168; the particle size of the nano-alumina is 10-50 nm.

[0008] The layered structure of mica powder in the protective layer forms a thermal barrier, reducing the thermal conductivity, and the low expansion coefficient of nano-alumina reduces thermal expansion deformation. The protective layer of the present invention can effectively protect the inner layer structure and increase the service life of the ultra-wide wear-resistant sanding belt.

[0009] Furthermore, the abrasive of the abrasive layer includes the following raw materials in parts by weight: 40-50 parts of 70-200 mesh silicon carbide; 40-50 parts of 200-380 mesh silicon carbide; 15-30 parts of 400-800 mesh silicon carbide; the surface of the abrasive is modified with a silane coupling agent KH-570;

[0010] The abrasive modification method is as follows: silane coupling agent KH-570 is mixed with ethanol or acetone to prepare a solution with a silane coupling agent concentration of 5wt.%-10wt.%, the pH value is adjusted to 3.5-4.5 with acetic acid, and the solution is evenly sprayed on the abrasive surface after standing for 30-60 minutes. The spraying amount is 0.5wt.%-2.0wt.% of the abrasive mass, and the modification is completed after drying.

[0011] The siloxy groups in the KH-570 molecule form chemical bonds with the hydroxyl groups on the surface of the abrasive, which increases the bonding strength between the abrasive and the resin matrix. At the same time, the coupling agent forms an organic monomolecular film on the surface of the abrasive, reducing abrasive agglomeration and improving the uniformity of dispersion in the resin. In addition, the organic silicone layer prevents water molecules from penetrating the interface, which can improve the performance of the abrasive belt in humid environments. Finally, the thermal stability of the siloxy bond is better than that of the organic bond, which can improve the performance stability of the abrasive belt under high-temperature grinding conditions. Ultimately, through simple modification of the abrasive, an organic-inorganic composite interface is formed on the abrasive surface, which significantly improves the compatibility and bonding strength between the abrasive and the resin matrix, avoids the risk of premature abrasive shedding, increases the overall service life of the abrasive belt, and reduces the unit grinding cost.

[0012] Furthermore, the adhesive layer includes the following raw materials in parts by weight: 45-60 parts of phenolic resin, 3-8 parts of nano-silica, 2-5 parts of nano-alumina, 8-15 parts of rubber particles, 0.2-0.8 parts of silane coupling agent, 0.5-1.5 parts of dispersant, and 0.1-0.3 parts of defoaming agent; the defoaming agent is an organic silicone defoaming agent, such as BYK-066N and DC-57; the particle size of the nano-silica is 10-30 nm; and the particle size of the nano-alumina is 20-80 nm.

[0013] Nanoparticles provide a skeletal support, improving the heat resistance of ultra-wide abrasive belts. The plastic deformation of the rubber phase dissipates crack propagation energy, while the flexible phase mitigates stress concentration, preventing crack formation. They also fully bond the abrasive particles, preventing them from falling off and extending the belt's service life.

[0014] Furthermore, the buffer layer comprises the following raw materials in parts by mass: 45-55 parts of flexible polyurethane resin, 10-20 parts of dioctyl phthalate, 15-25 parts of light calcium carbonate, and 2-5 parts of a crosslinking agent; the crosslinking agent is isophorone diisocyanate (IPDI) and / or hexamethylene diisocyanate (HDI).

[0015] The present invention introduces flexible polyurethane resin into the buffer layer, which effectively alleviates the impact and vibration during the grinding process and improves the impact resistance and service life of the abrasive belt.

[0016] Furthermore, the primer layer includes the following raw materials in parts by mass: 50-65 parts of epoxy resin, 15-25 parts of curing agent, 8-15 parts of toughening agent, 10-20 parts of heavy calcium carbonate, and 0.3-1.0 parts of silane coupling agent; the curing agent is triethylenetetramine (TETA) and / or polyetheramine D-230, the toughening agent is carboxyl-terminated nitrile rubber (CTBN), and the silane coupling agent is KH-560 and / or KH-570.

[0017] Furthermore, the positive scraping layer includes the following raw materials in parts by mass: 30-70 parts of adhesive, 30-50 parts of heavy calcium carbonate, 0.3-1 parts of emulsifier, and 5-15 parts of toughening agent; the adhesive is a styrene-acrylic copolymer emulsion, the emulsifier is a nonionic surfactant, preferably fatty alcohol polyoxyethylene ether (AEO-9), and the toughening agent is a rubber toughening agent, preferably styrene-butadiene rubber latex.

[0018] Furthermore, the back-scratching layer comprises the following raw materials in parts by mass: 30-50 parts of phenolic resin, 10-25 parts of acrylic resin, 20-50 parts of heavy calcium carbonate, 5-25 parts of conductive graphite, 1-5 parts of black color paste, and 0.5-1 part of emulsifier; the emulsifier is preferably a sulfonate emulsifier, more preferably sodium dodecylbenzenesulfonate (SDBS).

[0019] The invention adds conductive graphite to the back scraping layer, which makes it difficult for dust to adhere, thereby increasing the smoothness of the back of the sanding belt and the finish of the surface of the density board.

[0020] Furthermore, the fabric base layer is made of pure polyester grey fabric.

[0021] The second aspect of the present invention is to provide a method for preparing an ultra-wide wear-resistant abrasive belt, comprising the following steps:

[0022] Substrate pretreatment, layer coating, sand planting, adhesive coating, protective layer coating, segmented curing, and post-processing.

[0023] The first step of the preparation method of the present invention is substrate pretreatment, which is as follows:

[0024] The cloth base is inspected and repaired, and then cleaned with solvent to remove surface oil stains. After drying at room temperature for 24 hours, corona treatment is performed to improve the wettability of the material. After the corona treatment is completed, heat setting is performed at a temperature of 190℃-210℃;

[0025] Preferably, the drying temperature is room temperature, the drying time is ≥24 h, and the corona treatment power is 2-5 kW / m 2 The heat setting temperature is 190°C-210°C, and the heat setting time is 2-6 minutes.

[0026] In this invention, heat setting eliminates internal stress and deformation in the fabric base material during the initial processing, stabilizes the fabric base's dimensions, and prevents shrinkage or deformation during subsequent processing, providing a stable foundation for subsequent coating processes. Heat setting also improves the fabric base's mechanical strength and toughness, enhancing its adhesion to subsequent coatings.

[0027] The second step of the preparation method of the present invention is layered coating, which is as follows:

[0028] Applying a back scraping layer slurry and drying it to form a back scraping layer, then applying a front scraping layer slurry and drying it to form a front scraping layer, then applying a primer layer slurry and pre-curing it to form a primer layer, and then spraying a buffer layer slurry and drying it to form a buffer layer;

[0029] Preferably, the coating thickness of the back scratch layer is 0.08-0.12 mm, the drying temperature is 130°C-150°C, and the drying time is 10-15 min; the coating thickness of the front scratch layer is 0.10-0.15 mm, the drying temperature is 140°C-160°C, and the drying time is 10-15 min; the coating thickness of the primer layer is 0.12-0.18 mm, the pre-curing temperature is 100°C-110°C, and the pre-curing time is 30-40 min; the spraying thickness of the buffer layer is 0.05-0.08 mm, the drying temperature is 55°C-65°C, and the drying time is 8-12 min;

[0030] The back scraping layer and the front scraping layer are coated by a doctor blade coating process, the base glue layer is coated by a metering roller coating process, and the buffer layer is formed by a spraying process.

[0031] The present invention selects different coating processes based on the functional requirements and material properties of each layer. The back-scraping layer and the front-scraping layer contain heavy calcium carbonate as a filler, resulting in a high material viscosity and a relatively thick coating thickness, making them suitable for effective scraper coating. Furthermore, the back-scraping layer and the front-scraping layer primarily serve as foundation support and leveling, requiring high coating density. Scraper coating provides excellent compaction. The base adhesive layer, containing high-strength epoxy resin and silane coupling agent, is a key layer connecting the fabric base to the superstructure. High coating accuracy and uniformity are required, along with moderate viscosity. A metering roller can precisely control the coating amount, ensuring mechanical strength after curing. The buffer layer is designed to have a thickness of only 0.05-0.08 mm, requiring a spray coating process to form a thin, uniform coating. The flexible polyurethane resin and plasticizer system exhibits good fluidity and relatively low viscosity, making it suitable for atomized spraying. Furthermore, the buffer layer requires excellent flexibility and permeability, and the coating formed by spraying is more uniform and soft, meeting the requirements for the buffer layer. Thus, the present invention utilizes different coating processes for different structural layers, ensuring optimal performance for each layer of the sanding belt.

[0032] The third step of the preparation method of the present invention is sand planting, which is as follows:

[0033] The abrasive is implanted using an electrostatic sand implantation process with an electrostatic voltage of 18-22 kV and a total sand density of 20-25 g / dm 2 After the sand planting is completed, pre-press at a pressure of 0.2-0.5 MPa for 5-10 minutes. The pre-pressing and fixing process ensures the directional arrangement and preliminary fixation of the abrasive, creating a good foundation for the subsequent re-gluing process. In addition, since the present invention modifies the abrasive, the absolute value of its Zeta potential is increased, and the electrostatic adsorption is improved, which is conducive to improving the uniformity of the sand planting density and enhancing the abrasive orientation effect, so as to solve the problem of uneven coating unique to ultra-wide wear-resistant sand belts.

[0034] The fourth step of the preparation method of the present invention is to coat the adhesive, and the steps are as follows:

[0035] After the raw materials are mixed and dispersed, the slurry is applied and leveled, and then the temperature is raised to perform gradient curing to form a glue layer;

[0036] Preferably, the dispersion rate is 8000-12000 rpm, and the dispersion time is 25-35 min. The slurry is coated using a slot coating process with a coating thickness of 0.05-0.08 mm, a leveling temperature of 60° C., and a leveling time of 20-25 min. During the leveling stage, the solvent evaporates and the coating is leveled, thereby eliminating coating marks.

[0037] The curing process is as follows: heating to 80-100°C, keeping warm for 30-45 min, and heating rate of 2-3°C / min. During this process, the residual solvent evaporates further, the resin begins to pre-crosslink, and the nanoparticles are initially dispersed and stabilized. The heating rate of 2-3°C / min prevents blistering or cracking of the coating; 110-130°C, keeping warm for 45-60 min, and heating rate of 1-2°C / min. The phenolic resin body undergoes a cross-linking reaction, the silane coupling agent plays a coupling role, and the rubber particles are combined with the resin matrix. The heating rate of 1-2°C / min controls the cross-linking reaction speed; 140-160°C, keeping warm for 20-30 min, and heating rate of 1-2°C / min. Complete cross-linking and curing are achieved, and the nanoparticles are firmly combined with the matrix. The heating rate of 1-2°C / min avoids stress concentration caused by excessive curing.

[0038] The coating thickness of the adhesive layer is only 0.05-0.08 mm, which is a thin coating. The slit coating method can accurately control the thickness of the thin coating and ensure the uniformity of the coating. In addition, the adhesive layer contains multiple components such as phenolic resin, nano-silica, nano-alumina, and rubber particles. It is necessary to ensure the uniform dispersion of each component to avoid agglomeration and deposition. The scraper coating process is suitable for high-viscosity and thick coating materials and is not suitable for thin coatings. Although the metering roller coating process has high precision, it has the problem of uneven dispersion for systems containing nanoparticles. The contact of the rollers will produce a shear effect on the nanoparticles, affecting the dispersion effect. Therefore, the present invention adopts a slit coating process to coat the adhesive layer.

[0039] The fifth step of the preparation method of the present invention is the coating of the protective layer, which is as follows:

[0040] Spraying the protective layer slurry on the adhesive layer and then performing gradient drying to form a protective layer;

[0041] Preferably, the spraying thickness of the protective layer is 0.02-0.04 mm, and the gradient drying process is as follows: first keep the temperature at 50-55°C for 10-15 min, then increase the temperature to 80-85°C for 10-15 min, and finally keep the temperature at 95-100°C for 10-15 min.

[0042] The sixth step of the preparation method of the present invention is segmented curing, which is as follows:

[0043] Keep the temperature at 80-100°C for 30-45 minutes to remove the solvent; keep the temperature at 110-130°C for 45-60 minutes to carry out the cross-linking reaction; keep the temperature at 140-160°C for 20-30 minutes, and finally keep the temperature at 120°C for 8-12 hours to completely cure.

[0044] The seventh step of the preparation method of the present invention is post-processing, which includes the following steps:

[0045] The product is softened through a multi-roller kneading process and finally rolled and packaged to obtain the finished ultra-wide wear-resistant abrasive belt.

[0046] Compared with the prior art, the present invention has the following beneficial technical effects:

[0047] The ultra-wide wear-resistant abrasive belt of this invention adopts a multi-layer structure design, with each layer having a clear function, and the synergistic effect improves the overall performance. Different structural layers use different coating processes to ensure the functional integrity and good combination of each layer.

[0048] The ultra-wide wear-resistant sanding belt of the present invention has strong wear resistance, long service life, reduced unit grinding cost, and significant comprehensive benefits. It is particularly suitable for application scenarios of ultra-wide, especially grinding of density boards and other plates, and solves the technical difficulties of traditional sanding belts in ultra-wide applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The present invention will be further described below with reference to the accompanying drawings.

[0050] Figure 1 The figure is a flow chart of the preparation process of the ultra-wide wear-resistant abrasive belt of the present invention. DETAILED DESCRIPTION

[0051] The technical solutions in the implementation cases of this application will be described clearly and completely below. Obviously, the embodiments described are only some of the embodiments of this application, not all of them. Based on the embodiments in this application, other embodiments obtained by ordinary technicians in this field without making creative work are all within the scope of invention protection. In the following examples, all raw materials are commercially available.

[0052] Unless otherwise specified, all experiments were repeated three times, and the results were expressed as mean values. SPSS Statistics 26 was used for significance analysis.

[0053] In the examples and comparative examples, the abrasive modification method is as follows: silane coupling agent KH-570 is mixed with ethanol or acetone to prepare a solution with a silane coupling agent concentration of 12 wt.%, the pH value is adjusted to 4.5 with acetic acid, and the solution is evenly sprayed on the abrasive surface after standing for 45 minutes. The spraying amount is 1.0 wt.% of the abrasive mass, and the modification is completed after drying.

[0054] Example 1 An ultra-wide wear-resistant sanding belt is provided with: a protective layer, a rubber layer, an abrasive layer, a buffer layer, a base rubber layer, a front scraping layer, a cloth base layer, and a back scraping layer in order from top to bottom;

[0055] The protective layer is composed of the following raw materials in parts by mass: 50 parts of high-temperature resistant phenolic resin, 25 parts of mica powder, 8 parts of nano-alumina, 5 parts of HMMM, and 2 parts of antioxidant 168;

[0056] The abrasive layer is composed of the following raw materials in parts by weight: 45 parts of 200-mesh silicon carbide; 45 parts of 350-mesh silicon carbide; and 22 parts of 600-mesh silicon carbide. The abrasive surface is modified with a silane coupling agent KH-570.

[0057] The adhesive layer is composed of the following raw materials in parts by mass: 55 parts of phenolic resin, 40 parts of nano-silicon dioxide, 4 parts of nano-alumina, 12 parts of rubber particles, 0.5 parts of silane coupling agent, 1.0 parts of dispersant, and 0.2 parts of BYK-066N;

[0058] The buffer layer is composed of the following raw materials in parts by mass: 50 parts of flexible polyurethane resin, 15 parts of dioctyl phthalate, 18 parts of light calcium carbonate, and 4 parts of IPDI;

[0059] The primer layer is composed of the following raw materials in parts by mass: 60 parts of epoxy resin, 20 parts of TETA, 12 parts of CTBN, 15 parts of heavy calcium carbonate, and 0.6 parts of silane coupling agent KH-560;

[0060] The positive scratching layer is composed of the following raw materials in parts by mass: 50 parts of styrene-acrylic acid copolymer emulsion, 40 parts of heavy calcium carbonate, 0.7 parts of AEO-9, and 8 parts of styrene-butadiene rubber latex;

[0061] The base fabric is made of pure polyester grey fabric;

[0062] The back-scratching layer is composed of the following raw materials in parts by mass: 40 parts of phenolic resin, 17 parts of acrylic resin, 35 parts of heavy calcium carbonate, 15 parts of conductive graphite, 3 parts of black color paste, and 1.2 parts of SDBS.

[0063] The preparation method of the ultra-wide wear-resistant abrasive belt comprises the following steps:

[0064] S1. Substrate pretreatment

[0065] The cloth base was inspected and repaired, and then cleaned with solvent to remove surface oil stains. After drying at room temperature for 24 hours, the cloth was heated at 5kW / m 2 After the corona treatment, the steel sheet was heat-set at 200°C for 5 minutes.

[0066] S2, layered coating

[0067] The back scraping layer slurry was applied by doctor blade coating process with a coating thickness of 0.10 mm and dried at 150℃ for 10 min. The front scraping layer was applied by doctor blade coating process with a coating thickness of 0.15 mm and dried at 160℃ for 10 min. The base glue layer was applied by metering roller with a coating thickness of 0.15 mm and pre-cured at 100℃ for 30 min. The buffer layer slurry was sprayed with a spray thickness of 0.05 mm and dried at 60℃ for 10 min.

[0068] S3, sand planting treatment

[0069] The abrasive was implanted using an electrostatic sand implantation process with an electrostatic voltage of 20 kV and a total sand density of 25 g / dm2. After the implantation, the abrasive was pre-pressed at a pressure of 0.5 MPa for 5 min.

[0070] S4, glue coating

[0071] The raw materials were mixed and dispersed at 12000 rpm for 30 minutes, and then coated using a slot coating process with a coating thickness of 0.08 mm. After the slurry was leveled at 60°C for 25 minutes, the temperature was raised to 90°C at 2°C / min and kept warm for 30 minutes. The temperature was then raised to 120°C at 2°C / min and kept warm for 50 minutes. The temperature was then raised to 150°C at 2°C / min and kept warm for 30 minutes to form a double-layer adhesive layer.

[0072] S5, protective layer coating,

[0073] The protective layer slurry was sprayed on the adhesive layer with a thickness of 0.03 mm. The protective layer was then kept at 50°C for 15 minutes, then heated to 85°C for 10 minutes, and finally dried at 100°C for 10 minutes to form a protective layer.

[0074] S6, segmented curing, the steps are as follows:

[0075] Keep the temperature at 80℃ for 45 minutes to remove the solvent; keep the temperature at 120℃ for 50 minutes to carry out the cross-linking reaction; keep the temperature at 150℃ for 25 minutes, and finally keep the temperature at 120℃ for 8 hours to completely cure;

[0076] S7, post-processing

[0077] The product is softened through a multi-roller kneading process and finally rolled and packaged to obtain the finished ultra-wide wear-resistant abrasive belt.

[0078] Comparative Example 1

[0079] The difference from Example 1 is that the abrasive layer uses a single particle size of 320 mesh silicon carbide, evenly distributed, and the abrasive density is 25g / dm 2 .

[0080] Comparative Example 2

[0081] The difference from Example 1 is that the adhesive layer does not contain nano-silicon dioxide, nano-aluminum oxide and rubber particles.

[0082] Comparative Example 3

[0083] The difference from Example 1 is that the stress buffer layer is eliminated and the thickness of the primer layer is increased to 0.20 mm as compensation.

[0084] Comparative Example 4

[0085] The difference from Example 1 is that the protective layer is removed.

[0086] Comparative Example 5

[0087] The difference from Example 1 is that after all layers are coated (without omitting the drying step), curing is performed at a constant temperature of 120° C. for 16 hours.

[0088] Comparative Example 6

[0089] The difference from Example 1 is that a gravity sanding process is adopted and the abrasive density is increased as compensation.

[0090] The performance of the ultra-wide wear-resistant abrasive belts of the embodiment and the comparative example was tested, and the results were as follows:

[0091] (1) The test results of foundation mechanical properties are shown in Table 1.

[0092] Table 1 Basic mechanical properties test

[0093] sample Warp strength (N / 5 cm) Weft strength (N / 5 cm) Elongation in warp direction at 600 N (%) Weft elongation at 600 N (%) Example 1 3150 2850 1.6 1.7 Comparative Example 1 3100 2800 1.8 1.9 Comparative Example 2 2750 2450 2.3 2.5 Comparative Example 3 3050 2750 2.8 3.2 Comparative Example 4 3120 2830 1.7 1.8 Comparative Example 5 2900 2600 2.1 2.3 Comparative Example 6 2950 2650 1.9 2.1

[0094] Table 1 shows that nanoparticles and rubber particles enhance the strength of the ultra-wide wear-resistant belt and reduce its elongation, demonstrating that nano-toughening of the rubber layer significantly improves the mechanical properties of the belt. The absence of a stress buffer layer significantly increases elongation, indicating that the buffer layer effectively controls stress transfer. The one-shot curing process reduces the strength of the belt and increases its elongation, demonstrating that segmented curing can effectively improve its mechanical properties.

[0095] (2) After being kept at 60℃ for 24 hours, the performance retention rate was tested. The results are shown in Table 2.

[0096] Table 2 Performance retention test results

[0097] sample Strength retention rate (%) Elongation change (%) Surface state Example 1 92.3 8.5 No significant changes Comparative Example 1 91.8 9.2 No significant changes Comparative Example 2 85.4 23.6 Slightly softened Comparative Example 3 88.7 28.1 Slightly softened Comparative Example 4 78.2 35.4 Obvious softening, sticky surface Comparative Example 5 83.6 31.7 Slightly softened Comparative Example 6 90.1 12.3 No significant changes

[0098] Table 2 shows that without a heat-resistant protective layer, the ultra-wide wear-resistant belt retains only 78.2% of its strength at high temperatures, 14.1% lower than in Example 1. This demonstrates the importance of a protective layer in maintaining the strength of the ultra-wide wear-resistant belt. Nano-reinforcement and toughening also significantly contribute to improving the heat resistance of the ultra-wide wear-resistant belt.

[0099] (3) Grinding performance test

[0100] Test conditions: 18 mm density board, sanding belt speed 25 m / s, pressure 0.3 MPa. The test results are shown in Table 3.

[0101] Table 3 Grinding performance test results

[0102] sample <![CDATA[Grinding efficiency (cm 3 / min)]]> Surface roughness Ra (μm) Grinding distance (km) Service life Dropout rate after 5 km use (%) Shedding rate after 10 km use (%) Example 1 145 0.8 12.5 excellent 7.3 15.6 Comparative Example 1 118 1.2 11.8 good 7.9 16.2 Comparative Example 2 132 0.9 9.2 generally 13.2 25.9 Comparative Example 3 138 0.8 8.6 generally 12.4 22.1 Comparative Example 4 140 0.8 9.8 generally 11.8 21.3 Comparative Example 5 125 1.0 10.1 good 13.7 24.5 Comparative Example 6 108 1.1 10.8 good 14.9 32.2

[0103] Table 3 shows that abrasives with gradient particle sizes can improve the grinding efficiency of ultra-wide wear-resistant abrasive belts and the surface quality of the ground density board. Electrostatic sanding significantly improves grinding efficiency and surface quality compared to gravity sanding. Nano-reinforcement significantly enhances abrasive bond strength, and electrostatic sanding significantly enhances abrasive bond strength compared to gravity sanding.

[0104] Example 2

[0105] The difference from Example 1 is:

[0106] 2-1: The protective layer is composed of the following raw materials in parts by mass: 40 parts of high-temperature resistant phenolic resin, 20 parts of mica powder, 5 parts of nano-alumina (50 nm), 3 parts of HMOM, and 1 part of antioxidant 168;

[0107] 2-2: The protective layer is composed of the following raw materials in parts by mass: 55 parts of high-temperature resistant phenolic resin, 30 parts of mica powder, 10 parts of nano-alumina (10 nm), 6 parts of BPO, and 3 parts of antioxidant 1010.

[0108] Example 3

[0109] The difference from Example 1 is:

[0110] 3-1: The abrasive layer is composed of the following raw materials in parts by weight: 70 mesh silicon carbide, 40 parts; 200 mesh silicon carbide, 40 parts; 400 mesh silicon carbide, 30 parts; the abrasive modification method is the same as in Example 1;

[0111] 3-2: The abrasive layer is composed of the following raw materials in parts by mass: 50 parts of 200-mesh silicon carbide; 50 parts of 350-mesh silicon carbide; and 15 parts of 500-mesh silicon carbide. The abrasive modification method is the same as that in Example 1.

[0112] Example 4

[0113] The difference from Example 1 is:

[0114] 4-1: The buffer layer is composed of the following raw materials in parts by mass: 45 parts of flexible polyurethane resin, 10 parts of dioctyl phthalate, 15 parts of light calcium carbonate, and 2 parts of HDI;

[0115] 4-2: The buffer layer is composed of the following raw materials in parts by mass: 55 parts of flexible polyurethane resin, 20 parts of dioctyl phthalate, 25 parts of light calcium carbonate, and 5 parts of IPDI.

[0116] Example 5

[0117] The difference from Example 1 is:

[0118] 5-1: The primer layer is composed of the following raw materials in parts by mass: 50 parts of epoxy resin, 15 parts of polyetheramine D-230, 8 parts of CTBN, 10 parts of heavy calcium carbonate, and 0.3 parts of silane coupling agent KH-560;

[0119] 5-2: The primer layer is composed of the following raw materials in parts by mass: 65 parts of epoxy resin, 25 parts of TETA, 15 parts of CTBN, 20 parts of heavy calcium carbonate, and 0.8 parts of silane coupling agent KH-570.

[0120] Example 6

[0121] 6-1: The difference from Example 1 is that the positive scratching layer is composed of the following raw materials in parts by mass: 30 parts of styrene-acrylic acid copolymer emulsion, 30 parts of heavy calcium carbonate, 0.3 parts of AEO-9, and 5 parts of styrene-butadiene rubber latex;

[0122] 6-2: The difference from Example 1 is that the positive scratching layer is composed of the following raw materials in parts by mass: 70 parts of styrene-acrylic acid copolymer emulsion, 50 parts of heavy calcium carbonate, 1.0 part of AEO-9, and 15 parts of styrene-butadiene rubber latex.

[0123] Example 7

[0124] 7-1: The difference from Example 1 is that the back-scratching layer is composed of the following raw materials in parts by mass: 30 parts of phenolic resin, 10 parts of acrylic resin, 20 parts of heavy calcium carbonate, 5 parts of conductive graphite, 1 part of black color paste, and 0.5 parts of SDBS;

[0125] 7-2: The difference from Example 1 is that the back-scratching layer is composed of the following raw materials in parts by mass: 50 parts of phenolic resin, 25 parts of acrylic resin, 45 parts of heavy calcium carbonate, 20 parts of conductive graphite, 5 parts of black color paste, and 1.0 part of SDBS.

[0126] Example 8

[0127] 8-1: The difference from Example 1 is that the cloth base is 3 kW / m 2 The corona treatment was carried out at a processing power of 1000 nm and then heat-set at 210°C for 3 min after the corona treatment.

[0128] 8-2: The difference from Example 1 is that the cloth base is 4 kW / m 2 The corona treatment was carried out at a processing power of 1000 nm and then heat-set at 190°C for 6 min after the corona treatment.

[0129] Example 9

[0130] The difference from Example 1 is that the coating thickness of the back scratch layer is 0.12 mm, the drying temperature is 130°C, and the drying time is 15 min; the coating thickness of the front scratch layer is 0.15 mm, the drying temperature is 140°C, and the drying time is 15 min; the coating thickness of the primer layer is 0.18 mm, the pre-curing temperature is 110°C, and the pre-curing time is 30 min; the spraying thickness of the buffer layer is 0.08 mm, the drying temperature is 65°C, and the drying time is 8 min.

[0131] Example 10

[0132] 10-1: The difference from Example 1 is that the static voltage in the sand planting process is 18 kV and the total sand density is 20 g / dm 2 After the sand planting is completed, pre-press at 0.5 MPa pressure for 5 min;

[0133] 10-2: The difference between Example 1 and Example 1 is that the static voltage in the sand planting process is 22 kV and the total sand density is 25 g / dm 2 After the sand planting is completed, pre-press at 0.2 MPa pressure for 10 min.

[0134] Example 11

[0135] The difference from Example 1 is that the coating thickness of the adhesive layer is 0.06 mm; the curing process is: heating to 100°C, keeping warm for 30 minutes, and a heating rate of 3°C / min; 130°C, keeping warm for 45 minutes, and a heating rate of 2°C / min; 160°C, keeping warm for 20 minutes, and a heating rate of 2°C / min.

[0136] Example 12

[0137] The difference from Example 1 is that the sprayed thickness of the protective layer is 0.04 mm, and the gradient drying process is as follows: first, keep the temperature at 55°C for 10 minutes, then increase the temperature to 85°C for 10 minutes, and finally keep the temperature at 100°C for 10 minutes.

[0138] Example 13

[0139] The difference from Example 1 is that the staged curing steps are as follows: keeping warm at 100°C for 30 minutes for desolventizing treatment; keeping warm at 130°C for 45 minutes for cross-linking reaction; keeping warm at 160°C for 2 minutes, and finally keeping warm at 120°C for 8 hours for complete curing.

[0140] The performance of the ultra-wide wear-resistant abrasive belts of Examples 2-13 was tested, and the results showed no significant difference from the performance of the ultra-wide wear-resistant abrasive belt of Example 1 (p>0.05).

[0141] The above-described embodiments merely illustrate several implementations of the present invention, and while their descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent. It should be noted that a person skilled in the art would be able to make numerous variations and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the patent for this invention shall be determined by the appended claims.

Claims

1. An ultra-wide wear-resistant sand belt, characterized in that: From top to bottom, there are: protective layer, adhesive layer, abrasive layer, buffer layer, base layer, front scraping layer, cloth base layer, back scraping layer; The protective layer comprises the following raw materials in parts by mass: 40-55 parts of high temperature resistant phenolic resin, 20-30 parts of mica powder, 5-10 parts of nano-alumina, 3-6 parts of cross-linking agent, and 1-3 parts of thermal stabilizer; The abrasive of the abrasive layer includes the following raw materials in parts by weight: 40-50 parts of 70-200 mesh silicon carbide; 40-50 parts of 200-380 mesh silicon carbide; 400-800 mesh silicon carbide, 15-30 parts; the abrasive surface is modified with silane coupling agent KH-570; The adhesive layer comprises the following raw materials in parts by weight: 45-60 parts of phenolic resin, 3-8 parts of nano-silicon dioxide, 2-5 parts of nano-alumina, 8-15 parts of rubber particles, 0.2-0.8 parts of silane coupling agent, 0.5-1.5 parts of dispersant, and 0.1-0.3 parts of defoaming agent; The buffer layer comprises the following raw materials in parts by weight: 45-55 parts of flexible polyurethane resin, 10-20 parts of dioctyl phthalate, 15-25 parts of light calcium carbonate, and 2-5 parts of a cross-linking agent; The primer layer comprises the following raw materials in parts by weight: 50-65 parts of epoxy resin, 15-25 parts of curing agent, 8-15 parts of toughening agent, 10-20 parts of heavy calcium carbonate, and 0.3-1.0 parts of silane coupling agent; The positive scraping layer comprises the following raw materials in parts by weight: 30-70 parts of adhesive, 30-50 parts of heavy calcium carbonate, 0.3-1 parts of emulsifier, and 5-15 parts of toughening agent; The back-scratching layer comprises the following raw materials in parts by weight: 30-50 parts of phenolic resin, 10-25 parts of acrylic resin, 20-50 parts of heavy calcium carbonate, 5-25 parts of conductive graphite, 1-5 parts of black color paste, and 0.5-1 part of emulsifier; The fabric base layer is made of pure polyester grey fabric.

2. The ultra-wide wear-resistant abrasive belt according to claim 1, characterized in that: In the protective layer, the crosslinking agent is at least one of hexamethoxymethyl melamine resin, hexamethyloxymethyl melamine, benzoyl peroxide, isocyanate crosslinking agent, and epoxy crosslinking agent; the heat stabilizer antioxidant 1010 and / or antioxidant 168; and the particle size of the nano-alumina is 10-50 nm.

3. The ultra-wide wear-resistant abrasive belt according to claim 1, characterized in that: The abrasive modification method is as follows: silane coupling agent KH-570 is mixed with ethanol or acetone to prepare a solution with a silane coupling agent concentration of 5wt.%-10wt.%, the pH value is adjusted to 3.5-4.5 with acetic acid, and the solution is evenly sprayed on the abrasive surface after standing for 30-60 minutes. The spraying amount is 0.5wt.%-2.0wt.% of the abrasive mass, and the modification is completed after drying.

4. The ultra-wide wear-resistant abrasive belt according to claim 1, characterized in that: In the adhesive layer, the defoaming agent is an organic silicon defoaming agent; the particle size of the nano silicon dioxide is 10-30 nm; and the particle size of the nano aluminum oxide is 20-80 nm.

5. The ultra-wide wear-resistant abrasive belt according to claim 1, characterized in that: In the buffer layer, the cross-linking agent is isophorone diisocyanate and / or hexamethylene diisocyanate.

6. The ultra-wide wear-resistant abrasive belt according to claim 1, characterized in that: In the primer layer, the curing agent is triethylenetetramine and / or polyetheramine D-230, the toughening agent is carboxyl-terminated nitrile rubber, and the silane coupling agent is KH-560 and / or KH-570.

7. The ultra-wide wear-resistant abrasive belt according to claim 1, characterized in that: In the positive scratch layer, the adhesive is a styrene-acrylic acid copolymer emulsion, the emulsifier is a nonionic surfactant, and the toughening agent is a rubber toughening agent.

8. The ultra-wide wear-resistant abrasive belt according to claim 1, characterized in that: The emulsifier in the back-scratching layer is preferably a sulfonate emulsifier.

9. The method for preparing the ultra-wide wear-resistant abrasive belt according to any one of claims 1 to 8, characterized in that: Here are the steps: Substrate pretreatment, layer coating, sand planting, adhesive coating, protective layer coating, segmented curing and post-processing are used to obtain the finished product of ultra-wide wear-resistant sanding belt.

10. The preparation method according to claim 9, characterized in that The sand planting is electrostatic sand planting.

Images